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SPECFICATION FORAIR COOLED CONDENSER

PROJECT1 x 300 MW COAL BASED THERMAL POWER

PLANT, CHHATTISGARH, INDIA

Doc. No. 11V02-201-SPC-M-0001, REV.R0

Date: 04-11-2011VOL-II

PART-A, M0Page 1 of 37

VOLUME II

PART - A

MECHANICAL AND GENERAL

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VOLUME II

PART - A

SPECIFICATION: M0

GENERAL SPECIFICATION

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I N D E X

CLAUSE_NO. DESCRIPTION

1.00.00 Intent of Specification

2.00.00 General Information and Site Condition

3.00.00 Codes and Standards

4.00.00 Scope of Work and Terminal Points

5.00.00 Services to be provided by Bidder

6.00.00 Services to be provided by Owner/Purchaser

7.00.00 Technical Information & Data to be furnished by Bidder

8.00.00 Work Schedule

9.00.00 Performance Guarantee

10.00.00 Painting

11.00.00 Inspection & Testing

12.00.00 Quality Assurance

13.00.00 Anchor Bolts, Sleeves, Inserts, Foundations, Pack Plates, LiftingLugs, Eye Bolts etc.

14.00.00 Tools & Tackle

15.00.00 Spare Parts

16.00.00 Operation & Maintenance

17.00.00 Instruction Manual

18.00.00 Drawing, Document for Approval, Clearances

19.00.00 Co-operation with other Contractors & Consulting Engineers

20.00.00 Bid Evaluation Criteria

21.00.00 Noise Level

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22.00.00 Brand Name

23.00.00 Specification Drawings

24.00.00 Plant and equipment identification, labeling

25.00.00 Safety & Security

26.00.00 Packaging & Marking

27.00.00 Protection

28.00.00 Project Management Services

29.00.00 Site Services

30.00.00 Training of Owner's Personnel

ANNEXURES:

ANNEXURE I Site and General Plant requirement

ANNEXURE II Scope of work and Terminal Points

ANNEXURE III Site work and Erection requirements

ANNEXURE IV Inspection and Testing

ANNEXURE V Quality Assurance

ANNEXURE VI Tools and Tackles list

ANNEXURE VII Documentation

ANNEXURE VIII Drawings, Documents for approval, Clearances

ANNEXURE IX List of Mandatory spares

ANNEXURE X Training requirement

APPENDIX

APPENDIX-A Approved Vendor List

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M0: GENERAL SPECIFICATION

1.00.00 INTENT OF SPECIFICATION

1.01.00 This specification is intended to cover the design, engineering,manufacture, testing at manufacturer's works and site, delivery dulypacked for transportation for Site of the entire Air cooled condensercomplete with all equipment and accessories and all relevant Electrical,Control, Instrumentation, Civil & Structural works as specified hereinafteras a turnkey Air cooled condenser Package for 1 x 300 MW Thermalpower plant of MCCPL (Owner) at Korba.

1.02.00 The scope of work shall include Detailed Design, Construction Drawingsfor Civil, Architectural, and structural works, the fabrication and executionof all structural steel. However, civil works will be carried out by purchaser(IOT).

1.03.00 The scope of work also includes site unloading, handling, intra-sitetransportation, site storage, fabrication, erection, final check-up, testingand commissioning services and all other incidental works thereto (like alllabour, supervision, supply of erection equipment and consumables, asnecessary) of the equipment and accessories to be supplied under thisspecification, as specified hereinafter.

1.04.00 It is not the intent to specify completely herein, all aspects of design andconstruction of equipment. Nevertheless, the equipment shall conform inall aspects to high standard of engineering, design and workmanship andshall be capable of performing in continuous commercial operation in amanner acceptable to the Owner/Purchaser who will interpret themeaning of the specification, drawings and shall have a right to reject oraccept any work or material which in his assessment is not complete tomeet the requirements of this specification and/or applicableIndian/International Standards.

1.05.00 Bidders are requested to carefully examine and understand thespecifications and seek clarifications, if required, to ensure that they haveunderstood the specification. The bidders' offers should not carry anysections like clarifications, interpretations and/or assumptions.

2.00.00 GENERAL INFORMATION AND SITE CONDITION

2.01.00 Site condition

A. LOCATION AND EXISTING INFRASTRUCTURE

Country : India

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State : Chhattisgarh

District : Korba

Tehsil : Pali

Village : Bandakhar

Next Town : Korba (approx. 30 kms from site)

Road access : State highway connecting Bilaspur &

Katghora - approx 8.0 kms from site

Nearest Railway Station : Korba (approx. 30 kms from site)

B. GEOLOGICAL CONDITIONS

Seismic intensity

Seismic Intensity : As per IS : 1893

Zone : II

Zone factor (Z) : 0.1

Importance factor (I) : 1.75 for power plant buildings(As

per provisions of IS: 1893, Part 4)

Response Reduction Factor

(R)

: As per IS: 1893- 2005

C. METEOROLOGICAL CONDITIONS

Site Elevation

Site Elevation above MSL : Varying 320 meters - 334 metersAmbient Air Temperature

Average ambient air temp. : 35C

Maximum summer temp. : 48.4C

Maximum dry bulb temp. : 41.3C

Minimum dry bulb temperature : 12.9C

Relative humidi ty

Maximum humidity : 86%

Minimum humidity : 27%Annual Average : 62%

Rainfall

Annual Rainfall (Average) : 1390 mm

Maximum one (1) hour rainfall : 40 mm

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Maximum twenty four (24)

hour rainfall

: 325 mm

Duration : Mainly from June to October

Wind

Maximum direction : Predominantly from NE & SW

Maximum wind speed : 19.0 Km/hr

Minimum wind speed : 1.5 Km/hr

Basic wind speed (Vb) : As Per IS 875 Part 3 -1987

Risk coefficient (K1 factor) : 1.06 for plant structures

1.00 for non-plant structures

Terrain category (K2 factor) : Category 1

Topography factor (K3 factor) : 1.0FGL at ACC area

Finished Grade Level : 331.000 meters

2.03.00 All documents and drawings enclosed/issued with this specification formsa part of the specification.

2.04.00 The layout of the air cooled condenser and the relevant information havebeen furnished in the drawings enclosed. The above mentioned drawingsare conceptual and are indicative and give a guideline for design of thesystem, layout of equipment and other relevant data for the purpose of

estimation. Bidders must study the drawings in details. The bidder mustvisit the site to assess the complete scope of work. Bidder shall developactual drawings on the basis of tender drawings and his site visit withoutmajor deviation and shall submit them along with the offer.

2.05.00 In case any discrepancy exists between data sheets furnished andequipment/system details given, the stringent of the conditions given shallprevail.

2.06.00 Additional details on site condition and general plant requirement (as perEPC tender) are indicated in the Annexure-I.

2.07.00 The power plant will be operated in the base load mode for aminimum 8000 hours of operation in a year.

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3.00.00 CODES AND STANDARDS

3.01.00 Except as stated otherwise in this Specification, Indian / British /American or equivalent standards shall be followed. And EPC Contractor

shall provide the relevant standards. However for civil works thespecifications as stipulated in Indian standard codes shall be followedstrictly.

3.01.01 In case of any contradiction between the stipulations of the abovestandards and those made in this bid document, the latter will prevail.

3.02.00 All electrical equipment supplied shall comply with the latest revision ofthe Indian Electricity (Supply) Act, Indian Electricity Rules, IndianStandard (IS) or International Electric Technical Commission (IEC)Publication and also within the statutory requirements of the Governmentof India and Government of Chhattisgarh as regards safety, earthing and

other provisions specified therein for installation and operation ofelectrical equipment.

3.02.01 The responsibility of obtaining the necessary approvals ofInspection authorities of Government on behalf of the Owner/Purchaser,as may be required for design and design calculations, manufacturingand erection procedure, testing etc as called for, shall rest with theContractor. All such documentation submitted to statutory authoritiesshall also be submitted to the Owners Engineer for his review.However, all the fees for procedure in the form of challan or DD shallbe paid by the Owner/Purchaser to the government for statutoryapprovals. Any addition/alternations required for this shall be done by thecontractor free of additional cost to the Purchaser.

3.03.00 All moving parts of equipment which can conceivably cause injury to theoperator and otherwise authorized personnel within the vicinity of workingarea shall be suitably guarded according to the safety regulations. Thecomplete assembled units shall be designed so that all parts subject towear including shafts and bearings, shall be easily accessible forinspection, maintenance and replacement, with minimum loss of time.

3.04.00 Reference to special codes and standards, where designated eitherdirectly or as "relevant", is intended to provide a measure ofperformance, safety, in-shop and on-site testing, and methods ofconstruction and/or installation which must be equaled or exceeded inorder to be considered acceptable for use under this specification. Ifmore than a single degree of quality or accuracy is permitted withinthe scope of particular code or standard, the highest quality shall beapplicable and the degree of accuracy commensurate with the intendedfunction shall be selected, but with the understanding that the final

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decision will be made by the Owner. In all instances, the finally acceptedapplicable code or standard shall be the version, which is last published.

3.05.00 Where no appropriate standard is available, tests shall be

conducted in accordance with the manufacturer's standard practice,subject to the approval of the Owner.

In such cases the Contractor shall submit to the Owner complete dataand a suggested procedure for the testing to be performed. Manufacturecommenced before receipt of the Owner's approval shall be at theContractor's risk.

If the proposed procedures are accepted, the Contractor shall providethe Owner with four additional copies in English before any test isperformed.

3.06.00 Equipment furnished by the bidder shall be complete in every respect withall mountings, fittings, fixtures and standard accessories, which arenormally supplied even though not specifically detailed in thespecification. The Purchaser shall not be asked for any extra payment inrespect of such mountings, fittings, fixtures and accessories which areneeded for the safe operation of the equipment as required by applicablecodes within Indian territory though they may not have been included inthis document.

3.07.00 Derating Standards

The Bidders attention is drawn to the climatic conditions in the site area.Derating factors shall apply in accordance with the relevant andapproved standards if not specified in the specification.

4.00.00 SCOPE OF WORK AND TERMINAL POINTS

4.01.00 The scope of work will include all equipment, items and services asdetailed in various volumes Part A, Part B, Part C & Part D of thespecification and tender drawings enclosed. The contractor shall design,manufacture, assure quality, deliver document & equipment, erect,connect electrically, test, commission and make performance test. Theitems, though not specifically mentioned but needed to make the systemcomplete and reliable for safe trouble-free operation and guaranteedperformance shall be treated as included and the same shall also befurnished, unless specifically excluded elsewhere.

Scope of work and terminal points have been furnished inAnnexure-II of th is section

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4.02.00 Protection & CareAll construction and erection activities are to be carried out in the Aircooled condenser with great care so that the nearby structure is notaffected. Any damage to structure erected by other shall be rectified by

the Contractor at their cost speedily.

5.00.00 SERVICES TO BE PROVIDED BY BIDDER

Services to be rendered by the Bidder are described below. The servicesshall also conform to the requirements of "Conditions of Contract."

5.01.00 The Bidder shall take the responsibility for all the Testing and Inspectionsat Manufacturer's Works to be conducted in manner as specified in thisspecification.

5.02.00 Transportation of all equipment packed for transportation in the specified

way from the Manufacturer's works to the Project Site inclusive of allintermediate handling.

5.02.01 The storage-cum-erection insurance of the material under his custodyshall have to be arranged by the Contractor. Transit insurance shall bearranged by Purchaser.

5.03.00 Unloading of the equipment at site, transporting and proper storing at sitein the approved way under security.

5.04.00 Opening of packages, checking, tallying, sorting out and inspection ofequipment received at site and lodging of insurance claims.

5.05.00 Taking delivery of equipment/material from stores, transportation at siteand arrange for proper storage of the equipment/material in approvedway pending erection.

5.06.00 Erection including erection supervision, Inspection, Testing, Start-up andcommissioning of the equipment.

5.07.00 Performance Guarantee Test

5.08.00 Painting at Site

5.09.00 Trial Run, Performance & Guarantee Tests

For Trial Run, Performance & Guarantee Tests. Refer Volume-I.

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5.10.00 Notes to Erection Work

5.10.01 The Contractor shall arrange for his own supervisory personnel, skilledand unskilled workers, erection equipment, transport vehicles, lifting

tackle, tools, precision levels including micro- levels, dial and othergauges, straight edges, testing equipment/instruments/gadgets and allother elements in sufficient numbers as may be required for timelyerection, checkup, testing and commissioning of the plant.

5.10.02 All stair cases, ladders, platforms, temporary supports and structures,scaffolding, facilities required for handling of heavy packages at site etc.required for erection are to be provided by the contractor.

5.10.03 Any rectification of the equipment prior to erection shall be done by thecontractor in proper manner with the help of the Manufacturer and withPurchaser's knowledge and approval.

5.10.04 For erection of all equipment to correct level and position, the contractorshall take all necessary measurements of foundations, anchor bolt holesizes and location; set up correct reference lines for foundations andcarry out all final adjustments by chipping, bedding and dressing of thefoundation surfaces and anchor bolt holes, pockets etc. wherevernecessary.

5.10.05 Erection, leveling, bedding grouting of all foundation frames, bed plates,inserts, foundation and anchor bolts, plates etc. for all equipment andauxiliaries are included in the scope of work. The contractor shall makehis own arrangements for shuttering work, mixing, laying and curing of thegrouting.

5.10.06 Any existing civil, structural or electrical work, if damaged by thecontractor during erection due to his fault shall be made good by him athis own cost to the satisfaction of Purchaser/Consultant.

5.10.07 All work shall have to be done with proper liaison with the purchaser asstated in the "Conditions of Contract" with skilled & qualified personneland adopting the best engineering practice.

5.10.08 For further details on site and Erection requirement, refer Annexure-III.

6.00.00 SERVICES TO BE PROVIDED BY PURCHASER

6.01.00 Civil design and engineering above ground (RCC + Structural steel) willbe in Bidder's scope. Supply, Erection and construction of structural steelshall also be in Bidder's scope. RCC civil construction work will be carriedout by IOTL. Fan deck shall be in structural steel and columns with tiebeams upto fan deck level shall be of RCC.

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Bidders to indicate BOQ for RCC works for bid evaluation loading and LDon reinforcement steel and cement. Bidder to note that above groundRCC work will be designed by them and constructed by Purchaser(IOTL).

Optional price for total structural steel construction above ground (inbidder scope) shall be provided. Bidder shall provide schematic drawingfor both the options with the bid document.

7.00.00 TECHNICAL INFORMATION & DATA TO BE FURNISHED BY BIDDER

7.01.00 All data and information as asked for in different parts/ sections of thisSpecification.

7.02.00 Duly filled up Proposal Data Sheets.

7.03.00 Duly filled up price tabulation sheets in specified manner.

7.04.00 Without the duly signed drawings, documents, data and filled-up proposaldata sheets the proposal is liable to be rejected.

8.00.00 WORK SCHEDULE

8.01.00 The Air cooled condenser shall be commissioned as per Schedule givenin GCC/ SCC.

8.02.00 The bidder must submit schedule of completion in line with the above inhis offer, which will be treated as the prime pre-requisite for theacceptance of the offer.

8.03.00 The bidder shall include in his proposal the programme of supply,erection and commissioning of the Air cooled condenser. The programmeshall be in the form of a master network identifying the key phases invarious areas of the total work like design, procurement, manufacture andfield activities, inspection, erection, testing and commissioning etc.Bidder shall indicate clearly in his proposal total time required by him forcompletion of the entire Air cooled condenser, so as to match withschedule as given in Volume-I.

9.00.00 PERFORMANCE GUARANTEE

9.01.00 The successful bidder shall be responsible for proper design, smoothand trouble-free operation of all the systems, equipment and componentsoffered by him.

9.02.00 The successful bidder shall guarantee that the material of constructionand workmanship of all the equipment and components supplied by him

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are as specified under this specification and wherever there is nothingspecifically mentioned shall correspond to the best available grade andquality.

9.03.00 The successful bidder shall also guarantee that the system, equipmentand components covered by this specification shall be as per relevantstandard and code and shall be suitable for continuous operation (i.e. 24hours per day).

9.04.00 Performance/Acceptance test for the condenser shall be conducted inaccordance with the latest edition of ASME PTC-30.1 / VGB R-131. Thecondenser pressure shall be measured at turbine exhaust flange under100% TMCR condition, 0% make-up and design air flow and ambient airinlet temperature without considering the 5% margin on heat transfer areaand 10% tube plugging margin. For LD on performance guarantee andacceptable limit of increase in turbine back pressure, refer Volume-I.

9.05.00 Schedule of guarantees which attract penalties for various equipments asfollows:

9.05.01 Turbine exhaust pressure (0.022 MPa (abs)) at turbine exhaust boxflange at 100% TMCR condition with 0% make-up and all heaters inservice and design ambient temperature of 40 Deg.C without considering5% head load margin on heat transfer area and 10% tube pluggingmargin.

9.05.02 Auxiliary power consumption for all the auxiliaries including fans, pumpsetc. under rate steam conditions and at condenser pressure of 0.022 MPa(abs)) with 3% make-up and with ambient temp of 40 Deg.C for ACC fansand RH 51% shall be guaranteed. The total auxiliary power consumptionshall also include losses of the transformers supplied by the biddersbased on works tests reports. While guaranteeing auxiliary powerconsumption the bidder shall include all continuously operating auxiliariesunder complete package.

9.05.03 The unit availability shall be computed as follows: The unit availabilityshall not be less than 90% and the same has to be guaranteed. Anyshortfall in the availability of the unit will be subject to liquidated damages.

Unit availability = TB + TR x 100%TN

WhereTN = Nominal time covering one year (8760 hrs.) from the date of

successful completion of Performance Guarantee testsTB = Actual operating hours of the unit during the one year starting from

date of successful completion of Performance Guarantee tests.

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TR = Time in hours when the unit was idle in period TN due to reasonsnot attributable to the Contractor.

(a) Any time taken by the Contractor for attending to the defects only

that would have warranted shutdown of the unit will be reducedfrom TR.(b) The time shall be reckoned from safety/work permit (LC Line

Clear book) kept in unit control room and the period shall bebetween issue of LC and return of LC.

(c) The time TB & TR shall be reviewed jointly by thePurchaser and Contractor on weekly basis and the above suchperiods shall be noted accordingly.

(d) The availability of each unit shall be worked out separatelyand LD shall be levied accordingly.

(e) In case of dispute in reckoning the period for TB & TR, thePurchasers verdict will be final and binding.

(f) Actual operating hours of the unit (TB) shall mean the timeduring which the unit is in synchronization with the grid.

9.05.04 Vibration Level as per relevant standards.

9.06.00 Schedule of guarantees which do not attract penalties for variousequipments as follows:

9.06.01 Air Cooled Condenser and Condenser Vacuum pumps:

1) Turbine exhaust pressure (vacuum back pressure) at turbine exhaust boxflange during warranty period at 105% TMCR (VWO) and 80% TMCRcondition and design ambient temperature of 40 Deg.C withoutconsidering 5% head load margin on heat transfer area and 10% tubeplugging margin.

2) Time required to maintain vacuum up to 0.35 kg/cm2 (abs) whenboth pumps are in operation.

3) Temperature of condensate at outlet of air cooled condenser shall not beless than saturation temp. corresponding to the condenser pressure at allloads.

4) Oxygen content in condensate at hot well outlet shall not exceed 0.015 ccper liter over the entire load range and shall be determined according toan internationally approved code/standard.

5) When one half of the air cooled condenser fans are stopped, condensercapability shall be demonstrated to take at least 60% T.G. load.

6) Pressure drop on tube side with design ambient temperature of 40 Deg.C.

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7) Capacity and Power consumption at design conditions.

8) Utility consumptions. Bidder to indicate with bid document anddemonstate.

9.07.00 Bidder shall submit declaration along with bid documents inspecified proforma to furnish all his guaranteed parameters, short fall inwhich shall attract levy of liquidated damages as applicable.

9.08.00 Liquidated Damages for Short Fall in Performance

For Liquidated Damages for Short Fall in Performance, Refer Volume-I.

9.09.00 Liquidated Damages for Power Consumption

For Liquidated Damages for Power Consumption, Refer Volume-I.

10.00.00 PAINTING

All exposed metallic surfaces subject to corrosion shall be protected byshop application of suitable coatings. Surfaces not easily accessible aftershop assembly shall be treated before hand and protected for life of theequipment. Two coat each primer and finish paint at shop shall beprovided to reduce erection time and avoid blockage of free space. Patch-up paint shall be applied, if spoiled due to handling, shall be done at Site.In case of pipes and ducts, complete painting would be done at Site afterfabrication. For Bought out items this shall be brought in at Site dulyfinished painted.

All paints shall be used in accordance with the manufacturer'sinstructions. No thinners or other substance shall be added to the coatingmaterial without the approval of the Engineer. The quality and vendor ofthe paints shall require approval of the Owner/Purchaser.

All paints, when applied in a normal full coat, shall be free from runs,sags, wrinkles, patchiness, brush marks or other defects.

For detail of painting and surface preparation, refer Specification - M2,Surface preparation and painting of this specification.

11.00.00 INSPECTION & TESTING

For detail of inspection and testing, refer Annexure-IV of this specification.

12.00.00 QUALITY ASSURANCE

Quality assurance is indicated in the Annexure-V of this specification.

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13.00.00 ANCHOR BOLTS, SLEEVES, INSERTS, FOUNDATIONS PACKPLATES, LIFTING LUGS, EYE BOLTS ETC.This specification includes supply of all anchor bolts, foundation plates,sleeves, nuts and inserts to be embedded in concrete for the equipment

to be supplied by the bidder under this specification.Each equipment shall be provided with suitable lifting attachments, e.g.lifting lugs, eye bolts, etc. to facilitate maintenance.

14.00.00 TOOLS AND TACKLE

14.01.00 Special tools and equipment for the maintenance, inspection and repair ofthe individual main equipment and auxiliary equipment shall be suppliedby the Contractor in sufficient quantity to equip the shift personnel,maintenance personnel and workshop craftsman. The bidder shall furnisha complete and new set of all tools and tackle.

14.02.00 The special tools and equipment for maintenance and repair shall bedelivered by the Contractor in lockable steel boxes and they shall bemarked in an approved manner for identification purposes and acorresponding tool chart shall be supplied with the steel boxes.

14.04.00 Supply of all tools and tackle are included under bidder's scope of work.

14.05.00 All necessary maintenance tools for Electrical System in addition to theminimum requirement given in Annexure-VI.

15.00.00 SPARE PARTS

15.01.00 General

15.01.01 The Contractor shall indicate and include in his scope of supply all thenecessary start-up, commissioning spares, recommended (category-1)and operational (category-2) spares in addition to mandatory spares asspecified in the specification. The Owner/Purchaser reserves the right tobuy any or all recommended and operational spares. The contractor shallalso state for each item of spares both recommended and operational thenormal expected service life.

15.01.02 The spare parts must be able to replace the original part completely andhave the same technical specifications in quality, material, inspection and

mechanical aspects All spare parts supplied shall be packed and storedfor a 5 years preservation based on the local climatic conditions. Smallspare parts shall be packed and sealed by transparent plastic bags anddrying agents will be used if necessary. Every spare parts shall haveoperation instructions and design marks of the factory when it is supplied.

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15.01.03 When multiple spare parts are packed in one packing box or container,the general indication to the spare parts outside the packing boxes orcontainers shall include a detailed list. All packing boxes, containers, andother such tanks shall be marked properly and numbered clearly. All

electrical equipment including switches, fuse connection easy melting andother similar apparatus shall be protected and insulated.15.01.04 Contractors shall supply all measurement testing data of any spare parts

supplied, if applicable.

15.01.05 The identification of all spare parts shall be in the English language.Spare parts shall be supplied 6 months before start of acceptance test ofthe respective unit. The Contractor guarantees the availability of all spareparts within 15 years after Award of Contract. Wear and tear parts, to bereplaced by the Owner at his own cost, shall be marked separately.

15.01.06 Contractor shall identify spare parts having a delivery time of more than 3

months.

15.02.00 Mandatory Spare Parts

15.02.01 The list of mandatory spares which are considered essential by theOwner/Purchaser is indicated in the Annexure-IX. The Bidder shallinclude the itemized and total price for all these spares. Where the sparesare indicated as a percentage and result in a number plus fraction, thesame shall be converted to the near higher whole number.

15.02.02 The prices for mandatory spares must be given separately and shall beused for bid evaluation purposes.

15.03.00 Recommended (Category-1) and Operational (Category-2) Spares

15.03.01 In addition to the mandatory spares, the Contractor shall also provide alist of recommended spares (Category-1) and Operation spares(Catergory-2). This list shall take into consideration the mandatory sparesspecified elsewhere in the specification and should be a separate list.

15.03.02 Recommended spares (Category-1): These Spare parts shall be as perthe recommendations of the Contractor and required for the first 3 yearsof plant operation, following the successful completion of Test onCompletion. These spare parts are included in the scope of the bidder

and shall be considered for bid evaluation. Spare parts replaced duringthe warranty period will be paid for by the Contractor.

15.03.03 Category-2 (Operational Spares): Spare parts required for a majoroverhaul after 4 or 5 years of operation.

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15.03.02 While the award for mandatory spares will be finalized at the time of theaward of mechanical equipment, award for Recommended spares will befinalized within six (6) months thereafter.

15.04.00 Start-up and Commissioning Spares

15.04.01 Start-up commissioning spares are those spares which may be requiredduring the start-up and commissioning of the equipment/system. Allspares used until the plant is handed over to the Owner/Purchaser shallcome under this category.

15.04.02 The Contractor shall submit a complete list of all such start-up andcommissioning spares. Costs of the above spares which are consumedbefore the handing-over of the plant shall be deemed to have beenincluded in the lump sum proposal price of the Package, and theContractor shall have no claim on this account to the Owner/Purchaser.

15.05.00 When a particular item of spares is indicated as percentage, it shall beconsidered as percentage of total number of that item in the station,unless specified otherwise. The fraction shall be rounded off to the nexthigher whole number. Whenever the item of spares has been indicated asset, the same shall mean the supply for single equipment / system. Oneset of spares for particular equipment shall mean the total quantities ofthat particular spares for the single equipment e.g., set of bearings for apump shall include the total number of bearings in a pump.

16.00.00 OPERATION & MAINTENANCE

16.01.00 The plant shall be designed and constructed so that operation andmaintenance component requirements are minimised.

The design and layout shall facilitate inspection, cleaning, maintenanceand repair. The importance of continuity of operation is second only tothat of safety.

16.02.00 Spare parts for equipment shall be interchangeable with the originalcomponents and, so far as possible, be of common design andmanufacture.

16.03.00 All similar standard components/parts of similar standard equipmentprovided shall be interchangeable with one another. Further identicalequipments shall be provided for similar duties so that the same areinterchangeable with one another in totality and component wise.

16.04.00 All heavy parts (500 Kg and above) must be provided with a convenientarrangement for slinging and handling during erection and overhaul. Any

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item of plant normally stripped or lifted during periods of maintenance andweighing one tonne or above, shall be clearly marked with its weight.

16.05.00 On completion of commissioning a complete set of tools for the

maintenance of the entire plant shall be provided by contractor. This shallinclude all necessary spanners, special wrenches, extraction equipmentand any special tools reasonably required by the Engineer. Tools usedduring commissioning will not be accepted except with the specificapproval of the Engineer.

17.00.00 INSTRUCTION MANUAL

17.01.00 The instruction manual shall furnish the following basic categories ofinformation in practically complete and comprehensive manner preparedfor use by operating and/or maintenance personnel:

a) Instructions for initial commissioning, short duration and longduration shut down.

b) Instruction for operation, routine inspection and maintenanceincluding preventive maintenance.

c) Recommendation for inspection points, method of inspection andperiod of inspection.

d) Information on detection, cause and rectification of troubles andfaults.

e) Instructions on normal repairs and overhaul.

f) Complete parts list and ordering information for all replaceableparts. Wherever any oil seal, bearings, `O rings, gasket etc. areused, the same shall be in the drawing/part list. The identificationdetails of equivalent and alternative makes for these spare partswhich are not manufacturer's own product shall also be listed.

g) Lubrication charts.

h) List of all special tools, tackle and spares and instructions for use ofsuch tools and tackle and spares.

17.02.00 The information shall be organized in a logical and orderly sequence. Ageneral description of equipment including significant technicalcharacteristics shall be included to familiarize operating and maintenancepersonnel with the equipment.

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17.03.00 Necessary drawings, curves and other illustrations shall be included andcopies of appropriate approved drawings shall be bound in the manuals.Tests, adjustment and calibration information, as appropriate, shall beincluded. Safety and other warning notices and instruction, maintenance

and operating cautions shall be emphasized.

17.04.00 If a standard manual covering more than one equipment and/or model isfurnished, the information for the model and equipment supplied shall beclearly marked and identified.

17.05.00 The instruction manuals will need approval of Consulting Engineer in thesame fashion as that for drawings.

18.00.00 DRAWING, DESIGN AND DOCUMENT APPROVAL PROCEDURE

18.01.00 Within seven (7) days of issue of Letter of Award (LOA) by the

Owner/Purchaser, the Contractor shall furnish a schedule of drawingsand design document to be submitted by him to theOwner/Purchaser/Engineer indicating dates against each document.However, this schedule to match with engineering schedule as mentionedin Volume-I.

The documents shall be divided into two categories: (a) for approval and(b) for information/further engineering and co-ordination by theOwner/Purchaser.

In preparing this schedule, the Contractor shall allow two (2) weeks fromdate of receipt for review and comments by the Owner/Purchaser foreach submission of a document.

This document submission schedule shall require approval by theOwner/Purchaser.

18.02.00 All contract documents shall be marked, without fail, with the name of theOwner/Purchaser, the Project, the specification title and number. Forfurther details on documentation refer Annexure-VII.

18.03.00 Documents/drawings, submitted during tender stage, shall be revalidatedor revised as required and submitted as certified contract document forapproval/information of the Owner/Purchaser.

18.04.00 Unless specified otherwise, the following categories of documents/drawings would require approval of the Owner/Purchaser.

a. List of sub-vendors.

b. System scheme and instrumentation diagrams.

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c. Design basis justifying selection of equipment & process parameterswhere not specified in the Contract.

d. Equipment data sheets and general arrangement drawings.

e. Materials of construction.

f. Layout drawings.

g. Operation logic diagrams.

h. Typical control circuit.

i. Civil construction drawings.

18.05.00 For further details on drawings, documents for approval and clearances,

refer Annexure-VIII.

18.06.00 Upon review, the Owner/Purchaser shall put his remarks and one of thefollowing action stamps on the drawing/document.

a. Approved.b. Approved except as noted, forward final drawing.c. Approved except as noted, resubmission required.d. Disapproved.e. For information/reference only.

For action stamps in category (c) & (d), documents must be resubmittedfor review by the Owner/Purchaser. For action stamp in category (b),further review by Owner/Purchaser would not be necessary provided theContractor agrees & incorporates the minor components made on thedocument.

18.07.00 Drawings/documents generated by Contractor will be submitted toDCPL/IOTL/OWNER/FITCHNER INDIA (FI) in the soft copy through e-mail for their review and approval which shall be followed by Hard copiesas indicated below.

Sl.No.

Type / Status ofDrawings/Documents

No. of copiesto DCPL

No. of copiesto IOT (OWNER/FI)

1. For Approval Soft Copy Soft copy in .pdf format +Four (4) hard-copies

2. For Information /Reference

Soft Copy Soft copy in .pdf format +Seven (7) hard-copies

3. Final / RFC Issue Soft Copy Seven (7) copies + one(1) CD of .pdf soft copies

4. Progress Report Soft Copy Soft copy in .pdf format+Seven (7) hard-copies

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18.08.00 IOT (DCPL) will receive comments from the OWNER with the actionstamped which will be sent back to Contractor. Upon receipt of approval,Seven (7) hard copies and soft copy (with RFC stamp in pdf) will be sentto IOT (DCPL) for RFC (Released for Construction) distribution which will

be forwarded to OWNER (FICHTNER INDIA). OWNER/FI will bestamping the same and will be distributed by the IOT to all the concernedas per protocol.

The distribution of Seven (7) RFC copies will be IOT-Site (2 Copies),Fichtner India (1 Copy), Owner (3 Copies) and IOT-HO (1 Copies) shallbe carried out by IOTL

19.00.00 CO-OPERATION WITH OTHER CONTRACTORS ANDCONSULTING ENGINEERS

The Contractor shall agree to cooperate with the Owner/Purchaser's other

Contractors and Consulting Engineers and freely exchange with themsuch technical information as is necessary to obtain the most efficient andeconomical design and to avoid unnecessary duplication of efforts. TheEngineer shall be provided with copies of all correspondences addressedby the Contractor to other Sub-contractors and Consulting Engineers inrespect of such exchange of technical information.

20.00.00 BID EVALUATION CRITERIA

For Bid Evaluation criteria, Refer Volume-I.

21.00.00 NOISE LEVEL

21.01.00 The Plant will be designed and constructed to operate with the leastpracticable amount of noise.

i) Maximum noise level shall not exceed 85 dB (A) when measuredat 1.0m away from the noise emission source.

ii) Maximum noise level within the premises (10-15m from therespective equipment) shall not exceed 70 dB (A) during day timeand night time, as per Environment (Protection) Rules 1986,Schedule III, Ambient Air Quality Standards in respect of noise.

iii) Any statutory changes in stipulations regarding noise limitationthat may occur in future according to the State Pollution ControlBoard, or Central Pollution Control Board or Ministry ofEnvironment and Forests regulations during tenure of the contract,the contractor shall comply with the requirement.

An exception will be made for the plant at startup operation and other bigpressure reducing devices operating during emergency periods and forthe safety valves.

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22.00.00 BRAND NAME

The "Make" of equipment which would be required/would constitute theproposed air cooled condenser, the bidder shall furnish at least 2 (two)

makes of such equipment and shall also furnish/support with"performance certificates" to prove that such makes of the equipment areoperating satisfactorily in similar duties at least for 2 (two) projects formore than 2 years. The performance certificates would be obtained fromElectricity Boards/Public Undertakings/Reputed Private enterprises. Thechoice of sub-vendor shall be subject to approval of Owner/Purchaser.

23.00.00 SPECIFICATION DRAWINGS

The drawings, enclosed in Volume III of the specification, form a part ofthe specification and are for guidance only. These drawings shallsupplement other requirements as specified within the specification and

they should be read in conjunction with the text of specification. Thebidder shall have to prepare working drawings, during detail engineeringfollowing the basic parameters as specified. Work shall be carried out asper the drawings approved by Owner/Purchaser.

24.00.00 PLANT AND EQUIPMENT IDENTIFICATION, LABELLING

24.01.00 Nameplates which are to be firmly fixed on all the equipment shall beprovided. For equipment of small size, these are to be fixed on the pipingor structure adjacent to the equipment. The contents of nameplate are toinclude the designation and principal parameters of the equipment.

24.02.00 The nameplate within the field shall be made of stainless steel, withdesignation permanently engraved on them. Inside installed equipments(e.g Panels, Cabinets, Switchgear etc.) shall also be labeled byappropriate name plate of stainless steel.

24.03.00 The form, size, base color and color of contents of the nameplates andprompting plates will be agreed between the Contractor and the Owner.They shall be readily seen by the operator and the designation of warningtags shall be different from that of other tags.

24.04.00 Necessary caution plate shall also be provided.

24.05.00 The Contractor shall follow a common identification system showing thename and number of each item and its respective drawing number etc. asper whole plant equipment, facilities and systems to fully identify theplant. The structure of the designations shall be developed in such a waythat the symbols used can be handled by electronic data processingequipment. The identification system must be used by all subcontractors,vendors, etc and shall be a proven system for power plant application.

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Each item of plant shall be separately designed with a reference number,which shall be used consistently on the drawings, in the documents andon the catalogues as well as on the equipment items themselves.

25.00.00 SAFETY AND SECURITY

25.01.00 The design shall incorporate every reasonable precaution and provisionfor the safety of all personnel and for the safety and security of allpersons and property. The design shall comply with all appropriatestatutory regulations relating to safety. All structures and equipment shallbe designed and constructed to withstand every foreseeable static anddynamic loading condition, including loading under earthquake conditions,with an adequate margin of safety.

25.02.00 Ready and safe access shall be provided to all parts of the plant foroperation, inspection, cleaning and maintenance.

25.03.00 Escape routes and clear ways shall be provided to allow speedyevacuation of the plant in the event of fire or explosion, and the plantlayout shall allow for ease of access to all parts of the Works by rescueand fire fighting teams. The plant layout shall be designed to localize andminimize the effects of any fire or explosion. The recommendations ofNFPA, OSHA, TAC etc. as necessary shall be followed in all respects.

25.04.00 The use of corrosive, explosive, toxic or otherwise hazardous materialsshall be kept to a minimum during construction and the design of theplant shall minimize the requirement for such materials during operationand maintenance. Where such materials must be used, all necessaryprecautions shall be taken in the design, manufacture and layout ofequipment to minimize the resulting hazard, and all equipment necessaryfor the protection and first-aid treatment of personnel in the event ofaccidents shall be provided. Particular attention is drawn to the use ofmaterials containing asbestos in any form.

25.05.00 The Contractor shall notify the Owner/Purchaser of his intention to bringto site any equipment or material which may create hazard. TheOwner/Purchaser shall have the right to prescribe the conditions underwhich such equipment or material may be handled and the Contractorshall adhere to such instructions. The Owner/Purchaser may prohibit theuse of any construction machinery, which according to him is unsafe. Noclaim for compensation due to such prohibition will be entertained by theOwner/Purchaser.

25.06.00 Storage of petroleum products & explosives for construction work shall beas per rules and regulation laid down in Petroleum Act, Explosive Act andPetroleum and Carbide of Calcium Manual. Approvals as necessary from

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Chief Inspector of Explosives or other statutory authorities shall be theresponsibility of the Contractor.

25.07.00 The Contractor shall be responsible for safe storage of his and his sub-

contractor's radioactive sources.

25.08.00 All combustible waste and rubbish shall be collected and removed fromthe worksite at least once each day. Use of undercoated canvas paper,corrugated paper, fabricated carton, plastic or other flammable materialsshall be restricted to the minimum and promptly removed. Temporarydisposal area as instructed by the engineer shall be used by thecontractor for the said purpose.

25.09.00 The Contractor shall provide adequate number of fire protectionequipment of the required types for his stores, office, temporarystructures, labour colony etc. Personnel trained for fire-fighting shall be

made available by the Contractor at site during the entire period of theContract.

25.10.00 All workmen of the Contractor working in construction site shall wearsafety helmets, safety boots and safety belts. The Contractor shall takeappropriate insurance cover against accidents for his workmen as well asthird party.

26.00.00 PACKAGING & MARKING

All the equipment shall be suitably protected, coated, covered or boxedand crated to prevent damage or deterioration during transit, handling andstorage at site till the time of erection. While packing all the materials, thelimitations from the point of view of availability of railway wagon sizes inIndia should be taken account of. The details of various wagons normallyavailable with Indian Railways for transportation of heavy equipment shallbe considered by the Bidder. The Contractor shall be responsible for allloss or damage during transportation, handling and storage due toimproper packing.

As per the information available, the dimensions of OD consignmentfor transportation of the equipment by rail are as below:

a) Width of the Package : 3.2 Meters(from centre-line of rails- 1.6 metres on both sides)

b) Height of the package : 4.47 Metresfrom rail top

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The above indicates the dimensions which can be normally transportedon the wagons without infringement of the "moving gauge". This ishowever not indicative of the consignment which can be carried out withinfringement of "moving gauge" duly authorised and approved by the

Indian Railways. There may be difference between the "moving gauge"and the "fixed structure gauge" and consignments infringing the "movinggauge" can be moved after investigation regarding possible infringementwith the fixed structures. As the critical fixed structures in each route aredifferent, consignments infringing moving dimensions have to beindividually investigated to select a route and also determine therestrictions under which such movement is to be carried out. Such routesselected or other mode of transport envisaged is to be clearly brought outin the proposal wherever transport of over dimensional equipment isinvolved.

The identification marking indicating the name and address of the

consignee shall be clearly marked in indelible ink on two opposite sidesand top of each of the packages. In addition the Contractor shall includein the marking gross and net weight, outer dimension and cubicmeasurement. Each package shall be accompanied by a packing notequoting specifically the name of the Contractor, therefore number anddate of contract and names of the office placing the contract,nomenclature of contents and Bill of Material.

27.00.00 PROTECTION

Equipment having antifriction or sleeve bearings shall be protected byweather tight enclosures. Coated surfaces shall be protected againstimpact, abrasion, discoloration and other damages. Surfaces which aredamaged shall be repainted.

Electrical equipment, controls and insulations shall be protected againstmoisture and water damages. All external gasket surfaces and flangefaces, couplings, rotating equipment shafts, bearings and like items shallbe thoroughly cleaned and coated with rust preventive compound asspecified above and protected with suitable wood, metal or othersubstantial type covering to ensure their full protection. All exposedthreaded parts shall be greased and protected with metallic or othersubstantial type protectors.

All piping, tubing and conduit connections on equipment and otherequipment openings shall be closed with rough usage covers or plugs.Female threaded openings shall be closed with rough usage covers orplugs. Female threaded openings shall be closed with forged steel plugs.The closures shall be taped to seal the interior of the equipment. Openends of piping, tubing and conduit shall be sealed and taped.

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Returnable containers and special shipping devices shall be returned bythe manufacturer's field representative at the Contractor's expense.

28.00.00 PROJECT MANAGEMENT SERVICES

28.01.00 Responsibility

The Bidder shall identify a separate and independent projectmanagement team headed by a Project Manager for the execution of thisproject. Responsibilities of this project Management team shall cover theareas listed below:

a) Planning and Monitoring

b) Engineering Management

c) Contracts Management

d) Quality Assurance, Inspection & Expediting

e) Construction Management (Execution of civil works by separatecontractor to be appointed by Owner/Purchaser)

f) Fabrication and Erection management

g) Commissioning & Spares Management

Detailed responsibilities in the above areas are discussed below:

28.02.00 Organisation

28.02.01 Headquarters

The headquarters of the project management team shall be headed by asenior level executive designated as the Project Manager who shall beresponsible to Owner/Purchaser for the execution of the project.

Separately, designated leaders shall be identified for each of the areasmentioned under 28.01.00, who, in turn, will report to the Project Managerfor all matters relative to this contract.

28.02.02 Central Co-ordination Cell

The central coordination cell shall preferably be based in Mumbai andshall have sufficient technical personnel to coordinate technical mattersand to quickly resolve day to day queries or references made byOwner/Purchaser and his Consultants.

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28.02.03 Organisation Chart

The Bidder shall furnish a detailed organisation chart for the projectmanagement team, clearly identifying the key personnel in each of the

areas mentioned at 28.01.00 above. The expected number of executivesat different levels shall also be indicated, separately for headquarters,central coordination cell and site organisation.

28.03.00 Implementation Schedule

To achieve the completion schedule indicated elsewhere in thisspecification, the Contractor shall furnish to the Owner/Purchaser, variousschedules as defined below:

28.03.01 Engineering Schedules

These schedules shall cover various design submissions indicatingdifferent engineering activities to be performed. Such schedules shall befurnished by the Bidder for each and every plant/systems/ equipment itemcovered in the scope of this specification.

28.03.02 Manufacturing Schedule

The Contractor shall submit to the Engineer his manufacturing anddelivery schedules for all equipment within Twenty one (21) days from thedate of acceptance of the Letter of Award. Such schedules shall be inline with the detailed network for all phases of the work of the Contractor.Such schedules shall be reviewed, updated and submitted to theEngineer, once in every two months thereafter, by the Contractor.Schedules shall also include the materials and equipment purchased fromoutside suppliers.

28.03.03 Erection Schedules

In order to achieve the overall completion schedule, the Contractor shallprovide the Owner/Purchaser all the information covering erectionsequence, testing and commissioning activities. These schedules may bebased on the recommended erection procedures and will be subject todiscussions/agreements with the Owner/Purchaser subsequent to theaward of contract.

28.03.04 The successful Bidder shall have to provide all the above schedules in atabular form in addition to that in the form of network and these shallnecessarily include information not limited to the earliest and latest datesfor various activities/submissions and also any related constraints.However, the Bidder shall include in his proposal a Level-1 (L-1) network

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showing the major activities and various milestones to achieve the abovementioned completion schedule.

28.04.00 Detailed Responsibilities

28.04.01 Planning & Monitoring

a) Planning

The Bidder shall prepare a Master Network Schedule in the form ofPERT network. The master network should be submitted along withthe bid which would be mutually discussed and finalized before the

Award of Contract.

b) Monitoring & Progress Reporting

The progress reports would be emanated every month, once from thehead office of the Contractor and another from the site office. Theprogress report emanating from the head office should necessarilyinclude the following sections:

i. Report on key milestones.

ii. Management summary indicating critical areas with details ofactions initiated and effect of any on the project.

iii. Action needing attention of the Owner/Purchaser/Consultant.

iv. Detailed status of engineering submissions, quality plansubmissions and approval, procurement manufacture anddispatch.

28.04.02 Engineering Management

Based on the ground master network for the project (L-1) the Contractorwill prepare an exhaustive list of engineering activities for theequipment/systems covered in his scope and a detailed programme ofaccomplishing the same within the time frame specified in the masternetwork. This schedule will form the Level-2 (L-2) network for engineeringactivities.

The engineering management team should also co-ordinate all interfaceengineering activity between the Contractor and the equipment sub-vendors so as to ensure the correctness and completeness of relatedengineering documentation before the same is submitted to theOwner/Purchaser.

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28.04.03 Contracts Management

Based on the master network, the Contractor shall submit L-2programmes of manufacture and despatch. In addition, the master

network shall also include periods considered for site activities viz.erection, commissioning etc. These L-2 programmes would be submittedin 1 months time from the date of award of contract and finalized within 15days thereafter. The Contractor will also submit site mobilization plan.This programme would be submitted at the time of finalization of award ofcontract and agreed immediately thereafter so that immediatedevelopment of the various activities at site could take place.

In case all the manufacture is being done by the Contractor then the L-2programmes would be themselves amplified to cover details of themanufacture, inspection, clearance by Owner/Purchaser and despatch.

The Contractor shall also submit the programme for procurement ofboughtout items, detailed delivery schedule and cash flow statement forOwner/Purchaser's approval.

28.04.04 Quality Assurance, Inspection and Expediting

The Contractor shall submit the name of sub-vendor from whom theequipment will be procured and the quality assurance plans thereof forthe manufacture shall be approved by the QA group of Owner/Purchaserbefore the manufacture is commenced. The list of major suppliers wouldbe submitted along with the bid and this shall be mutually discussed andagreed to at the time of award of contract. On the quality plans, thecustomer hold points will also be identified based on whichOwner/Purchaser would give clearance for the manufacture to proceedfurther.

Quality assurance/Inspection group of Owner/Purchaser or itsrepresentative would issue a material dispatch clearance certificate(MDCC) after the inspection clearance which will enable the Contractor todispatch the equipment and claim the payment. In the dispatchprogramme, the Contractor shall indicate a schedule of estimatedprogramme, tonnages specifically identifying various oversizedimensioned consignments (ODC). All dispatch details & item lists shallbe made available to both Owner/Purchaser & site immediately afterdispatching.

The Contractor shall also expedite all dispatches from their ownworks/works of their sub-vendors, so as to match with the variousactivities mentioned at 28.00.00 above.

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28.04.05 Construction Management

Based on the L-1 Master Network Programme, within one (1) month ofthe award of the Contract, the Contractor shall submit a programme of

construction/erection/commissioning, either in continuation with themanufacture and dispatch or separately for the implementation.

These programmes would be amplified showing when the civil drawingsshall be released by him and construction of civil works shall becompleted by Owner/Purchaser through other agency to facilitate start oferection and subsequent activities and shall form the basis for siteexecution and detailed monitoring. The Contractor shall also be involvedalong with the Owner/Purchaser to tie up detailed resource mobilizationplan over the period of time of the contract matching with the performancetargets.

Erection and commissioning of the equipment shall also be done underthe supervision of experts from the respective equipment/ systemsupplier.

29.00.00 SITE SERVICES

These services shall be rendered by the Bidder as part of the overallproject management service. The services shall broadly include but notbe limited to the following:

29.01.00 Arranging material dispatch from the shop by rail/road and/or sea asapplicable.

29.02.00 Monitoring movement of materials & follow-up as necessary withRailways, transport, port clearance etc. from the time of dispatch F.O.R.works by Contractor till receipt of the same at site.

29.03.00 Unloading of materials at Railway Station/Railway Siding inside projectarea, transportation to site store, assessment of lost/damaged items intransit and arranging insurance claims and replacement of lost/damageditems. The Contractor shall submit to the Engineer a report detailing allthe receipts during the week.

29.04.00 Issuing materials from site store/open yard from time to time for erectionas per the construction programme. The Contractor shall be the custodianof all the materials issued till the plant is officially taken over by theOwner/Purchaser after complete erection and successful trial run &commissioning.

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29.05.00 Transportation of materials to their respective places of erection anderection of the complete plant & equipment as supplied under thisspecification.

29.06.00 Trial run and commissioning of individual equipment/sub-systems and theplant as a whole to the satisfaction of the Owner/Purchaser, includingsupply of temporary equipment & services for chemical cleaning, steamblowing as well as performance guarantee tests.

Provision for preservation of individual equipment after trial run andcommissioning as necessary shall also be in the scope of the Bidder.

29.07.00 Supply and application of the final paints on all the equipment to beerected under this specification.

29.08.00 For the purpose of erection and commissioning the Contractor's scope of

work shall include but not be limited to the following:

29.08.01 Deployment of all skilled and unskilled manpower required for erection,supervision of erection, watch & ward, commissioning and other servicesto be rendered under this specification.

29.08.02 Deployment of all erection tools & tackle, construction machinery,transportation vehicles and all other implements in adequate number andsize, appropriate for the erection work to be handled under the scope ofthis specification.

29.08.03 Supply of all consumables upto taking over the plant by the Purchaserincluding welding electrodes, cleaning agents, diesel oil, lubricant etc. aswell as materials required for temporary supports, scaffolding etc. asnecessary for such erection work except those listed under exclusionelsewhere in this specification.

29.08.04 Construction of all civil/structural/architectural works, includingconstruction of foundation for all equipment supplied as required, groutingof equipment on foundation after alignment, and all other incidental civilactivities as detailed elsewhere.

29.08.05 All structural steel fabrication and erection work as detailed elsewhere inthe specification.

29.08.06 Providing support services for the Contractor's erection staff e.g.construction of site offices, temporary stores, residential accommodationand transport to work site for erection personnel, insurance cover, watch& ward for security and safety of the materials under the Contractor'scustody etc. as required.

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29.08.07 Maintaining proper documentation of all the site activities undertaken bythe Contractor as per the proforma mutually agreed with theOwner/Purchaser; submitting monthly progress reports as also any suchdocument as and when desired by the Owner/Purchaser; taking approval

of all statutory authorities e.g. Factory Inspector, Inspector of Explosivesetc. for respective portions of work under the jurisdiction of such statutesor laws.

29.08.08 The Contractor shall provide Industrial Relations' unit and `Medical' unitto take care of his erection staff and the Owner/Purchaser shall have noobligation in the regard.

29.09.00 Site Organization

The Contractor shall maintain a site organization of adequate strength inrespect of manpower, construction machinery and other implements at all

times for smooth execution of the contract. This organization shall bereinforced from time to time, as required, to make up for slippages fromthe schedule without any commercial implication to the Owner/Purchaser.The site organization shall be headed by a competent constructionmanager having sufficient authority to take decisions at site.

On award of contract, the Contractor shall submit to the Owner/Purchasera site organization chart indicating the various levels of experts to bedeployed on the job. The Owner/Purchaser reserves the right to reject orapprove the list of personnel proposed by the Contractor. The persons,whose bio-data have been approved by the Owner/Purchaser, will haveto be posted at site and deviations in this regard will not generally bepermitted.

The Contractor shall also submit to the Owner/Purchaser for approval alist of construction equipment, erection tools, tackle etc. prior tocommencement of site activities. These tools & tackle shall not beremoved from site without written permission of the Owner/Purchaser.

29.10.00 General Guidelines for Field Activit ies

29.10.01 The Contractor shall execute the works in a professional manner so asto achieve the target schedule without any sacrifice on quality andmaintaining highest standards of safety and cleanliness.

29.10.02 The Contractor shall co-operate with the Owner/Purchaser and otherContractors (like civil contractor for foundation works) working in site andarrange to perform his work in a manner so as to minimise interferencewith other Contractors' works. The Owner/Purchaser's engineer shall benotified promptly of any defect in other Contractor's works that couldaffect the Contractor's work. If rescheduling of Contractor's work is

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requested by the Owner/Purchaser's engineer in the interest of overallsite activities, the same shall be complied with by the Contractor. In allcases of controversy, the decision of the Owner/Purchaser shall be finaland binding on the Contractor without any commercial implication.

29.10.03 The Engineer shall hold meetings of all the Contractors working at Site ata time and a place to be designated by the Engineer. The Contractor shallattend such meetings and take notes of discussions during the meetingand the decisions of the Engineer and shall strictly adhere to thosedecisions in performing his Work. In addition to the above weeklymeeting, Engineer may call for other meetings either with individualcontractors or with selected number of contractors and in such a case theContractor, if called will also attend such meetings.

29.10.04 Time is the essence of the Contract and the Contractor shall beresponsible for performance of his Work in accordance with the specified

construction schedule. If at any time the Contractor is falling behind theschedule, he shall take necessary action to make good of such delays byincreasing his work force or by working overtime or otherwise acceleratethe progress of the work to comply with the schedule and shallcommunicate such action in writing to the Engineer, satisfying that hisaction will compensate for the delay. The Contractor shall not be allowedany extra compensation for such action.

29.10.05 The Engineer shall however not be responsible for provision of additionallabour and or materials or supply or any other services to the Contractorexcept for the co-ordination work between various Contractors as set outearlier.

29.10.06 The works under execution shall be open to inspection & supervision bythe Owner/Purchaser's engineer at all times. The Contractor shall givereasonable notice to the Owner/Purchaser before covering up orotherwise placing beyond the reach of inspection any work in order thatsame may be verified, if so desired by the Owner/Purchaser.

29.10.07 Every effort shall be made to maintain the highest quality of workmanshipby stringent supervision and inspection at every stage of execution.Manufacturer's instruction manual and guidelines on sequence of erectionand precautions shall be strictly followed. Should any error or ambiguitybe discovered in such documents, the same shall be brought to the noticeof the Owner/Purchaser's engineer. Manufacturer's interpretation in suchcases shall be binding on the Contractor.

29.10.08 The Contractor shall comply with all the rules and regulations of thelocal authorities, all statutory laws including Minimum Wages, WorkmenCompensation etc. All registration and statutory inspection fees, if any, inrespect of the work executed by the Contractor shall be to his account.

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29.10.09 All the works such as cleaning, checking, leveling, blue matching,aligning, assembling, temporary erection for alignment, opening,dismantling of certain equipments for checking and cleaning, surfacepreparation, edge preparation, fabrication of tubes and pipes as per

general engineering practice at site, cutting grinding, straightening,chamfering, filling, chipping, drilling, reaming, scrapping, shaping, fitting-up bolting/welding, etc., as may be applicable in such erection and arenecessary to complete the work satisfactorily, are to be treated asincidental and the same shall be carried out by the Contractor as part ofthe work.

29.10.10 In case of any class of work for which there is no such specification aslaid down in the contract such as, blue matching, welding of stainlesssteel parts, etc., the work shall be carried out in accordance with theinstructions and requirements of the Engineer.

29.10.11 It may sometimes be necessary to remove some of the erected structuralmembers to facilitate erection of bigger/pre-assembled equipment. Insuch cases, the removal and re-erection of such members, which areessential, and if so agreed by the Engineer, will have to be done by theContractor.

29.10.12 Preservation of all materials/equipment under custody of the Contractorduring storage, pre-assembly & erection, commissioning etc., shall be theresponsibility of the Contractor. All necessary preservatives andconsumables like paints, etc., shall be arranged by the Contractor.Necessary touch up painting, periodic application of preservatives/paintson pressure parts/other equipment even after erection until completion ofwork shall be carried out by the Contractor.

29.10.13 It is responsibility of the Contractor to do the alignment etc. if necessary,repeatedly to satisfy Engineer, with all the necessary tools & tackles,manpower, etc. The alignment will be complete only when jointly certifiedso, by the Contractor's Engineer & Owner/Purchaser. Also the Contractorshould ensure that the alignment is not disturbed afterwards.

29.10.14 Additional platforms for approaching different equipment as per siterequirement, which may not be indicated in drawings, shall be fabricatedand erected by the Contractor. The materials required for these worksshall be supplied by the Contractor and he will have to fabricate them tosuit the requirement.

29.10.15 Equipment and material which are wrongly installed shall be removed andreinstalled to comply with the design requirement at the Contractor'sexpense, to the satisfaction of the Owner/Purchaser/ Consultant.

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29.10.16 Before erection of any equipment on a foundation, the Contractor shallcheck and undertake if necessary rectification of foundation bolts,reaming of holes, drilling of dowels, matching of bolts and nuts, makingnew dowel pin, etc.

29.10.17 Assistance for calibrating/testing the power cylinders, valves, gauges,instruments, etc., and setting of actuators coming under various groupsshall be provided by Contractor.

29.10.18 It shall be the responsibility of the Contractor to provide ladders oncolumns for initial works till such time stairways are completed. For this,the ladder should not be welded on the column and should beprefabricated clamping type. No temporary welding on any structuralmember is permitted except under special circumstances with theapproval of Owner/Purchaser.

29.10.19 Structural materials required for the supporting/operating platformsrequired for the valves at various levels for the same operation of valveswill be arranged by the Contractor.

30.00.00 TRAINING OF OWNER'S PERSONNEL

30.01.00 The scope of services for training of Owner's/Purchasers personnel shallnecessarily include training module covering at least 3 man months. Thisshall cover all disciplines viz. Mechanical, Electrical, C&I, Civil, etc. andshall include all the related areas like Construction / Erection,Commissioning, Quality Assurance & Testing, Operation & Maintenanceaspects at Manufacturer's/ Sub-vendors office/ works.

The Bidder shall ensure that training of Owner/Purchasers executivesshould be comprehensive & should ensure adequate/appropriate accessto all information in the relevant field so as to enable these executiveseither undertake individual responsibility i.e. O&M of the Air cooledcondenser and/or serve as the key resource person to train other officersin the Owner/Purchasers organization. For this purpose the Bidder shallensure that necessary documents/training manuals, drawings etc shouldbe provided as a training kit for Owner/Purchasers personnel.

Sr.No

Area Discipline DurationMan Months

1 Air cooled condenser- designfamiliarization, erection andcommissioning

MechanicalElectricalCivil

1

2 Plant operating features &performance improvement.

MechanicalElectrical

1

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3 Maintenance of Air cooledcondenser Equipments.PLChardware, software,troubleshooting, modifications,

logic building etc.

MechanicalElectricalC&I

1

30.02.00 Bidder shall furnish in his offer, details of training module(s) coveringabove requirements, which shall be subject to Owner/Purchaser'sapproval. Consolidated training period included above (i.e. 3 manmonths) is indicative only.

30.03.00 Exact details, extent of training and the training schedule shall befinalised based on the Bidder's proposal within two (2) months fromplacement of award.

30.04.00 In all the above cases, wherever the training of Owner/Purchaser's

personnel is arranged at the works of the manufacturer's it shall be notedthat the lodging and boarding of the Owner/Purchaser's personnel shallbe at the cost of Owner/Purchaser.

30.05.00 For further details on Training requirement, refer Annexure-X.

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Date: 04-11-2011VOL-II PART-A,

ANX-I, M0Page 1 of 4

ANNEXURE - I

SITE AND GENERAL PLANT REQUIREMENT

1.00.00 SITE CONDITIONS

1.01.00 Location of site

The proposed Project will be located near village Bandakhar at Tehsil:Pali, Dist: Korba, Chhattisgarh State. The site is accessible by road andrail. The site is 8 km from the State highway connecting Bilaspur &Katghora. The nearest Railway station is Korba railway station which isabout 30 km from the site. The nearest town is Korba which is about 30km from the site. The site is 320 meters Above Mean Sea Level.

1.02.00 Geological conditions, Soil data: Refer civil specification.

1.03.00 Metrological conditions: Refer General specification M0, Cl. 2.00.00.

1.04.00 Coal supply

Coal (F-Grade) will be the main fuel for this power plant. Coal is plannedto be sourced from Dipka Gevra coal fields located in Korba with in 15kms from the project site.

1.05.00 Ash disposal

Fly ash will be collected in dry form in Silos. Ash from the silos will beloaded in to closed bulk carriers for dispatch to users. In case if notutilized then, the ash will be disposed in the form of high concentratedslurry (HCSD) to ash dyke through pipe line.

1.06.00 Fuel oil supply

The boiler will be designed for cold start-up using Light Diesel oil (LDO)for light up and warm-up, stabilization & as support fuel at low loadoperation of the plant when operating on coal. Based on the aboverequirements, adequate numbers of LDO tanks of suitable capacity areenvisaged. The fuel oil will be received from the depots at Raipur(270 kms from proposed site) by road tankers.

1.07.00 Water supply

The source of make-up water will be from the Lilagarh River(anicut) and Khallari Reservoir shall be located at a distance of 1 kmsfrom the proposed site. The make-up water requirement will be metfrom this river by the pipe line

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between dam on the river and reservoir in the plant site. However,during exigencies make up from bore well is also envisaged.

1.08.00 Effluent disposal

All plant effluents such as from the pre-treatment plant, DM plant, CT blowdown etc., will be collected in a common monitoring basin (CMB) afterneutralization and treatment. The treated water from the CMB will beutilized for green belt development, coal yard sprinkling or ash slurrypreparation prior to ash disposal.

1.09.00 Power evacuation

Power evacuation is planned through 400 KV lines to PGCIL substationand also through 400kV lines to the grid of Chhattisgarh State ElectricityBoard.

2.00.00 GENERAL PLANT REQUIREMENTS

2.01.00 General

The design of the 1 x 300 MW coal fired power station will be based onunitized principle i.e. there will be one boiler and one turbine and a set ofauxiliaries for the unit.

The auxiliary systems and plant facilities shall be designed for serving thewhole power station with adequate redundancy.

Secondary system components shall be designed generally for100% redundancy in order to achieve high reliability and availability of thepower unit.

The life span to be considered in the design, equipment and componentselection shall be at least 30 years.

For the design of the power plant, it is necessary not only toconsider the requirements of operation, but also, by suitably planningthe layout, the convenience of inspection, cleaning, maintenance andrepair.

In order to achieve reliability, high efficiency and safe operation ofthe power plant, it is also necessary to consider various precautionsto safeguard the operating and maintenance personnel.

The design of the power plant shall ensure that the plant can, inthe state of normal operation, adapt itself to load, pressure andtemperature variations within the allowable range of design.

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The various parts and systems of the power plant shall be designed toachieve the object of providing an integrated and coordinated power plant.

In the design of the power plant and selection of equipment, the specialfeatures of this project and likely occurrences have to be taken intoconsideration to ensure that the power plant can, under thesecircumstances, operate continuously, safely and with high efficiency. Theselection of building materials shall be suited to local conditi