J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL
CONDITIONS (GTC)

Section VI-C
Page - 1 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
TABLE OF CLAUSES

1.

UNITS OF MEASUREMENT AND ABBREVIATIONS............................................... 4

1.1
1.2
1.3

Units of Measurement ..................................................................................... 4

Abbreviations................................................................................................... 6
Standards ........................................................................................................ 8

2.

STATUTORY REQUIREMENTS IN ETHIOPIA.......................................................... 8

3.

ENGINEERING STANDARDS.................................................................................... 9
3.1
3.2

4.

BASIC SPECIFICATIONS FOR MECHANICAL EQUIPMENT................................ 16

4.1
4.2
4.3
4.4
4.5
4.6
4.7

5.

Standards Applicable ...................................................................................... 9

List of British Standards and Code of Practices ............................................ 10
Materials ........................................................................................................ 16
Forgings ........................................................................................................ 16
Castings ........................................................................................................ 17
Foundation bolts ............................................................................................ 17
Fasteners ...................................................................................................... 17
Gaskets, Diaphragms .................................................................................... 18
Gear Units ..................................................................................................... 19

ELECTRIC MOTORS ............................................................................................... 19

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8

Scope ............................................................................................................ 19
Codes & Standards ....................................................................................... 19
Performance.................................................................................................. 19
Insulation ....................................................................................................... 20
Construction .................................................................................................. 20
Painting ......................................................................................................... 20
Tests.............................................................................................................. 20
Documents .................................................................................................... 21

6.

LOW VOLTAGE PANELS ........................................................................................ 21

7.

HIGH VOLTAGE & LOW VOLTAGE CABLES........................................................ 25

8.

MACHINERY STAGING ........................................................................................... 25

8.1
8.2
8.3

9.

Design and Supply ........................................................................................ 25

General Requirement .................................................................................... 25
Stairways, Ladders, Handrails and Handrail Stanchions............................... 25

PIPING ...................................................................................................................... 27
9.1
9.2
9.3
9.4
9.5
9.6
9.7

General.......................................................................................................... 27
Live 8 bar (a) Steam piping ........................................................................... 28
Valves in piping ............................................................................................. 28
Construction .................................................................................................. 28
Preparation for Site Assembly ....................................................................... 29
Flanges and Fasteners.................................................................................. 29
Pipe Supports ................................................................................................ 29

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL
CONDITIONS (GTC)

Section VI-C
Page - 2 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
TABLE OF CLAUSES
9.8
9.9
9.10
9.11
9.12
10.

VALVES.................................................................................................................... 31
10.1
10.2

11.

General.......................................................................................................... 31
Valve Types................................................................................................... 31

TANKS AND VESSELS ........................................................................................... 32

11.1
11.2

12.

Steam Expansion Joints ................................................................................ 30

Condensate Drain Out................................................................................... 30
Steam Traps .................................................................................................. 30
Strainers ........................................................................................................ 30
Colour coding ................................................................................................ 30

Tanks............................................................................................................. 32
Vessels.......................................................................................................... 32

INSTRUMENTATION ............................................................................................... 32
12.1.
12.2

Signals....................................................................................................... 32
General Construction and Supply.................................................................. 32

13.

PUMPS ..................................................................................................................... 33

14.

PAINTING ................................................................................................................. 35
14.1
14.2
14.3
14.4
14.5
14.6
14.7
14.8

15.

PACKING.................................................................................................................. 37
15.1
15.2

16.

General.......................................................................................................... 38
Insulation Materials ....................................................................................... 38
Insulation of Piping ........................................................................................ 39
Insulation of equipment ................................................................................ 39
Insulation of Vessels .................................................................................... 39
Insulating Material Thickness ........................................................................ 40

SUBMITTAL OF DRAWINGS AND DOCUMENTS.................................................. 40

17.1
17.2
17.3

18.

General Equipment .................................................................................... 37

Spare Parts ................................................................................................... 38

THERMAL INSULATION.......................................................................................... 38
16.1
16.2
16.3
16.4
16.5
16.6

17.

Painting ......................................................................................................... 35
Preparation of Surfaces................................................................................. 35
Recommended types of paints ...................................................................... 35
Preparation of Paints ..................................................................................... 35
Method of Painting ........................................................................................ 35
Painted Film Thickness ................................................................................. 36
Interval of Each Painting ............................................................................... 37
Painting Schedule ......................................................................................... 37

Submissions along with the bid ..................................................................... 40

Submittals after the award of the Contract ................................................... 41
Other Submittals............................................................................................ 42

ENGINEERING DRAWINGS .................................................................................... 43

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL
CONDITIONS (GTC)

Section VI-C
Page - 3 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
TABLE OF CLAUSES
19.

SPECIAL TOOLS AND TACKLES........................................................................... 44

20.

MATERIAL HANDLING............................................................................................ 44

21

ERECTION................................................................................................................ 44

22.

PROGRESS REPORTING OF ERECTION WORK.................................................. 44

23.

CONTRACTORS TOOLS AND TACKLES .............................................................. 45

24.

INTER CHANGEABILITY ......................................................................................... 45

25.

COMPATIBILITY ...................................................................................................... 45

26.

OILS AND LUBRICANTS......................................................................................... 45

27.

GUARANTEES ......................................................................................................... 45
27.1
27.2

Guarantee for Capacities .............................................................................. 45

Guarantee for Performance........................................................................... 46

28.

EQUIPMENT CODE NUMBERS .............................................................................. 46

29.

QUALITY ASSURANCE, TESTING & INSPECTION............................................... 46

29.1
29.2
29.3
29.4
29.5
29.6
29.7
29.8
29.9

Quality assurance programme ...................................................................... 46

Quality assurance documents ....................................................................... 47
General requirements for testing and inspection........................................... 47
Shop Tests .................................................................................................... 48
Heat Treatment ............................................................................................. 49
Notification for tests and inspection............................................................... 49
Tests on Other Equipment of the Facilities at Site ........................................ 50
Performance tests of other equipment .......................................................... 50
Inspection, testing and Inspection certificates ............................................... 51

30.

CONTRACTORS LABOUR ..................................................................................... 52

31.

TRAINING OF EMPLOYERS PERSONNEL ........................................................... 52

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 4 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

SECTION VI-C

GENERAL TECHNICAL CONDITIONS (GTC)

Note: The following General Technical Conditions (GTC) shall supplement the Technical
Specifications in Section VI-D. Whenever there is a conflict, the provisions in Section
VI-D shall prevail over those in GTC in this part.
1.

UNITS OF MEASUREMENT AND ABBREVIATIONS

The Bidder shall refer the following units of measurements & abbreviations wherever
necessary.

1.1

Units of Measurement
Units of measurement shall be according to the metric system as noted hereunder:
Quantity

Unit

Symbol

Acidity / Alkalinity

Hydrogen ion concentration

pH

Area

square centimeter
square meter
hectare

cm2
m2
ha

Conductivity

micro siemens per centimeter

Micromhos per centimeter

S/cm
mho/cm

Current

ampere
milli-ampere
Ampere hour
Mega volt ampere

A
mA
Ah
MVA

Density

Baume
gram per cubic centimeter
kilogram per cubic meter

deg Be or Be
g/cc or g/cm3
kg/cu.m or kg/m3

Energy

Calorie
Joule
Kilo Joule

cal
J
kJ

Electrical energy

Kilo watt hour

kWh

Enthalpy

Kilo Joule per kilo gram

kJ/kg

Dissolved Solids

Brix

Bx

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 5 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

Quantity

Unit

Symbol

Force

kilogram force

kgf

Frequency

Hertz

Hz

Heat
coefficient

transfer Btu per square feet per second Btu/(ft2.s.OF)

per degree F
Kilo calorie per hour per square kcal/(m2.h.OC)
meter per degree C
Kilo Watt per square meter per kW/(m2 . K)
degree kelvin

Latent heat

Kilo Joule per kilo gram

kJ/kg

Length

meter
Millimeter
kilometre

m
mm
km

Mass

Gram
kilogram
Tonne or ton

g
kg
t

Mass flow rate

kilogram per hour

Tons per hour

kg/h
t/h

Power

Brake Horse Power

kilowatt
Mega Watt
Kilo volt ampere

bhp
kW
MW
kVA

Power unit

kilo watt hour

kWh

Pressure (absolute)

metric
millimetre of mercury column
SI units
Meters of water column

kg/cm2 (a)
mm Hg
bar(a)
mwc

Pressure (gauge)

metric
SI units

kg/cm2 (g)
bar(g)

Sugar solution

Apparent purity
Polarization

pty
Pol

Temperature

Degree Celsius

deg C or C

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 6 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

1.2

Quantity

Unit

Symbol

Time

Hour
Minute
second

h
min
s

Torque

SI units

Nm

Velocity

kilometre per hour

meter per minute
meter per second
Revolutions per minute

km/h
m/min
m/s
rpm

Voltage

Kilo Volt
Volt
Kilo volt ampere

kV
V
kVA

Volume

Cubic meter
Liter
milliliter
Hecto litre

cu.m or m3
l
ml
HL

Volumetric flow rate

Cubic meter per hour

Cubic meter per minute
Cubic meter per second
liter per second

cu.m/h or m3/h
cu.m/min or m3/min
cu.m/s or m3/s
l/s

Abbreviations
Qualifying Words

Abbreviation

Above mean sea level

Air circuit breaker
Alternating current
Automatic voltage regulator
Centre distance
Current transformer
Diameter
Direct current
Distribution board
Electro magnetic force
Factory Floor level
General Arrangement
Heating surface area

amsl
ACB
AC
AVR
C.D.
CT
dia
DC
DB
e.m.f.
FFL
GA
HSA

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

BID DOCUMENT FOR
POWER GENERATION PLANT

Qualifying Words

Abbreviation

High pressure
High tension
High Voltage
Kilo volt ampere reactive
Low pressure
Low tension
Maximum
Maximum continuous rating
Meter liquid column
Miniature circuit breaker
Minimum
Most economical rating
Motor control centre
Nephelometer turbidity unit
Net positive suction head
Nominal Bore
Normal Continuous rating
Number
Onload tap changer
Parts per million
Phase
Pitch circle diameter
Potential transformer
Power control centre
Power factor
Pressure reducing and desuperheating
Pressure reducing valve
Quadruple
Quality assurance plan
Quality control plan
Reinforced concrete cement
Revolution per minute
Safe working load
Screen protected drip proof
Silicon controlled rectifier
Specific gravity
Standard wire gauge
Standby
Super heater
Tonnes cane per day
Tonnes cane per hour
Tonnes per hour
Total dissolved solids
Totally enclosed fan cooled

HP
HT
HV
kVAR
LP
LT
max
MCR
mlc
MCB
min
MER
MCC
ntu
NPSH
NB
NCR
No.
OLTC
ppm
ph
pcd
PT
PCC
pf
PRD
PRV
Quad
QAP
QCP
RCC
rpm
SWL
SPDP
SCR
sp gr
SWG
SB
SH
TCD
tch
TPH
TDS
TEFC

Section VI-C
Page - 7 / 52

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 8 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

1.3

Qualifying Words

Abbreviation

Turbo Alternator
Unearthed
Vapour cell
Variable frequency drive
Working
Materials

TA
UE
VC
VFD
W

Cast Iron
Chromium
Mild Steel
Polyvinyl chloride
Stainless steel
Sulphur Di-oxide
Raw juice
Sulphured juice
Clear juice
Carbon di-oxide
Calcium Oxide
Chlorine

CI
Cr
MS
PVC
SS
SO2
RJ
SJ
CJ
CO2
CaO
Cl

Standards
Standards

Abbreviation

British standard

BS
ASME
ANSI
NEMA
IEE
ISO
ASA
API
ISA
AGMA
TEMA
ASTM
IEC

American Society of Mechanical Engineers

American National Standards Institute
National Electrical Manufacturers Association, USA
Institution of Electrical Engineers, UK
International Standards Organisation
American Standards Association
American Petroleum Institute
Instrumentation Society of America
American Gear Manufacturers Association
Tubular Exchanger Manufacturers Association
American Society for testing and materials
International Electro-technical Commission
2.

STATUTORY REQUIREMENTS IN ETHIOPIA

Relevant Acts, Regulations, Notifications and Ordinances proclaimed by the
Government shall be applicable.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 9 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
3.

ENGINEERING STANDARDS

3.1

Standards Applicable
The Engineering standards required to be followed for all materials, equipment and
workmanship with regard to design, manufacture, supply, erection and
commissioning of the Plant shall be generally as per the standard specification
indicated elsewhere in these documents and in the absence of any such standard for
any particular item, latest British Standard Specifications and code of practices or its
equivalent shall apply.
The other standards and codes to be adopted are published by ANSI (American
National Standards Institute), ASA (American Standards Association), API (American
Petroleum Institute), NEMA (National Electrical Manufacturers Association, USA),
ISA (Instrumentation Society of America), ISO (International Standardization
Organization), IEC (International Electro technical Commission), BIS (Bureau of
Indian Standards) and IEE (Institution of Electrical Engineers UK).
All equipment, systems, hardware and services covered under this specification shall
comply with all currently applicable statutes, regulations and safety codes in the
locality where the equipment will be installed. The Facilities shall also comply with the
local statutory requirements.
Whenever reference is made in the Contract Specifications to the respective
standards and codes in accordance with which, Plant and Equipment and materials
are to be furnished, and work is to be performed or tested, the provisions of the latest
current edition or revision of the relevant standards and codes in effect shall apply,
unless otherwise expressly set forth in the Contract. Where such standards and
codes are national in character, or relate to a particular country or region, other
authoritative standards and codes, which ensure an equal or higher quality than the
standards and codes specified will be accepted subject to the Project Managers prior
review and written approval.
Difference between standards specified and the proposed alternative standards must
be fully described in writing by the Contractor and submitted to the Project Manager
at least 28 days prior to the date when the Contractor desires the Project Managers
approval. In the event the Project Manager determines that such proposed deviation
do not ensure equal or higher quality, the Contractor shall comply with the standards
set forth in the documents.
In the event that any aspect of the Contractors work is not adequately prescribed by
such standards and codes of practice, the Project Manager may prescribe this
preferred practices and standards.
The equipment and systems if required by virtue of their country of origin shall also
conform to the latest applicable British / American / German / French / Indian
Standards. Any other established national and international standards equal to or
superior to the above may also be used. The Contractor shall furnish English
translation of all standards for which his equipment and systems offered are

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 10 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
conforming to. In the event of any conflict between the codes and standards referred
to and the requirements to this specifications the more stringent of the two shall
govern.
3.2

List of British Standards and Code of Practices

Some of the applicable British Standards and Code of Practices are listed below. The
list is not meant to be comprehensive. For the Standards which are not mentioned in
the list, relevant latest British standard should be followed. Though year is indicated,
latest version of relevant British Standard or equivalent Standard should be
applicable.
Particulars
Material or service
Shaft forgings
Cast steel castings
Cast Iron Castings
Spur and helical gears

Standard

29: 1976
BS 3100: 1976
BS 1452: 1977
BS 436: 1940
BS 436: Part 1: 1967
BS436: Part 2: 1970
Worm gearing
BS 721: 1963
Bevel gear units
BS 545: 1982
Specification for gray iron castings
BS 1452: 1961
Vertical steel welded storage tanks
BS 2654: 1973
Wrought steel in the form of
bloom, billets, bars and BS 970: Part 1: 1972 ;
forgings
BS 970: Part 2: 1970
BS 970: Part 3: 1971
supplement (1973)
BS 970 Part 4: 1970
BS 970 Part 5: 1972
BS 970 Part 6: 1973
Specification for copper and copper alloys tubes
BS 2871: Part 1: 1971
BS 2871: Part 2: 1972
BS 2871: Part 3: 1972
Keys and key ways and taper pins
BS 46: Part 1: 1958
Part 3: 1951
Specification for metric keys and key ways (Parallel and BS 4235: Part 1: 1972
taper keys)
Valves
Gate valves
BS 5150: 1974 ,
BS 5151: 1974 (1983)
Globe and check valves
BS 5152: 1974
BS 1560: (1983)
Butterfly valves
BS 1123: 1976
BS 6759:

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 11 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

Particulars

Standard

Safety valves

BS 5155: 1984
BS 6759
BS 5793
BS 5353: 1980
BS 6494
BS 5156: 1985

Control valves
Plug valve
Hydraulic fluid power control valve
Diaphragm valve
Paints
Lead based priming paints
Red oxide linseed oil priming paint
Furnish coat (paint)
Corrosion protection
Piping and vessels
Methods for measurement of fluid flow in pipes
Steels for use in chemical, Petrochemical and allied
industries
Steel casting for pressure purposes.
Fusion welded pressure vessels
Steel pipes and tubes for pressure purposes
Steel for field and refined pressure vessels
Fusion Welded pressure Vessels for use in chemical
and
allied industries
Specification for domed ends for tanks and pressure vessels
Specification for steel pipes and tubes for pressure
purposes
Specification for steel pipes and tubes
Specification for unfired fusion welded pressure vessels
Steel tubes and tubular Flanges and for bolting pipes, valve
and fittings
Flanges and bolting for pipes, valves and fittings-metric
series
Cast iron flanged pipes and flanged fittings
Centrifugally cast iron pressure pipes
Steam piping (drawn)
Non - steam piping (drawn)

General
Graphical symbols for Instrumentation
Limits and fits for engineering

BS 2521: 1966
BS 2523; 1966
BS 2524: 1966
BS 632:
BS 5493: 1977
BS 1042: Part 1: 1964
BS 1501.6: 1958
BS 1504: 1976
BS 1500: Part 1: 1958
BS 3601: 1974
BS 1501: Part I: 1964
BS 1515: Part 1:
BS 1965 Part 2: 1968
BS 1966: 1967
BS 3602: 1962
BS 3604: 1963
BS 5500:1976
BS 1387: 1967
BS 10: 1962
BS 4504: Part I: 1969
BS 4504: Part 2: 1974
BS 2035: 1966
BS 1211: 1958
BS 3602 HFS 23
BS 3601 HFS 27
BS 1387 heavy weight
BS 1387 medium wt.
3601 HFS 23; BS
3687 medium
galvanized
BS 1646: 1964
BS 1916: Part 1: 1953,
BS 1916: Part 2: 1953
BS 1916: Part 3: 1953

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 12 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

Particulars
Structural Steel
Weldable structural steel
The use of cold formed steel sections
Hot Rolled Sections
Covered electrodes for the manual metal arc welding of
carbon and carbon manganese steels
Methods of testing fusion welded joints and weld metals
in steel
Method of Tensile testing of metals, steel
Steel plate, sheet ship: carbon steel plate, sheet and
strip
Specification for cold rolled sections
ISO metric precision hexagonal bolts, screws and nuts
ISO metric black hexagonal bolts screws and nuts
Metal washers for general Engineering purpose
Weldable Structural Steels
High strength friction grip bolts and associated nuts
and washers for structural engineering
General grade
Higher grade bolts and nuts and general grade washers
Higher grade bolts (waisted shank), nuts and general
grade washers
Industrial open type metal flooring and stair treads
Approved testing of welding procedures. Fusion welding of
steel
Approval, testing of welders working to approved welding
procedure. Fusion welding of steel
Fusion welding of steel
Metal arc welding of carbon manganese steel
Stainless steel
Electrical
Motor
Geared Motors
Alternators
High tension switch gear
High tension starters
Medium voltage Switchboards

Standard

BS 4360: 1972
Addendum No 1
(1975) to BS
449: Part 2: 1969
BS 4: Part 1: 1980
BS 639: 1986
BS 709: 1983
BS 18: Part 2:
BS 1449: Part 1: 1972
BS 2994: 1976
BS 3692: 1967
BS 4190: 1967
BS 4320: 1968
BS 4360: 1972
BS 4395: Part 1: 1969
BS 4395: Part 2: 1969
BS 4395: Part 3: 1973
BS 4592: 1970
BS 4890: Part 1: 1974
BS 4871: Part 1: 1974
BS 4872: Part 1: 1972
BS 5135: 1974
BS 4825
BS 5000: 1978:
Part 10
BS 4517: 1969
BS 4999:- and
BS 5000
BS 5311:1976
BS 775:1974 (part 2)
BS 4752: 1977
(Part 1)
BS 5419: 1977

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 13 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Particulars

Standard

Medium Voltage starter

BS 587: 1984
BS 5424:1977
(1977)
Cables
BS 6346,
6207,
6004; 1984
6007 (Part 1) 1985
6346: 1969 (1977)
Electrical Meters
BS 37
General Clauses
37 Part I 1952
Poly phase whole current and transformer operated meters. BS 37 Part 4 1954
Single phase 3-wire whole current and transformer operated
meters
Poly phase kilowatt minimum demand meters
BS 37 Pat 5 1935
Cartridge fuses for voltages up to and including 1000 volts BS 88
AC and 1500 VDC
General requirement
BS 88 Part 1 1975
Supplementary requirements of fuse links of standardised BS 88 Pat 2 1975
dimensions for industrial purpose
Specification for direct acting indicating electrical measuring BS 89 1977
instruments and their accessories
Direct acting electrical recording instruments and their BS 90 1975
accessories
Liquid starters and controllers
BS 140 1957
Electrical protective relays
BS 142 1966
Insulating oil for transformers and Switchgears
BS 148 1972
Marking and arrangement of switch- gear, busbars, BS 158 1961

main connections and small wiring

Busbars and busbar connections
Electrical power switchgear and associated apparatus
Protected type non reversible socket outlets, cable couplers
and appliance couplers, with earthing contacts for single
phase AC circuits up to 250 volts
Distribution fuse boards for low and medium voltages
Flameproof enclosure of electrical Apparatus
Field rheostats and rheostats for other purposes
Two-Pole and earthing pin plugs, socket outlets and
socket outlet adaptors upto 250 volts
Motor starters and controllers
Flexible steel conduit for cable protection and flexible steel
tubing to enclose flexible drives
Flexible steel conduit and adaptors for the protection of
electric cables

BS 159 1957
BS 162 1961
BS 196 1961
BS 214 1973
BS 229 1957
BS 280 1957
BS 506 1950
BS 586 1957
BS 731
BS 731 Part 1 1952

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 14 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

Particulars

Standard

Automatic change-over contactors for emergency lighting

system
Contactors
AC contactors for voltages above 1 KV and up to and
including 12KV
Requirement of electrical accessories
Terminal markings for electrical Machinery
Terminal markings for input terminals composite apparatus
Terminal markings for rotating electrical machinery
Flame proof electrical lighting fittings
General purpose fuse links for domestic and similar purpose
Capacitors for connection to power frequency system
Motors for general use
Cable sealing boxes for oil immersed Transformers
Electrical performance of rotating electrical machines
Fuses for voltages exceeding 1000 Volts AC

BS 764 1954
BS 775
BS 775 Part 2-1974

BS 816 1952
BS 822
BS 822 Part 5 1959
BS 822 Part 6 1964
BS 889 1965
BS 1362 1923
BS 1650 1971
BS 2048 Part 1 1961
BS 2562
BS 2613 1970
BS 2692 1956
BS 3871
Miniature and Moulded Case Circuit Breakers
Miniature circuit breaker for AC Circuits
BS 3871 Part 1 1965
Current transformers
BS 3938 1973
(IEC185:1977)
Electrical protective system for AC Plant
BS 3950 1965
Performance of AC control gear
equipment rated up to BS 4070 1966
660 volts for use on high prospective fault current systems
Colours of indicator lights, push button, Annunciators
BS 4099 Part I 1976
(IEC73:1975)
Current operated earth leakage circuit breakers
BS 4293 1968
Industrial plugs socket-outlets and couplers for AC and DC BS 4417
supplies
Electric luminaries (lighting fittings)
BS 4533
General requirements and tests
BS 4533 Part 1 1971
External and internal wiring
BS 4533 Section
1.5 1971
Terminations
BS 4533 Section
1.6 1971
Provision for earthing
BS 4533 Section
1.7 1971
Protection against electric shock
BS 4533 Section
1.8 1971
Miniature circuit breakers distribution boards
BS 4649-1970
for low and medium AC circuits
Cable trunking
BS 4678
Steel surface trunking
BS 4678 Part 1- 1971
Steel under floor (duct) trunking
BS 4678 Part 2 1973
Electric apparatus for explosive atmosphere
BS 4683

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 15 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Particulars

Standard

Circuit breakers of rated upto and including 1000 volts AC

and 1200 volts DC
Control switches for control and auxiliary circuits upto and
including 1000 volts AC and 1200 volts DC
General requirements
Special requirements for specific types of control switches
Push buttons and related control Switches

BS 4752 1971

BS 4794 Part-I-1977
(IEC:337-2-1972)
BS 4794 Part1 1973
BS 4294 Part 2
BS 4794 Section 2.1
1977
General requirement for rotating electrical machines
BS 4999
Classification of types of enclosures
BS 4999 Part
20 1972
Characteristics of synchronous Generators
BS 4999Part 40- 1972
Vibration and Noise level
BS 4999 Part 50,
51, 1972, 1973
Built in thermal protection for electric motors rated as 660 BS 4999Part 72- 1972
volts AC and below
Rotating electrical machines of particular type particular BS 5000
application
Electrical performance of small power electric motors and BS 5000 Part 1 1973
generators
AC disconnectors and earthing switches of rated voltage BS 5253 1975
above 1KV
Specifications for AC circuit breakers of rated voltage above BS 5311
1 KV
General and definitions Rating, Design and Construction, BS 5311 Part 1, 2, 3,4,
Rules for selection of Circuit breakers for services
5, 6, 7
Specification for air break switches, airbreak disconnectors, BS 5419-1977
air break switch disconnectors and fuse combination units ( IEC.410:1972)
for voltages up to and including 1000 volts AC and 1200
volts DC
Specification for degree of protection of enclosures of BS 5420-1977
switchgears and control gear for voltages up to and (IEC.144:1963)
including 1000 volts AC and 1200 volts DC
Control gear for voltages up to and including 1000 V AC BS 5424 Part I : 1977
and 1200 V DC
(IEC.158-1,1581A,
1790, 1975)
Factory built assy of switchgear and control gear for BS 5486Part I
voltages upto and including 1000 V AC and 1200 V DC
: 1990(IEC.439:1985)
PVC insulated cables non armoured for electric power and BS 6004 1969
lighting
Mechanical cable glands for elastomer and plastic insulated BS 6121 1973
cables
Mineral insulated cables
BS 6207
Copper sheathed cables with copper conductors
BS 6207 Part 1 1969
PVC insulated cables for switchgear and control gear wiring BS 6231 1978
PVC insulated cables for electrical supply
BS 6306 1969

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 16 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Particulars

Standard

A.C. circuit breakers of rated voltage above 1 KV

Voltage transformers
PVC insulated cables for switchgears and control gear
wiring.
Common Switchgear for HV Switchgear & Control gear
H V AC Circuit Breakers
International standard for metal oxide surge arresters
without gap of AC system

BS 5211 Part 1 - 7
BS 3941
BS6231
IEC 694
IEC 60056
IEC 99- 4

CODE OF PRACTICES
Particulars
ELECTRICAL
Protection of switch gear against lightning
Electrical apparatus and associated equipment for use
in explosive atmosphere of gas or vapour other than
wiring applications.
Protection of electrical power equipment against
climatic conditions
Electrical equipment of industrial machines
Earthing

Code

CP. 326
CP. 1003
CP. 1014 - 1963
CP. 1015 - 1967
CP 1013:1965

4.

BASIC SPECIFICATIONS FOR MECHANICAL EQUIPMENT

4.1

Materials
All materials supplied shall be new, and workmanship shall be of first class quality
and shall comply with the appropriate British Standards, and in the absence of such a
standards shall be of tested commercial quality.
All steel materials shall be free from laminations, folds and cracks.
Any materials not fully specified in the particular specifications and which may be
supplied shall also comply with above conditions.

4.2

Forgings
Forgings shall be free from all defects affecting their strength and durability, including
seams, pipes, flaws, cracks, scales, fins, porosity, hard spots, excessive non metallic
inclusion and segregations. All finished surfaces of forgings shall be smooth and free
from tool marks. Tool marks or tearing of metal by the finishing tool will not be
accepted on the surface of the fillets and such marks, if they occur, shall be removed
by grinding or finishing.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 17 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Heat number shall be stamped on all forgings at a place clearly visible after the
forging is assembled in a complete unit.
Forgings above 150mm diameter shall be subjected to internal examination for
detection of flaws and to heat treatment for relief of residual stresses.
4.3

Castings
All castings shall be of fine grain quality and shall conform to the relevant BS or its
equivalent specifications.
The surface of castings which do not undergo machining, particularly those of steel
or iron in contact with water shall be dressed smooth in the foundry with all joints
blended into the adjacent surface. The castings shall be free from foundry
irregularities, such as projections, ridges, hallows, honey combing, pock marks, blow
holes and cracks or chip marks, so that they will not require surface smoothing
operations prior to painting. All cast materials shall be as free as is practical of blow
holes and flaws. No welding plugging or filling of any defective parts shall be done.
No defective castings shall be accepted.
Heavy steel castings shall be rough machined and then normalized by heat treatment
before finish machining.

4.4

Foundation bolts
Foundation bolts, holding down bolts, rag bolts with nuts and washers for all the
equipment of the Plant, structure etc. are covered under the Contract, shall be
supplied by the Contractor. Wherever required grouting pads shall be supplied.

4.5

Fasteners
All screws, bolts, nuts and studs shall be of international standard (metric) form of
threads. Bolt heads and nuts shall be hexagonal. Hexagonal recesses shall be
provided in the head of counter sunk head bolts and machine screws. The bolt
length shall be such as to ensure at least two full threads are projecting after the nut
has been tightened.
Nuts and Bolts for pressure containing parts shall be of approved, high quality steel
machined on the shank and bearing faces of the head and nut.
Where there is a risk of corrosion, bolts shall be finished flush with the top of the nut
and the bolts and nuts shall be corrosion resisting steel or bronze.
All nuts shall be provided with washers, parallel or taper as appropriate. Where ever
there is a possibility of nuts becoming loose due to vibration, mechanical locking
devices of approved form shall be provided. Spring type washers shall not be
permitted where these washers may damage any protective coating. Special locking
compounds may be used as an alternative to mechanical devices subject to the
Employer's approval.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 18 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
In case of screw, nuts, springs, pivots etc. for instrumentation the use of iron and
steel shall be avoided. Steel screw when used shall be zinc, cadmium or chrome
plated. When painting is not possible owing to tolerance limitations, it shall be of
corrosion resisting steel.
Instrument screws (except those forming part of a magnetic circuit) shall be of brass
or bronze. Springs shall be of non rusting material, eg., phosphor bronze or nickel
silver as far as possible.
When fitting on outdoor equipment all bolts, nuts and washers shall be of non-rusting
material when in contact with non-ferrous parts.
Where fitted bolts are used there shall be a driving fit into the reamed holes they are
to occupy and be marked to ensure correct re-assembly on Site. The threaded
portion of such bolts shall be of a diameter that shall prevent damage to the thread
on assembly.
All nuts, bolts, fasteners required for assembly or mounting of any equipment of the
Plant procured through these documents, including foundation and holding down
bolts, are to be included in the supplies.
4.6

Gaskets, Diaphragms
Rubber or rubber-based materials shall not be used for gaskets, diaphragms, etc.
Instead, synthetic materials, not subject to deterioration due to climatic conditions
shall be employed.
The Contractor shall include for supply of all gaskets required for jointing of pipe
flanges, and sealing of mating faces. Generally specifications of gaskets for different
duties shall at least be equivalent to the following:
a)

For 8 bar (a), Steam piping connections: spiral wound flexatallic type gaskets
with inner and outer metal rings.

b)

For all steam piping for pressures 8 bar (a) and above, at temperatures 200
C and above: spiral wound flexatallic type gaskets with inner and outer
metal rings.

c)

For process Steam piping for 2.0 bar (a) pressure at 1270C temperature: wire
inserted synthetic red asbestos gasket, 3 mm thick.

d)

For air ducts: wire woven asbestos gaskets, 6 mm thick.

e)

For compressed air piping: synthetic red rubber gasket, 3 mm thick.

f)

For other piping: wire inserted synthetic rubber gasket, 3 mm thick, resin
cured to withstand temperatures up to 150 0C.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 19 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
4.7

Gear Units
Unless otherwise stated in the particular specification, all gear units for reducing or
increasing speed of a prime movers, shall be of the totally enclosed type with casing
cast in suitable materials and containing gears rated in accordance with British
Standards.
All gearboxes shall be designed with minimum 1.7 service factor as per AGMA rating
unless stated otherwise. All gearboxes above 25 hp shall be helical type.
The gears shall be mounted on steel shafts running in ball or roller bearings unless
otherwise specified.
As applicable to duty the gear case shall incorporate an integral type of anti-runback
gear. The gear case, bearings and couplings shall be as detailed in the particular
specification.
Speed ratio of worm reduction gears shall not be more than 50/1.

5.

ELECTRIC MOTORS

5.1

Scope
This specification covers the requirement of three phase Induction Motors to be
supplied by the Contractor within the terminal points.

5.2

Codes & Standards

The design manufacture and performance of the equipment shall comply with all
currently applicable statues, regulations and safety codes. Unless otherwise
specified the motors shall conform to latest applicable BS and other international
standards.

5.3

Performance
a.

Motors shall be capable of satisfactory operation for the application and

continuous duty as required by the driven equipment.

b.

Motors shall be capable of giving rated output without reduction in the

expected life span when operated continuously under following conditions
and using variable frequency controller:

c.

i.

Variation of supply voltage from the rated voltage

10%

ii.

Variation in supply frequency from the rated frequency

5%

iii.

Combined Voltage and frequency variation

10%

Motors shall be suitable for the method of starting as specified.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 20 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

5.4

d.

Motors shall be capable of starting and accelerating the load with the
applicable method of starting without exceeding acceptable winding
temperature, when the supply voltage is 85% of the rated voltage.

e.

The locked rotor current of squirrel cage motors shall not exceed 600% of
rated current subject to tolerance as per BS.

Insulation
The insulation shall be as specified and vacuum and pressure impregnated, shall be
given tropical and fungicidal treatment.
For motors specified for outdoor execution the account shall be taken of heating due
to direct solar radiation.

5.5

Construction
Bearing shall permit running of motor in either direction.
If oil lubricated type bearings are provided, a drain plug and oil level sight glass shall
be provided.
Terminal box shall be weatherproof construction suitable for outdoor application. It
shall be suitable for top and bottom entry of cables. Terminal box shall be suitable for
termination of Aluminium cables. Further it shall be capable of being turned through
360 Deg. on steps of 90 0.
Terminal box shall be complete with stud type terminals, plain & spring washers,
check nuts.

5.6

Painting
External parts shall be finished and painted to produce neat and durable surface,
which shall prevent rusting and corrosion. The equipment shall be degreased and all
rust, sharp edges, scales be removed and treated with one coat of primer and
finished with two coats of final paint.
A list of special tools and tackles required for erection and regular maintenance shall
be furnished.

5.7

Tests
The Contractor / Sub-Contractor shall conduct all the routine tests as per BS and
listed below without any extra charge.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 21 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Following Routine tests shall be conducted in the presence of Employers / Project
Managers representative on the motors at no additional cost: The Contractor shall
submit the type test certificate of the equipment to the Employer.

5.8

Insulation resistance test.

High voltage test.
No load running of motor and reading of current in the three phases and
voltages.
Locked rotor reading of voltage, current and power input at a suitable reduced
voltage.
Reduced voltage running up test at no load to check the ability of the motor to
run up to full speed on no load in each direction of rotation with 1/3 of the
rated line voltage applied to the stator terminals (For squirrel cage motors
only)

Documents
After the award of contract the following documents shall be furnished:
a.
b.
c.

6.

General Arrangement Drawings of each type of motor

Instructions Manual for erection, testing, commissioning, operation
and regular maintenance.
Test reports.

LOW VOLTAGE PANELS

The contractors scope covers design, construction features, material, manufacture,
inspection and testing, delivery to site and performance testing of metal enclosed
Low Voltage Switchgear (MCC) of voltage not exceeding 1000 V AC to feed power
supply to individual electrical equipment of the facilities. The supply, installation,
testing and commissioning of all equipment / materials / accessories, etc. shall
comply with the latest applicable standards and codes of practices.
Maximum current rating of LV Switchgear shall be limited to 8000 Amps.
1)

Sheet Metal Work

The switchgear frame shall be fabricated using Cold Rolled Sheet Steel or
Cold Rolled Cold Annealed of suitable thickness.

2)

Painting
Painting shall be of Synthetic Enamel / Powder coated. For painting seven
tanks method shall be followed. Shade shall be Light grey & Bright white as
exterior and interior respectively.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 22 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
3)

Constructional features
IP-5X construction shall be provided with power connections to the equipment
mounted on withdraw able mounting plate of the bolted type.
All identical equipment and corresponding parts including chassis of draw-out
modules of the same size shall be fully interchangeable.

4)

Bus bars
Switchgear shall be provided with E-91 grade, 50 kA for 1 Second three
phase or three phase and neutral bus bars with temperature range of 0 Deg.
C to 90 Deg. C. for Main and Auxiliary bus bars.

5)

Circuit breakers
Circuit breakers shall be air break draw-out type (EDO), 400 Volt, 50 kA,
Motorised in operation. Closing and tripping shall be possible with 85 % to
110 % of rated voltage and 50 % to 110 % of rated voltage respectively.

6)

Fuses for control circuit

HRC cartridge having rupturing capacity at 400/230 V, 80 kA at 400/230 V
and 16 kA at 230 V DC Shall be provided.

7)

Motor starters
Motor Protection Circuit Breakers or direct on-line starters of suitable size for
Class AC 3 shall be provided. Automatic star-Delta starters shall comprise
three sets of contactors of AC 3 duty. Reversing starters shall be suitable for
Class AC 4 duty.

8)

Moulded case circuit breaker

Moulded case circuit breakers (MCCBs) shall be provided for the motor
controls. The MCCBs shall conform to the latest applicable standards.
Under-voltage, Earth Fault release shall be provided.

9)

Miniature circuit breaker

Miniature circuit breakers for use on motor, space heater and control circuits
shall comply with of applicable standards.

10)

Current and voltage transformers

Shall be of the dry resin cast type, 15 VA, accuracy class 1.0 with instrument
safety factor of 5. Protective accuracy class 5P with accuracy limit factor of
10. Measuring VTs - 50 VA per phase with accuracy class 1.0. Protective VTs

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 23 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
- 50 VA per phase with accuracy class 3. Dual purpose VTs - 100 VA and
dual accuracy class 1.0 / 3.0 for metering and protection respectively.
11)

Relays
The relays shall be static / microprocessor type. Electromagnetic relays may
be considered for those type of relays which are not being manufactured as
static / microprocessor type.

12)

Transformers for control, space heater and annunciator

Suitable size single phase, two winding, dry type transformers shall be
provided.

13)

Indicating instruments and meters

Electrical indicating instruments shall be of 144 Sq. mm sizes for incomer and
96 mm sq. mm. size for outgoing feeder, suitable for flush mounting.

14)

Indicating lamps
Indicating lamps shall be LED type and of low watt consumption and easily
replaceable from the front.

15)

Control and selector switches

Control and selector switches shall be of the rotary type adequately rated.

16)

Push buttons
Push buttons shall be of momentary contact, push to actuate type rated to
carry 10 A at 230 V AC, 1A (inductive breaking) at 110 V DC. Emergency
Stop' push buttons shall be Mushroom head type.

17)

Space heaters, panel indication lamps

Filament type 230 V, 40 W lamps shall be provided in Cable Alleys and
wherever necessary.

18)

Window type alarm annunciators

The alarm annunciation scheme in control wiring drawings shall incorporate
visual indication of audible alarm on the occurrence of the fault.

19)

Capacitors and APFC relay

The capacitors of suitable type and rating shall be supplied to achieve pf of
0.9. It shall be indoor type, delta connected suitable for use of 3 phase, 400
volts, 50 Hz.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 24 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
20)

Internal Wiring
Switchgear internal wiring shall be carried out with 1100 V grade, PVC,
flexible, stranded, insulated copper conductor wires. For power circuits is 4
Sq. mm. and for control circuits 2.5 sq. mm. shall be used.

21)

Terminal blocks
Terminal blocks for CT and VT circuits shall be of finely threaded pairs of
brass studs. Minimum rating of the terminal block is 10 A.

22)

Labels
All labels shall comprise black letters of Min. 10 mm height on a white
background and shall be properly fixed.

23)

Earthing
Suitable size earth busbar running along the entire length of the board shall
be provided.

24)

Inspection
Stage and Final Inspection of L V Switchgear Assembly will be carried out at
the Bidders Works as per need to be assessed from time to time.

25)

Tests
The Contractor shall conduct all the routine tests as per BS or equivalent and
listed below without any extra charge. The Contractor shall furnish valid Type
test certificate for equipment at no extra cost.
a)
b)

26)

Type Tests
Routine Tests

Drawings & Data

The Contractor shall submit following drawings for clients approval.
a)

Complete assembly drawing of the Switchgear showing G A, Plan,

Elevation, Typical Sectional Views and Location of Cable
compartment, busbar chamber, metering and relay compartment and
terminal blocks etc.

b)

Schematic diagram for power and control of the switchgear.

c)

Bill of Material.

d)

Foundation details

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 25 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
7.

HIGH VOLTAGE & LOW VOLTAGE CABLES

1)

Scope
This specification covers requirement of Design, Manufacturing, Supply and
Delivery of 1.1 kV & 11kV grade cables and accessories like termination etc.

2)

Construction
The cables shall be of XLPE copper conductor with continuous conductor
temperature of 70 deg. C. For selection of cable 20 % deration factor shall be
considered.
For Three and Half core cables the current carrying capacity if the neutral
conductor shall be 50% of that of the main phase conductors.

3)

Tests
Following tests shall be conducted on cable length of each rating in the
presence of Employers representative free of cost:
a)
b)
c)
d)
e)

Conductor resistance test

High Voltage test
Insulation Resistance test
Continuity check
Check for standard mark and embossed rating.

8.

MACHINERY STAGING

8.1

Design and Supply

The design, detailing, materials, fabrication and supply, erection of structural
steelwork and staging shall comply with the provisions of relevant British Standard
Specifications, together with the specifications mentioned herein, except as
otherwise required by the particular equipment of the Facilities and outlined under
Technical Specifications.

8.2

General Requirement
Except where otherwise authorized, all materials shall comply with the requirements
of the particular specification and the relevant British Standard.

8.3

Stairways, Ladders, Handrails and Handrail Stanchions

For steel stairways, the treads and landings of stairways shall be open mesh
construction. All treads in a flight shall match one with another and also with the line
pattern of the landings and, where possible, with the floors served by the stairs.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 26 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Unless otherwise specified width of landings shall be 1000 mm and the width
between staircase stringers 760 mm. The inclination of stair stringers to the
horizontal shall not be more than 500 unless otherwise specified. Toe plates shall be
100 mm high and shall be provided at edges of all landings, platforms and floors.
Chequered plate flooring is to be of non-slip raised pattern or other equivalent type.
Individual plates are to be cut and fitted so that the pattern on the adjacent panels
matches in all directions.
The chequered plate shall be 6 mm thick on plain and shall be fastened to the
steelwork preferably by 6 mm counter set screws at a pitch not exceeding 535 mm
centres.
Ladders shall be with single rungs, shouldered at each end, inserted into prepared
holes in the stringers and welded. The pitch of additional rungs to bridge the gap
between the top rung of ladders and edges of platforms shall not exceed 57 mm.
Wherever required, the stringers shall open out at the top of the ladder to allow
adequate room for the user to turn to face the ladder when descending and the
stringers shall extend a minimum of 1060 mm above the level of the platform. Where
necessary the stringers shall be bent over to form a continuous connection with the
platform.
Stringers shall be attached to the adjacent structure by suitable cleats which shall be
firmly attached to the stringers and the supporting structure and be sufficiently close
together to make the ladder rigid throughout its length. The cleats shall be of
sufficient length to give required clearance at the back of the ladder. The top rung of
a ladder shall be at the same level as the floor or edge of the platform unless the
flooring of the platform has been extended to form the top rung. There shall be no
obstructions above this level.
Stairways and floor openings shall have double rail hand railing. Handrail standards,
top and bottom railing shall be out of minimum 40, 25 and 20 mm NB pipes
respectively.
All railing pipes shall be as per BS specifications.
For hand railings for platforms, stairways and landings, the standards shall be vertical
and spaced at not more than 1800 mm centres and the top rail shall be 1070 mm
above the platform or landing level as applicable. Standards shall be fixed to the
supporting steelwork with a minimum of two 16 mm diameter bolts or welded. Bends
in hand railing shall be carefully formed to give satisfactory continuity of curvature
and alignment and rails shall be jointed with a flush scarf joint held together by
means of a tapered pin or other approved joint.
Hand railing for ladders shall meet with the general requirements as above except
that the single rail shall be approximately 100 mm clear of the stringer and the
standards shall be short single ball type mounted at right angles to the stringer.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 27 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
9.

PIPING

9.1

General
All piping with valves and fittings in the facilities is in the scope of Contractor.
For calculating pipe sizes, velocities specified in table below shall not be exceeded.
Fluid to be handled
Live steam at 66 bar (a) pressure
Exhaust steam 2.6 bar (a) pressure
Compressed air
Juice
- pump suction
- pump discharge
Water
- pump suction
- pump discharge
- gravity

Maximum velocity m/sec

35-40
30
25
<1
1.8
<1
2
0.7

Valves on 2.6 bar (a) and below steam pressure and live steam piping (if required)
shall be as per Class 150 of ANSI Standard steel pipe flanges, flanged valves and
fittings.
Valves and fittings should preferably be of same make and of modular design so as
to facilitate interchange-ability and reduction in variety.
Bidder shall furnish schedule of valves covered under all sections compositely.
All piping shall be made of steel of a grade and thickness appropriate to the
substance it has to contain and its pressure and temperature, and all in accordance
with the relevant British Standard.
Gradient of 50 mm in 30 m length of pipe in the direction of Fluid flow shall be
provided on all horizontal pipelines to facilitate drainage.
Suitable drains, vents, valves, shall be provided in the pipelines wherever necessary.
All Carbon steel pipes and pipe fittings used for conveying of air, cold water, hot
water except feed water, oil shall conform to BS specifications listed elsewhere in this
document. The piping shall be Class 'C'. The thickness of Carbon steel pipes,
having diameter more than 200 mm shall, be 8 mm minimum.
In case of all piping above 25 mm NB, except for high pressure and Process Steam,
only flanged joints shall be used. All flanges shall conform to BS Specifications. The
distance between two flanges in straight portion of pipes shall not exceed 6 meters.
In case of bends, flanges shall be provided at least on one end. Flanges at ends of
pipeline shall be provided with bolted blind flanges.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 28 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
9.2

Live 8 bar (a) Steam piping

The thickness of Process Steam piping shall be minimum 8 mm for 300 mm dia and
above. All Steam expansion bellows shall be of stainless steel tested at 1.5 times
the working steam pressure.
On high pressure and reduced pressure lines, a branch line shall be taken from the
top of main line and not from bottom.
Steam piping shall be designed so that maximum pressure drop per 100 m pipe
length shall not be more than 1.0 bar (a).
Where steam piping is fitted in the plant, loads due to expansion are to be
compensated for by providing loops or bends, loop or vertical bend below main line is
preferred. Where fitting of bend or loop is not possible then bellows may be used.
Material of construction for bellows on steam lines shall be stainless steel.
Gradient of 50 mm in 30 m length of pipe in the direction of steam flow shall be
provided on all horizontal pipelines to facilitate drainage.
Safety valves are to be provided in the steam pipelines wherever necessary. Safety
valves in the process steam and reduced pressure steam lines shall be lever
operated, unless otherwise specified.
Suitable drains, valves, Steam trapping arrangement shall be provided in all Steam
lines wherever necessary. For 9 and 2.0 bar (a) Steam lines, steam traps shall be
provided at all natural drainage points.

9.3

Valves in piping
Valves shall be provided in each branch line of high pressure, reduced pressure
steam lines, water separator, drain, etc.
Suction and delivery lines of all pumps, shall be provided with isolating valves.
Delivery lines of all pumps shall be provided with non-return valves. Non return valve
shall be installed between pump delivery flange and isolating valve.

9.4

Construction
Where steel pipe work is to be welded it shall be carried out by the electric arc
process/shielded metal arc process/gas welding etc as relevant to the particular
application; and conform to the relevant BS Specifications. Welding hall only be
carried out by suitably qualified welders who shall be required to hold a valid welding
certificate in accordance with the appropriate British Standard.
Procedures for the testing of welders shall be in accordance with the relevant British
Standard.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 29 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
All welded pipe work is preferred on nominal bore 150 mm and above, unless
otherwise stated. Intermediate flanges are to be used wherever essential for
maintenance, design or transport reasons.
The Contractor shall be responsible for determining locations of site butt welds to
break the piping runs into separate sections for the purposes of transport to site, and
for properly and clearly designating each section for correct site assembly.
9.5

Preparation for Site Assembly

All pipe work supplied for site butt-welding shall have the ends machined and
protected for transportation.
Pre-fabricated piping sections shall be capable of being fitted into place without
springing or forcing except where cold pull is required.
The outside surface of the piping shall be painted with one coat of red oxide.
All flanges and nozzles shall be protected with wood or suitable covers and the
thread ends greased and protected.

9.6

Flanges and Fasteners

All bolt holes in flanges shall be equally spaced off vertical and horizontal centre lines
of pipes conforming to BS 10, Table D for all fluids such as water, air, oil, process
steam ( Pressure not exceeding 2.0 bar (a). For high pressure Steam above 2.0 bar
(a), the relevant BS standards shall apply. Orifice plate flanges shall be standard to
schedule unless otherwise stated.
Loose flanges and cutting lengths on pipelines shall be supplied to allow for
alignment errors in plant location.
All bolts, nuts and washers shall be supplied 10% more in quantity than actual
requirement.

9.7

Pipe Supports
Piping shall be installed on supports of suitable fabrication to ensure that no undue
stresses are placed on adjoining pipe work and equipment of the Plant.
Piping connected to equipment of the Plant shall be so supported that minor
equipment of the Plant, valves, etc., can be readily removed without additional
supports and with a minimum of dismantling.
Anchor sliding, spring, resting, etc. supports shall be provided for those pipe runs
demanding this form of fixing and shall be fabricated in accordance with the duty of
the pipe.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 30 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Flexibility of all high pressure, reduced pressure and process steam piping shall be
designed in accordance with BS Codes.
9.8

Steam Expansion Joints

Stainless steel expansion bellows suitable for the pressure and temperature rating
shall be provided steam and exhaust pipe line in places where expansion loops
cannot be accommodated.

9.9

Condensate Drain Out

All steam, and exhaust pipe lines shall be provided as per standards with suitable
drains at suitable locations to drain out the condensate. The drains provided shall be
of adequate size to prevent choking which would result in knocking. The drain
connection shall be fitted with suitable valve, strainer and steam trap to prevent the
steam from escaping through the drain pipe. The drain pipe shall be let open into the
factory concrete drain out side the building.

9.10

Steam Traps
Steam traps shall be provided for all 9 bar (a) and low pressure steam pipelines
including exhaust steam. The traps shall also be fitted on condensate lines.
Steam traps shall be provided on all points likely to collect condensate. Traps shall
also be fitted at the ends of high pressure, low pressure and exhaust steam and also
upstream side of all isolating valves.
The trap shall be fed from the reservoir fitted to the underside of the steam main pipe
or branch. The condensate pipe run from the reservoir shall include an isolating
valve. The steam trap shall be fitted with a full bore bypass drain and valve. These
traps and by pass drains shall be sized for a minimum rate equivalent to 15% of
normal steam flow with the valve and steam trap at the end and at the lowest point of
the high pressure steam main and also low pressure and exhaust steam main. The
traps shall be adequately supported and anchored.

9.11

Strainers
In-line pot strainers shall be provided at all points where it is necessary that the solids
in the fluid may otherwise damage the equipment. The pot strainers shall be efficient
and manufactured as per relevant BS or its equivalent code.
Strainers shall also be provided on the suction side of the pumps as detailed in the
particular specification and as per relevant BS or its equivalent code.

9.12

Colour coding
Colour coding of individual pipelines shall be given at the time of Contract finalisation,
but generally in accordance with BS-1710 or IS-2379:1990 or equivalent Standard.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 31 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
10.

VALVES

10.1

General
All valves shall be of the rising spindle outside screw type.
Valves shall be installed so that any plant item may be isolated from all services and
process lines and to allow tanks and vessels to be drained and vented.
Valves shall be supplied in order that standby pumps may be serviced during normal
factory operations.
Valves in infrequently used pipelines shall be positioned in such a manner as to
avoid piping remaining filled with fluid for prolonged periods of time.

10.2

Valve Types
The following is a general guide as to the type of valve required to be used for a
particular duty.
a)

Globe Valves
These shall be used on small bore pipelines (upto 50 mm) for such duties as :
-

b)

Process steam
Hot water

Wedge or Parallel Slide Gate Valves

These shall be used where control of flow is desired by direct hand operation
of spindle wheel. The pipeline duties envisaged for these valves are:
-

c)

High pressure Steam

8 bar (a) steam
Process steam
Steam stop valves at prime movers
Hot water
Condensate
Cold water

Butterfly valves
Where flow of materials is required to be controlled by gear operated spindle
wheels or by valve actuators, butterfly valves, shall be employed.

d)

Other valves
In addition, special duties shall have valves considered most suitable for
those duties.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 32 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Non-return valves, relief valves, ball float valves, bib nose test cocks, drain cocks,
etc., shall be provided as considered necessary for the efficient functioning of
equipment of the Plant and to facilitate repair work and maintenance.
11.

TANKS AND VESSELS

11.1

Tanks
Tanks of a capacity of upto 30 cubic meters of the open top or vented to atmosphere
type, shall be of rectangular or cylindrical construction as dictated by the particular
specification.
These shall be fabricated of Carbon steel, unless otherwise specified, of a minimum
thickness of 6 mm and shall be constructed with all necessary bracing, connection
branches and pads, flanged, screwed and tapped as necessary.
Each tank shall be supplied with, or have fitted, the necessary fittings such as
manhole cover, internal and external vertical caged ladders, peripheral roof handrail
as necessary.

11.2

Vessels
The design of pressure vessels shall be as per ASME Sec. VII, HEI and TEMA. All
heat exchangers and vessels for steam application shall be designed for full vacuum
conditions. The heat exchangers shall be provided with start-up vent connections.
The design shall have provision for complete drainage on both shell and tube sides.
The heat exchangers shall be provided with emergency drains, shell side safety
valves, and individual bypasses with manual valves. A minimum corrosion allowance
of 1.6 mm shall be provided. The tube bundle shall be of removable type. The tube
material shall be stainless steel, unless otherwise specified in the specifications.

12.

INSTRUMENTATION

12.1.

Signals
Electronic range of instruments shall be standardized on 4 to 20 mA signals. The
pneumatic range shall utilize signals of 0.2 to 1 kg/cm2 (g).

12.2

General Construction and Supply

All automatic controls, for Power Generation Plant shall be provided with electronic
instruments. Only the actuators shall be with pneumatic operation. The
instrumentation shall be suitable for full automatic operation of Power Generation
Plant and shall be suitable for hooking up to a centralised control system. The
centralised control system shall be DCS type, supplied by Employer.
All valves and dampers under automatic and remote control shall be motorised.
Standby units shall have automatic cut in/cut off.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 33 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
In addition to automatic and remote controls all indicating, integrating, recording
instruments, mounted on a panel for each Turbo-alternator are required.
Remote control instruments and indicating instruments on each Turbo-alternator unit
floor shall also be required.
Unless otherwise specified, all indicating and recording instruments shall be flush
mounting pattern with dust and moisture proof covers. Scales shall be of such
material that no decolourisation or peeling takes place with age under humid tropical
conditions.
The movements of all electrically operated instruments shall be of the dead beat type
and provided wherever necessary with an accessible zero adjustment. Where
appropriate, normal and other operating points shall be marked on the scale face.
All electrical instruments and meters shall comply with British Standards and unless
otherwise specified shall be of industrial grade accuracy.
Meters shall be calibrated to the appropriate grade in British Standards with due
allowance being made for the errors in the associated instrument transformers.
Calibration of all instruments shall be in the units of measurement specified in these
documents.
Temperature measurement for temperatures above 150
thermocouple type and below 150 0C of resistance type.

C shall be of the

Pressure gauges shall comply with requirements of British Standards. Stop Cocks
shall be fitted adjacent to each pressure gauge and isolating valves included where
pressure gauge piping is connected with the main system.
On-plant instruments and gauges are to be locally mounted and fitted in robust
cases.
13.

PUMPS
The head/flow characteristics of pumps shall be such that the head continuously
rises with decreasing capacity until a maximum head is reached at zero flow.
Maximum run-out flow should be at least 130 % of duty point flow.
The shut off head should be at least 1.1 times the duty point head and should not be
more than 1.2 times the duty point head.
The power curve should be non-overloading type with the maximum power occurring
at or near duty point or towards maximum run out flow.
NPSHR curve should be continuously rising in the range of operation, from the
minimum flow to the maximum flow in the range. Required NPSH values shall not
exceed available values over the entire range from minimum to rated flow.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 34 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
The efficiency curve should be fairly flat in the range of + 1 % of the Best Efficiency
Point (BEP) flow. The duty point of the equipment should preferably lie in this flat
region.
Unless otherwise stated, except for boiler feed water pumps, in the particular
specification, all centrifugal pumps shall run at speeds not exceeding 1500 RPM.
Maximum efficiency of the pumps shall be at 70-80% rated load.
Data for all pumps shall be tabulated indicating the following information:
a)
b)
c)
d)
e)
f)

g)
h)
i)
j)

Fluid to be pumped
Type of pump (e.g. split casing centrifugal)
Rotational speed
Impeller diameter
Power consumed and motor size
Materials of construction of :
i)
casing
ii)
impeller
iii)
shaft
iv)
neck ring
v)
bushes
Quantity of fluid to be pumped
NPSH required
Total net pumping head from all causes.
Bearing type and number.

For all pumps the following characteristic curves shall be furnished :

a)
b)
c)

Capacity against head

Capacity against efficiency
Capacity against power consumption

All pumps are to be supplied with water sealed packed glands unless otherwise
specified. Where fluid being pumped is water this may be fed from the pump
discharge into the gland. For pumps pumping hot water, condensate, Contractor
shall indicate whether separate gland cooling water is required and its quantity.
All centrifugal pumps shall be supplied fully assembled and aligned with electric
motor and shall be complete with coupling, common base plate, sole plates, coupling
guard, holding down and foundation bolts. Wherever required grouting pads shall be
supplied.
All positive displacement pumps shall be supplied with driving motor, gearbox,
couplings, base plate, sole plates for complete pump with drive assembly coupling
guards, holding down and foundation bolts. Wherever required grouting pads shall be
provided.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 35 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
14.

PAINTING

14.1

Painting
The equipment shall `be painted before dispatch to site. Painting specifications are
furnished hereunder.
To facilitate correct re-assembly at site, colour identification shall be applied to each
plant piece and its associated equipment of the Plant and parts, within a series or
train of similar pieces like Mills in the Milling tandem.

14.2

Preparation of Surfaces
Prior to treatment, the metal surface shall be cleaned of dirt and grease, layer of rust,
weld spatter etc. These shall be removed by pickling, power tool chipping, de-scaling,
sanding, wire brushing or grinding.
For wire brush cleaning, the wire brush shall be applied carefully over the surface in
vertical and horizontal direction.
For motor driven cleaning; brush, tube cleaner and disk sander shall be used. The
work shall be done in such a way that the brush is applied over two times on each
portion of the object to be treated. Either feather type or gear type cutter shall be
attached to the tube cleaner. Application of the cutter shall be done carefully in the
longitudinal direction except for unavoidable cases.

14.3

Recommended types of paints

Painting for Machinery, Equipment of the Plant, and Piping shall be applied as
follows :
a) Primary coat
b) Under Coat
c) Finish Coat

Red Oxide Paint

Pthalic Anhydride Paint
Pthalic Anhydride Paint

Corrosion protection (wherever required)

14.4

Pitch based resinous

Preparation of Paints
Dilution of paints shall be done in accordance with the paint manufacturer's
instructions utilizing the recommended thinners.
a)
b)
c)

14.5

Use of the paint thinner shall be limited to paint 1 : thinner about 10.
No other solution other than the thinner shall be used.
The prepared paints and the solvents shall be of the same manufacturer.

Method of Painting
Painting shall be done by brush painting or by airless spray.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 36 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Painting shall be done carefully by well experienced operators who know the
properties of paints sufficiently to obtain the best results.
Paint should be applied:
a)

The painting shall be carried out after successful completion of hydraulic and
leakage tests wherever applicable.

b)

Immediately after cleaning the metal surface, the first coating paint shall be
applied.

For the member of frame to be welded at site, area within 50 mm from the welding
lines shall be kept unpainted before welding.
The paints shall be stirred thoroughly and filtered before use.
Utmost care shall be taken not to spoil or damage the painted surface.
Surface and faces of the following items shall not be painted unless otherwise
indicated in the specification or instructed by the Project Manager.
-

Galvanized steel

Internal surfaces of vessels, tanks, heat exchangers, etc.

Machine finished surface where performance shall be adversely affected if

painted.

In the case of layered painting, the next painting shall be applied after cleaning the
surface of the previous layer and after a gap of minimum 8 hours drying.
The coating thickness of each layer shall be uniform. Notices, name plates, lettering,
gauges, sight glasses and similar items shall not be painted over and shall be
protected during painting by the application of masking tape and cleaned after
painting is over.
The paint work shall be stopped in the following cases:
14.6

When it rains
When the humidity is over 90 %
When the ambient temperature is high

Painted Film Thickness

The thickness of finish painted film shall be even. The standard thickness values to
be measured by net micro-thickness gauge shall be as follows:
-

Red Oxide paint

Pthalic acid resin paints

Over 125 (4 Coat Basis)

Over 150 (4 Coat Basis)

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 37 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
14.7

Interval of Each Painting

In accordance with the applicable specification and depending on the properties of
the paint, next coating shall be done after the necessary drying period of the paint as
instructed below:
a)

The optimum time shall be taken for drying, taking into consideration
temperature, humidity, ventilation, coating thickness, air pollution degree and
other related factors.

b)

No hardening or drying agents shall be used to shorten the drying hours

unless proper measures are taken. The following shall be the standard
intervals for painting.
-

14.8

Red Oxide Paints

Over 2 days and below 6 days
Pthalic acid resin
Over 1 day and below 6 days

Painting Schedule
The successful Bidder after award of Contract shall furnish for the Employer/Project
Managers approval, the painting schedule, covering all equipment under his scope
of supply, indicating the details like, cleaning, surface preparation, primer, final paint
colour, thickness etc.

15.

PACKING

15.1

General Equipment
All equipment of the Facilities shall be packed as necessary to provide adequate
protection during delivery to site.
The Plant and Equipment of the facilities shall be fully protected from weather and
corrosion by suitable paint, preserving grease or wax paper together with silica-gel or
any other protective hygroscopic material, as may be required.
The packing cases shall be lined internally with tarred paper or polythene and the lids
lined internally with roofing paper. The packing cases shall be of substantial timber
construction screwed or nailed together and shall be provided with skids preventing
direct contact with the ground or floor, and permitting the use of fork-lift trucks or
slinging for lifting by cranes.
Small items shall be gathered together and transported in packing cases.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 38 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
15.2

Spare Parts
The Contractor is required to submit as part of the Contract, essential spare parts
sufficient for two years operation of the Plant. These shall include spares necessary
for Commissioning of the Plant; all fast moving spares and spares considered
essential by the Manufacturer of respective equipment.
It shall be mandatory for the Contractor to supply manufacturing drawings and
specifications of fast wearing spare parts viz. all Journal, antifriction bearings and
thrust bearings, coupling components, V and flat belts, scaling strip and caulking
material, gland with springs, O ring and oil seals, springs; air, oil, water filter
elements, moving and stationary contacts, fuses, electronic components, etc All
spares supplied shall be strictly interchangeable with the corresponding parts
supplied with the original plant, and shall be treated and packed for long storage
under the climatic conditions prevailing at the Site.
Each spare part shall be clearly marked or labelled on the outside of its packing with
its description and purpose. When more than one spare is packed in a single case or
other container, a general description of its contents shall be listed.

16.

THERMAL INSULATION

16.1

General
These Specifications cover the general requirements for insulation work.
The Contractor shall refer to the relevant Indian Standards for selection, inspection
and application of the Insulation. In case of doubt, the matter shall be referred to the
Project Manager for any clarification. The insulation shall be provided for all
equipment above 60oC.

16.2

Insulation Materials
The Contractor shall supply all material, consumables, labour, tools and equipment of
the Plant necessary for executing the insulation work.
Insulating material such as Glass wool or Mineral wool shall be selected depending
upon the temperature of fluid handled. Form of insulting material either blankets or
loose shall be selected depending on shape of the equipment of the Plant to be
insulated.
The Contractor shall supply insulating materials for the Work as specified in the
relevant British Standard or described below, which ever thickness are higher.
a)
b)
c)
d)

Mineral wool in thickness specified below.

Glass wool blanket, 75 mm thick
Galvanized chicken wire Honey comb mesh, 22 SWG
Galvanized steel wire 18 SWG for equipment of the Plant, and 20 SWG for
piping

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 39 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
e)
f)
g)
h)
16.3

Insulating cement
Aluminium sheet metal for cladding 20 SWG
Cadmium plated sheet metal screws for securing cladding on steam turbines
Black washers for attaching binding wire to vessels

Insulation of Piping
Pipe insulation more than 75 mm shall be installed in multiple layers with joints
staggered around the circumference.
All fittings including valves and flanges shall be insulated. Clearance for removal of
flange bolts shall be provided. After insulating valve or other piping speciality, wrap
flange with Aluminium sheet and insulate the joint.
Pipelines shall not be insulated before the system is hydraulically tested and
approved by the Project Manager. Moulded insulation shall be secured to the pipe
with binding wire.
When insulation mat is split and wrapped around the pipe, joints shall be painted with
insulating cement to form a smooth, neat surface.
Insulation for valves and other piping specialities shall be securely wrapped with
chicken wire and coated with insulating cement.
Piping systems shall be clad with Aluminium sheets fastened by sheet metal screws.
On horizontal pipe runs, the joints of the cladding shall be at the bottom of the pipe.

16.4

Insulation of equipment
Glass wool blankets shall be cut and fitted to the contours of the equipment and
secured to chicken wire mesh so that each insulating pad can be removed and
reinstalled.
Fabricate sheet metal housing in sections and secure with sheet metal screws. The
housing shall be designed so that it is sturdy and can easily be removed and
replaced.

16.5

Insulation of Vessels
Hooks, rolled angles, flats are to be welded to the equipment of the Plant being
insulated, for securing and supporting the insulating material and Aluminium
cladding.
Washers are to be welded to the vessel surface to attach binding wire used to secure
insulating material to vessel.
Install blanket insulation and secure with binding wire.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 40 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
Aluminium sheet Cladding is to be installed over the insulating material and secured
to supports with sheet metal screws. The cladding shall be designed and installed so
that the joints are watertight.
16.6

Insulating Material Thickness

The following table indicates the minimum thickness of insulating material Mineral
wool of 120-125 kg/cum density; for piping, vessels and equipment of the Facilities.
Insulation thickness is in millimetres and temperatures in C.
Pipe Dia.
in mm

12
20
25
40
50
75
100
150
200
250
300
Surfaces

65
to
120

121
to
148

149
to
203

204
to
259

25
25
25
25
25
25
25
25
40
40
40
50

25
25
25
25
25
30
30
40
50
50
50
62.5

25
30
30
30
30
40
45
59
50
62.5
62.5
75

30
30
30
40
40
45
45
50
50
62.5
62.5
75

Temperature in C
260
315
371
to
to
to
314
370
425
30
40
50
50
50
50
62.5
62.5
62.5
75
87.5
87.5

17.

SUBMITTAL OF DRAWINGS AND DOCUMENTS

17.1

Submissions along with the bid

40
50
50
50
50
62.5
62.5
62.5
75
75
87.5
100

40
50
50
62.5
62.5
62.5
62.5
75
87.5
87.5
100
100

426
to
481

482
to
537

50
50
50
62.5
62.5
75
75
87.5
100
100
100
150

50
50
62.5
62.5
62.5
75
87.5
87.5
100
100
125
200

The bidder is required to submit with the Bid all technical information, in the form of
drawings, catalogues, technical leaflets, broachers, of Plant and Equipment offered
to be supplied by him for understanding and evaluation of his offers. All such
drawings and technical literature submitted shall be properly listed and indexed.
Following drawings and data sheets are specifically required to be submitted for the
option/s for which the bidder is bidding.
1.

General arrangement drawing with cross sectional elevations of Power

Generation Plant.

2.

Layout plan of the Power Generation Plant with accessories at ground and
other floor levels. The Power Generation Plant along with all the accessories
shall be accommodated in the space earmarked in the enclosed layout
drawing.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 41 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

17.2

3.

Foundation plan of Power Generation Plant, cooling tower, air compressor

etc.

4.

PI diagrams for instrumentation with terminal points and GA of instrument

panels.

5.

Single Line Diagram showing all relevant details, relay details.

6.

General arrangement, foundation layout drawings of LV, HV Switchgear

7.

List and make of bought out items

8.

Bar chart showing plant design, equipment delivery, erection, startup,

commissioning, and performance trial schedule.

9.

Performance of TA set under various modes of operation.

Submittals after the award of the Contract

The following drawings for the Option selected are to be submitted to the employer
within 8-10 weeks of signing of the contract.
1.

Layout of Power Generation Plant

2.

Detailed cross sectional elevations of the Power Generation Plant and other
equipment of Power Generation Plant.

3.

Detailed ground floor plan for the Power Generation Plant together with
berthing diagrams, equipment disposition, static and dynamic loadings at
various levels, with sufficient technical details to permit design of Civil
engineering works.

4.

Detailed Power Generation Plant floor plan at different levels showing

equipment disposition, together with berthing diagrams, static and dynamic
loadings at various levels, cut outs; openings and through holes, piping,
electric cabling, instrumentation cabling etc.; location of MCCs, lubrication
and control oil skid, and other details.

5.

Drawings showing exact location of terminal points of following facilities from

ground level.

5.1

Steam

5.2

Electrical power
Supply, Single Line Diagram showing relays, meters and switchgear

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 42 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
5.3

Cold/Hot Water
Cooling water inlet and outlet of cooling systems
Condensate of turbine condensers.

17.3

5.4

Drains

5.5

Electronic circuit diagrams for instrumentation with control philosophy.

6.

Any other drawings required by the Employer up-to commissioning stage of

the Power Generation Plant

7.

Manufacturing drawings of fast moving spares

8.

Single Line Diagram for Electrical system

9.

Detailed drawings of all the Electrical equipment in the scope.

10.

Detail drawings and data sheets of all the accessories and ancillaries of turbo
alternator, cooling tower, EOT crane, air compressor, HVAC system etc.

11.

G A, Foundation drawings of LV, HV Switchgear.

12.

Piping layout of steam piping, lub oil system, condensate piping etc.

13.

Bill of Material, list of manufacturers of bought out items, test certificates

Other Submittals
Six sets of installation, instructions, operating and maintenance instruction manuals,
properly bound and indexed for easy reference, shall be forwarded to the Employer
at the time of delivery of the related items of plant and including As built drawings of
the facilities generally described as below, but not limited to;
1)

General assembly drawings of Power Generation Plant station complete

supplied and installed by the Contractor within the terminal points of the
contract.

2)

General assembly drawings of each of the auxiliaries supplied and installed

by the Contractor.

3)

Sub-assembly drawings of equipment, systems and components supplied by

the Contractor.

4)

Piping layouts as laid.

5)

Wiring Diagram for Instrumentation: Wiring diagrams for instrumentation shall

indicate wire numbers, drawn as viewed from front or back of panels.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 43 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

18.

6)

Operating / Instruction manuals of each of the equipment supplied by the

Contractor.

7)

Test certificates (both material and fabrication) of major components of the

equipment manufactured / procured by the Contractor.

8)

Shop test data sheet of equipment load test; and characteristic curves

9)

Catalogues, technical leaflets of items like, insulation material, instrument

data sheets

10)

Spares list with detailed specification and catalogue numbers.

11)

Where specialized maintenance manuals are not available, standard

manufacture s literature shall be provided.

12)

As built drawings of all electrical equipment, Single Line Diagram, Relay logic
trip settings, trouble shooting guide, cable schedules, cable layouts etc.

ENGINEERING DRAWINGS
The Contractors drawings shall be clear and of good quality. Reproducible shall also
be of sufficient clarity so that under available reproduction process good prints are
taken from such tracings. The Contractor shall submit drawings covering the entire
extent of work including site assembly and erection and also the flow diagram.
Every portion of work shall be properly illustrated and the subcontractors drawings
submitted shall be only for back up information. The Contractor on his drawings shall
reproduce the information provided on the subcontractors drawing so that proper
physical, mechanical and electrical relationship of the whole of the works is clearly
illustrated. Only relevant standard shall be followed for drawing symbols for
electrical, mechanical and instrumentation.
Drawings shall be sized according to ISO series A and the sizes A 0 to A 4 are
detailed below (dimensions in mm)
Drg.
Sheet
Size
A0
A1
A2
A3
A4

Top
Bottom
20
14
10
7
7

Normal width of Borders

& Left hand side
Right
side
40
28
20
20
20

16
12
8
6
6

Dimensions of
hand rectangular
frame
801 x 1133
566 x 801
400 x 566
283 x 394
283 x 184

Digitized / Soft copies of all the drawings, single line diagrams and flow diagrams,
shall be submitted on Compact Discs.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 44 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
19.

SPECIAL TOOLS AND TACKLES

For operation and maintenance of the plant all special tools and tackles required
shall be included in the scope of the supply of the plant. These tools and tackles shall
be used by the Employer after commissioning of the plant. During erection, the
Contractor shall use his own tools and tackles.

20.

MATERIAL HANDLING
The scope of work under this specification shall cover unloading from road carrier
from Djibouti to Project site, stacking, verification, record specification, record
keeping and transportation from store to erection site.
It shall be the responsibility of the Contractor to examine the package on arrival and
bring to the notice of the Employer for any loss and damage.
The Contractor shall maintain accurate and exhaustive record detailing out a list of all
the equipment received from him. All the material will be stored as per
manufacturers recommendation.
It is the responsibility of the Contractor to apply preservative on equipment in store
during storage, erection and commissioning. The materials will be stored on sleepers
so that it does not touch the ground.

21

ERECTION
The Contractor shall provide all fixtures, scaffolding materials, concrete block sports,
steel structure required for temporarily sporting the pre-assembly or checking and
welding for lifting and handling during pre-assembly erection.
The Contractor shall check the various equipment foundations for correctness with
respect to level, orientation, dimensions etc. before erection.
The erection of the equipment shall be carried out as per quality plan provided by the
Contractor, but approved by the Employer. Necessary protocols and records for
inspection observation shall be maintained on the format provided.

22.

PROGRESS REPORTING OF ERECTION WORK

The Contractor shall prepare monthly progress reports, manpower report, materials
report and other reports considered necessary. The progress report shall indicate the
progress achieved against planned with reason indicating delays if any and
corrective measures to make good slippage of lost time.
The manpower report shall indicate the manpower deployed category wise daily
specifying also the activity in which they are deployed.
Progress review meetings shall be attended by the Contractor to discuss the
schedules, programmes and action taken to achieve the progress.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 45 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
23.

CONTRACTORS TOOLS AND TACKLES

The Contractor shall provide all tools and tackles required for successful and timely
completion of work. For the movement of cranes, it may become necessary to lay
sleeper beds for obtaining level safe approach for use of equipment. The Contractor
shall arrange all the materials for this.
All the Tools & Tackles shall be reliable/proven/tested with necessary test
certificates. The Contractor shall deploy the experienced operator and technicians for
operations and maintenance of these tools & tackles during erection.
All the tools and tackles including wire ropes, slings, shackles and electrical operated
equipment shall be tested before actually put in use.
The Contractor shall provide all consumables required for erection, commissioning
and testing.
Storage of electrodes will be done in control humidity room as per manufacturers
recommendation. All electrodes will be dried in an electrode drying oven to the
temperature and period specified by the manufacturers.
All services including labour shall be provided by Contractor for handling, filling,
emptying, re-filling etc.

24.

INTER CHANGEABILITY
All similar items of plant including spare parts shall be inter changeable and care
shall be taken to ensure that all spare parts fit accurately in place.

25.

COMPATIBILITY
The Contractor shall be entirely responsible for ensuring the compatibility of each
item of the plant, associated.

26.

OILS AND LUBRICANTS

The Contractor shall submit a list of oils and lubricants of approved grades and type
and also recommend the quantity required for operation of one complete season. He
shall provide 110 per cent of all lubricants, oils and greases required for the initial
filling, lubricants shall be of approved grades and types.

27.

GUARANTEES

27.1

Guarantee for Capacities

The Contractor must guarantee that the processing capacity and efficiency of all units
correspond to the conditions as specified in the Technical Specifications and
Drawings, Section-VI and as indicated in Section VII- Forms.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 46 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
27.2

Guarantee for Performance

The Contractor is required to guarantee that the plant offered shall fulfil all the
performance parameters as specified in Section VI, Part- G, of this bid document.
For non compliance of performance, Clause 26, GCC shall be applied.

28.

EQUIPMENT CODE NUMBERS

Detailed specification of all equipment constituting the plant is presented in Part D,
Section- VI of bid documents. Equipment code No. mentioned in Part D, Section - VI
of this document have to be adopted in all documents from bidding stage to
acceptance stage.

29.

QUALITY ASSURANCE, TESTING & INSPECTION

29.1

Quality assurance programme

To ensure that the equipment and services under the scope of this Contract whether
manufactured or performed within the Contractors works or at his Sub-Contractor's
premises or at Employers site or at any other place of work are in accordance with
specifications, the Contractor shall adopt a suitable quality assurance programme to
control such activities at all points necessary. Such programmes shall be outlined by
the Contractor and shall be finally accepted by the Employer/Project Manager after
discussions, before the award of the Contract. A quality assurance programme of the
Contractor shall generally cover the following:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)

Contractors organisation structure for the management and implementation

of proposed quality assurance programme.
Qualification data of his key personnel.
The procedure for purchase of materials, parts, components and selection of
Sub-Contractor's services including Contractor analysis, source inspection,
incoming raw material inspection, verification of materials purchased, etc.
System for shop manufacturing and site erection controls including process
controls and fabrication and assembly controls.
Inspection and test procedure both for manufacture and field activities.
Control of calibration and testing of measuring and testing equipment.
System for indication and appraisal of inspection status.
System for quality audits.
System for handling, storage & delivery.
System for authorizing release of manufactured product to the
Employer/Project Manager.
System for maintenance of records.
A quality plan, detailing out the specific quality control procedure adopted for
controlling the quality characteristics, relevant to each item of
equipment/component, shall be furnished.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 47 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
29.2

Quality assurance documents

The Contractor shall be required to submit the following Quality Assurance
Documents preferably three (3) weeks before dispatch of the equipment:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)

All non-destructive examination procedures, stress relief and weld/repair

procedure actually used during fabrication.
Welder and welding procedure qualification certificates.
Welder identification list, listing welder's and welding operator's qualification
procedure and welding identification symbols.
Material mill test reports on components as specified by the specification.
The inspection plan with verification, inspection plan check points, verification
sketches, if used, and method used to verify that the inspection and testing
points, in the inspection plan were performed satisfactorily.
Sketches and drawings used for indicating the method of traceability of the
radiographs to the location on the equipment.
Non-destructive examination result report.
Stress relief time temperature charts.
Factory test results for testing required as per applicable codes and
standards referred in the specification.
Insulation tests, earthing tests
Transformer oil test reports
Primary injection and secondary injection test reports on various circuit
breakers and protective relays.

The Employer / Project Manager shall be given reasonable notice of all tests, shall
have the right to witness all tests, and shall have access to the works of Contractor
and Sub-Contractor at all times for the purpose of carrying out system audits,
conducting quality surveillance, witnessing of tests and inspections etc.
The Employer/Project Manager or his authorised representative may periodically
check the work and the method of operation to assure that quality control practices
are being followed. At the time of Employers visit all quality documentation pertaining
to test, qualifications, inspections, etc., shall upon request be made readily available.
All reports of tests and inspections as per Quality Control Practices and Quality Plans
shall be furnished to the Employer/Project Manager.
29.3

General requirements for testing and inspection.

a)

All equipment covered under these specifications shall be subject to

inspection and tests by the Employer/Project Manager or his authorised
representative during manufacturing and erection & commissioning. The
approval of the Employer/ Project Manager or passing of such inspection of
test will not, however, prejudice the right of the Employer to reject the
equipment if it does not comply with specifications when erected and does not
give complete satisfaction in service. The cost of all such tests shall be borne
by the Contractor.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 48 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT

29.4

b)

The Contractor shall prepare quality plan in two sections, one for quality
control at shop and the other for quality control at site. The Contractor shall
furnish the quality plan for shop activities indicating stage-wise all tests and
inspections to be carried out right from raw materials stage, manufacturing
assembly, performance and final inspection.

c)

Testing/Inspection procedures indicated herein to give a basic quality control

programme to be followed by the Contractor are in no way comprehensive
and in no way form a complete quality assurance programme. Any other
inspection stages not mentioned in these Articles/Clauses but required as per
the Contractor's quality assurance programme or the Employer/Project
Manager shall be deemed to be included. Any tests necessary from
operation, safety and reliability point of view shall also be included. Such
quality plan shall be subject to the approval of the Employer/Project Manager.

d)

The Contractor shall furnish the quality plan indicating all tests and
inspections, procedures and acceptance norms to be adopted for assuring
quality for each piece of equipment under this specification from the receipt of
material at site, during storage, erection, pre-commissioning to final run and
commissioning of the plant. These procedures shall necessarily include all
checks/tests conducted at site for preservation, pre-assembly, alignment,
positioning of equipment, foundation preparation, grouting, welding/bolting,
heat treatment, non-destructive examination, hydraulic test, performance
tests, etc. The above shall be submitted to the Employer/Project Manager for
his review, comment and acceptance.

e)

All fabrication, manufactured items (including any proprietary item) motors,

gears, gearboxes, fans, switches, etc., shall be subjected to stage-wise
inspections and tests as per the relevant standards at the manufacturer's
works before despatch. It shall however, be the Contractor's responsibility to
supply all the materials as per specification and standard herein mentioned.
All the items falling under the purview of Boiler and Pressure Vessel
Regulations shall be inspected and approved by the appropriate authorities of
Boiler Inspectorate at the site as well as at shop.

Shop Tests
Shop tests shall include all tests to be carried out at Contractor's works, at works of
his Sub-Contractor and at works where raw material used for manufacture of the
equipment is manufactured.
Such tests shall include electrical, mechanical, performance and hydraulic tests in
accordance with relevant standards called for under these specifications to ensure
that the plant being supplied fulfils the requirement of the specifications. For
equipment not covered out shall be in accordance with Contractor's quality control
programme to be agreed to between the Contractor's and the Employer.
All material shall be of tested quality, supported with duly correlated test certificates,
and wherever called upon by the relevant Regulations or by the design code, the test

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 49 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
pieces shall be prepared and tested as per such regulations/code. If the
Employer/Project Manager is furnished with certificate particulars of tests, which
have been carried out by the Contractors of material, the Employer may, at his
discretion, dispense with separate test, which he would witness.
All welding procedures adopted for performing welding work shall be qualified in
accordance with the requirements of Section IX of ASME or by any equivalent design
code.
These welding procedures shall clearly state the type of material, thickness, the joint
details, the repeat temperature maintained, the post weld heat treatment given, the
welding current and voltage used during qualification of welding procedures.
For all pressure parts and high pressure piping welding, the latest applicable
requirements of the prevailing regulations in Employers/Contractors country must
also be complied with.
All records of the welding procedures, the welders qualifications, tests and welders
performance details for the work performed under these specifications shall be
maintained by the Contractor and be made available to the Employer on request.
29.5

Heat Treatment
Preheating and post weld heat treatment operations including stress relieving shall
be performed in accordance with the requirements of the applicable code.
Complete recording of the temperature throughout the stress relief cycle of the
material and weld subject to heat treatment shall be made. The thermocouples shall
be placed in direct contact with the job for recording the metal temperature during
heat treatment.

29.6

Notification for tests and inspection

Readiness to carry out the following tests and inspections at the site shall be
notified to the Project Manager.
(a)

Driven units shall be notified for inspection with couplings and any connecting
pipes unbolted and drives then checked for correct rotation.

(b)

Pressure tests of all piping shall be notified.

(c)

Running tests of all machinery shall be notified, and the no.1 amperages of
electrically driven units noted. All machinery shall be run for 30 minutes on
no load, except pumps which shall wherever possible run for 30 minutes
pumping water. Should this not be possible, the pumps will not be test run.

(d)

All oil and greases systems and sumps shall be notified when the final
flushing out is carried out prior to first filling. Flushing oil and first fills are
included in the plant supplies.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 50 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
(e)

The inspections and tests required by Ethiopian regulations and by the

Employers insurers shall be notified as above for machinery pressure
vessels, Mill house hoists & cranes .

(f)

All unpressurized tanks and vessels, shall be filled with water and notified as
above.

(g)

Pipe runs shall be notified as above with free ends, and all cold draw gaps
shall be similarly notified without bolts fitted. All drain pots, vessels, traps and
associated piping then shall be opened, cleared of foreign material and
notified as above. Process, water and air lines shall be run through by utilizing
their pumps head- tanks or compressors for 8 hours or such short time as the
Project Manager might accept.
Tanks vessels drain lines and strainers shall be then opened, cleared of
foreign materials and notified as above. Instrument air lines shall be
pressurized to the full air pressure and soap bubble or similar tests notified as
above.
The alignment and plumb of all structural steel shall be notified as above
before final grouting takes place. All steel work bolting shall be notified as
above before covering with concrete, masonry or other material takes place.

(h)

The Contractor shall provide all things and personnel necessary to carry out
these tests.

With respect to steam for testing, the Contractor shall co-ordinate with the Employer
through the Project Manager for steam supply to be provided by the Employer.
29.7

Tests on Other Equipment of the Facilities at Site

As and when erection of equipment of the Plant are completed, tests shall be
conducted, as appropriate which would include but may not be limited to the
following. The checks and tests shall be conducted in presence of the Employer's
and the Contractors representative.
a)
b)
c)
d)
e)
f)
g)
h)

29.8

Dimensional and quantity checks

Conformity to specifications
Hydraulic tests of tanks, vessels, pipelines etc.
Mechanical tests on rotating machinery like pumps, etc.
Standard running tests on rotating mechanical and electrical machinery
Vibration tests on rotating mechanical and electrical machinery
Measurement of surface temperatures of insulation.
No load test on other machinery drive system.

Performance tests of other equipment

Such performance tests shall be conducted in accordance with procedures
prescribed in the relevant British Standard Specifications and Codes of Practices or

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 51 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
its equivalent. Where BS or its equivalent do not provide for relevant test
procedures, the Contractor shall submit to the Employer, for approval, test
procedures to be adopted. In such cases the Employers decision shall be final.
29.9

Inspection, testing and Inspection certificates

a.

The Employer, his duly authorised representative and/or an outside

inspection agency acting on behalf of the Employer shall have access at all
reasonable times to inspect and examine the materials and workmanship of
the works during its manufacture or erection and if part of the works is being
manufactured or assembled on other premises or works, the Contractor shall
obtain for the Project Manager and for his duly authorised representative
permission to inspect as if the works were manufactured or assembled on the
Contractor's own premises.

b.

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

c.

The Employer/Project Manager shall within seven (7) days from the date of
inspection as defined herein give notice in writing to the Contractor, for any
objection to all or any equipment and workmanship, which in his opinion is not
in accordance with the Contract. The Contractor shall give due consideration
to such objections and shall make the modifications that may be necessary
to meet the said objections.

d.

When the factory tests have been completed at the Contractor's or SubContractor's works, the Employer/Project Manager shall issue a certificate to
this effect within seven (7) days after completion of tests but if the tests are
not witnessed by the Inspector, the certificate shall be issued within seven (7)
days of the receipt of the Contractor's Test Certificates by the
Employer/Project Manager Completion of these tests or the issue of the
certificate shall not bind the Employer to accept the equipment should it on
further tests after erection, be found not to comply with the Contract.

e.

In all cases where the Contract provides for tests whether at the premises or
works of the Contractor or any Sub-Contractor, the Contractor, except where
otherwise specified, shall provide free of charge such items as layout,
materials, electricity, fuel, water, stores, apparatus and instruments as may
be reasonably demanded by the Employer or his authorised representative to
carry out effectively such tests of the equipment in accordance with the
Contract and shall give facilities to the Employer or to his authorised
representative to accomplish testing.

J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

GENERAL TECHNICAL CONDITIONS (GTC)

Section VI-C
Page - 52 / 52

BID DOCUMENT FOR

POWER GENERATION PLANT
f.

30.

The inspection by Employer/Project Manager and issue inspection certificate

thereon shall in no way
limit the liabilities and responsibilities of the
Contractor in respect of the agreed quality assurance programme forming a
part of the Contract.

CONTRACTORS LABOUR
The Contractor shall arrange the skilled, semi-skilled and unskilled workmen required
for the works for handling erection, testing and commissioning. Fully trained and
competent men with previous experience on job shall be employed. They shall hold
valid certificate wherever necessary.
The supervisory staff employed by the Contractor and his Sub-Contractor shall
ensure proper out-turn of work and discipline on the part of labour put on the job.
Safety and co-ordination with Employer and Contractor shall be their prime
responsibility.
The Contractor shall furnish labour and progress reports as desired by the Employer.
The supervisory staff shall execute the work in the most substantial and workmen like
manner in the stipulated time. Accuracy of work and aesthetic finish are essential
part of their work.
It shall be the responsibility of the Contractor to engage his workmen in shift or
overtime basis for achieving the targets set by the Employer.

31.

TRAINING OF EMPLOYERS PERSONNEL

Contractor shall train Employers personnel on operation and maintenance of the
equipment within battery limits. The Bidder in his bid shall indicate the following;

Training Strategy for the Personnel of Employer

Type and details of training which he proposes for Senior Supervisory
Personnel both outside Ethiopia and at Site and indicating the duration;
Type and details of training which he proposes to impart to junior level
personnel outside Ethiopia and at site.

The cost of such training is to be indicated in price schedule.