BG - Tech Specs (Civ & HM)

Mountain Energy Corporation Mountain Energy Corporation Mountain Energy Corporation Mountain Energy Corporation
SUPER HYDRO ELECTRIC PRIVATE LIMITED

BHYUNDER GANGA HYDRO ELECTRIC PROJ ECT

(3 8.1 MW)

UTTARAKHAND

TENDER DOCUMENT FOR CIVIL & HM WORKS

VOL. 2 DESI GN MEMORANDUM & TECHNI CAL
SPECI FI CATI ONS

Consultants:
M/ s Halcrow Consulting I ndia Private Limited
B-11, 2
nd
Floor, Sector-4,
Noida-201301. (Uttar Pradesh)
Tel.: +91-120-4682500
Fax: +91-120-468-2534
www.halcrow.com

Bhyunderganga Small Hydro Electric Project
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Specifications: Volume II A Civil

Page i

BHYUNDERGANGA HYDRO ELECTRIC PROJ ECT

Volume II A
DESIGN MEMORANDUM AND
TECHNICAL SPECIFICATION
FOR
CIVIL WORKS

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INDEX

PART 1: GENERAL AND PRELIMINARY............................................................1
101 Description of the Area..................................................................................1
102 General Description of the Project.................................................................1
103 Scope of work................................................................................................1
104 Drawings........................................................................................................2
105 Site Installations.............................................................................................2
106 Construction Power........................................................................................2
107 Water Supply.................................................................................................3
108 Camps and Services.......................................................................................3
109 Communications............................................................................................4
110 Waste Disposal...............................................................................................4
111 Materials on and under the Site.....................................................................4
112 Boundaries Cut Through................................................................................4
113 Drains, Streams Watercourses etc.................................................................4
114 Compensation Water and Flow Past Structure..............................................4
115 Keeping Works Free from Water...................................................................5
116 Slips...............................................................................................................5
117 Protection of Completed Work......................................................................5
118 Traffic............................................................................................................5
119 Damage to Access Roads...............................................................................5
120 Setting Out.....................................................................................................5
121 Surface and River Bed Levels.......................................................................6
122 Testing Laboratory.........................................................................................6
123 Safety of Personnel ........................................................................................6
124 Protection of the Environment.......................................................................6
125 Interference with Existing Works..................................................................7
126 Photographs...................................................................................................7
PART 2: WORKMANSHIP AND MATERIALS ....................................................9
201 Workmanship and Materials in General ........................................................9
202 Inspection of Materials..................................................................................9
203 Tolerances....................................................................................................10
PART 3: EXCAVATION AND EARTHWORKS..................................................11
301 Definition of Earthworks Material...............................................................11
302 Site Clearance..............................................................................................11
303 Excavation General...................................................................................11
304 Excavation Beyond True Lines and Levels.................................................12
305 Approval of Excavations.............................................................................12
306 Excavations for Structures...........................................................................13
307 Disposal of Surplus Excavated Materials....................................................13
308 Procurement, Storage and Handling of Explosives.....................................13
309 Magazines....................................................................................................14
310 Blasting........................................................................................................14
311 Underground Excavations............................................................................15
312 Rockbolting..................................................................................................16
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313 Steel Rib Supports.......................................................................................18
314 Shotcreting...................................................................................................19
315 Fill ................................................................................................................21
316 Backfill to Structures...................................................................................22
PART 4: CONCRETE...............................................................................................23
401 Cement.........................................................................................................23
402 Storage of Cement........................................................................................23
403 Fine Aggregate.............................................................................................23
404 Coarse Aggregate.........................................................................................24
405 Testing of Aggregates..................................................................................26
406 Aggregate Reactivity Potential ....................................................................26
407 Water............................................................................................................26
408 Admixtures...................................................................................................27
409 Concrete Mixes............................................................................................27
410 Plum Concrete..............................................................................................27
411 Concrete Mix Designs.................................................................................28
412 Trial Mixes...................................................................................................28
413 Works Test...................................................................................................28
414 Test Failure..................................................................................................29
415 Workability..................................................................................................29
416 Concrete Returns and Records.....................................................................29
417 Batching and Mixing of Concrete................................................................30
418 Concrete Placing..........................................................................................30
419 Concrete Placing Equipment .......................................................................31
420 Time for Placing Concrete...........................................................................31
421 Compaction..................................................................................................31
422 Placing in Inclement Weather......................................................................31
423 Placing in High Temperature.......................................................................31
424 Formwork.....................................................................................................31
425 Preparation of Formwork.............................................................................32
426 Classes of Finish..........................................................................................32
427 Removal of Formwork.................................................................................33
428 Construction J oints......................................................................................33
429 Movement J oints..........................................................................................34
430 Steel Reinforcement.....................................................................................35
431 Storage of Reinforcement............................................................................36
432 Cover to Reinforcement...............................................................................36
433 Curing and Protection..................................................................................36
PART 5: MASONRY AND STONEWORK...........................................................38
501 Stone............................................................................................................38
502 Masonry.......................................................................................................38
503 Random Rubble Masonry............................................................................39
504 Masonry Lining to Waterways....................................................................39
505 Stone Masonry Armouring to Weirs............................................................39
506 Dry Rubble Walling.....................................................................................41
507 Hand-placed Rubble Filling.........................................................................41
508 Rubble Filling..............................................................................................41
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509 Gabions........................................................................................................41
510 Rock Armouring and Rip-Rap.....................................................................42
511 Filter Fabric / Geotextile..............................................................................43
512 Gravel Filter.................................................................................................43
513 Stone Pitching..............................................................................................43
PART 6: ROADWORKS ..........................................................................................45
601 Sub-grade Preparation..................................................................................45
602 Granular Sub Base (GSB)............................................................................45
603 Water Based Macadam (WBM) Road Surfacing.........................................45
604 Road Maintenance.......................................................................................46
PART 7: CULVERTS & DRAINAGE.....................................................................47
701 Culvert Material ...........................................................................................47
702 Unloading and Laying out Pipes..................................................................47
703 Laying and J ointing Pipes............................................................................47
704 Installation...................................................................................................47
705 Subsurface Drainage Slotted Plastic Pipework.........................................48
PART 8: BUILDING FINISHING WORKS ..........................................................49
801 General.........................................................................................................49
802 Applicable Codes and Specifications..........................................................49
803 Waterproofing Work....................................................................................50
804 Damp Proof Course......................................................................................51
805 Cement Plaster.............................................................................................51
806 Cement Pointing...........................................................................................52
807 Mosaic Flooring...........................................................................................52
808 Woodwork in Doors, Windows, Partition, Louvres, Railing etc.................52
809 Glazing and Metal Doors and Windows......................................................54
810 Painting........................................................................................................55
811 Water Supply and Sanitary Works...............................................................55
812 Electrical Works..........................................................................................56
813 Roof sheets and vertical cladding................................................................57
814 Fencing.........................................................................................................57
PART 9: EARTH MAT.............................................................................................58
901 General Description.....................................................................................58
902 Earth Rods....................................................................................................58
PART 10: STEELWORK.........................................................................................59
1001 Hot Rolled Steel.......................................................................................59
1002 Surface Condition....................................................................................59
1003 Structural Fasteners..................................................................................59
1004 Welding Consumables.............................................................................60
1005 Corrosion Protection System...................................................................60
1006 General Workmanship.............................................................................60
1007 Welding Workmanship............................................................................61
1008 Bolting Workmanship..............................................................................62
1009 Erection of Steelwork..............................................................................62
1010 Protective Treatment - General................................................................62
1011 Protective Treatment - Particular.............................................................63
1012 Painting Handrails....................................................................................63
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Appendix A: Primary Survey Stations ...................................................................64
Appendix B: Table of Tolerances .............................................................................65
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PART 1: GENERAL AND PRELIMINARY

101 Description of the Area
1) The proposed Bhyunderganga hydropower project is located near Gobindghat
village, Dist. Chamoli, Uttarakhand. The project is located on the river
Bhyunderganga on Rishikesh- Badrinath road and is at a distance of about 275 km
from Rishikesh. The Powerhouse site is proposed to be located on the left bank of
river Bhyunderganga. Diversion weir of the scheme is located about 5.0km upstream
from confluence of Alaknanda with Bhyunderganga at Gobindghat.

2) The topography of the project area is typically undulating, Himalayan with deep
river valleys and high ridges. The left bank of the river has thickly wooded forest,
and has a mixed usage as forest land as well as human habitation. Part of the right
bank area mostly belongs to private owners and is used for farming and rest of the
area is either barren or sparsely covered with shrubs or a forestland.

102 General Description of the Project
1) There is a motorable access road from Rishikesh to Badrinath via Srinagar,
Rudraprayag, Chamoli, J oshimath, Lambagarh and to Gobindghat .River Bhyunder
originates in the glacier regions of upper Himalayas. At present the project site is
approachable through a pedestrian suspension bridge about 50 meters upstream of
confluence of river Bhyunderganga and Alakananda, near Gobindghat Gurudwara.
Presently, the diversion site is approachable only by a pathway which also leads to
the famous shrine of Hemkunt Sahib.

103 Scope of work
1) The Works to be constructed under the Contract comprise the following components:

1) Diversion Weir and Intake structure on the Bhyunderganga River
2) Intake Channel
3) Desilting Basin
4) Power Channel
5) Tunnel in rock 2.5m diameter D shaped with concrete lined approximately
2747m long.
6) Penstock Valve House and Penstock 775m Underground excavation and
186m excavation in overburden with rock outcrops for construction of
penstock saddle support, crossings and anchor blocks, Concrete framed valve
house with boulder masonry or brickwork infill walls. Casting in penstock
pipe and transition (penstock, valves and associated steelwork supplied and
installed by others).
7) Surface Power House, Transformer and Potyard Construction of surface
Power House and Tail Race and Surface Transformer and Potyard civil
works (Electromechanical supply and installation by others).

2) In addition, the Contractor shall construct such accommodation, plant yard
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workshops, office, housing and camps for himself, his staff and employees as he
considers appropriate.

3) The scope of work shall also include all general and preparatory works and shall
include work of any kind necessary for the due and satisfactory construction,
completion and maintenance of the Works in accordance with the Drawings and
these Specifications and further drawings and orders that may be issued by the
Engineer from time to time.

104 Drawings
1) The Works are shown on the Contract Drawings in Section 6 - Drawings

2) Two copies of the Construction Drawings, shall be furnished free of cost to the
Contractor by the Engineer progressively according to the work programme
submitted by the Contractor and accepted by the Engineer. Drawings for any
particular activity shall be issued to the Contractor at least 30 days in advance of the
scheduled date of the start of the activity.

3) Examination and /or approval by the Engineer of any drawings or other documents
submitted by the Contractor shall not relieve the Contractor of his responsibilities or
liabilities under the Contract.

105 Site Installations
1) The extent of the areas of land which are to be made available by the Employer for
the use of the Contractor are as shown on the Drawings.

2) The Contractor shall be responsible for obtaining, at his own cost, any additional
areas of land he may require for his own temporary facilities or for the disposal of
spoil. Such areas shall be deemed to be part of the site.

3) Prior to the commencement of any work at the Site and not later than 28 days after
the Date of Commencement, the Contractor shall submit to the Engineer for approval
detailed drawings showing the locations and details of his proposed installations,
facilities, plant, stockpiling and "waste" areas in order that such proposed
installations, facilities etc may be co-ordinated with the requirements of the Engineer
and other Contractors. The Contractor shall not commence any of the proposed
installations/facilities until the Engineer's approval has been obtained. Any
subsequent changes must be the subject of the Engineer's prior approval
.
106 Construction Power
1) The Contractor shall be responsible for providing construction power for his own use
including all his site installations, offices, accommodation areas, workshops and
laboratory.

2) The Contractor shall present drawings and plans of the installations to the Engineer
and obtain his approval prior to the commencement of the work.

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3) The Contractor shall be responsible for providing lighting and ventilation at all
working areas as required.

107 Water Supply
1) Water from the Bhyunderganga River is suitable for construction purposes.

2) The Contractor shall provide water for the Works, including potable water. This
provision shall include the construction of necessary reservoirs and piping to cover
all demand peaks at any time.

3) Prior to any installation, the Contractor shall submit to the Engineer for his approval
a detailed description of the planned water supply system. The quality of, and the
designed pressure in, the water supply system shall be subject to the prior approval
of the Engineer.

108 Camps and Services
1) The Contractor shall provide camps for boarding, lodging and medical care for his
own personnel and those of his subcontractors.

2) The standards and regulations presently in force in India in respect of the treatment
of personnel, sanitation and accident prevention, shall duly be taken into account by
the Contractor. In the construction and maintenance of the camps and services, the
Contractor shall ensure that the camp and the buildings which form part of it are kept
in good hygienic condition.

3) The Contractor (including its sub-contractor) shall provide alternative fuel
arrangement i.e. cooking gas/kerosene oil, electricity free of cost to all its canteen
/mess, labourers and staff working in the Project during the whole period of
construction activity to avoid felling of trees for use as firewood. In case alternative
fuel supply i.e. kerosene, gas, electricity is not available in the project area, the
Contractor shall approach the forest department/ forest corporation to open fuel
depot in the project area for meeting the demand for fuel wood.

4) The Contractor shall provide, maintain, and remove on completion adequate sanitary
facilities to the approval of the Engineer. The Contractor shall prevent pollution of
the water supply and shall not discharge sewage which has not been properly treated
into natural streams/water courses etc.

5) The Contractor shall make arrangements for treatment on the Site of casualties and
sick persons in first-aid units or in such other wards as may be necessary in
accordance with the appropriate Regulations. The Contractor shall provide and
maintain adequately equipped first aid stations at each of the main working areas.

6) The Contractor shall construct, equip and administer at his cost fire points in such
positions and of such size as will provide an adequate service for the protection
against fire of all buildings, stores and property on the Site.

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109 Communications
1) The Contractor shall provide telephone, and radio-telephone facilities as are
necessary to permit communication between the various Sites and the offices of the
Contractor.

110 Waste Disposal
1) For the disposal of all waste, the Contractor shall designate a suitably located tip
which shall be subject to the prior approval of the Engineer. The Contractor shall
transport all waste to the tip and then incinerate and immediately bury it.

111 Materials on and under the Site
1) Materials arising from clearance of the Site, soil stripping and excavations shall not
be removed from the Site except as required by the Contract.

112 Boundaries Cut Through
1) Fences, walls, etc. crossed by the Works and forming boundaries of plots outside the
area occupied by the Works shall not be cut through or destroyed for more than the
distance necessary to permit the erection of new fencing etc. and the Contractor shall
make the ends of the cut fences secure. Where fences or walls are damaged or
destroyed, the whole shall be restored and reinstated with like materials to the
satisfaction of the owners, occupiers and the Engineer.

113 Drains, Streams Watercourses etc
1) Drains, pipes, canals, channels, water courses or streams affected by the Contractor's
operations shall be reinstated to their original condition. The Contractor shall notify
the Engineer in writing 14 days in advance of his intention to start any part of the
Works affecting watercourses, canals, streams, drains, pipes, channels etc. The
Contractor shall be responsible for maintaining the watercourses within the Site in
effective working condition. The Contractor shall take all practicable measures
(which shall be subject to the prior approval of the Engineer) to prevent the
deposition of silt or other materials in such watercourses etc from his operations.

114 Compensation Water and Flow Past Structure
1) The Contractor shall ensure that during the construction of weir and other structures
across rivers and existing channels and up to the time of completion of the relevant
parts of the Works, the whole flow of the rivers or channels shall be allowed to pass
the Works except for such quantity as the Contractor may reasonably require for the
execution of the Works, unless otherwise directed by the Engineer.

2) After completion of those parts of the Works or Temporary Works which form a
barrier to river or channel, the Contractor will be required by the Engineer to pass
such quantities of water into the river or channel downstream of the structures as
may be directed. The Contractor shall not alter the rate of flow of such water except
with the approval of the Engineer.

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115 Keeping Works Free from Water
1) Except where underwater construction is required, the Contractor shall execute all
work in the dry, and shall construct any temporary diversion works, drains,
pumping systems, and other works that may be necessary for the purpose. The
Contractor shall be responsible for the design of these temporary diversion works.

116 Slips
1) The Contractor shall make good any damage or defect caused by slips to any
cuttings, excavations or embankments on the site and shall do all necessary work to
prevent or remedy the same.

117 Protection of Completed Work
1) The Contractor shall protect completed work from damage during subsequent
operations, from the weather or any other cause, including the naturally aggressive
nature of the environment in which the Works are to be constructed and make good
any damage so arising.

118 Traffic
1) Prior to commencing any work in or which may affect the use of any highway, the
Contractor shall obtain the written approval of his proposed methods of working and
traffic management plan from the Engineer and the Highway and the Police
Authorities. Throughout the duration of the Contract, the Contractor shall co-
operate with the Highway and Police Authorities concerning works in, or access to,
the highway. Any requirements of such Authorities shall be notified in writing by
the Contractor to the Engineer.

2) Where required, the Contractor shall provide and maintain all necessary temporary
diversions which shall be operational before interference with existing
carriageways, footways or public right of way. The Contractor shall remove all
temporary diversions and reinstate the original carriageway as soon as they are no
longer required

119 Damage to Access Roads
1) The Contractor shall ensure that damage to any public or private roads, footpaths
and tracks used by any vehicles or plant proceeding to or from the Site is kept to a
minimum and he shall be responsible for the cost of all repairs necessary to restore
such roads, tracks or footpaths to the satisfaction of the Engineer and the owner
and/or controlling authorities.

120 Setting Out
1) The Contractor shall set out the Works according to the lines and levels shown on
the Drawings. . The coordinates and levels of the primary survey stations are given
in Appendix A to this Specification.

2) The Contractor is to protect all survey stations and benchmarks from disturbance or
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damage. Any stations or benchmarks that must be removed for construction of the
Works shall first be transferred to replacement points

121 Surface and River Bed Levels
1) Before commencing work on any section of the Works, the Contractor shall survey
and level the original ground surface and river-bed and shall prepare and submit to
the Engineer plans and sections for agreement.

2) At the commencement of the works the Contractor shall carry out a survey to check
the levels and co-ordinates of the primary benchmarks relative to each other.

122 Testing Laboratory
1) The Contractor will establish and maintain throughout the period of construction a
site laboratory. The laboratory shall be equipped to undertake all the tests on soil
and concrete required by the Specification. For other tests, the Contractor may utilise
facilities elsewhere in an approved laboratory which must be open for inspection by
the Engineer.

2) The Contractor shall, at his own cost, provide moulds, thermometer, slump testing
equipment, labour, etc for the sampling of fresh concrete and the preparation and
storage of test samples. The Contractor shall deliver the samples together with the
sampling records to the laboratory 24 hours before the due date for testing.

123 Safety of Personnel
1) The Contractor shall be responsible for the safety of all personnel on the Site and
shall provide his employees and his sub-contractors employees working on the Site
and all visitors to the Site with safety equipment appropriate to the tasks upon which
they are engaged, such as helmets, safety footwear, gloves, lamps, waterproof
clothing, dust masks and safety belts. The use of such safety equipment shall be
compulsory as deemed necessary by the Engineer.

2) The Contractor shall provide all lighting and ventilation necessary to ensure a safe
and healthy environment for personnel in cases when personnel are working at
night, or in enclosed spaces.

124 Protection of the Environment
1) The Contractor shall take all precautions for safeguarding the environment during
the course of the construction of the works. He shall abide by the laws, rules and
regulations in force governing pollution and environmental protection that are
applicable in the area where the works are situated.

2) The Contractor shall obtain materials from quarries or borrow pits only after the
consent of the Forest Department or other concerned authorities is obtained. The
quarry operations shall be undertaken within the rules and regulations in force.

3) The Contractor shall ensure that appropriate procedures are complied with for
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control of any materials used in the Works which are hazardous to the health of
persons, animals or vegetation. The procedures shall include, but not be limited to:

Spill containment & clear up
Segregation and Storage
Selection of low-impact materials where practicable.
Provision of protective clothing & equipment for workers handling hazardous
materials.

4) The Contractor must take all reasonable steps to minimize nuisance from dust, noise,
or other cause during the Construction of the works. Roads in frequent use with heavy
traffic shall be watered daily or more frequently if necessary to control dust. The
Contractor's attention is drawn to the damage to crops which may be caused by dust.
The Contractor is to take such measures as may be necessary to prevent such damage by
dust arising from the execution of the Contract.

5) All public roads used by the Contractor or any of his sub-contractors or suppliers of
materials or plant, shall be kept clean and clear of all dust/mud or other extraneous
materials dropped by the vehicles or arising from the Works.

6) Clearance shall be effected immediately by manual sweeping and removal of debris,
or, of so directed by the Engineer, by mechanical sweeping and clearing equipment,
and all dust, mud and other debris shall be removed entirely from the road surface.
Additionally, if so directed by the Engineer, the road surface shall be hosed or
watered using suitable equipment.

7) The Contractor shall observe all agreements entered into by the Employer with any
person or persons relating to occupation of the properties by the Employer and to the
execution of the Works thereon. The Contractor will be given on request copies of any
agreement or part thereof relating to such matters.

8) Compliance with the foregoing does not relieve the Contractor of any responsibility
for complying with the requirements of any Highway Authority in respect of the
roads used by him.

125 Interference with Existing Works
1) The Contractor shall not interfere in any way with any existing works whether the
property of the Employer or of a third party and whether the position of such works is
indicated to the Contractor by the Engineer or not, except where such interference is
specifically described as part of the Works either in the Contract or in the Engineer's
instructions.

126 Photographs
1) Progress colour photographs shall be taken at such times and of such portions of the
Works as the Engineer may require. The Contractor shall supply five unmounted copies
of each photograph of an overall size of 250 mm x 200 mm. Each copy shall have its
title, date and serial number printed in black on a 25 mm wide white margin along the
bottom edge. The negatives or digital files of the photographs shall be the property of
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the Employer and no prints from these may be supplied to any person or persons except
with the written authority of the Engineer.
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PART 2: WORKMANSHIP AND MATERIALS

201 Workmanship and Materials in General
1) All workmanship shall be of the best quality appropriate to each category of work.
Except where otherwise stated or approved by the Engineer, all materials used in the
Works shall be of the best quality of their respective kinds as specified or described in
the Specification, Drawings and Bills of Quantities and shall comply wherever possible
with the current issue of the appropriate standard published by the Indian Standards
Institution, or other equivalent national standard proposed by the Contractor and
approved by the Engineer.

2) Reference to Indian Standard Specifications or Codes of Practice in the Specification or
Bills of Quantities does not imply any bias in favour of equipment, fittings, finishing etc.
but is intended to indicate the standard acceptable to the Engineer. The Contractor may
relate his offer to other National Standards or Codes of Practice but shall explain the
system used and provide the Engineer with all the necessary information and
comparisons in English showing that his proposed standards are equivalent to the
specified Indian Standards or Codes of Practice. Six copies of such alternative standards
in English are to be supplied by the Contractor to the Engineer when required.

3) In all cases where the name of a particular type or make of plant or item is referred to
on the Drawings or elsewhere in this Specification, this is intended to indicate only the
acceptable standard.

4) The Contractor may offer alternative plant or materials to that specified and in all such
cases the Contractor's offer shall be at least of equal quality. When alternatives are
offered the Contractor shall submit to the Engineer for approval, a statement detailing
the alternatives, and shall include full technical descriptions, drawings and
specifications, and shall provide such full information as is required to enable the
Contractor to demonstrate to the Engineer that the alternative is equivalent to the item
specified. Any further information that the Engineer may require shall be produced by
the Contractor when called for.

5) The Contractor shall use locally produced materials in preference to imported materials
provided that they comply with the Specification and are available in sufficient and
timely quantities.

202 Inspection of Materials
1) The Engineer may employ an inspecting Engineer to inspect materials for the Works at
the suppliers' premises or elsewhere, and in this capacity the inspecting Engineer will be
regarded as the Engineer's Representative with the limitation imposed by Clause 3 of
the Conditions of Contract.

2) Whenever work is to be done at a time when work is not usually in progress, or
whenever the regular period for carrying on such work is changed, the Engineer shall be
given notice in sufficient time to arrange for proper inspection.

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3) If required by the Engineer, the Contractor shall supply copies of orders placed by him
for materials to be incorporated in the Permanent Works so that inspection of the
relevant materials can be arranged in sufficient time if considered necessary by the
Engineer.

203 Tolerances
1) All works shall be constructed to the tolerances shown in the Appendix B of this
Specification.

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PART 3: EXCAVATION AND EARTHWORKS

301 Definition of Earthworks Material
1) The following definitions of earthworks materials shall apply to this and other
Clauses of the Specifications in which reference is made to the defined materials:

a) top soil shall mean the top layer of soil that can support vegetation;
b) suitable material shall comprise all that material which arises from excavations
within the Sites and which is approved by the Engineer as acceptable for use in
the Works;
c) unsuitable material shall mean other than suitable material and shall comprise:
i) material from swamps, marshes and bogs;
ii) peat, logs, stumps and perishable materials;
iii) material susceptible to spontaneous combustion;
iv) clay of liquid limit exceeding 90 and/or plasticity index exceeding 65;
d) Common material shall mean all material other than that defined as rock
hereunder;
e) Rock shall mean those geological strata or deposits as described in the
Contract, and any material requiring the use of blasting or approved pneumatic
tools for its removal, but excluding individual masses less than 1.0 cu.m.

302 Site Clearance
1) The Contractor shall clear the Site as required by demolishing and removing
vegetation, debris, buildings etc and the like to approved locations as directed by the
Engineer. No access shall be permitted, or damage caused outside the area of the
Site.

2) As far as possible, trees greater then 150mm diameter shall be preserved, and no tree
greater than 150mm diameter shall be felled without prior approval of the Engineer.

3) Trunks, branches and stumps of trees shall be cleaned of limbs and roots and stacked.
Also boulders, stones and other materials suitable for re-use in the Works shall be
neatly stacked as directed by the Engineer.

4) Stumps and major roots shall be grubbed up and all combustible material arising
shall be gathered into windrows and burnt. The Contractor shall take precautions to
prevent the spread of fire to adjacent land.

303 Excavation General
1) Excavation shall be carried out to the lines, levels and profiles shown on the
Drawings or to such other lines, levels and profiles as the Engineer may direct or
approve in writing. The work shall be carried out by the Contractor in such a way as
to avoid disturbance to the surrounding ground. Particular care shall be taken to
maintain stability when excavating in close proximity to existing works or natural
slopes.

2) The work shall be carried out in a careful manner to ensure that the exposed surfaces
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are as sound as the nature of the material permits and that no point shall protrude
inside the lines shown on the Drawings except as otherwise specified or agreed by
the Engineer. In soft excavation which is to remain open permanently, exposed faces
shall be formed accurately to the required slopes and profiles. Excavations in rock
which remain open permanently shall be so trimmed that no point protrudes within
the required profile.

3) The Contractor shall dispose of all material arising from excavations. If it is suitable
and required for the Permanent Works it shall be placed directly in such Works or set
aside for use as and when required in suitable approved stockpiles, otherwise it shall
be disposed of in designated spoil areas.

4) The Contractor shall be responsible for keeping all excavations free from water from
whatever cause arising, and shall provide such pumping capacity and other measures
as may be necessary for this purpose.

5) The Contractor shall properly support the sides of temporary excavations and shall
be responsible for their safety.

6) Slope support and slope protection to cut slopes that are to be permanently exposed
shall be installed as directed or approved by the Engineer as excavation proceeds.

7) The Contractor shall notify the Engineer without delay of any permeable strata,
fissures or unusual ground encountered during excavation.

8) Where blasting is required the blasting to final profiles shall be carried out using pre-
splitting techniques.

304 Excavation Beyond True Lines and Levels
1) If from any cause whatsoever excavations are carried out beyond their true line and
level, the Contractor shall make good to the required line and level with the
appropriate grade of filling to be contained in the true excavation, or with concrete or
other approved material in such a manner as the Engineer may direct.

305 Approval of Excavations
1) When excavations have been taken out accurately to the profiles or dimensions
required for the work, the Contractor shall inform the Engineer so that he may carry
out an inspection.

2) If, after inspection, the Engineer requires additional excavation to be carried out, the
Contractor shall do so to such new profiles or dimensions as the Engineer may direct.

3) The Contractor shall obtain approval of excavations prior to placing pavement
layers, fill or concrete.

4) The Contractor shall maintain open excavations in an approved condition, and shall
rectify the effects of deterioration due to weather.

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306 Excavations for Structures
1) Open excavation to form foundations for a structure shall be carried out to the lines
necessary to permit the proper construction of the structure or as directed by the
Engineer.

2) If required, before any concrete for a foundation is placed, the bottom of the
excavation shall be re-compacted to achieve at least 95% of the maximum dry
density determined in accordance with (IS 2720 ( part 18).

3) The Contractor shall carry out the excavation in a safe manner such that the sides of
the excavation are adequately supported and stable.

4) The excavation shall be excavated and supported by methods which will not
endanger the stability of the surrounding slopes or works.

307 Disposal of Surplus Excavated Materials
1) Available spoil areas are to be used for disposal of surplus excavated materials.. If
additional areas are required, the Contractor shall be responsible for obtaining the
necessary approvals from the owners and the local authorities.

2) The Contractor shall organise and carry out the placing of spoil in such a way that
the natural drainage to existing waterways is not impeded. Contamination of existing
waterways shall be avoided and suitable drainage shall be provided, if necessary.

3) Spoil material shall be placed in the spoil areas to form stable, free-draining banks.

4) The Contractor shall submit to the Engineer for approval all necessary data showing
mucking areas, working methods and drainage and stabilizing provisions before
placing of spoil in any areas.

Excavation by Blasting

308 Procurement, Storage and Handling of Explosives
1) The Contractor will obtain the necessary licences for purchase and storage of
explosives and detonators and shall be responsible for the acquisition, transport,
custody and storage of explosives.

2) The Contractor shall submit to the Engineer his proposals for the use of explosives in
connection with the Works and the programme for their procurement and transport to
site. .

3) The Contractor shall be responsible for the quality and satisfactory performance of
explosives.

4) Only such quantities of explosives and sundries as are required for the working day
shall be released from the magazine and the Contractor shall not store additional
explosives and ancillary components elsewhere. Any unused materials shall be
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returned to the magazine and recorded accordingly.

309 Magazines
1) The Contractor will establish, operate and maintain the magazine for the storage of
his explosives.

310 Blasting
1) When blasting is permitted, it shall be carried out only after the Contractor has
provided adequate visible and audible warning systems, safety men and all such
measures as are necessary to prevent injury to persons and property and protect the
Works from damage during blasting, and shall be carried out with the greatest care,
strictly according to the arrangements approved by the appropriate Authority.

2) The Contractor may choose his own methods for drilling and blasting rock subject to
the approval of the Engineer.

3) Only workmen who are in possession of a blasting certificate valid for the type of
blasting to be carried out shall be permitted to be in charge of blasting operations.

4) All charging of drill holes, type of detonation, etc, shall be in accordance with
modern methods and recognised good practice.

5) If the prevalence of electrical storms makes it unsafe to use electrical firing in
blasting operations the Contractor shall use an alternative type of firing.

6) The Contractor shall take all necessary precautions with respect to the use of
electrical detonators in the vicinity of static and mobile radio transmitters including
normal radio and television broadcasting stations and radar units associated with
aircraft movements.

7) A register of all explosives used, firing amounts and location shall be maintained by
the Contractor and be available at all times to the Engineer for checking.

8) The use of explosives will not normally be permitted within 15m of any structure or
part of a structure. Where permission to use explosives is withheld, the Contractor
will not be entitled to any additional payment in respect of alternative methods
necessary for carrying out the work.

9) When blasting within 15m of a structure(s) is permitted it shall be carried out by
small charges and /or milli-second delay fuses in such a manner as to reduce the
level of vibration occurring which the Engineer may require to measure. Care shall
be taken that blasting does not open fissures in the rock or overburden under or
adjacent to parts of the Works.

10) Where blasting is proposed adjacent to a building or other structures existing or
under construction, the Contractor shall satisfy the Engineer that safe values of
vibrational amplitude and peak particle velocity will not be exceeded.

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11) Where required by the Engineer, the Contractor shall employ heavy mesh blasting
nets or other approved means to limit the scatter of debris and flying particles.

12) Blasting shall be restricted to such periods as the Engineer may prescribe.

311 Underground Excavations
1) The method and procedures for excavation in tunnel by tunnelling methods covered
under these specifications shall conform to latest revisions of the following Indian
Standards specifications or any International recognised standards.

IS 4756 Safety code for tunnelling work

IS 5878 Code of Practice for construction of tunnels conveying water:
(Part - I Precision Survey and Setting Out).

IS-5878 Code of Practice for Construction of Tunnel conveying water:
(Part 2 - Underground Excavation in Rock) Section I Drilling &
Blasting

IS 5878 Code of Practice for construction of tunnels conveying water.
(Part 2 - Underground excavation in rock) Section 2- Ventilating,
lighting, mucking and dewatering.

IS 5878 Code of Practice for construction of tunnels conveying water.
(Part 2 - Underground excavation in rock) Section 3- Tunnelling
method for steeply inclined tunnels, shafts and underground
power houses

(Part -3 Underground excavation in soft strata)

(Part - 4 Tunnel Supports)

IS 7209 General requirements for blast hole drilling rigs

2) The Clearance Line is shown on the drawings. It defines the minimum dimensions of
the clear opening which is obtained after excavation and installation of any required
support system. The ends of rockbolts may be permitted to protrude inside the
Clearance Line where concrete linings are provided. Otherwise, no projection will be
permitted within the Clearance Line without the written consent of the Engineer.

3) The quantity of excavation to be measured and paid for at the unit rate will be the
quantity included within the Clearance Line plus the thickness of any permanent
support system.

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4) The drilling pattern shall be such as to minimize over excavation, and also to cause
least disturbance to or shattering of surrounding rock mass. The drilling pattern shall
be adjusted to suit the geological conditions of rock strata.

5) Blasting shall be controlled and conducted in such a manner, not to endanger any
adjacent property or structures and as not to affect or hinder the progress of
adjoining works. The type of explosives to be used and the quantity of charge shall
be adjusted to suit the geological conditions of rock strata. The rules in force for
handling, transporting and storing explosives (as laid down in the Indian Explosives
Act or any other Act having the force of law) shall be strictly adhered to.

6) After blasting, the whole surface of excavation shall be carefully examined and all
loose rock and projections etc., removed in such a way that there shall not be any
danger of any piece of rock falling down subsequently; due to any cause whatsoever.
After the section is excavated, it shall be carefully trimmed to remove any
projections that may be found within the profile defined by the Clearance Line.
Geological mapping of the faces shall be prepared by the Contractor for every round
of blasting operation.

7) The whole excavated reach of the Tunnel shall be properly ventilated, either by
artificial means or by natural draft. The Contractor shall provide at his own cost,
ventilation fans of adequate capacity and ducts of suitable size to force in air into the
tunnel during working hours. The fans shall be of the reversible type so that the
gases released after blasting shall be sucked out of the tunnel in the shortest possible
time.

8) The workmen shall not be allowed to enter and start work unless and until all the
objectionable gases are removed to the extent considered safe and satisfactory.

9) The capacity of the ventilation plant shall be adequate to allow the removal of blast
gases within as short a time as possible to allow starting of mucking operations
commensurate with the schedule of progress of work.

10) The entire length of Tunnel excavated shall be adequately illuminated by electric
lights in accordance with IS: 5878-Part-2-Section-2. The working face and the
working area shall be brightly illuminated either by adequate floodlights or by other
means. The facility of lights in the tunnel shall also be made available for the use of
inspecting officers and any visitors, if required, during non-working hours, at no
extra cost. In addition every workman, working inside the tunnel shall have a battery
operated torch either fixed to the helmet or hand held.

312 Rockbolting
1) This specification covers supply and installation of rock bolts and associated works
conforming to I.S.1570 (PART-1):1978 or latest edition.

2) Rock bolts shall be 25mm diameter mild steel deformed bar threaded at one end as
shown in the drawings. The length of the rock bolts and pattern in which the rock
bolts shall be installed shall be as shown in the drawings or as otherwise prescribed
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by the Engineer. Rock bolts shall have a tensile strength of 410 MPa and minimum
yield strength of 250 MPa and minimum elongation of 23 percent and they shall be
threaded. All nuts for the rock bolts shall be heavy duty hexagonal, double chamfered
confirming to black hexagon bolts, nuts and lock nuts and black hexagon screw IS
1363-1967 or the subsequent revision.

3) Bearing plates shall be flat steel square plates 150 mm X 150 mm X 10 mm and
conforming to Structural steel (standard quality) IS 2062:1992 or its subsequent
revision. For the purpose of grouting the flat steel bearing plates shall have separate
holes for the grout tubes.

4) Cement for grout shall be ordinary Portland cement confirming to Ordinary and low
heat Portland cement IS8112-1989 or its subsequent revision. The average fineness
value of the cement shall not be less than 4,500 square centimetres per gram.

5) Rock bolts shall be installed as soon as possible after each blasting. The Contractor
shall be well prepared to perform such work and the equipment used for that work
shall allow the Contractor to insert the rock bolts up to the face with the necessary
speed and accuracy and if possible, without removing the recently excavated material
to install them. Any rock bolts that are affected by subsequent blasting shall be
replaced by new rock bolts installed nearby.

6) The diameter and depths of drilled holes and the method of cleaning the same for
rock bolts shall be such as will promote effective anchoring and grouting of the rock
bolts and ensure that the inner end of the rock bolts does not protrude beyond the
Clearance Line by more than 70mm.

7) Once the drilling is completed, the bore holes shall be cleaned by means of water and
air under pressure in order to remove small particles of rock or dust remaining in it,
so that the hole is perfectly cleaned before the insertion of the rock bolt.

8) Holes for rock bolts shall generally be drilled normal to the Clearance Line unless
otherwise shown on the drawings or ordered by the Engineer. The actual position of
the rock bolts shall be chosen such that the shank is not bent or stressed due to
excessive inclination between the rock face and the shank. The direction of bolts
shall be modified to suit the rock jointing pattern as observed at site on excavation as
per the instructions of the Engineer and rock bolt spacing shall be adjusted locally to
suit the joint spacing and pattern.

9) In general, cement capsule anchors shall be used. Where separate grouting is
approved by the Engineer, bolts shall have the grouting tube attached. The Contractor
shall supply plastic piping in rolls which shall be cut and attached to the bolts with
adhesive tape or another approved method. .

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10) Grout for rockbolting shall be made up of portland cement and water with a water-
cement ratio of approximately 0.4 by weight to which aluminium powder shall be
added if required in a proportion indicated by the engineer.

11) Unless otherwise directed or approved commercial grade extra fine aluminium
powder in an amount not exceeding 0.005 % by mass of cement shall be blended
with the cement to ensure the necessary expansion of grout.

12) Grouting shall be applied at a moderated pressure (2kg/cm
2
) unless indicated
otherwise until the voids between the bolts and the rock are completely filled. As
soon as the grouting is finished, the grouting holes shall be plugged to avoid leakage
of grout.

313 Steel Rib Supports
1) The Contractor shall maintain a minimum stock of 10 (ten) complete ribs and their
associated fittings at Site to allow immediate installation in cases where unstable
rock conditions are encountered.

2) The method and procedures for providing and fixing steel ribs covered under these
specifications shall conform to latest revisions of the following Indian Standard
Specifications or any International recognised standards.
IS 800 Code of Practice for general construction in steel.

IS 808 Dimensions for hot rolled steel beams, column, and channel and
angle section.

IS 2062 Specification for Weld able Structural Steel.

IS 4756 Safety code for tunnelling work.

IS 4880 Code of practice for design of tunnels conveying water-
(Part-VI) Tunnel Supports.

IS 5878 Code of Practice for construction of tunnels conveying water
(Part IV) Tunnel Supports.
3) Ribs shall be placed such that the inner face is not inside the Clearance Line. Any
extra excavation necessary for placing these supports shall be paid for at the same
rate as the main excavation. The exact type, design and extent of permanent supports,
required in the tunnel shall be proposed by the Contractor based on the condition of
rock and the likely rock loads and subject to approval by the Engineer.. The rib
support system shall include anchoring if required, lagging, supporting, wedging, etc.
to ensure proper supporting of excavated surface.

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314 Shotcreting
1) All methods and procedures for providing and installing shotcrete and wire mesh
reinforcement shall conform to Indian Standard specifications and other publications
listed below unless otherwise specified.

Indian Standards

IS 8112 - 1989 Specification for 43 grade ordinary Portland cement. (First Revision).

IS1566-1982 Specification for Hand Drawn Steel wire fabric for concrete
reinforcement.

IS 1570 (Part-I): 1978 Steel specified by Tensile and/or yield properties.

IS 9012- 1978 Recommended practice for shotcreting/ latest publication, if any.

2) Water to be used for shotcreting shall confirm to requirement given in IS 456: 1978.

3) Sand for shotcrete shall comply with the requirements given in IS : 383:1970 and
graded evenly from fine to coarse as per Zone II and Zone III grading of IS
383:1970.

4) Coarse aggregates shall comply with the requirements of IS: 383-1970. It shall,
generally confirm to one of the grading given below. The maximum size of coarse
aggregate to be used shall be restricted to 12.5 mm.

Grading of Coarse Aggregates

Percentage by Mass Passing for Aggregate
of Nominal Maximum Size
IS Sieve
Designation (mm)
10 mm 12.5 mm
25 - -
20 - 100
12.5 100 90-100
10 85-100 40-70
4.75 10-30 0-15
2.36 0-10 0-5
1.18 0-5 -

All oversize pieces shall be rejected by screening, since they are likely to cause
blockages in the equipment.

5) Admixtures shall be in accordance with the requirements of IS 9103 : 1979 and as
approved by the Engineer. The proportion of admixture (as a percentage of cement)
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shall be approved by the Engineer. Admixtures containing chlorides will not be
permitted.

6) Batching and Mixing

The ingredients of the mix for shotcrete and strength criteria shall be as follows

i) Aggregates shall be well graded to achieve good pumpability through the
spraying nozzle and the maximum size of coarse aggregate shall be limited to
12.5 mm, generally the mix design shall constitute one part of cement, one part
of sand (fineness modules of 2.4 and above) and two parts of well graded
aggregate however the mix proportions may vary as required by the Engineer.

ii) Shotcrete mix design shall ensure 28 day characteristic compressive strength of
over 25 MPa (25 N/mm
2
).

iii) Water cement ratio for shotcrete in place shall be in the range of 0.35 to 0.40 by
mass. The water content of the mix shall be limited to prevent sloughing.

iv) The rate of gain of strength of shotcrete shall conform to the following
compressive strength requirements.

Age Compressive Strength
of Shotcrete (MPa)
1 hour 0.2
2 hours 0.50 0.75
8 hours 4.00 4.50
12 hours 5.00
24 hours 10.00 11.00
72 hours 12.00 12.50
7 days 17.00 17.50
28 days >25

v) The cement to be used for shotcrete shall be weighed first before mixing with the
coarse and fine aggregate. Every batch of concrete for shotcrete shall be
prepared for 50 Kgs of cement or whole multiple thereof. The Contractor shall
use weighing equipment to the accuracy of 0.1 kg to measure weight of cement
added in each batch.

vi) Mixed dry aggregate and cement, which do not contain a set accelerating
admixture and which are not placed with in 30 minutes after mixing, shall be
discarded. Mixed dry ingredients, which contain a set accelerating admixture
shall be discarded if they are not placed within the time as determined by the
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Engineer depending on the moisture content of the mix and the amount of
admixture.

vii) Mix proportions shall be adjusted as necessary to obtain the required strength of
shotcrete and to keep rebound to the minimum.

7) Air and water shall be provided in such volume and under such pressure as may be
necessary for the best operating conditions. In applying shotcrete, the discharge
nozzle shall be held in such a way that the stream of material shall impinge as nearly
as possible at the optimum angle to the surface for minimum rebound, and the
velocity of the discharge from the nozzle. The distance of the nozzle from the surface
and the amount of water used in the mix shall be regulated so as to produce a coating
with a minimum rebound of the material, with no sagging. Obstructions, such as
service lines, shall be removed to enable direct application of shotcrete to the
surfaces. Rebound material shall not be used again, but shall be removed from the
work and disposed of by the Contractor. During application of shotcrete the
Contractor shall provide adequate ventilation facilities and take such other measures
as are necessary for safety of his workmen including provision of face protection for
nozzle men.

8) The locations where shotcrete is to be used shall be as shown on the drawings or as
directed by the Engineer. Where shotcrete is to be applied, the Contractor shall clean
and prepare the surface by removing loose or shattered rock, rock debris, clay or
other loose materials. The surface shall be washed, where required, with a strong air
and water jet or by other means approved by the Engineer.

9) Nozzle men shall have had sufficient previous experience in the application of coarse
aggregate shotcrete or shall work under the immediate supervision of a foreman or
instructor having such experience.

10) Alkali hydroxides and other chemicals contained in shotcrete admixtures are
moderately toxic and can cause skin and respiratory irritation unless adequate safety
measures are taken. In applying shotcrete containing toxic admixtures, the nozzle
men and helpers shall wear appropriate hoods to protect them against toxic or
objectionable material.

11) Gloves and necessary protective clothing shall be worn to protect against dermatitis.

315 Fill
1) Material for filling shall be obtained from approved sources or selected from
excavations containing no vegetable or perishable matter, graded to ensure a dense
stable and homogeneous fill when compacted.

2) Fill shall be placed in layers not exceeding 250mm thickness, each layer being
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scarified and thoroughly compacted by four passes of a vibratory steel drum roller
with a static drum weight of at least 7 tonnes. Unless otherwise specified,
compaction shall be not less than 90% of the laboratory maximum dry density as
determined in accordance with IS 2720 (part 18).

3) In places where space restriction prevents the use of compaction equipment
mentioned above, the compaction shall be carried out by means of approved small
size equipment. If necessary the thickness of layers shall be adjusted in order to
achieve the same degree of compaction as with normal equipment

4) The fill material prior to compaction shall be brought to a moisture content within
the range 2% of optimum. If watering is required it shall be carried out in such a
manner as to ensure the even distribution of water throughout the layer to be
compacted and the compaction operations will follow whilst the moisture content
remains within the specified range.

5) The Contractor shall take all necessary measures to prevent any damage or defects to
the Works which may be caused by settlements, slips or falls of embankments and
shall make good such damage or defects as may occur, to the satisfaction of the
Engineer.

6) Any instability of any adjacent excavation or slopes resulting from the embankment
not being formed to the lines, levels and profile shown in the drawings or as ordered
by the Engineer will be the responsibility of the Contractor.

7) All fill materials shall be handled in such a way that they are un-segregated once
they are in their final positions.

316 Backfill to Structures
1) Backfill shall generally be selected material from excavation, approved by the
Engineer.

2) Material shall be moisture conditioned and then compacted to provide not less than
95% of the laboratory maximum dry density as determined in accordance with IS
2720 (part 18).

3) The Contractors proposed method of working for compaction around structures
shall be subject to prior approval by the Engineer.
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PART 4: CONCRETE

401 Cement
1) Cement shall generally be Pozzolona Portland Cement (or Ordinary Portland Cement
as an alternative).
.
2) Cement procured by the Contractor in sealed bags, marked with manufacturers
name, shall be delivered to the Contractors storage facility and shall be protected
from the weather by approved coverings. Damp bags shall be rejected.

3) The Contractor shall ensure that the arrangements for the storage of the cement on
the Site as hereinafter specified are sufficient for the segregation and identification of
each consignment.

4) No cement shall be used in the Works until it has been passed as satisfactory by the
Engineer.

5) Where designated by the Engineer, fly ash (Pulverised fuel ash) conforming to
Grade-1 of IS:3812 may be used as a part replacement of ordinary portland cement
provided uniform blending with cement is ensured and that the design mix gives
required strength to concrete within the required period.

402 Storage of Cement
1) While being unloaded and during transit to the concrete mixers, whether conveyed in
vehicles or by mechanical means, the cement must be protected from the weather by
effective coverings.

2) Cement in bags shall be stored in weatherproof and well-ventilated sheds. On
delivery at the Site the cement is at once to be placed in these sheds and shall be used
in the order in which it has been delivered.

3) The Contractor shall be responsible for damage to cement bags while unloading and
transporting around the Site and in no case shall cement from a damaged bag or
hardened lumps be used in any of the Permanent Work.

403 Fine Aggregate
1) Fine aggregate for concrete shall be clean sand complying with (IS 2386 part 1 to
part 8). The sand shall be from approved sources and sand which, in the opinion of
the Engineer, is not clean shall be washed before use.

2) The fine aggregate shall be free from salt, alkali, calcium sulphate or vegetable
matter. It shall not contain more than 0.5 percent by weight of clay lumps.
3) Fine aggregate shall be capable of passing through a 5mm test sieve and shall be
graded so that when mixed with the coarse aggregate and cement a concrete of
maximum density is produced. It shall not contain appreciable amounts of flaky or
elongated particles.
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4) The grading of fine aggregate shall comply with one of the Coarse, Medium or Fine
classifications as given below. In the event that the grading of the sand changes to a
different classification from that used when concrete mixes were designed and
approved, new trial mixes shall be carried out.

Sieve size Percentage by mass passing IS sieve
Overall Additional limits for grading
Limits Coarse Medium Fine
10.00 mm 100
5.00 mm 89 to 100
2.36 mm 60 to 80 60 to 100 65 to 100 80 to 100
1.18 mm 30 to 100 30 to 90 45 to 100 70 to 100
600 m 15 to 100 15 to 54 25 to 80 55 to 100
300 m 5 to 70 5 to 40 5 to 48 5 to 70
150 m 0 to 15

5) Crushed sand may be added to natural sand in approved proportions in order to
achieve the required grading. Crushed sand alone may not be used without approval.
The amount of material passing a 75 micron sieve shall not exceed 3% by weight.

6) When subject to five cycles of the soundness test specified in IS 1607 : 1977, fine
aggregate shall show a loss not exceeding 10% when magnesium sulphate solution is
used.

7) Sand for mortar shall comply with IS 2386 Part 1 to Part 5.

404 Coarse Aggregate
1) Coarse aggregate for concrete and other purposes shall comply with (IS 2386 part 1
to part 8). It may be either natural gravel or stone broken to the desired size and shall
be obtained from quarries, pits or other sources approved by the Engineer.

2) Gravel or ballast shall be free from clay, earth, loam or other organic or similar
material and shall be approved by the Engineer. Any sand in the bulk gravel shall,
unless otherwise directed, be removed by screening and if required kept apart. The
sand thus obtained may be used in concrete provided that in the opinion of the
Engineer, it complies with the specifications for sand in the preceding Clause. Gravel
or ballast which, in the opinion of the Engineer, is not clean shall be thoroughly
washed before use.

3) Broken stone shall be of hard durable rock. Notwithstanding approval by the
Engineer of its source, the stone as delivered to the Works will be subject to rejection
if for any reason the Engineer considers it unsatisfactory. It must be perfectly clean
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and no soft, clayey, shaley or decomposed stone will be approved. The stone must be
broken in a stone crusher of approved type to the sizes hereinafter specified and any
dust or fine material below 5 mm in size made in the stone crusher is to be removed
by screening if so required and, if the Engineer so orders, the stone shall be
thoroughly washed by an approved method.

4) When so required and before construction commences, laboratory tests shall be made
of the aggregates to be used on the Works will be undertaken by the Employer to
establish their suitability for concrete. In addition to these laboratory tests the
Engineer may require check tests of actual deliveries to be made at the Site from
time to time.

5) The grading of coarse aggregate shall comply with the appropriate classification as
given below.

6) Coarse aggregate shall be graded so that when mixed with the approved fine
aggregate and cement, a workable concrete of maximum density is produced.
7) The amount of material passing a 75 micron test sieve shall not exceed 1% by
weight.
8) When subjected to five cycles of the soundness test specified in IS 1607, coarse
aggregate shall not show a loss exceeding 10% when magnesium sulphate solution is
used.
9) The flakiness and elongation indices of the predominant size fractions in each single
sized coarse aggregate, determined in accordance with BS 812, shall not exceed 20%
and 35% by weight respectively.

Coarse Aggregate Grading
Sieve Percentage by mass passing BS sieves for nominal sizes
size Graded aggregate Single-sized aggregate
40mm 20mm 14mm
mm - 5mm -5mm -5mm 40mm 20mm 14mm 10mm 5mm
50.0 100 - - 100 - - - -
37.5 90-100 100 - 85-100 - - - -
20.0 35-70 90-100 - 0-25 85-100 100 - -
14.0 25-55 40-80 90-100 - 0-70 85-100 100 -
10.0 10-40 30-60 50-85 0-5 0-25 0-50 85-100 100
5.0 0-5 0-10 0-10 - 0-5 0-10 0-25 45-100
2.36 - - - - - - 0-5 0-30
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405 Testing of Aggregates
1) Aggregates will be tested in accordance with the following schedule and shall
comply with the stated limits

Acceptable Limits Test Frequency
Coarse
aggregate
Fine aggregate
Grading
weekly 4% from the design mix target
Magnesium sulphate
soundness (ASTM C88)
monthly 10% 10%
Water absorption weekly 2% 2%
Clay, silt and dust
content
weekly 1% 3%
Organic impurities
(ASTM C40, C87)
monthly 1% 3%
Sulphate and
Chloride
weekly 0.4%
0.05%
0.4%
0.1%
Aggregate crushing
value
weekly 20% n/a
Flakiness and
Elongation
weekly 20%
35%
n/a
Moisture content twice daily* 3 times daily*
* daily during dry season. Mix proportions to be adjusted to
compensate for moisture content of aggregates

406 Aggregate Reactivity Potential
1) Aggregate shall not contain any materials that are reactive with alkalis in the
aggregate itself or in the cement, the mixing water or in water in contact with the
finished concrete or mortar in amounts sufficient to cause excessive localised or
general expansion of the concrete mortar.

2) The Contractor shall assess an aggregate source by testing in accordance with IS
2386 Part 1 to Part 8 and the results shall comply with the limits given in the relevant
Indian Codes for overall effect on the permanent works mixes, before use of the
aggregate is approved.

407 Water
1) Clean fresh water is to be used for the mixing of all concrete and mortar, and is to be
from a source approved by the Engineer. Bhyunderganga river water free from silt
and debris has been determined to be satisfactory. If required by the Engineer,
samples shall be taken from any other proposed source of supply and submitted to a
nominated laboratory for testing in accordance with IS 3025 (part 17, 18, 24 and 32)
and on the results of these tests the Engineer will decide whether the source is
acceptable.
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2) The acid soluble sulphate (SO
3
) content shall not exceed 500 mg/l and the acid
soluble chloride as NaCl (Cl x 1.65 =NaCl) content shall not exceed 600 mg/l. Tests
to establish the contents shall be carried out at monthly intervals.

408 Admixtures
1) Admixtures shall not be used in concrete without the Engineers approval.
Admixtures containing chloride or other corrosive agents shall not be used.

2) Where the mix design utilises admixtures, they shall be used in the correct quantities
in accordance with the manufacturers recommendations. Approved equipment and
methods shall be used for dispensing and incorporating the admixture in the
concrete; the dispensing unit shall be designed so that the discharge of the admixture
visible and is automatic in each batch.

3) The concrete tests described herein shall be conducted with the admixture
incorporated to establish that specified strengths are achieved, and that densities are
not reduced. If air entraining agents are used the density shall not be reduced by
more than 5%.

4) Set retarding and water-reducing admixture shall consist of lignosulphonate. Air
entraining agents shall consist of neutralised vinsol resin.

409 Concrete Mixes
Concrete shall be as shown below

Concrete
Grade
Characteristic
Strength at
28 days
Maximum
Aggregate
Size
Minimum
Quantity of
Cement
Maximum Free
Water-Cement
Ratio
Target
Slump
N/mm
2
mm Kg/m
3
mm
M40 40 20 375 0.50
75
M25 25 20 350 0.50
75
M25/12 25 12 350 0.50
75
M20/20 20 20 330 0.50
75
M20/40 20 40 300 0.55
75
M15 15 20 240 0.60
75
M10/20 10 20 130 -

M10/40 10 40 130 -

410 Plum Concrete
1) Plums shall be hard clean natural stones embedded in mass concrete, Class M20/40,
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during the placing of the concrete. The plums shall not be larger than one third of
the cross section of the concrete, with a maximum size of 300mm and should not be
placed closer than 50mm to each other. The volume of plums shall not exceed
twenty five per cent (25%) of the mass concrete volume and care shall be taken to
ensure that the minimum concrete cover over any plum is 75mm.

411 Concrete Mix Designs
1) Preliminary tests will be carried out by the Contractors laboratory to determine the
mixes which will satisfy the Specification with the available materials. These mixes
will be designed with due regard for the workability necessary to allow the
Contractor to place and compact the concrete with the equipment he proposes to use
in any particular situation.

2) The mixes will be designed to have mean strengths that are greater than the specified
characteristic cube strengths by a margin of 1.64 times the standard deviation
expected from the concreting plant. The standard deviation will be calculated from
at least 40 individual cube results each representing separate batches of similar
concrete produced by the same plant and under the same supervision except that no
standard deviation less than 2.5 N/mm
2
shall be used as a basis for designing a mix.
A standard deviation of 5N/mm
2
shall be used for initial mix design purposes.

412 Trial Mixes
1) Trial mixes shall be prepared under full scale conditions and tested in accordance
with (IS 9013 : 1978). Trial mixes shall be made subsequently whenever a change is
intended in materials or in the proportions of the materials to be used.
Representative samples of the materials to be used shall be taken and three trial
mixes using the proposed proportions shall be made on different days. The
workability of each of these three mixes shall be determined by measurement of
slump and a batch of six cubes from each mix shall be made, three for tests at 7 days
and three for tests at 28 days. The Engineer will normally approve the proposed mix
proportions provided the average strength of the three trial mixes is not less than the
designed mean strength minus the designed standard deviation and subject to the
conditions noted below. Further trial mixes shall be made if the range of strength
that is the maximum minus the minimum, of the three cube results in any batch
exceeds 15% of the average of that batch, or if the range of the three batch averages
exceeds 20% of the overall average of the batches.

413 Works Test
1) Test cubes shall be made by the Contractor and cured, stored and transported to the
laboratory in accordance with IS 9013: 1978. The cubes shall be tested in
compression at the Contractors laboratory. The method of compacting cubes by
vibration shall be subject to the approval of the Engineer

2) A sample of concrete shall be taken at random each day of concrete of each grade
made. The number of samples per day and the time when they shall be taken shall be
varied at random or as directed by the Engineer.

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3) From each sample two cubes shall be made for testing at twenty eight (28) days and
one for testing at seven (7) days for control purposes.

414 Test Failure
1) Should any works test cube fail to attain the specified strength, an immediate
examination shall be made to find the cause of the failure and a report sent to the
Engineer who will take suitable action which may be one of the following:

Order the concrete corresponding to the cubes to be cut out and replaced. The
Engineer shall determine the extent of the concrete at risk.

When the failure, in the opinion of the Engineer, is slight and occurs in a
continuing concreting operation for a large mass of concrete, the next works test
result may be awaited and, if the failure then persists, the Engineer may order
that concreting shall cease forthwith and not be resumed until further
preliminary tests indicate that the mix has been corrected. Otherwise the
concreting may be allowed to continue with the same mix.

When the failure is serious and relates to a concrete mass which lends itself to it,
the Engineer may order one or more test cylinders to be drilled out and tested in
accordance with (IS 9013: 1978). According to the result of these tests the
Engineer may order the suspected concrete to be cut out and replaced.

2) The cost of these tests including the cutting out and replacing of concrete of inferior
quality shall be borne by the Contractor if the test results show the concrete not to be
in accordance with the Specification.

415 Workability
1) The wet concrete shall be of such consistency that it can be readily transported,
placed and compacted in the Works without segregation of the materials. The
resulting concrete shall be uniform and free from honey-combing

2) The Contractor shall carry out slump, compaction factor or other workability tests as
required during concreting of the permanent works in order to confirm that the
degree of workability of the mix complies with the numerical value obtained during
the trial mixes

416 Concrete Returns and Records
The Contractor shall send weekly to the Engineer a return showing the quantities of
cement and the number of mixings of each class of concrete used in each section of the
Works.

1) Records shall be kept by the Contractor of the positions in the Works of all batches
of concrete, of their class and of all test cubes or other specimens taken from them.
Copies of these records shall be supplied to the Engineer and Contractors
laboratory.

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417 Batching and Mixing of Concrete
1) The aggregates and cement shall be proportioned by weight. The weigh batching
equipment shall be carefully maintained and cleaned and shall be provided with
simple and convenient means of checking the accuracy of the weighing mechanism.
The equipment shall be checked when required by the Engineer.

2) The concrete is to be mixed in machines of the batch mixing or other approved type.
The machines shall ensure that all the concreting materials including the water are
thoroughly mixed together before any portion of the mixture is discharged. The
machines must be capable of discharging their contents while running.

418 Concrete Placing
1) Concrete shall be placed in the position and sequence indicated on the Drawings, or
as directed. Placing shall not be commenced until the fixing and condition of
reinforcement and items to be embedded and the condition of the containing surfaces
or formwork has been approved by the Engineer.

2) Concrete shall be transported by means which prevent contamination (by dust, rain
etc.) segregation or loss of ingredients, and shall be transported and placed without
delay.

3) Concrete shall be placed directly in its final position without segregation or
displacement of the reinforcement, embedded items and formwork. Concrete shall
not be placed in water, except as specified. Concrete shall not be dropped through a
height greater than 1.5 metres.

4) Surfaces of excavations or filling which are to receive reinforced concrete work
shall, where indicated, be prepared with a blinding layer of concrete as shown on the
drawings or in such other manner as will provide a suitable surface at the correct
lines and levels to the satisfaction of the Engineer. Placing of this blinding layer shall
be carried out immediately following excavation inspection approval by the
Engineer, to prevent any deterioration of the excavated surface.

5) The concreting shall be carried out in such a way that the struck exposed faces of
concrete shall be sound and solid, free from honeycombing and excrescences. No
plastering of imperfect concrete faces will be allowed in any circumstances. All
concrete that is defective in any way will, if so ordered by the Engineer, be cut out
and replaced to such depth or be made good in such manner as the Engineer may
direct.

6) Where concrete is required to be placed against undisturbed ground, the entire space
between the finished concrete surface and the ground, including any overbreak, is to
be completely filled with concrete of the specified class. The concrete shall be well
rammed and compacted to ensure that all cavities are filled and the concrete is
everywhere in contact with the ground. Where permitted by the Engineer, patches of
overbreak may first be filled with concrete Class M10/40, as directed, to within
100mm of the payment line.

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419 Concrete Placing Equipment
1) Concrete shall be placed without segregation. If chutes are used their slopes shall not
cause segregation and spouts or baffles shall be provided

420 Time for Placing Concrete
1) Concrete and mortar must be placed and compacted within 30 minutes of water
being added to the mix or otherwise included via damp aggregates, unless
admixtures are in use. Partially set concrete shall not be used in the Works

421 Compaction
1) Concrete shall be compacted during placing by approved internal vibrators. The
vibrators shall operate at a frequency of not less than 10,000 cycles per minute, and
shall be designed for continuous operation. The performance of vibrators shall suit
the working conditions, and they shall generally not be less than 50mm diameter.
The radius of influence shall ensure that the mass under treatment is compacted at a
speed commensurate with the rate of supply of concrete.

2) Vibrators shall penetrate the full depth of the layer of concrete placed and just into
the layer below, and be withdrawn slowly to avoid the formation of voids.

3) Vibration shall not be applied directly or indirectly to concrete after the initial set has
taken place, nor shall it be used to make concrete flow in formwork.

422 Placing in Inclement Weather
1) Placing shall not take place in the open during storms or heavy rains. If such
conditions are likely to occur, the Contractor shall provide protection for the
materials, equipment and formwork so that work may proceed. If strong winds are
prevalent, protection from driving rain and dust shall be provided.

423 Placing in High Temperature
1) The temperature of concrete shall not exceed 32
o
C at the time of placing and the
maximum concrete temperature after placing shall not exceed 65
o
C.

424 Formwork
1) The Contractor shall obtain approval of the methods and materials proposed.
Formwork shall provide concrete of the shape, lines and dimensions shown on the
Drawings.

2) Formwork shall be constructed from materials of sufficient strength, supported to
provide rigidity during placing and compacting concrete without discernible
deflection and shall be removable without disturbing the concrete. Metal ties or
anchors within the formwork shall be so constructed or sleeved so as to permit either
their complete removal or their removal to a depth of at least the minimum specified
cover from the face without damage to the concrete. All fittings for removable metal
ties shall be of such design that, upon removal, the cavities left are of the smallest
possible size. After removal of formwork and tie bars, the holes shall be plugged
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with mortar.

425 Preparation of Formwork
1) Before concrete is placed, the formwork shall be thoroughly cleaned; free from
sawdust, shavings, dust or other debris. Temporary openings shall be provided to
assist in removal of the rubbish.

2) After cleaning, the formwork shall be coated with an approved release agent, which
shall not be allowed to run on to reinforcement, other embedded steelwork or
concrete at any construction joint. In general, coating shall be carried out before
final assembly of formwork.

3) All formwork shall be inspected and approved in writing by the Engineer before
concrete is placed in it, though this shall not relieve the Contractor from the
requirements as to soundness, finish and tolerances of the concrete specified
elsewhere.

426 Classes of Finish
Formed finishes comprise:
1) Class F1 Finish: Formed surfaces which are not exposed to view and where
roughness is not objectionable shall, in general, require no treatment after form
removal other than repair of defective concrete and filling of holes left by form ties.

2) Class F2 Finish: All permanently exposed, formed surfaces shall be smooth and
dense, free from offsets, abrupt irregularities and other prominent surface blemishes.
Unless specified otherwise, formwork shall be Class F2.

3) Class F3 Finish: Permanently exposed, formed surfaces with high quality
appearance. In addition to the requirements for Class F2 finish, formwork panels
shall be arranged in a regular pattern with joints between panels vertical and
horizontal. Panels that have been damaged or that have any holes (other than the tie-
bar holes in use) shall not be used. Internal ties shall be arranged in a regular pattern.
Surfaces shall be rubbed with carborundum brick or other abrasive until uniform
colour and texture are produced.

Unformed finishes comprise:
1) Class U1 surface finish: This surface is required on those portions of the Works
which are to receive concrete surfacing or which are to be covered by backfilling
material, or as otherwise shown on the Drawings.

On completion of placing and compacting the concrete the top surface shall be
levelled and screeded off with a template to the required cross section and tamped
with a tamping board to compact the surface thoroughly and to bring mortar to
the surface, leaving a uniform surface to the profile shown on the Drawings.

2) Class U2 surface finish: Required on sidewalks; tops of wingwalls and retaining
walls; exposed concrete shoulders and unsurfaced areas on bridge decks, and inverts
of box culverts, or as otherwise shown on the Drawings.
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The surface shall first be given a Class U1 surface finish and after the concrete
has hardened sufficiently, it shall be wood-floated to a uniform surface free of
trowel marks. For non-skid surfaces such as on sidewalks and bridge decks, the
surface shall thereafter be given a broom finish. The corrugations produced shall
be approximately 1 mm deep, be uniform in character and width and have a
pattern perpendicular to the centre line of the pavement.

3) Class U3 surface finish: Required at bearing areas and tops of concrete railings, or as
otherwise shown on the Drawings. The surface shall be given a Class U1 finish, and
after the concrete has hardened sufficiently it shall be floated by means of a steel
float under firm pressure to produce a dense uniform smooth surface to within the
dimensional tolerances.

Rubbing with carborundum stone after the concrete has hardened shall be allowed
but under no circumstances will plastering be permitted.

427 Removal of Formwork
1) Formwork shall be removed without damage to the concrete, but not until the
concrete has sufficient strength to support itself. Centres and props may be removed
when the member has sufficient strength to carry itself and any loading with a
reasonable factor of safety. External loading shall not be applied until the concrete
has reached the 28-day Characteristic Strength. Formwork shall not be removed
without prior approval.

2) The following is a guide to the minimum periods between placing and the removal of
formwork:-

Vertical sides of beams, walls, columns
- lift not exceeding 1.2m 12 hours
- lift exceeding 1.2m 36 hours

Soffits of main slabs and beams
- props left under 5 days

Beams and main slabs
- removal of props 18 days

3) After removal, remedial work shall not be undertaken until the concrete has been
inspected and approved.

428 Construction Joints
1) Concreting shall be carried out continuously up to construction joints, the position,
arrangement and sequence of which shall be as approved by the Engineer, or as
indicated on the Drawings. The Contractor is to allow for working beyond the
ordinary working hours where necessary in order that each section of concrete may
be completed without any lapse while the work is in hand. All construction joints
are to be formed square to the work with keyways included.
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2) Where vertical construction joints are required, the joint face of the first cast
concrete shall be finished against a stopping-off board, or vertical end shutter,
suitably notched to pass the reinforcement. When the concrete is hard and the
shutter is removed, the whole joint surface shall be thoroughly roughened or
scabbled with suitable tools so that no smooth skin of concrete is visible and that all
aggregates and solid matrix around them is exposed; the aggregate shall not be
damaged.

3) For horizontal or slightly inclined construction joints, the surfaces shall preferably be
prepared when the concrete has set but not hardened by jetting with a fine spray of
water and brushing with a stiff brush to remove the smooth skin and expose the
aggregate without disturbing it. Where this treatment is impractical and work is
resumed after the concrete surface has hardened, a similar procedure shall be adopted
as on vertical joints.

4) If, in the opinion of the Engineer, any deleterious material has come into contact
with the concrete of the construction joint or if the concrete is honeycombed or
unsound for any reason, the concrete shall be cut back to such a depth as the
Engineer shall order and the roughened surfaces shall be thoroughly cleaned by
compressed air and water jets or other approved means.

5) Immediately before concreting is resumed, the roughened joint surface shall be
thoroughly cleaned with compressed air and water jets and slightly wetted. The
Contractor shall take precaution to avoid segregation of the concrete along the joint
plane and to obtain thorough compaction.

429 Movement Joints
1) Movement joints shall include contraction joints, expansion joints, sliding joints and
other special joints as may be detailed and shall be formed in the position and
manner shown on the Contract Drawings. The concrete surfaces shall be plane and
smooth and the Contractor shall ensure that there is no obstruction to free movement.

2) Where a movement joint includes a continuous waterbar, concrete shall be well
worked around the embedded part of the waterbar and be free from honeycombing.
Projecting portions of the waterbar shall be protected from damage during operations
and, in the case of rubber and plastic, from light and heat.

3) Contraction joints shall be treated to prevent bond between joint surfaces by the
application of two coats of an approved bond-breaking paint to the joint surface first
constructed and allowing the paint to dry before placing new concrete against it.

4) Expansion joints shall be formed by a separating strip of preformed durable resilient
joint filler which shall be continuous through the joint. No broken pieces of joint
filler shall be used. Where dowel bars are to be incorporated in expansion joints,
they shall be round mild steel bars conforming to the requirements of the steel
reinforcement specification. The capped end of the dowel bar shall be sawn square
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and bar cropping will not be permitted. The capped section of the bar shall be
painted with two coats of an approved bond-breaking paint. The cap shall be of such
a diameter as to provide a sliding fit on the bar and shall be partially filled with
approved compressible filler.

5) J oints shall be provided with waterbars, dowels, joint fillers, joint sealants, bond-
breaking compounds and other jointing materials as specified or detailed on the
Drawings. All such materials shall be as approved by the Engineer and their
installation shall be strictly in accordance with the manufacturers instructions. If
required by the Engineer, the Contractor shall demonstrate that the jointing materials
can be applied satisfactorily.

6) Waterbars shall be manufactured of extruded PVC or nitrile rubber. They shall be of
the types and general shapes specified on the Drawings. Waterbars shall be jointed
by an approved jointing process. Waterbars shall comply with the requirements in
the following table:

WATERBAR CHARACTERISTICS AT 25C

PROPERTY

RUBBER - BS 903

PVC - BS 2782

Density

1100 kg/m
3
(+5%)

1300 kg/m
3
(+5%)

Hardness

60 - 65 I.R.H.D.

70 - 75 I.H.R.D.

Softness Number

--

42 -52

Tensile Strength

>20 N/mm
2

>15 N/mm
2

Elongation at Break Point

>450%

>285%

Water absorption (48 hrs
immersion)

<5%

<0.7%

Web Thickness

10 mm

10 mm

Centre Bulb Dimension

18 mm

18 mm

Rubber and PVC waterbars shall be suitable for storage, handling, installation and
service within a range of 15C to 50C. Waterbars shall include means, such as
eyelets or reinforced nailing flanges, to facilitate the accurate fixing within the
structure.

430 Steel Reinforcement
1) Reinforcement for use in reinforced concrete shall comply where appropriate with
IS432, IS 1786, IS 1566, IS 2062

2) High-yield deformed bars Fe415 shall be Type 2 complying with IS 1786 unless
otherwise specified.
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3) Reinforcement shall be cut, bent and fixed in accordance with IS 2502

4) The number, size, form and position of pieces of reinforcement shall be as shown on
the Drawings. They shall be held in position in the formwork during the placing of
concrete by use of distance pieces and spacer bars.

5) Links shall be taut so that bars are braced and the inside of their curved parts shall be
in contact with the bars being connected. Tying wire shall be black annealed mild
steel approximately 1.5mm diameter or similar approved twisted tight with pliers; the
free ends shall be bent inwards.

6) Reinforcement shall be free from loose rust, oil, grease, salt and other deleterious
matter. If necessary, reinforcement shall be cleaned by grit-blasting or wire brushing
before use. Partially set concrete adhering to exposed bars during concreting
operations shall be removed.

7) Reinforcement temporarily projecting from the concrete at joints shall not be bent
out of position without approval, in which event the reinforcement shall be bent over
a suitably sized former to prevent any damage or over stressing.

431 Storage of Reinforcement
1) Steel reinforcement shall be stored in an approved manner clear of the ground.

432 Cover to Reinforcement
1) The location of reinforcement and minimum dimensions of concrete cover shall be
as shown on the Drawings. Where no such dimension is given, the minimum cover
to links shall be 25mm and main bars 40mm.

2) Reinforcement shall be located within tolerances as specified herein.

3) When inspected in the forms, the cover to the reinforcement shall be the nominal
cover within plus 10mm and minus 5mm tolerances.

4) Only approved spacers may be used in permanent works. Before spacers are
approved for use in the works, their capacity to hold the reinforcement securely in
position during concreting without detriment to concrete placement, compaction or
durability shall be fully demonstrated. Concrete spacers shall be of similar concrete
grade to the parent concrete and shall comply with the specified requirements for
water absorption.

433 Curing and Protection
1) Concrete shall be wet cured continuously for a period of 7 days. Concrete shall be
protected during the first stage of hardening from the harmful effects of sunshine,
drying winds, cold, rain or running water. The Contractor shall pay particular
attention to the need to protect concrete immediately after the finishing operation and
prior to its final set. Protection of concrete, both horizontal and vertical surfaces,
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which has achieved its final set shall consist of the following:
i) A layer of hessian, straw mats or similar absorbent material or a layer of
sand shall be placed over the concrete and kept constantly moist by
spraying with water, as necessary, for seven (7) days.
ii) A layer of approved waterproof paper or plastic membrane shall be placed
over the wet absorbent material to prevent evaporation and maintain in
position for seven (7) days.

2) The use of saline water for curing purposes will not be permitted.
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PART 5: MASONRY AND STONEWORK

501 Stone
1) Stone for all purposes shall be the best of its kind, sound and durable, free from flaws
and from soft, weathered or decomposed parts. The stone and the quarry from which
it is obtained shall be subject to the approval of the Engineer. Samples shall be
submitted by the Contractor of the stone he proposes to use in the Works and the
Engineer's approval shall be obtained before such stone is used or any order is
placed. The stone used shall be clean and must be washed if deemed necessary in
the opinion of the Engineer.

2) Stones for face work shall be as far as possible quarry split and not bullnosed or
hammer dressed. A moderate amount of dressing to trim off large projections will
however be permitted. Exposed faces of stones for masonry shall be free from tool
marks except such as are inherent in the nature of any dressing that may be specified.
In masonry-lined waterways the roughness on the surface shall not project more than
30mm for stone less than 0.3 square metres face area and not more than 50mm for
larger stones.

502 Masonry
1) Masonry shall be built to the lines and levels shown on the Drawings or required by
the Engineer. Notwithstanding any local usage it shall be built in the manner
specified below.

2) The stones shall be set in mortar with their natural bedding plane (if any) as near
normal as possible to the face or normal to the line of thrust in the case of load
bearing structures. Particular care must be given to obtaining a sound bond both
longitudinally and transversely and there shall be at least one bonder, of length not
less than two-thirds of the wall thickness, in each square metre of wall face.

3) Both faces of the wall shall be raised in lifts not exceeding 600mm high. The cavity
between the faces shall be completely filled with mortar or concrete before
proceeding with the next lift.

4) The mortar, unless otherwise specified, shall be Ordinary Portland Cement and sand
mixed in the proportion of 1:4. Mortar shall completely fill all interstices between
the stones.

5) The face joints in rubble masonry may vary in thickness from 10 mm to 20 mm.
They shall be finished with mortar as a neat weathered joint while the work
proceeds.

6) Before a general start on a structure of large dimensions is begun the Contractor will
be required to build a small portion of the walling of required type for approval by
the Engineer. After approval has been given, the remainder of the work will be
required to conform to the samples.

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7) Building of masonry will not be allowed in heavy rain or at temperatures below 3
o
C
without the written consent of the Engineer.

503 Random Rubble Masonry
1) Random rubble uncoursed masonry shall be built with stones of irregular shapes
taken generally as they come from the quarry, preparation being limited to the
removal of inconvenient corners and excrescences. They shall be selected as the
work proceeds to give a uniformly random appearance and no attempt shall be made
to form courses. All stones shall be carefully set with a bond stone provided at the
rate of 1 to every sq.m. of exposed face. Bond stones shall measure not less than 150
mm by 150 mm on the exposed face, and not less than 450 mm in length or the full
thickness of the wall if the latter is less than 450 mm.

2) Random rubble brought to courses shall be generally as the preceding type except
that it shall be levelled up to courses between 300 and 400 mm in depth and
coinciding with the quoin stones.

504 Masonry Lining to Waterways
1) Masonry lining shall be built to the lines and levels shown on the Drawings or
required by the Engineer. Notwithstanding any local usage it shall be built in the
manner specified below.

2) The lining shall be formed as two layers infilled with mortar. The stones shall be set
in mortar with a smooth face forming the surface of the waterway. Protrusions inside
the line of the waterway shall be kept to a minimum and shall not exceed the
dimensions specified in Clause 501 above. Particular care must be given to obtaining
a sound bond both longitudinally and transversely, however, to avoid forming
seepage paths, bonders (stones extending across the full thickness of the lining) shall
not be used,

3) Both faces of the lining shall be raised in lifts not exceeding 600mm high. The cavity
between the faces shall be completely filled with mortar or concrete before
proceeding with the next lift.

4) The mortar, unless otherwise specified, shall be Ordinary Portland Cement and sand
mixed in the proportion of 1:4. Mortar shall completely fill all interstices between
the stones.

5) Before a general start on the lining is begun the Contractor will be required to build a
small portion of the required type for approval by the Engineer. After approval has
been given, the remainder of the work will be required to conform to the samples.

6) Building of masonry linings will not be allowed in heavy rain or at temperatures
below 3
o
C without the written consent of the Engineer.

505 Stone Masonry Armouring to Weirs
1) Stone masonry armouring shall be provided where specified on the Drawings to give
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a hard wearing surface to weirs and other structures as shown on the Drawings.

2) The concrete surface on which the armouring is to be placed shall be clean and
sound. The surface shall be mechanically roughened by scabbling or needle gun or
manually with hammers to remove all laitence and produce a rough exposed
aggregate finish. The surface shall then be thoroughly cleaned with air and/or water
jets to ensure that it is free from dust, oil, grease or any other deleterious substance.
The concrete surface shall be thoroughly dampened with water and any excess water
removed before applying the bedding concrete.

3) The stone used for the stone armouring of weirs shall be extremely hard and durable,
of the best of its kind and free from flaws, soft, weathered or decomposed parts.
Samples of the stone proposed for use in the works shall be provided to the Engineer
and written approval shall be obtained before such stone is used or any order placed.

4) The sizes and tolerances of the individual stones and face finishes are as given on the
Drawings and as specified. The stones shall generally have an upper exposed face of
250mm x 250mm, but with an area not less than 0.05sq.m. The bottom face of the
stone shall be parallel to the top in order to achieve a good bond with the bedding
concrete. The bottom face shall generally be 200mm x 200mm; but with an area not
less than 0.04sq.m. The overall depth of the stone shall be not less than 300mm and
not greater than 450mm. the roughness on the exposed surface shall not project more
than 25mm.

5) The stone armouring shall be laid, tamped and bedded in concrete to produce an
exactly flat surface, level or sloping to the lines and levels shown on the Drawings.

6) The weir crest shall be exactly level as shown on the Drawings, with only variations
due to the roughness of the stones. Along the crest line, no part of the stone surface
shall be more than 5mm below or 30mm above the specified level. The tolerance on
other faces of the weir, such as the upstream or downstream slopes and stilling basin,
shall not exceed -20mm or +50mm for any point on the surface of the stone.

7) The individual stones shall be embedded in concrete Class M25/12. The Contractor
shall carry out trials to determine the optimum mix and water/cement ratio which
gives required characteristics for bedding and anchoring the masonry armouring with
absolutely no voids between the stones.

8) The stone armouring shall be laid in an interlocking bond pattern as shown on the
Drawings. Under no circumstances shall the joint between any stones in any two
adjacent rows be aligned together in the direction of the water flow.

9) A priming layer comprising cement mixed with an approved Styrene Butadyne Resin
(SBR) shall be used in accordance with the manufacturers application instructions.

10) The Class M25/12 concrete shall be applied in an even layer, of such depth and over
such an area as will permit the masons to properly place and compact the stone into
the wet concrete. The Contractor shall undertake such trials as are necessary in order
to determine the optimum method of placing the stone in the wet concrete, the depth
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of the concrete layer and the extent of the working area for the concrete and priming
slurry in advance of the stone laying operation. The concrete and priming slurry
shall be freshly laid and under no circumstances shall be reworked to increase
workability. The stones shall be forced into the fresh concrete to the required level
when the voids between the stone being laid and previous stones shall be completely
filled with concrete and the concrete fines and grout is extruded through the joint
between the stones at the top surface. On no account shall the joint between the
stones be filled with concrete, mortar or grout from the top. Any final pointing or
finishing of the joints between the stones shall only be carried out with the express
written permission of the Engineer.

11) The Contractor shall obtain the written approval of the Engineer to the method of
placing the stone following completion of the trials and prior to commencing the
main works. Under no circumstances shall any deviation from the agreed placement
method be considered without the written approval of the Engineer.

506 Dry Rubble Walling
1) Dry rubble masonry shall be constructed generally to the requirements for uncoursed
random rubble masonry, as specified in Clause 503 but with the omission of mortar.
All stones shall be carefully shaped to obtain as close a fit as possible at all beds and
joints, any interstices between the stones being filled with selected stone chippings
or spalls. The exposed tops or copings of dry rubble walls shall be formed as shown
on the Drawings.

507 Hand-placed Rubble Filling
1) Hand-placed rubble filling shall consist of stones individually selected and placed by
hand firmly in place in bearing contact with each other or with the sides of the space
to be filled; the voids shall be carefully filled with small rock and spalls wedged
together to form a compact mass. The sides of stones shall be roughly trimmed if
necessary with a spalling hammer to obtain a reasonably close fit. On the exposed
face the stones shall be placed with their flattened sides uppermost and in the place
of the face.

508 Rubble Filling
1) Any filling for which "rubble filling" is specified shall be done with approved quarry
run rock filling obtained from works excavations, from a borrow pit, or from any
other source. The rock shall be dumped in such a manner that the filling will be
adequately compacted.

509 Gabions
1) Gabions and mattresses shall be of the types and sizes shown on the Drawings or as
specified by the Engineer. The cages shall be constructed from mild steel wire
complying with Mild steel Wire for General Engineering Purposes (IS 280),
galvanised in accordance with "Electro galvanised coatings on round steel wire"
(IS 12753). The wire shall be 2.70mm diameter and formed into a fabric having a
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mesh of 80mm x 100mm for gabion baskets and 60mm x 80mm for mattresses. The
fabric shall be of the "hexagonal double twist" type.

2) Stone filling for gabions shall consist of hard durable rock, and shall be free from
weathered or decomposed parts. The minimum dimension of each stone shall not be
less than half its maximum dimension. The stone shall be 200mm to 100mm size.
The stone shall be obtained from a source approved by the Engineer. No stone shall
be smaller than the size of the gabion mesh openings. In carrying out the filling,
selected pieces of stone of elongated shape shall be placed with their flatter and
elongated faces in contact with the mesh wherever possible.

3) The empty gabion baskets shall be placed to line and level as shown on the Drawings
or as directed by the Engineer and then stretched so that the gabions retain their
shape on being filled. Diaphragms shall be provided at not more than 1 metre
intervals. The gabions shall be filled with approved stone by hand. No basket or
mattress forming part of an intended continuous line of gabions shall be completely
filled until an adjacent basket or mattress has been half filled, unless otherwise
directed, in order not to cause displacements from bulging during filling.

4) For baskets at least two horizontal connecting wires shall be tied between front and
back of the gabion in each 1 metre compartment, at a height of 330mm and 660mm
from the bottom as the stone fill reaches these levels. Additional tie wires shall be
provided if necessary and in no case shall the gabion basket bulge by more than
40mm. Where a continuous line of gabions is required, adjacent gabions shall be
securely tied together at the top and bottom of the gabions with tying wire.

5) Particular care shall be taken to ensure tightness of mesh, well packed filling with
minimum voids and secure lacing.

6) The gabions shall be filled to a level just sufficient to require the lid to be forced into
place with a bar. The lid and all joints between basket and between diaphragms and
basket shall each be tied down with a continuous running wire.

7) Where gabions are to be shaped, the shape shall be formed by folding the mesh
internally and tying it with a continuous running wire.

8) All tying wire shall be 2.7 mm dia galvanized wire.

510 Rock Armouring and Rip-Rap
1) Rock armouring and rip-rap shall consist of selected rock or stone complying with
Clause 501 of this Specification.

2) The maximum and minimum mass of individual rocks to be used in armour
construction shall as stated on the Drawings. Where rock is detailed by size, the
following grading shall apply:

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Nominal 1000mm Nominal 500mm
Size (mm) %age passing Size (mm) %age passing
1500 100% 750 100%
1000 50% 500 50%
500 0% 300 0%

3) Before placing armour, an area not exceeding 100 square metres, shall be clearly
marked out upon the area to be protected. The Contractor shall place armour by
means to be approved by the Engineer, on this area in such a thickness that the
specified mass/m
2
is achieved. In order that the requirements of the average mass
specification above may be observed, all armour stone to be placed on the marked up
area shall be weighed on a weigh bridge.

511 Filter Fabric / Geotextile
1) The filter fabric beneath gabions shall be of a non-woven melded fabric consisting of
a mixture of polypropylene and polythene or other similar materials. The grade of
the fabric shall weigh not less than 800gm/sq.m and have a minimum thickness of
6mm. Where overlapping of fabric is required, the overlap shall not be less than
500mm.

2) P80 as manufactured by Bidim will satisfy the above requirement. The Contractor
may propose alternative suppliers for the Engineers approval.

512 Gravel Filter
1) A 150mm thick gravel layer shall be placed under riprap stone and gabion boxes and
mattresses and over geotextile as shown on the drawings or as instructed by the
Engineer. Gravel protection layer shall have the following characterisations:

Gravel layer grading

Particle diameter mm

%age passing

5

0

20

50

50

100

513 Stone Pitching
1) Stone for pitching shall be obtained from an approved source and shall be hard,
sound, durable, clean and generally follow the specification of stone for facing. The
minimum dimension of any stone shall be at least equal to the specified thickness of
the pitching.

2) After excavation and trimming, slopes to be pitched shall be spread with a 75 mm
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thick layer of crusher run rock or graded coarse aggregate ranging from 75 mm
particle size of fines. The slope shall then be hand packed with hard broken rock to a
total thickness of 150 mm, each stone being individually placed and rammed home,
with smaller stones wedged into the cracks. 50 mm dia weep holes shall be provided
at intervals not exceeding two metres in both directions.

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PART 6: ROADWORKS

601 Sub-grade Preparation
1) Before placing the gravel topping, the sub-grade shall be prepared to a depth of
200mm to remove debris and rock greater than 100mm before being mixed with
water or left to dry to provide optimum water content within 3% of laboratory
optimum. The surface shall then be graded to the correct profile and compacted with
four passes of a vibratory steel drum roller with a static drum weight of at least 7
tonnes

602 Granular Sub Base (GSB)
1) The material used for Granular Sub Base shall be naturally occurring gravel or
crushed rock complying with the following grading

IS Sieve Size
(mm)
Percentage passing by
Weight (Square Mesh)
75
20
2.36 (No 7)
100
40-60
0

2) Compaction shall be carried out by a minimum of three passes of a vibratory steel
drum roller with a static drum weight of at least 7 tonnes and reach not less than 90%
of the maximum dry density (laboratory Proctor compaction) at optimum water
content as determined in accordance with IS 2720 (part 18).

603 Water Based Macadam (WBM) Road Surfacing
1) The material used for WBM top surface of roads, shall be naturally occurring gravel
or crushed rock complying with the following grading, and capable of being
compacted to achieve a well-knit dense layer.

Natural Gravel Crushed Stone
IS Sieve Size
(mm)
Percentage passing
by Weight
Square Mesh
IS Sieve Size
(mm)
Percentage passing
by Weight
Square Mesh
37.5
20
10
5
2.36 (No 7)
0.6 (No 25)
0.075 (No 200)
100
80-100
55-80
40-60
30-50
15.30
5-15
50
37.5
20
10
5
2.36 (No 7)
0.6 (No 25)
0.075(No 200)
100
95-100
60-80
40-60
25-40
15-30
8-22
5-12
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2) Road surfacing material shall be spread evenly in layers and compacted thickness of
each layer should not exceed twice the maximum size of stone. The layers shall be
compacted to obtain a well-bound surface finish, any loose areas or segregated areas
being made good by addition of fines or by removing and replacing with fresh
material as directed by the Engineer. Fines should be less than 6.3mm maximum
size, preferably well graded and must be non-plastic.

3) Compaction shall be carried out by a minimum of four passes of a vibratory steel
drum roller with a static drum weight of at least 7 tonnes and reach not less than 95%
of the maximum dry density (laboratory Proctor compaction) at optimum water
content as determined in accordance with IS 2720 (part 18).

604 Road Maintenance
1) The Contractor shall maintain and repair the Access Roads until the Completion
Date for the whole of the Works.

2) Maintenance and repair of the road shall include; but not be limited to;

i) grading at regular intervals

ii) repairing of road surfaces

iii) replacement of gravel topping

iv) cleaning and repairing of ditches and culverts

v) removal of debris including, rockfall, landslide, or stream deposits

vi) dust control by application of water to the road surface.

vii) filling and repair of Access Road washed away by floods or heavy rain

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PART 7: CULVERTS & DRAINAGE

701 Culvert Material
1) Unless otherwise shown on the drawings, culverts shall be NP4 pre-cast concrete
pipe complying with (IS 458). All pipes shall have gasket type joints of spigot &
socket, rebated or separate factory made collar form.

702 Unloading and Laying out Pipes
1) When delivered to Site, pipes shall be carefully unloaded without breakages. If the
pipes have to be unloaded singly and by hand, skids and check ropes shall be used,
and pipes shall not be dropped nor allowed to roll unchecked. Pipes shall be wedged
together to prevent further movement.

703 Laying and Jointing Pipes
1) All pipe systems shall be laid to the lines and levels shown on the drawings.

2) Where ground water is encountered, it shall be kept below the sockets when jointing
by means of pumping.

3) Each pipe shall be carefully lowered onto the prepared bed by means of the
necessary slings and tackle.

4) No pipe or pipeline may be used for trench drainage purposes without the permission
of the Engineer.

5) Unless otherwise approved by the Engineer, pipes shall be laid from the downstream
end with the pipe sockets facing upstream.

704 Installation
1) At the downstream end erosion shall be prevented by masonry or stone pitching.

2) The excavation for the culverts shall be done to such a width that there is a free space
of 500 mm between the pipes and the side of the excavation in order to allow for a
careful packing of the backfill.

3) If the bottom of the excavation consists of rock or stones, a 200mm thick layer of
well-compacted sand shall be placed at the bottom.

4) Filling around pipes shall be carried out concurrently on both sides in layers not
exceeding 150 mm. Maximum size of stone close to the culvert shall be 40 mm.
Packing shall be done so that no lifting or major deformation of the culvert takes
place. Before any compaction of fill above the culvert takes place the fill thickness
shall be at least 500 mm.

5) Backfill material shall not contain organic material and shall not contain more than
5% of material retained on a 19 mm sieve. The Contractor shall obtain the Engineer's
approval of the backfilling material he proposes before any backfilling is carried out.
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All equipment not required for compaction shall be kept a minimum distance of 3
metres from the sides of the culvert during backfilling.

705 Subsurface Drainage Slotted Plastic Pipework
1) Subsurface drainage shall comprise 200mm diameter slotted uPVC or Polyethylene
slotted well casing with a minimum wall thickness of 8mm in accordance with
IS12818. Slots shall be 1.0mm x 40mm length in accordance with the IS standard
for well screen not exceeding 250m depth.

2) J oints may be threaded, solvent welded or O seal with factory formed threads or
sockets respectively. All Tee pieces and bends shall be factory formed and jointed in
accordance with the manufacturers recommendations in respect of general pipe
jointing.

3) Plain pipe shall compatible with the slotted screen and of the same dimensions and
wall thickness.
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PART 8: BUILDING FINISHING WORKS

801 General
1) This specification covers the requirements for building finishing works comprising
brick and stone masonry, floorings, doors, windows, ventilators, wood/ aluminium
work, water proofing, plastering, painting plumbing, sanitation, electrical fittings and
such other related works forming a part of this job. The work under this
specification shall consist of furnishing of all tools, plants, labour material and
everything necessary for carrying out the work,

802 Applicable Codes and Specifications
1) The following specifications, standards and codes, including all official
amendments/revisions and other specifications and codes referred to therein, should
be considered a part of this specification. In all cases the latest issue/
edition/revision shall apply. In case of discrepancy between this specification and
those referred to herein below or other specifications forming a part of this bid
document, Engineers decision shall be required for interpretation.

2) Materials

IS:280 Specification for mild steel wire for general engineering
purposes.
IS:348 French polish
IS:412 Expanded metal steel sheets for general purposes
IS:428 Distemper, oil emulsion, colour as required
IS:702 Specification for industrial bitumen
IS:712 Specification for building limes
IS:777 Specification for glazed earthenware tiles
IS:1038 Specification for steel doors, window and ventilators
IS:1077 Specification for common burnt clay building bricks
IS:1081 Code of practice for fixing and glazing of metal (steel and
aluminium) doors, window and ventilators
IS:1124 Method of test for determination of water absorption, apparent
specific gravity and porosity of natural building stones.
IS:1477 Code of practice for painting of ferrous metals in buildings
(Part 1 and 2)
IS:1542 Specification for sand for plaster.
IS:1597 Code of practice for construction of stone masonry
IS:1661 Code of practice for application of cement and cement-lime
plaster finishes
IS:1834 Specifications for hot applied sealing compound for joint in
concrete.
IS:1838 Specification for preformed fillers for expansion joint in
concrete pavements and structures (non-extruding and resilient
type): Part 1 Bitumen impregnated fiber.
IS:2074 Ready mixed paint, air drying, red oxide-zinc chrome, and
priming.
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IS:2114 Code of practice for laying in-situ terrazzo floor finish.
IS:2116 Specification for sand for masonry mortars.
IS:2185 Specification for concrete masonry units (Part 1, 2 and 3).
IS:2202 Specification for wooden flush door shutters (Solid core type):
(Part 1 and 2)
IS:2212 Code of practice for brickwork.
IS:2250 Code of practice for preparation and use of masonry mortars.
IS:2338 Code of practice for finishing of wood and wood based
materials (Part 1 and 2).
IS:2395 Code of practice for painting Concrete, masonry and plaster
surfaces (Part 1 and Part 2)
IS:2402 Code of practice for external rendered finishers.
IS:2572 Code of practice for construction of hollow concrete block
masonry.
IS:2645 Specification of integral cement waterproofing compounds.
IS:2690 Specification for burnt clay flat terracing tiles: Part 1 Machine
made.
IS:2691 Specification for burnt clay facing bricks.
IS:2721 Specification for galvanised steel chain link fence fabric
IS:2750 Specification for steel scaffoldings
IS:3067 Code of practice of general design details and preparatory work
for damp proofing and waterproofing of buildings.
IS:3068 Specification for broken brick (burnt clay) coarse aggregates
for use in lime concrete.
IS:3384 Specification for bitumen primer for use in waterproofing and
damp proofing
IS:3536 Specification for ready mixed paint, brushing, wood primer,
pink.
IS:3696 Safety code of scaffolds and ladders (Part 1 and 2)
IS:4021 Specification for timber door, window and ventilator frames
IS:4351 Specification for steel door frames
IS:4948 Specification for welded steel wire fabric for general use
IS:5318 Code of practice for laying of flexible PVC sheet and tile
flooring
IS:6248 Specification for metal rolling shutters and rolling grilles.
IS:7452 Specification for hot rolled steel sections for doors, windows
and ventilators
IS:9862 Specification for ready mixed paint, brushing, bituminous,
black, lead-free, acid, alkali, water and chlorine resisting
IS:15489 Specification for plastic emulsion paint

803 Waterproofing Work
1) All surfaces to be waterproofed shall be dry, clean, smooth and free from dust and
loose particles. Water proofing treatment shall be as per specifications of approved
specialist waterproofing company and shall consist of brickbat coba covered with
jointless waterproof plaster finished smooth with trowel in cement mortar with false
marking of 30 mm squares.
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2) Waterproofing treatment shall be taken up the parapet walls to a height of about 300
mm in shape of round wattas or as directed by the Engineer.

3) Bitumen felt waterproofing - the layers of bitumen felt shall conform to IS:1322.
The first layer of bitumen felt shall be bonded to the dry, clean and smooth concrete
surface by bitumen bonding compound. Bitumen felt shall be Shalimar or similar
approved, laid with 50 mm side laps and 75 mm end laps staggered. The felt shall be
laid continuously over the surface of the roof and shall not be terminated at
expansion joints. Hot bitumen shall be applied on clean, dry and dust free surface.
Tarflet or similar approved equivalent shall be laid over it. Then stone grit-bitumen
mix shall be spread and compacted to form a 25 mm thick layer. Where specified,
precast concrete tiles/paving slabs on a mud bound sand mix base course shall be
provided.

804 Damp Proof Course
1) Unless otherwise specified damp proof course shall be formed from bituminous felt
conforming to IS:1322 with a minimum lap at joints of 150 mm. Material for damp
proof course shall be subject to the Engineers approval.

805 Cement Plaster
1) Cement and Sand - Cement and sand shall conform to the Specification for
Concrete Works.

2) Workmanship - All stone or brick masonry shall be thoroughly wetted and joints
raked out to a depth of at least 20 mm and walls washed before any plastering is
done. The surface shall then be rendered with a mortar of specified parts of cement
and fine sand, to 20 mm thickness and specified roughness. The surface shall then
be floated or set with a thin coat of 3 mm thick cement and polished well with a
trowel or flat board. The cement mortar shall be used within 30 minutes after it
leaves the mixing board or mill. Before any plasterwork is started patches of plaster
150 mm x 150 mm shall be put on at every 3 metres apart as gauges so as to ensure
an even thickness throughout the work. Cement plaster shall be done in even squares
or strips. Care shall be taken to keep the whole surface thoroughly wetted for at least
a week. The finishing surface shall be as specified and directed. Neeru finish shall
be applied to the prepared and partially set but somewhat plastic surface, with steel
trowel to a thickness slightly exceeding 1.5 mm, (1/16) and rubbed down to 1.5 mm
(1/16) thickness and polished to a perfectly smooth and even finish working from
top to bottom

3) The junction between beams and brickwork shall be plastered after fixing the
expanded metal wire mesh of 300 mm width. The wire mesh shall be of size 20 mm
x 20 mm gauge thickness.

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806 Cement Pointing
1) General - Before pointing work is taken up, the old mortar in the masonry or pitching
work shall be raked out of the joints at least to a depth of 20 mm. The dust shall be
brushed out of the joints and the walls shall be well wetted with fresh water until the
old mortar in the wall is set to the satisfaction of the Engineer. The pointing shall
then be made with fine mortar, of cement and fine sand, in the proportions as
specified. The joints shall be neatly defined by the joining, and the same shall be
raised or sunk as directed. In no case shall false joints be allowed. The pointing
shall be kept wet until the cementing material sets and becomes hard. The whole
surface shall be left clean at the completion of the work.

807 Mosaic Flooring
1) Mosaic flooring shall comprise a mixture of white cement and coloured marble chips
or similar approved coloured stone. Individual panels not exceeding 1m
2
shall be
separated by 4mm glass or plastic strips in a pattern approved by the Engineer. The
whole of the area shall be wet ground and polished to give a dense even and polished
surface.

808 Woodwork in Doors, Windows, Partition, Louvres, Railing etc
1) Wood used for all work shall be best of the respective class specified, and properly
seasoned by at least 6 months air drying, suitable for joiners work, should be of
natural growth, uniform in texture, straight grained, free from sapwood, dead knots,
open shakes, boreholes, rot, decay and any all other defects and blemishes.

2) The thickness specified for joiners wrought timbers, are unless otherwise specified,
prior to planning and 3 mm will be allowed from the thickness stated for each
wrought faces.

3) All joining shall be wrought on all faces and finished off by hand with sand paper,
with slightly rounded arises.

4) Door, windows and ventilator frames, transformers and mullions shall be rebated.
The top framing member of doors and top and bottom framing of windows and
ventilators shall project about 150 mm in brickwork. The vertical of door frames
shall project about 50 mm below finished floor. Surface coming in contact with
brickwork shall be painted with bitumen as directed by the Engineer. Each of the
door and window frames shall be provided with 3 Nos. M.S. 225 x 25 x 6 mm flat
spilt hold-fasts on each side. These hold fasts shall be embedded in masonry or
concrete work. The work shall conform to IS:4021.

5) The doors shall be panelled or solid flush doors.

Single Leaf Doors
a. 3 Nos. heavy duty railway type butt hinges 150 mm long.
b. Godrej 6 lever mortice lock with one oxidized brass 350 mm long 16 mm
diameter aldrop and with handles on both sides 1 Nos. (chromium plated
brass).
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c. Tower bolt 300 mm long.
d. Door stop 1 No.

Double Leaf Doors
a. 6 Nos. heavy duty railway type butt hinges 150 mm long.
b. Aldrop 1 No.
c. Tower bolt 300 mm long, 2 Nos.
d. Cast handles 4 Nos.
e. Door stops 2 No.

6) Where the single leaf doors are 1200 mm wide the number of hinges used shall be
four. Similarly, if the height of the door exceeds 2200 mm, the number of hinges
shall be suitably increased.

7) Door closures shall be of heavy duty hydraulic type.

8) Panelled doors shall comprise of 250 mm wide bottom rail, 150 mm wide middle rail
and all other rails middle, top and vertical 100 mm wide. All rails shall be 40 mm
thick. Panels shall be 20 mm thick.

9) The type of window shall be as specified. All fixtures fixed to windows shall be
oxidized brass fittings. Each shutter shall have one pair of hinges, two tower bolts
(one 225 mm long and another 150 mm long), one handle and one hook with eye and
pegstay. Ventilators shall have two mild steel holdfasts and hinges, one handle and
one hook and eye at each and one small tower bolt in the centre. Where so directed
by the Engineer, the doors and windows shall be provided with parliamentary type
hinges at no extra cost.

10) The workmanship of all door and window shutters shall conform to the requirements
of IS:1003 (Parts 1 and 2) and IS:2202 (Parts 1 and 2). If required, flush door panels
shall be tested as per IS:4020 at no extra cost to the Engineer.

11) Cupboards, almirahs and shelves shall be provided as required by Engineer. The
doors could be of either hinged type or sliding type as approved by Engineer.
Fixtures and fittings shall be of standard make or as directed by Engineer.

12) Railings and architraves shall conform to the standard shape, or as approved, and
fixed by means of screws (counter sunk or otherwise) or bolts.

13) The finish expected is of a very high order, complete in all respects and the work
shall be free from blemish.

14) Iron bars or grills shall be provided in the windows or ventilators are of standard
make or as directed by the Engineer. Glass louvered ventilators and windows where
specified shall be provided.

15) Woodwork shall not be painted, oiled or otherwise treated before the Engineer has
approved it.
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16) The whole of the woodwork shall first be treated with two coats of anti-termite wood
preservative chemical of an approved make. All the wood shall thereafter be treated
with primary coat of paint. The application of primer shall not be done within 24
hours of the application of the second coat of anti-termite treatment.

809 Glazing and Metal Doors and Windows
1) Glass Generally - Glass shall conform to the requirements of relevant IS codes and
shall free from bubble, smoke wanes, air holes, scratches and other defects and shall
be cut to fit the rebates with due allowance for expansion.

2) Sheet Glass - Sheet glass shall be flat, transparent and clear as judged by the unaided
eye. It shall be free from cracks. Sheet glass shall be of B quality or ordinary
quality and with appropriate thickness. Sheet glass used for glazing in building shall
conform to IS:2825. Modulus of rupture of sheet glass shall be 380 kg/cm
2
. Density
of sheet glass shall be 2500 kg/m
3
.

3) Glazing - Putty for glazing to wood shall be prepared in accordance with IS: 1635.
Glazing work in buildings shall conform to IS: 3548.

4) Compound for glazing to metal is to be an approved special compound manufactured
for the purpose.

5) Glass Blocks - Hollow glass blocks shall be Insulight as manufactured by
Pilkingtons or similar approved. They shall be joined in cement mortar but the edge
of the panel shall be set in non-setting mastic.

6) Where required, the blocks shall be set in a reticulated steel security frame. Steel
frames for glass blocks shall have a thickness of 5 mm. There shall be no distortion
in frames. The whole frame with the exception of lugs and external faces of
channels shall be precoated with approved bitumen emulsion or galvanized after
manufacture.

7) Fittings for Doors
Two floor springs of suitable make such as Everite, Prabhat etc. or
equivalent having double action spring, unless specified otherwise.

Each door leaf shall be fitted with two Nos. of suitable size of aluminium
anodized handles from extruded tube of 100 mm x 50 mm minimum.

One leaf cut of two shall be fitted with tower bolt at top or bottom of 230 mm
size of chromium plated brass.

6 lever brass lock concealed in section tube and open able from both sides with
two keys.

8) Fitting for Windows
One opener, one handle and 15 cm. long tower bolt of brass, chromium plated.
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9) Steel Window and Doors - Steel windows and doors, including folding doors shall be
supplied complete with frames and fitted with door furniture.

10) Steel is used in fabrication of windows and door shall have a minimum thickness of
3 mm.

11) Steel frame for glass block windows shall have a thickness of 5 mm. There shall be
no distortion in the frames. The whole frame with the exception of lugs and external
faces of channels shall be precoated with approved bitumen emulsion or galvanised
after manufacture.

12) Rolling Shutters - The rolling shutters shall conform to the size to fulfil functional
requirements. The rolling slats shall be in one piece and be made of heavy gauge
steel sheets minimum thickness 18 SWG. A cylindrical hood shall be provided on
the top to enclose the shutter when it is open. The rolling shutters shall be provided
with suitable locking arrangements and deep channel guides. For galvanised slats,
deep channel guides shall preferably be in one piece.

810 Painting
1) Unless otherwise specified in the Drawings or Contract documents, painting shall
generally be:
Interior walls & ceilings Three coats water based plastic emulsion.
Woodwork Pretreated as Clause 808, primed and finished with two coats
synthetic enamel.
Architectural steel work and exposed steel fittings In accordance with Clause
1012

2) The finished colour of all paint work is subject to the prior approval of the Engineer.
If instructed by the Engineer, the Contractor shall prepare sample panels of at least
1 m
2
at a location determined by the Engineer.

811 Water Supply and Sanitary Works
1) General - Plumbing shall be carried out by a specialist Sub-Contractor approved
Engineer and all works shall conform to the requirements of Engineer and the
relevant Indian Standards. Building drainage shall conform to IS:1742. Water
supply to buildings shall comply with IS:2065.

2) Applicable Codes - The following Indian Standard Codes, unless otherwise specified
herein, shall be applicable. In all cases, the latest revision of the codes shall be
referred to.

IS:1172 Code of basic requirements for water supply, drainage and
sanitation
IS:1239 Specification for mild steel tubes and wrought steel fittings
(Part 1 MS pipes), to be read in conjunction with IS 4736
(Hot dipped zinc coatings to MS tube)
IS:1742 Code of practice for building drainage
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IS:4111 Code of practice for ancillary structures in sewerage system
(Parts 1 and 2)
IS:3114 Code of practice for laying of cast iron pipes
IS:783 Code of practice for laying of concrete pipes
IS:4127 Code of practice for laying of glazed stoneware pipes
IS:5329 Code of practice for sanitary pipe work above ground for
buildings
IS:2065 Code of practice for water supply in buildings

3) PVC Pipes - The Contractor shall install PVC pipes in the location and to the lines
grades and dimensions according to detailed design drawings. Plastic pipes for sub-
surface drainage shall be in accordance with Sub-clause 705 of this Specification.

4) Galvanised Steel Tubing - Galvanised mild steel tubing and fittings shall be steel
tube for water supply to IS:1239 Class M galvanised in accordance with IS:4736. All
pipes shall be supplied by an approved manufacturer with screw and socket joints,
tested hydraulically to a pressure of 48 bars. Pipes shall be secured to structures at
not more than 1.5 centres, with galvanized malleable cast iron brackets of an
approved pattern.

5) Cocks and Valves - All cocks and valves shall be of types approved by the Engineer
and in accordance with IS:6157. Stop valves, which are generally concealed, shall
be made of brass or gunmetal. Stop cocks, which are exposed and bib and pillar
cocks attached to sanitary fittings shall be brass or gunmetal bodies chromium plated
and marked hot or cold as required.

6) Ball valves shall be brass in accordance with IS:1703.

7) Water Pipes and Fittings - All plumbing works shall be carried out through a
Licensed Plumber and the pipes and fittings shall be as per the requirements of the
water byelaws. The Contractor shall submit the name of the Licensed Plumber to
whom the work is to be entrusted for approval of the Engineer. On completion of the
work the Licensed Plumber shall submit a Drainage Completion Certification,
certifying that the works carried out by him have been done in accordance with
specifications and provisions of and the relevant byelaws.

8) Glazed Stone Work - The pipes used in the works shall be of the best approved
quality. All pipes shall be perfectly straight and truly cylindrical, glazed inside and
outside, free from cracks and flaws, and perfectly burnt. Those not perfectly straight
and truly cylindrical, well and uniformly glazed, free from cracks and flaws etc. shall
be rejected.

812 Electrical Works
1) The general layout of electrical works shall be submitted by Contractor to the
Engineer for approval. The Contractor shall then submit a detailed layout of each
building to the Engineer for approval before commencing the works.

2) Samples of all important material including PVC conduits, wire, ordinary wires, for
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power points, switches, holders, tubelight fittings, cutouts & boards shall be
submitted to the Engineer for his approval.

3) In general surface mounted GI conduit shall be used. Where specified, 25 mm dia
PVC pipes shall be used for concealed wiring.

813 Roof sheets and vertical cladding
1) Unless otherwise specified on the drawings or specified elsewhere, roof sheets and
vertical cladding shall be factory colour-coated steel profile sheet with a minimum
steel thickness before coating of 1.0mm (20 gauge sheet).

2) The spacing of purlins and supports shall be in accordance with sheet sizes and laps
recommended by the manufacturer but, in general, the maximum spacing of supports
shall be 1.8m.

3) Fixings and laps shall be in accordance with the manufacturers recommendation but,
in general, laps shall be 150mm for sheet ends and one full profile section for edges.
Factory made edges for corners and ridge pieces shall be used.

4) Where shown on the drawings or specified elsewhere, translucent panels and/or
louvre ventilators from the same manufacturer/cladding system shall be used. All
ventilators shall be provided with heavy duty compatible metal wire insect and bird
proof mesh.

5) Prior to ordering, the Contractor shall supply samples of the proposed sheets,
translucent panels, ventilators and colour samples for the Engineers approval.

814 Fencing
1) Unless otherwise specified on the drawings or specified elsewhere, fencing shall be
galvanised steel chain link fence fabric to IS: 2721 with a minimum steel wire
thickness before coating of 4.0mm (8 gauge). The fabric shall be formed from
continuous, single-interlocked, wires across the width of the fabric to form a
diamond mesh of 50mm x 50mm.

2) All straining and edge wires shall be similarly galvanised steel wires 4.0mm
diameter.

3) Unless otherwise specified, the wire shall be left as factory finished galvanised
coating without plastic coating or paint treatment.

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PART 9: EARTH MAT

901 General Description
1) The earth mat shall comprise steel strips 75mm x 8mm laid in a grid pattern beneath
the foundations of Power House, Tail Race and Switchyard. The Engineer will carry
out measurements of ground conductivity, following which he shall instruct the
spacing of earth strips and the area of the mat.

2) Steel strips shall be welded at every intersection to form a continuous mat.

3) Earth straps of 50mm x 6mm steel strips shall be connected to the earth mat at
locations to be directed by the Engineer and brought to the surface at the locations of
plant foundations.

4) The earth mat and earth straps shall be protected against damage from subsequent
construction operations.

902 Earth Rods
1) Earth rods shall be installed below the earth mat at locations to be directed by the
Engineer. The number of rods shall be instructed following the ground conductivity
measurements.

2) The mild steel earth rods shall be 32mm diameter solid steel 3m in length. The top
of each rod shall be connected with 75mm x 6mm steel flats to the earth mat through
welded joints.

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PART 10: STEELWORK

1001 Hot Rolled Steel
1) Hot rolled steel in hot rolled sections, structural hollow sections, plates and bars shall
comply as a minimum with the basic specification of IS 1732. All steel shall have
been tested in accordance with IS 1732 and the Contractor shall obtain the relevant
manufacturers test certificates.

2) Except where otherwise specified, structural steel, connections and fittings shall be
grade 250.

3) All steel materials shall comply in dimension, weight and tolerance with those
shown on the drawings and with the following standards:

(i) Plates and bars IS 1732
(ii) Universal beams, columns, rolled joists, channels
And tees IS 808 & IS 1170
(iii) Angles IS 808 & IS 1170
(iv) Structural hollow sections IS1161 and IS 806

1002 Surface Condition
1) Steel surfaces when used shall not be more heavily pitted or rusted than Grade C of
the Swedish Standard SIS 05 59 00.

2) Surface defects in hot rolled sections, hollow sections, flats, rounds and square bars
revealed during surface preparation which are not in accordance with the
requirements of IS 1732, for quality of finished steel, shall be rectified in accordance
with clause 9 of IS 1732.

1003 Structural Fasteners
1) Bolts, nuts and washers etc, shall be of mild steel unless otherwise specified. The
heads of the bolts shall be forged out of the solid bar and the ends shall be cleanly
cut with standard threads and the nuts must fit the bolts accurately and tightly.

Shop, site bolts, nuts and washers shall conform to following relevant standards:
IS 3757 High Strength Friction grip bolts
IS 6623 High Tensile Friction grip Nuts
IS 6639 Hexagon Bolts for Steel Structures
IS 6649 High Tensile Friction Grip Washers
IS 7215 Tolerance for fabrication of steel structures

Any bolt assemblies which seize when being tightened shall be replaced.

2) Plain metal washers shall be made in accordance with IS 6610- 1972. Black metal
washers to Form E shall be used unless otherwise specified.

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1004 Welding Consumables
1) Consumables for use in metal arc welding shall comply with the requirements of IS
814 Part 1 and Part 2 & IS 1149 as appropriate.

2) Consumables shall be stored in the Contractors works and on site in a controlled
atmosphere, in accordance with relevant Indian Standard. Any drying and baking of
consumables before issue shall be carried out in accordance with the manufacturers
recommendations and the authority of the Engineer.

1005 Corrosion Protection System
1) Material for blast cleaning shall be chilled iron shot in accordance with relevant
Indian Standard.

2) Surface coatings shall be in accordance with the guidance given in IS 1477 and IS
2544

1006 General Workmanship
1) All steel shall be covered by a test certificate. The material grades of all steel shall
be identifiable.

2) Individual pieces of steelwork shall be capable of positive identification at all stages
of fabrication. Completed components shall be marked with a durable and
distinguishing erection mark in such a way as not to damage the material.

3) Steelwork shall be bundled, packed, handled and transported in a safe manner so that
permanent distortion does not occur and surface damage is minimised.

4) Cutting and shaping of steel may be carried out by shearing, cropping, sawing,
nibbling, laser cutting or machine flame cutting, except where machine flame cutting
is impractical, hand flame cutting may be used. Flame cut edges which are free from
significant irregularities shall be accepted without further treatment except for the
removal of dross, otherwise cut edges shall be dressed to remove irregularities.

5) The thickness of elements shown on the drawings as requiring machining shall mean
the minimum thickness after the machining operations.

6) Cut edges shall be dressed to remove dross, burrs and irregularities. Holes shall be
dressed as required to remove burrs and protruding edges. Sharp edges shall be
dressed, but a 90 rolled, cut or sheared edge is acceptable without further treatment.

7) All matching holes for fasteners or pins shall register with each other so that
fasteners can be inserted without undue force through the assembled members in a
direction at right angles to the faces in contact. Drifts may be used but holes shall
not be distorted.

8) Drilling shall be permitted through more than one thickness where the separate parts
are tightly clamped together before drilling. The parts shall be separated after
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drilling and any burrs removed.

9) All components shall be assembled within tolerances specified and in a manner such
that they are not bent, twisted or otherwise damaged. Drifting of holes to align the
components shall be permitted, but must not cause damage or distortion to the final
assembly.

10) When it is necessary to introduce or correct camber, or to straighten components, one
of the following methods may be used:

i) mechanical means, taking care to minimise indentations, or change of cross
section.

ii) the local application of heat, ensuring that the temperature is carefully
controlled, and does not exceed 600C.

11) Sufficient components shall be checked for dimensional accuracy and conformity to
drawing to prove that the manufacturing process is working satisfactorily.

12) Fabricated components which are stored prior to being transported or erected shall be
stacked clear of the ground and arranged so that water cannot accumulate. They
shall be kept clean and supported in such a manner as to avoid permanent distortion.

1007 Welding Workmanship
1) Welding shall be a metal arc process in accordance with IS 816 and IS 9595, as
appropriate, unless otherwise specifically permitted by the Engineer.

2) The Contractors proposed welding procedures shall be submitted in writing to the
Engineer for his approval before any work is undertaken. The procedure shall
identify material, weld geometry, tolerances, welding process, pre-heat temperature
and welding position to be used. In the case of site welds, the welding procedure for
making each type of joint shall be approved by the Engineer before the work is
commenced.

3) All welding shall be carried out by qualified welders who shall be under competent
supervision. The Engineer may call for a test of a welders capabilities in accordance
IS 817 and IS 7310, as deemed appropriate. In the case of site welds the Contractor
shall make such trial welds as the Engineer may require to demonstrate the
soundness of the proposed method and the competence of his workmen.

4) The results of non-destructive testing of welds shall be recorded and be available for
inspection by the Engineer. Visual inspection shall be made in accordance with
guidance given in IS 7318 after completion of all welding over the full length of the
weld. Any welds which will be rendered inaccessible by subsequent work shall be
examined prior to the loss of access. Where a closer examination of a weld surface
is required dye penetrant inspection may be used in accordance with the
recommendations given in IS 7215. Any welds that are in the opinion of the
Engineer defective, shall be cut out and the welds remade to the satisfaction of the
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Engineer. The cost of such corrective measures including any resultant delays, shall
be borne by the Contractor.

1008 Bolting Workmanship
1) Washers shall be placed under the nut or bolt head being rotated when the members
are being connected.

2) Connected parts shall be firmly drawn together. If there is a remaining gap which
may affect the integrity of the joint, it shall be taken apart and a pack inserted.

1009 Erection of Steelwork
1) A method statement, giving details of the erection scheme and programme, shall be
submitted to the Engineer for his approval, before erection commences.

2) Components shall be handled and stored in such a manner as to minimise the risk of
surface abrasion and damage. Fasteners and small fittings shall be stored under
cover in dry conditions. Any steelwork damaged during transportation, off-loading,
storage or erection shall be restored to conform to the standards of manufacture as
specified.

3) The Contractor shall ensure that all supports upon which the steel gates are to be
erected are in the correct position and that the steelwork fits correctly in required
positions without forcing or straining in any way. Any check by the Engineer of the
Contractor's measurements shall not relieve him of his responsibility for obtaining
this fit unless any errors in position are clearly not attributable to him.

4) No permanent bolting or site welding shall be done until proper alignment has been
obtained. The Contractor may use temporary jigs, anchors or supports during
erection, but must allow for thermal movement to take place freely at all times.

1010 Protective Treatment - General
1) The Contractor shall submit to the Engineer for his approval details of the types and
manufacturers of paints he is proposing to use, together with the manufacturer's
recommendations concerning preparation of surfaces, primers and undercoats,
application methods, safety precautions and drying times for each type of paint. All
paints used in the Works must be supplied ready-mixed in unbroken, sealed
containers, which clearly show the type, colour and manufacturer of the paint and
carry detailed "instructions for use".

2) All metal surfaces on which paint is to be applied shall be blast cleaned to grade SA
2 , or other approved mechanical means and fully prepared in accordance with the
manufacturer's recommendations. Applications of paint coatings on external work
shall not be carried out or continued in mist, rain or excessively damp conditions.
The Contractor shall take all necessary precautions to prevent dust and dirt coming
into contact with freshly applied paint before it has dried.

3) Paints shall be applied either by brushing or spraying in accordance with the
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manufacturer's instructions. The thinning of paints shall not be permitted without the
approval of the Engineer. Unless otherwise recommended by the manufacturer, the
minimum interval between the application of a first coat of paint and the second shall
be twenty four hours (24hrs). Special care shall be taken to ensure complete
coverage of all corners, arises and openings without causing an excessive build-up of
paint and avoiding runs.

4) Steelwork to be painted shall be clean and free from all rust, grease, oil and mill
scale.

5) The Contractor shall provide a magnetic paint thickness gauge or other suitable
instrument for measuring paint thickness.

1011 Protective Treatment - Particular
1) Steelwork shall be immediately coated before leaving the factory with zinc
phosphate or similar compatible metallic inhibitive primer with a minimum dry film
thickness of 0.05mm. Following drying of the primer, the steelwork shall be coated
with one coat of non-toxic, non-tainting, high build bituminous paint to IS 1477 part
1 & 2, having a minimum dry film thickness of 0.125mm.

2) After erection, damaged areas of steelwork shall be mechanically cleaned and
touched up with primer and bituminous paint to fully restore the factory applied
coating system and thickness.

3) Finally, two overall finish coats of bituminous paint with a minimum dry film
thickness per coat of 0.10mm giving an overall minimum dry film thickness of the
complete coating system of 0.375mm.

1012 Painting Handrails
1) Handrails shall be thoroughly cleaned and painted prior to leaving the factory with:

i) one coat of zinc phosphate or similar compatible metallic inhibitive primer with
a minimum dry film thickness of 0.05mm.
ii) one coat of red lead primer with a minimum dry film thickness of 0.05mm.
iii) two coats of micaceous iron oxide undercoat paint with a minimum dry film
thickness per coat of 0.05mm.

2) After erection, damaged areas of steelwork shall be mechanically cleaned and
touched up with primer and under coat to fully restore the factory applied coating
system and thickness.

3) Finally, one overall finish coat of enamel gloss micaceous iron oxide paint with a
minimum dry film thickness of 0.05mm giving an overall minimum dry film
thickness for the complete coating system of 0.25mm.
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Appendix A: Primary Survey Stations

DETAILS TO BE ADVISED PRIOR TO START DATE
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Appendix B: Table of Tolerances

The following are the tolerances within which the works are to be executed or as directed
by the Engineer:

EARTHWORKS

Top level of Embankments after compaction +100/-0 mm

Sides of Embankments over a 10m length +100/ -0 mm

Channel (or Excavation cutting) over a 10m length +100/ -0 mm

Channel Water Way Area -0

Horizontal Alignment of Channels Maximum 300 mm
Over 20m length 75 mm

Vertical Alignment of Channels Maximum +100/-100 mm
Over 20m length 50 mm

Formation Level for Structures +0/-ve (filled
with concrete refer
specification)
Formation Level for Gabions +0/ -100 mm

CONCRETE STRUCTURES

The following tolerances shall apply to all wrought formed and fair or fine unformed
finishes.

Tolerance from Specified Position

Maximum departure of plan position of structure 300 mm

Tolerance from Specified Dimension

Maximum departure in thickness, cross-sectional
dimension or position of columns, beams, walls,
footings and the like +15/ -5 mm

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Surface Tolerance on Straightness or Departure from Specified Curve

General Surfaces

Maximum deviation in horizontal or vertical direction

gradual over a 10 metre length 25 mm
abrupt 5 mm

Surfaces in Contact with Flowing Water

Maximum deviation in direction of flow or normal to flow

gradual over a 10 metre length 10 mm
abrupt 2 mm

Reinforcement

Maximum departure in required spacing +10/ -5 mm

Stonework

Masonry on weir crest over a 2 metre length +5/ -5 mm

Masonry on other weir faces over a 2 metre length +10/ -10
mm

Ashlar masonry over a 2 metre length +5/ -5 mm

Masonry in hydraulic structures over a 2 metre length +10/ -10 mm

Masonry walls over a 2 metre length +75/ -25 mm

Face of gabion basket +50/ -25 mm

Thickness of gravel layer +50/ -10 mm

Thickness of tipped rock +100/ -0 mm

Steelwork

Fabricated steelwork +1/ -1 mm

Machined steelwork +0.1/ -0.1 mm

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Specifications: Volume II B Hydro Mechanical Part A
i

VOLUME II-B

DESIGN MEMORANDUM AND TECHNICAL
SPECIFICATION
FOR
HYDRO MECHANICAL WORKS

PART A GENERAL TECHNICAL SPECIFICATION
PART B GATES, STOPLOGS, TRASHRACKS AND HOISTS
PART C PENSTOCKS
PART D TECHNICAL DATA SHEETS

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INDEX

GENERAL TECHNICAL SPECIFICATION
SECTION 1 : GENERAL DESCRIPTION............................................................................................................1
1.1 INTRODUCTION .....................................................................................................................................................1
1.1.1 Location & Communication...................................................................................................................................1
1.2 SCOPE OF WORK...................................................................................................................................................1
1.2.1 General ..................................................................................................................................................................1
1.2.2 Diversion Weir Under Sluice vertical lift Gates, Rope Drum Hoists, Stop Logs and Monorail Crane..............2
1.2.3 Trash rack, Intake gate, stop logs and hoist for Intake..........................................................................................3
1.2.4 Desilting Inlet & Outlet Gates:.............................................................................................................................3
1.2.5 Trash rack for HRT intake.....................................................................................................................................4
1.2.6 Draft Tube Gates ..................................................................................................................................................4
1.2.7 One Diesel Generator Set .....................................................................................................................................4
1.2.8 Sluice Valves.........................................................................................................................................................4
1.2.9 Steel Penstock and Power Waterway Steel Lining................................................................................................4
1.2.10 Operation and Maintenance Manuals...................................................................................................................4
1.2.12 Notes: ....................................................................................................................................................................5
1.3 STANDARDS.......................................................................................................................................................5
1.3.1 General ..................................................................................................................................................................5
1.3.2 STANDARDS FOR GENERAL APPLICATION...........................................................................................................5
1.3.3 General ..................................................................................................................................................................5
1.3.4 Standards for Design & Testing ............................................................................................................................6
1.3.5 Material Standard..................................................................................................................................................7
1.4 PERMISSIBLE STRESSES......................................................................................................................................11
1.4.1 General ................................................................................................................................................................11
1.4.2 Permissible Stresses for all Gates........................................................................................................................12
1.4.3 Permissible Stresses for Rope Drum Hoist Equipment........................................................................................13
1.4.4 Permissible Stresses for Hoist Trestles & Hand Railing (Clearly above Water).................................................13
1.4.5 Permissible Stresses for Lifting Beams................................................................................................................14
1.4.6 Permissible Stresses and Safety Factors for Steel Pressure Tunnel Lining and Bifurcation...............................14
2. TECHNICAL DOCUMENTS ..........................................................................................................................15
2.1 GENERAL.............................................................................................................................................................15
2.1.1 Scope of Work......................................................................................................................................................15
2.1.2 Design & Drawings .............................................................................................................................................16
2.1.3 Diagrams .............................................................................................................................................................17
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2.1.4 Lists of Schedules.................................................................................................................................................17
2.1.5 Installation and Commissioning Procedures.......................................................................................................21
2.1.6 Operation and Maintenance Manuals .................................................................................................................21
2.1.7 Progress Reports .................................................................................................................................................21
SECTION 3 : SPARE PARTS AND TOOLS................................................................................................................23
3.1 SPARE PARTS......................................................................................................................................................23
3.1.1 General ...............................................................................................................................................................23
3.1.2 General Spare Parts ...........................................................................................................................................23
3.1.3 Mandatory Spare Parts........................................................................................................................................24
3.1.4 Recommended Spare Parts ..................................................................................................................................24
3.2 TOOLS AND APPLIANCES ....................................................................................................................................24
3.2.1 Scope of Work......................................................................................................................................................24
SECTION 4 : DESIGN AND MANUFACTURE..........................................................................................................25
4.1 DESIGN AND CONSTRUCTION REQUIREMENTS..................................................................................................25
4.1.1 General ................................................................................................................................................................25
4.1.2 Design Criteria....................................................................................................................................................26
4.1.3 Tolerance and Clearance.....................................................................................................................................27
4.1.4 Standardisation of Works.....................................................................................................................................28
4.1.5 Quality of Materials and Works...........................................................................................................................29
4.1.6 Works Identification System.................................................................................................................................29
4.2 IDENTIFICATION PLATES....................................................................................................................................30
4.2.1 General ................................................................................................................................................................30
4.2.2 Manufacturers Name plates ...............................................................................................................................30
4.2.3 Instruction Plates.................................................................................................................................................30
4.2.4 Warning Plates ....................................................................................................................................................30
4.3 WORKMANSHIP ...........................................................................................................................................................30
4.3.1 General ................................................................................................................................................................30
4.3.2 Finished Surfaces.................................................................................................................................................31
4.3.3 Protection of Machined Surfaces.........................................................................................................................31
4.3.4 Mechanical Works ...............................................................................................................................................31
4.3.5 Welding................................................................................................................................................................32
4.4 CORROSION PROTECTION ..................................................................................................................................35
4.1.1 Surface Treatment and Protection.......................................................................................................................35
4.4.2 Painting System ...................................................................................................................................................36
4.4.3 Colour Scheme.....................................................................................................................................................38
4.4.4 Galvanizing..........................................................................................................................................................38
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4.4.5 Repair of Primer and Finish Coats......................................................................................................................39
4.4.6 Quality Control....................................................................................................................................................39
4.4.7 Guarantee ............................................................................................................................................................39
4.5 METAL WORK.....................................................................................................................................................40
4.5.1 Embedded Metal Works.......................................................................................................................................40
4.5.2 Miscellaneous Metalwork....................................................................................................................................40
4.6 FABRICATION AND INSTALLATION WORKS........................................................................................41
4.6.1 Scope of Work......................................................................................................................................................41
4.6.2 FABRICATION......................................................................................................................................................41
4.6.2.1Gates and Stop Logs................................................................................................................................................41
4.6.2.2 Embedded Parts ..............................................................................................................................................42
4.6.3 Installation..........................................................................................................................................................43
4.6.3.1 Installation of Gates and Stop Logs ................................................................................................................43
4.6.4 Installation of Frame, Guide and Tracks............................................................................................................43
4.6.4.1 Assembly and Erection....................................................................................................................................43
4.6.4.2 Placing Concrete in Block Outs......................................................................................................................43
4.6.4.3 Hoist & Cranes ...............................................................................................................................................43
4.6.5 DIVERSE ITEMS ..................................................................................................................................................44
4.6.5.1 Fasteners.........................................................................................................................................................44
4.6.5.2 Seals................................................................................................................................................................44
4.6.5.3 Drives and Gears ............................................................................................................................................45
4.6.5.4 Lubrication, Lubricants and Fuel ...................................................................................................................45
SECTION 5 : ELECTRICAL WORKS.........................................................................................................................47
5.1 GENERAL.............................................................................................................................................................47
5.1.1 Scope of Work......................................................................................................................................................47
5.1.2 Standards.............................................................................................................................................................47
5.1.3 Colour Code ........................................................................................................................................................47
5.2 ELECTRIC MOTORS ............................................................................................................................................48
5.2.1 General ................................................................................................................................................................48
5.2.2 Rating...................................................................................................................................................................48
5.2.3 Starting ................................................................................................................................................................48
5.2.4 Windings and Insulation Class ............................................................................................................................49
5.2.5 Ventilation and Type of Enclosure.......................................................................................................................49
5.2.6 Bearings...............................................................................................................................................................49
5.2.7 Shafts and Couplings ...........................................................................................................................................50
5.2.8 Terminal Boxes and Earthing..............................................................................................................................50
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5.2.9 Noise-Level and Vibrations .................................................................................................................................50
5.2.10 Tests ................................................................................................................................................................51
5.3 AUXILIARY WORKS ............................................................................................................................................51
5.3.1 Auxiliary Switches ...............................................................................................................................................51
5.3.2 Control Switches..................................................................................................................................................51
5.3.3 Anti-Condensation Heaters..................................................................................................................................52
5.3.4 Protection Devices...............................................................................................................................................52
5.4 TERMINAL POINTS..............................................................................................................................................53
5.4.1 Scope of Work......................................................................................................................................................53
5.4.2 Supply Tolerances................................................................................................................................................53
5.5 CABLES................................................................................................................................................................53
5.5.1 General ................................................................................................................................................................53
5.5.2 Colour Code ........................................................................................................................................................54
5.6 EARTHING SYSTEM.............................................................................................................................................54
5.6.1 General ................................................................................................................................................................54
5.7 LABELS AND PLATES...........................................................................................................................................54
5.7.1 General ................................................................................................................................................................54
5.7.2 Equipment Labels and Instruction Plates ............................................................................................................54
5.7.3 Warning Labels....................................................................................................................................................55
5.7.4 Labels for Conduits, etc. ......................................................................................................................................55
5.7.5 Labels for Cables.................................................................................................................................................55
5.7.6 Rating Plates........................................................................................................................................................55
5.8 KEY SYSTEM FOR ELECTRIC BOARDS ...............................................................................................................55
5.8.1 General ................................................................................................................................................................55
SECTION 6: TRANSPORT AND STORAGE..............................................................................................................57
6.1 GENERAL.............................................................................................................................................................57
6.2 PACKING..............................................................................................................................................................57
6.3 MARKING ............................................................................................................................................................58
6.4 STORAGE.............................................................................................................................................................58
SECTION 7: INSPECTIONS AND TESTS .................................................................................................................59
7.1 GENERAL.............................................................................................................................................................59
7.2 WORKSHOP INSPECTIONS AND TESTS................................................................................................................60
7.2.1 General ................................................................................................................................................................60
7.2.2 Material Tests ......................................................................................................................................................61
7.2.3 Checking of Dimensions ......................................................................................................................................61
7.2.4 Workshop Assembly.............................................................................................................................................62
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7.2.5 Functional Tests...................................................................................................................................................62
7.2.6 Operational Tests.................................................................................................................................................63
7.2.7 Electric Tests .......................................................................................................................................................64
7.3 SITE INSPECTION AND TESTS..............................................................................................................................64
7.3.1 General ................................................................................................................................................................64
7.3.2 Commissioning and Trial Run .............................................................................................................................65
7.3.3 Acceptance...........................................................................................................................................................65

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1
SECTION 1: GENERAL DESCRIPTION
1.1 Introduction
1.1.1 Location & Communication
The proposed Bhyunderganga hydropower project is located near Gobindghat
village, Dist. Chamoli, Uttarakhand. The project is located on the river
Bhyunderganga on Rishikesh- Badrinath road and is at a distance of about 275 km
from Rishikesh. The Powerhouse site is proposed to be located on the left bank of
river Bhyunderganga. Diversion weir of the scheme is located about 5.0km
upstream from confluence of Alaknanda with Bhyunderganga at Gobindghat.
The main works of the project comprise of Diversion Weir and Intake structure on
the Bhyunderganga River, Intake Channel, Desilting Basin, Power Channel, Tunnel
in rock (2.5m diameter D shaped with concrete lined approximately 2747m long),
Penstock Valve House and Penstock (775 m in underground excavation and 186m
excavation in overburden with rock outcrops for construction of penstock saddle
support, crossings and anchor blocks), Surface Power House, Transformer and
Potyard and Tail Race channel
The Document
i) The Contractor shall strictly observe the General Technical Specifications in
conjunction with the Particular Technical Specifications. He shall carry out all
works in a skilled and workman like manner in compliance with modern
methods of engineering. All design calculations, materials, works,
manufacture and testing shall conform to the latest applicable standards.
ii) In addition, the Contractor shall conform to all applicable regulations
regarding the execution of construction and installation work, and shall follow
all instructions issued by the competent authorities, and the Engineer-in-
Charge.
iii) The Particular Technical Specifications shall take precedence over the
General Technical Specifications in case of any contradiction. Clause number
cross-references refer to the volume in which they occur unless stated
otherwise. However, in case the General Technical specifications / Particular
Technical Specifications are silent on any particular issue, the relevant IS:
Codes shall prevail.
1.2 Scope of Work
1.2.1 General
i) The broad scope of the work shall include the following:
Design, manufacture, inspection, shop assembly, testing, painting,
transportation, site storage & site erection, testing and commissioning
including provision for all labour, plant & material for all the Hydro-mechanical
equipment and penstock steel liners for the above, handing over to owner,
and supply of necessary spares for 5 years trouble free operation. Supply
and installation of all incidentals not specified but are necessary for the
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proper completion and satisfactory functioning of works and guarantee of the
permanent equipment, along with all auxiliary equipment in the designated
location of the project as specified in the scope of work. The Contractor shall
provide detail specifications for the various equipments for Purchasers
approval.
ii) It is not the intention of these specifications to specify the complete details of
equipment; however the Contractor shall supply the equipment, which will
meet in all respect, the requirements of the Purchaser in regard to
performance durability and satisfactory operations. All the equipment
supplied shall conform to the relevant Indian Standard. Wherever the Indian
Standards are not existent or silent, relevant ASTM, ISO (The International
Standard Organization), DIN (Deutsche Industry Norm), J IS (J apanese
Industrial Standards) or BSI (British Standards Institution) standard shall be
adopted.
1.2.2 Diversion Weir Under Sluice vertical lift Gates, Rope Drum Hoists, Stop
Logs and Monorail Crane

i) Diversion Weir Gates
a) Two numbers of submerged type vertical lift fixed wheel type gates with
individual electrically operated rope drum hoists each of adequate
capacity for a clear opening size 2.50m x 3.00m, including seal
assemblies, track bases assemblies, sill beam assemblies, guide roller
assemblies, lifting arrangement , dogging arrangement and other
miscellaneous fittings i.e. Hoist bridge, ladders etc. as specified complete
in all respects.
b) Two Nos. Electrically Operated Rope Drum Hoists of adequate capacity
and Hoist Bridges.
c) Two Nos. independent control points for the two sets of gates to be
operated individually or simultaneously.
d) 2 (Two) sets of 1
st
stage as well as 2
nd
stage embedded parts complete in
all respect.
ii) Diversion Weir Under Sluice Stop logs
a) One set of Slide Type Stoplogs consisting of two non - interchangeable
units for a clear opening size 2.50m x 3.00 m including Seal assemblies,
Slide Blocks , Guide Roller assemblies, filling valve cum - lifting
arrangement and other miscellaneous essential components etc.
complete in all respect.
b) Two sets of 1
st
stage as well as 2
nd
stage embedded parts complete with
slide tracks and seal, sealing frames, sill beam and side guides etc.
c) One No. electrically operated Mon Rail Crane of adequate capacity and
having long travel along with one No. lifting beam of adequate capacity.
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1.2.3 Trash rack, Intake gate, stop logs and hoist for Intake.
a) Three set of Trash Rack consisting of equal size panels of 4.00 m x 3.60
m each comprising of trash bars, spacers, framing channel/ angles etc,
complete for 4.00 m x 7.20 m size opening complete in all respects in
accordance to these specifications .
b) One set of Intake Service gates Fixed Wheel Type for clear opening of
3.0 m x 1.50 m with electrically operated Rope Drum Hoist of adequate
capacity including seal assemblies, track bases assemblies, sill beam
assemblies, guide roller assemblies, lifting arrangement , dogging
arrangement and other miscellaneous fittings i.e. Hoist bridge, ladders
etc. as specified complete in all respects.
c) One set of Slide Type Stoplogs consisting of two equal size units for clear
opening size of 3.0 m x 1.50 m with an Electrically Operated Mono Rail
Crane and a lifting beam of adequate capacity including Seal assemblies,
Slide Blocks , Guide Roller assemblies, filling valve cum - lifting
arrangement and other miscellaneous essential components etc.
d) One No. Electrically Operated Rope Drum Hoists of adequate capacity
and Hoist Bridges.
e) One No. independent control points for the two sets of gates to be

f) Two sets of 1
st
stage as well as 2
nd
stage embedded parts complete with
slide tracks and seal, sealing frames, sill beam and side guides etc.
complete in all respect for Intake Service Gates as well as for Stoplogs
g) One No. electrically operated Mon Rail Crane of adequate capacity and
having long travel along with one No. lifting beam of adequate capacity.
1.2.4 Desilting Inlet & Outlet Gates:
a) Three Nos. each Fixed Wheel Type Gates for Inlets and Outlets of
clear openings of 4.25m x 2.00m with electrically operated Rope
Drum Hoist of adequate capacity including seal assemblies, track
bases assemblies, sill beam assemblies, guide roller assemblies,
lifting arrangement , dogging arrangement and other miscellaneous
fittings i.e. Hoist bridge, ladders etc. as specified complete in all
respects.

b) Six Nos. Electrically Operated Rope Drum Hoists of adequate
capacity and Hoist Bridges.
c) Two Nos. independent control points for the two sets of gates to be
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d) 2 (Two) sets of 1
st
stage as well as 2
nd
stage embedded parts
1.2.5 Trash rack for HRT intake
a) One set of Trash Rack consisting of one panel of size 3.70 m x 4.50
m comprising of trash bars, spacers, framing channel/ angles etc,
complete for 3.70 m x 4.20 m size clear opening complete in all
respects in accordance to these specifications .
1.2.6 Draft Tube Gates
a) Three sets of Slide Type Draft Tube Gates for a clear opening size
2.0m x 3.2m including Seal assemblies, Slide Blocks , Guide Roller
assemblies, filling valve cum - lifting arrangement and other
miscellaneous essential components etc. complete in all respect.
b) Three sets of 1
st
stage as well as 2
nd
stage embedded parts
complete with slide tracks and seal, sealing frames, sill beam and
side guides etc. complete in all respect.
c) One No. electrically operated Mon Rail Crane of adequate capacity
and having long travel along with one No. lifting beam of adequate
capacity.
1.2.7 One Diesel Generator Set
To operate Diversion Weir Gates in case of power failure.
1.2.8 Sluice Valves
Three sets of Knife Edge Gate Valve of 600 mm dia for silt flushing conduits.
1.2.9 Steel Penstock and Power Waterway Steel Lining
Depending on the rock conditions, which will be studied in detail during the
final design phase, a steel lining will be provided in the water conductor
portion (drawing no. WH/BGYU/601) of HRT to the inlet of MIV of power
house. A single penstock of 1.60 meter dia takes off with its centre line at EL
2007.8 meter, and Trifurcates into three branches of 0.8 meter dia each
near the power house.
1.2.10 Spares and Tools
Spares as mandatory and optional for the purchaser in separate lists for 5
years trouble free operation.
One set of tools and appliances including special tools required for repair and
maintenance works.
1.2.11 Operation and Maintenance Manuals
Six (6) sets of operation and maintenance manuals in English only containing
drawings A-1 Size, A-3 Size as well as soft copy of all catalogue and brochures
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for plants and machinery, handling procedures for assemblies & sub assemblies
of all equipment covered under this specification.
1.2.12 Notes:
i. The layout of gates, hoists, penstock liners is tentative and may undergo
changes in size, head, elevation, location during final design stage.
Nothing extra shall be payable on a/c of these changes to the contractor.
ii. Purchaser reserve the right to delete any item(s) from the scope of work
and no claim whatsoever due to this shall be entertained.
iii. The contractor shall quote for the total scope of work for Barrage vertical
lift gates. In case the purchaser himself procures the gate operating
mechanism i.e. Rope Drum Hoists/ Mono Rail Cranes, etc as per the
recommended sizes and operating parameters, specifications of the
contractor, then the contract shall also quote his rates for all these
services and erection of hoisting mechanism separately.
iv. The Contractor shall also keep a provision in the power packs of Barrage
vertical lift gates, where the purchaser can connect in future an engine
driven oil pumps to operate hoists at the rated speed.

1.3 STANDARDS
1.3.1 General
i) Although Indian Standards for design, testing, workmanship, material and
Works have been selected mostly in these specifications as a basis of
reference, other standards and recommendations of standard international
organizations will be acceptable provided they ensure equal or higher quality
compared to those specified, and provided, furthermore, that the Contractor
submits for approval copies of the standards which he proposes to use.
ii) Except where modified by this specification, works and materials shall be in
accordance with INDIAN STANDARDS. If relevant Indian Standards are not
available in any case or cases, then relevant International Standard shall be
proposed by the Contractor for approval by the Engineer-in-Charge.
iii) When IEC or ISO Recommendations or other Standards are referred to shall
be the issue current at the time of actual design, together with any
amendments issued prior to that date.
iv) The Contractor shall supply at his own expense two copies in English and
one in the original language of any international standards, which are
approved for use under the Contract.
1.3.2 Standards for General Application
1.3.3 General
Standard publications issued by the following organizations of standardization are
considered being approved standards for the works with a priority to use Indian
Standards:
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BIS: Bureau of Indian Standards
ASTM: American Society for testing & material
ASME: American Society of Mechanical Engineers
DIN: Deutsche Industrie Norm
BSI: British Standard Institution
IEC: International Electromechanical Commission
ISO: The International Standard Organization
J IS: J apanese Industrial Standard
1.3.4 Standards for Design & Testing
The following list of Indian Standard Specifications (latest edition) shall be followed
wherever the detailed requirements have not been outlined in these
specifications:
IS: 456 Code of practice for plain & reinforced concrete
IS: 800 Code of practice for general construction in steel.
IS: 807 Code of practice for design, manufacture, erection & testing
structural portion of cranes & hoists
IS: 875 Code of practice for design loads for buildings and structures
IS: 1893 Criteria for earthquake resistant design of structures
IS: 2595 Code of practice for radiographic testing
IS: 2825 Code for unfired pressure vessels
IS: 3177 Code of practice for electric over head travelling cranes and
gantry cranes other than steel work cranes
IS: 3658 Code of practice for liquid penetrate flaw detection
IS: 3664 Code of practice for ultrasonic pulse echo testing by contact
and immersion methods
IS: 3703 Recommended practice for magnetic flaw detectors
IS: 4622 Recommendations for structural design of fixed wheel gates
IS: 4623 Recommendation for structural design of radial gates
IS: 5620 Recommendation for structural design criteria for low head slide
gates
IS: 6938 Code of practice for design of rope drum and chain hoists for
hydraulic gates
IS: 7307 Approval tests for welding procedures (Part-I) fusion welding of
steel.
IS: 7310 Approval tests for welders working to approved welding
procedures (Part 1) fusion welding of steel.
IS: 7318 Approval tests for welders when welding procedures approval is
not required
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IS: 7718 Recommendations for inspection, testing & maintenance of
fixed wheel & slide gate
IS: 9349 Recommendations for structural design of medium & high head
slide gates
IS: 10096 Recommendations for inspection, testing & maintenance of
radial gates & their hoists (Part I to III)
IS: 10210 Criteria for design of hydraulic hoists for gates
IS: 11855 Guide lines for design and use of different types of rubber seals
for hydraulic gate
IS: 13591 Criteria for design of lifting beams
IS: 14177 Guidelines for painting system for hydraulic gates & hoists
IS: 15466 Rubber seals for hydraulic gates-specifications.
Bolts, Studs, Nuts and Screws: They shall have standard threads and be of
high quality steel. All standard size bolts, studs, nuts and screws (including
their washers) shall be heavily protected against corrosion or made of
stainless steel if so specified in the Technical Specifications. Nuts and bolts
heads shall be hexagonal in shape & truly faced. Nuts & bolts and screws,
which might become loose during operation, shall be locked in fastened
position by means approved by the Engineer-in-Charge.
Reference should be made only to the relevant Indian Standard Specification.
However, where such code is silent on certain specified provision, reference
may be made to other appropriate to the relevant ASTM, ASME, DIN, J IS or
BSI standard.
If these specifications conflict in any way with any of the above standards or
codes, these specifications and drawings shall take precedence.
1.3.5 Material Standard
i) All materials used for the fabrication of the equipment shall conform to
relevant Indian Standard or equivalent International Standard as DIN, ASTM,
or BS unless otherwise specified.
ii) Materials for Gates, Stop logs, Embedded Parts and Lifting Beam:
Sl.
No.
Component Part
Recommended
Materials
Code
Reference
1 Structural parts of gate leaf
including skin plate, stiffeners,
horizontal girders, diaphragms,
track base, seal base, seal seat
base, liners, seal clamp, lifting
lugs, structural parts of lifting
beam rail guide, sill beam, anchor
bolts, load carrying anchors etc.
Structural steel until and
unless specified else
where
IS: 2062
2A Wheels Cast-steel/forged steel IS:1030, IS:
2004
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Sl.
No.
Component Part
Recommended
Materials
Code
Reference
2 B Self aligning spherical roller
bearings
Standard SKF make or
equivalent approved
make

2 C Wheel pins Chrome nickel steel or
corrosion resisting steel
IS: 1570(V), 20
Cr 13

2 D Retainers Structural steel
IS: 2062
2 E Sleeves for pin (distant piece) Structural steel IS: 2062
3 A Guide roller Cast steel/forged steel IS: 1030
IS : 2004

3 B Guide roller pin corrosion resistant steel IS: 1570, 20 Cr
13

3 C Bushing Bronze IS: 305
IS: 318
4 Track base, sill beam, side seal
seat base, guide roller track &
bumper track
Structural steel IS: 2062
5
Seals Rubber IS: 11855 & IS:
15466
6 Track Plate Corrosion resistant steel IS: 1570, 20 Cr
13
7 Seal seats Stainless steel

IS: 1570(V)
04 Cr 19 Ni 9
8 Seal fasteners Stainless steel IS: 1570 (V)
04 Cr 19 Ni 9
9 Ballast if any Cast Iron IS: 210
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Sl.
No.
Component Part
Recommended
Materials
Code
Reference
10 Lifting hooks (for lifting beam) Forged steel IS: 2004
11 Material for filling-in-valve
11
A
Spring Spring steel
11
B
Seal Rubber seal IS: 11855
11
C
Stem Corrosion resistant steel 20 Cr. 13
iii) Material for components of hoist bridge, trestles, walkway railing, gantry
girder etc:

Sl.
No.
Component Part
Recommended
Materials
Code
Reference
1 Base plate, anchors, bridge
beams, columns, stiffeners,
bracings, lugs, gantry-girders etc.
Structural steel IS: 2062
Rolled sections
IS: 808
2 Walkway Chequered Plate Standard
3 Bridge bearings Neoprene or plate
bronze
IS: 305
IS: 318
4 Handrails & posts Mild Steel pipe Black
medium duty

IS: 1239

iv) Materials for hoists and crane:

Sl.
No.
Component Part
Recommended
Materials
Code
Reference
1 Wire rope
Improved plough
IS: 2266
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Sl.
No.
Component Part
Recommended
Materials
Code
Reference
steel
2 Turn buckles
Forged Steel
Galvanised
IS: 2004
3
Dead end/open end wire rope
sockets
Forged steel IS: 2485
4 Drums Cast steel/M.S. IS: 1030,
IS: 2062
5 A

Gears

Cast steel IS: 1030

5B Pinions Forged steel/ Carbon
steel
IS: 1570, C40
IS: 2004, Cl IV
6 Sheaves and pulleys Cast steel IS: 1030
7 Shafts Forged steel &
Carbon steel
IS: 2004, Cl 4
IS: 1570, C-40
8 Speed reducer, motor
electromagnetic brakes, plumber
blocks, couplings, chains,
bearings, limit switch, control
equipment etc.
Standard materials
of approved
manufacturers of
repute
Crompton , Elecon
9 Gate position indicator Non rusting metal
10 Electrical bought out items Standard approved
makes
Siemens/ Crompton
11 Wheels Forged Steel /Cast
Steel
IS: 2004 Cl 4
IS: 1030
12 Threaded Fasteners

IS: 1363 - 1365 &
1367
13 Keys & Keyways IS: 2048
14 Bushing Al-Bronze IS: 305
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Sl.
No.
Component Part
Recommended
Materials
Code
Reference
15 Steel for shrunk fit gear rims Forged steel/Alloy
steel
IS: 2004
IS: 1570
16 Liners Structural steel IS: 2062
v) Materials for trash rack cleaning machine:

Sl.
No.
Component Part
Recommended
Materials
Code
Reference
1 Structural parts, steel apron,
rake & debris trolley guiding
chute
Structural Steel IS: 2026
2 Rake comb & fasteners Stainless/corrosion
resistant steel
IS: 1570, 15 Cr 13
3 Rake Wheels Cast Steel IS: 1030

vi) Materials for steel linings:
- ASTM 537 Gr.-II/ASTM 517
- DIN No. 1.0486, 1.0562
1.4 Permissible Stresses
1.4.1 General
i) Y.P. stands for minimum guaranteed Yield Point stress and U.T.S. stands for
Ultimate Tensile Strength. For materials, which have no definite Yield Point,
the Yield Point, may be taken at 0.2% proof stress.
ii) The term wet condition applies to skin plates and those components of gate,
which may be in sustained contact with water. For example, horizontal girder
and other components located on upstream side of skin plate. The term dry
condition applies to all components, which generally do not have a sustained
contact with water. For example, girders, stiffeners, etc. on downstream side
of skin plate, even though there may be likelihood of their wetting due to
occasional spray of water.
iii) The term accessible applies to gates, which are kept in easily accessible
locations and can, therefore, be frequently inspected and maintained. For
example, gates and stop logs, which are stored above the water level and are
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lowered only during operations. The term inaccessible applies to gates,
which are kept below water level and/or are not easily available for frequent
inspection and maintenance. For example, gates kept below water level or in
the bonnet space even while in the raised position or gates, which on account
of their frequent use are generally in water.
1.4.2 Permissible Stresses for all Gates
i) Structural Steel:
Wet condition Dry condition
Material and type of stress
Accessib
le
Inaccessib
le
Accessi
ble
Inaccessib
le
Direct compression & compression in
bending
0.45 YP 0.40 YP 0.55 YP 0.45 YP
Direct tension & Tension in bending 0.45 YP 0.40 YP 0.55 YP 0.45 YP
Shear stress 0.35 YP 0.30 YP 0.35 YP
Combined stress 0.60 YP 0.50 YP 0.75 YP 0.60 YP
Bearing stress (1) For Slide gates
0.35
UTS
0.25 UTS
0.40
UTS
0.35 UTS
(ii) For fixed wheel Gates 0.65Y.P 0.45 Y.P 0.75Y.P 0.65Y.P

ii) Bronze or brass:
Bearing stress
0.035
UTS
0.030
UTS
0.040
UTS
0.035
UTS

iii) Bearing stress in concrete: 0.25 fck
iv) Wheel: For Crest and Med.& high
low head sluice gates head sluice gates
a) line contact 1.6 U.T.S. 1.4 U.T.S
b) Points contact 2.4 U.T.S. 2.1 U.T.S
v) Wheel pin:
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a) Bearing As per annex B of
b) Shear IS: 4622
c) Bending
vi) Stresses under occasional forces:
The stresses in the various parts of the gate under the action of occasional
force like earthquake effect etc. shall not exceed 133% of the permissible
stresses mentioned above subject to the maximum of 80% of the yield
stress. In case of nuts and bolts increase in stresses may be more than 25%
of allowable stress.
vii) Corrosion allowance of 1.5 mm for the skin plate of gate and stop logs shall
be added to the actual computed thickness to arrive at the thickness to be
adopted.
1.4.3 Permissible Stresses for Rope Drum Hoist Equipment
i) Drum: Normal Condition BDT condition
a) Cast steel 0.2 U.T.S. 80% of Y.P
b) Structural steel 0.17 U.T.S. 80% of Y.P
ii) Gears:
Allowable stress 0.2 U.T.S.
iii) Shafts:
a) Maximum allowable bending stress 0.5 Y.P. or 0.2 U.T.S.
whichever is less
b) Maximum allowable torsion shear stress (t) 0.3 Y.P.
c) Combined stress 0.24 U.T.S. or 0.60Y.P
(Whichever is less)

d) Allowable stress for shafts with keys will be 75% of above value
e) Equivalent bending or twisting stress shall not exceed 1.2 times maximum allowable
Bending stress/shear stress at a) and b) above.
1.4.4 Permissible Stresses for Hoist Trestles & Hand Railing (Clearly above Water)
As per IS: 800, if not specified otherwise.
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1.4.5 Permissible Stresses for Lifting Beams
i) Structural Steel:
a) Direct compression and compression in bending 0.55 Y.P.
b) Direct tension & tension in bending 0.55 Y.P.
c) Shear stress 0.40 Y.P.
d) Combined stress 0.75 Y.P.
e) Bearing stress 0.40 U.T.S.
ii) Bearing stress:
a) In concrete 0.25 Fck.
b) In bronze/Brass 0.04 U.T.S.
1.4.6 Permissible Stresses and Safety Factors for Steel Pressure Tunnel Lining and
Bifurcation
i) Liners without stiffeners shall be calculated according to the method of
Amstutz, published in Schweizerische Bauzeitung No. 28, J uly 10, 1969.
Lines with stiffeners shall be calculated using the method suggested by S.
J acobson in Water Power, December 1974 and April 1991. The Amstutz
method should be applied as a check. The most conservative thickness of
the two results shall govern. Buckling between the stiffeners shall be
calculated according to the theory of Flugge.
ii) The steel lining in the pressure tunnel must be designed for internal pressure
including water hammer effect and as well as external. Poisson effect must
be considered if unfavourable.
Design criteria in respect of consideration of loads and stresses as well as seismic
effect shall be as per IS: 11639(part-2) Buried/embedded penstock and,
a) IS: 11625,IS: 11639(part-3).
b) The resulting stress shall be calculated according to the theory of V.
Mises, Hencky and Huber.
iii) The allowable stresses shall be adopted for design of penstock/liner as per
Para 4.2.2 of IS:11639 (part-2).
iv) The following safety factors shall be applied to the yield point strength of the
steel.

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Description Penstock & Steel Lining
(Incl. Branch Pipes)
Bifurcation
(Manifold)
Safety factor for internal
pressure excluding normal
water hammer effect
1.8 2.0
pressure including normal
water hammer effect
1.67 2.2
Safety factor against
buckling with external water
or grouting pressure on an
empty lining (for embedded
steel lining)
1.5 1.8
buckling with 50% internal
under-pressure and external
atmospheric condition
1.1
v) The nominal yield strength should not exceed 80% of the tensile strength for
steel with yield strength below 560 Mpa and should not exceed 87% for
ASTM A517 Gr. F steel, or similar high strength steel. The calculations
performed by the Contractor when dimensioning the main parts of the works
shall be submitted to the Engineer for his approval.

2. TECHNICAL DOCUMENTS
2.1 General
2.1.1 Scope of Work
i) This Chapter specifies the general scope and gives a definition of the documents
which, together with those listed in the particular Specifications, shall be delivered by
the Contractor to the Engineer-in-charge within the periods, and in a number and
quality as specified in the General and Special Conditions of Contract.
ii) The Engineer-in-Charge reserves the right to request the Contractor for supply of
additional documents as may be required for proper understanding and definition of
constructional, operational, co-ordination or other matters.
iii) The Contractor shall co-operate with other contractors in the exchange of drawings,
dimensions, data and all other information required to ensure proper co-ordination of
the work. All documents to be supplied shall be submitted in accordance with the
agreed programme so that any comment and change requested by the Engineer-in-
Charge can be taken into account before starting of the manufacture in the
workshop and/or erection or installation at the Site.
iv) If the Contractor fails to submit such documents, then the later execution of changes
requested by the Engineer-in-Charge and the resulting additional cost and/or delays
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should be the Contractors responsibility. The Contractor shall not be released of his
responsibility and guarantee after the Engineer has approved drawings and
computations.
v) The preparation of drawings, computations or other technical documents shall not be
subcontracted by the Contractor without the written authorization of the Engineer-in-
Charge. In such a case of subcontracting the Contractor shall be fully responsible for
such drawings, computations and other technical documents as if he did them.
vi) On drawings, catalogue sheets, or pamphlets of standard works submitted to the
Engineer-in-Charge the applicable types, paragraphs, data, etc., shall either be
marked distinctively or the non-applicable parts shall be crossed out. Documents not
marked in such a manner will not be accepted and approved by the Engineer-in-
Charge.
vii) If required for proper understanding of the documents, additional
descriptions/explanations shall be given on these documents or on separate sheets.
All symbols, marks, abbreviations, etc., appearing on any document shall clearly be
explained by a legend on the same document or on an attached sheet.
viii) Each device appearing on any document (drawing, diagram, list, etc.) shall clearly
be designated. The abbreviation mark used for an individual device shall be identical
throughout the complete documentation so as to avoid confusion. All documents
shall have a uniform title-block as outlined in the specification and agreed by the
Engineer-in-Charge. Beginning with the very first submittal to the Engineer-in-
Charge, the Contractors drawings shall bear a serial number corresponding to a
drawing classification plan to be agreed upon by the Contractor and the Engineer-in-
Charge.
ix) Revised technical documents, replacing previously submitted documents, shall be
marked accordingly. Also, the revised part in the document itself shall be marked
clearly. The documents, which are required to be supplied, shall be clearly marked
as regard to their status namely FOR APPROVAL (A) or FOR INFORMATION (I),
respectively.
x) Any comment given by the Engineer-in-Charge on an I type drawing shall have the
same effect as if it were given on an A type drawing.
2.1.2 Design & Drawings
The Manufacturer shall submit detailed design computations and drawings to the
Engineer-in-Charge for approval, which shall include in sufficient detail to show:
a) Design calculation for all components and parts with relevant drawings in
accordance with design criteria & specification to prove their adequacy supported
by catalogues/technical literature of all bought out components with selection
criteria & characteristics within 60 days of award of contract including as well the
following
b) General arrangement and sub-assembly arrangement and detailed dimensions of
the parts of the equipment to be supplied under the Contract,
c) Block out drawings dimensioning locations of anchors and 1
st
stage concrete
outlines,
d) Material lists covering specifications, sizes, quantities, weight of each component
from which the various parts will be made and the finish of machined surfaces.
These material lists shall include the equivalent Indian Standard,
e) For all larger pieces of work which, due to their dimensions and/or weight and
transport limitations, will require special means for their transportation, the
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contractor shall submit binding loading drawings indicating dimensions weights,
etc. of the respective pieces of work and the necessary trailer for its transportation
to the site,
f) Weld details, welding rod specifications and inspection method,
g) Machining and assembly tolerances and fits.
h) Machinery imposed loads on concrete structures, location of anchors, grout
pockets and checks in structures construction constructed by others shall be
provided within 60 days of award of Contract.
2.1.3 Diagrams
i) The Manufacturer shall submit the following diagrams:
a) The circuit diagrams shall show the power circuits in all phases with the main
apparatus as well as the pilot circuits (measuring and control circuits). It shall
show in full the functioning of part or all installations, works or circuits with all
required technical information. This shall show all technical blocks control
cubicle, cable details, cable tracks etc.,
b) Electrical wiring diagrams of hoist, drawings, performance curves,
specifications and catalogue numbers of all motor control centres, control
panels, motors and accessories,
c) Automatic or manual lubrication system, controls, control panels, motors and
accessories,
d) All handling attachment for site assembly; painting systems including
cleaning and application procedures, priming and final coats,
e) Controls & Indicators,
f) Quality assurance programme, plans, procedures, formats of inspection &
tests and inspection and test results.
ii) The Manufacturer shall carefully check all drawings for accuracy, completeness and
clarity before submission to Engineer-in-Charge for review. The Manufacturer shall
be responsible for correctness and adequacy of the design in relationship to the
specifications.
iii) Approval to the Contractors design and drawings shall not be held to relieve the
Contractor for any part of the Contractors obligation to meet all the requirements of
the specifications or of the responsibility for the correctness of the Contractors
drawings and designs.
iv) The Purchaser shall have the right to ask the Contractor to make any change in the
designs and drawings, which may be necessary in the opinion of the Purchaser to
make the equipment conform to the provision and intent of those specifications
without additional cost to the Purchaser.
v) The requirements of any such alterations requested by the Purchaser or the
Engineer-in-Charge, shall not be construed to mean that the drawings have been
checked in detail and shall not be accepted as justification for an extension of time
and shall not relieve the Manufacturer from responsibility for the adequacy of the
designs and correctness of the drawings.
2.1.4 Lists of Schedules
i) The following schedules are required to be furnished by the Contractor after the
approval and commissioning of the equipment. This information is to be appended
with the operation and maintenance manuals.
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ii) The Motor Lists shall be prepared according to the power distribution boards the
motors are connected to and shall contain at least the following information/data:
a) Works identification number
b) Description
c) Manufacturer, type, rating and data of driven machine
d) Manufacturer and type of electric motor/consumer
e) Rated capacity
f) Service factor (ratio between motor output and power requirement of the
driven machine)
g) Rated speed
h) Rated voltage
i) Rated current
j) Ratio of starting current to rated current
k) Ratio of pull-out torque to rated torque
l) Power factor at rated capacity
m) Efficiency at rated capacity
n) Power consumption at machine design loading
o) Design/enclosure/cooling (according To IEC)
p) Duty (continuous/intermittent/start-up)
q) Starting method/permissible starting frequency
r) Denomination of feeder
s) Motor protection
t) Applicable Standard Circuit Diagram (Category)
u) Maximum number and overall diameter of power cable(s)
v) Manufacturer and type of bearing(s)
w) Manufacturer, type and quantity of lubricant, service interval
x) Manufacturer, type, number, size, spring pressure and service interval of
brushes (if applicable)
iii) The Motor Starter Lists shall include all starters and contactors used for motors and
contain the following technical information as a minimum:
b) Electrical design data as nominal and actual current rating, voltage rating,
coil rating, making and breaking capacity, mode of operation
c) Maximum power cable size
d) Maximum control cable size
e) Current transformer ratio, class and capacity
f) Type of protection relaying and catalogue number
g) Setting of protection relays and maximum continuous rating of the protected
circuit
h) Type and current rating of the back-up fuses/MCBs (Miniature Circuit
Breaker) for the main and control circuits
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iv) The Cable/Interconnection Lists shall include for each individual cable the following
as a minimum:
a) Cable number, in accordance with Identification System
b) Cable type
c) Rated voltage
d) Number and size of conductors
e) Overall diameter
f) Cable termination at each end
g) Connection point at each end with cubicle/works identification and terminal
numbers
h) Cable routing
i) Using interconnecting cubicles list shall be prepared to show:
- Cable termination for incoming and outgoing cable
- Interconnecting wing
v) The List of Measurements shall indicate all measurements, local as well as remote,
and shall contain at least:
a) Item/code number, function code
b) Description and denomination of measuring loop
c) Data of tapping point
d) Data of local devices (as detectors, instrument transformers, transmitters)
e) Data of remote devices
vi) The Alarm Lists shall indicate all alarms and shall contain at least:
a) Item/code number and function code
b) Description and denomination of measuring loop
c) Data of alarm detector (contact) referring to applicable circuit diagram
d) Data of alarm annunciator (location and clear text labelling)
vii) The List of Final Control Elements shall indicate all control actuators and control
valves and shall contain at least:
a) Item/code number
b) Data of pipe and valve connections
c) Data of valve layout
d) Maximal required and rated power
viii) Individual Workshop Test Schedules shall be prepared for Works/installations (such
as gates, pipes, bifurcation, cranes, hydraulic hoists, machines, switchgears,
control gear, cables) and shall contain at least:
b) Manufacturer
c) Place of manufacturer
d) Place of test
e) Date of test
f) Objective of test (all individual tests)
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g) Standards applied
h) Certification
i) Inspection (by Engineer-in-Charge/independent test
authority/Contractor/subcontractor)
j) Release for shipment
k) Remarks
On the above schedule or on separate sheets the Test Procedure shall be specified
giving for each test item (kind of test) a description, test method/Standards, used
instruments, sample/routine test, test judgment.
ix) Site Test Schedules:
b) Manufacturer
c) Place of manufacturer
d) Place of test
e) Date of test
f) Objective of test (all individual tests)
g) Standards applied
h) Certification
i) Inspection (by engineer/independent test authority/contractor/subcontractor)
j) Release for shipment
k) Remarks
x) The List of Tools and Appliances shall detail for all tools and appliances included in
the scope of supply:
a) Item and code number
b) Description
c) Quantity
d) Weight
e) Gross storage requirements (separate for open-air, indoor, air conditioned)
for individual component sets
xi) Spare Part Lists detail for all parts shall be included in the scope of supply:
a) Item and code number
b) Description
c) Quantity
d) Weight
e) Gross storage requirements (separate for open-air, indoor, air conditioned)
for individual component sets
xii) List of Works Identification Numbers shall contain the used Works identification
numbers in alphanumeric order and for each of them a description (the defined
works denomination, for example as written on the Works label) and the location
(short definition of outdoor area and level elevation or building/room with elevation
and room number).
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2.1.5 Installation and Commissioning Procedures
i) The installation procedures shall describe in sequential steps the erection of major
equipment and shall contain sufficient details such as equipment preparation on
erection bay, handling of large and heavy pieces, levelling, anchoring, site welding,
site painting, erection checks, site pressure tests, site flushing and cleaning of
hydraulic systems, alignment and run out checks to allow the Engineer-in-Charge to
plan and supervise the Works at site. The Contractor may submit his proposals for
such installation but shall have to obtain the approval of the Purchaser before acting.
Detailed instruction to the installation of the gates shall be given by the Purchaser or
his authorised agents at site and shall be binding on the Contractor.
ii) The commissioning procedures shall sequentially and in sufficient detail describe
activities and tests for all systems covered by the Contract Document.
2.1.6 Operation and Maintenance Manuals
i) The operation and maintenance manuals shall be prepared in English only and
provided by the Contractor and shall contain following information in sufficient detail
to enable the Purchaser to maintain dismantle, reassemble, adjust and operate the
work with all its works and installation.
ii) The manuals shall include a separate and complete section description of the
following:
a) Description of works & equipment
b) Operating principle & characteristics
c) Operating instruction (for normal & emergency operation)
d) Testing & adjustment
e) Maintenance instructions
f) As build drawings
g) Spare parts
iii) The manuals shall describe and illustrate the procedure for assembling, adjusting,
operating and dismantling of each component and control system. The maintenance
of each component shall be described, including the recommended frequency of
inspection and lubrication.
iv) Six (6) copies of the manuals shall be submitted in English in draft for approval of
the Engineer-in-Charge within 3 months after the final approval of the equipment,
with a CD of the text & drawings.
v) If revision of the manuals becomes necessary, as a result of information gained
during installation and initial operation, the Manufacturer shall make the necessary
revisions and furnish ten (6) copies of the revised section sheets with the revision
symbols along with the CD of the same.
vi) The manuals shall include a complete list of all drawings prepared by the
Manufacturer, a list of spare parts and a list of parts for each component or item of
equipment. The parts list shall include the manufacturers name and serial numbers.
The manual shall include data, literature and catalogues of bought out items.
vii) The Manufacturer shall ensure that his installation supervisor has a copy of all
approved drawings and the manuals in his site office.
2.1.7 Progress Reports
i) During design and manufacturing the Contractor shall before the tenth (10
th
) day of
each calendar month submit four (4) copies of the monthly progress reports in a
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format acceptable to the Engineer-in-Charge, detailing the progress of the work
during the preceding period. The report shall contain (but not be limited to) the
following information:
a) A general description of the works performed during the reporting period on
each main activity,
b) Overall percentages of the works completed, with reference to the CPM
programme,
c) The percentages of each main work activity completed during the reported
month with reference versus the scheduled programme,
d) A list of activities scheduled to be started within the next period of three (3)
months, with expected starting and completion dates. Any notable problems,
differences, comments with reference to the schedule may be supported with
appropriate documents.
ii) During erection the Contractor shall, before the tenth (10
th
) day of each calendar
month, submit four (4) copies of the monthly progress reports in a format acceptable
to the Engineer-in-Charge, detailing the progress of the work during the preceding
month. The report shall contain but are not be limited to following information:
a) A general description of the Works performed during the reporting period on
each main activity,
b) The total overall percentages of erection works completed, with reference to
the CPM program,
c) A list of all activities of scheduled and actual progress during the reporting
period including actual starting dates versus scheduled starting dates; and
actual completion dates versus scheduled completion dates for each activity,
d) A list of activities scheduled to be started within the next period of two (2)
months, with expected starting and completion dates. If the expected starting
and/or completion dates are different from those shown on the CPM
program, an explanation shall be given,
e) Contractor shall also briefly report the manpower strength and expatriate
personnel employed, equipment etc. deployed during the reporting period,
f) A statement concerning potential problems and recommendations on how
they could be resolved.

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SECTION 3 : SPARE PARTS AND TOOLS
3.1 Spare Parts
3.1.1 General
i) All spare parts to be supplied shall be interchangeable with the corresponding parts
of all the works supplied under these Specifications and shall be of the same
material and workmanship. They shall be replaceable without cutting or destruction
of adjacent components. Before issue of the Completion Certificate the spare parts
shall be checked and tested at the Site by the Contractor in the presence of the
Engineer-in-Charge.
ii) Acceptance of any spare parts will not take place before the Contractor has
submitted the complete final detailed list of all spare parts and tools.
iii) All spare parts shall be protected against corrosion and shall be marked with
identification labels in the Ruling Language. The identification shall be in accordance
with the agreed Works Identification System.
iv) All spare parts, tools and material shall be delivered in marked boxes of sufficiently
sturdy construction to withstand long-term storage.
3.1.2 General Spare Parts
i) At least the quantity of general spare parts specified below shall be included in the
Total Tender Price and consequently in the scope of Works of the Contract.
ii) If the same spare parts are listed twice under General Spare Parts as well as
under Specific Spare Parts, the quantity listed under Specific Spare Parts shall
take priority over the quantity stipulated under General Spare Parts.
iii) Spare Parts for Wear and Tear Items:
For each installed assembly such as servo motors, pumps, motor, pressure oil units,
gates, valves, crane, machine tools etc. the following general spare parts shall be
delivered Two (2) complete sets of:
a) Facing rings of mechanical seals
b) Protection sleeves
c) Carbon brushes for motors (if applicable)
d) Inserts of filters
e) Bearing bushings
f) Brake liners
g) Packing and seals for rotating shafts
h) Driving belts
i) Wearing parts of couplings
j) Frequently actuated springs
k) Outdoor installed pressure hoses
l) Roller bearing for rotating shafts
iv) Parts with a special size or properties, as listed below are excluded as General
Spare Parts:
a) Bolts, screws, nuts, washer, spanner rings and cotters with a nominal
diameter of more than 80 mm,
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b) Roller bearings, bearing shells, sleeves and bushings for movable parts
including spherical joints with an inner diameter of more than 200 mm,
c) All valves and gates with a nominal diameter of more than 600 mm,
d) Main seals for gates, valves, access doors and openings with a total length
of more than 2.40 m in straight length or circumference.
3.1.3 Mandatory Spare Parts
The required mandatory spare parts are listed separately in the Particular Technical
Specifications. The price for each listed special spare part shall be quoted individually in
the Price Schedule; the total price shall be included in the Total Tender Price.
3.1.4 Recommended Spare Parts
If any additional spare parts are recommended by the tenderer these shall be stated in
quantity and description in the Technical Data Sheets for each item.
3.2 Tools and Appliances
3.2.1 Scope of Work
i) The scope of work shall include all special tools, as well as all special appliances
including lifting devices, ropes, etc. necessary for total assembly and disassembly of
all parts of the supplied Works. Furthermore, all accessories for maintenance shall
be supplied and included in the Tender. The total price for these special tools and
appliances as required by this article shall be included in the Total Tender Price.
ii) The tools, ropes, etc. shall be new and unused and shall be provided with means for
ready identification.
iii) All delivered tools and appliances will be taken over by the Purchaser after finalizing
the works.

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SECTION 4 : DESIGN AND MANUFACTURE
4.1 Design and Construction Requirements
4.1.1 General
i) The following directions, information and technical requirements for layout,
design and erection shall be observed as far as they are applicable to the
Works to be offered. The technical requirements of the General Technical
Specifications are valid for all parts of the Works except where they are
varied by additional and/or special requirements, specified in the Particular
Technical Specifications.
ii) Whenever a Tenderer deviates from these Specifications, he shall furnish the
data called for in the Technical Data Sheets and give a summary of and the
reasons for all deviations in the List of Technical Deviations from
Specifications. Failure to accomplish this may cause the elimination of his
Tender, especially when a major deviation is involved. Any changes of the
design of any part of the Works, which may become necessary after signing
the Contract, have to be submitted in writing to the Engineer-in-Charge for
approval, being sufficiently substantiated and justified.
iii) Additional cost can only be accepted in case of basic design change by the
Engineer-in-Charge after award of Contract.
iv) The Works shall be designed, manufactured, arranged and installed to
provide functional design and neat appearance. All parts of the Works shall
be arranged to facilitate surveillance, maintenance and operation. All control
sequences shall be simple and rational.
v) The parts of the Works shall be designed and arranged so that they can be
easily inspected, cleaned, erected and dismantled without involving large
scale dismantling of other parts of the Works. They shall be designed, and
manufactured in accordance with the latest recognized rules of workmanship
and modern engineering practice.
vi) The regulations, standards and guidelines listed in these Specifications shall
be observed in the design, calculation and manufacture of the Works.
vii) All parts of the Works shall be suitable in every respect for continuous
operation at maximum output under the climatic conditions and operating
conditions prevailing at the Site.
viii) Special attention shall be given to Works, parts of which are delivered by
different manufacturers. Problems arising in this conjunction shall be solved
by the Contractor and be defined in writing.
ix) For individual items of the Works, materials and design are to be selected
which are best suited for the operating conditions to which the parts in
question will be subjected. Only such design and type of Works shall be
offered which has confirmed its reliability in long-term continuous operation.
Innovations cannot be accepted for the main Tender but can be offered as an
alternative proposal.
x) All live, moving and rotating parts shall be adequately secured in order to
avoid danger to the operating staff. All electrical components shall be
electrically earthed as per the latest practice.
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xi) Manufacturers shall take appropriate measures to prevent the ingress of dust
into any Works (such as bearings, relays, control and measuring equipment
etc.), which may be endangered thereby.
xii) Suitable lifting eyes and backing-out bolts shall be provided where required or
where they will be useful for erection and dismantling.
xiii) Pockets and depressions likely to hold water shall be avoided, and if not
avoidable they shall be properly drained. Parts of the Works principally
intended for standby purposes shall be protected from corrosion by careful
choice of material and if necessary, by additional means; these should not
reduce their continuous standby readiness.
xiv) All design details and layout matters shall be discussed in periodic meetings
with the Engineer-in-Charge. The first design meeting between the Contractor
and the Engineer-in-Charge shall take place within 28 days after the date of
Commencement. Further design meetings shall take place as agreed
between the participants until the design work is completed.
xv) Lettering of the drawing shall be at least 3 mm high in block capitals. Lines
shall be of sufficient weight to reproduce clearly. The size of Manufacturers
drawings shall confirm to International Organization for Standardization (ISO)
sizes. All drawings shall bear the following heading in the title block:
xvi) All drawings shall be drawn in accordance with Indian Standards, to scale,
and shall be legible. Wording on drawings shall be in English. Symbols shall
be in accordance with Indian Standards. The Manufacturer shall submit to the
Engineer-in-Charge 4 sets of all drawings for approval. If revisions are
required after a drawing has been submitted, the Manufacturer shall resubmit
4 additional prints for approval after incorporating the comments. Fabrication
shall not commence until drawings have been approved by the Engineer-in-
Charge and thereafter no change shall be made on any drawing without the
approval of the Engineer-in-Charge.
xvii) After designs and drawings are completed and approved, the Manufacturer
shall supply 8 prints of all the design and drawings. However, prior to
completion of contract Manufacture shall supply 6 prints of all approved as
built drawings and one copy of electronic file containing design and drawings
of all the gates as well as steel liners( in Compact discs)
xviii) Drawings shall be submitted to the Engineer-in-Charge for approval in
sufficient time to allow for the Engineer-in-Charges comments, the
subsequent amendment and resubmission by the Contractor and the
Engineer-in-Charges approval but in any case at least 45 days prior to the
date on which they will be required to ensure that the work is carried out in
compliance with approved schedule of work.
4.1.2 Design Criteria
v) The Works shall be designed for the worst of possible combination of the following
loading conditions:
a) All static and dynamic hydraulic loads
b) All loads due to dead weight and frictional forces
c) Seismic or wind loads
d) All temperature loads
e) Other loads
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vi) The full reservoir level, maximum flood level, sill elevation and design criteria are
described in the Particular Technical Specifications required for the design.
vii) The basic normal wind load of 500 N/m
2
and storm load of 1500 N/ m
2
shall be
applied on the vertical projected area of exposed equipment, multiplied with the
following factor for the different type of structures:
a) For plane surface: 1.2
b) For a cylindrical surface: 0.7
c) For a lattice member, at front side: 1.6
d) For a lattice member, at rear side: 1.2
viii) The wind load for the stability check of gantry cranes, etc. shall be 800 N/m
2
while
operating and 1500 N/m
2
when out of service.
ix) Other Loads:
a) Load on foot paths, balcony floors, platforms: 5000 N/m
2

b) Vertical load on steel roof structures: 2500 N/m
2

c) Vertical load on each part of ladders: 1800 N/m
2

4.1.3 Tolerance and Clearance
i) The following design clearances shall be submitted to the Engineer-in-Charge for
approval:
a) Clearance between end of main roller housing (side of gate) and gate guide,
b) Clearance between moving gate components with respect to face of
concrete/steel lined grooves.
ii) The following general clearances shall be provided:
a) Side guide to guide track: 6 mm in any direction
b) Pre-compression of side and top seals: 3 mm
c) Projection of bottom wedge type seal: 5 mm
d) Minimum clearance between gate/stop log
Bottom face to dogging or deck: 500 mm
e) Minimum clearance from extreme top
Part of gate/stop log to bottom of the main beam
of Crane / hoist: 300 mm
f) Minimum recess from concrete face to rubber
seal of gate/stop log: 50 mm
g) Minimum recess for Track plate : 50 mm
iii) Water tightness of gates and stop logs:
a) The allowable average water leakage tolerances for gates and stop logs
under any head and without the use of any additional sealing material (such
as slag etc.) per metre length of seal shall be as listed below:
- For gates 0.05 l/s
- For stop logs 0.10 l/s
iv) All components shall be fabricated in accordance with relevant Indian Standard
Codes / International Standard duly approved by Engineer- In- charge .
a) All dimensions under 400 mm shall be 0.8 mm unless otherwise specified
and are non cumulative. All other dimensions shall be 1.5 mm,
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b) The machined sealing surface of the sill and lintel beams and side guide
shall be straight within 0.5 mm and level within 1.0 mm over the whole length
with a straight edge,
c) The roller path below the lintel shall be straight within 0.4 mm in any 3 m
length and within 0.8 mm over the whole length and shall not deviate from a
vertical line in any direction by more than 1.0 mm. Roller path faces for the
same gate shall be in the same line within 1.0 mm,
d) The roller path above the lintel shall not deviate from a vertical line in any
direction by more than 2 mm and shall be straight within 2 mm over the full
length,
e) The side roller paths shall be straight within 1.0 mm in any 3 m length and
within 2 mm over the full length. The side roller path shall not deviate from a
vertical line in any direction by more than 2 mm,
f) The distance between the side roller paths and the main roller paths shall not
vary by more than 3 mm,
g) Radial run out of assembled roller shall not exceed 0.025 mm measured at
the roller tread,
h) The bearing surfaces of roller tread on an assembled gate section shall be
straight within 0.1 mm over the full height of the section. The roller axis shall
be parallel to the machined bottom and seal faces of the gate within 15
minutes of 360.
v) Installation tolerances shall not exceed 1.5 times the corresponding fabrication
tolerance or the tolerances specified in the relevant Indian Standard Codes/
International Standard duly approved by Engineer- In- Charge. Design and
fabrication of the gates hoist and embedded parts shall be suitable for the
achievement of such tolerances during installation, including supply of dummy gate
section to facilitate the accurate setting of guides.
4.1.4 Standardisation of Works
i) Every effort shall be made to standardize parts and minimize costs of the works
throughout the HM-Works in order to facilitate replacement, interchange ability, etc.
keeping stocks, maintenance.
ii) The Engineer-in-Charge, therefore, reserves the right to request the different
Contractors to use uniform type or makes of Works and materials. The Contractor
shall not be entitled to claim extra payment due to this request. This request shall
especially the applicable to small mechanical and electrical Works such as:
a) Seals
b) Fasteners
c) Oils and lubricants
d) Valves
e) Thermometers
f) Pressure gauges
g) Flow meters
h) Water level gauges
i) Terminals and terminal racks
j) Indicating instruments and meters
k) Auxiliary relays
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l) Contactors, fuses
m) Motor protection switches
n) Control devices
o) Lights, bulbs, plugs, sockets
iii) The types or makes to be used shall be decided later by the Engineer-in-Charge.
iv) All instrument scales shall be written in the Ruling Language of the Contract.
4.1.5 Quality of Materials and Works
i) For general requirements concerning the quality of materials and Works refer to the
General Conditions of Contract.
ii) All materials shall comply with the latest IS standards, or other Standards unless
otherwise specified. All drawings and/or material lists shall show the applicable IS
Standard. The materials and workmanship throughout shall be the best of their
respective kind and free from defects. The design of all equipment shall be such that
installation, replacements and general maintenance may be undertaken with the
minimum of time and expense. All fitted joints shall be machined and castings shall
be spot faced for nuts. All components shall be built in accordance with approved
drawings only. No patching, plugging or other such means of overcoming defects,
discrepancies or errors shall be done without written permission of Engineer-in-
Charge.
iii) No welding, burning, filling or plugging of defective castings or any other
components shall be permitted without the Engineer-in-Charges agreement in
writing.
iv) Where stainless steel cladding consists of plates welded to mild steel sections, the
welds shall be adequate to ensure that the stainless steel is securely fixed for all
conditions of load and wear. Generally, all stainless steel parts shall be welded with
stainless electrodes. The thickness of the stainless steel cladding shall not be less
than 3 mm.
v) Similar part shall be made to gauge where possible, to ensure that such parts are
interchangeable one with the other.
vi) The Contractor shall be responsible for the accurate manufacture and fabrication of
equipment in accordance with the best modem practice in the manufacture and
fabrication of materials of the types covered by these specifications not withstanding
minor errors or omissions there in.
vii) Dimensions shown on the drawings shall be adhered to closely and the work shall in
all cases be of high grade and carefully performed to the satisfaction of the
Engineer-in-Charge. The Contractor shall warrant all materials and workmanship
furnished by him to be free from injurious defects. He shall replace free of cost any
defective materials or workmanship discovered during erection or in the guarantee
period and shall pay the actual cost of the correction in the field of any errors for
which he is responsible.
4.1.6 Works Identification System
An approved, uniform Works Identification System shall be applied for all mechanical,
electrical and Instrumentation and Control (I&C) Works to be agreed upon during detailed
design.
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4.2 Identification Plates
4.2.1 General
i) Each important part to be delivered under this Contract shall be equipped with
permanent identification plates in readily visible locations. Whether a part shall be
considered as important in this respect shall be decided by the Engineer.
ii) The identification plates shall be protected during erection and especially during
painting. Damaged or illegible identification plates shall be replaced by new ones.
The identification plates of non-corroding, non-disintegrating material (except
manufacturers nameplates of small standardized components) shall be inscribed in
the Ruling Language of the Contract.
iii) The inscription shall be printed, stencilled, or handwritten, but in any case,
waterproof, oil-proof and wear-resistant. Works (machines, transformers, etc.)
nameplates shall be either of the enamelled type or be of stainless steel covered
after stamping with a transparent paint. Wording, size and material of all labels and
plates shall be subject to the Engineer-in-Charges approval.
4.2.2 Manufacturers Name plates
All equipment shall be provided with a securely fastened name plate showing the makers
name, model, serial numbers, year of manufacture, main characteristics data of the
respective equipment and further relevant information specified in the applicable standards
or necessary for the proper identification of the equipment involved.
4.2.3 Instruction Plates
i) All plates showing designations or instructions for operation, safety, lubrication, etc.,
shall have a uniform design. Instruction plates, sequence diagrams or instruction to
operating staff shall be displayed on the inside of the front door of the control
panel/switch board. All works inside cubicles, panels, boxes etc. shall be properly
labelled with their item numbers. This number shall be the same as indicated in the
wiring diagrams works lists, operation and maintenance manual.
ii) All instruction plates displayed on the sub-assemblies like servomotors; power pack
hoist etc. shall show operational parameters, safety, lubrication etc., which shall
have a uniform format.
4.2.4 Warning Plates
Warning labels for safety of equipment as well as operating staff shall be provided and shall
be of synthetic resin with letters engraved in the Ruling Language of the Contract.
4.3 Workmanship
4.3.1 General
i) For general performance of workmanship, refer to the General Conditions of
Contract.
ii) The Contractor shall supervise the levelling and adjustment of all parts of the
equipment on the foundations. After each item is set up and the Engineer-in-
Charges approval obtained, grouting or concreting will be carried out by the civil
works contractor and verified by the Contractor. The Contractor shall be responsible
for ensuring that such work is carried out to his satisfaction and that levels and
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adjustments made by him are not disturbed by the grouting operating. The
Contractor shall be responsible for ensuring that the positions, levels and
dimensions of the Works are correct according to the drawings notwithstanding that
he may have been assisted by the Engineer-in-Charge in setting out the said
position, levels and dimensions.
4.3.2 Finished Surfaces
i) Where the finish is not indicated or specified, the type of finish shall be that type
which is most suitable for the surface to which it applies and shall be consistent with
the class of fit required.
ii) Surfaces to be machine-finished shall be indicated on the shop drawings by
symbols. Compliance with the specified surface shall be determined by the sense of
feel and by visual inspection of the work compared to applicable Standard
Roughness Specimens, or with roughness feeler gauge instruments. Both
Standard Roughness Specimens and feeler gauge instrument shall be provided by
the Contractor at the request of the Engineer-in-Charge.
4.3.3 Protection of Machined Surfaces
Machine-finished surfaces shall be thoroughly cleaned of foreign matter. Finished surfaces
of large parts and other surfaces shall be protected with wooden pads or other suitable
means. Unassembled pins or bolts shall be oiled or greased and wrapped with moisture-
resistant paper or protected by other approved means.
4.3.4 Mechanical Works
i) Rounding, Chamfers, Edges: The edges of surfaces to be painted shall be rounded
(minimum radius 2 mm) or chamfered accordingly. This requirement must be stated
in all shop drawings for the relevant parts.
ii) Structural steel: Work shall conform to the requirement hereinafter specified, unless
otherwise called for in these specifications or on the drawings. Finished members
shall be free from twists, bends and open joints. Compression joints depending upon
contact bearing shall have surfaces truly faced so as to have full contact bearing
when aligned and riveted or bolted.
iii) Straightening of materials: Before being laid off or worked, rolled material shall be
straight and shall be cleaned of all rust and dirt. If straightening is necessary, it shall
be done by methods approved by the Engineer-in-Charge.
iv) Shearing and cutting: Shearing and cutting by torch shall be performed carefully and
in all work which will be exposed to view after completing shall be finished neatly.
Sheared or cut edges of plates more than 16 mm thick, which carry computed
stresses shall be planed to a depth of 6 mm. Re-entrant cuts shall be filleted before
cutting.
v) Holes: Holes in structural steel members carrying calculated stresses shall be sub-
punched to 3 mm less than the nominal diameter of the rivet and reamed to full size
or drilled after assembly. All other members may be punched to full size. Main
members shall be assembled in the shop prior to reaming or drilling holes for field
connection.
vi) Punching: For sub-punching and for punching to full size, the diameter of the punch
shall be 5 mm smaller and 1.6 mm larger, respectively, than the nominal diameter of
the hole and the rivet. The diameter of the die shall not be more than 2.5 mm larger
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than the diameter of the punch. All holes shall be cleaned cut and without torn or
ragged edges. If any hole must be enlarged to admit the rivet, it shall be reamed.
vii) Accuracy of punched holes: Holes shall be punched so accurately that after
assembling the component parts of a member, a cylindrical pin 3 mm smaller in
diameter than the nominal diameter of the punched hole may be entered
perpendicular to the face of the member, without drifting in not less than 75% of any
group of continuous holes in the same plane. All holes shall be punched by a punch
5 mm smaller in diameter than the nominal diameter of the holes.
viii) Reaming: Reamed holes shall be cylindrical, perpendicular to the member, and not
less than 1.5 mm nor more than 2.5 mm greater than the nominal diameter of the
rivets. Built up members shall be assembled and firmly bolted together before any
reaming is done. Reamed parts shall not be interchanged. Burrs and shavings from
reaming shall be removed and, if necessary, reamed pieces shall be taken apart
before being riveted and the shavings removed.
ix) Drilling: Drilled holes shall be cylindrical perpendicular to the member and 1.5 mm
larger than the nominal diameter of the rivet.
x) Accuracy of reamed and drilled holes: Holes shall be drilled and reamed so
accurately after assembly that not less than 85% of any group of continuous holes in
the same plane shall show no off-set greater than 0.8 mm between adjacent
thickness of metal.
xi) Burr resulting from reaming or drilling shall be removed with a tool making a 1.5 mm
bevel.
4.3.5 Welding
i) Members to be joined by welding shall be cut accurately to size, and where required,
shall be rolled or pressed to proper curvature in accordance with the approved
drawings. The dimensions and shape of edges to be joined shall be such as to allow
thorough fusion and complete penetration and plates shall be planed if necessary, to
accomplish this result. Members to be welded together shall be in sufficiently
intimate contact at the time of welding so that members will not be forced more
closely together with the cooling of the weld, thus setting up additional strains and
distortions in the weld and parent metal.
ii) The cut surface shall be free from all visible defects such as lamination surface
defects caused due to shearing or cutting or flame cutting operations. The surface of
plates to be welded shall be free from dust, grease and scale for a distance of
12 mm back from the welding edge at the time of welding. Flame cutting may be
used in the preparation of the various members provided the operation is performed
carefully, and the edges so cut are cleaned thoroughly after being cut so as to
expose clean metal. Any contour irregularities at points of critical stress shall be
removed by grinding.
iii) All welding shall be carried out using a suitable welding sequence/procedures
approved by the Engineer-in-Charge and in such a way that harmful effects of
welding are avoided.
iv) When the welding process has been approved by the Engineer-in-Charge, the
Contractor shall produce a record drawing to show the approved process. The
drawing shall include details such as the form of edges to be welded, electrodes and
other welding materials, welding sequence etc. Changes in the welding process after
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the welding method has been approved shall require the consent of the Engineer-in-
Charge.
v) Additional copies of all records of all welding procedures, including preheating and
stress relieving, chemical analysis and physical properties, shall be made available
to the Engineer-in-Charge upon request.
vi) Unless otherwise allowed by the Engineer-in-Charge all welded parts to be welded
shall be manufactured of steel produced by open hearth or electric furnace with
carbon content not more than 0.20% and a phosphorous content not more than
0.05%.
vii) A welding process approved by the Engineer-in-Charge and generally in accordance
to the standards specified in the Technical Specification shall be followed. Approval
of the welding procedure shall not relieve the Contractor of his responsibility for
correct welding and correct selection of electrodes and minimising
deformations/distortions in the finished structure.
viii) All welding shall be done by the electric arc method or by a process, which will
exclude the atmosphere from the molten metal, except where otherwise specifically
permitted. The welding electrodes shall be a heavily coated type designed for all
position welding. In assembling and during welding, the components parts of built up
members shall be held in place by a sufficient number of clamps or other adequate
means to keep all parts in proper position.
ix) The Contractor shall follow the steel manufactures instructions or recommendations
concerning electrodes and other materials and post & preheat treatment.
Notwithstanding the above, the suitability of electrodes to be used for welding for
both shop and field welding shall be demonstrated by trials to the satisfaction of the
Engineer-in-Charge.
x) The strength of welding of all equipment subject to high and/or alternating stresses,
vibrations etc. shall be at least equal to the strength of the parts being welded.
Between plates and other sections where such stresses are to be transmitted only
butt welds shall be permitted. At welded butt joints, where the weld material is
required to be deposited on both sides of the joints, the weld shall be chipped
thoroughly to obtain a clean surface prior to the application on the first bead of the
welding on the opposite side of the joint. Where fillet welds are used, the lapped
sections shall fit closely and shall be held together during the welding operation.
Surfaces to be welded shall be cleaned of losses scale, slag, rust, paint and other
foreign matter, except that a thin coat of linseed oil need not be removed before
welding. When weld metal is deposited in two or more layers, each layer shall be
brushed with a wire brush or otherwise cleaned before the subsequent layer is
deposited. In welding precautions shall be taken to minimize stresses due to
expansion or contraction by peening the welds while hot, or by other satisfactory
methods. Correction of distortion by blows, after welding is completed and the place
is cold, will not be permitted. Upon completion, the welds shall be brushed with wire
brushes and shall show uniform section, smoothness of weld metal, featheredges
without excessive overlaps and freedom from porosity and clinker. Visual inspection
at edges and ends of fillets and butt joints welds shall indicate good fusion and
penetration into base metals.
xi) The specification regarding welding including the technique of welding employed,
the appearance and quality of welds made, and the methods used in testing of the
welds and in correcting defective work shall conform to relevant Indian Standard or
other standards specified.
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xii) All shop and field welding performed on the work shall be subject to inspection by
Engineer-in-Charge when welding plates, of which one or both exceed 25 mm in
thickness. The continuous areas of plates around the welding operation shall be
preheated to not less than 70 C and kept at a substantially uniform temperature
throughout the process. The temperature shall be measured by Temperature sticks
or other approved means. Low hydrogen electrodes shall be used wherever
necessary, particularly if the temperatures are below 10 C. Peening of multiple pass
welds to control distortion or to minimize residual stresses may be carried out with
light blows from a power hammer using an elongated round nosed tool. Peening
shall be done after the weld has cooled to a temperature warm to the hand. Care
shall be exercised to prevent scaling, flaking or rupturing of weld and base metal
from over penning. Neither the first nor the last pass of a multiple pass weld shall be
peened.
xiii) All welds on stress-carrying members shall be done in the Manufacturers shop
unless otherwise agreed by the Engineer-in-Charge. In general, only non-load-
carrying seal welds will be permitted in the field. All fields welding shall have prior
agreement of the Engineer-in-Charge. Tack welds shall be permitted only as
temporary welds required for assembly purposes.
xiv) The welding sequence shall be planned to control and minimize distortion and,
where necessary, shall include stress relief to minimize residual stresses. Minimum
stress-relieving requirements are specified in the appropriate sections of these
specifications.
xv) Welded components subject to vibration and stress reversals shall be fabricated with
full-penetration welds.
xvi) For welding of principal stress carrying parts, the standards of welding procedures,
qualification of welders and welding accessories shall conform to relevant Indian
Standards or equivalent to the requirements of the ASME Boiler and pressure vessel
codes section VIII and IX, DIN EN 287. All welders assigned to the work shall have
passed a performance qualification test. If more than one year has elapsed since the
welder passed his last test, then he shall be tested and qualified again.
xvii) In addition to the above the following aspects shall be considered for welding of
Pressure Shaft Liners:
a) All welds in the Pressure Shaft Liner pipe shells and for the stiffener rings
shall be either double welded butt joints or single welded butt joints with
backing up strips. Where single ended butt joints are provided the roots of
the weld shall be chipped off to sound metal after the backing strip is
removed. All wells shall be in accordance to the requirements of IS: 2825 for
unfired pressure vessels. Allowance shall be made to minimise shrinkage
due to welding circumferential joints. Care also shall be taken to keep close
tolerances in length of individual ferrules so that the combined length shall be
as per drawings,
b) After welding is completed all weld splatters should be removed by grinding
and made flush with the shell plates. All welding shall be made under cover
and liners shall be protected from the Sun,
c) When two plates at a welded joint differ in thickness the thicker plates shall
be trimmed to have a smooth transition as per Para 6.3.5 of IS: 2825.
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4.4 Corrosion Protection
4.1.1 Surface Treatment and Protection
i) The Manufacturer shall provide as part of his work/supply the surface treatment,
priming, corrosion protection and painting of the equipment furnished. Such work
shall include the coating and painting work at the workshop and at the site up to and
including the finish painting. Unless otherwise specified the coating and painting
shall be carried out in accordance with the latest Indian Standards or equivalent
approved standards.
ii) All priming and painting material shall satisfactorily fulfil the requirements imposed
by the site conditions, as well as the stresses to which the respective equipment is
subjected during operation of the works. Shades of the finishing coatings shall be as
approved by the Engineer-in-Charge.
iii) Each coat of primer and paint shall be compatible with the previous and subsequent
coats. All pigmented primers and paints which will be used for priming and painting
at the site shall be delivered in original and sealed containers packed by the
manufacturer, bearing brand name, colour designation, storage and handling
instructions.
iv) The Manufacturer shall supply full details regarding the extent to which sandblasting,
priming and paintings will be carried out in his workshops (or his sub-contractors, as
the case may be) at the Site and after erection. A properly equipped paint shop shall
be set up at the Site using a specialist organisation experienced and skilled in the
preparation and application or protective coatings under the conditions prevailing at
the site.
v) Materials shall be thoroughly mixed at the time of application. It is essential that
before any primer and coat of paint is applied. The surface is properly prepared.
Such preparation shall include any cleaning, soothing, drying and similar operation
that may be required to ensure that the primer and/or paint is applied on suitable
surfaces. Cleaning cloths and cleaning fluids shall be used to avoid having film or
grease residue on the surfaces being painted.
vi) Each coat shall be free from runs, drops, pinholes, waves, laps, sags and
unnecessary brush marks and shall be allowed to dry or to harden before the
succeeding coat is applied.
vii) Machinery paint may be thinned, if necessary to permit satisfactory application, but
the amount of thinner shall be kept to a minimum.
viii) For removing rust and mill scale from structural steel, plate sheets, piping and other
steel surfaces, as well as from other parts blast cleaning shall be carried out to clean
bare metal. The average surface roughness after sand blasting shall not exceed 40
microns. Sand blasting shall be performed with corundum or sand of type approved
by the Engineer-in-Charges. Parts, which cannot be blast-cleaned, shall be cleaned
free from rust and scale by power tool cleaning to the highest possible degree.
ix) All ferrous surfaces including non-mating finished surfaces, portion of gates, stop
logs, gate frames, guides etc. exposed to atmosphere or water shall be given a coat
of rust inhibitive phosphate wash by brush immediately following the cleaning
operation. Proper reaction of the phosphate wash is indicated by a light grey film
after drying. A dark sticky residue results if the reaction is not complete. This should
be wiped off with dampened rags and area retreated. If the surface is very hot, it
may be necessary to dilute the phosphate wash solution with water to obtain proper
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reaction. Within one hour after the rust inhibitive wash has dried thoroughly, one
coat of priming paint shall be applied by brushing, without thinning.
x) Stainless steel and bronze surfaces shall only be cleaned but not painted. All
surfaces of the embedded parts, which are to come in contact with concrete, shall be
cleaned as mentioned above and given two coats of cement latex to prevent rusting
during shipment and while awaiting installation. Exposed machined surfaces of
ferrous metal which are to be in rolling and sliding contact shall be given a coat of
gasoline soluble rust preventive.
4.4.2 Painting System
i) The following painting system shall be adopted for radial gates, fixed wheel gates
and stop logs:
a) Perfect cleaning of all surfaces, which are not to be covered with concrete,
shall be carried out by sand blasting to the requirements of Sa-2-1/2 quality
of Swedish Standard or as per class A IS-14177.
b) Over the prepared surfaces one coat of inorganic zinc silicate should be
applied by spray (preferably airless spray) giving a dry film thickness of 70 5
microns or alternatively two coats of zinc rich primer(containing not less than
85% of zinc on dry film) shall be applied to give a dry film thickness of 70 5
microns. The interval between surface preparation and painting shall be as
short as practicable and in no case longer than 4 hours,
c) Over the primer, two coats of solvent less coal tar epoxy paint shall be
provided at an interval of about 24 hours. Each coat shall give a dry film
thickness of 150 microns. The total dry film thickness of all the coats shall not
be less than 350 microns.
d) Gates exposed to sunlight shall be given one coat of aluminium paint over
and above the above paint thickness.
ii) Painting of embedded parts in contact with concrete
All surfaces of embedded parts which are to come in contact with concrete shall be
cleaned as given in clause 4.2.1.4 of IS: 14177 to meet the requirement of class D
and shall be given a coat of cement latex to prevent rusting.
iii) All unfinished surfaces of embedded parts exposed to atmosphere or water shall be
sand blasted to
Sa -2-1/2 of Swedish Standard or as per class A ,of clause 4.2.1.1 of IS:14177 and
given one coat of inorganic zinc epoxy primer by spray (preferably airless spray)
giving a dry film thickness of 705 microns per coat shall then be applied by brush.
The total dry film thickness of all the three coats shall not be less than 350 microns.

iv) Cranes, Hoist and Trash Rack cleaning machine:
a) Structural components: Cleaning of all the surfaces shall be done by sand
blasting to Sa -2-1/2 quality of Swedish Standard or as per class B given in
clause 4.2.1.1. of IS: 14177. In such areas where it is not possible the parts
shall be cleaned by brushing and scraping .
The parts after surface preparation shall be given two coats of zinc rich primer
paint.
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The primer coats shall give a minimum dry film thickness of 40 microns per coat.
The finish paint shall consist of one coat of alkyed based micaceous iron oxide
paint (dry film thickness of 655 micron) followed by two coats of synthetic
enamel paint. Each coat of synthetic enamel paint shall give a dry film thickness
of 255 microns. The minimum time interval between coats of paint shall be 24
hours. Each coat of paint shall give a dry film thickness of 50 microns. The total
dry film thickness of all coats including primer should not be less than 175
microns,
b) Machinery: All surfaces of machinery (except machined surfaces) including
motor, gearing, housing, shafting bearing pedestals shall be given one coat
of zinc phosphate priming paint followed by three coats of aluminium paint, at
a coverage rate of 6 m
2
/litre and 8-10 m
2
/litre respectively or synthetic
enamel conforming to IS: 2932 to give a dry film thickness of 255 micron
per coat.. Unfinished interior surfaces of oil reservoir and gearboxes and
unfinished surfaces of gears, which will run in oil, need not be painted.
v) Machined surfaces shall be protected with adhesive tapes or other suitable means
during the cleaning and painting operations of other components.
vi) Pressure Shaft Liners & Bifurcations:
a) All interior surfaces of the pressure shaft steel liners including bifurcations
and branch pipes shall be protected against corrosion. The Contractor shall
furnish, prepare and apply all materials for cleaning, primer coating and
painting of the liners. Cleaning, primer coating and painting shall be
performed prior to, during or after installation of the penstocks subject to the
approval of the Engineer-in-Charge, provided that the completed coatings
shall in all respects conform to the detailed requirements of these
specifications at the time of the final acceptance by the Purchaser,
b) Primer and coal tar epoxy: Before the application of zinc rich primer the
surface shall be cleaned by sand blasting to Sa -2-1/2 of Swedish standard
quality or to any approved equivalent. Over the prepared surface, two coats
of zinc rich primer with epoxy resin, containing 90% zinc on the dry film, shall
be applied, to have a total dry film thickness of 705 microns. This shall be
followed by application of three coats of solvent less coal tar epoxy paint;
each coat providing a dry film thickness of 100 microns. The total dry film
thickness of all the four coats shall not be less than 350 microns. The
application of zinc primer and epoxy paint and related operations shall be
performed under experienced supervision by workmen skilled in the trade.
Exterior surface of penstock liners shall be given a dry film thickness of 705
microns. A minimum width of 300mm on either side of girth joints of penstock
shells shall be given a coat of zinc rich primer on inner surface in shop for
facility of welding. After the field welding of girth joint is over , one coat of zinc
rich primer & three coats of solvent less coal tar epoxy paint shall be given to
the inner surfaces of the shell where one coat of zinc rich primer has been
given in the shop. The paint damaged during welding and erection shall be
repainted as per standard practice both on the inner and outer surfaces.

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4.4.3 Colour Scheme
Sl.
No.
Item Colour/Scheme
1 Exposed embedded parts excluding machined
surface and other components immersed in
water
Black
2 Super structure including columns, trestles,
hoist platform, lifting beam, staircase etc.
Grey
3 Hoist Machinery Grey
4 Trash rake/gantry Orange
5 Handrails Black & White (Alternately)
4.4.4 Galvanizing
i) Unless otherwise specified, all steel including ladders, platforms, hand rails bolts and
nuts associated with galvanized parts shall be hot-dip galvanized, electrolytically
galvanized or sheradized, as maybe appropriate to the particular case.
ii) Galvanizing shall be performed in accordance with VDE Standard 0210 (Verband
Deutscher Elektrotechniker).
iii) Material:
a) For galvanizing, only original blast furnace raw zinc shall be applied, which
shall have at least purity of 98.5%,
b) The thickness of the zinc coat shall be:
- For bolts and nuts, approx. 60 microns
- For all other parts, except for hydraulic steel structures or parts
intermittently or permanently submerged in water approx. 70 microns
- For hydraulic steel structures or parts intermittently or permanently
submerged in water, approx. 140 microns.
c) Cleaning:
All material to be galvanized shall be cleaned carefully of rust, loose scale, dirt, oil,
grease, and other foreign matters. Particular care shall be taken to clean slag from
welded areas.
iv) Galvanising of plates and shapes:
Where pieces are of such lengths that they cannot be dipped in one operation, great
care shall be exercised to prevent warping.
v) Galvanising of hardware:
Bolts, nuts, washers, locknuts and similar hardware shall be galvanised in
accordance with the relevant standards. Excess spelter shall be removed by
centrifugal spinning.
vi) Straightening after galvanising:
All plates and shapes, which have been warped by the galvanising process, shall be
straightened by being re-rolled or pressed. The material shall not be hammered or
otherwise straightened in a manner that will injure the protective coating. Materials that
have been harmfully bent or warped in the process of fabrication or galvanizing shall be
rejected.
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vii) Repair of galvanising:
a) Material on which galvanising has been damaged shall be redipped unless
the damage is local and can be repaired by soldering or by applying a
galvanising repair compound; in this case, the compound shall be applied in
accordance with the manufacturers instructions,
b) Soldering shall be done with a soldering iron using 50/50% solder (tin and
lead). Surplus flux or acid shall be washed off promptly and the work shall be
performed so as not to damage the adjacent coating or the metal itself. Any
member on which the galvanising coating becomes damaged after having
been dipped twice shall be rejected,
c) Items, which are not to be painted, shall be given a protective coating of e.g.
Tectyl 506 or another adequate material before leaving the Contractors
workshop. This protective coating shall be removed and the surface cleaned
before erection.
4.4.5 Repair of Primer and Finish Coats
For touching up, the same paint shall be used as for the original painting work. Repaired
finish coats shall be of identical appearance with the original and no difference in the
colour shall occur. The Engineer-in-Charge may require severely damaged coating to be
removed and repainted.
4.4.6 Quality Control
i) The first and each successive coat shall not be applied without the approval by the
Engineer-in-Charge.
ii) The minimum dry film thickness defined in these Specifications shall be observed.
Of each 100 m
2
one area of 10 m
2
will be measured for dry film thickness. No
measured thickness shall be less than the specified thickness. Where the minimum
thickness is not achieved, the coat shall be repaired to reach the specified minimum
dry film thickness.
iii) The dry film thickness shall be measured by approved gauges, and the cost of two
new electronic gauges shall be included in the Tender for the use of Engineer-in-
Charge.
iv) For checks on porosity, the Contractor shall furnish a D.C. variable high-tension test
instrument with built-in pore counter. The test voltage shall not exceed 2000 V. The
tests shall not be performed within 0.5 m distance from uncovered, corrosion
resistance surfaces.
v) Upon completion of each coat, the painter shall make a detailed inspection of the
painting finish and shall remove from all adjoining works all splattering of paint
material. He shall make good all damage that can be caused by such cleaning
operations.
vi) A detailed inspection of all painting work shall likewise be made, and all abraded,
stained, or otherwise disfigured portions shall be touched up satisfactorily or
refinished as required to produce a first-class job throughout and to leave the entire
work clean and acceptable condition.
4.4.7 Guarantee
i) The guarantee period for all painting shall be 5 years, starting from the issue of
Completion Certificate. This painting guarantee period shall be effective regardless
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of any other guarantee periods for the project or parts of the project, or any Defect
Liability Certificate issued prior to the lapse of the painting Guarantee period.
ii) The Contractor shall perform requested painting repair work at no extra cost to the
Purchaser if the painting quality is not met.
iii) At the end of painting guarantee period the anti-corrosive protection of the painted or
galvanised surfaces shall not have degree of rusting higher than RE1 (one) on the
European scale of degree of rusting for anti-corrosive paints, (The corrosion
committee of the Royal Swedish Academy of Engineering Sciences, Stockholm).
4.5 Metal Work
4.5.1 Embedded Metal Works
i) Unless otherwise specified, any foundations, wall and roof openings and coverings,
concrete floor filling, sleeves in foundations and walls and trenches with floor plates
for cables, will be provided by the civil works contractor.
ii) The Contractor shall supply all anchors, fasteners, embedded metalwork, piping,
and sleeves associated with and required for the equipment to be installed under
this Contract, except if otherwise mentioned in the Specification.
iii) As far as practicable, the supports shall be of consistent design throughout and
preferably of an approved proprietary type.
iv) Attachments to concrete shall wherever practicable be by means of embedded
inserts of an approved proprietary type.
v) The Contractor will be responsible for the determination and details of all loads and
forces exerted by his equipment and transferred to the foundation.
vi) The Contractor shall show the location and full details of all embedded components
on his drawings and shall be responsible for the completeness and accuracy of his
drawings and the information supplied to others. Anchorages to be embedded in
primary concrete will be installed by the civil works contractor to the Contractors
drawings. The Contractor shall be responsible for the adequacy and accuracy of the
location of all embedded components supplied by him whether installed by him or by
others.
vii) All adjustments to foundation levels, embedment, bedding and grouting of Works on
foundations and concreting into walls and floors will be carried out by the civil works
contractor, but all levelling and adjusting of Works on foundations shall be carried
out by the Contractor.
viii) The grouting will be carried out by the civil works contractor under the supervision of
the Contractor. The mix and grouting pressure shall be approved by the Contractor.
The Contractor shall satisfy himself that the grouting has been carried out to his
entire satisfaction.
ix) Any steel work, which is to be built into the concrete foundations, shall not be
painted or coated unless otherwise approved or specified.
4.5.2 Miscellaneous Metalwork
Except where otherwise indicated elsewhere in the Particular Technical Specifications, the
Contractor shall supply the following:
a) All platforms, ladders, guards and handrails necessary for easy and safe
access to Works supplied under the Contract. Handrails shall be of tubular
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steel construction except that the top rail shall be of flat bar, fitted with a
formed plastic covering,
b) The use of ladders shall be kept to a practicable minimum. Where ladders
are approved for use they shall be of steel, have an inclination of 70 to the
horizontal and a minimum width of 450 mm,
c) Safety guards at each point where normal access provision would permit
personnel to come within reach of any moving equipment to be provided
under the Contract,
d) All covers for pipe and cable trenches, required for completing the floors
around and over Works supplied under the Contract will be supplied and
installed by the civil works contractor. Unless otherwise approved, floor
plates shall be of an angular pattern,
e) The civil works contractor will provide covers and curbing for the dismantling
hatches in main floors.
f) Edging angles covers for gate slot openings shall also be supplied by the
contractor.
4.6 FABRICATION AND INSTALLATION WORKS
4.6.1 Scope of Work
i) All mechanical works of any mechanical or electrical installation shall comply with
these General Technical Specifications and the requirements of the Particular
Technical Specifications.
ii) The Works shall be of an approved, reliable design providing the highest possible
degree of uniformity and interchange ability.
iii) The design and arrangement of Works and installations shall facilitate erection,
testing, operation and maintenance.
iv) All works shall be pre-assembled in the Manufactures premises to an utmost extent.
Revolving parts shall be truly balanced both statically and dynamically such that
when running at normal speed and at any load up to the maximum, there will be no
vibration due to lack of such balance.
v) Unless otherwise stipulated in Volume 2, Part II, all materials used for tunnel liner
shall have impact strength (Charpy V-notch) of not less than 35 J /cm
2
(at (-)20 C)
whereby this figure shall be the minimum of each of 3 specimens. For steel plates
this figure shall be understood for the transverse direction.
4.6.2 Fabrication
4.6.2.1Gates and Stop Logs
i) The gates shall be of welded steel construction with dimensions as shown in
drawings. All parts of the gates shall be fabricated in strict accordance with the
Standard as per specifications. Special care shall be taken in fabrication of parts
affecting the strength, rigidity or water tightness of the gates. All pockets or
depressions shall be provided with drain holes to prevent collection of water.
ii) The structural members of gates shall be securely connected by welding or by fit
bolts. Highly important joints and connections, which will be heavily stressed under
load, shall be made without flaw. These joints shall include the connection between
horizontal girders and end girder box, splicing joints in gates and stop logs. For
welding of such connections only, the best-qualified welders shall be assigned. The
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splicing arrangement shall be designed to allow flexibility in the gate assembly to
facilitate installation. All splices shall be designed with watertight sealing
arrangements. The welding procedure for the gate body shall be planned to control
and minimise distortion. All welded connections shall be fully welded.
iii) Care shall be taken that the side seals of gates bear evenly and with uniform
pressure throughout their length on the side seal seats embedded in the faces of the
piers and that the bottom seals bear evenly on the bottom seal seat (sill) embedded
in the crest. Elsewhere welded plates thicker than 28 mm will also be stress relieved.
The roller axle supports and lifting connection shall be accurately line bored and
machine faces maintained in proper location, alignment and tolerance so that the
axis of all such holes be perpendicular to the vertical centre line of the gate and shall
lie in a common plane which shall be parallel to the finished surface for the seal
bases. The wheel pins shall be machined very accurately. Boring of main roller axle
support hole shall be done on the assembled gate section. The sealing faces for the
vertical seals, bearing bars and lintel seal shall be machined on the assembled gate
to ensure the gauge distance and alignment are maintained. Stop log seal bases
and thrust pads shall be machined after the stop log assembly (i.e. welding of all
components) for which suitably shop welded full strength joint shall be provided in
the stop logs. The bolt holes for guide rollers shall be bored only after the gate has
been completely field assembled and position of guide rollers located in stop
logs/gates. Seal bases and thrust pads for stop logs, seal bases for gates shall be
machined after the plates have been welded to gate units and stress relieved if
required. The machined surfaces of the seal bases/thrust pads shall be in the same
plane within a tolerance of plus or minus 0.5 mm without offsets at the joints.
iv) The structural members of radial gates shall be securely connected by riveting or
welding or by fit bolts. Highly important joints and connections, which will be heavily
stressed under load, shall be made without flaw. These joints shall include the
connection between thrust block, rest beam and trunnion pedestal (bracket);
trunnion bearing hub and end arms, arms and the horizontal girders, horizontal
girders and vertical stiffeners. For splicing joints or welding of such connections only,
the best qualified riveters or welders shall be assigned.
v) Trunnion bearing hub prior to machining of casting shall be stress relieved if welded.
4.6.2.2 Embedded Parts
All structures, parts of the gate frames and anchorages shall be straight and free
from twist. The bottom sill beam, seal seats etc., shall be fabricated from steel
plates/structural sections and shall be provided with suitable anchorages for rigid
connection to the crest and the piers.
Both faces of the track flanges carrying the track shall be truly perpendicular to the
web. The flange face shall be machined to provide a truly plane surface for the track.
The faces of the seal seats shall be machined so as to lie in one plane within
permitted tolerances. The crowns of the track shall lie a true vertical plane.
The faces of the corrosion resistance metal shall have the scale removed and
passivated. All areas of corrosion resistant metal, which are subsequently worked in
any manner, which tends to destroy the original passivated condition, shall be again
passivated. After passivating, surfaces shall be free from pits and surface defects.
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4.6.3 Installation
4.6.3.1 Installation of Gates and Stop Logs
The gate complete with the seal arrangement and guides shall be properly
assembled and installed as per the drawings approved by the Purchaser. All these
assemblies and installations have to be done in the most workmen like, manner to
the specifications and tolerances etc. indicated in the drawings. After installation, it
shall be checked that all the parts are smooth with no wavy surface. Each gate leaf
shall be transported in sub-assemblies and sub-assemblies shall be assembled and
erected in strict compliance with the details shown on the final approved shop
drawing and with Manufacturers instructions. Special precautions have to be taken
to ensure joints are made water tight where required. The side, top and bottom of
gates shall be in true alignment so that rubber seals when installed shall have tight
and even bearing on the sealing surface of the embedded frame.
4.6.4 Installation of Frame, Guide and Tracks
4.6.4.1 Assembly and Erection
Each set of frames, guides, tracks and seal seat arrangements shall be assembled
in the respective block outs, brought to line, grade and plumb within the erection
tolerance and secured in place by anchorages as shown on the drawings or
otherwise, according to best modern practice and as necessary for successful
functioning of these units. The erection tolerances for frames and guides will be as
indicated on the drawings. Extreme care should be taken to ensure that their
surfaces are in a true plane within the tolerances (as stated above) throughout their
length, otherwise serious damage to the gate may result during operating. Assembly
shall be by bolting and welding and connections to embedded anchorages shall be
adjusted and firmly tightened to hold the frames and guides securely in position
while concreting is being placed in the block outs.
4.6.4.2 Placing Concrete in Block Outs
Placement of concrete in block outs will be done by the civil works contractor, under
the supervision of H.M Contractor or his representative. The Contractor shall give a
detailed programme of fixing and aligning the embedded parts to the Corporation for
this purpose. Before placing the concrete in any one lift and between placements of
successive lifts, alignment tolerances shall be checked and remedial action taken if
any displacement has occurred. The crushing strength of 2
nd
stage concrete in block
outs shall be one grade higher than that of Ist stage concrete. However it will not be
leaner than M-25 grade conforming to IS: 456 -2000.
4.6.4.3 Hoist & Cranes
Hoist bridge and hoist/crane sub-assemblies shall be assembled and erected in
strict compliance with the details shown in the final approved drawing and with the
manufacturers instructions. Special precautions shall be taken to ensure perfect
alignment between mating components and for placements of the hoist drums so as
to match with the centre to centre of lifting lugs of the gates. For hoist and gantry
crane/monorails hoist the contractor shall prepare a complete erection procedure
which shall describe the sequence of operations to be carried out, the methods to be
used, the measurements to be taken and the tolerances to be met, in the erection
and alignment of the equipment.
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4.6.5 Diverse Items
4.6.5.1 Fasteners
i) Rivets and Riveting: Rivets shall be heated uniformly to a light cherry red colour and
shall be driven while hot. When heated and ready for driving, they shall be free from
slag, scale and other adhering matter. When driven they shall completely fill the
holes. The heads shall be of an approved shape, of full and equal sizes, neatly
formed, free from fins, concentric with the shanks, shall have full contact with the
surface of the member, and shall grip the assembled parts firmly together. Loose,
bored, badly formed or otherwise defective rivets shall be replaced. In removing
defective rivets, cares shall be taken not to injure the adjacent metal and, if
necessary they shall be drilled out. Caulking or recouping of loose or defective rivets
not be permitted. Rivets shall retain the pressure after the upsetting is completed. If
the rivets are driven with a pneumatic hammer, a pneumatic backer shall be used for
holding up, where practicable.
ii) Bolts, Studs, Nuts and Screws: They shall have standard threads and be of high
quality steel. All standard size bolts, studs, nuts and screws (including their washers)
shall be heavily protected against corrosion or made of stainless steel if so specified
in the Technical Specifications. Nuts and bolts heads shall be hexagonal in shape &
truly faced. Nuts & bolts and screws, which might become loose during operation,
shall be locked in fastened position by means approved by the Engineer-in-Charge.
4.6.5.2 Seals
i) Rubber seals shall be of the moulded type only. The basic polymer shall be natural
rubber or a copolymer of butadiene and styrene, or a blend of both & the compound
shall contain not less than 70% by volume of the basic polymer and the remainder
shall consist of reinforcing carbon black, zinc oxide, accelerators, anti-oxidants,
vulcanizing agents and plasticizers. The Contractor shall provide all seal with
adequate temperature and age resistant properties, which will provide, in the
moulded form, suitable sealing properties. All adjusting screws & bolts for screwing
the seals assembly in place shall be of stainless steel. The seals shall conform to
the provision contained in IS: 11855.
ii) All corners shall be remoulded and have a suitable radius on the inside edge. All
joints, both shop and field, shall be located at reasonable distance from the corners
and shall meet the following requirements:
a) All shop joints shall be vulcanized. J oint geometry shall be such as to avoid
featheredges on the sealing surfaces,
b) Field joints shall be kept to a minimum and shall be accurately machine cut
and carefully butted during assembly to an interference fit. The field joints
shall be held with double fasteners on each side of the joint,
c) Vulcanised joints shall not break or tear when bent 180 around a mandrel of
a diameter equal to the maximum cross section thickness of the seal,
d) The longitudinal strength in tension of vulcanised joints shall be not less than
71.4 kg/cm
2
as verified by tests on a tensile specimen prepared from one
joint in accordance with ASTM D15 Part C. The joint tested shall be located
at the midpoint of the test specimen and its strength determined in
accordance with ASTM D412,
e) The joints in the rubber seal shall be vulcanized butt joints and at right angle
to the rubber seal. Oblique joints at the corner shall not be permitted in the
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rubber seal. Vertically placed strips of rubber seals shall be formed in one
piece and no joints of any sort shall be permitted in them,
f) Sufficient quantity of seal jointing compound shall be supplied along with
rubber seals for site requirements.
iii) J oints shall be water tight and seal materials shall have following physical properties
as determined by tests made in accordance with the relevant Standards:
a) Tensile strength 14.5 Mpa minimum
b) Elongation at break 450% minimum
c) Durometer hardness (Shore, Type-A) 60-70
d) Specific gravity 1.1 to 1.3
e) Water absorption (70 C for 48 hours) 5% by weight (max.)
f) Compression set 30% maximum
4.6.5.3 Drives and Gears
i) All moving parts of machinery including shafts, couplings, collars, projecting key
heads, gear wheels, rope/belt-drives shall be completely guarded to provide full
protection. All set screws on revolving shafts shall be countersunk or suitably
protected. The guards shall be of approved design and shall be fitted, where
necessary, with inspection doors/openings. All guards shall be arranged so that they
can be removed without disturbing the parts of the gears and works, which they
protect.
ii) Gears shall be designed so that all stresses are within allowable limits when the
maximum loads are being handled. All gears shall be designed and calculated in
accordance with DIN, or equivalent international standards, or widely approved
methods and to the individual experience of the manufacturer. On request of the
Engineer-in-Charge, the Manufacturer shall submit the calculation of the gears.
iii) Where worm gears are used as a direct drives, they shall have the same load and
time rating as the motors driving them. The gears shall work in oil and the
temperature rise of the oil bath shall not exceed 40 C 50 C under normal working
conditions at Site. The materials of the mating faces of worm wheel and worm shall
be of a bronze/steel alloy.
iv) Where practicable gear wheels shall be force fitted on the shaft and in addition, shall
be keyed adequately to prevent any relative motion between the wheel and shaft.
Where gears and couplings are secured in position by means of keys, they shall be
easily accessible for tightening or removal. All keyways shall be machine cut.
Couplings and collars shall be the shrouded or protected-type, free from projections
of any kind.
v) All bearings shall be mounted in dustproof housings. Bases of bearing supports shall
be machined, and shall rest on machined-surfaces.
4.6.5.4 Lubrication, Lubricants and Fuel
i) Efficient means of lubrication, suitable for use under Site conditions, shall be
provided for all moving parts.
ii) Self-lubricating types of bearings shall be given preference, unless otherwise
specified or practicable.
iii) The contamination of the air, water and soil by lubricants and fuel shall by all means
be avoided by applying an appropriate design and layout of the Works in conformity
with the latest recognized standards for modern engineering practice.
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iv) The number of different lubricants, transformers oils, oils for pressure systems, etc.,
used in the items of Works throughout the Works shall be limited to a minimum in
order to facilitate keeping stocks and maintenance.
v) The Purchaser reserves the right to request the different contractors to use certain
types of lubricants, oils, etc. The Contractor shall not be entitled to claim extra
payment for this request. All different types of oils, lubricants, etc., shall be stated in
the Tender and are subject to the written approval of the Engineer-in-Charge.
vi) Unless otherwise stated in the Particular Technical Specifications, the first oil or
grease filling for bearings, pressure oil systems, transformers, etc., including the
necessary quantity for flushing and for the first oil change, shall be included in the
Tender Price.
vii) Also, reference must be made to the quantity of lubricants to be kept in stock for a
time of operation as stated in the Data sheets. The respective quantities shall be
quoted in the Data Sheets, the respective costs in the Price Schedule.

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SECTION 5 : ELECTRICAL WORKS
5.1 General
5.1.1 Scope of Work
i) The electrical items of works of any electrical or mechanical installation to be
provided under this Contract according to the Particular Technical Specifications
shall if not stated otherwise therein-fulfil the requirements of this section.
ii) All components shall be of an approved and reliable design. The highest extent of
uniformity and interchange ability shall be reached. The design shall facilitate
maintenance and repair of the components.
iii) The works shall be pre-assembled to the highest possible extent in the Contractors
or Sub-Contractors workshop, complete with all devices and wired up to common
terminal blocks.
iv) The power supply and control cables shall be laid up to these common terminal
blocks. The required control and protection devices, instruments, etc. within the
different scopes of work shall be supplied by and connected by the relevant
Contractor.
V) Unless otherwise agreed, ratings of main electrical works (in feeders, bus-ties) as
selected or proposed by the Contractor, whether originally specified or not, shall
generally include a safety margin of 10% under consideration of the worst case to be
met in service. Prior to approval of such basic characteristics, the Contractor shall
submit all relevant information such as consumer lists, short circuit calculations, de-
rating factors, etc.
VI) Short-circuit calculations shall be evaluated giving full evidence that every electrical
component can withstand the maximum stresses under fault conditions, for fault
levels and durations obtained under the worst conditions, e.g., upon failure of the
corresponding main protection device and time delayed fault cleaning by the back-
up protection device.
vii) All works shall be suitable for the prevailing climatic conditions.
viii) Outdoor installation shall be protected against solar radiation by means of adequate
covers, where required by the Engineer-in-Charge.
ix) The Contractor shall ensure that all the supplied works are insensitive to any signals
emitted by wireless communication equipment.
5.1.2 Standards
The design, manufacture and testing of all works and installations shall strictly comply with
the latest edition of the relevant IEC publications.
5.1.3 Colour Code
The manufacturers painting systems shall be used to the maximum possible extent, but
shall by all means be subject to the approval of the Engineer-in-Charge. Final coats of
paint shall be matching adjacent installations, where required by the Engineer-in-Charge.
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5.2 Electric Motors
5.2.1 General
i) All motors shall be of approved manufacturers and shall comply with the
requirements of this Chapter. Motors of the same type and size shall be fully
interchangeable and shall comply with Indian Standard and to IEC standard motor
dimensions.
ii) The general construction shall be stiff and rigid, no light metal alloy casings will be
accepted. All precautions shall be taken to avoid any type of corrosion.
iii) All motors shall be fitted with approved types of lifting hooks or eye bolts as suitable.
iv) AC motors shall have squirrel cage type rotors.
5.2.2 Rating
i) The rating of the motors shall be adequate to meet the requirements of its
associated equipment. The service factor, being the ratio of the installed motor
output to the required power at the shaft of the driven machine at its expected
maximum power demand, shall be applied as follows:

Power Demand of Driven Machine Service Factor
Up to 5 kW 1.2
More than 5 kW 1.1

ii) AC motors shall be capable of operating continuously under rated output conditions
at any frequency between 95% and 105% of the rated frequency and/or with any
voltage variation between 90% and 110% of the nominal voltage. A transient over
voltage of 130% of the nominal voltage shall as well be sustained.
iii) Further, the motors shall be capable of maintaining stable operation when running at
70% nominal voltage for a period of 10 seconds. The pullout torque for continuously
loaded motors shall be at least 160% of the rated torque and for intermittently loaded
motors 200% of the rated torque.
5.2.3 Starting
i) AC motors shall be designed for direct on-line starting. They shall be capable of
being switched on without damage to an infinite busbar at 110% of the nominal
voltage with an inherent residual voltage of 100% even in phase opposition. For
starting the motors from the individual main and auxiliary busbars, a momentary
voltage drop of 20% referred to nominal voltage should be taken into consideration.
With 85% of the nominal voltage applied to the motor terminals, each motor shall be
capable of accelerating its associated load to full speed with a minimum accelerating
torque of 5% of full load torque.
ii) The maximum starting currents (without any tolerance) shall not exceed value 5 time
of rated current for motors.

iii) Generally, all motors shall be able to withstand three cold starts per hour, equally
spaced. In addition, each MV motor shall be capable of enduring two successive
starts with the motor initially at operating temperature. Each LV motor shall be
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capable of withstanding three successive starts under the same conditions or once
every twenty minutes without detrimental heating.
iv) Motors for frequent automatic starting shall have an adequate rating. In the motor list
the Contractor shall state the frequency of starts permitted in compliance with the
motor design.
5.2.4 Windings and Insulation Class
i) The insulation of all motors shall be of class F but maintain in operation the
temperature limits of class B materials. It shall be suitable for operation in damp
locations, for occasional contact with corrosive gases and vapours and for
considerable fluctuations in temperature.
ii) The stator winding shall be suitably braced to withstand the forces due to direct-on-
line starting and transfer conditions as mentioned before. The winding envelopment
and tails shall be non-hygroscopic. The stator winding shall withstand the maximum
fault current for the period determined by the associated protective devices.
iii) The rotor winding (if applicable) shall be designed to give trouble-free continuous
service including repeated direct-on-line starting. The rotor shall be subjected to a
120% overspeed test for 2 minutes without showing any winding dislocation.
5.2.5 Ventilation and Type of Enclosure
i) All motors shall be of the totally enclosed fan-cooled type, protection class IP 54
according to IEC Recommendation 144. Cable terminal boxes shall be of class IP
55.
ii) They shall have a closed internal cooling air circuit recooled by an external cooling
air circuit drawn from the opposite side of the driving end.
iii) Where motors are installed outdoors, a weatherproof design shall be chosen. MV
motors and LV motors of IE size 132 and above shall be equipped with automatically
controlled heating elements for protection against internal condensation of moisture
during standstill periods. Such AC heater shall be suitably fixed inside the motor
casing; the leads shall be led to a separate LV terminal box.
iv) Motors installed outdoors and directly subjected to solar radiation shall be rated such
as not to exceed a minimum metal temperature of 85 C. Where necessary, such
motors shall be provided with sun shields.
v) Vertical motors shall be provided with a top cover to prevent the ingress of dirt, etc.
5.2.6 Bearings
i) As far as possible, the motors shall have sealed ball or roller bearings lubricated for
life. All other motors with ratings of about 1 KW and above shall be equipped with
lubricators permitting greasing while the motor is running and preventing over-
lubrication. Additionally, the bearings shall be fitted with grease nipples permitting
the use of a universal grease gun. Vertical motors shall have approved thrust
bearings.
ii) All bearings shall be easily controllable during operation or standstill without
dismantling the bearings. The bearings shall further be protected and sealed against
dust penetration and oil leakage.
iii) In case of independent bearings, motor and bearing pedestals shall be fitted on a
common base plate.
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iv) For the transport of motors equipped with ball or roller bearings, special bearing
inserts shall be provided to prevent transport damage.
5.2.7 Shafts and Couplings
The motors shall be provided with a free shaft extension of cylindrical shape with key and
keyway according to IEC Recommendation 72-1 and with the motorside-coupling, which
shall be pressed on the motor shaft and be balanced together with it. A coupling guard
shall be provided.
5.2.8 Terminal Boxes and Earthing
i) The terminal leads, terminals, terminal boxes and associated equipment shall be
suitable for terminating the respective type of cables as specified in these General
Technical Specifications and in the Particular Technical Specification.
ii) The terminal boxes shall be of ample size to enable connections to be made in a
satisfactory manner. Supports shall be provided at terminal boxes as required for
proper guidance and fixing of the incoming cable.
iii) The terminal boxes with the cables installed shall be suitable for connection to
supply systems with the short-circuit current and the fault clearance time determined
by the motor protective devices.
iv) A permanently attached connection diagram shall be mounted inside the terminal
box cover. If motors are provided for only one direction or rotation, this shall be
clearly indicated.
v) Terminal boxes shall be totally enclosed and designed to prevent the ingress of
moisture and dust. All joints shall be flanged with gaskets of neoprene or similar
material. For motors above 1 kW, the terminal box shall be sealed from the internal
air circuit of the motor.
vi) Depending on the size, the terminal box of LV motors shall be fitted either with an
approved cable sealing-end or with a gland plate drilled as required and provided
with suitable fittings for cable fixing and sealing. Such openings shall be temporarily
plugged or sealed during transportation.
vii) Terminal boxes of MV motors shall be fitted with an approved cable sealing end and
a pressure relief diaphragm suitably located. For plastic insulated and sheathed
cables filing with compound is not required. The three neutral ends of the windings
of MV motors shall be brought out to separate terminal box.
viii) For earthing purposes, each motor shall have adequately sized bolts with washers at
the lower part of the frame. In addition, each terminal box shall contain one earthing
screw.
5.2.9 Noise-Level and Vibrations
i) Under all operating conditions, the noise level of motors and pumps shall not
exceed 85 dB (A).
ii) In order to prevent undue and harmful vibrations, all motors shall be statically and
dynamically balanced.
iii) Vibration displacements or velocity shall be measured in accordance with DIN 45
665 for IEC motor sizes 80 to 315. The results for all motors shall be within the R
(reduced) limits.
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5.2.10 Tests
i) Each motor shall be factory tested and shall undergo a test at Site. The following
tests shall be performed under full responsibility of the Contractor.
ii) Workshop Tests:
a) Measurement of winding resistance
b) No-load and short-circuit measurements
c) Measurement of starting current and torque
d) Efficiency measurement (type test)
e) Heat test run
f) Dielectric test
g) Measurement of insulating resistance
h) Overspeed test
iii) Site Tests:
a) Measurement of insulation resistance
b) Measurement of motor vibrations
c) Measurement of starting time
5.3 Auxiliary Works
5.3.1 Auxiliary Switches
i) Where appropriate, each item of works shall be equipped with all necessary auxiliary
switches, contactors and devices for indication, protection, metering, control
interlocking, supervision and other services. All auxiliary switches shall be wired-up
to terminal blocks on the fixed portion of the works.
ii) All auxiliary switches and mechanisms shall be mounted in approved accessible
positions clear of the operating mechanism and are to be protected in an approved
manner. The contacts of all auxiliary switches shall be strong and shall have a
positive wiping action when closing.
5.3.2 Control Switches
i) Control switches for electrically operated circuit breakers shall be of the pistol grip or
discrepancy type. They shall operate clockwise when closing the circuit breakers
and anti-clockwise when opening them. The control switches shall be so designed
as to prevent them from being operated inadvertently, and where switches of the
discrepancy type are used they shall require two independent movements to effect
operation. Control switches shall be so designed that when released by the operator,
they return automatically to the neutral position after having been turned to the
closed position and shall at the same time interrupt the control voltage supply to
the operating mechanism of the circuit breaker.
ii) Switches for other apparatus shall be operated by shrouded push buttons or have
handles of the spade type; the pistol grip type shall be used for circuit breaker
operation only.
iii) Control, reversing, selector and test switches shall be so mounted, constructed and
wired as to facilitate the maintenance of contacts without the necessity for
disconnecting wiring.
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5.3.3 Anti-Condensation Heaters
Each individual enclosure accommodating electrical works which is liable to suffer from
internal condensation due to atmospheric or load variation shall be fitted with heating
devices suitable for electrical operation at the specified standard AC voltage, being of
sufficient capacity to raise the internal temperature by about 5 C above the ambient
temperature. Heaters in motors and similar shall be switched on automatically upon
opening of the motor starter, and vice-versa. Heaters in switchgear/MCC cubicles, control
cubicles, panels, desks, etc., shall be controlled automatically by adjustable hydrostats
(setting range about 50 100% relative humidity). The electrical apparatus so protected
shall be of such design that the maximum permitted temperature is not exceeded if the
heaters are energized while the apparatus is in operation. Heaters shall be equipped with
a suitable terminal box. All works, whether fitted with a heating device or not, shall be
provided with suitable drainage and be free form pockets in which moisture can collect.
5.3.4 Protection Devices
i) The main parts of the works shall be protected and interlocked so as to prevent
malfunctions and other fault occurrences, and to maintain safety during all operation
phases.
ii) Electric protection relays shall be the standard product of an experienced and
reliable protection relay manufacturer. They shall be of the static or
mechanic/magnetic, tropicalized type and be mounted in suitable dust proof and
shock-absorbing casings. They shall not be affected by external magnetic fields or
any other influence (radio, computer, signals, impulses, etc.) consistent with the
place or method of mounting. Electro-magnetic relays shall have a transparent cover
with appropriate seals.
iii) The protection relays shall be equipped with all necessary auxiliaries such as
tripping unit, time relay, external resetting device (hand reset flag with seal-in
operation). The relays shall provide easy access for testing and setting purposes.
iv) Pre-warning alarms shall be initiated as early as possible before the protection
system trips, in order to enable the operators to take precautions. Tripping of a
protection system as well as the sources of the protective action shall be indicated
and recorded as an alarm.
v) Unless otherwise required for special purposes, protection relays shall remain in the
tipped position until the operator resets the relay manually. The protection and
auxiliary relays shall be grouped and mounted on plug-in modules or stationary-
mounted on swing frame with separate plugs and sockets to feature easy
replacement and testing. The construction shall be sturdy and such that all parts are
easily accessible for adjustment. Relays installed in switchboards shall be arranged
in compartments separated from the switchgear.
vi) Besides the mechanically-operated flag type indicator, all relays shall have sufficient
contacts and/or auxiliary relay contacts to perform all the tripping, inter-tripping,
interlocking, indication and alarm functions required. Spare contacts (1 NO 1 NC)
shall be provided for later use. The contacts shall be silver-plated or of the seal-in
type with the main contacts adjustable. The relay contact rating shall be for the
specified standard voltage and for 200% of the nominal passing current. The relay
coil shall be able to operate properly at voltage variations of 25% to +15%.
vii) Relays shall be capable to withstanding at least one million operations without any
defect.
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viii) Testing of the individual relays shall either be effected by stationary-mounted or
portable testing device.
5.4 Terminal Points
5.4.1 Scope of Work
The Contractor shall supply all terminals, control boxes and cables in sufficient capacity,
conduits, fittings etc. from terminal points for the distribution of electric power supply to the
electrical equipment and its controls including lighting to be supplied under this Contract.
The power supply cables shall be designed so that the voltage drop between the terminal
points and the respective equipment shall be limited to within 2.5% of the rated voltage.
The electric service power provided by the Purchaser or the other contractors shall be as
follows:
a) 415/230V, 50 Hz, three-phases system with earthed neutral for feeding three
phase and single-phase consumers (connected between neutral),
b) 230V, 50 Hz, permanent supply, single phase earthed,
c) 48V DC system, isolated from earth, for the supply of electronic equipment,
telecontrol, telecommunications, etc. wherever necessary shall be provided by the
Contractor.

5.4.2 Supply Tolerances
For supply tolerances system limits of the supply voltage see the following table:

Description 415/230 V 230 V 48 V, DC
a) Steady +5/-10% 2% +10/-15%
b) Transient +30% 10%
Limits of the frequency 2% 1%
5.5 Cables
5.5.1 General
i) The Contractor shall provide the relevant design and engineering of the relevant
cable systems and, in close co-operation with the Lot V Contractor (Electro-
Mechanical Equipment), prepare the cable installation drawings with cable routing,
connection diagrams, and cable lists, details etc.
ii) The power cables and control cables shall be of copper as per Indian Standards or
IEC publications and the power cables shall be of minimum size 2.5mm and control
cables shall be of minimum size 1.5 mm.
iii) All cables and accessories shall be suitable for installation under site conditions (e.g.
aggressive soil condition, etc.)
iv) The Contractor shall select the most suitable cable routes and raceways ensuring a
minimum of interference with other installations.

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5.5.2 Colour Code
i) Live parts of electrical connections shall be colour coded as follows:

ii) Colour coding for Mimic Diagrams:
Mimic diagrams to be arranged on switchgear cubicles, control panels/desks etc. shall be
colour coded as below:
a) 415 V white
b) 110 V DC violet
5.6 Earthing System
5.6.1 General
All electrical systems shall be properly earthed as per the latest ruling practice for the
safety of the equipment and operating staff as well as the system. All protection devices
shall be provided in the control equipment.
5.7 Labels and Plates
5.7.1 General
Labels and data plates shall be provided in accordance with applicable standards and as
detailed hereunder:
c) The proposed material of the labels, size, exact label lettering and proposal for
the arrangement of the labels shall be submitted to the Engineer-in-Charge for
approval,
d) Where applicable, designations in the selected local language shall appear above
or to the right of the designation in the Ruling Language of the Contract. The
translations into and writing in the local language shall be submitted for approval.
5.7.2 Equipment Labels and Instruction Plates
i) Labels written in the Ruling Language of the Contract shall be provided for all
instruments, relays, control switches, push buttons, indication lights, breakers, etc. In
case of instruments, instrument switches and control switches, where the function is
indicated on the device, no label is required. The label shall be fixed close to the
devices in such a way that easy identification is possible. Fixing on the dial glass of
instruments will not be accepted. The wording shall conform to the wording used in
the engineering documents.
Description Coding Symbol Colour
AC Network
Phase 1
Phase 2
Phase 3
Neutral
L 1
L 2
L 3
N
red
yellow
blue
black
DC Network
Positive
Negative
Neutral
L+
L-
M
+white
- black
blue
Protective earthed
Earth
Neutral
Earth
PE/N
E
green/yellow
grey
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ii) Each separate construction unit (cubicle, panel, desk, box, etc.) shall be identified by
its works identification number on the rear side if rear access is possible. The overall
designation of each unit shall be given in the Ruling Language of the Contract and
if required also in a selected local language. These labels shall be made of
anodized aluminium with black engraved inscriptions, arranged at the top section of
the units. Manufacturers trade labels shall if required appear in the bottom
section of the units.
iii) All works inside cubicles, panels, boxes etc., shall be properly labelled with their item
number. This number shall be the same as indicated in the pertaining documents
(wiring diagrams, works list, etc.)
iv) Instruction plates sequence diagrams or instructions for maintenance shall be fitted
on the inside of the front door of the electrical switchboards. These shall be in the
Ruling Language of the Contract and if required in the selected local language.
5.7.3 Warning Labels
i) Warning labels shall be made of synthetic resin with letters engraved in the Contract
language, and in particular cases, where required in the selected local language.
ii) For indoor circuit breakers, starters, etc., transparent plastic material with suitably
contrasting colours and engraved lettering would be acceptable.
iii) Details are stated in the Particular Technical Specification or will be fixed at a later
date.
5.7.4 Labels for Conduits, etc.
The material shall be non-corrosive and the description be done with 4 mm high
letters/figures.
5.7.5 Labels for Cables
i) Each cable when completely installed shall have permanently attached to each end
and at intermediate positions as may be considered necessary by the Engineer,
non-corrosive labels detailing identification number of the cable, voltage, and
conductor size.
ii) The cable identification numbers shall comply with those of the cable list
iii) All cables in cable pits and at the entry to buildings shall be labelled utilising the
aforementioned type of label.
5.7.6 Rating Plates
Works (hoists, machines, transformers, etc.) rating plates and other technical
data/informative plates shall either be of the enamelled type or be of stainless steel
suitably protected after engraving with a transparent paint resistant to aggressive
atmosphere and solar radiation.
5.8 Key System for Electric Boards
5.8.1 General
i) The locks or padlocks shall be coordinated for the different applications and shall be
supplied with three keys. A key cabinet at the end of each board (distribution board,
MCC, Control Cubicles, etc.) shall be provided for storing the keys of that board. For
all locks supplied there shall be six master keys to open any lock or padlock
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supplied. Each key shall have one identification label fixed above the key hanging
hook inside the cabinet.
ii) The cabinet door keys shall be similar and shall be six (6) in number.

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SECTION 6: TRANSPORT AND STORAGE
6.1 General
i) Shipping, transportation, loading and storage shall be performed by or
under the responsible direction of the Contractor. An appropriate period
for transportation shall be considered.
ii) The general co-ordination of storage and erection work will be done by
the Engineer-in-Charge.
iii) The delivery dates, transportation and erection periods indicated in the
Contract Documents shall be strictly adhered to.
iv) From the time of manufacturing until commissioning, all parts shall be
protected against damage of any kind. Parts, which are damaged during
transportation, shall be replaced at the Contractors expense.
v) The Contractor shall provide the Engineer-in-Charge with complete
packing lists of each performed shipment.
6.2 Packing
i) After the workshop assembly and shop inspection and tests including
witness inspection by the Engineer-in-Charge or his authorised
representative wherever specified and prior to dismantling for shipment to
the Site, all items shall be carefully marked to facilitate site erection.
Wherever applicable, these markings shall be punched or painted so that
they are clearly visible.
ii) Dismantling shall be done into convenient sections, so that the weights
and sizes are suitable for transport to Site and for handling at the Site
under the special conditions of the Project.
iii) Marking shall be done preferably by punching the marks into the metal
before painting, galvanising, etc., and shall be clearly legible after
painting, galvanising etc. In labelling, the Contractor shall endeavour to
use as few designations as possible and each part of identical size and
detail shall have the same designation, regardless of its final positioning
the plant.
iv) All parts of the Works shall be packed at the place of manufacture; the
packing shall be suitable for all special requirements/limitations of the
transportation to Site. Where necessary, double packing shall be used in
order to prevent damage and corrosion during transportation, unloading,
reloading or during intermediate storage.
v) All parts including electrical parts shall be suitably protected against
corrosion, water, sand, heat, atmospheric conditions, shocks, impact,
vibrations, etc. by packing them in heavy duty polyethylene foil.
vi) The Engineer-in-Charge reserves the right to inspect and approve the
packing before the items are despatched but the Contractor shall be
entirely responsible for ensuring that the packing is suitable for transit and
such inspection will not exonerate the Contractor from any loss or
damage due to faulty packing.
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vii) All packing costs shall be included in the scope of Work.
6.3 Marking
The Contractor shall mark all containers with the implementing document
number pertinent to the shipment. Each shipping container shall also be clearly
marked on at least two sides as follows:
a) Consignee SUPER HYDRO ELECTRIC
PVT. LTD.
b) Contract No.:
c) Port of destination:
d) Item number (if applicable):
e) Package number, in sequence:
f) Quantity per package:
g) Description of works:
h) Net and gross weight, volume:
6.4 Storage
i) The Contractor shall also be responsible for obtaining from the railway or
highway authorities any permit that may be required for the transport of
loads exceeding the normal gauges.
ii) The Contractor shall be responsible for all Custom clearance of the
consignments from the Indian port if by sea and or from airport by
shipped as air cargo, local storage and further transportation to site.
iii) The Contractor shall provide means for all unloading and reloading for all
consignments of the plant, during transport to Site. Unloading on the Site
will be provided for by the Contractor. Consignments shall be unloaded
immediately on arrival at Site. The Contractor is required to take the
necessary steps in order to provide the carriage, special supporting
structures for heavy loads, etc.
iv) If large parts are in the open air, they shall be provided with weather
resistant and fire-resistant covers. Electrical parts, should be packed in
heavy-duty polyethylene foil and those whose packing has been
damaged shall be kept at insatiable places from the moment of storage to
the moment of installation.
v) All insulation materials which will be taken from the warehouse for
installation and which are stored temporarily in the station shall be
protected from weather or humidity.

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SECTION 7: INSPECTIONS AND TESTS
7.1 General
i) In addition to the provisions established in the Conditions of Contract
regarding general procedure of inspections and tests, terms and
definitions, and time schedules for inspections and tests the following
stipulations shall apply.
ii) Approval of assemblies, tests, inspections, related procedures etc. and
acceptance of pertinent test and inspection certificates, or waiving of
inspections or tests, shall in no way relieve the Contractor of his
contractual obligations for finishing the Works in accordance with the
provisions of the Specifications.
iii) Three (3) sets of all test records, test certificates, performance curves,
tables etc. of all inspections and tests, whether or not attended by the
Engineer-in-Charge shall be supplied soon after performance of each
inspection or test. After completion of all testing two (2) sets of the above-
mentioned documents shall be supplied properly bound in books.
iv) All test certificates shall be endorsed with sufficient information for
identification of the equipment and material to which the certificates refer.
v) In addition, the following references shall be entered in the top right-hand
corner:
a) Contractors name
b) Project title
c) Plants (stages) name
d) Number of Contractors drawing
e) Date
vi) Inspection and testing of equipment shall include all inspections, tests,
checks, procedures etc. Whether mechanical, hydraulic or electrical, as
required to ensure that the equipment supplied meets the requirements of
the Specifications.
vii) They shall comprise, but not be limited to the following:
a) Chemical analysis of materials
b) Destructive and non-destructive tests of materials
c) Checks and examination of welds
d) Checks of fits and assemblies
e) Dimensional checks
f) Balancing tests
g) Inspection of paints and coatings (thickness and porosity)
h) Hydrostatic pressure and tightness tests
i) Electrical test
j) Running tests (incl. Measurement of sound level)
k) Functional tests
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l) Performance tests
m) Load and overload tests
n) Acceptance tests
o) Type tests
viii) The technique, equipment and instrumentation to be used for these tests,
checks, inspections, examinations, etc. shall be in accordance with the
pertinent and internationally accepted Standards, rules or Codes, in
particular those mentioned in the Specifications.
ix) If in the Engineer-in-Charges opinion instruments apparatus, devices,
etc, used by the Contractor (or his Subcontractor) need calibration or
recalibration, then such instruments, apparatus, devices etc. shall be
calibrated at the contractors cost by an independent authority or institute
subject to approval by the Engineer-in-Charge.
7.2 Workshop Inspections and Tests
7.2.1 General
i) As far as practicable, quality of materials, workmanship and performance
of all items of the works to be furnished under this Contract shall be
inspected by the Engineer in-charge or his authorized representative(s)
at the places of manufacture.
ii) When placing orders for major material and equipment with sub
contractors, the Contractor shall send unpriced copies of such orders in
triplicate to the Engineer-in-Charge.
iii) Where the Contractor desires to use stock material, not manufactured
specifically for the Works, satisfactory evidence that such material
conforms to the requirements of the Contract shall be submitted. Tests on
these materials can be waived.
iv) Any painting work as well as transport to the site of the Works shall not
be started before the approval of the Engineer-in-Charge has been
obtained.
v) Free and unrestricted access to the Contractors factory and shops
(including those of his Subcontractors) shall be granted to the Engineer-
in-Charge, and upon reasonable notice by the Engineer-in-Charge or
others nominated by him if deemed necessary by the same for additional
witnessing of assembly work or inspection and tests.
vi) Should an agreed inspection not be carried out as proposed because of
lack of preparation, obvious negligence or material and/or equipment
being presented in a state, which does not correspond to the proposed
procedure or is clearly not acceptable such an inspection shall be
repeated. The cost incurred for all regular as well as repeated inspections
shall be fully borne by the Contractor. The travel expenses for each
additional or repeated inspection shall be borne by the Contractor.
vii) The Contractor shall organize all shop tests and inspections, which shall
be witnessed by the Engineer-in-Charge in such a manner that total
number of these shall be kept to minimum.

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7.2.2 Material Tests
i) Unless otherwise specified, the quality of materials shall be verified
generally by:
a) Chemical analysis,
b) Mechanical tests (yield point, tensile strength, elongations, notch
impact strength, etc.),
c) Welding tests (welding procedure, welding material, welding
tensile strength, welding bend test, welding reversed bend test
etc.),
d) Non-destructive test such as x-rays, ultrasonic, magnetic particle
test, liquid penetration tests, visual inspection, magnetic properties
etc.,
e) Electrical tests (voltage losses, tan-delta, insulation, magnetic
properties).
ii) Certified mill test reports of plates will be acceptable when these comply
with the requirement for Report of Inspections and Tests as stated in the
Special Conditions. Test specimen and samples for analysis shall be
plainly marked to indicate the material they represent.
iii) Castings and forgings shall be tested in the rough state in order to detect
flaws in time thus avoiding delays. Magnetic particle inspection of
important castings shall cover the whole surface of the casting. After
partial machining further tests can be conducted. Important castings and
forgings like of Gate wheels, hoist drum, gears, crane wheel etc. shall be
ultrasonically tested. The acceptable limit for ultrasonic testing of castings
shall be level I of SA-603 of ASME Section-5 and that of forgings shall be
as per SA 388 of ASME Section-5. Load tests on crane hooks, steel wire
ropes, chains, etc. shall be considered as material tests.
7.2.3 Checking of Dimensions
The dimensions, especially clearances and fits, (ISO 286), which are essential
for operation and efficiency shall be carefully checked in an approved manner,
as for example:
a) Run out and roundness tolerances of shafts, pistons, etc., to be
measured on single parts as well as (wherever possible) on the
assembled components,
b) Fits and clearances of gates, bearings, servomotor pistons, valves,
guiding, distributing and actual actuating elements, etc.,
c) Accuracy, surface roughness and shape of sliding and guiding
surfaces of seals, bearings, water passages in hydraulic machinery,
valves, etc.,
d) Dimensions of couplings or connections for assembly with other
deliveries from the Contractor, sub-contractors or other contractors.
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7.2.4 Workshop Assembly
i) In addition to the quality and production control tests, the following shop
assembly work and tests shall be made to check measurements, fitting
and functioning.

ii) Works to be furnished shall be shop assembled to a status sufficient to
prove that the design and workmanship have been executed in
accordance with the Specifications, that the delivery is complete, and that
no work remains to be done at Site, which reasonably can or should be
done in the shop. To commence the shop assembly, of Radial gates the 2
gate arms shall be supported in their relative position, at the same
elevation properly spaced center to center and so that the machined pin
holes have a common horizontal axis. With the arms in the position, the
gate leaf shall be erected between them. The vertical lift gates shall be
assembled in a vertical position and holes for field connections carefully
drilled or reamed. Connections, which have to be dissembled for
shipment, shall be made by the use of erection pins, one size less in
diameter than the designed size or temporary machine bolts.
iii) Where applicable, each item of the Works shall be assembled completely
prior to painting.
iv) Field joints shall be temporarily connected.
v) All parts shall be properly matched marked, identified and doweled where
practicable, to facilitate correct and quick field assembly and alignment.
Where necessary, suitable dowels shall be provided for insertion after
field assembly and drilling. The holes for any fitted bolt shall be accurately
reamed.
vi) During workshop assembly all instruments, control devices and piping
shall be fitted.
vii) If the assembly shows defects in the design or manufacture or
unforeseen difficulties in assembling and dismantling, these shall be
eliminated. If required, design alterations or corrective measures can be
executed provided that reliability of operation or interchangeability is not
reduced and provided that the agreement of the Engineer-in-Charge has
been obtained.
viii) If the corrections cannot be carried out in accordance with the terms
mentioned above, the components concerned will be rejected. The
decision on possible subsequent corrections is reserved exclusively to the
Engineer-in-Charge. Faulty parts or Works shall by no means be
delivered.
ix) The assembled parts shall subsequently be subject to tests as per
applicable standards or required by the Engineer-in-Charge.
7.2.5 Functional Tests
i) Functional tests shall be defined as tests of the function of assemblies,
sub-assemblies or parts of the Work under no load conditions. Functional
tests shall be performed on all works prior to the execution of operational
tests.
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ii) The testing of gates and embedded parts shall be carried out in
accordance with the provisions of relevant Indian standards IS: 7718
Part-I, II and III. In case excessive vibration/noise is experienced in
gate/hoist/supporting structure during any gate opening, the same shall
be investigated and monitored for vibration level/noise level by the
Manufacturer and remedial measures/rectification adopted to overcome
the same. The Manufacturer shall be responsible for excessive
vibration/noise,
iii) Hoist/Cranes:
a) After erection but before the crane is connected to the supply, the
insulation of the electrical equipment shall be tested by a suitable
instrument and any defects revealed shall be rectified. The voltage
required for the insulation resistance test shall be DC voltage not
less than twice the rated voltage.
b) Any reading less than 0.5 mega-ohm obtained with an insulation
resistance tester of the un-regulated type shall be dis-regarded
and the wiring under test shall be sub-divided until a reading
higher than 0.5 mega-ohm is obtained. Failure to obtain a higher
reading shows an unsatisfactory state of insulation. If an
installation has been sub-divided for test purposes, each sub-
division shall meet the requirement.
c) The insulation resistance of each wiring circuit exclusive of
connected apparatus shall be not less than 2 mega ohm, if
necessary; it shall be permissible to disconnect individual items of
equipment while making this test.
7.2.6 Operational Tests
i) As far as practicable operational test shall be carried out on all works,
simulating operating conditions.
ii) Parts to be delivered by sub suppliers shall be tested either at the
premises of the sub supplier or of the Contractor, as agreed by the
Engineer-in-Charge.
iii) Before testing the Contractor shall submit a notice containing full
information on the tests with detailed tables or graphs on the latest edition
of the characteristic value of the works to be tested and on the test
facilities and equipment.
iv) Testing of the electrical works shall be performed in accordance with
applicable Standards; they shall include but not be limited to tests of
heating, loading, overloading, losses. However before the complete
installation is put to commercial service, tests shall be carried out to
ascertain the following:
a) The satisfactory operation of each controller, switch, contactor,
relay and other control devices and in particular the correct
operation of all limit switches under the most unfavourable
conditions,
b) The correctness of all circuits and interlocks and sequence of
operation,
c) Satisfactory operation of all protective devices,
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d) The satisfactory operation of each motion of the crane,
e) The compliance of the crane with the specified performance
requirement,
f) Tolerances on specified speeds on full load shall be within 10%.
v) Operational tests of lifting equipment and other machinery of cranes and
rope drum hoists shall include tests under nominal load and 125% of
nominal loads in shop unless otherwise specified. The deflection tests
shall be carried out with the safe working load at rest.
7.2.7 Electric Tests
Electrical works shall be tested in accordance with applicable Standards and
agreed test programs and procedures.
7.3 Site Inspection and Tests
7.3.1 General
i) During erection, commissioning and trial operation the Contractor shall
organize at suitable intervals all inspections and tests in the presence of
the Engineer-in-Charge in order to prove the orderly execution of the
works in accordance with the Contract.
ii) Unless otherwise specified, all costs for testing at site and of the works
and charges associated with it shall be borne by the Contractor. This
includes the measuring devices, properly calibrated, and any pertinent
accessories, which shall be made available by the Contractor for the
entire duration of the tests. The Contractor shall delegate his experts to
supervise the tests at site.
iii) The tests, checks, examinations at site shall comprise but not be limited
to:
a) Checks and examinations of welds,
b) Hydrostatic pressure test,
c) Dielectric tests,
d) Functional checks (on protective devices, automatic and manual
controls, monitoring, supervisory equipment etc.),
e) Running tests,
f) Operational and overload tests (on cranes and hoists) after
erection,
g) Reliability tests,
h) Performance tests and determination of characteristic data.
iv) All such tests and checks shall be performed in the presence of the
Engineer-in-Charge. If not satisfied with the performance of the tests and
checks the Engineer-in-Charge shall have the liberty to ask for additional
tests or repetition of it.
v) The testing at Site shall be complete in every respect to prove the
successful performance and operation of all the works and Works
supplied and erected under the Contract.
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7.3.2 Commissioning and Trial Run
i) After the Contractor has notified the Engineer-in-Charge and received his
agreement that the equipment is ready for the commissioning tests, the
Contractor shall start with the Tests as stipulated in the Conditions of
Contract.
ii) The tests shall comprise the following stages:
a) Pre-commissioning test
b) Commissioning test
c) Trial run
iii) During the trial operation period the Contractor may request any minor
adjustments which do not in any way interfere with or prevent the use of
the equipment by the Purchaser or result in reducing the output or
decreasing the efficiency.
iv) If any failure or interruption occurs in any portion of the equipment
covered by the Contractor due to, or arising from faulty design, materials,
workmanship (but not otherwise sufficient to prevent full use of the
equipment) the trial operation period is to recommence after the
Contractor has remedied the cause of defect.
v) Immediately upon termination of commissioning of a part of section of the
permanent Works, which can operate as an independent unit a
Certificate of Suitability for Operation, shall be issued by the Engineer-
in-Charge.
vi) This document shall be signed by an authorised representative of the
Engineer - in-charge and the Contractor.
vii) This Certificate shall state:
a) The supplier of the Work concerned
b) The quantity and type of works concerned
c) The conditions of commissioning
d) The name of the participants
e) The date of commencement of trial run
f) The list of minor defects, if any
viii) During the trial run the Contractor shall make Purchasers personnel
familiar with the properties, the operation and maintenance of the Works
and its auxiliaries to such extent that thereafter the duties can be
assigned to the Purchasers trained personnel.
7.3.3 Acceptance
i) The taking-over testing of any part of section of the permanent Works
which can operate as an independent unit, shall be performed in
accordance with the standards and regulations laid down in the
Particular Technical Specifications and following the test procedure
agreed upon between the Engineer-in-Charge and the Contractor.
ii) Immediately upon termination of any such testing of a part of section of
the permanent Works a Protocol of Acceptance which shall be deemed
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to be the Test Certificate required by Conditions of Contract shall be
issued by the Engineer-in-Charge.
iii) This document shall be signed by the Engineer-in-Charge and the
Contractor and shall form an integral part of the later Completion
Certificate.
iv) This Protocol of Acceptance shall state:
a) The date of testing,
b) The quantity and type of Works concerned,
c) Statement of all minor defects and/or irregularities, which have to
be corrected by the Contractor,
d) That Confirmation that the guaranteed data have been proven,
e) Confirmation all contractual documents have been submitted,
f) Confirmation that the Purchasers personnel have been
familiarized with the works and that they will be able to operate
and maintain the Works.
v) If any test for the verification of the guaranteed data could not be
performed for operational reasons beyond the Contractors responsibility,
this part of the acceptance shall be stated in the Protocol of Acceptance
and be postponed for a mutually agreed period.

Tender Documents
Specifications: Volume II B Hydro Mechanical Part B


VOLUME II-B

SPECIFICATION
FOR

PART C PENSTOCKS

Tender Documents

INDEX

PART B - GATES, STOPLOGS, TRASHRACKS AND HOISTS

SECTION 1 - GENERAL DESCRIPTION OF EQUIPMENT

1.0 GENERAL 1
1.1 DIVERSION WIER UNDERSLUICE GATES 4
1.2 DIVERSION WEIR UNDERSLUICE STOPLOGS 6
1.3 INTAKE GATE 8
1.4 INTAKE STOPLOG 9
1.5 INTAKE TRASHRACKS 10
1.6 DESILTING GATE OF DESANDER 11
1.7 HRT INTAKE TRASHRACKS 13
1.8 DRAFT-TUBE GATE 14
1.9 ROPE-DRUM HOISTS 15
1.10 MONO-RAILHOIST 17

SECTION 2 - TECHNICAL SPECIFICATIONS AND REQUIREMENT

2.0 GENERAL 18
2.1 DESIGN AND STRESS LEVEL 18
2.2 PERMISSIBLE STRESSES 20
2.3
2.4 MATERIALS 22
2.5 EMBEDDED FRAMES FOR GUIDES AND WHEEL PATHS 23
2.6 ELECTRICAL EQUIPMENT 24
2.7 SHOP ASSEMBLY AND TESTING 25
2.8 SITE TESTING AND COMMISSIONING 28
2.9 WELDING PROCEDURE 30
2.10 SURFACE PREPARATION AND PAINTING 33
2.11 INSTALLATION, OPERATION AND MAINTENANCE MANUALS 36
2.12 ERECTION TOLERANCES 37

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1

PART B - GATES, STOPLOGS, TRASHRACKS AND HOISTS

SECTION 1 GENERAL DESCRIPTION OF EQUIPMENT

1.0 GENERAL

The equipment included in the scope of work shall be as per general description
given here under and as shown in the appended drawings, suitable for operating
functions as defined. It shall be simple in design and give long trouble free service
with minimum maintenance. Any item which is essential for the efficient
performance of the equipment but not specifically mentioned in these specifications
shall be considered included in the Scope of supply of the contractor.

a) Two sets of fixed wheel type service gates of size 2500 mm x 3000 mm for Diversion
Weir are proposed. The gates are to be operated under un-balanced head condition
with the help of individual electrically operated rope drum hoists of adequate capacity.
The gates and embedded parts shall be designed to withstand an un-balanced Hydro
static head of 8.27 m corresponding to MWL condition.
b) One set of sliding type stoplogs of overall size 2500 mm x 3,000 mm consisting of (Two)
equal size units as non-interchangeable units. The stoplogs shall be designed to with
stand an un-balanced hydrostatic head of 8.27 m corresponding to MWL. The stoplogs
are to be operated under balanced head-achieved by two filling valves provided in the
top unit the help of an electrically operated Mono - Rail crane and a lifting beam of
adequate capacity.
c) One set of trash rack at the inlet is proposed. The Trash Rack shall be designed as type
III in accordance with IS: 11388 for a deferential water head of 1.50 m. The trash race
shall be cleaned manually.
d) One set of slide type stoplogs of size 3000 mm x 1500 mm consisting of one unit is
proposed for one opening of intake. The stoplogs shall be designed for an un-balanced
head of 6.77 m corresponding to MWL condition. The stoplogs shall be operated under
balanced head achieved with the help of filling valves provided in the gate leaf with the
help of Mono - Rail Crane and a lifting beam of adequate capacity.
e) One set of fixed wheel type gates of size 3000mm x 1500 mm for Intake are proposed.
The gates shall be designed for an un-balanced head of 6.77m corresponding to MWL
conditions. The gate shall be operated with the help of an electrically operated Rope
Drum Hoist of adequate capacity.
f) One set of fixed wheel type gate of size 4250 mm x 2000 mm is proposed for Desilting
chamber inlet & outlet. The gate shall be designed for an un-balanced head of 2.0 m.
The gate shall be operated under un-balanced head conditions with the help of an
electrically operated Rope Drum Hoist of adequate capacity.
g) Three nos Knife Edge Gate Valve of 600mm (NB) to be provided in silt flushing pipe,
shall be capable to with stand an un-balanced head of 7.50m corresponding to MWL
plus silt load of fully filled pipe. The inner surface including disc shall be Teflon
cladded to take core of abrasion due to silt. The valve shall be power driven.

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2

h) Three sets of Slide Type Draft Tube Gates of size 2000 mm x 3200 mm for three draft
tube openings are proposed. The gate shall be designed for an un-balanced head of 2.0
m corresponding to max TWL and operated under balanced head condition achieved
with the help of two filling valves to be provided in the gate leaf with the help of an
electrically operated Mono - Rail crane and a lifting beam of adequate capacity.
Requirements
It is required that the contractor shall design, fabricate, deliver at site, erect and conduct Test
trial run to the satisfaction of Engineer in charge. The equipment, its material, accessories,
supplies and services must be complete in every respect in accordance with these technical
specifications and drawings as set forth in these tender documents.
Contents of Tenders
The contractor shall furnish the following along with his tender:
i. Preliminary designs and drawings showing the principal features and dimensions of the
following:
A. All Gates
a) General arrangement with overall dimensions
b) Gate structure showing the field joints if any.
c) Gate seals and their fixing arrangements.
d) Wheels assemblies and wheel bearings.
e) Tracks and seal seats
f) Method of installation of embedded parts.
g) Materials proposed to be used for different parts of the gates.
h) Any other special features.
B. Rope Drum Hoists
a) General arrangements with overall dimensions.
b) Various parts of the hoists.
c) Method of fixing rope to the gate leaf
d) Schematic electrical control diagrams for gate hoist.
e) Materials proposed to be used in different parts of the hoist.
f) Hoist supporting structures.
g) Any other special feature.
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3

i. Manufacturers name and salient features of the Hoist, if bought out.
ii. Rating of motors, name of manufacturer and characteristics including starting
and breakdown torque etc.
iii. Brake types and sizes including torque rating.
iv. Reducer type, size and rating.
v. Manufacturers name of major control equipment.
vi. Materials proposed to be used for major components.
ii. Data in respect of the following:
A. All Gates
a) Weight of complete assembled gate and gate frame to be supplied (kg) and its
split in (I) gate leaf (ii) tracks and seals (iii) embedded parts (iv) lifting beam (v) any
other details.
B. Rope Drum Hoists & Mono rail cranes
a) Proposed speed of lifting and lowering (cm. per minute)
b) Weight of assembled hoists.
iii. Estimated weights and sizes of major items involved in transport of the gates cranes
and hoists with sufficient data on chargeable weights and sizes during transportation.
iv. A statement of all items and services to be furnished under the bid if not fully covered in
the schedule of equipment including extra work places.
v. A statement that purchasers specifications shall form the part of contract with any
exceptions noted.
vi. A statement containing detailed descriptions of all proposed deviations from these
descriptions, if any by the Contractor with copies of other relevant International
Standards in English.
vii. Lists of projects where similar equipment has been supplied by the Contractor along
with their particulars and performance / tests reports.
viii. Complete lists of all the spare parts proposed to be supplied under each schedule of
supply.
Schedule of Delivery
The contractor shall deliver the equipment within the following periods, to be reckoned from
the date of issue of letter of intent

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S. No. Item No. of calendar days
1.
Embedded parts/ gate frames and gate
assemblies for Intake gates, draft tube gate,
Desilting gates, Silt Flushing valves, Surge
shaft gate and Tail race outlet gate.
To be filled in by project office
separately for each equipment
2.
Ropes drum Hoist assemblies for Intake
gates, Surge shaft gate and Tail race gate.
To be filled in by project office
3.
Gantry Crane To be filled in by project office
4.
Mono - Rail Cranes To be filled in by project office

The contractor shall submit 4 (four) sets each of the complete designs and drawings for each
of the gates, in not more than three groups as mentioned below for the approval of the
purchaser before commencing any fabrication work.
i. Gates: Embedded parts, etc.
ii. Gates: Gate details.
iii. Hoists & its Supporting Structure Complete
iv. Mono Rail Cranes & H\Supporting Structures Complete
The time required for the approval of drawings and designs by the purchaser or his
representative will be 45 days from the receipt of such drawings and designs by the purchaser
or his representatives. Any fabrication work performed by the contractor prior to approval of
the drawings shall be at his risk. The purchaser shall have the right to ask the contractor to
make changes in the designs / drawings which, in the opinion of the purchaser, may be
necessary to make the equipment conform to the provisions and intent of these specifications
without additional cost to the purchaser.

1.1 DIVERSION WEIR UNDERSLUICE GATES

The gates are vertical lift, fixed wheel type and having skin plate & seals on the
upstream side designed to withstand full static head corresponding to Reservoir
Level as indicated in the data given hereafter. The lowering/raising of gates shall
be under unbalanced head conditions and therefore these shall be capable of
gravity closing (i.e. due to weight of gate) under these conditions. The gates shall
normally remain closed. When the water level in the reservoir starts exceeding the
reservoir level EL 2245.27 m, the raising of the gates shall start. For operation of
gates, rope drum hoists shall be provided. The gates shall be operated from the
Local Control panel located on the top of piers near the gates.

The gates shall be of fabricated steel construction consisting of upstream skin
plate, horizontal girders and vertical stiffeners spaced according to design loads,
end vertical girders and wheel assemblies mounted in between end vertical girders.
Each gate shall have two lifting points and shall be provided with seals on
upstream sides. Side & top seals shall be of rubber / Teflon cladded rubber music
note type and bottom seal shall be of rubber wedge type. The seals shall be
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fastened to gate using stainless steel bolts/counter sunk screws and nuts. To limit
the sway of the gate during operation, two guide shoes shall be provided on each
side of the gate, which will remain engaged with embedded guides.

The gates operate within fabricated steel gate frames embedded in concrete. The
gate frame consists of wheel tracks (base of structural steel and track of corrosion
resisting steel); side and bottom seal seats (Base of structural steel and faces of
corrosion resisting steel) and structural steel guides.

Each gate is operated by independent electrically operated rope drum hoist
consisting of central drive unit (electric motor), reduction unit, shaft, rope drums etc.
Provision in the hoist mechanism shall also be made to operate it manually in the
event of power failure. The hoists shall be installed on hoist bridge supported
above top of piers. Access ladders shall be provided on each side of hoist bridge.
Local controls for all the hoists shall be housed in a Control Panel located on top of
piers / abutments.

Data

i) Type of Gate : Fixed wheel with upstream skin plate and
upstream seals, regulating type i.e. may be
kept at partial opening.

ii) No. of Bay : 2

iii) No. of gates : 2

iv) Clear width of opening : 2500 mm

v) Clear height of opening : 3000 mm

vi) c/c of side seal seats 2650 mm

vii) c/c of track plates 3100 mm

viii) C.L. of top seal seat ( from sill) 3100 mm

ix) Sill level : 2237.00 M

x) Reservoir Level : 2245.27 M

xi) Level of Top of Structure : 2246.50 M
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xii) Level of bottom of breast wall : 2240.00 M

xiii) Design head : 8.27M

xiv) Type of Wheel Assembly : Wheel mounted on corrosion resisting steel
axle with roller bearings and having line
contact with track.

xv) Type of side & top seals Music note Teflon cladded rubber.

xvi) Type of bottom seal : Rubber, wedge

xvii) Position of skin plate & side seal : Up Stream

(xviii) Lowering/raising speed of hoist : 50 cm/min

xix) Operation : Lowering / raising under un-
balanced head conditions by Rope
Drum Hoist..

xx) Permissible Stresses : Wet & Accessible, IS: 4622

(xxi) Second stage concrete in block-outs : M-30 Min.

1.2 DIVERSION WEIR UNDERSLUICE STOPLOGS

Provision to close the bays of the Weir by stoplogs has been made to facilitate
repair and maintenance of one Weir Gate at a time. For this purpose stoplog
grooves have been provided on upstream of Weir Gates. The stoplogs shall be
lowered/raised under balanced head conditions i.e. under no flow conditions.

A set of stoplog gate shall consist of not more than two units of almost equal
height. Each stoplog unit shall be capable of self closing i.e. by gravity under its
own weight. Embedded metals for stoplog gates shall be provided in all the weir
bays. Stoplog units when not in use shall be supported on dogging latches
provided near the top of the structure.

The stoplog is vertical lift, slide type of fabricated steel construction and shall be
formed by two vertical end girders between which horizontal girders are spaced
according to design loads and the downstream face is covered with a skin plate.

The stoplog in two Non_Interchangeable of equal size units is provided with two
lifting lugs. Stoplog units shall be provided seals on downstream side. Side seals
shall be of rubber music note type and bottom seal of rubber wedge type. The
seals shall be fastened to the stoplog unit using stainless steel bolts and nuts.
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Stoplog unit shall be provided with two guide shoes on each side. The stoplog units
shall be handled by a monorail hoist using a lifting beam capable of grappling and
ungrappling of stoplog unit under water. The lifting beam shall be attached to the
hoist at two points. Two filling valves of 150 mm dia. shall be provided in the top
unit of stoplog for creating balanced head conditions.

Fabricated steel frames shall be provided in the weir bays to receive the stoplog.
The frames shall consist of side and bottom seal seats, tracks i.e. load carrying
faces to bear the thrust pads fixed on the stoplog units and guides on both ides.
Faces of seal seats and tracks shall be of corrosion resisting steel.

The Mono-rail Hoist shall be installed on steel structure above stoplog grooves.
Electric power will be provided through a trailing cable and reeling drum
arrangement. Necessary brakes, overload protection, interlocks etc. shall be
provided. All drive and hoist gears will be fully enclosed.

Data

i) Type of Stoplog gate : Vertical lift, slide with down
stream skin ate and
downstream seals, non-
regulating type i.e. not to be

ii) No. of Bays : 2

iii) No. of stoplog gate sets required : One


v) Clear Height of stoplog : 3000 mm

vi) C/C of side seal seats : 2650 mm

vii) C/C of Track Plates : 3100 mm

viii) C.L. of top seal seat ( from sill) 3100 mm

vi) Sill level : 2237.00 m

vii) Reservoir Level : 2245.27 m

viii) Top of civil structure level : 2246.50 m

ix) Breast Wall bottom level : 2240.00 m

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x) Design head : 8.27m

xi) Type of side seals : Rubber, music note Type

xii) Type of bottom seal : Rubber, wedge Type

xiii) Position of skin plate & seals Down Stream
xiv) Permissible Stresses : Dry & Accessible, IS:5620

xv) Lowering / raising speed of hoist : 0.75 m/min to 1.5 m/min

xvi) Traveling speed of hoist : 4.0 m / min. to 8.0 m / min.

xvii) Operation : Lowering / raising under balanced
had conditions by Mon-rail Hoist. & Lifting
Beam of adequate capacity

xviii) Second stage concrete in block-outs : M-30 Min.

1.3 INTAKE GATE

The gate is vertical lift, fixed wheel type and having skin plate & seals on the
Level as indicated in the data given hereafter. The lowering/raising of gate shall be
under unbalanced head conditions and therefore this shall be capable of gravity
closing (i.e. due to weight of gate) under these conditions. For operation of gate,
rope drum hoist shall be provided. The gate shall be operated from the Local
Control panel located on the top of abutments near the gate as well from the
Control panel located in the Power House Control Room. The gate shall normally
remain open and shall be closed in emergency from remote control panel installed
power house or it shall be for planned repairs / maintenance of penstock etc. from
the local control panel.

The gate shall be of fabricated steel construction consisting of upstream skin plate,
horizontal girders and vertical stiffeners spaced according to design loads, end
vertical girders and wheel assemblies mounted in between end vertical girders.

The gate shall have two lifting points and shall be provided with seals on upstream
sides. Side seals shall be of cladded rubber music note type and bottom seal shall
be of rubber wedge type. The seals shall be fastened to gate using stainless steel
bolts/counter sunk screws and nuts. To limit the sway of the gate during operation
two guide shoes shall be provided on each side of the gate, which will remain
engaged with embedded guides.

The gate operates within fabricated steel gate frames embedded in concrete. The
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The gate is operated by an electrically operated rope drum hoist consisting of
central drive unit (electric motor), reduction unit, shaft, rope drums, etc. Provision in
the hoist mechanism shall also be made to operate it manually in the event of
power failure. The hoist shall be installed on hoist bridge supported above top of
abutments. Local Controls for the hoist shall be housed in a Control Panel located
on deck top of the abutments near the gate. The emote control panel shall be
installed in the control room of power house.

Data

i) Type of Gate :Fixed wheel with upstream skin plate and upstream
seals, regulating type i.e. may be

ii) No. of Bays : One

iii) No. of gates : One


v) Clear Height of gate : 1500 mm



viii) C.L. of top seal seat ( from sill): 1600 mm

ix) Sill level : 2238.50 m

x) Reservoir level : 2245.27 m

xi) Top level of civil structure : 2246.50 m

xii) Breast wall bottom level : 2240.00 m

xiii) Design head : 6.77m

xiv) Type of side seals : Rubber, music note cladded

xv) Type of bottom seal : Rubber, wedge

xvi) Lowering/raising speed of hoist : 50 cm/min
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xvi) Operation : Lowering / raising under un-balanced
head conditions by Rope Drum Hoist.

xvii) Second stage concrete in block-outs : M-30 Min.

xviii) Permissible Stresses : Wet & Accessible, IS:4622

1.4 INTAKE STOPLOG

Provision to close the bay of the Intake by stoplog has been made to facilitate
repair and maintenance of one Intake Gate whenever required. For this purpose
stoplog grooves have been provided on upstream of Intake Gate. The stoplog shall
be lowered/raised under balanced head conditions i.e. under no flow conditions.

The stoplog shall be capable of self closing i.e. by gravity under its own weight.
Embedded metals for stoplog gate shall be provided in the intake bay. Stoplog unit
when not in use shall be supported on dogging latches provided near the top of the
structure.

The stoplog is vertical lift, slide type of fabricated steel construction and shall be
The stoplog is provided with two lifting lugs. Stoplog shall be provided seals on
downstream side. Side seals shall be of rubber music note type and bottom seal
of rubber wedge type. The seals shall be fastened to the stoplog unit using
stainless steel bolts and nuts. Stoplog shall be provided with two guide shoes on
each side. The stoplog shall be handled by a monorail hoist using a lifting beam
capable of grappling and ungrappling of stoplog unit under water. The lifting beam
shall be attached to the hoist at two points. Two filling valves of
150 mm dia. shall be provided in the stoplog for creating balanced head conditions.

Fabricated steel frames shall be provided in the weir bays to receive the stoplog.
The frames shall consist of side and bottom seal seats, tracks i.e. load carrying
faces to bear the thrust pads fixed on the stoplog units and guides on both ides.
Faces of seal seats and tracks shall be of corrosion resisting steel.


Data

i) Type of Stoplog gate : Vertical lift, slide with down stream skin
plate and downstream seals, non-regulating
type i.e. not to be kept at partial opening.
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ii) No. of Bay : One

iii) No. of stoplog gate required : One

v) Height of stoplog : 1500 mm



viii) C.L. of top seal seat ( from sill) : 1600 mm

vi) Sill level : 2238.50 m

vii) Reservoir Level : 2245.27 m

viii) Top level of civil structure : 2246.50 m

ix) Breast wall bottom level : 2240.00 m

x) Design head : 6.77m

xi) Type of side seals : Rubber, music note .

xii) Type of bottom seal : Rubber, wedge

xiii) Lowering / raising speed of hoist : 0.75 m/min to 1.5 m/min

xiv) Travelling speed of hoist : 4.0 m / min. to 8.0 m / min.

xv) Operation : Lowering / raising under balanced
had conditions by Mon-rail Hoist.

xvi) Second stage concrete in block-outs : M-30 Min.

xvii) Permissible stresses : Dry & Accessible, IS: 5620

1.5 INTAKE TRASHRACKS

The trash racks shall be required to be installed in the inclined grooves of Intake
structure U/S of stop log groove to prevent entry of extraneous material into the
power house. These shall be of fabricated steel construction consisting of trash
bars supported on horizontal bars, which in turn shall be supported on end
channels/members to bear against the downstream face of slots. Trash racks shall
be split into units of equal height for easy handling. The units shall be
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interchangeable and each unit shall have two lifting points. The trash racks units
shall be handled by Mono-rail Hoist using a lifting beam capable of grappling/ un-
grappling under water. The lifting beam shall also travel in the same groove as the
trash racks. Cleaning of trash racks shall be done manually. Alignment pins shall
be provided between consecutive units of the trash racks for their alignment during
placement. Height of trash racks is kept such that its top is above Reservoir Level
El. 2245.27

Data

Clear width of opening : 4000 mm

No. of openings : Three

Sill level : El. 2238.50 m

Reservoir Level : El. 2245.27 m

Top of structure : El. 2246.50 m

Top of trash rack : El. 2245.50 m

Clear spacing between trash bars : 75 mm

Thickness of Trash Bars : 12 mm

Differential head for design : 1.5 m

No. of sets of trash racks required. : One set consisting of not
. more than 3 units.

Operation : Lowering / raising by Mon-rail Hoist.

Second stage concrete in block-outs : M-30 Min.

Design standard IS: 11388

1.6 DESILTING GATE OF DESANDER

Provision to close the bays of the Desilting Basin bays by gates has been made to
facilitate repair and maintenance of one bay at a time. For this purpose gate
grooves have been provided in all the bays at the d/s end & u/s end of the Desilting
Basin. The gates shall be lowered when water level in the reservoir is at Reservoir
Level or below it. Inspection, maintenance and repairs of Desilting Basin shall be
planned to be started and completed in lean flow period. The water level in the
reservoir shall remain at Reservoir Level or below it, as long as the gates are in
position and these shall be removed before water level in the reservoir rises above
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Reservoir Level. The gates shall be lowered/raised under balanced head conditions
only i.e. under no flow conditions. Balanced head conditions shall be obtained by
crack opening of the gate. The gate shall be capable of self closing i.e. by gravity
under its own weight.

The gates shall be handled by a mono-rail hoist of suitable capacity using a Lifting
Beam capable of grappling / in -grappling of gate under water.

Embedded metals for gates shall be provided in all the bays at d/s & u/s ends. The
gates when not in use shall be supported on dogging latches provided near the top
of the civil structure.

The gate is vertical lift, fixed wheel type and having skin plate & seals on the
Level as indicated in the data given hereafter. The lowering/raising of gate shall be
under balanced head conditions only and therefore this shall be capable of gravity
closing (i.e. due to weight of gate) under these conditions. The gates shall normally
remain open and shall be closed when cleaning of Desilting Basin is required to be
done.

The gate shall be of fabricated steel construction consisting of upstream skin plate,
horizontal girders and vertical stiffeners spaced according to design loads, end
vertical girders and wheel assemblies mounted in between end vertical girders.
The gate shall have two lifting points and shall be provided with seals on upstream
sides. Side seals shall be of cladded rubber music note type and bottom seal shall
be of rubber wedge type. The seals shall be fastened to gate using stainless steel
bolts/counter sunk screws and nuts. To limit the sway of the gate during operation
two guide shoes shall be provided on each side of the gate, which will remain
engaged with embedded guides.

The gate operates within fabricated steel gate frames embedded in concrete. The

Data

i) Type of Gate :Fixed wheel with upstream skin plate and upstream
seals, regulating type i.e. may be

ii) No. of Openings : Six ( Three for Inlet & three for outlet)

iii) No. of gates : Three +three


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v) Height of gate : 2000 mm



vi) Sill level : 2238.25 m of Inlet and 2238.20 of Outlet

vii) Reservoir : 2240.0 m

viii) Design head : 2.0 m
( Including 0.2 free board )

ix) Level of Top of Structure : 2241.00 m

x) Type of Wheel Assembly :Wheel mounted on corrosion resisting steel
axle with roller bearings and having line contact
with track.

xi) Type of side seals : Rubber, music note Teflon cladded

xii) Type of bottom seal : Rubber, wedge

xiii) Lowering / raising speed of hoist : 0.75 m/min to 1.5 m/min

xiv) Traveling speed of hoist : 4.0 m / min. to 8.0 m / min.

xv) Operation : Lowering / raising under balanced

xvi) Second stage concrete in block-outs : M-30 Min.

xvi) Permissible Stresses : Wet & Accessible, IS:4622

1.7 HRT INTAKE TRASHRACKS

The trashracks shall be required to be installed in the grooves of HRT Intake
structure U/S of stoplog groove to prevent entry of extraneous material into the
power house. These shall be of fabricated steel construction consisting of trashbars
supported on horizontal bars, which in turn shall be supported on end
channels/members to bear against the downstream face of slots. Trashracks shall
be split into units of equal height for easy handling. The units shall be
interchangeable and each unit shall have two lifting points. The trashracks units
shall be handled by Mono-rail Hoist using a lifting beam capable of
grappling/ungrappling under water. The lifting beam shall also travel in the same
groove as the trashracks. Cleaning of trashracks shall be done manually.
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Alignment pins shall be provided between consecutive units of the trashracks for
their alignment during placement.

Data

Clear width of opening : 3700 mm

Clear height of opening : 4200 mm

No. of openings : One

Sill level : El. 2234.30 m

Reservoir Level : El. 2239.5 m

Top of structure : El. 2240.2 m

Top of trash rack : El. 2238.80 m

Clear spacing between trash bars : 75 mm

Thickness of Trash Bars : 12 mm

Differential head for design : 1.5 m

No. of sets of trash racks required :One set.
more than 3 units.

Operation : Lowering / raising by Mon-rail Hoist.

Second stage concrete in block-outs : M30 Min.

Design Standards : IS: 11388

1.8 DRAFT-TUBE GATE

Provision to close the bays of the Draft-tubes by GATE has been made to facilitate
repair and maintenance of one Draft-tube at a time. For this purpose gate grooves
have been provided in at the Tail-race end of the Draft-tubes.

The gate shall be lowered/raised under balanced head conditions i.e. under no flow
conditions. The gate shall be capable of self closing i.e. by gravity under its own
weight. Embedded metals for gate shall be provided at the Tail-race end of the
Draft-tube. gate when not in use shall be supported on dogging latches provided
near the top of the structure.

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The gate is vertical lift, slide type of fabricated steel construction and shall be
The gate is provided with two lifting lugs. gate shall be provided seals on
downstream side. Side seals shall be of rubber music note type and bottom seal
of rubber wedge type. The seals shall be fastened to the stoplog unit using
stainless steel bolts and nuts. Stoplog shall be provided with two guide shoes on
each side. The stoplog shall be handled by a monorail hoist using a lifting beam
capable of grappling and ungrappling of stoplog unit under water. The lifting beam
shall be attached to the hoist at two points. Two filling valves of
150 mm dia. shall be provided in the stoplog for creating balanced head conditions.

Fabricated steel frames shall be provided in the bays to receive the stoplog. The
frames shall consist of side and bottom seal seats, tracks i.e. load carrying faces to
bear the thrust pads fixed on the stoplog units and guides on both ides. Faces of
seal seats and tracks shall be of corrosion resisting steel.


Data

i) Type of gate : Vertical lift, slide with skin
plate on Tail Pool side and seal on Power
House side non-regulating
type i.e. not to be kept at partial opening.

ii) No. of Bay : Three.

iii) No. of gate required : Three


v) Height of gate : 3200 mm


vii) C/C of Track Plates : 2500mm

viii) C.L. of top seal seat ( from sill) : 3300 mm

ix) Sill level : 1717.00 m

x) Max. Tail-race Level : 1718.30 m

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xi) Top of civil structure level : 1720.00 m

xii) Design head : 2.00m

xii) Type of side seals : Rubber, music note

xiv) Type of bottom seal : Rubber, wedge

xiv) Lowering / raising speed of hoist : 0.75 m/min to 1.5 m/min

xvi) Travelling speed of hoist : 4.0 m / min. to 8.0 m / min.

xvii) Operation : Lowering / raising under balanced

xviii) Second stage concrete in block-outs : M-30 Min.

xix) Permissible Stresses : Dry & Accessible, IS:5620

1.9 ROPE DRUM HOISTS (For Weir Gates & Intake Gate)

For each gate, one electrically operated mechanical hoist is proposed. The
capacity of the hoist to meet the operation requirements as outlined in paras 1.1, &
1.3 and shall be worked out by contractor and shall be 20% more than all the
forces opposing the raising of gate. The hoists shall raise or lower the gate at a
speed of 50 cm/minute. The hoists shall be designed to conform to Indian
Standards Specification IS:6938 and other relevant IS: Specification or their
corresponding International Standards. The hoists shall be installed on the hoist
bridge as shown in the appended drawings. The hoists shall be capable to perform
the operation of crack opening of the gate under maximum unbalanced head
conditions and shall also take care of down pull, if any, in this operation.

A clear walkway for the operating/maintenance personnel of 1.0 m width shall be
provided on either side of the hoist.

Normal operation of the hoists shall be by electric motors. Manual operation shall
be provided for operation of the hoists in the event of electric supply failure.
Manual operation system shall conform to Clause 6.7 of IS:6938.

The hoists and their components shall be simple in design and rugged in
construction so as to give trouble free operation with minimum maintenance.
These shall be suitable for out-door service. The driving unit shall comprise of an
electric motor, electro magnetic brake, reduction unit, limit switches, electric control
elements, necessary shafts, bearings and flexible couplings. The driven unit shall
comprise of two rope drums, reduction units, shafts, couplings and bearings. The
electric motor, brakes, reduction unit and rope drums shall be provided with
removable weather proof metal covers.
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The controls of the hoists shall be so arranged that the cycle for either closing or
opening shall be completed and the hoist shall stop automatically at the fully closed
or fully open position by the limit switches. Over travel limit switches shall also be
provided in both directions of travel which shall trip the motor circuit when the
normal limit switches fail to operate. It shall also be possible to stop the hoist in any
intermediate position of any cycle and restart or reverse as desired during the
normal operation.

The control panels shall be installed near the gates on top of piers as outlined in
paras 1.1& 1.3 above. The panels shall have three push buttons marked, open ,
close and stop . The open push button shall initiate raising of gate. The
close push button shall initiate closing of gate. By pressing the stop push button
the gate shall be stopped in any intermediate position. Indicating lamps shall be
mounted on the control panels to know the position of gate.

Blue and green lamps shall show that the gate is being lowered and raised
respectively and these lamps shall go off automatically with the stoppage of gate
movements. The red lamp shall show that he gate is in open position.

The controls shall also fulfill the following requirements:

A solenoid brake shall be provided to hold the gate in any position. It shall come
into action automatically as soon as it is de-energized on cutting or failure of
power supply to motor.

Extreme position of gate shall be restricted by limit switches when the gate
reaches the extreme positions, blue / green lamp is switched off and the solenoid
brake applied automatically.

The design of hoist mechanism shall be based on the gate opening / lowering
speeds mentioned in the above paras. The gates shall fall under their own weight
so as to effect closure of the bay, the only operation involved shall be to release the
brakes. It shall be possible to accomplish this operation in any one of the following
two ways. However during closing operation, the controls will come into play when
the gate is about 150 mm above the sill ( i. e. the last 150 mm of the fall of gate ) to
ensure smooth landing of the gate on the sill.

(i) By pressing the push button on the panel to close position.
(ii) By hand lever provided on the brake in case of failure of power.

The controls and hoist drive equipment of a hoist shall consist of an electric motor
with reversible contactors, main contactor, electro-magnetic brake, disconnection
switch, push buttons, limit switches and other appurtenances etc.

The control cabinets shall be of the frame mounting type having sufficient size so
as to neatly and methodically accommodate all the electric, power and control
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equipment. The cabinets shall be of a repute make. Equipment such as indicating
lamps, push buttons etc. shall be installed flush mounted on the door of the control
cabinet so that the gate can be operated with the cabinet door closed. The
remaining equipment shall be installed inside the cabinet, being accessible when
the door is opened. The cabinets shall have access only at the front. The cabinets
shall be suitable for outdoor use in tropical climate and shall be provided with
suitable protection against ingress and moisture.

1.10 MONO-RAIL HOIST (For Weir & Intake Stoplogs, Intake Trashracks,Desilting
Gates and Draft-tube Gates )

Electrically operated monorail hoist shall raise/lower stoplog gate units. The hoist
shall traverse all bays of the Stoplog. Lowering/raising and traverse speed shall be
as specified in paras 1.2, 1.4, 1.5, 1.6 & 1.7 above. The hoist capacity shall be
adequate to meet the operation requirements and shall be 20% more than all the
forces opposing the raising of a stoplog.

The hoists shall be designed/manufactured to conform to Indian Standards
Specifications IS: 3938 or their corresponding International Standards. The hoists
shall be installed on the monorails supported on hoist structure as shown in the
appended drawings.

Mono-rail Hoist will consist of two electric motors (one for hoisting and the other for
traversing mechanism), two independent electro-magnetic/thruster brakes, gear
reduction units for both the motors (working independently), rope-drum, ropes,
pendant switch, limit switches, main hoisting controls, PVC insulated cable for
power supply and its mounting structure, other accessories etc. Electric interlocking
shall also be provided to ensure that either raising / lowering operation or traverse
motion is operative at a time. The hoists shall be suitable for outdoor service.
Amber indicating lamp shall be provided on the pendant itself to indicate that the
electric Supply is on .
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SECTIQN 2 TECHNICAL SPECIFICATIONS AND REQUIREMENTS

2.0 GENERAL

The Hydro-mechanical equipment included in scope of work shall conform to the
following basic requirements and specifications.

2.1 DESIGN & STRESS LEVELS

2.1.1 GATES (DIVERSION WEIR UNDERSLUICE, INTAKE& SESILTING)

(a) Various components of the gates and embedded parts shall be designed
in accordance with the provisions IS:4622 or its corresponding International
Standard. The horizontal girders and wheels shall be so spaced that they carry
equal load (approximately).

(b) Loads to be considered for design:

(i) The gate shall be designed for the hydrostatic head corresponding to
Reservoir Level El. 2245.27 m and as indicated in Paras 1.1 & 1.3 in Section
1 of these specifications.

(ii) The design of gates shall be checked for the combination of above design
head and earthquake effect in accordance with IS 1893 Indian Standard
Criteria for Earthquake Resistant Design of Structures or its corresponding
International Standard. Allowable stresses in this case shall be increased by
33.3% subject to an upper limit of 85% of Y.P.

2.1.2 STOPLOGS (DIVERSION WIER UNDERSLUICE, INTAKE & DRAFT-TUBE)

(a) The stoplog for Diversion Weir Undersluice & Intake shall be designed for the
hydrostatic head corresponding to Reservoir Level El. 2245.27. The D.T. Gate
Stoplog shall be designed for head corresponding to Max. Tail Water Level El.
1718.30.

b) Various components of stoplog gate and embedded parts shall be designed in
accordance with the provisions of IS-5620 or its corresponding International
Standard.

(c) The design of stoplog shall be checked for the combination of above
hydrostatic head and earthquake effect in accordance with IS: 1893 or its
corresponding International Standard. Allowable stresses in this case shall be
increased by 33.3% subject to an upper limit of 85% of Y.P.

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2.1.3 INTAKE TRASHRACKS

a) The trashracks shall be designed for a differential head of 1.5 m.

b) Various components of trashracks shall be designed in accordance with the
provisions of IS: 11388 or its corresponding International Standard.
Permissible stresses shall be as per IS: 11388.

2.1.4 ROPE DRUM HOISTS

Various components of hoist such as wire rope, drums, sheaves/pulleys, gears
and pinions, worm gear reducer, shafts, keys, bearings and coupling etc. and their
design shall meet the requirements of IS:6938 and IS:800 or its corresponding
International Standard.

The worm gear reducer shall be a standard superior quality product of
established/reputed manufacturer of such equipments. The openings in the
housing of the reducer etc. shall be provided with dust proof seals/packing.

All gears/pinions shall be enclosed in fabricated steel cases having air tight covers
with windows at the top for inspection. The openings in the gear cases for shafts
shall be provided with dust proof seals.

The wire rope shall be ungalvanised of suitable construction having adequate
diameter and shall conform to IS: 2266 or its corresponding International Standard.

Bolts, buts and screws used shall conform to relevant Indian Standards. Bolts and
screws in rotating parts shall be locked. Bolts in tension shall be avoided as far as
possible. Wherever necessary net section of such bolts at the root shall be
increased by 15%. Flexible coupling between the motor, worm gear, reducer shall
permit both angular and off set misalignment between the coupled shafts. These
shall be of the size rated for the shafts to which these are connected and shall have
torque rating suitable for the loads transmitted. These shall be of flanged type fully
enclosed and dust proof and shall conform to relevant clause of IS:6938 or its
corresponding International Standard.

2.1.5 MONO-RAIL HOISTS (For Stoplog gate)

Various components of these equipment shall be designed in accordance with
provisions of IS: 3177, IS: 6938 and IS: 807. Capacities of these shall be125
percent of all the forces opposing the hoisting with loads intended to be handled.
These equipments shall be of class 2 classification as per IS: 807. Corresponding
International Standards for the above Standards may also be followed.

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2.1.6 LIFTING BEAMS

The lifting beam for stoplog gate and trashracks shall be designed in accordance
with provisions of IS: 13591 or its corresponding International Standard.

2.1.7 Sluice Valves for Silt flushing

One No. Flanged Type Knife Edge Gate Valve of 600 mm (NB) shall be provided in the silt
flushing pipe. The gate valves shall be designed for an un-balanced Hydro-static head of
7.50m plus Wet Silt load upto one valve height. The gate valve shall be power driven with the
provision of emergency manual operation in case of Power Failure. The valve shall be suitable
for heavy duty. The Knife of the valve shall be stainless steel plant precision buffed for leak
light shut off even in heavy silt.
The plane surface of the valve seat shall have no recess to however heavy silt deposits, that
control buildup and swamp the valve. The gland gasket shall be Teflon-impregnated asbestos
layered with molded rubber for total sealing. Two bosses shall be welded to the valve seat to
press the knife plate truly against the side of the seat ring for bubble tight shut off.
For manual smooth and speedy opening/closing the double thread screw on the stem shall be
provided.

2.1.8 Bought-out Items

All bought out items shall be of the best available make and shall be the product of
manufacturers of repute bearing standardization marks.

2.2 PERMISSIBLE STRESSES

GATES (Diversion Weir Under sluice & Intake)

The permissible stresses shall be taken those corresponding to wet inaccessible
conditions as per Annex. B of IS: 4622-2003 or its corresponding International
Standard and are given as under:

Material and Type of Stress Permissible Stress

Structural Steel Wet & Accessible condition

(i) Direct Compression/tension 0.45 Y.P.
(ii) Compression/tension in bending 0.45Y.P.
(iii)Shear 0.35 Y.P.
(iv)Combined 0.55 Y.P.
(v) Bearing 0.45 Y.P.

Concrete M-30 (In Block-outs)

(i) Bearing 0.25 fck 76.50 kg/sq.cm
(ii) Shear 4.0 kg/sq.cm

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DESILTING GATES

The permissible stresses shall be taken those corresponding to dry accessible
conditions as per Annex. B of IS:4622-2003 or its corresponding International
Standard and are given as under:


Structural Steel Wet & Accessible condition

(ii) Compression/tension in bending 0.45 Y.P.
(iii)Shear 0.35 Y.P.
(v) Bearing 0.45Y.P.

Concrete M-30 (In Block-outs)

(i) Bearing 76.50 kg/sq.cm

2.2.3 STOPLOGS (diversion Weir Undersluice, Intake & Dtaft-tube)

As these are stored above water level and are only occasionally used, permissible
stresses have been taken those corresponding to Dry-accessible conditions as
given in Appendix B of IS:5620 or its corresponding International Standard.


Structural Steel Dry & Accessible conditions

(ii) Compression/tension in bending 0.55 Y.P.
(iii)Shear 0.4 Y.P.
(v) Bearing 0.75 Y.P.

Bearing Stress Bronze on Steel 0.04 U.T.S.

Concrete M-30 (In Block-out)

(i) Bearing 7650 kg/sq.cm

2.3 DELETED

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2.4 MATERIALS

All materials incorporated in the equipment shall be new, unused and of first class
quality, free from defects and in accordance with relevant Indian Standard (Latest
revisions) or their corresponding International Standards. Materials and Proprietary
items shall be selected taking into consideration customary use for type and class
of equipment having regard to strength, the durability and best engineering
practice.

As a general guidance materials used for various items of gates and hoists are
given as under: In the Tables for Materials only the Indian Standards have been
indicated. Corresponding International Standards can also be followed.

2.4.1 GATES (Diversion Wier Undersluice, Intake & Desilting )
_______________________________________________________
S.No. Component Part Material Material
Specs. (Latest)

(i) Structural parts of gates Structural IS: 2062
i.e. skin plate, horizontal girders,
end vertical girders, Vertical
stiffeners,seal bases, seal
clamps, guide shoes, etc.

(ii) Wheel track bases, seal seat , Structural IS: 2062
bases, Sill beam base, guides, Steel .
anchor bolts etc

(iii) Wheels Cast Steel IS: 1030

(iv) Wheel Axle Pin Corrosion Resistant 20 Cr 13
Steel IS: 1570 Part IV

(v) Wheal Bearings Spherical roller SKFmake or
Bearing equivalent

(vi) Seals (a) Side Music Note type IS: 11855
44 mm dia (Hollow)
(Plain rubber for Barrage & Barrage Under Sluice Gates and Teflon cladded for
Head Regulator Gate).

(b) Bottom Rubber Wedge Type IS: 11855

(vii) Wheel track and Seal Seats Corrosion Resistant 30 Cr 13 for Track
Steel 04 Cr 18 Ni 10
for seal seat IS:1570
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Part IV
2.4.2 STOPLOGS (Diversion Weir Undersluice, Intake & Draft-tube)
__________________________________________________________________
S.No. Component Part Material Material
Specs. (Latest)
__________________________________________________________________
(i) Structural parts of stoplogs Structural IS:2062/
i.e. skin plate, horizontal Steel
girders, end vertical girders,
vertical stiffeners, seal bases,
seal clamps, guide shoes, etc.

(ii) Track bases, seal seat bases, Structural IS: 2062.
Sill base, guides, anchor bolts Steel
etc

(iii) Tracks, seal seats Corrosion Resistant 04 Cr 18 Ni 10
Steel IS: 1570 Part IV

iv) Seals (a) Side Rubber IS: 11855
- music note type
44 mm dia (Hollow)

(b) Bottom Rubber Wedge Type IS: 11855

(v) Thrust Pad Structural Steel Cladded IS: 2062
with Bronze (Min.10 mm thick) IS: 305

2.4.3 INTAKE TRASHRACKS

Materials for various components of trashracks shall be Structural Steel conforming
to IS: 2062.

2.4.4 ROPE-DRUM HOISTS, MONO-RAIL HOISTS

Materials for various components of the equipments shall conform to provisions of
IS: 807, IS: 3938 and IS: 6938 or their corresponding International Standards..

2.5 EMBEDDED FRAMES FOR GUIDES AND WHEEL PATHS

Wheel paths, seal path and guide tracks shall be provided up to following heights:

Guide Tracks : Full range of gate/stoplog travel

Wheel Paths : Fixed Wheel Gates --- up to twice the gate height
Stoplogs-gate height plus 0.5 m

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Seal Paths : Sill level to one gate height or up to lintel seal.

For installations of embedded parts in 1ststage blockout, suitable and adequate
number of anchor bolds welded to first stage anchor plate shall be provided to align
and level embedded parts and retain them during concreting. Necessary stainless
steel sealing faces and corrosion resistant roller paths machined accordingly shall
be provided. The spacing of first stage embedded parts (anchor plate) shall be not
more than 500 mm.

2.6 ELECTRICAL EQUIPMENT

The electric motors furnished shall be suitable for operation on 415. volts. 3 phase,
50 cycles A.C. supply. The motors shall be squirrel cage, reversing type with high
starting torque characteristics and shall conform to Indian Standard IS:325 or its
corresponding International Standard. The motors shall be totally enclosed fan
cooled an d suitable for outdoor use in tropical climate and highly humid
atmosphere. The rated sped of the motor shall not be more than 1000 r. p m.
The electric motors shall be designed having starting current kept as low as
practicable consistent with good design. The motor shall be suitable for frequent
start, stop operation.

The winding insulation shall be class 'F' and the entire coil, system shall be
completely void free and impregnated with an impervious epoxy resin forming a
completely solid integrated insulation structure. The entire insulation system shall
be moisture free type, mechanically stable, abrasion resistant and sufficiently
resilient to withstand effects of thermo cycling without developing defects
throughout the life of the electric motor.

The maximum temperature rise of the winding when the electric motor is delivering
rated output continuously at rated voltage and frequency shall not exceed 40"C
(104
0
F) above ambient temperature at project site. The temperature rise of other
parts of the motor shall be in accordance with the Indian Standards.

The electric motors shall be equipped with either ball or roller type self lubricating
bearings which shall be properly sealed against loss of lubricant or entrance of
dust.

To prevent condensation, the electric motors shall be equipped with 240 volt single
phase anti-condensation heater mounted in or on the frame. The leads of the
electric motor and the heater shall be brought out in a terminal box on the motor
having suitable cable entry lugs.

For isolating the electric motors from the supply system manually operated triple
pole disconnecting switch of suitable capacity shall be installed in the cabinet. The
disconnecting switch shall conform to IS:2607 Air break isolator for voltage not
exceeding 1 000 volts or its corresponding International Standard and shall be
suitable for operation on 41 5 volts.
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For the electric motors, following contactors of suitable capacity shall be provided.

Two phase Raise contactors

Two phase Lower contactors

Three phase Main contactors

The contactors, shall be direct on the line starting air break type and suitable for
operating on 415 volts, 3 phase, 50 cycles A.C. supply. The contactors shall
conform to IS: 1822, "AC motor Starters of voltage not exceeding 1000 volts" and
IS: 2959 "A.C. Motor contactors of voltage not exceeding 1000 volts".
Corresponding International Standards may also be followed.

H.R.C. fuses of suitable capacity shall be provided in the main power circuit and
control and heater circuit for protection against short circuits.

Limit switches, provided for normal stopping of the gate at extreme position of
travel, shall reset automatically on reversing the direction. Over travel limit switches
shall be provided to take care if normal limit switches fail to operate or the raise
flower contactor fails to open. These limit switches shall also be capable of being
reset by reversing the direction of travel or pressing the 'Reset' push button. The
limit switch shall be of totally enclosed type.

The cables shall be P.V.C. insulated, P.V.C. sheathed conforming to IS:694 'P.V.C.
insulated cables for voltage up to 1000 V'. Consideration shall also be given to
such factors as ambient temp. grouping and disposition of cables and to the
limitation of voltage drop while selecting the cables. The cables from the power and
control cabinet to the various equipment shall also be supplied by the contractor.
Power cables shall not be less than 4 sq.mm nominal copper area.

The conduits and conduit fittings shall be heavy gauge galvanised steel conforming
to IS: 1653 "Rigid at Steel Conduits for Electrical Wiring", and IS: 2667 'Fitting for
rigid steel conduits for electrical wiring". -Flexible conduit may also be used
wherever required.

2.7 SHOP ASSEMBLY & TESTING

All equipment fabrications and structures covered by the specifications shall be
fully assembled in Manufacturer's shop for inspection by Engineer to the extent
necessary to demonstrate matching of structural components. All necessary
adjustments shall be made in the shop to achieve the specified tolerances. Checks
on dimensions and tolerances shall be recorded by Manufacturer and three (3)
copies furnished to Engineer within a week of shipment of the material.

Without limiting the foregoing. the following shop assemblies shall be carried out.
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The gate components such as
- Wheel assemblies (in case of fixed wheel type gates);

- The electrical control panels, starter, contactors, position indicators etc.

Prior to dismantling, each assembly shall be permanently and clearly match
marked in the shop to facilitate site erection. Dismantling shall be done only to the
point required for shipping. In particular. there shall be minimum disconnection of
electrical wiring.

Engineer will inspect all equipment during fabrication and before shipment and
witness the shop tests after final assembly.

2.7.1 Gate Frames

The metal work shall be shop assembled to the extent necessary to ensure that all
parts are properly fitted and that the dimensional and tolerance requirements
shown on the drawings have been obtained. All holes for field connections of parts
furnished under these specifications shall be drilled or reamed as noted on the
drawings, with the embodiments so assembled. Members to be shop-riveted shall
have all parts well pinned up and drawn together with bolts before riveting is
commenced.

2.7.2 Gates

Each component of gate and stoplog shall be assembled in the shop to the extent
necessary for inspection and to ensure that all parts fit properly and that
dimensions. clearance and tolerances required in the specifications and drawing
have been achieved. Holes for field connections shall be carefully drilled or
reamed. Connections which have to be disassembled for shipment shall be made
by the use of erection pins, one size less in diameter than the designed size or
temporary machine bolts.

Proper functioning/operation of filling in valve and lifting beam, automatic
engaging/disengaging shall be checked during shop assembly.

2.7.3 Hoists

All electrical and mechanical components shall be tested in accordance with the
appropriate Indian Standards at either the Maker's or equipment manufacturers
works and tests certificate provided.

The hoist shall be assembled in the shop to the extent necessary to ensure that all
parts are properly fitted. Surfaces of metal which will be in contact shall be cleaned
before the parts are assembled. The parts shall be adjusted to line and fit and shall
be well pinned and bolted so that the surfaces are in close contact before reaming,
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drilling, rivetting or welding is commenced. Drifting done during assembly shall be
only that is necessary to bring the parts into position and not so much as to enlarge
the holes or distort the member, if any, hole must be enlarged to admit fastening, it
shall be reamed. The field connections shall be fitted and checked in the shop to
assure proper fit during field erection.

After shop assembly the hoist shall be tested at manufacturer's works in
accordance with relevant Standards. The manufacturer shall supply all material
equipment and labour required for shop assembly and tests. and cost thereof shall
be included in the bid price.

All shop tests shall be made in the presence of the Engineer or his representative.
The hoist shall be prepared for shipment in as large units as practicable. One print
of a diagram of match marks shall be enclosed with the shipment and four prints
shall be forwarded to the Engineer.

2.7.4 Place of Manufacture and Inspection

The contractor shall intimate the place of manufacturer, testing and inspection of
the various portions of the work. Authorised representative of the Purchaser may
be present at the time of any or all tests and the Manufacturer shall provide all
necessary facilities for the same. Representatives of the Purchaser shall also be
entitled to access to Manufacturer's sub-contractors work at any time during the
working hours for the purpose of inspecting the manufacture of equipment and
materials.

To satisfy himself that the materials and equipment comply with the conditions of
contract, the Engineer-in-Charge of the Purchaser reserves to himself the right of
having at his expense, any inspection or tests of a reasonable nature carried out in
addition to the routine tests specified in the appropriate Indian Standards.

2.7.5 Inspection

All materials furnished shall be of tested quality and all work performed shall be
subject to rigid inspection and no articles or materials or supplies shall be
despatched until all tests. analysis and shop inspection have been completed or
certified copies of reports or results of tests and analysis shall have been accepted.
Duplicate copies of manufacturers test certificate shall be submitted to the
Engineer in Charge of the Purchaser as soon as the tests are completed. In case
tests certificate are not available for any of the materials, the same may be got
tested and only those materials which fulfil the requirements of the specifications
shall be used.

From any part/item, it should be possible to locate its manufacturer Batch/Lot mark,
which shall be achieved by transferring the batch mark before parting the materials.

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All supplies (which include without limitation raw materials. components.
intermediate assemblies and assemblies and end products) shall be subject to
inspection and test by the Purchaser to the extent practicable at all times and
places. If any inspection or test is made by the Purchaser in the premises of the
Manufacturer or subcontractor, the Manufacturer without additional charge shall
provide all reasonable facilities and assistance and the safety and convenience of
inspectors in the performance of their duties. If on the request of the Purchaser,
inspection or test is made at a point other than the premises of the Manufacturer or
sub-contractor of the Manufacturer, it shall beat the expense of the Purchaser
except as otherwise provided in the contract, provided that in case of rejection, the
Purchaser shall not be liable for such expenses.

2.8 SITE TESTING & COMMISSIONING

2.8.1 Operational Tests

(a) The Manufacturer shall carry out in the presence of Purchaser such tests
on the equipment to determine that the same will fulfil the functions for which they
have been designed. The tests shall be carried out in accordance with provisions of
IS: 7718. Tests shall be repeated, if necessary, until successfully carried out to the
satisfaction of the Purchaser. leakage tests and operational tests shall be carried
out after completion of other portions of the work and when the reservoir is at full
reservoir level. Purchaser shall have the right to carry out such tests also when
reservoir is at a level other than full reservoir level.

(b) For hoists the following tests shall be carried at site after erection.

(1) Insulation tests:

After erection but before the hoist is connected to the supply. the insulation of the
electrical equipment shall be tested by a suitable instrument and any defects
revealed shall be rectified. The voltage required for the insulation resistance test
shall be d.c. voltage not less than twice the rated voltage.

i) Any reading less than 0.5 mega ohm obtained with an insulation resistance
tester of the unregulated type shall be disregarded and the wiring under test shall
be sub-divided until a reading higher than 0.5 mega ohm is obtained. Failure to
obtain a higher reading shows an unsatisfactory state of insulation. If an installation
has been sub-divided for test purpose. each sub-division shall meet the
requirements.

ii) The insulation resistance of each wiring circuit exclusive of connected apparatus
shall be not less than 2 mega ohms. If necessary, it shall be permissible to
disconnect individual items of equipment while making this test.

(2) Test for operation:

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After the supply has been connected and before the complete hoist installation is
put to commercial service, tests shall be carried out to prove the following:

i) The satisfactory operation of each controller, switch, contactor, relay and other
control devices and in particular the correct operation of all limit switches under the
most unfavourable conditions.

ii) The correctness of all circuits and interlocks and sequences of operation.

Satisfactory operation of all protective devices.

iv) The satisfactory operation of each motion of the hoist.

v) The compliance of the hoist with the specified performance requirements.

vi) Tolerances on specified speed on full load shall be within 10%.

(3) Deflection tests

The deflection test shall be carried out with the safe working load at rest. The
measurement shall not be taken on the first application of the load.

(4) Overload tests

After the above tests but before the hoist is put into service, it shall, with overload
relays appropriately set, be tested to lift and sustain a minimum test load of 125
percent of the working load.

2.8.2 Dry Test

Operational tests in dry shall be carried out as soon as possible after completion of
erection and all controls and permanent power supply have been connected. The
tests shall include at-least two complete traverses from the maximum raised
position to the full sealing position. All adjustments, clearances, brakes etc. shall be
checked for proper and smooth operation.

2.8.3 Wet Test

These tests should simulate the actual operating conditions as closely as possible.
At-least two complete traverses will be made from the fully closed position to the
fully raised position as follows:

a) When gate is closed, raise gate to its fully open position in steps and observe
the performance including vibration.

b) Lower the gate to the full closed position in steps and observe the performance
of the gate vibration.
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c) Check up operation of limit switches.

2.8.4 Leakage Tests

Leakage tests shall be carried out with the gate resting on to the sill. Before
measuring the leakage the gate shall be raised and lowered several times by about
20 to 40 cms or so in order to dislodge any debris that may have lodged in the side
seal seat. The leakage shall then be measured and recorded. The maximum
leakage past the seals shall not be more than 15 liters per min. per meter length of
seal under maximum head conditions.

2.8.5 Final Acceptance

Final acceptance of the equipment shall be based on the following:

a) Quality and workmanship of the equipment including dimensional accuracy.

b) Satisfactory operation of the equipment after erection as required under these
specifications.

c) Acceptance of various tests or test certificates by the Purchase.

All tests may be witnessed by the Manufacturer or his authorised representative.
On successful completion of all tests the equipment shall be accepted but all the
responsibilities shall remain with the Manufacturer within the guarantee period.

The labour and material for the field tests shall be provided by the Contractor. The
test load and necessary lifting tackles shall be provided by the Purchaser and
Contractor respectively.

2.8.6 Guarantee

Within one year after issue of Certificate of Completion if any part of the gates,
embedded parts, hoists etc. are found defective because of workmanship or
material or otherwise. the Manufacturer shall, at his own expense furnish and install
new parts and materials approved by the Purchaser.

2.9 WELDING PROCEDURE

2.9.1 The edges of plates and shapes to be joined by welding shall be properly
formed to suit the type of welding selected. Where plates and shapes have been
sheared. edges to be joined by welding shall be machined or chipped to sound
metal. Plates and shapes to be field welded shall have their edges prepared in the
shop for the type of weld selected.

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Where bending or forming of plates or shapes is required, the plates or shapes
shall be bent by cold forming. Heating and hammering to correct bends will not be
permitted.

2.9.2 Welding

(a) Members to be joined by welding shall be cut accurately to size, and
where required, shall be rolled or pressed to proper curvature in accordance with
the approved drawings. The dimensions and shape of edges to be joined shall be
such as to allow thorough fusion and complete penetration and plates shall be
planned, if necessary, to accomplish this result. Members to be welded together
shall be in sufficiently intimate contact at the time of welding so that members will

(b) not be forced more closely together with the cooling of the weld, thus
setting up additional strains and distortions in the weld and parent metal.
The surfaces of plates to be welded shall be free from rust, grease and scale for a
distance of 12 mm back from the welding edge at the time of welding. Flame
cutting may be used in the preparation of the various members provided the
operation is performed carefully, and the edges so cut are cleaned thoroughly after
being cut so as to expose clean metal.
Any contour irregularities at points of critical stress shall be removed by grinding.

(c) Welding Technique Care shall be taken in designs that the welds when
being made, are well accessible. Overhead welding is to be avoided. if possible
and flat position welding is to be strived for. Drawings should clearly indicate the
joint position, or field welding, kind of welding, method of welding, welding sizes
and other required information/data. Symbols to be shown on the drawing would
conform to relevant lndian Standards. All welding shall be done by the electric arc
method by a process which will exclude the atmosphere from the molten metal,
except where otherwise specifically permitted. All welding electrodes required shall
be furnished by the contractor. Correct selection of electrodes shall be done taking
due care of welding method and base metals of components to be welded. The
welding electrodes shall be of heavily coated type designed for all position welding.
The make, type and size of all welding electrodes shall be subjected to the
approval of the purchaser. In assembling and during welding the component parts
of built up members shall be held in place by sufficient clamps or other adequate
means to keep all parts in proper alignment and position.

Radiographic tests shall be carried out for all critical full strength butt welds.

i) Butt joints

In principle, butt joints shall be made with back-run. Backing strap should be laced
and welding should be so made that the molten metal fully penetrates and a full
penetration is achieved. Dye-penetration test shall be carried out after each pass of
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the weld. Radiographic testing of butt welds shall be carried out to the extent
required by the Purchaser.

ii) Fillet J oints

All fillet welds shall be continuous. For the main member, no fillet welding should
be made on members whose thickness differs substantially. Fillet weld at T J oints
should be made, as a rule, on each side of the joint unless it is otherwise agreed
due to some practical reasons. Radiographic test is not normally required for fillet
welds. All the fillet welds shall be checked by Dye Penetrant Test by the
Manufacturer in the shop. However 20% to 30% of fillet welds shall be checked by
dye-penetrant test in presence of Purchaser to check soundness of weld.

At Welded butt joints, where the weld material is required to be deposited on both
sides of the joints, the weld shall be chipped or melted to obtain a clean surface
prior the application of the first head of the welding on the opposite side of the
joint. Where fillet welds are used, the lapsed sections shall fit closely and shad be
held together during the welding operation. When weld metal is posited in two or
more layers, each layer shall be brushed with a wire brush or otherwise cleaned
before subsequent layer is deposited. In welding, precautions shall be taken to
minimise stresses due to expansion or contraction either by peening the welds
while hot, or by other satisfactory methods and also by using the proper sequence
in welding. Correction of distortion by blows after welding is completed and the
place is cold, will not be permitted. Upon completion, the welds shall be brushed
with wire brushes and shall show uniform section, smoothness of weld metal,
feather edges without excessive overlaps and freedom from porosity and clinkers.
Visual inspection at edges and ends of fillets and butt joints welds shall indicate
good fusion and penetration into base metals.

(d) Welding Process

A specification of the welding process, that is proposed to be used. shall be
established and recorded and if required, a copy of such specification together with
a certified copy of report for results of tests made in accordance with the process
and specifications shall be furnished. The qualification of the welding process shall
be at least equal to that required by 'Standard Qualification Procedure' of the Indian
Standards and the minimum requirement of the tests shall be atleast as stated in
the said 'Standard Qualification Procedure':

(e) Qualification of Welders

The Manufacturer shall be responsible for the quality of the work performed by his
welding staff. All welders assigned to the work shall have passed qualification tests
for welders. If at any time the work of any welder appears questionable, welder
shall be required to pass additional qualification tests to determine his ability to
perform the type of work on which he is engaged.

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2.10 SURFACE PREPARATION & PAINTING

2.10.1 General

a) The Manufacturer shall provide as part of his supply the surface treatment,
priming, corrosion protection and painting of the equipment furnished. Such work
shall include the coating and painting work at the workshop and at the site up to
and including the finish painting. Unless otherwise specified the coating and
painting shall be carried out in accordance with provisions of IS: 14177 or its
corresponding International Standard. All paints, painting material and accessories
for painting shall be included in the price bid. All finished and unfinished surfaces of
metal work (other than of aluminum brass, bronze or stainless steel)- except screw
threads, mating surfaces, sliding surfaces, rolling surfaces shall be cleaned and
protective coatings applied as specified in the above mentioned Standard. As a
general guidance following is given.

b) All paints and painting material shall satisfactorily fulfill the requirements
imposed by the site conditions, as well as the stresses to which the respective
equipment is subjected during operation of the works. Shades of the finishing
coatings shall be as approved by the Purchaser or his representative.

c) The paints and shades of the finished coatings proposed by the Manufacturer
must be got approved by the Purchaser before application of the same. The
analysis in respect of paint properties, paint composition and performance
requirements of the paints shall be submitted by the Manufacturer for check and
approval. All painting material shall conform to relevant Indian Standards.

Each coat of printer and paint shall be compatible with the previous and
subsequent coats. All pigmented primers and paints which will be used for priming
and painting at the site shall be delivered in original and sealed containers packed
by the manufacturer.

e) The Manufacturer shall supply full details regarding the extent to which sand-
blasting, priming and painting will be carried out in his workshops (or his sub-
contractors, as the case may be) at the site and after erection. A properly
equipped paint shop shall be set up at the site using a specialist organisation,
experienced and skilled in the preparation and application of protective coatings
at the conditions prevailing at the site.

2.10.2 Surface Preparation

After the equipment has been fabricated, it is essential that before any primer and
coat of paint is applied, the surface is properly prepared. Such preparation shall
include through cleaning, smoothing, drying and similar operation that may be
required to ensured that the primer and/or paint is applied on suitable surfaces.
Clean cloths and clean fluids shall be used to avoid greasy film or greasy residueon
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the surfaces being cleaned. The procedure for surface preparation shall be as
follows:

a) Weld spatters or any other surface irregularities shall be removed by any
suitable means before cleaning.
b) All oil grease and dirt shall be removed from the surface by the use of clean
mineral spirits, xylol or white gasoline (lad free) and clean wiping materials.

c) Following the solvent cleaning, the surfaces, to be painted shall be cleaned of all
rust, mill scale, and other tightly adhering objectionable substances by sand
blasting or grit blasting to uniform bright base metal. Average surface roughness
for sand blasted area shall not exceed 40 microns. Any grit or dust remaining
after the cleaning operation shall be completely removed from the surface by wire
brushing; air blowing, suction or other effective means before the surface is
painted.

d) Surfaces of stainless steel, nickel, bronze and machined surface adjacent to
metal work being cleaned or painted shall be protected by masking tape or by other
suitable means during the cleaning and painting operations.

e) Primers shall be applied as soon as the surface preparation is complete and
prior to be development of surface rusting. In case there is considerable time gap,
the surface shall be recleaned prior to priming.

2.10.3 Shop Painting

a) Stainless steel and bronze surfaces shall only be cleaned but not painted.

b) All surfaces of the embedded parts which are to come in contact with concrete
shall be cleaned as mentioned above and given two coats of cement latex to
prevent rusting during shipment and while awaiting installation.

c) Two coats of zinc rich primer with epoxy resin shall be applied to all unfinished
surfaces of the embedded parts and gates which shall remain exposed to
atmosphere or submerged in water to obtain a dory film thickness of 70 microns,
which shall be followed by two / three coats at an interval of 24 hours of solventless
coat-tar epoxy paint, so as to get a dry film thickness of 150 / 100 microns in each
coat. Total dry film thickness of all the coats including primer coating shall be less
than 350 microns.

d) All finished surfaces of ferrous metal including bolts, screw threads, etc., that will
expose during shipment or while awaiting installation shall be cleaned and given a
heavy uniform coating of gasoline soluble rust preventive compound or equivalent.

e) AJ I exposed surfaces for hoists supporting structures shall be given two coats
of zinc phosphate primer to obtain dry film thickness of 40 microns per coat
which shall be followed by one coat of alkyed based micaceous iron oxide paint
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at dty film thickness of 65 microns and then two coats of synthetic enamel paint
to obtain dry film thickness of 25 microns per coat. The total dry film thickness
of all the coats including primer coat shall not be less than 175 micron.

f) All other surfaces to be painted shall be primed with one coat of an approved
synthetic varnish vehicle, rust preventive and lead paint. The surface which will be
inaccessible after assembly shall be given an additional coat (total two coats) of the
same paint.

2.10.4 Measures During Painting

a) Any bare spots or holidays shall be recoated with additional application of
primer.

b) All runs, sags, floods, or dips shall be removed by scrapping and cleaning, the
cleaned area shall be retouched or all such defects shall be remedied by re-
blasting or re-priming.

c) Special attention shall be given to obtaining good coverage on rivets, welds and
sharp edges and corners.

d) Suitable measures shall be taken to protect applied primer from contact with
rain, fog, mist, dust or other foreign matter until completely hardened and next coat
applied.

e) The air temperature at the time of application must not be below 10 Deg. C and
relative humidity must not be above 60%.

2.10.5 Application Procedure

All paints and coating materials shall be in a through mixed condition at the time of
application and shall not be thinned except as hereinafter specifically provided. Any
warming of the paint shall be performed by means of hot water bath. On all
surfaces, to which paint shall be applied immediately after cleaning, and except
otherwise specifically provided, shall be applied by either brushing or by spraying.
When paint is applied by spraying, a mechanical agitator type of paint pot shall be
used. Means shall be proved for removing all free oil and Posture from the air
supply lines of spraying equipment. Each coat of paint shall be free from runs,
sags, pin holes and holidays.

Each coat of paint shall be allowed to dry or harden thoroughly before the
succeeding coat is applied.
ll paints shall be applied by skilled workmen in a workmanlike manner. Paint shall
not be applied during damp weather and on surfaces that are not entirely free from
moisture. Rust preventive compound shall be applied by any convenient method to
ensure complete coverage of heavy coating. After the final application. the paint
film shall be allowed to cure at least for 7 days.
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2.10.6 Field Painting

The painted metal work shall be handled with care so as to preserve the shop
coats. The area of the shop paint which has been damaged during transport shall
be cleaned to base metal and repainted. Paint applied to such areas shall be of the
same type as used originally in shop painting. All unfinished surfaces of embedded
parts and gates that are exposed to atmosphere or submerged in water shall be
given a finishing paint of Aluminium-Epoxy paint to as to obtain shining surface of
pleasing colour. This finishing coat should be able to reflect light and limit the heat
absorption when exposed to sun.

2.11 INSTALLATION, OPERATION & MAINTENANCE MANUALS

For guidance during the installation of the work and subsequently for guidance of
the plant operating and maintenance staff, Manufacturer shall prepare requisite
manuals.

The manuals shall include a separate and complete section describing the normal
and emergency operating procedures for the gates and control equipment and shall
include easily read diagrammatic drawings of the equipment to facilitate
understanding of the descriptive information.

The manuals shall describe and illustrate the Procedure for assembling. adjusting,
operating and dismantling of each component and control system. The
maintenance of each component shall be described, including the recommended
frequency of inspection and lubrication.

Manuals shall also describe and illustrate procedures for installation, storage,
handling, unloading, reloading, unpacking and upkeep of each component and of
the system.

Three (3) copies of the manuals shall be submitted in English in draft form for
approval of Engineer three months prior to the time the information is at site. Six
(6) suitably bound copies shall be provided to Engineer not later than days after
receipt of approval.

If revision of the manuals becomes necessary, as a result of information gained
during installation and initial operation, Manufacturer shall make the necessary
revisions and furnish six (6) copies of the revised sections.

The manuals shall include a complete list of all drawings prepared by
Manufacturer, a list of spare parts and a list of parts for each component or item of
equipment. The parts list shall include manufacturer's name and serial numbers
and source of their procurement.

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Manufacturer shall ensure that his Erection, Installation Supervisor has a copy of all
approved drawings and the manuals in his site office.

2.12 ERECTION TOLERANCES

The Erection Tolerances shall be as per relevant Indian Standards or their
corresponding International Standards. However the following is given as a general
guidance.

2.12.1 Gates (Diversion Weir Undersluice, Intake & Desilting)

A. Embedded Parts Tolerance limit in mm

1.0 Track Plates
1.1 Alignment in plane parallel to flow 1.0
1.2 Distance between centre line of opening and track 1.5
1.3 Coplanerness 1.0

2. Guides

2.2 Distance between centre line of opening and face of guide 1.0

3. Side Seal Seats

3.2 Distance between centre line of opening and side seal seat 1.5

4. Top Seal Seat

4.1 Alignment 2.0
4.2 Height above sill 3.0

4.3 Coplanemess with side seal seat 1.5

5. Critical Dimensions

5.1 Centre to centre distance between track plates 3.0
5.2 Centre to centre &stance between side seal seats 3.0
5.3 Face to face &stance between guides 2.0
5.4 Face of track to face of side seal seat 0.0
5.5 Face of track to centre fine of guide 2.5

B. Gate
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1 Wheels

1.1 Alignment of treads in zero eccentricity position 1. 5

2 Side and Top Seal Base

2.1 Alignment 1.0

3. Critical Dimensions

3.1 Centre to centre distance between seal bases 2.0
3.2 Centre to centre distance between centre line of wheel treads 2.0
3.3 Face to face distance between faces of guide shoes or guide rollers 3.0
3.4 Face to face distance between wheel tread to side seal base +2.0
-0.0
3.5 Distance between faces of wheel tread& centre line of guide shoe/roller 2.5

2.12.2 STOPLOG (Diversion Wier Undersluice, Intake & Draft-tube)

(A) Embedded parts
1 Side Seal Seat
1.2 Distance between centre line of opening and seal seat 1.5

2. Side Guide Track

2.1 Alignment in plane normal to flow 1.00
2.2 Distance between centre line of opening and guide track 1.00

3. Bottom Seal Seat

3.1 Alignment in horizontal plane 0.25

Tender Documents
Specifications: Volume II B Hydro Mechanical Part C

i

BHYUNDERGANGA HYDRO ELECTRIC
PROJ ECT

VOLUME II-B

SPECIFICATION
FOR

PART C PENSTOCKS
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PART C - PENSTOCKS

PART C - PENSTOCKS............................................................................................................................... I
C. PENSTOCKS....................................................................................................................................... 1
1. INTRODUCTION................................................................................................................................. 1
1.1 SCOPE OF WORK ............................................................................................................................... 1
1.2 DESIGN DATA ................................................................................................................................... 1
1.2.1 GENERAL REQUIREMENTS............................................................................................................ 2
1.2.2 LAYOUT ....................................................................................................................................... 2
1.2.3 SPECIFICATIONS & STANDARDS................................................................................................... 2
1.2.4 DESIGN CRITERIA......................................................................................................................... 3
1.2.5 MATERIALS.................................................................................................................................. 3
1.2.6 LOADS TO BE CONSIDERED.......................................................................................................... 4
1.3 CONSTRUCTION FEATURES............................................................................................................... 5
1.3.1 FABRICATION OF STEEL LINER..................................................................................................... 5
1.3.2 PREPARATION OF PIPE SECTIONS ................................................................................................. 5
1.3.3 CUTTING THE PLATES .................................................................................................................. 5
1.3.4 PREPARATION OF PLATE EDGES AND OPENINGS.......................................................................... 6
1.3.5 STIFFENER RINGS......................................................................................................................... 6
1.3.6 BENDS.......................................................................................................................................... 7
1.3.7 UNIT AND MATCH MARKING....................................................................................................... 7
1.3.8 PREHEATING AND THERMAL STRESS RELIEVING......................................................................... 7
1.3.9 BUTT STRAPS............................................................................................................................... 8
1.3.10 ALIGNMENT AND TOLERANCES............................................................................................... 8
1.3.11 NON DESTRUCTIVE EXAMINATION.......................................................................................... 9
1.4 ERECTION ....................................................................................................................................... 10
1.4.1 INSPECTION DURING FABRICATION AND ERECTION................................................................... 11
1.4.2 TESTING AT CONTRACTORS PREMISES...................................................................................... 11
1.4.3 TESTING AT SITE........................................................................................................................ 12
1.4.4 CORROSION PROTECTION........................................................................................................... 12
1.4.5 SUBMITTALS .............................................................................................................................. 12

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C. PENSTOCKS
1. Introduction
i) A single penstock of 1.60 metre dia takes off from RD with its centre line at EL 2207.80
metre. The entire length of penstock has been proposed to be laid underground/burried.
Penstock trifurcates into three branch penstocks of 0.80 metre dia each.

ii) Economical diameter of the main penstock and two branches have been worked out by cost
optimization studies. The main penstock is 1.60 m dia circular steel designed to carry 5.512
cumecs of discharge at a flow velocity of 2.741 m/s, while three branches are 0.80 m dia
circular steel and each has been designed to carry 1.84 cumecs of discharge at a velocity of
3.66 m/s.

iii) The specifications take into consideration that the maximum width of steel-plates in India is
limited to 2.50 m.

iv) The Contractor has to decide whether the pipe sections will be fabricated in his workshop
and transported to the site or he will build a field work shop to produce the 1.60 m and 0.80
m diameter pipes at Site in order to prevent the damage or de-shaping of pipes during
transportation

v) The total length of the branches and penstock given above may vary subject to adjustment
to suit the final dimensions adopted for the detailed layout.

1.1 Scope of Work
The work comprises of the design, fabrication, shop assembly, testing, stress relieving, Shop
painting, transportation, supply, erection, field painting, testing and commissioning of the
penstock comprising of straight shells, bends, bifurcation, reducer, make up pieces, connection
piece between penstock branches and flanged connection of main inlet valve etc. & piezometric
connection complete in all respects in accordance with these specifications, specification
drawings. The scope of work also covers supervision of unloading, stacking, storage and
preservation of components of penstock and its accessories, in the stock yard of the contractor at
the project site before the same are transported, installed, tested and commissioned at their
respective sites. In addition to above, scope of work also includes spares parts required for
satisfactory operation and maintenance of penstock liners and its accessories for a period of 5
years from the date of commissioning of the project. Not withstanding brief description of items,
all accessories, apparatus or works not sufficiently mentioned in these specifications but which
may other wise be necessary for ensuring complete supply, erection, testing and commissioning
of the equipment covered under these specifications shall be deemed to be the responsibility of
the contractor.

1.2 Design Data
The design data for the penstock and steel lining is broadly appended below:

a) Full reservoir Level (FRL) 2240.0 m

b) Max Water Level (MWL) 2245.20 m

c) Surge level 2317.80 m (Approx)

d) Axis of Butterfly valves 1790.80 m.

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e) Axis of Inlet Value 1719.05 m

(f) Max. Tail water level 1718.30 m

(g) Rated flow 5.512 cumecs

h) Max. pressure due to water hammer and 596.50m (Tentatively based on 15% pressure rise)
water column (WC), related to the access of the turbine C.L. intake elevation of 1721.30m.

i) Headloss in the Penstock at design discharge of 5.512m
3
/s shall not exceed 3.42m

1.2.1 General Requirements
i) Plates of normalized fine grain steel conforming to IS:2002 Grade 2 or approved equivalent
shall be used and shall be 100% ultrasonically tested and certified at the Manufacturers shop.
The penstock and steel liner, bends and branch pipes bifurcation etc shall be subjected to
hydrostatic testing. The welded joints shall be subjected to appropriate NDT as specified. It is
intended that all shop fastenings and field fastenings shall to be of welded type unless otherwise
specified.

ii) Wherever possible, fabrication at site should be done by automatic welding. Suitable equipment
for doing such type of work is a pre-requisite for a tender being considered. The manufacturer
must have in his shop, satisfactory facility of plate bending, edge preparation and end milling of
members as advised by Engineer-in-Charge.

iii) Fabrication of steel work shall be at the manufacturers regular workshop or at a field workshop
to be set up by the Contractor in the project area. Shop fabrication of heavy parts and other
specials, requiring precessions finishing such as bends, bifurcation and branch pipes shall be
done in regular workshops. The Contractor shall arrange at his own cost the transport of such
materials to the site as well as fabricated materials from his regular workshop to the project site
and finally to the erection site. Any loss or damage in transit on account of this shall be to the
Contractors account.

1.2.2 Layout
i) The Contractor shall prepare complete all preliminary works at site well before the arrival of
penstock and steel liner such as keeping in readiness of electrical winches, rail tracks, mobile
cranes, all poles, all tools and tackles, welding sets etc. as part of this contract, together with any
other work that may be necessary to start erection immediately. The Contractor shall arrange for
such number of erection equipment, supervision, labour and other arrangements as are necessary
to carry out the work efficiently and in accordance with an approved programme of work.

ii) The Contractor shall be solely responsible for correctness of laying the penstock and steel liners.
The checking and approval by the Engineer-in-Charge will not absolve the Contractor from the
responsibility of erecting the penstock and steel liner in true alignment. Establishing and
maintaining temporary benchmarks and connecting to the permanent benchmarks by double
leveling shall be the responsibility of the Contractor for which no extra payment shall be made.

1.2.3 Specifications & Standards
These specifications are intended for the partial description of quality, workmanship etc. desired
for the items covered in the General Technical Specification and scope of work. Specifications
are not however, intended to cover all the minute details and the work shall be executed in
accordance with the spirit of the tender specifications. In the absence of specifications for any
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particular item of work it shall be executed as per relevant IS Code (latest revisions) IS: 2825
i.e. Indian Standard Code for Unfired Pressure vessels. In case neither of the above mentioned
specification and code are available for any particular item of work, the work shall be executed
as per section VIII ASME Unfired pressure Vessel code and ASTM Standard or as directed by
the Engineer-in-Charge. These specifications shall be read in conjunction with the description of
the items in the schedule of items.

1.2.4 Design Criteria
The Penstock and steel lining shall be designed with the following objectives:

a) Internal water pressure corresponding to the Max, Water Level (MWL) of 2239.50 m is
520.45 m,
b) Internal dynamic water pressure including water hammer, 596.50- m water head,

c) External static water pressure of 417 m while the steel liner is empty.

1.2.5 Materials
i) All materials incorporated in the Works shall be of first-class quality, free from defects and
imperfections and, where shown, of the classifications and grades designated. Materials not
specifically designated here in shall be suitable for the purpose intended and shall, as far as
practicable, comply with the latest specifications of the American Society of Testing Materials
(ASTM) and the ASME Boiler and Pressure Vessel Code Section VIII, division 2 or equivalent
European Standard.

ii) Plate material for penstock and steel liners shall be IS:2002 Grade 3 or approved equal. All steel
shall be fine grained, fully killed, not subject to brittle fracture, non-ageing, and highly weldable
with yield strength of 285 Mpa.

iii) Material certification and testing shall be per ASTM A 20 (suitable for IS:2002 Grade 3) and ASME
Boiler and Pressure Vessel Code Section VIII, Division 2 and with supplementary requirements as
in the following paragraphs of ASTM A20:

a) S5: Charpy-V-Notch toughness tests at-20 C in transverse direction of each plate.
b) S4: On total 3 plates of y =285 Mpa steel material.
c) One bend test as follows:
One on plate with most frequently used wall thickness,
One on plate with maximum wall thickness,
One on plate with an intermediate wall thickness.
d) S8: Ultrasonic examination.

iv) Complete mill test reports are to be submitted with above certification showing results of all
mandatory and supplementary requirements:

a) Steel Tubes Certification; The Contractor shall provide a certificate for each steel pipe section
and bifurcation as stipulated in this Chapter.
b) Steel material of the same quality (IS:2002 Grade 3) or approved equivalent shall be used.
c) All materials used, fabricated and welded to the liners and penstocks which are not
particularly specified above shall be compatible in respect to chemical, mechanical and
welding properties as defined by ASME Code.
d) Welding consumables shall be as per AWS Filler Metal specifications as recommended by the
steel manufacturer. Only suitable Low hydrogen welding consumables shall be used for
welding. Consumables shall be baked as recommended by the consumable manufacturer to
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moisture levels required by the steel manufacturer. FCAW electrodes and SAW flux
electrode combinations shall be certified by the manufacturer to meet the diffusible hydrogen
limits given below. Diffusible hydrogen shall be determined in accordance with AWS A 4.3-
86.

Specified weld Max. Hydrogen
Metal strength (ml/100 g)
485 Mpa (70,000 psi) 15
760 Mpa (110,000 psi) 5

e) Temporary and embedded supports for securing liners and penstocks during concreting shall
be of good quality and suitable for the intended purpose. In addition, the same precautions
shall be exercised when any attachment is welded to the steel liners.

1.2.6 Loads to be Considered
i) The following loading conditions shall be considered in the design of penstock and steel lining:

a) Normal Operating Condition:

- Internal water pressure corresponding to maximum water level in the reservoir along with
pressure rise, due to normal operation or head at transient maximum surge, whichever is
higher.
- External water pressure on steel liner corresponding to 417 m terrain height.
- Internal Water Pressure due to water hammer.

b) Intermittent condition includes those during filling and draining of penstocks and maximum surge
in combination with pressure rise during normal operation.
c) Emergency condition includes partial gate closure in critical time of penstock (2L/a second) at
maximum rate, and the cushioning stroke being inoperative in one unit.
d) Exceptional condition includes slam shut, malfunctioning of control equipment in the most
adverse manner resulting in odd situation of extreme loading. This should not be taken as design
criteria.
e) The steel lining shall also be designed for the external water pressure head corresponding to 417m
terrain height. .
f) The penstock steel liners and their anchor rings shall be designed to transfer the complete axial
thrust under transient condition to the powerhouse upstream rock-mass. No load shall be
transferred to the inlet valve foundation.
ii) The penstock rests on support and acts therefore as a longitudinal beam It must be designed for
internal pressure and as well as external load due to 50% vacuum in the empty tubes. Poisson effect
must be considered if unfavorable.
a) The following loads shall be taken in to consideration:
- Weight of the tube
- Weight of the water filling,
- Internal dynamic pressure,
- Stresses due to supporting and stiffening rings,
- Stresses in bends and anchor points,
- stresses due to temperature variation,
- Seismic effects.
b) Stress calculations:

The resultant stresses shall be calculated according to the theory of V. Mises, Hencky and Huber.
iii) The following safety factors shall be applied in relation to the yield strength of the steel:
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Description Penstock & Steel Liner
(including Branch Pipes)
Trifurcation (Manifold)
water hammer effect
1.8 2.0
water hammer effect
1.5 1.8
buckling with external
water or grouting pressure
on an empty lining (for
embedded steel lining)
1.5 1.8
buckling with 50% internal
under-pressure an external
atmospheric condition
1.2

iv) The allowable stresses in design of steel penstocks shall be as per IS: 11639 (part-1, 2 & 3).
1.3 Construction Features
1.3.1 Fabrication of Steel Liner
The fabrication of the penstock pipes, the steel liners, the bifurcation and the turbine branch pipes shall
be in accordance with the specifications, drawing and the corresponding approved design and
fabrication drawings and Indian Standard for unfired pressure vessels (IS: 2825) or the equivalent
standard specified under this Chapter. In case of any difference between the above this particular
Technical Specification shall govern.
1.3.2 Preparation of Pipe Sections
i) Each section of pipe shall be made with the minimum number of plates depending upon the
availability of plate sizes or as directed by the Engineer-in-Charge.

ii) In the case that three plates are used the longitudinal welds shall be staggered at approximately 120
about the centre line of the pipe. When two plates of almost equal lengths are made available, the
longitudinal joints shall be located at quarter points and staggered between sections. When two
plates of equal lengths are not made available or when the section is made of a single plate, the
longitudinal joints/joint shall be placed approximately at 90 from the vertical centerline of the pipe
and shall be staggered in adjoining sections. The longitudinal welds shall be located so that they do
not intersect the nozzles, manholes, or other outlets. The normal lengths of each section shall be
limited to plate width available. When three plates are used, the displacement angle of the joint
from the vertical centerline may be approximately 45.
1.3.3 Cutting the Plates
Plates to be welded shall be cut to size and shaped by machining and/or flame cutting, where the plate
thickness does not exceed 25 mm, cold shearing may be used provided that the sheared edge is cut back
by machining or chipping for a distance one quarter of the plate thickness but in no case less than 3 mm.
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1.3.4 Preparation of Plate Edges and Openings
i) Weld preparation and openings of the required shapes may be formed by the following methods:

a) Machining/chipping or grinding: Chipped surfaces which are not covered with weld material shall
be ground smooth after chipping,

b) Plate cutting, which includes plasma arc, oxy-acetylene gas with or without flux injection or
equivalent fusion cutting process. Any material damaged in the process of cutting plates of size
shall be removed by machining, grinding or chipping back to sound metal. Surfaces which have
been flame cut shall be cut back by machine grinding so as to remove all burnt metal, notches,
slag and scale but slight discoloration of machine flame cut edges on mild steel shall not be
regarded as detrimental.

ii) After the edges of the plates have been prepared for welding they shall be given a through visual
examination for flaws, cracks, laminations, slag inclusion or other defects. When plates are
flame cut, the edges should be examined after this operation. Edges which have been flame cut
shall be cut back by machining or chipping for a distance of one quarter of plate thickness but in
no case less than 3 mm.

iii) Rust, Scale, painting, oil, slag etc. from the flame cutting or other contamination of the fusion
pieces shall be removed before welding is commenced. The surfaces to be welded shall be free
from foreign materiel such as grease, oil or marking paint for a distance of at least 25 mm from
the welding edges. Irregularities in fusion face, which are likely to affect the quality of welding,
shall be removed before welding is commenced. All plates edges after cutting and before
carrying out further work upon them shall be examined for lamination and also to make certain
that marks have not been caused by shearing. Plates for shell sections shall be formed to
required shape by a process that does not impair the quality of the material. However,
correction of curvature by blows will not be permitted. Cold-formed plate material shall not be
subjected to a deformation of more than five percent, unless suitable heat treatment is carried out
after such forming. Heat treatment shall, however, be carried out even when the deformation is
less than 5 percent if there is pronounced risk of brittleness through ageing. The deformation
expressed as a percentage is obtained from the formulae:

Deformation =(t x 100)/D,
t =thickness of plate,
D =internal diameter to which the plate is being bent or formed.

iv) Cold forming shall not be undertaken when the temperature of the metal is less than 0C. If the
forming or bending takes place in hot condition and if the final shape in process terminates
within the correct temperature limits for the particular material, no subsequent heat treatment is
required.

v) Where two plates at a welded joint differ in thickness the thicker places shall be trimmed to a
smooth taper as per Para 6.3.5 IS 2825-1969.
1.3.5 Stiffener Rings
Stiffener rings shall be fabricated in not more than eight circumferential sections butt welded together
and properly fitted and welded to the pipes, so that the plane of rings will be normal to the axis of the
pipe. The height of the rings shall be less than 175 mm.

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1.3.6 Bends
i) Bends shall be made of short segment of pipe with mitered ends. The segments shall be made
with equal deflection angles except for the end ones, which shall be of smaller deflection angles
than the other segments. The number of segments along with stiffener rings shall be adequate to
take care of the loads.

ii) The plates of miter bends shall be arranged such that in the centre line the angel deflection
between two adjoining plates does not exceed 7.
1.3.7 Unit and Match Marking
i) Each part of the penstock and steel liner section, curvature of the shell or surface to which they
are attached or its auxiliary parts shall be legibly marked to show the unit of which it is a part
and match marked to show its relative position w.r.t the finished structure to facilities assembly
in the field. To ensure proper matching of sections at the joints, expanding struts, spiders may
be used. Each section shall be marked to show top of vertical diameter and the direction of the
flow. Unit marks and match marks shall be made with heavy stamps and with paints. The
contractor shall prepare marking drawings of each penstock and steel liner section, indicating
clearly the location of each section an appurtenant parts w.r.t. the completed structure and shall
furnish such drawings.

ii) If penstock and steel liner sections are transported for a long distance temporary
bracings/spiders shall be provided to prevent deformation.
1.3.8 Preheating and Thermal Stress Relieving
i) When preheating is the part of the approved welding procedure, weld joints shall be preheated in
accordance with the kind of steel materials and plate thickness. Maximum inter-pass
temperature of preheating shall be 200C and preheating area shall be over a distance of more
than four times of plate thickness for each side from the welding joints.

ii) If welding work is made under the condition of ambient temperature less than 5C, steel
materials on weld joints shall also be preheated even though application of preheating is not
required due to the kind and thickness of the steel materials under normal welding conditions.

iii) The relation between the carbon equivalent and the preheating temperature in cases of manual
welding, shall be as follow:

Carbon equivalent
(Ceq)
[%]
Plate thickness

[mm]
Preheating temperature for
low hydrogen welding rods
[C]
0.00-0.28 0-100 -
0.28-0.38 0-25 -
0.28-0.38 25-100 40-60
0.38-0.48 0-25 40-60
0.38-0.48 25-100 80-100
More than 0.48 0-100 100-150

Note: Ceq (%) =C+1/6 Mn +1/24 Ni +1/5 Cr + Mo +1/14 and Cu, P, etc., could be added as
necessary.
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iv) Post weld thermal stress relieving shall be a part of approved welding procedure and shall be
carried out in accordance with the relevant provisions of ASME boiler and pressure vessel code
Section VIII Division-2 or IS:2825. The method statement and procedure for conducting
thermal stress relieving shall depend upon the particular structure, grade and composition of
steel and thickness involved. The contractor shall obtain prior approval regarding the above
from the Engineer-in-Charge.
1.3.9 Butt Straps
Butt straps on the outside of sections, are foreseen to be used on the penstock and steel lining to
facilitate making the circumferential joints in-situ. Each complete butt strap should be arranged
in two halves, the bottom half being welded in the shop to the erection section to be erected first,
the other half of the butt strap being also welded in the shop to the following erection section.
This arrangement facilitates placing the adjoining erection sections at the site. When adjoining
sections are in their final positions the butt straps should fit closely to the adjoining shell thereby
enabling satisfactory welded joint to be obtained. All in-situ welding of the penstock and steel
lining must be carried out from the inside.

After finishing the welding work inside the pipe the outside connection between pipe and butt ring must
be closed by a sealing weld on both sides of the butt strap.
1.3.10 Alignment and Tolerances
General: The sections of the completed penstock and steel liners shall be circular within the limits
defined here under. Measurement shall be made to the surface of the parent metal and not to a
weld, fitting or other raised part. There shall be no flats or peaks at welded seams and the local
departure from circularity shall be gradual.

Alignment : Before any welding is commenced, it shall be ascertained that the chamfered edges are in
alignment and that the defects in alignment at the surfaces of the plates are less than:

For plates of thickness 5 mm or less t/6 for a longitudinal seam and t/4 for circumferential seam subject
to a maximum of 1 mm,

For plates over 5 mm in thickness

Before any welding is commenced it shall be ascertained that the prepared edges are in alignment to
meet the requirement of the welding process and that the defects in alignment at the surface of the plates
are not more than:

10 percent of the nominal plate thickness with a maximum of 3 mm for longitudinal joint.
However, for plates up to and including 10 mm thick a misalignment of 1 mm is
permitted,
10 percent of the maximum nominal plate thickness plus 1 mm with a maximum of 4 mm for
circumferential joints.
Circumference: The circumference shall conform to Para 6.6.3 of IS: 2825-1969.

Out of roundness of sections: The difference between the maximum and minimum diameters at any
cross section of a section welded longitudinally shall not exceed 1 % of the nominal internal
diameter subject to a maximum of (D1 +1250)/200 where D1 is internal diameter in mm.

The individual cylindrical section shall be reasonably square and straight. The plane of the pipe section
ends shall be normal to the axis of the pipe within a tolerance of 2 mm on the radius. The edges
of the plates of each section shall be properly prepared of field welding. Unless otherwise
specified the out of straightness of the section shall not exceed 0.3% both of the total cylindrical
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9

length or any 5 m length (This tolerance may be omitted where the individual section length
does not exceed 2m).

Attachments and fittings: All lugs, brackets, saddle type nozzle, reinforcement around openings and
other attachments shall conform reasonably to the curvature of the section or surface to which
they are attached.
1.3.11 Non Destructive Examination
Radiographic examination:

All longitudinal joints and shop circumferential joints of penstock and steel liner including
bends, shall be subjected to 100% radiographic examination. 10% length of each of the field
circumferential joints along with all T-joints shall also be tested radiographically. The
procedure of the radiographic examination, the acceptable standards of welds, the repair of
defective welds and the re-examination of repaired welds shall conform to the relevant section
of IS: 2825, IS: 2595, IS: 1182 and IS: 4853. All repairs shall be fully radiographed.
If the examination shows major defects the qualification of the welder must be tested and the
radiographic examination will be extended according to the instruction of the Engineer-in-charge at the
costs of the contractor.

Ultrasonic examination:
The remaining all length of all circumferential field welds, which were not spot radiographed or
such joints, which in the opinion of engineer-in-charge are difficult to be radiographed, or
inaccessible to radiographic examination shall be subjected to 100% ultrasonic examination. The
procedure for the ultrasonic examination, the acceptance standards for welds etc. shall conform
to the relevant articles of ASME Boiler and pressure vessel code-Section-V.
Other Examination:
Discontinuities such as cracks, seams, laps, cold shuts, laminations and porosity can be detected
using other methods viz:
Dye Penetrate Examination, (DPE)

Magnetic Particle Examination, (MPE)

All weld metal build up shall be examined over the full surface of the deposit either by liquid penetrant
examination or by magnetic particle examination. All permanent hold down logs or devices welded to
the steel penstock shall be examined by either of the above two methods. Removal of temporary lugs
and devices tack welded to the penstock and steel liner section and subsequent dressing shall be follows
by either of the above two examinations viz. DPE or MPE of the connection area .The procedure and
acceptance standards for the above methods shall conform to the relevant articles of ASME boiler and
pressure vessel code-Section-V.
The notch toughness of welds and heat-affected zones shall be determined using charpy-V notch impact
tests. Impact tests shall be in accordance with the requirement of relevant article of ASME
Code3, Sec. VIII, and Div. 2 and made on procedure qualification test plates and vessel test
plates of the material to be fabricated.

The cost of welds tests such as radiographic, ultrasonic, magnetic particle/dye penetrant examination
shall be borne by the Contractor and shall be included in the rates. Prior to making the
radiographs of the welds such markings shall be so designed and located that the images will
appear in the radiographs. The markers shall be painted, stamped or fastened to the shells as
directed by the Engineer-in-Charge and shall not be removed until all the welds have been
accepted. All X-ray films of the joints shall be the property of the Purchaser and shall be
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forwarded properly identified to the Engineer-in-Charge for record.

Radiography by X-ray may be replaced by Gamma ray methods using Cobalt-60, Iridium-192,
Ceasium-187. Records of all non destructive tests including radiography, ultrasonic test, dye-
penetrant test, magnetic particle inspection shall be maintained in a suitable format to be
evolved in consultation with the Engineer-in-Charge showing the unique identification of the
weld, its location, size, extent of flow, if any and interpretation of the results of the non-
destructive test along with the results of repairs, if any.
1.4 Erection
i) Before erection is started the Contractor shall supply eight complete sets of erection schedules,
procedures and erection drawings to the Engineer-in-Charge for approval. The Contractor will
be required to erect the penstock and steel liners in place and do the welding of field joints. All
civil works e.g. excavation, concreting and back-fill as also of the anchor and foundation for
supports etc. will be done by others.

Erection Procedure:

a) The steel liners shall be assembled in the field in accordance with erection drawings. The liners
sections shall be installed in place accurately, to line and grade/plumb and held securily by
means of steel straps over the temporary erection supports and supporting brackets and
embedded in concrete. When assembled and ready for welding, the distance between the ends of
adjoining sections which are to be connected together with the field circumferential welds shall
not be greater than 3 mm as per joint details and shall be of 6 mm in case of joint with backing
strips. Care shall be taken to avoid excessive length, growth or shrinkage in pipe lengths,

b) The Contractor shall furnish and install such permanent structures, erection supports permanent
or temporary including holding down straps and internal bracings as may be required to support
the liners securely in place and prevent distortion during erection, welding and placing of
concrete. Cost of all such structures including erection supports (permanent or temporary) shall
be included in the unit rate of various items. The circumferential seams shall then be welded as
soon as practicable. After field welding by the electric arc method of circumferential seems the
joints are to be tested radiographically/ultrasonically/penetrate method or spot radiography as
given under non destructive examination, and if any joint is found defective the same shall be
repaired to the satisfaction of Engineer-in-Charge

c) To ensure the matching of sections at the joints expanding struts or spiders may be used. Tack
welds where used to hold the sections in line, shall be removed so that they may not become part
of the joints. A clear space of 0.8 m at the bottom portion of steel lining from bottom bend to
bifurcation shall be made enable the welding of circumferential joints and spot radiography etc.
at erection site,

d) The schedule of installation of pressure steel liner on the supports and the field welding and
embedment in concrete have to be carefully synchronized with the works of the civil contractor
who shall be doing the concreting of pressure shaft. When the penstock and steel lining has been
installed, with all structural supports, rods, wedges, etc. as may be required to hold the pipes
securely in place, all such work shall be inspected and approved by the Engineer-in-Charge for
embedding in concrete,

e) It shall be ensured by the Contractor that the provision of supports (permanent or temporary) and
chairs are sufficient to prevent any misalignment of the pressure shaft due to buoyancy of wet
concrete during concreting,

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f) When erection, welding and inspection of the steel lining have been completed in accordance
with these specifications, the steel lining, bifurcation, and branch pipes shall be encased by
concrete. The Contractor shall supply and install sufficient interior bracings in addition to that
required for welding to maintain the roundness within the specified tolerances until the
encasement is completed. The Contractor shall supply and install sufficient exterior bracings
and anchor bands and bars to resist the loading due to the placing of concrete from the outside of
the steel liner. All the internal bracings and foreign matter shall be removed from the inside of
penstock after the penstock has been erected and embedded in concrete.
1.4.1 Inspection During Fabrication and Erection
i) The Engineer-in-Charge or his duly authorized representative shall have at all reasonable times
access to the Contractors premises of works and shall have the power at all reasonable time to
inspect and examine the materials and workmanship of the penstock and steel liner during its
manufacture or erection at Contractors premises or works site respectively. If part of the plant is
being manufactured or erected in other premises or works, the Contractor shall obtain for the
Engineer-in-Charge and for his duly authorized representative permission to inspect during
fabrication and erection of the penstock and steel liner as if the plant of material were
manufactured on the Contractors own premises or works.

ii) The Engineer-in-Charge shall, on giving seven days notice in writing to the Contractor setting
out the grounds of objections which he may have in respect of the work and he would be at
liberty to reject all or any materials plants or workmanship which is the subject of any of the
said grounds of objection and which in his opinion are not in accordance with the Contract or
are in his opinion defective for any reasons whatsoever. The contractor shall withdraw
immediately all such defective material/components and replace them completely. If such notice
is not sent to the Contractor within reasonable time after the grounds upon which notice is based
have come to the knowledge of the Engineer-in-Charge, he shall not be entitled to reject the said
materials, plants or workmanship on such grounds, unless specifically provided otherwise. All
tests shall be made at the Contractors works before transport. The Contractor shall give the
Engineer-in-Charge or his duly authorized representative notice of group of components that are
ready for testing and engineer-in-charge shall, on giving twenty four hours previous notice in
writing to the Contractor, attend at the Contractors premises of works within twenty one days of
the date on which the material is notified as being ready failing which, the Contractor may
proceed with the tests, which shall be deemed to have been made in the Engineer-in-Charges
presence and he shall forthwith forward to the Engineer-in-Charge duly certified copies of the
test certificates induplicate.
1.4.2 Testing at Contractors Premises
i) In all cases, where the Contractor provides for test whether at his premises of work or of any sub
contractor, the Contractor except where otherwise specified shall provide free of charges, such
labour, material electricity, fuel, water, stores, apparatus and instruments as may reasonably be
demanded to carry out efficiently such tests of the plant in accordance with the Contract and
shall give facilities to the Engineer-in-Charge or his authorized representative to accomplish
such testing. If special tests other than those specified in the Contract are required, they shall be
paid for by the employer as Variations.

ii) When the tests have been satisfactorily completed at the Contractors/Sub Contractors premises
or works, the Engineer-in-Charge shall issue a certificate to that effect and no plant shall be
transported before such certificate has been issued. The satisfactory completion of these tests or
the issue of the certificate shall not bind the Engineer-in-Charge to accept the plant so passed for
dispatch, should it on further tests be found not to comply with the specifications.

iii) Hydrostatic Testing

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12

Each section of the penstock liner (including bends as fabricated for field erection) shall be tested
Under hydrostatic pressure equal to 1.5 times design pressure, where the design pressure for the
hydrostatic tests, shall be computed from the following formula:-
P=(1.33Yp x t)/D
Where,

P= Test pressure in kg/cm
2.

Yp=Yield point stress of steel used in the particular ferrule under test in kg/cm
2
.

T= Actual minimum wall thickness of pipe in cm in the pipe length tested.

D=Internal Diameter of pipe in cm.

Each pipe shall be completely filled with water and the pressure shall be slowly and uniformly
increased until the required test pressure is reached. The test pressure shall be applied and released three
times successively and after each application shall be held steady, for at least 15 minutes or till such
time until all welded joints and plate has been examined for defects, leaks etc.
Any defects in welds or plates disclosed by the hydrostatic test shall be repaired by the contractor to the
satisfaction of the Employer and all repaired sections shall be re-tested hydrostatically.
1.4.3 Testing at Site
Wherever possible all tests shall be carried out before dispatch. Should however, it is necessary for the
final tests as to performance and guarantees to be held over until the plant is erected at site they shall be
carried out in the presence of Contractors representative within one month of the completion of
erection. In all such cases except where otherwise specified, the Contractor shall provide free of charge
all the facilities, equipment and material as may be required from time to time and as may reasonably be
demanded for efficiently carrying out such tests of the penstock and steel liner, material, or
workmanship in accordance with the Contract. Should the results of test not come within the margin
specified, then test shall, if required, be repeated within one month from the date of the steel lining
being ready for re-test and Contractor shall repay to the Engineer-in-Charge all reasonable expense to
which he may be put by such tests.
1.4.4 Corrosion Protection
For corrosion protection and surface treatment of penstock liner refer General Technical specifications.
1.4.5 Submittals
i) The Contractor shall provide drawings and other technical data to the Engineer-in-Charge for
approval, as per the following to the extent applicable:

a) Drawing List: A complete list of all drawings and technical data, by title,

b) General Arrangement Drawings: Outline drawings to scale, showing relation of the equipment
components, materials, and accessories,

c) Detail Drawings: All penstock and liner thickness shall be clearly defined, including stiffener
dimensions, if any, and respective welding details shown. All details of equipment and materials
required for fabrication and / or assembly shall be clearly defined. These drawings are to be cross-
referenced to all other drawings,

d) A QA/QC plans as per ASME Section VIII, Division 2, or equal, shall be submitted. This plan
shall also cover subcontract monitoring. The QA/QC plan shall ensure weld trace ability to the
welder both for field and shop weld,
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e) The plan shall address frequency and scope of fabrication, shop audits and job site erection audits.
Also the plan shall define the procedure to be used to ensure that test coupon welding is
representative of the actual procedures being executed,

f) Welding procedure specifications with procedure qualification records shall be submitted. All
other documents required by ASME Section-IX shall be made available,

g) For high strength steel with yield strength in excess of 285 MPa such as IS:2002 Gr. 3 material,
the steel manufacturers detailed welding and post weld thermal stress relieving recommendations
shall be submitted for information and review,

h) Material certification shall be submitted to the Engineer-in-Charge with all test results for
approval. This also includes welding consumables and miscellaneous materials,

i) All deviations from the Specifications and/or Drawings shall be clearly noted and submitted to the
Engineer-in-Charge for approval,

j) Liner Certificates.

ii) The Contractor shall provide a certificate with the following information for each penstock, steel
liner and bifurcation section:

a) Identifying number of the plates used for the section,

b) Heat number of the plates,

c) Numbers of the appropriate acceptance certificates for the plates

d) Records and numbers of certificates relating to tests performed on plates and on the completed
section,

e) Theoretical weight of the complete section,

f) Documentation for welder tractability, to welds,

g) Measured dimensions including plate thickness, section length, circumference, two perpendicular
diameters, one of which is measured through the longitudinal weld, ovality and out of roundness,

h) Radiographs,

i) Results of ultrasonic tests

j) Results of surface examination, (MT or PT),

k) Thermal treatment,

l) Results of water pressure tests.

m) Special remarks,

n) Number and dates of the relevant reports.

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iii) Each certificate shall show in sketch form the sequence of the welds, the position of the
radiographs and repair locations. A sample certificate (with hypothetical entries) shall be
submitted to the Engineer-in-Charge for review prior to liner shipments.

Tender Documents
Specifications: Volume II B Hydro Mechanical Part D


VOLUME II-B

SPECIFICATION
FOR

PART C PENSTOCKS

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1

1.0 DATA SHEET FOR DIVERSION WEIR SERVICE GATE / ROPE DRUM HOIST

Sl No DESCRIPTION

UNIT

CONTRACTOR
DATA

1 Clear Width of Opening

M

2 Clear Height of Opening

M

3 Design Head

M

4 Number of Openings

Nos.

5 Number of Elements Provided

Nos.

6 Number of elements in each gate and
how they are assembled at site

Nos.
7 Type and No. of Bearing in the Wheels

8 Location of Skin plate U/S or D/S

9 Location of Seals U/S or D/S

10 C/c of Tracks

M

11 C/c of Side Seals

M

12 Type of Side Seal

13 Type of Bottom Seal

14 Type of Top Seal

15 Weight of One assembled Gate

16 Weight of Embedded Parts
1
st
stage
2
nd
stage

Tonne
17 Type of Hoist and capacity
( To be supported by design
calculations)

18 Material Specifications

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2
i. Skin Plate

ii. Wheel

iii. Wheel Pin

iv. Bearing Make & No.

v. Roller Track

vi. Seal Seats

19. Gate Operating System

i. Opening Speed

M/min

ii. Closing Speed

M/min

iii. Operation procedure

20. Forces considered for hoist capacity

i. Down pull considered during lifting for
calculation of hoist capacity

Tonne

ii. Uplift force considered while lowering
the Gate for calculation of hoist
capacity

Tonne

21 Complete opening time

Second

22 Complete closing time

Second

23 Material Specifications, thickness, dia,
size etc. etc.

i. Skin Plate

ii. Wheel

iii. Wheel Pin

iv. Bearing Make & No.

v. Roller Track

vi. Seal Seats

vii Guide Rollers

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24. Gate Operating System

i. Opening Speed

M/min
ii. Closing Speed

M/min
iii. Operation under balance/ Unbalanced
head

25. Forces considered for hoist capacity

i. Down pull considered during lifting of
gate
for calculation of hoist capacity

Tonne
ii. Uplift force considered while
lowering the Gate for calculation of
hoist capacity

Tonne
26. Corrosion protection system/ Painting
schedule

Note: Similar Data sheet shall be submitted for Intake Service Gate and Desilting inlet gate.
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2.0 DATA SHEET OF ROPE DRUM HOIST FOR DIVERSION WEIR SERVICE GATE

Sl
No
DESCRIPTION

UNIT

CONTRACTOR DATA

1. HOIST Capacity including 20 %
Reserve ( To be supported by design
calculation)

Tonne
Capacity

2. Hoisting Speed

3. Total lift of gate considered.

4. H P and type of motor for hoist

5. Size, type and make of brake for hoist

6. Size , type and make of standard gear box
for hoist

7. No. of rope falls and the size,
construction of wire rope , its breaking
strength

8 No. of rope drum and no. of layers of
rope on drum

9. Size and no. Spur gear reduction
provided.

10. Size, type and make of flexible couplings
provided.

11. Type of position indicator provided.

12. Facility for manual operation of
the hoist.

13. Material specification for

i. Rope drum

ii. Spur gears
iii. pinions.

iv. Shafts

v. Wire rope sockets

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vi. Bush bearings.

viii. Make of plummer blocks.

14. Weight of Rope Drum Hoist & Structure
i. Hoisting Equipment

ii. Supporting Structure

15.

i.

Type of control

Cabin Operated

16.
Corrosion protection system/ Painting
schedule

Note Similar Data sheet shall be submitted for Intake Service Gate and Desilting inlet gate.

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3.0 DIVERSION WEIR STOPLOG AND MONO Rail CRANE

1.0 DATA SHEET FOR WEIR STOPLOG

S.NO DESCRIPTION

UNIT

CONTRACTOR
DATA

1. Clear Width of Opening

2. Top of the Gate

3. Sill Level

4. Height of each Stoplog Unit

5. Number of Units Provided

6. Location of Skinplate U/S or D/S

7. Location of Seals U/S or D/S
8. C/c of Tracks
9. C/c of Side Seals
10. Type of Stoplog (Fixed Wheel Type or
Sliding Type)

11. No. of Horizontal Girders in Each Unit

12. Are the units interchangeable
13. Type of Side Seals

14. Type of top seal

15. Type of Bottom Seal

16. Weight of Each Stoplog Unit

Tonne
17. Weight of Embedded Parts
Ist stage
2
nd
stage
Tonne
18. Operation under balanced/ unbalanced
Head

19. Top of track plate

20. Corrosion protection system/Painting
schedule

Note: Similar data sheet for Intake stoplogs and Draft Tube Gate shall be submitted separately.
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7

2.0 DATA SHEET OF MONO-RAIL CRANE FOR DIVERSION WEIR STOPLOGS

Sl
No
DESCRIPTION

UNIT

CONTRACTOR DATA

1. HOIST Capacity including 20 %
Reserve ( To be supported by design
calculation)

Tonne
Capacity

2. Hoisting Speed

3. Total lift of gate considered.

4. H P and type of motor for hoist

5. Size, type and make of brake for hoist

6. Size , type and make of standard gear box
for hoist

7. No. of rope falls and the size,
construction of wire rope , its breaking
strength

8 No. of rope drum and no. of layers of
rope on drum

13. Material specification for

i. Rope drum

ii. Gears
iii. pinions.

iv. Shafts

v. Wire rope sockets

vi. Bush bearings.

14. Weight of Rope Drum Hoist & Structure
i. Hoisting Equipment

ii. Supporting Structure

15.

i.

Type of control

Pendent

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16.
Corrosion protection system/ Painting
schedule

Note: Similar data sheet for Intake stoplogs and Draft Tube gate shall be submitted separately.
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9
4.0 DATA SHEET FOR TRASHRACK FOR INTAKE

SR.
NO.

DESCRIPTION

CONTRACTOR
DATA

1. Maximum differential head considered for
the design of vertical bars

2. Maximum differential head considered for
other structural members

3. Size of vertical bars and their upstream
Profile

4. of Horizontal & vertical beams
5. of each panel and the total height of
trash racks provided.

6. Inclination of the trash rack to the vertical.

7. Clear space between the vertical bars.

8. Weight of each panel and the total weight of
trash rack

9. Weight of embedded parts.

10. Material specification of various
components.

11. No. of trashracks

12. Sill level

13. Operating deck level

14. Maintenance procedure

15.
Corrosion protection system/ Painting schedule

Note Similar Data sheet shall be submitted for HRT Intake Trashrack.

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STEEL LINER/PENSTOCKS

5.0 DATA SHEET FOR PENSTOCK/STEEL LINER

S.NO
DESCRIPTION

UNIT

CONTRACTOR DATA

1 Normal Water Pressure

2 Design Pressure
3 Water Hammer
4 Inside Dia
i) Pressure Pipe
ii) Y Section
iii) Branch Section
5 Horizontal Angle of Bends
6 Vertical angle of bends
7 Thickness of Pipe
i) Pressure pipe
ii) Y Section
iii) Branch Section
8 Size of stiffener rings
9 Man holes
10 Load at anchor blocks
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11 Material specifications
12 Size of ferrule for transportation
13 Weight
i) Steel liner
ii) Y Sections
iii) Bends
iv) Branch Section
14 Corrosion protection system
/painting schedule

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INSTRUMENTATION AND CONTROL

SR.NO.

DESCRIPTION

UNIT

PARAMETERS

1.0

LOCAL CONTROL PANELS

1.1

Make and place of manufacture

2.0 INSTRUMENTATION POWER
SUPPLY
AND SIGNAL CABLES

2.1 Make

2.2 Type of Signal Cables

3.0 SURGE PROTECTION DEVICES

3.1 Make and Model number

4.0 PRESSURE SWITCHES

4.1 Make and model numbers

5.0 PRESSURE GAUGES

5.1 Make and model numbers

5.2 Accuracy

6.0 SOLENOID VALVES

6.1 Make and model number

7.0 POSITION MEASURING SYSTEM


7.2 Type (Operating principle)

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7.3 Accuracy

8.0 LIMIT SWITCHES

8.1 Make, model number and type

9.1 Type of instrument


10.0 DATA LOGGER


10.1 Number of channels

10.2

Type channels
10.3 Type of communication port and
protocol
for communicating with PLC system

11.0 UPLIFT PRESSURE METERS
Make and model no.

11.1 Make and model no.

11.2 Quantity

12.0 SEEPAGE MEASUREMENT


12.2 Quantity

13.0 TEMPERATURE MEASUREMENT


13.2 Quantity

14.0 DISPLACEMENT
MEASUREMENT

14.1
Make and model no.

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14.2 Quantity

15.0 SEISMOGRAPH SYSTEM


15.2 Quantity
16.0 RAINFALL MEASURMENT


16.2 Quantity

17.0 STRESS METERS


17.2 Quantity

18.0 STRAIN METERS


18.2 Quantity

19.0 PORE PRESSURE


19.2 Quantity

BG - Tech Specs (Civ & HM)

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