All Specs Latest - 16th June 2017

SHIMIZU CORPORATION INDIA PVT LTD Cilent
No.2, Prestige Emerald, 5th Floor, Levelle Road,, Madras Bank Road, Bangalore-560 001, India Logo
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3.6 Technical Specification.
TECHNICAL SPECIFICATION
For
Electrical Works
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CONTENTS
BASIC ELECTRICAL REQUIREMENTS
HIGH VOLTAGE,LOW VOLTAGE CABLES
TRANSFORMER
11KV/HT PANELS
LT SWITCHBOARDS/PANELS
BUSDUCTS
UNINTERRUPTIBLE POWER SUPPLY SYSTEM
CABLE TRAYS/RACEWAYS
CONDUTING
WIRING FOR LIGHTING & SMALL POWER
MCBs, RCDs, RCBOs, ISOLATORS & MCB DISTRIBUTION BOARD
LUMINAIRES
EARTHING
LIGHTNING PROTECTION
FIRE BARRIERS
MISCELLEANEIOUS ITEMS
TESTING OF INSTALLATION
COMMISSIONING CHECK LIST
APPROVED PREFFERED MAKE OF MATERIAL

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I Basic Electrical Requirements
1.0 General
1.1 Scope
The scope of work covers complete electrical installation system for all buildings
including but not limited to:
 Supply, storage, installation, testing and commissioning of all equipment,

components, accessories as per the specifications and approved make of
materials list.
 Organize for day to day adequate labor, tools, machinery andtesting

instruments required for the unhampered progress of works, operation of the
building..
 Day to day supervision of the installation work by at least 1 full time

competent & experienced Engineer having minimum qualification of Diploma
in Electrical Engineering with at least 10 years experience in similar
installations and holding valid supervisory permit issued by the State
Government apart from supervisors.
 Civil works such as excavation for cable trenches, making openings in the
walls wherever required, Plastering to the required quality.
 Co ordination for construction of HT/LT panel, transformer foundations,

Completing dependency works for unhampered progress of works etc,
 Any work which can be reasonably inferred as necessary for the safe,
satisfactory operation whether such work is specified or shown on the
drawings or not.
Testing and commissioning of the installation in accordance with the relevant/recent

Indian Standard Codes of Practice.
 House keeping during the Execution of the contract.

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 Shall be responsible for the safe custody of any free issue equipment till they
are installed, Tested, commissioned and handed over.
 Shall submit samples of all discrete components, like conduits, switches,

wires, cables, wire ways & earthing materials, Light Fittings etc., for the
approval of main contractor. The samples submitted shall conform to the
relevant specifications and approved makes specified.
 Shop drawing/method statements shall be prepared before starting the work

for approval from the concerned for relevant/specific items/equipment.
 All equipment included in scope of supply shall be tested at

Manufacturer's facility, before delivery and necessary Test Certificates shall be
submitted to the main contractor.
 Shall get all performance tests as per specification after installation carried
out by individual testing agency in the presence of the main contractor, site
team and shall bear all expenses for such tests.
 Liaisoning with Local Electrical authority/CEIG and other statutory

authorities as required ,for power sanction, obtaining power sanction,
obtaining authority approvals for the installation.
1.2 Licensed Electrical Contractor

All work shall be carried out by a Electrical Contractor who is approved by the Main
Contractor and who possesses a valid registered Class-I Electrical Contractor's
license, having employed licensed Supervisors and licensed Electricians, Helpers, as
required. Required 3 years of documented experience at least.
1.3. STANDARDS:
The installation shall conform to the requirements of latest edition of Indian
Electricity Rules, NEC, NBC, Supplementary regulations of local statutory bodies,
power supply authorities and following Indian Standards.
All the materials shall carry ISI mark unless otherwise agreed.
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1.3.1 H.T SWITCH GEARS
IS : 2099 : Bushings for alternating voltage above 1000V.
IS : 2516 : AC Circuit Breakers
IS : 2705 : Current Transformers
IS : 3156 : Voltage Transformers
IS : 3427 : Metal enclosed switch gear & Control gear for

Voltage Above 1000V but not exceeding 11000V
IS : 6875 : Control switches for Voltages up to and including

1000V AC and 1200V DC.
IEC : 60056 : HV Alternating current circuit breakers.
IS : 2147 : Degree of protection for enclosure
IS : 3842 : Specification for HRC fuse link up to 650V.
1.3.2 DISTRIBUTION TRANSFORMERS
IS : 2026 Part-I to IV, : Power Transformers IEC : 76 BS-171
IS : 3939 : Fittings and Accessories
IS : 6600 : Guide for Loading of oil immersed Transformer
IS : 8468 : On Load Tap Changers
IS : 10028 Part-II : Installation & Maintenance of Transformers
IS : 335 : Insulating oil.
IS : 2099 : Bushing for alternating voltage above 1000V.

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IS : 4257 : Porcelain bushings for Transformer
IS : 2705 : Current Transformers
IS : 8478 : Application guide for tap changers.

1.3.3 L.T SWITCH BOARDS
IS : 13947(Part-II) : Air circuit breakers & MCCB’s
IS : 13947 : Air break contactor
IS : 4237 : General Requirements for Switchgear
IS : 2147 : Degree of protection provided by enclosure for

Switchgear
IS : 8623 : Factory built assembly of switchgear & control gear.
IS : 1248 : Electrical Indicating instruments
IS : 2705 : Current Transformer
IS : 3156 : Potential Transformer
IS : 375 : Marking and arrangement of Bus bars.
IS : 8828-1996 : MCB (Miniature circuit breakers)IEC : 898-1995
IS : 12640-2000 : RCBOs/RCCBs IEC:61008-1996,IEC-61009-1
IS : 13947, Part-III : Load Break Isolators IEC 947-3
IS : 13779I : kWH Meter IEC –1036
IS : 6875 : Indicating lamps
IEC:60255, IEC:61000 : Protection Relays IS3231, IS8686
IS : 2959 : AC Contactors up to 1000V.
IS : 4047 : Air break switches for Voltage not exceeding 1000V.

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IS : 1822 : Motor duty switches.

IS : 12021 : Specification for control Transformer
IS : 3842 : Specification for electrical relays for AC system.
IS : 3231 : Electrical Relays for power system protection
1.3.4 EARTHING AND LIGHTNING PROTECTION
IS : 3043 - 1987 : Earthing
IS : 2309 – 1989 : Code of Practice for Lightning Protection
IS : 2629 - 1985 : Recommended practice for hot dip galvanized of
iron and steel.
IEEE : 80 : IEEE guide for safety an AC substation grounding
1.3.5 RELAYS AND METERS.

IS-3231, IEC-571-1 : Earth Leakage Relay
IS-8686, 3231 : Earth fault relay, Frequency relay, AC Voltage
relay Phase Failure Relay
IEC-60255, 60068 : Over current & Earth fault relay
1.3.6 CAPACITORS
IS : 2834 : Shunt Capacitors for power system
IS : 3231 : Electrical relays for power system protection
IS : 2705 : Current transformer
IS : 1248 : Direct acting electrical indicating instrument.
IS : 3202 : Code of practice for climate proofing of electrical eqpt.
IS : 2147 : Degree of protection
IS : 375 : Marking & Arrangement of switchgear, Bus bars,
Mai Connection and Auxiliary Wiring.
IS : 7752 : Guide for improvement of power factor improvement.
1.3.7 LUMINAIRES AND LAMPS

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IS : 3646 (Part-2) 1966 : Interior Illumination

IS : 10322 (Part-5 Sec-1) – 1987 - General Purpose Lighting
IS : 10322 (Part-5 Sec-2) – 1987 - Recessed Luminaries
IS : 2418 (Part-1) 1977 – General Lighting Service
IS : 12449 (Part-1) – 1988 - General Safety Requirements
IS : 13021 - Electronic Ballasts.
IS : 8913 - Methods of measurements of lamp temp. rise.
IS: 5077 - Decorative Light Fittings
1.3.8 MCB DBs AND MCB, RCBO, ELCB & SURGE SUPPRESSOR
IS : 8828 – 1996, IEC – 898-1995 - For MCBs
IS : 12640 – 1988, IEC-1008 – 1996 - For RCCB/RCBO
1.3.9 GENERAL
a) All equipment and HT/LT installation work shall generally

conform to the requirements of relevant Indian Standards and Codes of
Practice mentioned below.
b) All the materials shall carry ISI mark unless otherwise agreed.
c) The installation shall further conform to the requirements of Fire

Regulations.
d) Indian Electricity Rules (1956) amended up to date.
e) National Electrical Code 1985.
f) IS:732 - Code of practice for Electrical Wiring :

1989 Installation (System Voltage below 650V)
g) IS:2309 - Protection of buildings against lightning.

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The installation shall conform in all respects to the Latest Indian Standard Code of
Practice for Electrical Wiring Installation also should conform with the current
Indian Electricity Rules and the Regulations and requirements of the Local Electric
Supply Authority / Local Electrical Inspectorate . Wherever this specification calls for
a higher standard of materials and /or workmanship than those required by any of
the above Regulations, this Specification shall take precedence over the said
Regulations and Standards.
In general, the materials, equipment and workmanship not covered in the above shall
conform to the latest Indian Standards.
1.4 DRAWINGS:
The contractor shall examine all electrical drawings before starting the work and
report to the main contractor for any discrepancies which in his opinion will hamper
his work and get them clarified.
The contractor shall prepare shop drawing for the equipment in scope and same
should be duly approved by the main contractor for records.
The contractor shall prepare all drawings required to be submitted to the local
electrical authority inspectorate or any statutory authority to obtain any
approval/power sanction.
1.5 Documentation
The indication and / or description of and item on the drawings or in the
Specifications, unless otherwise specifically stated, imply an instruction to supply
and fix such items.
Notes on drawings referring to individual items of work generally take precedence

over specifications, however all discrepancies shall be referred to the Main
Contractor before ordering materials or commencing work.
Drawings show general run of cables, approximate locations of outlets and

equipment, utility symbols and schematic diagrams of no dimensional significance.
Refer to the Architectural drawings for locations and also obtain approval from the
Main Contractor wherever dimensions are not shown, or locations cannot be
determined from the drawings. Do not scale drawings to obtain locations.
1.6 Design Criteria
Electrical materials and equipment shall comply in all respects, as a minimum to the
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latest Indian Standards Institution's recommendations.
Should any difference arise between ISI and the specification, the requirement of the
Specification shall prevail.
The components of sub-main switchboards, distribution boards and other electrical
equipment shall be clearly labeled in English.
Distribution boards shall have circuit schedules fastened to the inside cover of the
board showing rating of the circuit breakers, type and number of points and their
connected loads.
2.0 Engineer / Foreman / Supervisor
2.1 Qualifications
The Electrical Contractor shall employ a competent, licensed qualified full time
Electrical Engineer / Foreman / Supervisor to direct the work of electrical
installations in accordance with the Drawings and Specifications. Required 3 years
of Documented Experience at Least.
2.2 Responsibility
The foreman/supervisor shall be available at all times on the site to receive
instructions from the Consultant / Main Contractor in the day to day activities
throughout the duration of the work.
The Engineer/foreman/supervisor shall correlate the progress of the work in
conjunction with all the relevant requirements of the Project Manager. The skilled
workers employed for the work shall have the requisite qualifications and shall
possess competency certificates from the Electrical Inspectorate of Local
Administration.
3.0 Tests
The Main Contractor shall have full powers to require the materials or works to be
tested by an independent agency at the Contractor's expense in order to establish
their soundness and adequacy.
The Contractor shall notify the Main Contractor at least 7 working days before testing
of each system. The Main Contractor reserves the right to be present when such tests
are being made.
If the Electrical Inspectorate requires manufacturer's test reports for HT cables, HT
switch gear, Transformers or any other equipment used in the project, the Contractor
shall obtain such approvals at no extra cost to the Main Contractor. Such approved
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reports shall be handed over to the Consultant / Main Contractor.

Calibration certificates shall be obtained from the Meter and Relay Testing
Department of the Electricity Board for all relays and meters used in the project at no
extra cost to the Main Contractor.
4.0 GUARANTEE:
The equipment supplied and the installation shall be guaranteed for satisfactory
performance and workmanship, for a period of 12 months from the date of handing
over the entire installations. Also shall replace free of cost all equipment or parts
supplied by him and found defective/missing within this period.
In case there is a failure to replace or render services for defective/missing materials

& parts, the main contractor reserves the right to do so, at your risk and expenses
without prejudice.
5.0 SAFETY PRECAUTIONS:

All Safety norms are to be strictly adhered to throughout the contract period. The
following points should be specifically noted and complied with.
The construction power installation shall be protected by RCCBs at the source as per
Statutory regulations.
a) All Electrically operated hand tools shall be of the double insulated type.
b) All workmen should be provided with tools having insulated handles.
c) All workmen operating at heights of more than 3M above floor level shall use
safety belts.
d) Properly designed ladders or scaffolding shall be used while working at
heights.
e) All workmen shall be provided with rubber shoes.
f) Safety gloves shall be used while operating energized HT equipment.
g) The welding sets to be used shall have proper terminal box for cable
termination and earthing.
DANGER SIGNS
Danger signs will be posted in following conditions:

Open Trenches
Men at work overhead
Special warning for dangerous typical situation.
In typical situation where signs prove insufficient, lead site engineer will station a
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watchman to ensure proper protection.
SAFETY HELMETS
Each workman shall be provided with safety helmet.
Individual agency shall have helmets of different colour for easy identification.
ELECTRICAL SAFETY CODE:
Only certified electricians shall make electrical connections, soldering and taping of
coils and cables shall meet with the requirements of National Building Code.
Wherever possible, all wires shall be placed in conduit and the current-carrying parts
of utilization equipment shall be completely enclosed.
Wires not in conduit shall be placed at least 8” above the ordinary working level of
platforms readily accessible to workmen other than qualified electrician.
Where electrical equipment cannot be isolated by being placed in special rooms, it
should, wherever practicable, be provided with suitable enclosure, cabinets so as to
prevent persons or objects from coming into direct contact with live electrical parts.
Do not depend on insulation to protect you from injury from electrical shock.
Insulation goes bad with age, chemical fumes, acid, etc. Consider every wire a bare
wire.
Tapping live wires is dangerous. Never do it without the express permission of your
foreman. Remove insulation from only one line at a time, and do not expose the
second wire until the first is soldered and taped.
Never over fuse a circuit under any circumstances. This rule must be rigidly adhered
to.
Before working on any circuit see that the switches are in off position and wherever
working facility is provided, the same is locked.
Use of tools with metallic handles in the electrical department is forbidden.
Do not take hot solder in buildings without first obtaining permission from the shift
foreman or operators in charge.
Do not connect extension cords unless they have vapor-proof globes.
Do not connect extension cords to inside lights. always connect them to outside lights
or lighting panels.
Extension cords for temporary lights and motors should be supported from steel or
pipes. Do not let them lie on the ground to be cut by something
MEDICAL SERVICE – FIRST AID & CASUALITY TREATMENT
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BASIC FIRST AID RULES
1. Do not move an injured person unless absolutely necessary to prevent further

injury.
2. Act fast if the victim is bleeding severely, appears to have stopped breathing, or has
swallowed poison.
3. Keep the person lying down, if he has vomited – and you are sure his neck is not
broken – turn body and head to one side. Keep him warm.
4. Get medical help as early as possible.
5. Examine the person gently. Loosen or cut away clothing to lessen pain – but do not
pull clothing from burns.
6. Reassure the person, and stay calm your self.
7. Always expect and be ready to treat shock.
8. Do not give fluids or alcohol and do not try to rouse an unconscious person before
getting medical advice.
SERIOUS EMERGENCIES
BLEEDING
Stop bleeding by pressing a pad over the wound. If this is ineffective, press on
nearest pressure point – just below armpit for the arm, below groin for leg. Or
apply a tourniquet loosen it for one minute in every ten.
BREATHING STOPPAGE
Mouth-to-mouth artificial respiration is easiest and best. First, with the victim
on his back, tilt his head back so the chin points upward. Make sure nothing is
blocking air passage. With your fingers, pull person’s tongue forward, if
necessary, and remove any loose objects from mouth. Then place your mouth
over the victim’s mouth and pinch his nostrils shut. (With a small child, you
may need to pinch the nostrils shut if you can cover both his nose and mouth
with your own mouth.) Blow 12 times a minute for an adult – 20 for a child –
letting the air return each time.
The heart may be re-started by closed-chest heart massage. Press firmly and
relax 60 times a minute on the lower part of the chest. Place hands one on top
of the other, and with heel of bottom hand, press downward about two inches
at bottom of breastbone.
POISONING
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Do three things:
1. Dilute the poison by giving water or milk.
2. Induce vomiting with a finger in throat or with salt or mustard in water BUT
not induce vomiting if victim in unconscious or has taken a corrosive or
petroleum product.
3. Save container and poison for medical identification.
SHOCK
Shock may follow any serious, sudden injury. Danger signals are clammy skin, rapid
breathing and rapid pulse. Keep person quiet and warm with feet higher than head –
except in head injury. Effects of shock can be lessened by stopping bleeding, relieving
pain and talking reassuringly to victim.
ELECTRIC SHOCK
Immediately break the body contact with the electric current. Use dry board to
remove the wire, or hook an article of your clothing around the person to pull him
away from it. Be sure that you are standing on a dry surface.
If you can’t feel the person’s pulse, mouth-to-mouth resuscitation in combination

with Cardio-Pulmonary Resuscitation (CPR) should be used.
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GENERAL SPECIFICATIONS FOR ELECTRICAL ITEMS, EQUIPMENT
High Voltage /Low Voltage CABLES.
General
Cables shall be selected from one manufacturer who has been manufacturing such
cables for at least Ten (10) Years using the Indian Standard Institution (ISI)
certification produced for each cable.
High Voltage CABLES

The H.T cable shall be of 11000V grade, Aluminium Conductor, Conductor
Screened, XLPE insulated, insulation screened, tapped inner sheathed, galvanized
steel armoured overall PVC sheathed conforming to I.S 7098 and suitable for
EARTHED system.
 The cable shall be manufactured using the dry curing and cooling process.
 The design shall allow the operation of the cable at a maximum continuous
conductor temperature of not less than 90 Deg.C under normal conditions and short
time temperature upto 250 Deg. C during faults.
 The design and construction of the cable shall permit a minimum bending radius of
15 times the diameter or lower as per manufacturers recommendations.
 Routine tests shall be conducted on the as per IS 7098 and test certificates shall be
submitted.
 The cable shall be supplied on non-returnable wooden/steel drums with both ends
properly sealed to prevent entry of water.
 In order to avoid straight through joints, single length shall be supplied as far as
possible, the details of which will be conveyed at the time of order.
Low Voltage Cables

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 The L.T power cables shall have Aluminium / copper conductor, XLPE / PVC
insulation with FR (Fire Retardant) properties, unvulcanised rubber inner sheathing,
galvanized steel tape armouring and FRLS outer sheathing. The cable shall be of the
heavy duty type conforming to IS: 1554.
 The Copper conductor cables shall be with, PVC insulation inner sheathing PVC outer
sheathing and galvanized steel tape armouring. The cable shall be of the heavy duty
type conforming to IS : 1554
 All L.T Cables shall be of 1100V grade.
 The design shall permit continuous operation of the cable at a conductor

temperature upto 70 degree centigrade for PVC insulation / 90 degree Centigrade for
XLPE insulation under normal conditions and 160 degree Centigrade / 250 degree
Centigrade respectively during faults without causing any permanent damage.
 The cables shall be designed to allow a bending radius of not less than 12 times the
diameter or lower as per manufacturer's instructions.
Power cables up to and including 16sq mm shall be with single/multi strand Copper
conductor and those of higher sections shall be of stranded Aluminium conductor
unless otherwise specified.
L.T. CONTROL CABLES

The L.T control cables shall be with electrolytic grade copper conductor only. The
control cables shall be PVC Insulated, GI wire armoured, PVC sheathed type.
The control cables shall also be of 1100V grade conforming to IS : 1554
FLEXIBLE CABLES
These shall be of 660V grade, multistrand copper conductor, FRLS grade PVC
insulated type conforming to IS : 694.
FIRE SURVIVAL/DISASTER PREVENTION SYSTEM CABLES

Fire survival cables shall be used wherever the fire mode of operation equipment are
connected from the respective panels if indicated in SLD
These cables shall be solid stranded copper / aluminium conductor insulated with
specially formulated PVC / XLPE to form a core. Cores laid up together or twisted to
form a pair depending upon the individual requirement
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These cables does not produce noxious smoke & fumes which hinder fire fighting and
endanger the life
CONDUCTOR
The Aluminium conductor for the Cables shall be of Electrolytic grade, 99.9% purity
& 3/4 H Hardness.
The Copper Conductor for Control cables shall be of the Electrolytic grade and
99.9% purity.
The conductor shall be of circular/sector shaped type and insulation of phase and
neutral shall be colour coded.
All sizes of conductors above 10sq.mm shall be of the stranded type in power cables
The Conductor shall be conforming to IS: 8130 – 1984.
GENERAL REQUIREMENTS
The cables shall be suitable for laying directly in ground or in trenches or overhead in
cable trays.
The 11kV cables shall be suitable for EARTHED system. VENDOR SHALL ALSO
QUOTE THE COST DIFFERENCE if required.
BETWEEN UNEARTHED SYSTEM CABLES & EARTHED SYSTEM CABLES FOR EACH
ITEMS.
TESTING
All routine tests shall be carried out on the cables as per relevant BIS standards and
type, routine test certificates shall be furnished in hard and soft copies.
PACKING
All cables shall be supplied duly packed on non-returnable wooden/ steel drums.
The manufacturers name or brand name with logo and the ISI mark shall be
embossed at regular intervals on all sizes of cables.The length shall be marked at 1M
interval.
TThe following information shall be provided on the flange of each cable drum:-
a) Type of cable
b) Size of cable
c) Length
d) ISI Mark
e) Gross weight
f) Direction of rolling &
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g) Year of manufacture
Both ends of the cables wound on the drums shall be sealed to prevent ingress of
water.
DOCUMENTATION
As a part of the supply, soft, hard copies of following documentation shall be

furnished by the contractor.
a) Technical literature giving constructional details and current ratings of cables.
b) Installation & Testing instructions.
c) Test Certificates.
INDICATIVE QUANTITIES
The various sizes and the quantity of the cables are indicated in BOQ. These are liable
to be revised and the exact quantities should be procured based on the working
drawings and approved cable schedule.
Cable shall be previously unused and less than 12 month old on delivery.
Storing, Laying, Jointing and Terminations
Storing
Cables shall be stored in accordance with the manufacturer’s recommendations and
labeled with its Manufacturing Date, Indian Standard for manufacture, cable grade,
description, number of cores and cross sectional area, and length. On receipt of
cables at site the cables shall be inspected and stored in a safe place.
Laying
Cables shall belaid in a manner to prevent stain and damage with no kinks or twists
or stripping and be mechanically supported throughout their length. An adequate
number of cable rollers, each of which shall be undamaged and completely free to
rotate shall be used to support the cable during pulling in such a manner that not
part of the cable can touch the ground, the trench bottom or side, or the wall of the
buildings or the tray.
Winches whether power driven or hand operated and other mechanical aids shall only
be used with the prior authorization of the main contractor. Whenever a winch or
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similar appliance is used, an approved tension gauge shall be fitted into the haulage
line between the winch and the cable. The pulling tension must at all times be within
the limit advised by the cable manufacturer, which shall be communicated in writing
to the main contractor before the laying is commenced.
All cables shall be pulled into position in such a manner as to avoid any damage
whatsoever to the cable or its sheath. Cables shall wherever possible, be pulled
directly from the top of the drum, which shall be supported throughout the operation
in such a manner that it is completely free to rotate. In the event of damage to the
sheath or armoring of any cable, the cable shall be replaced throughout its entire
length at no cost to the contract.
When a cable stocking has been used on a XLPE or LSF sheathed cable and the sheath,
after removal of the stocking, shows signs of having been stretched, the cable shall be
left for 30 minutes to recover. At the end of this period, if the sheath has not
completely returned to its original position, the cable end shall be cut back by an
amount equal to the length of the stocking plus 300mm, then immediately resealed.
During the course of pulling operations, the cable shall not be allowed, under any
circumstances, to twist or rotate about its longitudinal axis because of excessive
pulling tension or for any other reason.
The manufacturer’s minimum bending radii recommendations shall be adhered to.
In rising ducts open to access, all cables shall be protected against mechanical damage
by the installation of a 300mm high mild steel ‘kick-shield’ suitably fixed at floor
level. The ‘kick-shield’ to be of a suitable robust nature and treated against corrosion.
Where cables are installed on the surface they shall be mechanically protected to a
height of 1.5 meter above finished floor level.
Cables terminating at distribution boards shall have adequate length to connect to all
outgoing ways leaving spare if re-termination is required further into the life of the
cable.
Cable ties shall not be used to support cables. They shall be used to secure cables on
cable trays.
Unskilled labor shall not be permitted for cable installations.

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Cables in Outdoor Trenches

Cables shall be laid in outdoor trenches wherever called for. The depth of the trenches
shall not be less than 75 cm from the final ground level. The width of the trenches shall
suit easy laying of cable. Where more than one cable has to be laid in the same trench, all
attempts shall be made to keep the axial distance between successive cables to be at least
1d where’d’ is the diameter of the bigger cable. The trenches shall be cut square with
vertical sidewalls and with uniform depth. Wherever cables are bent, the minimum
bending radius shall not be less than 12 times the diameter of the cable. After the cable is
laid and straightened, it shall be covered with sand cushion. Over this a course of cable
protection tiles or burnt brick shall be provided on either sides and above. Trench shall
be back filled with earth and consolidated. Cables shall be laid in Hume pipes / stoneware
pipes at all road crossings & wall entries. Approved cable markers at intervals not
exceeding 30 meters made of CI indicating the cable size, voltage, no. of cables and the
direction of run of the cables shall be installed.
Cable in Indoor Trenches
Cables shall be laid in indoor trenches wherever specified. Suitable angle iron brackets,
clamps, hoods and saddles shall be used for securing the cable in position.
Cable on Trays/Racks
Cables shall be laid on cable trays/racks wherever specified. Cables shall be installed in
parallel or at right angles to the building structure. No diagonal cables shall be installed.
Cables shall be installed with free space on all side, not in contact with insulation and not
bunched unless specified.
Cables shall be installed in one length point to point, without joints.

Cable ends shall be sealed against moisture unless to be directly terminated after cutting. In
case of MICS and SWA cables the seals shall be as manufactured to ensure no moisture
ingress that may affect test results.
Where cables or containment pass through fire compartment fire barriers shall be installed
and the location recorded on the record drawings. Fire barriers shall be reinstated by
approved installers with certification issued on completion of the reinstatement or
renewal.
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Cables shall not be laid in contact with polystyrene and in the case of timber frame
buildings careful coordination will be required to prevent this. The contractor shall also
take great care not to damage or puncture any vapor barriers.
Cable and duct entries to buildings shall be sealed to prevent the ingress of moisture,
rodents, insects and vermin.
Jointing and Terminations
Cable jointing shall be done as per the recommendations of the cable manufacturer.
Jointing shall be done by qualified & skilled cable jointers.
HT Cable Termination:
All HT cable termination/11kV Incoming and outgoing cables shall be terminated using
heat shrinkable indoor type cable termination kits Terminal boots shall be used at the
Transformer / Switchgear terminals.
The termination kits should be of approved make.
Aluminum Cable Termination Methods

Glands shall be selected for appropriately for the environment in which the cable is to be
used. Each termination shall be carried out using brass double compression glands and
cable sockets. Hydraulic crimping tool shall be used for making the end terminations.
Cable gland shall be bonded to the earth by suing suitable size Cu/G.I. wire/tape
The general requirements for all joints and terminations of aluminum cables shall be:
a. To remove oxide from the conductor and prevent the oxide re-forming.
b. To prevent corrosion resulting from contact between dissimilar metals.
c. To retain contact pressure under cyclic loading conditions.
For all aluminum cables, the oxide shall be removed by thoroughly wire-brushing the bare
end of the cable. After brushing, a liberal coating of approved oxide-inhibiting, moisture-
excluding thermally stable grease shall be applied, and the cable shall be wire-brushed
again through the grease. Cable strands shall not be separated before brushing.
Bare aluminum lugs, ferrules and other connectors, unless factory-tinned or factory pre-
filled with inhibiting grease, shall be wire-brushed and grease coated in the same way as
cables.
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Before making any joints or terminations in aluminum cables, the Contractor shall submit
the proposed method for the Consultant / Main Contractor approval. Notice of at least
three working days shall be given before making any joints or terminations, to enable the
Consultant / Main Contractor to witness the work.
Acceptable Termination Methods
Aluminum to aluminum connections shall be made by one of the following methods:

o Aluminum crimp lugs or tinned copper ferrules.
o Fusion welding with aluminum lugs.
Tinned copper ferrules shall be terminated using the compression method. For
compression connections on stranded cables, a hexagonal die shall be used, on solid
conductor cables, indent type dies shall be used, with at least two indentations per cable
connection. Lugs of ferrules shall be selected to suit the size and shape of the conductor.
Compression dies shall be selected to suit the particular lug or ferrule. Aluminum crimp
lugs shall be filled with oxide inhibiting grease.
Joints by the fusion welding method shall be made by jointers experienced in this method.
Particular care shall be taken to protect the cable insulation from heat by fixing
substantial heat sinks to the cable near the joint. After completion of the weld the joint
shall be wire brushed and all sharp projections filed smooth.
a. Aluminum to copper connections shall be made by one of the following

methods:
b. Bi-metal connectors, or
c. Tinned copper ferrules. Or
d. Electro-tinned cast aluminum lugs.
Bi-metal connections shall consist of lugs or pin type connectors having a cast copper
palm or pin, friction-welded to an aluminum barrel section which is subsequently factory
filled with oxide-inhibiting grease. The aluminum cable shall be inserted in the barrel
section and fixed using the compression method as detailed above. The copper pin or
palm section shall be fixed to copper or brass connectors or bus-bars in the conventional
manner.
Tinned copper ferrules shall be terminated using the compression method.
Where electro-tinned aluminum lugs are used, they shall be fixed to the cable using the
compression method. The palm of the lug shall be bolted to the copper bus-bar or
terminal using a stainless steel bolt and nut, with one large diameter stainless steel flat
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washer and two "Belleville" spring cup washers.
All nuts shall be adequately torque tightened to manufacturer's recommended levels.

Identification tags for feeder designation shall be by using `Phoenix' plastic
cable markers, tied to either end of each cable.
Identification:
A permanent non-corroding securely retained identification label shall be provided at both

ends of each cable identifying its cable schedule reference and at all termination points
including joint boxes. An acceptable means of identification is an engraved trifoliate label
fixed to the cable with plastic cable ties. Self-adhesive labels will not be accepted.
Road Crossings
All cables laid below roads shall be taken through suitable underground Hume pipes / GI
Pipes / trenches. The size of Hume pipes / GI pipes/ trenches shall be as per drawings.
Construction across Roads
All works across roads shall be carried out as per the directions of the Project Manager.
Necessary safety measures shall be taken to divert traffic. Care shall be taken not to
disturb other service lines.
Protection of Existing Services
All pipes, water mains, cables, etc. met with during the course of excavation shall be
carefully protected and supported. In any case damage is caused, the same shall be made
good at no extra cost, failing which necessary rectification will be done by Project
Manager at the risk and cost of the Contractor.
Backfilling:
The backfilling shall be done in layers not exceeding 15mm in depth. Each layer shall be
watered, rammed and compacted. Ramming shall be done with iron rammers where
possible and with blunt end of the crow bars where rammers cannot be used. Special care
shall be taken to ensure that no damage is caused to the pipes, drains, masonry or
concrete in the trenches.
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Filling in trenches shall be commenced soon after the joints of pipes, cables, conduits etc.
have been tested and approved by Development Manager. The space around the pipes
shall be cleared of all debris where the trenches are excavated in hard/soft soil. The
filling shall be done with earth on the sides and top of pipes in layers not exceeding
15mm in depth. Each layer shall be watered rammed and compacted. The clods and
lumps of earth exceeding 8cm in any direction shall be broken or removed before the
excavated earth is used for filling. Generally no test is done to determine the inset density
of filled earth but on the discretion of Development Manager the 95 proctor’scompaction
test may be done to ensure the in situ density after filling. Consolidation is removal of
water from the pores and compaction is the expulsion of air from the pores. In case of
refilling consolidation places most important role as the watering of the each layer is
being done properly. If required by the Development Manager proctors needle may also
be used for theproper checking of the refilling items of in situ density.
Contractor Shall Restore Settlement and Damages:

The Contractor shall at his own cost make good promptly during the whole period the
works are in hand, any settlements that may occur in the surfaces or roads, beams,
footpaths, gardens, open spaces etc. Whether public or private caused by his trenches or
by his other excavations due to not using the method of compaction as given in clause 4.3
and he shall be liable for any accidents caused thereby.
He shall also at his own expense and charges, repair and make good any damage done to
the building and other properties.
Testing
Cables shall be tested at the factory as per the requirements of 1S 1554 Part 1. The tests
shall incorporate routine tests, type tests and acceptance tests. A copy of such test
certificates shall be furnished to the Consultant / Main Contractor prior to dispatch.
The cables shall be visually inspected and installation resistance shall be checked before
commencing the installation.
Megger test and continuity test shall be conducted on the cable after carrying out the end
termination.
SPECIFICATION FOR POWER DISTRIBUTION TRANSFORMER
SCOPE:
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This specification covers the requirements of design, manufacture, assembly, testing and
Supply, delivery of 11kV/415V, ______nos _______________kVA Distribution Transformers
OCTC/OLTC. The Data Sheet with the specification shall be shall be filled in by the
supplier/Subcontractor w.r.t. the specification provided by the main contractor.
ACCESSORIES :
Following accessories shall be provided on the transformer.
a) Oil conservator and main tank oil with oil filling hole with cap and drain valve
arrangement, with OCTC.
b) Double float type buchholz relay with shut off valves on both sides and alarm and trip
contacts wired out to marshalling box.
c) Thermometer pockets
d) Oil temperature Thermometer pockets.
e) Silica gel breather complete with first charge.
f) Inspection cover.
g) Off Circuit tap Changer
h) Oil draining, sampling/filtering valve at the bottom, one filling valve at the top.
i) Weather proof marshalling box having Dial type one no., oil temperature
indicator(OTI), 1no., Winding temperature indicator (WTI) with maximum reading
pointer, alarm and trip contacts and capillary tubing of requisite length.
j) Bi-directional rollers.
k) Air Release plug.
l) Explosion vent with diaphragm on main tank.
m) Rating, name plates and connection diagram.
n) Detachable radiator banks with shut off valves.

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o) Two earthing studs on the body of the transformer.
p) Jacking pads, Lifting Lug.
q) Plain oil level gauge duly calibrated for maximum, minimum and normal filling levels for
transformer oil conservator.
r) Weather proof 32 Amps, 3 phase Industrial socket.
s) LV Neutral terminal.
t) Terminal for LV Neutral CT.
Any other accessories supplied with the transformer shall be indicated or information to
be provided with the data sheet.
CONSTRUCTIONAL FEATURES :-
a) TANK
The transformer tank shall be made out of cold rolled sheet steel suitably reinforced by
stiffeners to withstand the forces generated during the short circuit conditions. All
welded joints shall be stress relieved. All joints shall be oil-tight. Flanged joints shall be
provided at the top to provide access to the core and coils for maintenance and
inspection.
b) CORE
The core shall be constructed from high grade cold rolled grain oriented silicon steel
laminations having low magnetizing losses. The core shall be laid up to minimize
vibration.
c) CLAMPING BOLTS
The clamping bolts for current carrying parts shall be of high tensile steel, cadmium
plated.
d) GASKETS
Non-deteriorating type gaskets shall be provided at the joints.
e) PAINTING
The tank shall be painted with temperature resistant paint capable of withstanding upto
100 0 C. Two coats of finishing paint shall be applied over one coat of primer. All parts to
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be painted shall be degreased, pickled and phosphatised prior to painting.
f) INSULATION
Insulation materials shall be of superior quality non-hygroscopic type suitable for use in
hot oil.
g) AUXILIARY WIRING:
i. The internal wiring for signaling and protection and instrumentation shall be carried
out using 660V FRLS grade PVC insulated, multistrand copper conductors. The sizes of
wires shall be as follows:
For Controls & : 1.5 Sq.mm. for internal

Signaling : wiring.
2.5 Sq.mm. for external
cabling.
For C.Ts : 2.5 Sq.mm. for internal

: wiring
4.0 Sq.mm. for external
cabling.
ii. Inter panel wiring shall be carried out using PVC troughs.
iii. Each wire shall preferably be terminated at a separate terminal. Termination of upto two
outgoing wires at a single terminal will be acceptable. Wires shall not be joined between
terminal points. Shorting links shall be provided for all C.T terminals. Wiring shall be
neatly bunched.
iv. Each wire shall be identified at both ends by yellow color PVC ferrules marked with
black letters. Supporting facilities shall be provided for clamping the control cables.
Inter panel wiring shall be done by the switch gear manufacturer before dispatch
with disconnection facility at the shipping section with plug in type multi way connector.
v. Rubber grommets shall be provided so that metal parts should not come in contact with
any power or control wires / cables.
vi. Minimum size of terminals for control wiring shall be 2.5 sq.mm or higher to suit the
wiring sizes Stipulated. Clipon type terminals shall be provided. 20% spare terminals
shall be provided on each terminal block. The terminal blocks for C.T connections shall
have C.T disconnection and shorting facility.
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vii. Stranded conductors shall be terminated with tinned copper lugs at both ends before
connections are made.
viii. The entire wiring shall be finger touch proof.
ix. Wiring of different voltages shall be identified by color code.
h) TRANSFORMER LOSSES
Guaranteed total maximum losses shall not exceed the values indicated in relevant IS &
specified by ECBC. Offer with lower losses will be preferred. The loss values shall be
furnished in the Technical particulars to be submitted along with the quote.
i) INSULATING OIL
The transformer shall be supplied complete with the insulating oil required for first
filling. The oil shall conform to Indian Standard IS: 335.
j) INSPECTION & TESTING
i) Inspection and expediting will be carried out by the client. The manufacturer shall
provide reasonable inspection facilities to their representatives.
ii) All routine tests as specified in IS: 2026 shall be conducted on the transformers in the
presence of the client's representative.
4.0 DOCUMENTATION :
As a part of the equipment supply, following sets of documents shall be

furnished.
Wi Fo For
th r Record
Te Ap s
nd pr
er ov
al
a General arrangement 1 4 3
) drawing of Transformer copies
giving outline dimensions + 1 soft
and list of accessories copy
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c Rating and name plate data 1 4 3

) copies
+ 1 soft
copy
d Marshalling box details and 1 4 -“-
) terminal wiring diagram
e Instruction booklets - - 3
) outlining the installation, copies
testing & commissioning of
OCTC & Transformer.
f Test certificates for routine & - - 3

) type tests copies
5.0 SHIPPING :
The transformer shall be shipped by road with oil and all accessories fitted up.
TRANSFORMER INSTALLATION:
The Transformer shall be transported from the manufacturers works after inspection and
installed in the locations as marked in the layout drawing.
Adequate clearances shall be maintained all around the transformer. A minimum

clearance of 6” to 8” inches below the transformer enclosure for the free movement of Air
shall be ensured.
Inside the enclosure all bolts in the current carrying parts shall be tightened. All the
shrouds shall be fixed in position.
Any of the components such as Marshalling Box & Fan control box dismantled for
transportation shall be assembled and connected.
11kV XLPE Cables shall be terminated using heat shrinkable indoor type cable
termination kits. Terminal boots shall be used at the Transformer / Switchgear terminals.
LT cables of required numbers and the rating shall be terminated on the LV side of
Transformer
OCTC Shall be tested for all operations as per manufacturer’s recommendations in the
presence of manufacturer’s representative.
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All control cables shall be glanded and terminated at the terminal blocks in the
marshalling box. The contractor shall study manufacturer's wiring diagram before
making any connections.
The neutral and safety earthing connections using Copper / GI Strips respectively shall be
made before energizing the transformers. The neutral earth conductor shall be sleeved in
the visible portion and the exposed Neutral / earth joint at the transformers shall be
insulated.
The neutral CT shall be installed and connected.
The Safety and Neutral earth conductors shall be connected to the earth mats provided.
1. TRANSFOMER
0
:
a) Make
b) kVA Rating
c) No. of Phases :
d) Voltage Ratio ( Nominal ) :
e) Rated Frequency :
f) Type of winding connection (Vector Group) :
g) Type of Cooling :
h) Impedance Voltage at rated current on :

principal tapping
i) Zero sequence reactance :
2. OLTC
0
a) Type of OFF Load Tap Changeover :
b) Make of OCTC :
c) No. of Taps. :
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d) Voltage Variation per step. :
3. LOSSES
0
a) No load loss in KW (Guaranteed figure) (Refer :
Note 1)
b) Full load loss in KW (Guaranteed figures) :

(Refer Note 1)
c) Total loss at rated Voltage and frequency on :

principal tapping.
d) No load current in Amps :
e) Efficiency at 75°C & U.P.F

At full load :
At 3/4 load :
At 1/2 load :
f) Regulation at full load at 75 °C

At U.P.F :
At 0.8 P.F :
g) Maximum temperature rise in oil °C. :
h) Insulation level :
i) Whether all accessories specified are :

included?
j) Quantity of oil :
k) Total weight of trafo. with oil :
l) Dimensions of Transformer ( L x B x H) :
All pre-commissioning tests shall be conducted on the Transformers as specified

elsewhere.
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The temperature controller shall be tested and the temperature setting shall be carried
out as per manufacturer’s recommendations.
SCHEDULE OF TECHNICAL PARTICULARS TO BE FILLED IN BY SUPPLIER :
Note1:
GUARANTEE: The transformer and the OCTC/OLTC shall be guaranteed for trouble-free
operation for a period of 18 months from date of supply or 12 months from the
date of commissioning whichever is earlier. Any defects noticed during this period
shall be rectified free of charges at the shortest possible time.
6.0 PRICE:
The price break-up shall be furnished as required by the main contractor.
11 KV HT PANELS
The 11kV Switchgear Panels and the components mounted therein shall conform to the
requirements of relevant Indian Standards, which shall include the following.
I.S : 12729 : Switchgear & Control gear for High Voltages.
I.S : 13118 : High Voltage A.C Circuit Breakers
I.S : 2705 : Current Transformers
I.S : 3156 : Voltage Transformers
I.S : 1248 : Electrical indicating instruments
CONSTRUCTION
OUTDOOR CIRCUIT BREAKER PANELS
a) The HT CB Panels at the RMU yard and the transformer yard shall be of the outdoor
type, housed in a weather proof Kiosk fabricated from 3.15 mm thick CRCA sheet steel.
b) The panel shall be totally enclosed dust, vermin proof with a degree of protection of
not be less than IP 55.
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c) The sheet steel used shall undergo surface treatment using 7 tank process involving,
degreasing, rust removal and pickling before phosphating. The panel shall be thereafter
epoxy powder coated to Siemens gray shade RAL-7032.
d) The door shall have padlocking provision.
e) Separate gland plate for Power and control cable entry shall be provided.
f) Lifting eyebolts shall be provided on each shipping section.
g) Each Panel shall be compartmentalized into five sections viz.
i) Circuit breaker compartment withdrawable trolley at the front bottom.
ii) Relay and metering compartment at the front on top of Circuit Breaker compartment.
iii) Totally segregated bus bar compartment at the top on the rear side of metering
compartment.
iv) Cable termination compartment wherever specified for incoming cable either at the
rear or on the side. This shall have a caution plate fitted outside the rear cover.
v) Cable terminal compartment for outgoing cable either at the rear bottom side or in a
separate panel on one of the sides as specified.
h) Inspection window shall be provided for checking the circuit breaker position.
I) All bolted covers & doors shall have provision for sealing.
j) The panel shall ensure complete safety of operating personnel.
k) All live parts/terminals, which become accessible on opening any compartment shall
be provided with insulating shrouds. The instrument/relay terminals on the front panel
shall be shrouded.
l) Provision shall be made for earthing the panel at two points. A continuous copper
earth bus of 50x6 mm size shall be run along the switchboard and the circuit breaker
carriage shall have a scraping earth connection, which shall earth the trolley before the
circuit breaker safety shutters are opened.
m) Rating plate and nameplate shall be provided.

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n) Danger boards with voltage rating shall be fixed both on the front and rear side.
o) The design shall have the approval of BESCOM or the power supply Authority
designated for the region.
Compact Ring Main Unit (RMU):
The HT RMU shall be provided as per local Electrical board/authority specifications and
statutory norms.
METERING PANEL
a) Metering cubicle panel shall be as BESCOM NORMS and SLD attached .
b) The metering panel shall house epoxy resin cast single phase PTs, CTs and the
electronic Tri-vector meter apart from the 11 kV CB.
c) View window shall be provided for the meter.
d) The metering compartment design shall have the approval of the local power supply
Authority.
e) The meter shall be protected from direct sunrays in any part of the day. Necessary
canopy shall be provided for this purpose.
6.0 CIRCUIT BREAKERS
6.1 The circuit breaker shall be of the Vacuum interrupter type conforming to IS :13118.
6.2 The circuit breaker design shall have been type tested at reputed test Institutes and
copies of type test certificates shall be furnished.
6.3 Unless otherwise specified, the circuit breaker shall be of the triple pole, single
break horizontal draw out type with self-aligning contacts.
6.4 The Circuit breaker trolley shall have 3 positions viz. service, test and isolated. The
operation of VCB shall not be possible at any other intermediate position.
6.5 The closing mechanism shall be of the motor operated spring charged type. Manual
spring charging and closing facility shall also be provided.
6.6 The circuit breaker shall be trip free.

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6.7 The operating mechanism shall be designed for 30000 operations and shall not call
for any maintenance for the first 10000 operations.
6.8 The contact life shall not be less than 10000 operations at rated current.
6.9 The circuit breaker ratings shall be as follows:
Service voltage (Nominal) : 11kV
Maximum voltage : 12kV
Fault interrupting capacity : Not less than 20kA RMS at 11kV
Fault withstand time : 1 Second.
Continuous current rating : 630A.
Power frequency withstand : 28 KV for 1 Min
Impulse withstand voltage : 75 KV
Operating Duty Cycle : 0-3 min-CO-3 min-CO
Standard applicable : IS: 13118
6.10 The circuit breakers shall be complete with the following. :-
i. Vacuum bottle having the main contacts
ii. Electrically Operated Spring charged closing & tripping mechanism.
iii. Closing coil and shunt trip coils suitable for 24V, 2 wire D.C supply. These shall
operate satisfactorily between 70% to 110% of rated voltage. 24 VDC Power pack details
are furnished in this specification.
iv. 6 NO + 6 NC Auxiliary contacts wired to external terminals.
v. Safety shutters of the self-locking type with pad locking facility wherever draw
out arrangement is specified.
vi. Mechanical ÒN-OFF' indicators and operation counter.

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vii. Emergency trip button.
viii Positive sliding contact arrangement for earthing on the draw out carriage.
ix. Safety interlocks to prevent inadvertent contact with live parts and faulty
operation.
x. Provision for housing the control units for remote monitoring and operation.
xi. Electromechanical interlock to be provided for the incoming Breakers.
7.0 CURRENT TRANSFORMERS (C.T.)
7.1 The C.Ts shall be of the wound primary, 12kV class epoxy resin cast type conforming
to IS : 2705.
7.2 The C.Ts shall have 5A secondary and multi-cores, with accuracy class & VA burden as
specified.
7.3 The metering core shall have class 0.5 accuracy for check metering & class 1 for other
metering and 10/15VA burden while the protection core shall be of 5P20 class and
requisite VA burden. Class `B' insulation shall be provided.
7.4 The short time rating shall match that of the circuit breaker.
7.5 The instrument Accuracy Limit Factor / security factor shall be less than 5.
7.6 The C.Ts shall be housed in the cable terminal compartment.
7.7 The C.Ts shall be tested as per I.S and the tests shall include partial discharge test.
Test certificates shall be furnished.
7.8 C.T. secondary wiring shall be carried out using 660V grade, copper conductor wires
with FRLS grade insulation.
8.0 POTENTIAL TRANSFORMERS (P.T.)
8.1 The P.Ts shall be of the single phase 12 kV class epoxy resin cast type conforming to
IS:3156.
8.2 The PT s shall have Class 'B' insulation and voltage factor of 1.2.
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8.3 The P.T s shall be provided on the incoming side and mounted separately.
8.4 The P.T s shall be provided with HRC fuse protection on H.T side and MCBs on
secondary side.
8.5 The P.T s shall be of class 0.5 accuracy and 100VA burden and connected in star / star,
YYO configuration.
8.6 The P.T s shall be tested as per IS and the tests shall include partial discharge test.
8.7 Test Certificates to be submitted.
9.0 INDICATING LAMPS & PBs
9.1 INDICATING LAMPS

Type : Panel mounting, LED type.
Standard applicable : IS : 6875
Diameter : 22 mm
Lamp voltage : 110V A.C / 24V DC
Lamp wattage : Less than 0.5 W.
Terminals : Finger touch proof.
Electric shock : Class-2 (IEC 536)

protection
Degree of protection : IP65 (IEC 259)
Color of indicators : OFF – Green, ON – Red, TRIP - Amber
9.2 PUSH BUTTONS
Type Manually operated spring return type.

Illuminated push buttons with LED
:
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lamps wherever specified.
Standard applicable : IS 6875
Diameter : 22 mm
Type of mounting : Snap type
Terminals : Finger touch proof
Switch Type : TNC Type Switch with Spring returns to

Neutral with NAC & NAT Contacts
Electric shock : Class-2 (IEC 536)

protection
Color of actuator : Start PB – Green, Stop PB – Red
Test / reset PB – Black, Accept-Blue,

Ack-White
Contact configuration : 2 NO + 2 NC.
1NAC + 1 NAT
10.0 POWER PACK
The Power pack shall provide auxiliary power for the operation of relays and circuit
breaker tripping. The capacity of the power pack shall be suitable for 3 consecutive
tripping operations after input supply failure. The unit shall be housed in the metering
compartment and shall be suitable for 240 Volts single phase input. The unit shall provide
24V DC output. One power pack each should be provided in the 2 Nos. 11kV outdoor
main HT switchboards at the RMU yard and the transformer yard. The specifications of
the power pack shall ensure that the unit shall perform continuously without any failure
under the worst power supply conditions specified.
11.0 METERS
Type : Solid state Digital.
Trivector meter shall have RS 485 port

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for PC communication to down load the

data in the PC. Specification should be
got approved from BESCOM / KPTCL
before procurement.
Standard applicable : IS : 1248
Mounting : Flush Panel mounting
Range : To suit specific requirements.
Size : 96 x 96mm
Accuracy class : 1.5
Test Certificates : To be furnished.
12.0 RELAYS
Relays shall confirm to IEC60255 / 610000 OR IS 3231 / 8686

12.1IDMT OVER CURRENT & EARTH FAULT RELAY
The Relay shall be of Numerical draw out type with display of currents, Settings, Trip
data & Trip History for Analysis and troubleshooting.
The relay should have 4 user programmable output relays with the RS485 port for
communication with PLC and Breaker Control.
Aux. voltage 24V DC.
O\L Setting range of 50-200% with definite time current characteristics.
E\F Setting range 10-80% and with built-in self-supervision facility.
The relay shall be similar to L&T type MC61C OR C&S type MRI1- 1E or approved
make or equivalent
12.2 IDMT OVER CURRENT / EARTH FAULT RELAY WITH INSTANTANEOUS OVER
CURRENT & EARTH FAULT ELEMENTS.
The Relay shall be similar to the above and shall have high set instantaneous units
with a setting range of 200-2000% for O\C & 100-800% for E\F with a provision for
setting intentional time delay.
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12.3AUXILIARY / SECONDARY RELAYS
The Relay shall be voltage operated type with auxiliary contacts & flag. These shall be
suitable for the specified applications and include 94, 95 & 60.
12.4 MASTER TRIPPING RELAY WITH HAND RESET

The Relay shall be voltage operated with High speed pickup and hand reset type with
4 NO & 2 NC contacts.
12.5PHASE SEQUENCE RELAY
This Relay shall determine the phase sequence and detect any discrepancy. This shall
measure the amplitude and angle of the voltages. The relay shall be of solid state
automatic type. This shall be similar to C&S Type BV1
12.6U/V & O/V RELAY

Relays shall be suitable for 110V AC supply from PTs and shall have setting range of
110 to 170% for over voltage and 50 to 90% for under voltage.
Relays shall have 1 NO + 1 NC self reset contacts. The relay shall have built-in timers.
Alternatively static relays of reputed make may also be offered.
The relays shall be of Alstom type VDG 11 and VDG 13 or approved equivalent.
The Test certificates for Relays and Meters to be furnished.
13.0 BUSBARS
a) Bus bars shall be of Electrolytic grade Aluminium.

b) Bus bars shall be enclosed in a separate compartment and shall be sleeved.
c) Bus bars shall be supported on non-hygroscopic epoxy resin cast insulators.
Type test certificates of resin cast insulators shall be furnished.
d) The bus bars shall have continuous current rating as specified elsewhere and
shall be designed to withstand the specified fault level for 3 sec without any
deformation/damage.
e) All bus bar joints shall be tinned and provided with high tensile passivated bolts
and nuts. Spring washers shall be provided. The joints shall be tightened using torque
wrench only.
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14.0 AUXILIARY WIRING
a) The internal wiring for signaling, protection and instrumentation shall be carried out
using 660V FRLS grade PVC insulated, multi strand copper conductors. The sizes of wires
shall be as follows:
(i) For Controls & Signaling: 1.5 Sq. mm. for internal wiring, 2.5 Sq. mm. for
external cabling.
(ii) For C.T.s: 2.5 Sq. mm. for internal wiring, 4.0 Sq. mm. for external cabling.
b) Inter compartment wiring shall be carried out using PVC troughs.
c) Each wire shall preferably be terminated at a separate terminal. Appropriate type of

terminals shall be used where more than one wire has to be terminated at one point.
Wires shall not be joined between terminal points. Shorting links shall be provided for all
CT terminals. Wiring shall be neatly bunched.
d) Each wire shall be identified at both ends by yellow color PVC ferrules marked with
black letters. Supporting facilities shall be provided for clamping the control cables.
e) Rubber grommets shall be provided so that metal parts should not come in
contact with any power or control wires/cables. Control wiring for the door mounted
equipments to be sleeved & dressed properly.
f) Minimum size of terminals for control wiring shall be 2.5 Sq. mm or higher to suit the
wiring sizes stipulated. Clipon type terminals shall be provided. 20% spare terminals
g) Multistrand conductors shall be terminated using suitable sleeves such that the
entire wiring is rendered finger touch proof
h) Wires of different voltages shall be identified by color code.
i) Test terminal blocks shall be provided for the relays.
j) All spare contacts of the Breaker/ Relays/ Contactor shall be wired to external
terminals.
INSTALLATION OF HT PANELS
11kV SWITCHGEAR(HT PANELS)
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Check the floor / foundation level and correct if required by leveling properly.
Switchgear panels shall be transported from the manufacturer’s works after obtaining the
clearance from the consultants / employer and installed at the locations indicated in the
drawing maintaining the statuary clearances.
All meters and relays packed in separate containers shall be installed and connected.
All Bus bar joints shall be tightened using the torque wrench.
11kV Incoming and outgoing cables shall be terminated using heat shrinkable indoor type
cable termination kits of approved make.
All control cables shall be terminated to the terminal blocks. Contractor shall study
manufacturer's wiring diagram before making any connections.
Safe / Statutory clearances shall be strictly maintained.
Any shrouds removed for terminating the cables shall be refixed carefully.
The switchboard shall be connected to the earthing grid at two points using GI Strips of
the specified elsewhere.
The circuit designations and cable sizes shall be pointed on the rear side.
All installation and operation instructions provided by the manufacturer shall be strictly
followed.
The Switchboards shall be tested as specified in the presence of Client / Management
contractors presence before energisation. The test shall include the relay testing and
setting the protective relays to ensure proper discrimination and grading.
LT SWITCHBOARD SPECIFICATIONS
Statutory requirements
The equipment offered shall conform to the stipulations of the local power supply
authorities and statutory bodies. Modifications if any, suggested by the authorities
during their inspection shall be carried out at site without any extra cost.
All Switchboard design offered shall have successfully undergone Type tests and certified
by CPRI / Approved test house for short circuit withstand capability, degree of protection
and temperature rise.
CONSTRUCTIONAL FEATURES OF SWITCHBOARDS

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 Type of construction : Cubicle, compartmentalized, totally enclosed,

floor mounting,
free standing, flush front, single front, single
bus suitable for drawout ACBs and drawout /
non- drawout MCCBs.
 Thickness of sheet steel : 3.15mm for frame and cable gland plate.
mounting frames. : 2mm for body/door/equipment

: 1.6mm for barriers.
 Degree of protection : Dust and Vermin proof - Not less than

IP52 of IS 2147.
 Base frame : Fabricated from 75x40mm ISMC
 Height of switch boards : Not more than 2200mm until and
unless specified.
 Maximum operating height : Not more than 1800mm until and unless
specified.
 Minimum operating height : Not less than 400mm until and unless specified.
 Type of doors/covers : Doors shall have concealed hinges. Door

locks shall be of the quick opening,
industrial type. Cable alley doors shall be
hinged one side bolted on the other. All
doors shall have pad-locking provision.
 Position of cable alley & cable entry : Cable alley shall be on the rear for t
he metering panel and on the front for all
other switchboards, unless specified otherwise.
: Space provision should be available for

10% spare cables.
: Cable clamping facility should be provided.
: Incomer for the metering panel shall be as
indicated in the drawing. Outgoing cables
shall be as per the drawings/Schedule.
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: Gland plate shall be split into sections to

facilitate cable terminations. Gland plates
for terminating single core cables shall be
of Aluminium while those for the 3C/ 3½C
/ 4C shall be of 3.15mm thick M.S.
 per vertical panel in switchboards

having busbar rated 600A and above : One only
 Max. No. of feeders :Up to 63A- 7 Nos. per vertical panel

100 / 125A- 5 Nos.
200 / 250A / 400A/630A - 3 Nos.
I/C MCCB upto 800A- 1 Nos.
I/C ACB upto 1600A- 1 Nos.
 Maintenance of Components : From the front side only.
 Safety features totally shrouded : All live parts/terminals to be.
: On the metering panel and EB/DG breaker

panel the breaker compartment design
shall ensure complete segregation
between the bus sections such that the fire
on one side will not travel directly to the
other side. Fire seal to be provided around
bus bar & control cable entry
: Finger touch proof wiring to be provided.
: Busbars to be sleeved and bus bar

joints to be provided with insulating
shrouds.
: Switch operating handle shall be interlocked
with door.
: Pad locking provision in OFF position for all

Switches/MCCB/ACBs.
: Supply to all door mounted meters, lamps,

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relays etc. Shall be limited to 110V by

providing PTs.
 Other features : Shipping section length to be limited to 2.5 M.
: Lifting eye bolts to be provided.
: All hardware should be high tensile zinc

passivated type.
: Spring washers to be provided at all

busbar and equipment fixing joints.
: Endless neoprene gaskets to be provided

on all doors and covers.
: Danger boards to be provided on live part

covers.
: Continuous earth bus.
: Pad locking provision on all feeder doors.
: All doors having components mounted on

them shall be earthed.
: Provision of a document pouch in the rear

of the incoming door with às built'
schematic SLD & wiring drawings
pertaining to the panel duly laminated.
 Additional requirements for
a. Capacitor control panels : Shock proof construction to

ensure that
capacitor terminals can be approached
only after they are discharged. Suitable
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guarding should be designed to meet this

requirement.
: Ventilation louvers covered with

removable fine brass mesh shall be
provided for capacitor compartment.
: Contactors designed for capacitor

switching duty should only be offered.
: Current limiting wiring coils shall be

formed out of copper conductor, FRLS
insulated wires to restrict the in rush
current and connected in series with the
capacitors.
BUS BARS
 Material of busbar : Electrolytic grade aluminium
Further the ACB terminal connection should be of copper. Wherever two dissimilar metals
are to be jointed, a bimetallic sheet shall be provided or Copper shall be tinned..
 Size of busbars : Busbar size shall be based on following

maximum permissible current densities.
: Aluminium - 0.8Amps /Sq.mm

Copper - 1.25Amps/Sq.mm
: The neutral bus shall be of same size as the phase bus for all boards.
: The minimum size of the bus bar shall not be less than 25x6mm aluminium and
25x3mm for copper.
: For tap off connection between ACBs/ MCCBs and the bus bars, copper links of
suitable size shall be provided based on terminal pad size and continuous current
rating of ACBs/MCCBs.
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: Each feeder shall have independent tap off provision on the busbars.
 Type of bus bar supports : SMC/FRP
 Short time rating : 25/35/45/50 KA at 415V for 1 second as

specified in the drawing.
 Temperature rise : Not more than 5Deg.C over 38 Deg C ambient.
 Bus bar clearance for : Not less than 50mm clear for the main phase bus
bars and not
less than 25mm clear for neutral bus and main Bus.
 Material of earth bus : GI, until and unless specified
 Size of earth bus : 50x6mm for all switchboards rated 1000A and
above. 25x6mm for smaller DBs.
COMPONENTS
 ACBs
 Type : Air circuit breaker horizontal drawout type

suitable for rear horizontal and vertical connection and
line load reversable without any deviation.
: The Breaking capacity performance certificate shall be available . The service short
circuit breaking capacity(ICS) should be equal to short time withstand (ICW) and
ultimate breaking capacity (ICU)
 No. of poles : Three/ four with 100% Neutral, settable at site,

unless
otherwise specified.
 Operating mechanism : Motor operated spring charged stored energy

type trip free mechanism as specified. Manual
operating feature shall also be available.
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 Trip coil voltage : 240 V A.C
 No. of auxiliary contacts : 6 NO + 6 NC. Spare contacts to be wired

to
external terminals.
 Breaking Capacity : Not less than 65kA.
 Operating duty : Ics=Icu = Icw / 1Sec.

 Standard applicable : IS 13947 (Part I & II)
IEC 60947 ( 1 and 2)
Shall comply with the isolating function requirement of IEC 60947-2 section 7.1.2.
Sequence test I is Mandatory.
 Trip time : Not more than 30 milli secs
 Protection : Thermal, Magnetic based with O/C, S/C, & E/F.

(if specified) releases. The Trip unit shall have
thermal memory, EMC and battery backup.
 For Transformer main incomer, The trip unit shall also have IDMTL settable curves for
co-ordination with the HT Switchgear. The setting range available shall cover the
following.
I setting T setting (Delay)

(i) Over load : 40-100% In Steps
(ii) Short circuit : 200-1000% Ir 0.1 to 0.5 Sec
(iii) Instantaneous : Adjustable from 2 to 15 times In.
(iv) Earth fault : 10 to 40% of nominal current (In)
The trip unit shall have segregated O/L, S/C,E/F and trip unit malfunction / failure alarm
indication.
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 Accessories : Mechanical ON-OFF indicator.
: ON-OFF PB with lockable cover on “ON “ PB.
: Emergency trip push button.
: Operation counter.
: Safety shutters-lockable in closed position.
: Door interlock with operating handle.
: Withdrawing handle, if any.
: Provision for castell lock.
: Padlocking provision on door.
: Padlocking in ÒFF' position.
: Communication port (Including chasis communication ) with modbus protocol for

remote monitoring and control along with Ripple free battery backup wherever
specified in SLD/BOQ.
: All parameters metering unit – digital type.
: LED Fault indication (O/C, S/C, E/F & Mp

malfunction failure)
: Plug in type auxiliary contact block.
 Safety interlocks : Mechanical anti pumping feature .
: ACB cannot be closed, if the doors are open.

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: ACB cannot be closed, if it is not in engaged/test/withdrawn position.
: ACB cannot be withdrawn if it is in closed position.
: Safety shutters should close automatically when

ACB is withdrawn.
: It shall not be possible to withdraw the breaker when

the springs are charged.
: When withdrawing the breaker springs should get

discharged automatically.
: It shall not be possible to insert breaker racking

handle when outside door is open . Interlock defeat
facility shall be available.
Duty Category : P2
 Type of Operating handle : Front drive with for door interlock

and Pad locking
position in “OFF” position. The handle shall give positive indication of “ON”, “OFF” & “TRIP”
conditions.
 MCCB’s
 Type : Air break, current limiting type, Cat A up to

630 A - single or double break, withdraw able / non-draw out type having following service
fault interrupting capacities (ICs) :
Up to 100A- Not less than 25KA.

160A up to 250A - Not less than 35 KA.
400A and above - Not Less than 45KA.
800A & above shall be Category B Icw/0.5 sec 20kA

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If a higher rating is specified in the drawing, the same shall govern.
: The unit shall have a fire retardant, insulating moulded case. MCCB shall not have
any line-load connection restrictions & shall be suitable for isolation as per IEC
60947 Part II.
: Release shall have thermal memory and EMC.
: The operating mechanism shall be either manual or motor operated , Withdraw able /
Fixed as specified.
 No. of poles : Three/ four with 100% Neutral, settable at site,

unless otherwise specified.
 Standard applicable : IS 13947 (Part I & II)

IEC 60947 ( 1 & 2)
 Type of operating : Front drive with provision for motor opreating

mechanism. Provision for door interlock and pad locking position in ÒFF' position.
The handle shall give positive indication of ON, OFF & trip conditions.
 Type of protection for rating above 250A : The releases shall be thermal, magnetic
type
I&T
(i) Over load : 40-100% In Steps less than or equal to 40Ms.
(ii) Short circuit : 200-1200 % of Ir.
(iii) Earth fault : 10 –40 % In. with settable time delay of 0-300 mS.
(iv) Auxiliary contacts : 1 NO +1 NC and 1 trip contact wired up to Terminals.
(v) Tripping Facility : Through shunt trip coil, suitable for 240V.A.C for all MCCB’s on
BESCOM metering panel. On others 240V, AC S/T Coil wherever specified.
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 Type of protection for ratings up to 250A : Thermal overload release adjustable at

site
between 80–100% of the rating.
: Fixed, Magnetic short circuit release.

( adjustable 200A &250A ).
 Auxiliary contacts : 1 NO + 1 NC and 1 trip contact wired to terminals.
 Tripping facility : Through shunt trip coil, suitable for 240V, A.C for all
MCCBs
on BESCOM metering panel. On others shunt trip coil rated
240V AC shall be provided wherever specified.
 Other accessories : Terminal shrouds.
 MCBs
 Type : Energy limiting Class 3, DIN rail mounting with no line load
restrictions.
 Standard applicable : IS 8828 - 1996 IEC 898 - 1995
 Breaking capacity : 10kA
 Protections : Thermal overload magnetic short circuit.
 Power loss/Pole : In accordance with IS 8828-1996.
 Tripping characteristics : B for Lighting load, C for Motive loads and D for Electronic
equipment protection or as specified.
 Terminal size : Suitable for both aluminium and copper cables upto 25
Sq.mm size up to 32A MCB, 35 Sq. mm size up to 40A up to 100A, MCB.
 RESIDUAL CURRENT CIRCUIT BREAKER (RCBo)
 Type : Din rail mounting direct acting type withover current, short
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circuit and earth leakageprotection. There shall be no line load

limitations.
: Earth leakage trip indication is to be provided.
: RCBO ‘A’ Class as per IEC 1008-1996 suitable for circuits with DC pulses.
RCBOs shall not trip due to switching surges.
 Standard applicable : IS 12640- 1988

IEC 1008- 1996 – RCCB
With isolation duty as per 947-3
IEC 1009 – 1996 - RCBO
 Breaking capacity : 10kA
 Protections : Thermal overload , Magnetic short circuit and

Earth Leakage. Nuisance tripping due to transient over
voltages should be eliminated by design.
 Sensitivity : 30/100/300mA with time delay or as specified.

Wherever required special designs to suit non linear loads shall be offered.
 Tripping characteristics : B, C, D or as specified.
 Terminal size : Suitable for both aluminium and copper cables

upto 25 Sq.mm upto 25A & 35 Sq.mm for 80A.
 Testing provision : A push button shall be provided to check

the integrity of earth leakage detection system.
 LOAD BREAK ISOLATORS (MCCB SD)
 Type : Load break, Fault making with positive contact indication.
 Standard applicable : IS 13947 Part – III , IEC 947 - 3
 No. of poles : TP + Neutral Link / Four.

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 Contacts : Double break silver plated copper roller spring assisted type.
 Operating mechanism : Front drive with adjustable telescopic shaft.
 Safety features : Front drive with door interlock with defeat facility.
: Padlocking facility on handle.
: Phase barriers.
: Mounting at any angle in the vertical plain. Fault withstand

capability upto 50KA.
: Bolted Neutral link to be provided.
 Duty Category : AC 23A or Better.
 CURRENT TRANSFORMERS
 Type : Epoxy moulded ring type either bar or wound

primary.
 Standard applicable : IS 2705
 Secondary current : 5A
 VA burden : 5/10/15 VA as specified.
 Accuracy class : Class-I for metering

: Class 5P20 for protection.
: Class PS for restricted E/F protection
 POTENTIAL TRANSFORMERS
 Type : Epoxy moulded.

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 Primary Voltage : 415/3
 Secondary Voltage : 110/3
 VA Burden : To suit the no. of meters provided on the DBs.
 Accuracy class : Class-1 for Metering.
 INDICATING METERS
 Type : Moving iron/solid state digital as specified.
 Mounting : Flush mounting
 Scale : 90 Deg.
 Range : To suit specific requirements.
 Size : 96 x 96mm
 Accuracy class : 1.5
 Additional features : Ammeters for motor feeders shall be ofsuppressed scale

type.
: P.T/C.T ratio shall suit the specific requirements.
: Shrouding of terminals.
 MULTI DATA METER
This shall be of the solid state flush mounting type capable of Measuring / Recording
following Electrical Parameters.
a) Amperes
b) Voltage / Frequency.
c) KVA / KVAR
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d) KW
e) PF.
f) KWH ( Energy module attachment to be provided)
g) Communication port with RS 485.
h) Harmonics from 3 to 21.
 KILO WATT HOUR METER
This shall be solid state digital type with mechanical counter to read the energy
consumption. The meter shall be of CT operated type and suitable for 110V, 3Ph. 4Wire
supply. The meter should have capability to integrate with Building automation system
with RS-485 port or pulse output if specified any wherever in this document.
Type : Flush mounting.
Standard applicable : IS 13779 – 1999 or International Standard IEC-

1036.
Accuracy : Class 0.5 as per CBIP-88, Class 1.0 & 2.0 as

per IS-13779, IEC-1036.
Nominal Voltage Rating : 240V
Working Voltage : 120 to 300V (- 50% to + 25%)
Frequency : 50Hz
Burden : Less than 0.1VA
Temperature : 0 to 60 deg. C
Humidity : < 95%, Non condensing
Casing Material : Magnetically shielded steel casing.
 LOAD MONITOR
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The load monitor with communication module shall be of the solid state, micro
processor based programmable type capable of measuring, following electrical
parameters for 3phase systems in the digital mode.
a) Amperes
b) Voltage
c) Frequency
d) KVA
e) KW
f) P.F
g) KWH/RKVAH
h) The unit should have provision to give relay outputs on any 3 pre-set parameters.
 INDICATION LAMPS
Type : Panel mounting, LED type.
Lamp voltage : 240V A.C
Lamp wattage : Less than 0.5 W.
Electric shock protection : Class- 2 (IEC 536)
 PUSH BUTTONS
Type : Manually operated spring return type.
Diameter : 22mm
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Type of mounting : Snap type
Electric shock protection : Class- 2 (IEC 536)
Colour of actuator : Start PB - Green

Stop PB - Red
Test/rest PB - Black
Contact configuration : 2 NO + 2 NC
 PROTECTIVE RELAYS
Restricted earth fault relay (64(c) : Alstom make, type CAG 14 or equivalent, self
powered, flushmounting type single pole relay.
CT secondary : 5A
Setting : 10 - 40%
Contacts : 2 N.O SR
Flag : YES
Case size : 1D, vertical
Stabilizing resistor : 50 Ohms
Trip circuit Supervision Relay with :The relays shall be of high speed operation and Hand
Reset (86) lockout type with hand reset. The functions of this relay shall be line breaker
tripping, contact multiplication and circuit opening and closing. The relay shall be
suitable for electrically or manual operation with electrically separated contact
circuits and auto-cut contacts.
 EARTH LEAKAGE RELAY

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Type : Residual current type of PROK DVS/

JVS / Alstom make or equivalent
Setting : 0 - 3000mA
Time delay : 1-3 Sec.
Aux (r) supply : 240V A.C
Earth Leakage relay having following Parameters:
o Consistent reliability with Accuracy

o Fixed or variable current Sensitivity by Dip switch selection.
o LED’s for visual fault indication.
o High barrier connector at rear for easy termination and safety standards.
o Tamper proof poly carbonate cover in the front.
o Input rated Auxiliary voltage : 110,230, 415, 550V AC 50Hz.48, 110 & 220V DC
Current sensitivity range : 30 – 300mA, 300 – 3000mA

0.5 – 2A, 1 – 4A, 1 – 8A Variable
30mA, 100mA, 300mA, 500mA, Fixed.
Tripping Time : 0.15 – 3 Sec. Variable

100mS, 500mS, 1 Sec. & 3Sec. Fixed.
Relay contacts : 1 Pair of potential free No & NC Contacts.
Contact Rating : 6Amps / 230V AC / 28V DC
Mounting Type : Flush / Din Rail
 UNDER VOLTAGE/ OVER VOLTAGE RELAY
The relays shall be of Alstom type VDG 11 and VDG 13 Relays shall be suitable for 240V
AC supply and shall have setting range of 110 to 170% for over voltage and 50 to
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90%for under voltage Relays shall have 1 NO + 1 NC self reset contacts. The relay shall
have built-in timers. Alternatively static relays of reputed make may also be offered.
 POWER FACTOR CORRECTION RELAY
The PF Correction relay if specified shall be of the micro processor based,

programmable, panel mounting type, housed in a 144x144mm draw out case.
The relay shall be suitable for operation on 240V, AC supply and 5A C.T. secondary
current.
The relay shall have surge protection circuit.
The relay shall measure the reactive current and control the same by switching
in capacitor banks, either serial or binary switching shall be
possible with a total number of 8 steps.
The relay shall ensure that the switching interval between the successive switching of
the same bank shall not be less than 5 minutes.
The relay shall have inbuilt arrangement to avoid hunting of switching equipment.
The relay shall display the following:

i) Power factor
ii) Harmonics content.
iii) The status of switching
Failure of the operation or low p.f alarm
An auto/ manual facility shall be available.
Relay shall be of Beluk make type BLR - CB or FRAKO make or approved equivalent.
 AUXILIARY RELAY : Voltage operated auxiliary relays to be incorporated on I/C to

provide annunciation/ trip functions.
 CONTACTORS
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Type : Air break, load break, fault making type.
Standard applicable : IS 2959.
Duty category : AC3
No of poles : Three/ four
Coil voltage and voltage : 240V 1 phase A.C & suitable variation limits for
voltagelimits of 75% to 110% Insulation class of
operating coil shall be class H or better.
Auxiliary contacts : 2 No + 2 N.C
Terminal arrangement : Finger touch proof shrouded type
Mounting arrangement : Din rail mounting preferred upto 70A. Base

mounted for higher rating.
Co-ordination with MCCBs : “TYPE C' co-ordination required (Test certificate to be

furnished).
Capacitor Duty : Special contactors (ABB/Schenider/Siemenmake or

equivalent) These contactors shall have inbuilt esistors to
limit the inrush current.
OVER LOAD RELAYS
 Thermal overload relay shall be capable of withstanding short circuit equal to 17 times
the rated thermal current ( 17 Ie )
 Trip Class shall be 10A as standard or Class 20 wherever specified.
 Shall be provided with built tin Single phase protection & Phase unbalance protection as
per IEC 60947-4
 Shall have built-in NO & NC Contacts.

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 Settings shall be adjustable type & there should be a provision of sealing the same to
make it tamperproof.
 Suitable for Aluminum termination with max. permissible temperature rise of 5 Deg.C
with Ambient of 38 Deg.C
 CAPACITORS & FILTERS

The capacitors shall be of the dry, Heavy duty gas filled air cooled MPP type and
200%continuous overload capacity and capable of withstanding repeated inrush
currents upto 200 times the rating.
The capacitor shall be suitable for operation on 415V, 3 phase 50 C/s supply.
The watt loss / kVAR shall not be more than 0.5 with discharge resistors connected.
Each capacitor shall be complete with internal silver fuses for protecting each element
and external discharge resistors.
The capacitor shall conform to IS: 2834 and shall be guaranteed for continuous
operation without deterioration for a period of 24 months.
External discharge resistor shall be provided to discharge the capacitor and bring the
voltage to less than 50V within 1 minute of power disconnection.
Each unit shall have finger touch proof terminals of adequate capacity to which external
supply can be connected.
It shall be possible to mount the capacitors in any position.
The capacitors shall withstand H.V test at 1.1KV for 1 Minute.
The capacitors shall be guaranteed for continuous operation without any deterioration for a
period of 24 Months.
Applicable Standards : IEC-831-1, 1996 EN 60831-1 : 1993

IEC 831-2, 1995 EN 60831-2 : 1993
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Capacitance tolerance : -5 % + 10%
Inrush Current : Up to 200 Times rated current.
Losses (Dielectric) : < 0.2W / Kvar.
Service Life : 100 000 Operating hours.
Degree of Protection : IP-20, Indoor mounting.
Ambient temperature Category : 38ºC
Cooling : Naturally Air-cooled or Forced air cooling
Safety Features : Fuse for over current protection, Self-healing
Case : Aluminium can or sheet steel.
Dielectric : Metallised Polypropylene film.
Impregnation : Non-PCB, Dry type with inert gas filling.
Terminals : Three way finger touch proof terminals.

Discharge resistors : To be mounted on terminal block.
 MAIN AND AUXILIARY WIRING
 Control wiring of BESCOM metering panel & Fire pump panel shall be carried out using
copper wires with HFFR (Halogen free) wiring. Internal power wiring of power circuits
rated upto 63A shall be carried out using 1100V, FRLS grade PVC insulated, flexible
copper conductor wires. Minimum size of wiring shall be 6 Sq.mm and maximum
shall be 25 Sq.mm. For rating above 63A, busbars of appropriate size shall be used.
The bus bar sizes shall be selected as specified elsewhere.
 The internal wiring for signaling and protection and instrumentation in all other
switchboards shall be carried out using 660V FRLS grade PVC insulated, multistrand
copper conductors. The sizes of wires shall be as follows:
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 For Controls & Signaling : 1.5 Sq.mm. for internal wiring.
: 2.5 Sq.mm for external cabling.
 For C.Ts : 2.5 Sq.mm for internal wiring
: Inter panel wiring shall be carried out using PVC troughs.
 Each wire shall preferably be terminated at a separate terminal. Termination of upto

two outgoing wires at a single terminal will be acceptable. Wires shall not be joined
between terminal points. Shorting links shall be provided for all C.T terminals. Wiring
shall be neatly bunched.
 Each wire shall be identified at both ends by yellow colour PVC ferrules marked with
black letters Supporting facilities shall be provided for clamping the control cables.
Inter panel wiring shall be done by the switchgear manufacturer before despatch
with disconnection facility at the shipping section with plug in type multiway
connector.
 Rubber grommets shall be provided so that metal parts should not come in contact
with any power or control wires/cables.
 Minimum size of terminals for control wiring shall be 2.5 sq.mm or higher to suit the
wiring sizes stipulated. Terminals shall be of the screwless type. 20% spare terminals
 Standard conductors shall be terminated with insulated tinned copper lugs at both
ends before connections are made.
 Wiring shall be finger touch proof at all places. Where the terminals of
equipments meters/relay and accessories are not finger touch proof, insulating
shrouds shall be provided.
 Communication parts to be wired to terminals using appropriate connectors and wires

to avoid any loss of data or corruption in transmission.
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 Hooter & bell to be provided for audible annunciation.
SPECIFICATION FOR D.G SYNCHRONIZING PANEL
This specification covers the requirements of DG synchronizing panel cum Switchboard

being installed at the new facility.
CONSTRUCTION & COMPONENT DETAILS.
The synchronizing panel is free standing, floor mounting sheet steel clad and
cubicle type with flush front. The panel is fabricated from sheet steel of min
thickness of 2mm(for doors)/1.6 mm(for body). Gland plate thickness shall be 3
mm.The panel is fabricated to ensure totally enclosed bus bar chamber complete
shrouding of live parts when the panel is open after switching off the circuit
breaker and ample space for cabling. The LT cable entry shall be from top/bottom
as specified.
The panel shall be extendable type in order that power and control parts can be
added as required for a standby DG addition.The instruments and control MCB’s for
the instruments are located in a separate compartment to enable maintenance of
the instrument without switching off alternator.
The bus bars are made of Aluminium to withstand the fault level of the DG set. The
supports for the bus bars are non hygroscopic.All indicating instruments shall be
flush mounted and size of 96mm x 96mm.
The synchronizing panel is complete with wiring necessary for proper functioning
of the DG set. The control wires are ferruled. Neoprene gaskets shall be provided
between all openings & joints. The degree of protection shall be IP-52. Tinned
copper flat of adequate size shall be provided for earth connection.Paint shade shall
be Siemens grey RAL-7032 or as per approval.
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Panel shall be provided with panel illumination lamp operated by door switch and
thermostat space heater.
The synchronizing panel shall be of the indoor type, fabricated out of 2mm
thick/1.6 mm thick CRCA sheet steel.
The synchronizing panel shall be free standing floor mounting with IP52 degree of
protection and NEMA1 enclosure containing the following:
a. Easygen-3500 with RS-485 Communication port for BMS Connectivity.

b. A full colour high resolution operator interface located on the door
with an 8’ colour touch and graphical user interface screen
c. Battery charger
d. Digital power transducer.
e. The Easygen shall be of Woodward make and shall include power
supply unit, CPU, I/O cards as required, Generator control and
protections, network interface card and accessories.
f. PLC unit with adequate I/O s and CPU, for sequencing, interlocking and
control
g. Engine Status Monitoring by connecting to a PLC and in the turn PLC to
PC with SCADA software shall have RS-485 port for BMS Connectivity.
Synchronizing Panel with switchgears
The fabricated panel shall undergo surface treatment of 7 tank process and shall
be powder coated the unit shall have compartmentalized such that each incoming
& outgoing feeder is housed in a separate compartment. The switchboard design
shall be such that the circuit breakers, metering unit, bus bars and cabling are in 4
separate compartments. The switchboard shall be suitable for operation on 3
phase, 4 wire supply. The bus bars shall be of Aluminium and rated as per SLD.
 Neutral bus bar shall be of the same size as the phase bus.
 50x6mm copper earth bus shall be provided all along the switch board.
 The temperature rise shall not exceed 40 deg. C. over ambient.
 The bus bar system shall be designed to withstand a fault level of not less
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than 50kA for 1 sec.
Controls and Indications
The following controls (Both local & remote) shall be provided in the
synchronizing panel
For which a local remote selector switch is provided
 Starting
 Stopping
 Speed Control – Raise / Low
 Voltage control – Raise / Low
 Motorized Pots Synchronization.
The following indication shall be provided in the synchronizing panel.
 AC Voltmeter & Ammeter with selector switches.

 Wattmeter & watt hour meter.
 Frequency meter
 DC Ammeter & DC Voltmeter of battery charger.
 AC Supply / DC Supply healthy.
 Battery charger On / Off.
 L.T breaker of DG
The provision for following status / Signal shall be provided
 DG fail to start
 DG start command actuated / reset.
 DG Working / stop signal
 DG Trouble / Normal signal
 DG Control supply failure / Normal signal
Starting
The DG set shall be automatically started once the grid supply has failed.
There should be provision given for manual starting incase AMF system has failed.
The starting of the DG set shall be through a starting switch for manual start.
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Remote starting facility shall also be provided. DG set shall send automatic closing
command to its Breaker on achieving rated voltage frequency on its terminals.
Necessary relays for the purpose shall be included.
Three attempt starting facility shall be provided using impulse timer and
summation timer. The DG shall lockout in case of failure of above.
Stopping
The DG Set shall be stopped manually both from Local and remote.
In auto mode interlock shall be provided to prevent shutting down operation

when its breaker is in closed condition.
Tripping and Alarms
The following alarm / Trip signals shall be provided in DG synchronizing panel to

indicate and protect against abnormal operating condition.
Condition Trip Alarm
Fail to start --
Lube oil pressure low - --

/
Over Speed ---
DG over Load ---
High cooling water temperature ---
Stator temperature high ----
Electrical protection operated
Priming pump tripped ---
In case of tripping restart shall be protected until the faults are removed and manual
resetting is done.
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CIRCUIT BREAKERS
Circuit breakers shall be of the manual / motor operated, as indicated in SLD, insulated
case draw out type with requisite number of auxiliary contacts, alarm contacts, micro
processor based O/C, S/C & E/F trip, shunt trip and under voltage coils.
The generator control circuit breakers shall be of the 3 pole with neutral Contactor design.
The outgoing circuit breakers shall be of the 3P design with neutral link.
The circuit breakers shall have 50kA fault interrupting capacity ( Ics ).
The ratings of Incoming and Outgoing circuit breakers shall be as indicated in the
SLD.
INDICATING LAMPS
Type : Panel Mounting LED Type
Standard Applicable : IS-6875
Lamp Voltage : 24V DC
Lamp Wattage : Less than 0.5Watt.

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Electric shock protection : Class-2 (IEC-536)
Degree of Protection : IP-65 (IEC-259)
Colour of actuator : OFF-Green, ON-Red, Trip-Amber
PUSH BUTTONS
Type : Manually operated spring return type, illuminated
Push button with LED lamps wherever specified.
Diameter : 22mm
Type of Mounting : Snap type.
Electric shock protection : Class -2 (IEC-536)
Degree of protection : IP-65 (IEC-259)

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Colour of Actuator : Start PB-Green, Stop PB-Red, Test/Reset PB-
Black, Accept-Blue, Ack-white,
Contact configuration : 2No + 2NC
METERS
Type : Solid state digital
Mounting : Flush panel mounting
Range : To suit specific requirements.
Size : 96x96mm
Accuracy class : 1.5
RELAYS
IDMT over current & earth : The relay shall be of numerical draw out
Fault Relay type with display of
currents, Settings, Trip data & trip
history for analysis and troubleshooting.

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The relay should have 4 user programmable

output relays
With the RS-485 port for communication with

Controller and Breaker Control.
Aux. voltage 24V, DC or 110V AC.
O/L setting range of 500-200% with definite time

Characteristics.
Earth fault setting range 10-80% and with built-in

current
self Supervision facility.
The relay shall be similar ABB / Siemens /

Schneidemake.
Instantaneous over current & : The relay shall be similar to the above and
Earth fault relay shall have high set instantaneous units
with a setting range of 200-2000% for O/C
and 100-80% for E/F, with a Provision for setting for
intentional time delay.
Auxiliary / Secondary Relays : The relay shall be voltage operated type

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with auxiliary Contacts & flag. These shall
be suitable for the Specified application.
Master Tripping Relay with : The relay shall be voltage operated with high speed
Hand Reset pickup and hand reset type.
Under Voltage relay : The Relay shall be of Voltage operated type with
Auxiliary contacts.
Over Voltage relay : The Relay shall be of Voltage operated type with
Auxiliary contacts.
Timer : Voltage operated type with Auxiliary contacts.
Restricted Earth fault relay : The relay shall be of the solid state type with
instantaneous operation.
The setting range shall be 5-40%
Relay shall be similar to ABB/Schneider
AUXILIARY WIRING
i The internal wiring for signaling and protection and instrumentation shall be
carried out using 660V FRLS grade PVC insulated, multi strand copper
conductors. The sizes of wires shall be as follows:
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ii For Controls & Signaling : 1.5 Sq.mm. for internal wiring, 2.5 Sq.mm. for
external cabling.
iii Inter compartment wiring shall be carried out using PVC troughs.
iv Each wire shall preferably be terminated at a separate terminal. Termination

of up to two outgoing wires at a single terminal will be acceptable. Wires
shall not be joined between terminal points. Shorting links shall be
provided for all CT terminals. Wiring shall be neatly bunched.
v Each wire shall be identified at both ends by yellow color PVC ferrules marked
with black letters. Supporting facilities shall be provided for clamping the
control cables.
vi Rubber grommets shall be provided so that metal parts should not come in
contact with any power or control wires/cables.
vii Minimum size of terminals for control wiring shall be 2.5 Sq.mm or higher to
suit the wiring sizes stipulated. Clip-on type terminals shall be provided. 20%
spare terminals shall be provided on each terminal block. The terminal blocks
for C.T connections shall have C.T disconnection and shorting facility.
viii Multistrand conductors shall be terminated using suitable sleeves such that
the entire wiring is rendered finger touch proof
ix Wires of different voltages shall be identified by color code.
x Test terminal blocks shall be provided for the relays.
xi All the panels On/Off, Trip Contacts of all MCCB’s and ACB’s, Isolators
(Incoming & Outgoings) shall be wired to a common terminal block in one of
the compartment of each panel for multicore cable connection to BMS.
xii All RS-485 ports shall be looped and terminated in the above terminal
compartment.
SYNCHRONIZATION USING WITH EASYGEN – 3500 PLC Controller or Equivalent(approval

to be obtained).
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i) It shall be possible to automatically / manually synchronize a DG on to a

reference bus. The SYNCHRONIZING MODULE shall compare the
synchronizing and reference bus parameters continuously. When the
synchronization conditions are met, the SYNCHRONIZING MODULE shall
issue “Close breaker command to the controller processor. The controller
processor then shall energize the output channel, to close the breaker.
Microprocessor control shall ensure very fast response and precise load
control of generators including active & reactive load sharing. Time based
as well as load based switching of the Generators shall be possible using
controller control. The selection of Generator shall also be possible using
the controller.Switch on/off/synchronizing functions shall be based on the
load.
ii) The SYNCHRONIZING MODULE shall adopt the acceptance window

method for synchronizing the generator in Auto as well as manual mode.
The acceptance window method specifies the tolerance limits allowed for
voltage, frequency & phase angle. The following parameters shall be
checked.
Voltage mismatch : SYNCHRONIZING MODULE to generate voltage

error
Frequency mismatch : SYNCHRONIZING MODULE to generate frequency error
and gives signal to governor.
Phase angle mismatch : SYNCHRONIZING MODULE to generate phase angle

error
and gives signal to governor.
iii) When the system achieves required limits the SYNCHRONIZING MODULE
shall give a
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command to the Controller to close the breaker, in turn synchronizing the

Generators.
iv) A common manual Synchronizing facility with synchroscope /check

synchronizing relay /
double voltmeter & frequency meter, synchronizing lamps & selector
switches shall be provided for paralleling of the DG sets. Manual
synchronizing shall be by dark lamp method. These shall be housed in a
separate compartment in the DG synchronizing panel and shall have
provision to connect 2 nos., DG sets in future.
CONTROL FEATURES
The Easygen-3500 control features shall include
a) Bus paralleling
b) Alarm annunciator
c) Provision of automatic load shedding & load restoration
d) Providing detailed operational data of the system
e) Display screens listed below.
f) One line diagram
g) Generator control & summary
h) Load Trending
i) Load control
j) Analog meter
k) Current & historical alarm display
ADDITIONAL PROTECTION & METERS
In order to meet statutory requirements the following items shall be supplied in a

separate box indigenously fabricated to match the features of the panel.
1. Restricted earth fault relay for each DG set

2. KWH meter with sealable CTs.
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The relay operation shall be annunciated and recorded. The kWH & CTs shall be
calibrated at utility company’s lab if required.
Load Sharing:
a). Apart from auto synchronization, SYNCHRONIZING MODULE shall have

built-in Load sharing feature, which shall eliminate the need for any
external auto active/ reactive load sharing relay.
b). Easygen-3500 with software shall generate Raise / Lower pulse signals to
the motorized potentiometer which controls the AVR and Increase /
Decrease signals to the second motorized potentiometer which controls
the Governor to Raise or Lower the fuel flow to the turbine / DG thus
achieving speed control.
c). The Active load sharing shall be by adjusting the engine speed, and
reactive load sharing by adjacent of AVR.
Anti-Motoring Security:
The SYNCHRONIZING MODULE shall execute critical measurements

simultaneously then digitizes the time synchronized signals. Generator
frequency and phase angle shall be maintained greater than the bus, thus
providing anti-motoring protection during the connection process. Once
breaker closure has been established, data from SYNCHRONIZING
MODULE can be used for analysis for reverse energy flow.
Power Monitoring:
In addition to the synchronization function, the SYNCHRONIZING

MODULE shall monitor different electrical parameters of the
synchronizing bus and parameters of the Reference bus. The
SYNCHRONIZING MODULE shall communicate all monitoring information
to Controller via back plane. All the parameters can be seen through the
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Man Machine Interface. The system shall have provision for load shedding
to prevent a complete shutdown should any abnormal overload occur.
Communication with Controller:
Following components/accessories shall be provided along with the DG

sets in order to communicate with Controller for above mentioned
functions:
a). Alternator : QDCT

b). Bearing Temperature Detector : Scanner 2 channel drive & non
drive end
c). Winding Temperature detector : Scanner 6 channel 2 channel per
phase
d) KVAR sharing : Motorized pot of 5 K if required.
e) KWH sharing : Motorized pot if required (for governor
control)
f) Potential Free Contacts : for controller communication.
Note: 1. The components /accessories shall not be limited to the list mentioned
above but shall include all necessary items that may be required for proper
functioning of the DG set at no extra cost
2. The system offered should have necessary interface for integration with the BMS
system being contemplated for the AC / Power System management.
MAIN & AUXILIARY WIRING :
Internal wiring of power circuits rated up to 63A shall be carried out using 1100V,
FRLS grade PVC insulated, flexible copper conductor wires. Minimum size of
wiring shall be 6 Sq.mm and maximum shall be 25Sq.mm. For rating above 100A,
bus bars of appropriate size shall be used. The bus bar sizes shall be selected as
specified elsewhere.
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The internal wiring for signaling and protection and instrumentation shall be
carried out using 660V grade PVC insulated, multistrand copper conductors. The
sizes of wires shall be as follows:
For Controls & Signaling : 1.5 Sq.mm. for internal wiring.
For C.Ts : 2.5 Sq.mm for internal wiring
: Inter panel wiring shall be

carried out using PVC
troughs.
Each wire shall preferably be terminated at a separate terminal. Termination of

upto two outgoing wires at a single terminal will be acceptable. Wires shall not be
joined between terminal points. Shorting links shall be provided for all C.T
terminals. Wiring shall be neatly bunched.
Each wire shall be identified at both ends by yellow colour PVC ferrules marked
with black letters. Supporting facilities shall be provided for clamping the control
cables. Inter panel wiring shall be done by the switchgear manufacturer before
dispatch with disconnection facility at the shipping section with plug in type multi
way connector.
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Rubber grommets shall be provided so that metal parts should not come in
Minimum size of terminals for control wiring shall be 2.5sq.mm or higher to suit
the wiring sizes stipulated. Clip-on type terminals shall be provided. 20% spare
terminals shall be provided on each terminal block. The terminal blocks for C.T
connections shall have C.T disconnection and shorting facility.
Stranded conductors shall be terminated with tinned copper lugs at both ends
before connections are made.
Wiring shall be finger touch proof at all places. Where the terminals of equipment
meters/relay and accessories are not finger touch proof, insulating shrouds shall
be provided.
Control wiring requirements will be communicated to the successful bidder. The

bidder shall include necessary auxiliary contactors, A/M switches, timers &
wiring for the same.
Complete control wiring shall be fuse less.
CONTROL WIRING
a) The internal wiring for signaling and protection and instrumentation shall be
carried out using 660V FRLS grade PVC insulated, multistrand copper conductors.
The sizes of wires shall be as follows:
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For Controls & Signaling : 1.5 Sq.mm. for internal wiring.
For C.Ts : 2.5 Sq.mm for internal wiring
: Inter panel wiring shall be carried out using PVC troughs.
b) Each wire shall preferably be terminated at a separate terminal. Termination of

upto two outgoing wires at a single terminal will be acceptable. Wires shall not
be joined between terminal points. Shorting links shall be provided for all C.T
terminals. Wiring shall be neatly bunched.
c) Each wire shall be identified at both ends by yellow colour PVC ferrules
marked with black letters Supporting facilities shall be provided for
clamping the control cables. Inter panel wiring shall be done by the
switchgear manufacturer before dispatch with disconnection facility at the
shipping section with plug in type multiway connector.
d) Rubber grommets shall be provided so that metal parts should not come in
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e) Minimum size of terminals for control wiring shall be 2.5 sq. mm or higher to
suit the wiring sizes stipulated. Terminals shall be of the screw less type.
20% spare terminals shall be provided on each terminal block. The terminal
blocks for C.T connections shall have C.T disconnection and shorting facility.
f) Standard conductors shall be terminated with insulated tinned copper lugs at

both ends before connections are made.
g) Wiring shall be finger touch proof at all places. Where the terminals of
equipments meters/ relay and accessories are not finger touch proof,
insulating shrouds shall be provided.
EARTHING
All cubicles shall be connected to a common copper earth busbar of specified

size running throughout the length of the switchboard. All doors and movable
parts shall be connected to the earth bus with flexible connections.
Provision shall be made to connect the earthing busbar to the plant earthing
grid at two ends. All non current carrying metallic parts of the mounted
equipment shall be earthed.
SINGLE LINE DIAGRAM& FEEDER DETAILS
The single line diagram shall form a part of the specification. The bidder
shall quote as per single line diagram. Discrepancies if any shall be
clarified before submitting the bid. Bidder shall enclose a feeder chart
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indicating the components considered by him for each type of feeder in his
offer.
The exact components required shall be as per the Single line schematic. The
drawing does not quantify the auxiliary items like terminals, auxiliary
contactors and internal power & control wiring accessories which shall be
assessed by the supplier and included in the prices. No extra claims will be
entertained for any variation in the quantities of these items.
The bus bar ratings and physical disposition of the feeders shall be
determined from the
accompanying single line diagram.
INSPECTION & TESTING
The Switchboard shall be offered for inspection before dispatch. Following tests
shall be conducted in the presence of clients representative.
1). Routine tests as per IS
2). Heat run test for BESCOM metering and EB/DG changeover panel.
FIELD TESTING & COMMISSIONING
The field testing , will be carried out by other agencies. However the vendor
shall depute representatives for testing and commissioning the switchboard &
PLC at no extra cost.
DRAWINGS AND DOCUMENTATION

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The manufacturer shall submit for approval a schedule of drawings

which shall include the single line diagram, schematic wiring &
general arrangement of switch board indicating safe clearances,
component list with all protective devices, their settings, rated
current, foundation plan and control wiring along with terminal chart.
The approval of general arrangement should be obtained before the
fabrication of cubicles is started. Approval of schematic drawings, single
line and control wiring drawings shall be obtained before the
manufacturer proceeds with the cubicle wiring.
The approval of drawings shall not relieve the manufacturer of his responsibility
of supplying equipment conforming to the relevant specifications and standards.
Once manufacturer's schematic diagram have been finally approved, the manufacturer
shall prepare wiring connection diagram for each cubicle. These diagrams shall show
all wiring inside the cubicle starting from the cubicle terminal strips. These diagrams
which will be used for trouble shooting.
A detailed B.O.Q with component specifications and recommended spares with unit
rate there of shall be submitted one month before the delivery of the switchboards.
As a part of the contract, following documentations shall be furnished.

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Sl.N Description With For For records

o T A
. e p
n p
d r
e o
r v
a
l
Prin Softcop
t y
s
a) General
arrangemen
t and
foundation
plan of
switchboar
ds with
cross
sectional
details. 1 6 6 1
Schematic
wir
b) ing - 6 6 1
dia
gra
ms
Terminal
c) dia - 6 6 1
gra
ms
d) Switchboar
d-wise bill
of quantity
- 6 3 1
with
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detailed
component
specificatio
ns and
makes.
List of
rec
om 1
e) me - 6 3
nde
d
spa
res
Test 1
cer
tifi (Scann
cat e
f) es - - 3 d
for
swi
)
tch
boa
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g) Test
certificates
for all
1
bought out
components (Scann
like relays, e
meters, d
capacitors,
ACBs etc. - - 3 )
h) Installation 1
and
(Scann
maintenanc
e
e
d
instructions - - 3
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for ACBs, )
Relays and
Electronic
meters.
INSTALLATION
LT SWITCH BOARDS:
The Contractor shall assemble the panels dismantled for dispatch, install the
meters / relays and connect the same to the respective terminals.
The assembled panels shall be installed, aligned and grouted at the locations
indicated. Necessary bus bar inter connection shall be carried out.
The installation shall ensure that a minimum clearances 1M at the front and
750mm at the back is provided as per statutory requirements. The side clearance
shall not be less than 750mm.
All bolted joints in the busbar connections shall be tightened and busbar
clearance should be checked.
The Cables shall be terminated at the respective feeders as per drawing.
The incoming and outgoing cable sizes along with feeder identification shall be
painted on the rear side.
All Switchboards shall be earthed at two points to the Grid.
All pre-commissioning tests shall be conducted on the switchboards as specified

elsewhere.
GUARANTEE
The switchboards shall be guaranteed for trouble-free operation for a period

of 12 months from the date of substantial completion of the installation at site.
Any defects noticed during this period shall be rectified free of charges at
the shortest possible time.
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TRAINING
The contractor shall train the client’s engineers in the servicing of ACBs and
testing of releases.
STATUTORY APPROVAL
The contractor shall ensure that the design of the switchboards conforms to the
stipulations of the local authorities and shall obtain the approval. Any changes/
modifications suggested by the authorities shall be carried out at no extra cost
to the employer and to the complete satisfaction of the authority within the
shortest time.
AUTOMATIC TRANSFER SWITCH. (ATS)
The ATS shall be provided with current ratings and number of poles as shown on
the drawings. The transfer switches shall be rated for continuous duty when
installed in a non ventilated enclosure constructed in accordance with ISI and IEC
standards.
Construction and performance
1. ATS shall be double throw, actuated by two electrical operators momentarily

energized and connected to the transfer mechanism by simple overcurrent
linkages with a minimum contact-to-contact transfer time of 25 Hz. An adjustable
time delay shall be provided between the opening of the closed contacts and the
closing of the open contacts to allow additional time if required to demagnetize
motor or transformer loads before transfer.
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2. All transfer switches shall be capable of transferring successfully in either

direction with 70% of rated voltage applied to the switch terminals. The normal
and emergency contacts shall be positively interlocked mechanically and
electrically to prevent simultaneous closing. Main contacts shall be mechanically
locked in position in both the normal and emergency positions and shall be silver-
tungsten alloy. Arcing contacts with magnetic blowouts shall be provided on all
transfer switches. Interlocked moulded case circuit breakers or contactors are not
acceptable.
3. All relays, timers, control wiring and accessories shall be front accessible, all
adjustable timers shall be capable of being adjustable, while energized, through
calibrated dials. All control wire terminals shall be ring or locking spade terminals
and all wiring shall be identified by tabular sleeve type markers.
4. An external manual operator shall be provided in accordance with IEC and ISI
standards so that transfer switch can be manually operated under load, without
opening the enclosure door.
Sequence of operation
a. Engine starting contacts shall be provided to start the generating plant should the
voltage of the normal source drop below 80% (adjustable) on any phase, after a non-
adjustable time delay of 3 seconds to allow for momentary dops.
b. The transfer switch shall transfer to emergency as soon as the voltage and frequency
have reached 90% of rated voltage and as soon as directed by the load control section of
the emergency generator synchronizing switchgear.
c. After restoration of normal power on all phases to 90% (adjustable)of rated

voltage, an adjustable time delay period of 0-30 minutes shall delay retransfer to
normal power until it has time to stabilize. If the emergency power source should fail
during this time delay period, the time delay shall be bypassed and the switch shall
return immediately to the normal source.
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d. The transfer switch shall include a keyed test switch to stimulate normal power
failure, pilot lights on the enclosure door to indicate the switch closed on normal
emergency and two auxiliary contacts on the main shaft: one closed on normal, the other
closed on emergency. In addition, one set of relay contacts shall be provided to open
upon loss of the normal power supply.
Transient Suppression:
The entire transfer switch and relay plate assembly shall be capable of withstanding a
2500 volt crest transient per IEEE Standard 472-1974. The transient voltage test shall
be conducted across the normal source terminals, and (separately) across the emergency
source terminals. A certified laboratory shall be furnished to verify conformance.
Approval
a. As a condition for approval, Contractor shall furnish verification by the manufacturer

of the ATS that its switches are ISI and IEC listed with withstand and close-in values per
ISI and IEC Standards.
b. The transfer switch shall have a 3-cycle short circuit withstand capability in excess of
the minimum requirement as follows:
 4000A (amperes) - 100,000 RMS amperes symmetrical

 A withstand rating series with special breaker or fuse is not acceptable.
c. During the 3-cycle short circuit closing and withstand tests, there shall be no contacts
welding or damage. The three cycle short circuit tests shall be performed without the use
of current limiting fuses and oscillograph traces across the main contacts shall be
furnished to verify that contact separation has not occurred and there is contact
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continuity across all phases after completion of testing. Test procedures shall be in
accordance with IEC and ISI standards.
d. When conducting temperature rise tests, the manufacturer shall include post
endurance temperature rise tests to verify the ability of the transfer switch to carry
full rated current after completing the overload and endurance tests.
ACCESSORIES
A. Accessories furnished with the automatic transfer switch shall include without
limitation the following: 1. Function
a. Transfer relay energized from normal source.

b. Engine start control directly connected to normal source with fuse block (2 fuses)
and terminals.
c. Time delay to override momentary normal source power outages to delay
engine start signal
and transfer switch operation adjustable 0.5-3 seconds, factory set at one
second.
d. Time delay on retransfer to normal. Motor driven type, adjustable 0-25 minutes,
factory set 5
minutes.
e. Close differential solid state adjustable phase sensing relay energized form
normal source set to pick up at 90% of rated voltage drop out at 70%.
f. Toggle switch to manually bypass time delay on re-transfers to normal.
g. Load test switch to simulate normal power failure. (Momentary contact type).
h. Contact to close on failure of normal source to initiate engine starting or other
custom. functions.
i. Contact to open on failure to normal source to initiate engine starting or other
customer functions.
j. Green pilot light to indicate switch in normal position.
k. Red pilot light to indicate switch in emergency position.
l. Auxiliary contact closed in normal position. Quantity of 4.
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m. Auxiliary contact open in emergency position. Quantity of 4.

n. Auxiliary contact open when switch bypassed to the emergency source.
o. Relay to prevent transfer to emergency until voltage and frequency have reached
90% rated value.
p. 20A fused circuit energized from emergency source. Line to line. N1 and N3.
circuit with 10A fuses plus 2-
q. 10A fuses spare. Fuses shall be current limiting, 50,000 A.I.C (2) PoleProvide an
engraved nameplate as
"ATS No" and “Name","415V, 3 phases 4 pole" "By- pass" if applicable.
INSTALLATION OF AUTOMATIC TRANSFER SWITCHES
Each ATS and its associated bypass/isolation switch (BPA) shall be mounted in a
freestanding enclosure painted light gray and bussed together with copper bus to
provide a complete and protested assembly. Aluminum bus and cable interconnections
are not acceptable. The ATS shall be completely isolated from the BPA by means of
insulating barriers and separate access doors to positively prevent exposure to operating
personnel from the BPA while servicing the ATS.
BUSDUCT & RISING MAINS
The busduct should be of Sandwich type and must comply with

IS 6031,6032 international IEC 439-2 standards and the
European EEN 60439-2 standards and should be as per the
specified BOQ .
4.01. Electrical characteristics below to be filled up by the Contractor/Supplier/Separate data

sheet to be submitted for Different rating of Busducts
BUSDUCT DATASHEET
S Description Un DATA
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N it
1 System nominal voltage Vo

lt
2 System frequency Hz
3 Number of phases
4 Rated Continuous current A
Overload capacity
5 Clearances
a. Minimum phase to phase clearance mm
b. Phase to body clearance mm
6 Neutral grounding
7 Insulation level
a. 1 minute dry power frequency kV rms

withstand voltage
b. Impulse withstand voltage
8 Short time rating (symmetrical kA for 1 kA

second)
9 Cooling
10 Design ambient temperature °C

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N it
11 Location
12 Degree of protection
13 Maximum temperature rise (over 40°C

ambient)
a. Bus conductor °C
b. Bus enclosure and support °C

structure
14 Material
a. Busbar
b. Enclosure
15 Constructional features
a. Busbar joints
b. Flexible / expansion
i. Material
ii. Type
iii. Short circuit & continuous rating

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N it
c. Cover over chamber
16 Enclosure joints
17 Disconnecting link
18 Insulators
Non-hygroscopic FRP/SMC with high Anti-

tracking index(Hylem Sheet support of any
grade is not acceptable)
19 Creepage distance
20 Seal off Bushing at wall entries
21 Ground bus
22 Grounding terminal
23 Paint finish
a. Inside
b. Outside
c. Coating thickness
24 Applicable standards
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25 Acceptance tests
26 Inspection
The busduct system shall have a degree of protection as follows :
 IP 40 to IP 52.
 IP 54 with sealing accessories.
 The bus duct system shall include 4 active conductors. The length of the straight
sections of the bus duct system shall be 3mtrs.
 The bus duct system may be mounted vertically.
Construction and operation
 The casing shall be made of hot-galvanized steel plate and shall include the
required tap-off trap doors per floor on both sides.
 The tap-off trap doors shall be fitted with automatic blanking shutters that
prevent any accidental contact with live parts. The protective conductor shall be
electrically connected to the casing at each section joint.
 The conductors shall be mounted on fibre glass reinforced polyester isolators.
 Electrical junctions would be two sections shall be by elastic contacts designed to

absorb differential dilation between the conductors and the casing.
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 It shall be possible to visually ensure that the electrical junctions has been made.
 The mounting brackets shall be designed to be attached to the wall every 3mtrs.
 To optimize performance, the trunking shall be equipped with aluminium

conductors (for a very good weight / conductivity / heat dissipation
compromise). All the electrical contacts at the ends of the section and at the tap-
off windows shall be made of silver-plated copper (for excellent conductivity).
 The bus duct system may accommodate a wide range of tap-off boxes equipped
with circuit breakers (with adjustable O/I & S/C protection) which guarantee
discrimination with the upstream protections. These boxes may also be used with
the high rating bus bar trunking system range.
 Special sections shall be used to allow any change in direction of by passing of

obstacles.
Protection and safety
 All the insulating and plastic materials (shutters, boxes, etc.,) that are used shall
have improved fire behavior: hot wire ignition test withstand in compliance with
the IEC 695-2- 1 standard.
 The tap off boxes shall have the following characteristics ;
 Plugging in and unplugging with the door open only.
 The protective conductor contact shall automatically open the blanking shutter
and polarize the tap-off.
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 When the tap-off box is plugged in, the earthing contact shall be established
before the contact of the active conductors, inside the trunking and protected
from dirt.
 There shall be no access to active parts when the door of the tap-off box is open.
(IP 42).
 It shall be impossible to close the door of the box unless the boxes mechanically
locked to the busduct.
 It shall be possible to position the box on the bustduct without using tools.
. The power control panels shall be metal clad, totally enclosed, rigid, floor
mounting, air insulated, cubical type for use on 415 volts, 3 phase, 4 Wire 50
cycles system. The equipment shall be designed for operation in high ambient
temperature and high humidity tropical atmospheric conditions. Means shall be
provided to facilitate ease of inspection, cleaning and repairs, for use in
installations where continuity of operation is of prime importance.
The equipment shall be designed to confirm to the requirements of:
IS 4237 - General requirements for switchgear and control gears for voltages not
exceeding 1100 volts.
IS 2147 - Degree of protection provided by enclosures for low voltages switchgear and
control gear.
IS 375 - Marking and arrangements of busducts. Individual equipment housed in the

power control to the following IS specifications:
i) Air circuit breakers - IS 2516 (Part I & II/Sec.1) 1977.

ii) Fuse switch and switch fuse units - IS 4064: 1978.
iii) HRC fuse links - IS 1108: 1962 or IS 9114: 1979.
iv) Current Transformer - IS 2705.
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v) Voltage Transformer - IS 3156.

vi) Relays - IS 3231.
vii) Indicating Instruments - IS 1248.
viii) Integrating Instruments - IS 711.
ix) Control Switches and push buttons - IS 6875.
x) Auxiliary contractors - IS 2959.
CONSTRUCTIONS:
The power control panels shall be:
i) Of the metal enclosed, indoor, floor mounted, free standing type.
ii) It shall be made up of the requisite vertical section, which when coupled together
shall form continuous dead front switch boards.
iii) Provide dust and dump protection, the degree of protection being not less than IP 52
to IS - 13947.
iv) Be readily extensible on both sides by the addition of vertical sections after removal
of the end covers.
Each vertical section shall comprise:
i) A front framed structure rolled / folded sheet steel channel section of minimum 3mm thick,
rigidly bolted together. This structure shall house the components contributing to the
major eight of the equipment, such as circuit breaker cassettes, fuse switch units, main
horizontal bus ducts, vertical risers and other front mounted accessories.
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ii) The structure shall be mounted on a rigid base frame of folded sheet steel of minimum 3mm
hick and 100mm height. The design shall ensure that the weight of the components is
adequately supported without deformation or loss of alignment during transit or during
operation.
iii) A cable chamber shall house the cable end connections of power / control cable
termination. The design shall be to ensure generous availability of space for easy
installation and maintenance of cabling, and adequate safety for making in one vertical
section without coming into accidental contact with live parts in and adjacent sections.
iv) A cover plate at the top of the vertical section, provided with a ventilating hood where
necessary. Any aperture for ventilation shall be covered with a perforated sheet having
less than 1mm diameter perforated to prevent entry of vermin.
v) Front and rear doors shall be fitted with nuts/bolts including neoprene gaskets with
fasteners designed to ensure proper compression of the gaskets. When covers are
provided in place of doors, generous overlap shall be assured between sheet surfaces
with closely space fasteners to preclude the entry of dust. The height of the panel should
not be more than 2400mm. The maximum height of any operating mechanism shall not
be more than 2100mm. The total depth should be adequate to cater for proper cabling
space.
vi) Doors and covers shall be of minimum 14 gauge sheet steel. All sheet steel work
forming the exteriors or switchboards shall be smoothly finished, leveled and free
from flaws. The corners should be rounded. The apparatus and circuits in the
power control panels shall be so arranged as to facilitate their operation and
maintenance and at the same time to ensure the necessary degree of safety.
Apparatus forming part of the power control panels shall have the following minimum
clearances:
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i) Between phases - 25 mm
ii) Between phases and neutral - 25 mm
iii) Between phases and earth - 25 mm
iv) Between neutral and earth - 25 mm
If for any reason, the above clearances are not available suitable insulation shall
be provided. Clearance shall be maintained during normal services conditions.
Creep age distances shall comply to those specified in relevant standards. All
insulating materials used in the construction of the equipment shall be arranged
in multi-tier formation, except that not more than two air circuit breakers shall be
housed in a single vertical section. Metallic / insulated barriers shall be provided
within vertical sections and between adjacent sections to ensure prevention of
accidental contact with:
i) Main bus ducts and vertical risers during operation, inspection or maintenance of
functional units and front mounted accessories.
ii) Cable termination of one functional units, where working of those of adjacent
unit / units.
All covers providing access to live power equipment / circuits shall be provided with
tool operated fasteners to prevent unauthorized access. Provision shall be made
for permanently earthing the frames and other metal parts of the switch gear by two
independent connections.
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METAL TREATMENT AND FINISH:
All steel work used in the construction of the switchboards should have undergone a
rigorous metal treatment process as follows:
a) Effective cleaning by hot alkaline degreasing solution followed by

cold water rinsing to remove traces of alkaline solution.
b) Picking in dilute sulfuric acids to remove oxide scales and rust

formation, if any, followed by cold water rinsing to remove traces of
acidic solution.
c) A recognized phosphating process to facilitate durable coating of the

paint on the
metal surfaces and also to prevent the spread of rusting in the event of
paint film
being mechanically damaged. This again, shall be followed by hot water

rinsing
to remove traces of phosphate solution.
d) Passivating in de-oxalite solution to retain and augment the effects of

phosphating.
e) Drying with compressed air in a dust free atmosphere.
f) Primer coating, with two coats of highly corrosion resistant primer,

applied wet
on stove dried under strictly controlled conditions of temperature and
time.
g) A finishing coat of stoving synthetic enamel paint to the specified shade of

IS. The total thickness of paint should not be less than 25 microns.
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BUS BARS
1. The bus bars shall be Sandwich type and made of high conductivity, high strength
aluminium /copper alloy complying with the requirement of grade E91E of IS
5082.
2. High tensile bolts and spring washers shall be provided at all bus bar joints.
3. The main phase bus bars shall have continuous current rating throughout the
length of each power control panel, and the neutral busbars shall have a continuous
rating of at least 50% of the phase bus bars.
4. Bus bars shall be colour coded for easy identification of individual phases and
neutral and protective earth.
5. CURRENT TRANSFORMER: Current transformer shall comply with the requirements

of IS 2705. They shall have ratios, outputs and accuracy’s as specified / required.
6. INDICATING/INTERGRATING METERS: All indicating instruments shall be of flush

mounting industrial pattern, conforming to the requirements of IS 1248. The instrument
shall have non-reflecting dial, clearly divided and legibly marked scales and shall be
provided with adjusting devices in the front.
7. CABLE TERMINATION: Cable entries and terminals shall be provided in the switch-
board to suit the number, type and size of aluminum conductor, power cable and
copper conductor control cable specified in the detailed specifications.
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8. Provision shall be made for top or bottom entry of cables as required. Generous size
of cabling chambers shall be provided, with the position of cable glands and terminals
such that cables can be easily and safely terminated. The minimum depth of the panel
shall be restricted to 1600 mm for this purpose.
9. Barriers or shrouds shall be provided to permit safe working at the terminals of one
circuit currents without accidentally touching that of another live circuit. Cabling risers
shall be adequately supported to withstand the effects of rates short circuit currents
without damage and without causing secondary faults. Cable sockets shall
be of copper and of the crimping type as specified.
CONTROL WIRING:
All control wiring shall be carried out with 1100 / 660 V grade single core VC cable
conforming to IS 694 / IS 8130 having standard copper conductor of minimum 1.5 Sqmm
section for potential circuits and 2.5 mm section for current transformer circuits. Wiring
shall bear neatly bunched, adequately supported and properly routed to allow for easy
access and maintenance.
Wire shall be identified by numbered ferrules at each end. The ferrules shall be of the
ring and of non-detoriating materials. They shall be firmly located on each wire so as to
prevent free movement. All control circuit fuses shall be mounted in front of the panel
and shall be easily accessible.
TERMINAL BLOCKS:
Terminal blocks shall be of 500 volts grade of finger touch proof type. Insulating
barriers shall be provided between adjacent terminals.
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LABELS:
Labels shall be on anodized aluminium, with white engraving on black

background. They shall be properly secured with fasteners.
TESTS:
Routine tests shall be conducted on each power control panel in accordance

with CI 81, 2.2 of IS 8623 and shall comprise:
i) Inspections of the power and control circuits including inspection of wiring and
electrical operational tests where necessary.
ii) Dielectric tests.
iii) Checking of protective measures and electrical continuity of the protective

circuits.
STORING:
The panels shall be stored in well-ventilated dry places. Suitable polythene covers
shall be provided for necessary protection against moisture.
ERECTION:
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Switch boards shall be installed on suitable foundation. Foundation shall be per

the dimensions supplied by the panel manufacturer. The foundation shall be flat
and level. Suitable grouting holes shall be provided in the foundation. Suitable MS
base channel shall be embedded in foundation on which the panel can be directly
installed. The switch boards shall be properly aligned and bolted to the foundation
by bottom plate or top plate as the case may be, by using brass Siemens type
compression glands. The individual cables shall then be led through the panel to
the required feeder compartments for necessary terminations. The cables shall
be clamped to the supporting arrangements. The switch board earth bus shall be
connected to the local earth grid.
PRE-COMMISSION TESTS:
Panels shall be commissioned only after the successful completion of the following
tests.
The tests shall be carried in the presence of main contractor.
a) All main and auxiliary bus bar connections shall be checked and tightened.
b) All wiring terminations and bus bars joints shall be checked and tightened.
c) Wiring shall be checked to ensure that it is according to the drawings.
d) All wiring shall be tested for insulation resistance by a 1000 Volts Megger.
e) Phase rotation tests shall be conducted.

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f) Suitable injection tests shall be applied to all the measuring instruments to

establish the correctness and accuracy of calibration and working order.
g) Suitable injection tests shall be applied to all the measuring instruments to

establish the correctness and accuracy of calibration and working order.
h) All relay and protective devices shall be tested for correctness of settings and
operation by introducing a current generator and ammeter in the circuit.
Static Uninterruptible Power Supply
1. General
The scope involves design, supply, installation testing and commissioning of the
UPS as per the BOQ which should be in line with the latest IS standards. The UPS
should be as per the specified make until and unless an approval for alternate is
provided by the main contractor. All prior i
2. Work Included
A. Static uninterruptible power supply (UPS).
B. The system shall be fully coordinated and compatible with electrical,

environmental, and space conditions at the facility.
2.2. Related Work
A. This Section shall be used in conjunction with the following other

specifications and related Contract Documents to establish the total
requirements for static uninterruptible power supply:
1) Section 16010-A (European) - Basic Electrical Requirements.
2) Section 16430-A (European) – Low-Voltage Metal-Clad Switchgear.
B. CAUTION! Use of this Section without including the above-listed item will
result in omission of basic requirements.
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C. In the event of conflict regarding static uninterruptible power supply

requirements between this Section and any other section, the provisions
of this Section shall govern.
2.3. System Description
A. System Configuration: as shown on the drawings and appendix to this

specification in the BOQ.
1) Continuity of electric power to the load shall be maintained for a period as
indicated in the schedule, with the UPS supplied by battery power until
restoration of the normal power supply.
2) The UPS system shall consist of two or more modules of the same size sharing
load. The system shall be a “N+1” redundant system, sized as required/ as
specified/approved.
3) The UPS system shall be isolated or parallel redundant operation. The UPS
system shall have one module more than that required to supply the full-rated
load. The UPS system shall be sized to provide the minimum required kVA and
the minimum required kW output with one UPS module out of service. Fully
rated static and maintenance bypass switches shall be provided in separate
enclosures.
4) The UPS system shall be sized to maintain a kVA and kW load per approved
design and be equipped with a battery able to supply this load for the time
indicated in the schedule, at a temperature of 25 degrees C. The battery is to
provide 100 percent of the specified capacity after 10 years of operation.
B. Components: System shall include battery to provide continuous source of

electrical power; rectifier/battery charger to maintain battery charge and
to provide input to inverter when utility power is available; inverter to
provide power to load during normal operation; static switches to transfer
load automatically and without disturbance between inverter and utility
power in case of inverter failure; manual switches to bypass static
switches for maintenance; input and output filters to provide appropriate
disturbance attenuation; and necessary monitors, sensors, and control
circuits.
C. Utility Power Available: Rectifier/charger shall supply load through

inverter and maintain battery in fully-charged float condition. System
power walk-in shall be accomplished within 15 seconds of energizing, with
provision for an adjustable timer function to delay start of power walk-in
to facilitate power restart from a generator.
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D. Utility Power Failure: Load shall be supplied from battery through static
inverter if utility power drops below preset limits, or fails. There shall be
no output disturbance transmitted to load.
E. Utility Power Returns: Rectifier/charger shall supply power to load

through inverter while it recharges battery. There shall be no output
disturbance transmitted to load.
F. Rectifier/Charger or Battery Failure: Static switch shall transfer load to

synchronized utility power, without disturbance, when inverter output
deviates beyond specified quality limits. When inverter output returns to
acceptable operation, it shall synchronize to utility power, and after preset
timing interval, static switch shall return load to inverter without
disturbance.
G. Overload or Short Circuit: Static switch shall transfer load to utility power
during load inrush and clearing of faulted branch circuits; load shall
automatically transfer back to inverter without disturbance.
H. Inverter Failure: In the event of failure of all inverters static switch shall
transfer to utility power without disturbance and remain until manually
returned. In the event of failure of an individual inverter, the load will be
shared by the remaining modules without disturbance.
I. Maintenance Operation: For simultaneous maintenance of all parallel

modules load shall be transferred manually to utility power using bypass
switch. During bypass mode, operation of system or static switch shall not
affect power to load. For maintenance of an individual module, load shall
be shared by remaining modules.
J. The batteries shall be with 2 Strings.
2.4. Warranty
A. UPS: Provide a 1-year warranty. Acceptance occurs when UPS has

satisfactorily passed all startup and field tests, operates satisfactorily, and
meets these specifications fully.
B. Battery: As per approved design/specification.
C. General: Include coverage of travel, labor, parts, and service.

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2.5. Regulatory Requirements
2.6. The UPS and battery system shall comply with the latest editions of
the relevant IS, British standards, IEC regulations and all current EU
directives.
2.7. Quality Assurance
A. Manufacturer: company specializing in packaged UPS systems and

manufacturing the product specified in this Section with minimum 5 years'
documented experience.
B. Vendor shall be an authorized distributor of UPS or a manufacturer with

service facilities within 100 km of project site.
2.8. Environmental Requirements
A. Environmental Range: The UPS shall be able to withstand any

combination of the following environmental conditions, and maintain
operation without mechanical or electrical damage or degradation of
function when the UPS module is mounted inside an enclosure with access
doors closed:
1) Temperature: zero degrees C to plus 40 degrees C.
2) Humidity: relative humidity up to 95 percent noncondensing.
3) Barometric Pressure: sea level to 1,200 meters above sea level.
4) Storage: minus 20 degrees C to plus 70 degrees C, sea level to 1,200 meters
above sea level.
2.9. Submittals
A. Provide the following within 10 days of award of Subcontract:

1) System configuration and rating with final single-line diagrams/shop drawings
for approval. All circuit breakers and disconnects shall be identified by location,
frame size, trip setting, and with manufacturer type and number.
2) Functional relationship of various equipment including weights, dimensions,
normal and service access areas, heat dissipation, and airflow requirements of
each unit. Details of battery rack dimensions, battery type, size, dimensions, and
weight.
3) Details and scaled layouts of all UPS equipment, including battery racks.
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4) Detailed descriptions of equipment to be furnished, including product data for

major components such as batteries. Include catalogue sheets and technical
data sheets to indicate physical data and electrical performance.
5) Size and weight of individual shipping units to be handled by Subcontractor in
the field.
6) Detailed layouts of all metering, alarm, and mimic panels. The metering sensing
points are to be shown on the single-line diagram.
7) Detailed layouts and locations of customer power and control cable connection
points.
8) Manufacturer's certificate that system meets or exceeds specified requirements.
B. Provide the following within 10 days of award of Subcontract:

1) Detailed installation drawings including all terminal locations.
2) Interconnect wiring diagrams showing all external power and control cable runs
with terminal numbers for each wire.
3) Full system schematic wiring diagram.
4) Sequence of operations of the UPS system in Microsoft Word for Windows
electronic document format.
2.10. Operation and Maintenance Data
A. Provide the following at least 1 week prior to UPS delivery:

1) Operation and maintenance manual which includes functional description of the
equipment with detailed block diagrams, safety precautions, installation and
startup procedures, and maintenance procedures, including drawings and
illustrations.
2) Onsite written test procedure as defined by the main contractor.
2.11. Maintenance Service
A. Furnish service and maintenance of UPS including batteries for 1 year

from Date of Substantial Completion.
3. Products
3.1. Acceptable Manufacturers
A. APC
B. Mitsubishi..
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C. Emerson.
D. Numeric.
3.2. System Ratings and Operating Characteristics
A. System Continuous Rating: _______kVA and __________kW as per approved

specification, over entire battery voltage range at specified power factor.
Maintain output voltage within specified limits at any load from full load to
no load.
B. Battery Capacity: as scheduled.
C. Input:
1) Voltage:
a. Nominal: as per approved specification.
b. Configuration: three-phase, four-wire plus earth.
c. Limits: plus 10 percent, minus 15 percent.
2) Frequency Range: plus or minus 5 percent (50 Hz).
3) Current In-Rush Limiting: 20 percent to 100 percent of full rated load over
15 seconds.
4) Magnetizing Subcycle In-Rush: eight times normal full load input current
maximum.
5) Power Factor: 0.83 to 0.95 lagging from 10 percent to 100 percent.
6) Current Limit: determined by upstream circuit breaker. Vendor to advise
upstream circuit breaker ratings and setting.
7) Harmonic current injection: 4 percent maximum.
8) Fault Current: prospective fault level of 65 kA rms symmetrical.
D. Output:
1) Voltage Level: as per Approved specification.
2) Voltage Regulation: three-phase, four-wire plus ground, plus or minus
0.5 percent for balanced load, plus or minus 2 percent for 50 percent
unbalanced load.
3) Voltage Adjustment Range: plus or minus 5 percent manually.
4) Frequency regulation: 0.1 percent.
5) Phase Displacement:
a. Balanced Loads: 120 degrees plus or minus 1 degree.
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b. 50 Percent Unbalanced Loads: 120 degrees plus or minus

3 degrees.
6) Voltage Unbalance:
a. Balanced Load: plus or minus 1 percent from the arithmetic
average of the three phases.
b. 20 Percent Unbalanced Load: plus or minus 1 percent from the
arithmetic average of the three phases.
c. 50 Percent Unbalanced Load: plus or minus 2 percent from the
arithmetic average of the three phases.
7) Voltage Transients (load step to include both “on-loading” and “off-loading”):
a. 20 Percent Load Step: plus or minus 4 percent.
b. 30 Percent Load Step: plus or minus 5 percent.
c. 50 Percent Load Step: plus or minus 8 percent.
d. Loss or Return of Ac Input Power: plus or minus 1 percent.
e. Manual transfer of 100 Percent Load: plus or minus 4 percent.
8) Voltage Transient Recovery Time: to within 1 percent of output voltage rating
within 59 milliseconds.
9) Harmonic Content: maximum 3 percent rms total, maximum 1 percent any
single harmonic across full load range and full battery voltage range.
10)Overload with Full Voltage: 125 percent of full load rating for a period of
10 minutes. 150 percent of full load rating for a minimum of 60 seconds.
11)Current Limit: 150 percent of full load current.
12)Fault Clearing: subcycle current of at least 300 percent, but not more than
500 percent of normal full load current.
E. Audible Noise: Noise generated by the UPS under any condition of normal
operation shall not exceed 69 dBA in accordance with ISO 3746.
F. Grounding: The UPS module ac neutral shall be electrically isolated from

the UPS module chassis. The UPS module chassis is to be provided with a
separate equipment ground system terminal. The battery rack
components shall be bolted together to form a completed earthed rack.
G. Efficiency: The efficiency of the UPS is to be measured under the following

conditions:
1) UPS, operating at full-rated load, ___kVA, and______ kW.
2) Battery, fully charged and floating on the system.
3) Input voltage within specified range.
4) Efficiency is defined as output kW divided by input kW.
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5) Minimum Efficiency at Full Load: 94 percent.

6) Efficiency of individual modules and of complete system to be measured at 10
percent to 100 percent load in 10 percent increments.
3.3. Design and Construction
A. Line-Up Arrangement: Each UPS system shall be arranged in a single

continuous line-up with UPS modules and bypass static switches unit
mounted side-by-side
B. Rectifier/Charger Unit:
1) Each rectifier/charger unit shall be solid state and shall provide direct current
to the inverter unit and for battery charging.
2) Each UPS module shall be provided with an input disconnect switch.
3) In addition to supplying power for the load, the rectifier/charger shall be
capable of recharging the batteries. The charging rate shall be sufficient to
restore the battery from discharge to 95 percent of full charge within ten times
the discharge time. After the battery is recharged, the rectifier/charger shall
maintain the battery at full charge until the next emergency operation.
4) The battery charger shall have float voltage temperature compensation facility.
5) The initial magnetization in-rush current shall be limited to 600 percent of the
rectifier/battery charger full-load current. The rectifier/battery charger shall
have a minimum power factor of 0.8 lagging at nominal input voltage and
frequency, and with the inverter operating at full-rated load.
6) The input ac current limit shall be designed so that demands in excess of the dc
output current needed to operate the inverter at rated load and simultaneously
recharge a discharged battery to 95 percent of its original capacity shall not
cause a corresponding decrease in the output dc voltage from the
rectifier/battery charger.
7) The rectifier/battery charger shall be provided with output filtering to limit the
ipple voltage to less than 2 percent RMS maximum in the automatic float charge
state with the battery disconnected.
8) The system shall monitor end of battery discharge voltage and automatically
cut-off the charger when this voltage is reached, to protect the batteries. In
addition, when the discharge time is greater than one hour, the shutdown
voltage shall be automatically increased to avoid deep discharge of the batteries
due to a light load.
C. Inverter:
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1) Each inverter unit shall be a solid-state device capable of accepting the output of
the rectifier/charger or battery and providing rated output within the required
specified limits.
2) Electronic controls shall be incorporated to provide individual phase voltage
compensation to obtain phase voltage balance under all conditions, including up
to a 50 percent current unbalance.
3) Each inverter unit in the system shall have fault sensing and static isolation, as
well as output circuit protection, for removal of a faulted module from the
system without affecting the critical load bus. Output circuit shall be suitably
protected for single module load testing using a load bank.
4) The inverter shall be constructed of solid-state devices capable of providing the
specified rated volt-amperes (VA) within the operating range of the battery
while connected to a 1 to 0.8 leading or lagging power factor load. The inverter
shall current-limit for loads in excess of 150 percent of its full-load rating.
Maximum effective current at the output of the inverter (when bypass ac input
is not available) shall be 150 percent.
5) Static voltage regulation of the inverter steady-state output shall not deviate by
more than plus or minus 2 percent under any of the following conditions:
a. Ambient temperature variations.
b. Minimum to maximum dc bus voltage.
c. Maximum frequency excursions.
6) The inverter shall have a manual adjustment control to regulate output voltage
plus or minus 5 percent from the rated value.
7) For balanced load conditions, the inverter phase displacement shall be
120 degrees, plus or minus 1 degree maximum. For 50 percent unbalanced
loads, phase displacement shall be 120 degrees, plus or minus 3 degrees
maximum.
8) The frequency transients for system disturbances shall not deviate by more than
plus or minus 0.1 percent.
9) The inverter shall provide harmonic neutralization and filtering to limit the total
harmonic distortion (THD) in the output voltage to 3 percent and single
harmonics to 1 percent over the entire linear load range.
10)Output voltage shall not exceed plus or minus 6 percent for 50 percent step-load
change or transfer of full-rated load to/from bypass, plus or minus 2 percent
loss or return of input ac.
D. Protection:
1) Each UPS module shall have built-in self-protection against overvoltage power
line surges, undervoltages, and overcurrent introduced by the primary ac
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source, plus overvoltage and voltage surges introduced at the output terminals
by paralleled sources, load switching, and circuit breaker operation in the
distribution system. Each UPS module shall be self-protected against
overcurrent, sudden changes in the output load, and short circuits at the output
terminals.
2) Under parallel redundant operation, the protection system shall have control
logic capable of isolating only the faulted module, and shall not shut down the
entire UPS system for a fault in one module.
3) Each UPS module shall be provided with a control section to provide monitoring
and control of the UPS module. The meters, alarms, controls, and mimic panel
shall be located on the control section door. Failure of the control section shall
not inhibit operation of the UPS module.
4) Provide a recommendation for the upstream and downstream circuit breaker
setting ranges to achieve full discrimination and coordination for the overall
protection scheme.
E. Static Bypass Transfer Switch:

1) Description: The UPS shall contain fully rated solid-state static bypass transfer
switches which allows a "make before break" or overlap type transfer of the
load from the UPS output to the utility power source or back again without
interruption of power to the critical load. Forward and reverse contactors shall
not be used. The system shall provide for two separate bypass cabinets
complete with static switch, input/output and maintenance bypass isolation.
The control unit shall provide a facility for selecting either bypass unit. The
control unit shall contain an automatic transfer circuit which senses the status
of the inverter logic signals and alarm conditions and initiates uninterrupted
transfer of the load in case of malfunction of the UPS or external overload. The
static bypass transfer switches shall be rated at 1,000 percent of UPS output
rating for 16 milliseconds, 400 percent for 1 second, and 150 percent for
1 minute and 125 percent continuous. The switches shall be rated for the
full kVA system rating. In addition, the static switches shall be sufficiently rated
to meet the following criteria:
a. No damage shall occur while the upstream circuit breaker is
clearing a short circuit fault on the output side of the static switch.
b. No damage shall occur while the downstream branch circuit
breaker is clearing a fault on its output.
2) Transfer Conditions:
a. The static bypass switch shall transfer from the inverter to the
bypass normal power source for the following conditions:
i. System Inverter Undervoltage: less than 90 percent of nominal.
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ii. System Inverter Overvoltage: greater than 110 percent of

nominal.
iii. Inverter overload.
iv. Manual signal.
b. The static bypass switch shall inhibit transfer to the bypass
normal source for the following conditions:
i. Bypass Normal Source Undervoltage: less than 84 percent of
nominal.
ii. Bypass Normal Source Overvoltage: greater than 116 percent of
nominal.
iii. Inverter not synchronized and in phase with the bypass normal
source.
c. Automatic Retransfer Conditions -- The system shall automatically
retransfer the load to the inverter provided all of the following
conditions are met:
i. The inverter logic and the bypass normal source are synchronized
and in phase.
ii. Inverter conditions are normal for 32 seconds.
iii. The retransfer selection is in the automatic mode.
iv. The UPS output is not overloaded.
F. Maintenance Bypass Switch: An externally mounted, manually operated,

aintenance bypass switching arrangement shall be provided which
permits bypassing the critical loads to the bypass (reserve) ac power
source without interruption of power to those loads and also electrically
isolates the static bypass switches and inverter from the bypass normal
power source. The switches shall be rated for the full kVA system rating.
G. All internal circuit breakers shall comply fully with Section 16430-A
(European) – Low-Voltage Metal-Clad Switchgear, with regard to
acceptable manufacturers.
H. Battery Circuit-Breaker, Input and Output switchgear:

1) Include for the supply and delivery of the battery circuit breakers. The battery
circuit-breakers shall be of Merlin Gerin or ABB manufacture mounted in
freestanding cubicles. The complete assembly of two or more battery circuit-
breaker cubicles for each UPS system shall be mounted on a rigid channel iron
plinth. The degree of enclosure protection shall be IP 44 minimum. The design
of the circuit-breaker cubicles shall conform to BS EN 60439-1: 1994, Form 4.
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2) Where input and/or output switchgear is being provided by the UPS vendor,
they shall comply fully with Section 16430-A (Europe)- Low-Voltage Metal-Clad
Switchgear and be supplied to the UPS vendor by the acceptable OEM
switchgear vendors stated within this Section.
I. Controls and Indicators:

1) Control Panel: The UPS shall provide microprocessor-based monitoring and
control for the complete system via a control panel equipped with monitoring,
controls, digital displays, light emitting diode (LED) common alarm indicator,
and an audible alarm as described below.
2) Meters: The following functions shall be monitored by a digital meter with plus
or minus 2 percent accuracy:
a. Ac input voltage.
b. Ac input current.
c. Ac input kVA.
d. Ac input kW.
e. Ac input power factor.
f. Ac output phase voltage.
g. Ac output current/phase.
h. Ac output kVA.
i. Ac output kW.
j. Ac output power factor.
k. Ac output frequency.
l. Ac output current phases A, B, and C (on the load side of the UPS
and static switch).
m. A dc battery charge/discharge current meter.
n. A dc battery voltage meter.
o. A dc battery time remaining.
3) Controls:
a. Input/output voltmeter phase selector.
b. Output current selector.
c. Bypass voltmeter phase selector.
d. Output frequency selector.
e. Alarm acknowledge (alarm silence).
f. LED test.
g. On bypass switch (protective cover).
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h. On UPS switch (protective cover).

i. Emergency power off (protective cover).
j. Ac input disconnect switch.
k. Switch phase select.
l. Switch function select.
m. Lamp test/reset push button.
n. Facility to enable controlled shutdown of batteries and inverter in
an emergency.
4) Digital display of alarm and operating conditions shall be as follows:

a. Fuse blown.
b. Input power fail.
c. UPS on.
d. Bypass on.
e. Low battery.
f. Overload.
g. Equipment overtemperature.
h. Battery dc breaker open.
i. Emergency power off.
j. Bypass fail.
k. Battery discharge.
l. Fan failure.
m. Dc ground fault.
n. Dc overvoltage.
o. UPS operating from battery supply; also provide two auxiliary
normally closed contacts for remote indication of this condition.
p. The UPS shall be equipped with a self-test function to verify
correct system operation. The self-test function shall identify any
faulty sub-systems of the UPS.
q. The UPS shall be equipped with a system providing start-up and
operating assistance and offering the following function:
i. Display of installation parameters, configuration, operating
conditions, alarm status and step-by-step instructions for
switching operations.
ii. Storage in memory and automatic or manual recall of all
important status changes, faults, alarms and malfunctions. The
system shall record the time and date of all such events.
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5) Audible Alarm: A horn shall be located on the system control and status panel.
The horn shall be a solid-state acoustical transducer and shall produce an
audible warning of not less than 60 dB. It shall be activated whenever one or
more warning or malfunction indicators are energized.
6) Interface Requirements to Intel's BMS (Building Management System):
normally closed, 24-Vdc rated volt-free contacts shall be available to perform
the following functions:
a. Provide common alarm signal to indicate faults to the BMS from
each UPS Unitary module.
b. A signal that will automatically shut down production tools
(equipment) when the UPS supplying that tool is on batteries due
to power failure. The necessary signals shall be via the BMS. Note:
During a discharge test or momentary switchover to batteries, the
shutdown signal must not be initiated to the tool via the BMS.
c. If any of the modules are isolated and equipment is being supplied
via the remaining modules, the BMS must be given a signal.
d. If a module is faulty, it shall provide the facility to signal this to the
BMS.
e. If the UPS system supplying load switches to raw mains via the
static bypass due to fault or overcurrent, the BMS shall receive a
signal.
f. If the UPS goes on batteries due to a loss of voltage (out of
tolerance) on the input to the UPS and this is a genuine case where
the batteries are going to discharge for the autonomy time stated
in the appendix, then the BMS must be able to determine this
situation as soon as possible taking into consideration the note in
paragraph b) above.
g. All the above mentioned alarm/signaling contacts shall be fully
accessible without exposure to other live components. The
contacts shall be wired out to labeled terminals suitable for
connection to field control cabling.
7) Mimic Panel: Each UPS shall have a mimic panel in the format of a module
single-line diagram with status indicators for input, output, and battery circuit
breakers. Each circuit breaker shall have two lights, one lit when the circuit
breaker is closed and the other lit when the circuit breaker is open.
8) Emergency Shutdown: The UPS system control panel shall be provided with
local “yellow” break glass units for emergency shutdown provision. Activation
of the local emergency shutdown shall cause:
a. The critical load to be automatically transferred to bypass
uninterrupted.
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b. All the module input, output, and battery circuit switches to open,
completely isolating the UPS modules form all sources of power.
9) RF Interference: The control system shall not be susceptible to RF interference.
J. Storage Battery:
1) A storage battery shall be furnished for the UPS with sufficient capacity to
maintain UPS output at the required load for the minimum time shown in the
schedule. The battery is to provide 100 percent of the specified capacity after
the specified years of operation. The battery shall be of the heavy-duty
industrial type designed for stationary power service. The battery shall be
designed for a service life of fourteen years with a guaranteed minimum life of
ten years.
2) The battery cells shall be either of the following types as specified:

a. Free venting, wet cell, lead-calcium or lead antimony type. The
containers shall be manufactured from impact-resistant and flame
retardant plastic of a design proven by field experience. Batteries
shall be manufactured and tested to IEC 896-1 and shall conform
to the design and manufacturing requirements stated in BS 6290
Parts 1 and 2:1984.
b. Lead-calcium sealed, maintenance-free type characteristics. The
containers shall be impact-resistant and flame retardant plastic of
a design proven by field experience. The container and lid
material shall have oxygen index in excess of 28 to ensure flame
retardency. A category rating of FVO must be demonstrated when
the components are tested to BS6334/IEC707 method FV. The
cover shall be permanently welded to the container. The complete
assembly shall be able to withstand an internal pressure of 30 psi
(2 bar) without external support. Batteries shall be manufactured,
tested and certified in accordance with BS 6290 Part 4:1987. Cells
shall be of the “10+ years Design Life-High Integrity” category of
the Eurobat Guide to VR Lead Acid cells and proof of compliance
shall be supplied.
3) Batteries shall be fitted with flame arresting vent plugs and battery terminals
shall be fitted with transparent plastic covers. Batteries shall be supplied with
intercell connector insulators.
4) The battery shall be supplied with:
a. Racks (multitiered) protected with electrolyte-resistant paint.
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b. Intercell and interior connectors for racks, end-to-end and/or

back-to-back. Maximum connection voltage drop of 30 mV
between adjacent units.
c. Special tools and fittings required to assemble the battery.
d. Cell numerals.
e. Dc protection circuit breaker and continuous insulation
monitoring or earth leakage device. The earth leakage device
shall be wired to protect the UPS dc circuits when the batteries are
in discharge model.
K. Mechanical Design Features - Enclosure:

1) The UPS shall be housed in a freestanding, single lineup enclosure with doors of
minimum 2mm steel and framework of 2.8mm steel. All indicators and controls
shall be mounted either on the front of the UPS or internally. Installation and
maintenance of UPS shall not require the removal of or access to side or rear
panels.
2) Adequate space and termination facilities shall be provided for glanding and
terminating the input and output cables or power busduct, preferably in
separate cubicles suitably busbarred to the UPS modules, which shall be top
entry only. Where cables are used, they shall enter each section by means of
6-mm heavy-gauge removable blank gland plates. Gland plates shall be screwed
into tapped holes; self-tapping screws are not permitted. Supply the cable lugs
to suit the cable and termination studs. Cable details will be finalized after
award of Subcontract and during drawing approval stage.
3) Sapphire windows, to enable infra-red camera scanning on the main
cable/busduct connections, shall be provided on the face of the cable/busduct
enclosure.
4) The degree of enclosure protection shall be IP 31 minimum to BS EN 60947-1. If
the manufacturer's standard equipment is IP 20, enhance the IP rating by the
use of fine mesh screens, particularly over the air exhausts to ensure foreign
objects dropped from overhead do not enter.
5) Cooling shall be by forced air. Air intake will be at the bottom front and air
exhaust at the top of the unit. Air filters, which shall be removable without
shutting down the UPS, shall be readily accessible and located at the air intakes.
6) The cooling system shall ensure that all components operate within their
environmental ratings. Power switching modules shall be cooled by redundant
fans located directly above critical components. Thermal over -temperature
shall cause unit to transfer to bypass and cause the inverter and charger circuits
to shut down.
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7) Where a cubicle door is provided to give access to components for maintenance

or inspection purposes, bare bus bars and associated conductors, etc., shall be
protected from inadvertent contact by persons while the door is open. This will
normally consist of a barrier/screen with a suitable warning label, which can be
removed only by means of a tool.
8) Adequate lifting means shall be provided, preferably by a lifting angle fixed to
the top of each shipping section.
9) The phase sequence and coloring of the supply and load conductors shall be L1,
L2, L3, red, yellow, and blue or as per local codes/standards. All power
conductors and connections shall be arranged to follow this sequence, reading
from left to right or top to bottom, when observed from the front of the UPS.
Neutral conductors shall be sized at 170 percent of the phase conductors and
shall be colored black or as per local codes/standards. Earth conductors shall
be colored green and yellow. Alternatively offer standard wiring colors
provided all wires are adequately identified.
10)Electrically earth each gland plate to the main earth bar.
L. Vibration Isolation:
1) Application: UPS shall be mounted on double neoprene pad (DNP) isolators.
The entire assembly consisting of inverters and output cabinets shall be
mounted on DNP isolators.
2) DNP:
a. Neoprene pad isolators shall be formed by two layers of 6-mm- to
8-mm-thick ribbed or waffled neoprene, separated by a stainless
steel or aluminum plate. These layers shall be permanently
adhered together. Neoprene shall be 40 to 50 durometer. The
pads shall be sized so that they will be loaded within the
manufacturer's recommended range. Steel top plate equal to the
size of the pad shall be provided to transfer the weight of the
support unit to the pads and to distribute the load evenly over the
surface of the pads.
b. DNP isolators shall be formed from one of the following products
or approved equal:
i. Type NR: Amber/Booth.
ii. Type Korpad: Korfund Dynamics.
iii. Type WSW: Mason Industries.
iv. Type NPS: Peabody Noise Control.
M. Labels:
1) The UPS cubicles shall have a main designation label.
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2) Labels shall be engraved black on white background, Traffolyte or similar.

3) Labels shall be fixed with nonferrous rivets or screws.
4) Lettering shall be a minimum of 4 mm high.
5) Each compartment on the UPS system shall have an external label. The
Subcontractor shall agree nameplate designations with the Contractor before
engraving.
6) All warning labels shall be engraved red on white background, Traffolyte or
similar. In addition to the above, warning labels shall be supplemented with an
appropriate sized yellow/black triangular shaped (DANGER - ELECTRICITY)
sign, as recommended by the Health and Safety Authority.
7) All door-mounted equipment shall be clearly identified.
8) All internal components, wiring, and terminals shall be clearly identified.
3.4. Factory Testing
A. Each power module and the UPS shall be tested as defined here for
compliance with this Specification. Tests described in this Section shall be
performed at the UPS manufacturer's facility and may be witnessed by the
Contractor.
B. All equipment, instruments, load banks, and apparatus for testing shall be
provided by the UPS manufacturer. All instruments shall be of sufficient
accuracy to verify the specified performance parameters.
C. All testing shall be performed at normal ambient conditions within the test
facility.
D. Power Module Tests: Each individual power module shall be subjected to

the following tests as a minimum. Control and power tests may be
conducted simultaneously if appropriate.
1) Control Tests - Operation of the following items/functions shall be tested:
a. Instrumentation:
i. Accuracy on display.
ii. Operation upon command.
b. Annunciation:
i. Sensor operation.
ii. Distinction between manual override and normal status alarm.
iii. Status command.
iv. Display operation, normal alarms.
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c. Logic:
i. Protective functions.
ii. Normal operation functions.
d. Operator controls.
e. Troubleshooting controls.
2) Power Tests: For the steady-state tests in this paragraph, all phase voltages, all
three-line currents, frequency, and power factor (or kilowatts) shall be
measured at the module input and output terminations and continuously
recorded.
a. No load.
b. 50 percent of rated power module kW load, balanced.
c. 100 percent of rated power module kW load, balanced for
24 hours.
d. Output harmonic voltages at 100 percent rated kW load.
3) System Tests: System tests shall b performed exclusive of the battery bank. The
system may be tested in increments, as long as it is demonstrated that each
power module performs as specified when operating with any other power
module. Systems with two power modules shall be tested with both power
modules operational. The modules under test shall be appropriately connected
to the system output/bypass module. Control and power tests may be
conducted simultaneously, if appropriate.
i. Control Tests: Operation of the following system items/functions
shall be tested,as specified/standards:
(a) Accuracy on display.
(b) Operation upon command.
ii. Annunciation:
(a) Sensor operation.
(b) Distinction between troubleshooting controls, normal status, Priority 1
alarm, and Priority 2 alarm.
(c) Status command.
(d) Display operation normal alarms.
iii. Logic:
(a) Protective functions.
(b) Normal operation functions.
iv. Operator controls.
v. Troubleshooting controls.
b. Power Tests: For the steady-state tests in this paragraph, all
three-phase voltages, all three-line currents, frequency, and power
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factor (or kilowatts) shall be measured at the system input

termination and the output termination of the system
output/bypass module and continuously recorded.
i. No load.
ii. 50 percent of rated system kW load, balanced.
iii. 100 percent rated system kW load, balanced.
c. Power Tests: For the transient tests in this paragraph, all voltages
shall be measured with continuous recording instruments at the
output termination of the system output/bypass module.
i. Zero to 50 percent load addition.
ii. 50 to 100 percent load rejection.
iii. Manually initiated transfer.
iv. Manually initiated retransfer.
v. 125 percent of rated system load, balanced.
vi. 150 percent of rated system load, balanced.
vii. Automatic transfer.
viii.Automatic retransfer.
Note: All tests shall be conducted in the presence of the main

contractor and the test certificates shall be duly signed by all the
personnel present during the activity.
4. Execution
4.1. Installation
A. Subcontractor's Scope:
1) The Subcontractor shall be responsible for offloading the UPS equipment and
placing in final position for final connection by the UPS vendor.
2) The UPS vendor shall be responsible for all UPS interpanel wiring and
connections.
3) The Subcontractor shall supply and install cables as indicated on cable
schedules.
4) The Subcontractor shall assemble the battery systems under the supervision of
the UPS vendor.
4.2. Field Quality Control
A. Field Testing and Startup:

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1) After completion of the UPS installation, but prior to final output connections,
tests shall be conducted on the assembled UPS and associated accessories,
complete with the battery banks.
2) Initial energization of the UPS and all onsite testing shall be provided by the UPS
vendor.
3) Any load banks required or a dummy load equal to the rated UPS output shall be
furnished by the UPS vendor.
4) All instruments, equipment, materials, and associated devices for proper
performance of these onsite tests shall be included in the Bid.
5) Onsite tests shall preferably be performed under ambient temperature
conditions of a minimum of 25 degrees C.
6) An onsite written test procedure shall be submitted to the Contractor by the UPS
vendor at least 2 weeks prior to the start of any field testing. This test
procedure shall include, but not be limited to, the following:
a. Visual Inspection:
i. Inspect equipment for signs of damage.
ii. Verify installation per the Drawings.
iii. Inspect cabinets for foreign objects.
iv. Verify neutral and ground conductors are properly sized and
configured.
v. Inspect all battery cell cases and interconnections.
vi. Inspect all battery cells for proper polarity.
vii. Verify all printed circuit boards are configured properly.
b. Electrical Inspection:
i. Check all power and control wiring connections for tightness.
ii. Check all terminal screws, nuts, and/or spade lugs for tightness.
iii. Check all fuses for continuity.
iv. Check all breakers for proper settings.
v. Confirm input and bypass voltage and phase rotation is correct.
vi. Verify control transformer connections are correct for voltages
being used.
vii. Ensure battery connection and voltage of the battery strings.
c. Unit Startup:
i. Perform control/logic checks and adjust to meet specifications.
ii. Verify dc float and equalize voltage levels.
iii. Verify dc voltage clamp and overvoltage shutdown levels.
iv. Verify battery discharge, low-battery warning, and low-battery
shutdown levels.
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v. Verify fuse monitor alarms and system shutdown.

vi. Verify inverter voltages and regulation circuits.
vii. Verify inverter/bypass sync circuits and set overlap time.
viii.Perform manual transfers and returns.
ix. Simulate utility outage.
x. Verify proper battery operation by measuring and continuously
recording the battery discharge and recharge rate.
xi. Transient tests as per paragraph 2.4 (Factory Testing) of this
specification, all voltages shall be measured with continuous
recording instruments at the output termination of the system
output/bypass module.
xii. Zero to 50 percent load addition.
xiii.50 to 100 percent load rejection.
xiv.Full system rated load test for 8 hours.
xv. Test results shall be documented, signed, and dated for future
reference.
SPECIFICATION DATA TABLE Below has to be filled in by the sub-contractor

UPS Schedule
1. UPS Identifier
2. Input voltage level
3. Output voltage level
4. Isolated or parallel redundant
5. Battery autonomy
6. Battery type
7. Number and size of modules per
UPS system (______ x ______ kVA)
8. Total UPS working capacity in
kVA
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1. UPS Identifier
2. Input voltage level
3. Output voltage level
4. Isolated or parallel redundant
5. Battery autonomy
6. Battery type
7. Number and size of modules per
UPS system (____ x ____ kVA)
8. Total UPS working capacity in
kVA
Small Static Uninterruptible Power Supply
1. General
1.1. Work Included
A. Static uninterruptible power supply (UPS), non redundant

configuration and ratings of up and including 75kVA or as indicated
on the drawings or appendix sheet..
1.2. Related Work
A. This Section shall be used in conjunction with the following other

specifications and related Contract Documents to establish the total
requirements for static uninterruptible power supply:
1) Section 16010 (European) - Basic Electrical Requirements.
2) Section 16430 (European) – Low-Voltage Metal-Clad Switchgear.
B. CAUTION! Use of this Section without including the above-listed item

will result in omission of basic requirements.
C. In the event of conflict regarding static uninterruptible power supply

requirements between this Section and any other section, the
provisions of this Section shall govern.
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1.3. System Description
A. System Configuration: As shown on the Drawings.

1) Continuity of electrical power to the load shall be maintained for a battery
period as indicated on the Drawings, with the UPS supplied by battery power
until startup of the engine generator system.
2) The UPS system shall be sized to maintain a load as indicated in the Appendix
and shall be equipped with a battery able to supply this load for the time
indicated, at a temperature of 25 degrees C.
B. Components: System includes battery to provide continuous source of

electrical power; rectifier/battery charger to maintain battery charge and
to provide input to inverter when utility power is available; inverter to
provide power to load during normal operation; static switch to transfer
load automatically and without disturbance between inverter and utility
power in case of inverter failure; bypass circuit breaker to bypass static
switch for maintenance; input and output isolation transformers and
filters to provide appropriate disturbance attenuation; and necessary
monitors, sensors, and control circuits.
C. Design Standards: In accordance with relevant BS standards, IEC

publications and all current EU Directives(EN 50091-1, EN 50091-2 and EN
50091-3). The system shall be CE marked.
D. System Operation:
1) Utility Power Available: Rectifier/charger supplies load through inverter and
maintains battery in fully charged “float” condition.
2) Utility Power Failure: Load supplied from battery through static inverter if
utility power drops below preset limits, or fails. There is no output disturbance
transmitted to load.
3) Utility Power Returns: Rectifier/charger supplies power to load through
inverter while it recharges battery. There is no output disturbance transmitted
to load. System power walk-in shall be accomplished within 15 seconds of
energizing, with provision for an adjustable time function to delay start of
power walk-in to facilitate power restart from a generator.
4) Failure of Rectifier/Charger or Battery: Static switch transfers load to
synchronized utility power, without disturbance, when inverter output deviates
beyond specified quality limits. When inverter output returns to acceptable
operation, it is synchronized to utility power, and after preset timing interval,
static switch returns load to inverter without disturbance.
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5) Inverter Failure: Static switch transfers to utility power without disturbance

and remains until manually returned.
6) Overload or Short Circuit: Static switch transfers load to utility power during
load inrush and clearing of faulted branch circuits; load automatically transfers
back to inverter without disturbance.
7) Maintenance Operation: Manual load transfer to utility power using bypass
circuit breaker. During bypass mode, operation of system or static switch does
not affect power to load. System rectifier, inverter, and static bypass
components shall be removable for service without compromise to system
operation. The bypass circuit breaker shall be in a separate compartment
external to the UPS.
8) The Batteries shall be of two strings.
1.4. Submittals
A. Provide the following information in addition to the standard

requirements with the Bid:
1) Itemized list of all exceptions and deviations from these specifications.
2) System configuration and rating with single-line diagrams. All circuit
breakers and disconnect switches shall be identified by location, frame
size, trip rating, and with manufacturer type number.
3) Functional relationship of various equipment including weights,
dimensions, normal and service access areas, heat dissipation, and airflow
requirements of each unit. Include battery rack dimensions, battery type,
size, dimensions, and weight.
4) Detailed and scaled layouts coordinating all UPS equipment, including
battery racks and disconnects with the Drawings.
5) Detailed descriptions of equipment to be furnished, including product data
for major components, such as batteries. Include catalog sheets and
technical data sheets to indicate physical data and electrical performance.
6) Size and weight of individual shipping units to be handled in the field.
7) Detailed layouts of all metering, alarm, and mimic panels. The metering
sensing points are to be shown on the single-line diagram.
8) Detailed layouts and locations of customer power and control cable
connection points.
9) Detailed installation drawings including all terminal locations.
10) Interconnect wiring diagrams showing all external power and control
cable runs with terminal numbers for each wire.
11) Operating and maintenance manual which includes a functional
description of the equipment with detailed block diagrams, safety
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precautions, installation and startup procedures, instructions on step-by-

step operating and maintenance procedures, including drawings and
illustrations.
12) Onsite written test procedure.
13) Sequence of operations of the UPS system in Microsoft Word for Windows
electronic document format.
1.5. Maintenance Service
A. Furnish service and maintenance of uninterruptible power supply

and batteries for 1 year from date of Substantial Completion.
1.6. WARRANTY
A. UPS: Provide a 1-year warranty. Acceptance occurs when the UPS has
satisfactorily passed all startup and field tests, operates satisfactorily,
and meets these specifications fully.
B. Battery: The UPS manufacturer shall warrant the VRLA battery on a

prorated basis for 10 years to deliver no less than 80% of it’s rated
capacity at end of life, providing the ambient temperature of the
battery area does not exceed 25 degrees C
2. Products
2.1. Acceptable Manufacturers
a. APC.
b. Mitsubishi.
c. Emerson.
d. Numeric.
2.2. System Ratings And Operating Characteristics
A. System Continuous Rating: As indicated in the Appendix, over entire

battery voltage range at specified power factor. Maintain output
voltage within specified limits at any load from full load to no-load.
B. Voltage Ratings:
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1) Input: 400V, 3-phase, 4 wire, 50 Hz. Or 230V, 1-phase and neutral, 50Hz, as
indicated on the drawings/appendix.
2) Output: 400/230V, 3-phase, 4 wire, 50 Hz. Or 230V, 1-phase and neutral, 50Hz,
as indicated on the drawings/appendix.
C. Input Voltage Limits: Plus or minus 10 percent.
D. Integrated Equipment Short-Circuit Rating: As shown on the

drawings or Appendix sheet.
E. Input Frequency: 50 plus or minus 3 Hz.
F. Input Current Limit: Adjustable to a maximum of 125 percent of that

required to operate at full load with battery bank on float charge.
G. Current Walk-In: 25 to 100 percent in 15 seconds.
H. UPS Power Factor Over Full Range of Loads and Input Voltages:
85 percent, lagging.
I. Total Harmonic Distortion (THD) of Input Power Supply Current and

Voltage Wave Forms: Provide input harmonic filters to limit THD of
input power supply to 6 percent, maximum at full load.
J. Output Voltage Regulation: Plus or minus 0.5 percent for balanced

load, plus or minus 2 percent for 50 percent unbalanced load.
K. Output Voltage Adjustment: Plus or minus 5 percent. Manual

adjustment shall be provided.
L. Frequency Regulation: 0.1 percent.
M. THD of Output Voltage Wave Form: Maximum 8 percent rms THD

and maximum 5 percent any single harmonic, at rated frequency and
voltage, from 10 percent load to full load and over battery voltage
range, measured into a nonlinear load.
N. Nonlinear Load Rating: UPS system shall be capable of handling

nonlinear load currents.
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O. Voltage Transients (load step to include both “on-loading” and “off-

loading”):
1) 50 percent Load Step: Plus or minus 4 percent.
2) 100 percent Load Step: plus or minus 5 percent.
3) Loss or Return of ac Input Power: Plus or minus 2 percent.
4) Manual Transfer of 100 Percent Load: Plus or minus 4 percent.
P. Voltage Transient Recovery Time: To within 2 percent of output

voltage rating within 20 milliseconds.
Q. Phase Displacement:
1) Plus or minus 1 degree for balanced loads.
2) Plus or minus 2 degrees for 100 percent unbalanced loads.
R. Three-phase Overload Ratings at Full Voltage:

1) 150 percent for 60 seconds, minimum.
2) 125 percent for 10 minutes.
S. Output Current Limit: 150 percent of rated output current.
T. Voltage Unbalance: 3 percent maximum line-line with 100 percent

load unbalance.
U. Audible Noise: Noise generated by the UPS under any condition of

normal operation shall not exceed the allowable sound pressure level
of 69 dBA at 2 metres in accordance with ISO 3746.
V. Efficiency: The efficiency of the UPS is to be measured under the

following conditions:
1) UPS, operating at full-rated load, kVA, and kW.
2) Battery, fully charged and floating on the system.
3) Input voltage within specified range.
4) Efficiency is defined as output kW divided by input kW.
5) Minimum efficiency at full load: 91.5 percent.
6) Efficiency to be measured at 10 percent to 100 percent load in 10 percent
increments.
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2.3. Design And Construction
A. Rectifier/Charger Unit:
1) Each rectifier/charger unit shall be solid state and shall provide direct current
to the inverter unit and for battery charging.
2) Each rectifier/charger unit shall be provided with an input circuit breaker. The
circuit breaker shall be of the frame size and trip rating to supply a full-rated
load to the critical load and recharge the battery at the same time. The circuit
breaker shall be provided with an undervoltage trip so the circuit breaker will
open automatically when the control voltage is lost.
3) In addition to supplying power for the load, the rectifier/charger shall be
capable of recharging the batteries. The charging rate shall be sufficient to
restore the battery from discharge to 95 percent of full charge within ten times
the discharge time. After the battery is recharged, the rectifier/charger shall
maintain the battery at full charge until the next emergency operation.
4) The initial magnetization in-rush current shall be limited to 600 percent of the
rectifier/battery charger full-load current. The rectifier/battery charger shall
have a minimum power factor of 0.8 lagging at nominal input voltage and
frequency and with the inverter operating at full-rated load.
5) The input ac current limit shall be designed so that demands in excess of the dc
output current needed to operate the inverter at rated load and simultaneously
recharge a discharged battery to 95 percent of its original capacity shall not
cause a corresponding decrease in the output dc voltage from the
rectifier/battery charger.
6) The rectifier/battery charger shall be provided with output filtering to limit the
ripple voltage to less than 2 percent RMS maximum in the automatic float
charge state with the battery disconnected.
7) The system shall monitor end of battery discharge voltage and automatically
shut-off the charger when this voltage is reached, to protect the batteries. In
addition, when the discharge time is greater than one hour, the shutdown
voltage shall be automatically increased to avoid deep discharge of the batteries
due to a light load.
8) A facility shall be provided for automatically or manually initiating a batter
discharge test. The automatic test shall be at the following user selectable
intervals:
a. Weekly.
b. Fortnightly.
c. Monthly.
d. None.
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The test will comprise a one minute charge to ensure that the battery, cables,
links and connections are in a satisfactory condition. Prior to testing the
system shall ensure that conditions exist which do not risk continuity of
supply to the load and that a discharge did not occur in the previous 24
hours. The battery test shall be performed without any risk to the load, even
with the battery disconnected or defective. The test procedure shall not
cause any degradation of the expected battery life-time. A detected battery
failure shall be alarmed to the user.
B. Inverter:
1) Each inverter unit shall be a solid-state device capable of accepting the output of
the rectifier/charger or battery and providing rated output within the required
specified limits. Inverter shall be IGBT high frequency PWM type.
2) Electronic controls shall be incorporated to provide individual phase voltage
compensation to obtain phase voltage balance under all conditions, including up
to a 50 percent current unbalance.
3) Each inverter unit in the system shall have fault sensing and static isolation, as
well as an output circuit breaker, for removal of a faulted module from the
system without affecting the critical load bus. Output circuit shall be suitably
protected for load testing using a load bank. A facility shall be provided for
switching the UPS to bypass mode and connecting a load bank for testing,
without effecting the critical load.
4) The inverter shall be constructed of solid-state devices capable of providing the
specified rated volt-amperes (VA) within the operating range of the battery
while connected to a 1.0 to 0.8 leading or lagging power factor load. The
inverter shall current-limit for loads in excess of 150 percent of its full load
rating. Maximum effective current at the output of the inverter (when bypass ac
input is not available) shall be 150 percent.
5) Static voltage regulation of the inverter steady-state output shall not deviate by
more than plus or minus 2 percent under any of the following conditions:
a. Ambient temperature variations.
b. Minimum to maximum dc bus voltage.
c. Maximum frequency excursions.
6) The inverter shall have a manual adjustment control to regulate output voltage
plus or minus 5 percent from the rated value.
7) For balanced load conditions, the inverter phase displacement shall be
120 degrees, plus or minus 1 degree maximum. For 50 percent unbalanced
loads, phase displacement shall be 120 degrees, plus or minus 3 degrees
maximum.
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8) The inverter’s output frequency shall be controlled within plus or minus

2 degrees. The frequency transients for system disturbances shall not deviate
by more than plus or minus 0.1 percent.
9) The inverter shall provide harmonic neutralization and filtering to limit the total
harmonic distortion (THD) in the output voltage to 8 percent and single
harmonics to 5 percent over the entire linear load range.
10)Output voltage shall not exceed plus or minus 6 percent for 50 percent step-load
change or transfer of full rated load to/from bypass, plus or minus 2 percent
loss or return of input ac.
C. Protection:
1) Each UPS module shall have built-in self-protection against overvoltage power
line surges, undervoltages, and overcurrent introduced by the primary ac
source, plus overvoltage and voltage surges introduced at the output terminals
by paralleled sources, load switching, and circuit breaker operation in the
distribution system. Each UPS module shall be self-protected against
overcurrent, sudden changes in the output load, and short circuits at the output
terminals.
2) Each UPS module shall be provided with a control section to provide monitoring
and control of the UPS module. The meters, alarms, controls, and mimic panel
shall be located on the control section door.
3) A fully rated two-position 4 pole manual transfer switch and associated cable
termination facility shall be provided on the input power section of the UPS to
provide a dual power provision facility (Normal/Emergency). The cable
termination points shall be 206tilize “Normal” and “Emergency”.
D. Static Bypass Transfer Switch:

1) Description: The UPS shall contain a fully-rated solid-state static bypass
transfer switch which allows a “make before break” or overlap type transfer of
the load from the UPS output to the utility power source or back again without
interruption of power to the critical load. Forward and reverse contactors shall
not be used. The control unit shall contain an automatic transfer circuit which
senses the status of the inverter logic signals and alarm conditions and initiates
uninterrupted transfer of the load in case of malfunction of the UPS or external
overload. The static bypass transfer switch shall be rated at 1,000 percent of
UPS output rating for 100 milliseconds, 700 percent for 600 milliseconds,
400 percent for 1 second, and 150 percent for 1 minute and 125 percent
continuous.
2) Transfer Conditions:
a. The static bypass switch shall transfer from the inverter to
the bypass normal power source for the following conditions:
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i. Inverter Undervoltage: Less than 90 percent of nominal.

ii. Inverter Overvoltage: Greater than 110 percent of nominal.
iii. Inverter overload.
iv. Inverter shutdown for any reason.
v. Manual signal.
vi. The static bypass switch shall inhibit transfer to the bypass source
for the following conditions:
vii. Bypass Source Undervoltage: Less than 90 percent of nominal.
viii.Bypass Source Overvoltage: Greater than 100 percent of nominal.
ix. Inverter not synchronized and in phase with the bypass source.
b. Automatic Retransfer Conditions: The system shall
automatically retransfer the load to the inverter provided all
of the following conditions are met:
i. The inverter logic and the bypass source are synchronized and in
phase.
ii. Inverter conditions are normal for 5 seconds.
iii. The retransfer selector switch is in the automatic position.
iv. The UPS output is not overloaded.
E. Maintenance Bypass Circuit Breaker: A manually operated maintenance

bypass switching arrangement shall be provided which permits bypassing
the UPS loads to the bypass ac power source without interruption of power
to those loads and also electrically isolates the static bypass switch and
inverter from the bypass power source.
F. All internal circuit breakers shall comply with Section 16430 (European)
with regard to acceptable manufacturers.
G. Output Switchboard: Where shown on the Drawings, a UPS output

switchboard shall be provided by the UPS vendor. Switchboards shall be
fully in accordance with Section 16430 (Europe)- Low-Voltage Metal-Clad
Switchgear and be supplied to the UPS vendor by the acceptable OEM
switchgear vendors stated within this Section.
H. Controls and Indicators:

1) Control Panel: The UPS shall provide monitoring and control for the
complete system via a control panel equipped with monitoring, controls,
light emitting diode (LED) indicators, and an audible alarm as described
below.
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2) Meters: The following functions shall be monitored by a digital meter with

plus or minus 2 percent accuracy:
a. Ac input voltage.
b. Ac input current.
c. Ac input kVA.
d. Ac input kW.
e. Ac input power factor.
f. Ac output phase and line-to-neutral voltage.
g. Ac output current/phase.
h. Ac output kVA.
i. Ac output kW.
j. Ac output power factor.
k. Ac output frequency.
l. Meter Phases A, B, and C.
m. A dc battery charge/discharge current meter.
n. A dc battery voltage meter.
o. A dc battery time remaining.
3) Controls:
a. Input/output voltmeter phase selector.
b. Output current selector.
c. Bypass voltmeter phase selector.
d. Output frequency selector.
e. Alarm acknowledge (alarm silence).
f. LED test.
g. On bypass switch (protective cover).
h. On UPS switch (protective cover).
i. Emergency power off (protective cover).
j. Ac input circuit breaker, lockable in OFF position.
k. Switch phase select.
l. Switch function select.
m. Lamp test/reset push-button.
n. Battery circuit breaker trip push button.
o. Inverter output circuit breaker trip push button.
4) LED Indicators and Volt-Free Contacts: The operating status panel shall
consist of LEDs. Normal functions shall be green, and abnormal but
provisional operation and such conditions as prohibit system operation,
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red. The LEDs shall be available as a NC or NO 5 amp, 24 Vdc, dry contact

as follows:
a. Fuse blown (red).
b. Input power fail (red).
c. UPS on (green).
d. Bypass on (red).
e. Low battery (red).
f. Overload (red).
g. Equipment overtemperature (red).
h. Battery dc breaker open.
i. Emergency power off (EPO).
j. Bypass fail (yellow).
k. Battery discharge (red).
l. Fan failure (red).
m. Dc ground fault (red).
n. Dc over voltage (red).
o. UPS operating from battery supply (red); also provide two
auxiliary normally closed contacts for remote indication of this
condition.
p. Provide two fail-safe dry contacts for UPS system summary alarm
for remote annunciation by others.
q. The UPS shall be equipped with a self-test function to verify
correct system operation. The self-test function shall identify any
faulty sub-systems of the UPS.
r. The UPS shall be equipped with a system providing start-up and
operating assistance and offering the following functions:
s. Display of installation parameters, configuration, operating
conditions, alarm status and step-by-step instruction for switching
operations.
t. Storage in memory and automatic or manual recall of all
important status changes, faults, alarms and malfunctions. The
system shall record the time and date of all such events.
5) Audible Alarm: A horn shall be located on the system control and status
panel. The horn shall be a solid-state acoustical transducer and shall
produce an audible warning of not less than 60 dB. It shall be activated
whenever one or more warning or malfunction indicators are energized.
6) Mimic Panel: Each UPS shall have a mimic panel in the format of a module
single-line diagram with status indicators for input, output, and battery
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circuit breakers. Each circuit breaker is to have two lights, one lit when the
circuit breaker is closed and the other lit when the circuit breaker is open.
7) Emergency Shutdown: The UPS system control panel shall be provided
with a “yellow” break glass unit for local emergency shutdown provision.
Activation of the local emergency shutdown shall cause:
a. The critical load to be automatically transferred to bypass
uninterrupted.
All the module input, output, and battery circuit switches to open,
completely isolating the UPS modules from all sources of power
8) RF Interference: The control system shall not be susceptible to RF
interference.
9) [The UPS Supplier shall propose a system by which the UPS can be
continuously monitored at the Suppliers Service Centre by skilled,
experienced Engineers. This system shall be fully independent of action by
Intel or other site personnel and shall allow detailed remote diagnosis of
routine data and the immediate response, 24/7, in the event of system
fault
I. Storage Battery:
1) A storage battery, comprising of a minimum of two (2) strings, shall be
furnished for the UPS with sufficient capacity to maintain UPS output at the
required load for the minimum time shown in the schedule. [Option for
project team regarding (VRLA) batteries where they shall be provided with
a battery monitoring system from Alber Corporation which is capable of
monitoring and tracking the status of all cells at all times].
a. The battery cells shall be:-
i. Maintenance-free, valve-regulated lead-acid (VRLA) oxygen,
lead, and sulphuric acid gas recombinant that limits hydrogen
gas evolution.
ii. Immobilised electrolyte utilising absorbent glass mat
separator.
iii. Positive grids consisting of an alloy of lead and antimony.
iv. Vent with flame arrestor.
v. Minimum 400-cycle life at 80 percent nominal capacity.
vi. Maximum water loss of 0.2 percent over cycle life.
vii. Cell case material shall be flame retardant V0 rated
viii.The battery shall be fully compliant with BS 6290 Pt 4 1997
with design life exceeding 10 years.
ix. Battery monitor system as manufactured by Alber Corporation
x. Manufacturer/type: Hawker Powersafe or Yuasa Endurance.
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2) The battery shall be supplied with:

a. Racks (maximum three tiers) protected with electrolyte-resistant
paint. Racks shall be withdrawable or of the open-stand format
with lift-off screens to facilitate access to the batteries.
b. Intercell and interior connectors for racks, end to end and/or back
to back. Maximum connection voltage drop of 30 mV between
adjacent units. Batteries shall be supplied with intercell connector
insulators.
c. Special tools and fittings required to assemble the battery.
d. Cell numerals.
e. Dc protection circuit breaker and continuous insulation
monitoring or earth leakage device shall be provided. The earth
leakage device shall be wired to protect the UPS dc circuits when
the batteries are in discharge mode.
f. Gas recombination shall be at least 95 percent efficient at 2.27 Vpc
(at 20 degrees Centigrade). No forced ventilation shall be
required.
g. A safety release valve shall permit the escape of gas at
approximately 5 psi (0.35 bar) pressure in the event of severe
overcharge. The valve shall be self resealing, and incorporate a
flame retardant barrier to reduce explosion risk.
J. Mechanical Design Features – Enclosure:

1) The UPS shall be housed in a freestanding, front access, enclosure with doors of
minimum 2mm steel and framework of 2.8mm steel. All indicators and controls
shall be mounted either on the front of the UPS or internally. Installation and
maintenance of UPS shall not require the removal of or access to side or rear
panels.
2) Adequate space and termination facilities shall be provided for glanding and
terminating the input and output cables, which shall be top entry only. All
cables shall enter each section by means of heavy-gauge, removable blank gland
plates. Gland plates shall be screwed into tapped holes; self-tapping screws are
not permitted. The seller shall supply the cable lugs to suit the cable and
termination studs. A schedule of cable sizes will be provided after award of
contract.
3) The degree of enclosure protection shall be IP [20] [31] minimum to BE EN
60947-1.
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4) Cooling shall be by forced air. Air intake will be at the bottom front and air
exhaust at the top of the unit. Air filters, which shall be removable without
shutting down the UPS, shall be readily accessible and located at the air intakes.
5) The cooling system shall ensure that all components operate within their
environmental ratings. Power switching modules shall be cooled by redundant
fans located directly above critical components. Thermal overtemperature shall
cause unit to transfer to bypass and cause the inverter and charger circuits to
shut down.
6) Adequate lifting means shall be provided, preferably by a lifting angle fixed to
the top of each shipping section.
7) The phase sequence and coloring of the supply and load conductors shall be L1,
L2, L3; coloured as per local code and regulations. All power conductors and
connections shall be arranged to follow this sequence, reading from left to right
or top to bottom, when observed from the front of the UPS. Earth conductors
shall be colored green and yellow.
8) Electrically ground each gland plate to the main ground bar.
K. Vibration Isolation:
1) Application: UPS shall be mounted on double neoprene pad (DNP) isolators.
The entire assembly consisting of transformers, inverters, and output cabinets
shall be mounted on DNP isolators.
2) DNP Isolators:
a. Neoprene pad isolators shall be formed by two layers of ribbed
or waffled neoprene, separated by a stainless steel or aluminum
plate. These layers shall be permanently adhered together.
Neoprene shall be 40 to 50 durometer. The pads shall be sized
so that they will be loaded within the manufacturer’s
recommended range. A steel top plate equal to the size of the
pad shall be provided to transfer the weight of the support unit
to the pads and to distribute the load evenly over the surface of
the pads.
b. DNP isolators shall be formed from one of the following
products or approved equal:
i. Type NR: Amber/Booth.
ii. Type Korpad: Korfund Dynamics.
iii. Type WSW: Mason Industries.
iv. Type NPS: Peabody Noise Control.
L. Labels:
1) The UPS cubicles shall have a main designation label.
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2) Labels shall be engraved black on white background, Traffolyte or similar.

3) Labels shall be fixed with nonferrous rivets or screws.
4) Lettering shall be a minimum of 4 mm high.
5) Each compartment on the UPS system shall have an external label. The
Subcontractor shall coordinate the nameplate designations with the Contractor
before engraving.
6) All warning labels shall be engraved red on white background, Traffolyte or
similar. In addition to the above, warning labels shall be supplemented with an
appropriate sized yellow/black triangular shaped (DANGER – ELECTRICITY)
sign, as recommended by the Health and Safety Authority.
7) All door-mounted equipment shall be clearly identified.
8) All internal components, wiring, and terminals shall be clearly identified.
2.4. Factory Testing
A. Each power module and the UPS shall be tested as defined herein for
compliance with this specification. Tests described in this Section shall be
performed at the UPS manufacturer’s facility and may be witnessed by
TDC.
B. All equipment, instruments, load banks, and apparatus for testing shall be
provided by the UPS manufacturer. All instruments shall be of sufficient
accuracy to verify the specified performance parameters.
C. All testing shall be performed at normal ambient conditions within the test
facility.
D. Power Module Tests: Each individual power module shall be subjected to

the following tests as a minimum. Control and power tests may be
conducted simultaneously if appropriate.
1) Control Tests: Operating of the following items/functions shall be tested:
a. Instrumentation:
i. Accuracy on display.
ii. Operation upon command.
b. Annunciation:
i. Sensor operation.
ii. Distinction between manual override and normal status alarm.
iii. Status command.
iv. Display operation, normal alarms.
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c. Logic:
i. Protective functions.
ii. Normal operation functions.
d. Operator controls.
e. Troubleshooting controls.
2) Power Tests: For the steady-state tests in this paragraph, all phase voltages, all
three-line currents, frequency, and power factor (or kilowatts) shall be
measured at the module input and output terminations and continuously
recorded.
a. No load.
b. Fifty percent of rated power module kW load, balanced.
c. One hundred percent of rated power module kW load,
balanced for 24 hours.
d. Output harmonic voltages at 100 percent rated kW load.
3) System Tests: System tests shall be performed exclusive of the battery bank.
The system may be tested in increments, as long as it is demonstrated that each
power module performs as specified when operating with any other power
module. Systems with two power modules shall be tested with both power
modules operational. The modules under test shall be appropriately connected
to the system output/bypass module. Control and power tests may be
conducted simultaneously, if appropriate.
a. Control Tests: Operation of the following system items/functions
shall be tested, if they were not tested under paragraph 2.4D1.
i. Instrumentation:
(a) Accuracy on display.
(b) Operation upon command.
ii. Annunciation:
(a) Sensor operation.
(b) Distinction between troubleshooting controls, normal status,
Priority 1 alarm, and Priority 2 alarm.
(c) Status command.
(d) Display operation normal alarms.
iii. Logic:
(a) Protective functions.
(b) Normal operation functions.
iv. Operator controls.
v. Troubleshooting controls.
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b. Power Tests: For the steady-state tests in this paragraph, all

three-phase voltages, all three-line currents, frequency, and power
factor (or kilowatts) shall be measured at the system input
termination and the output termination of the system
output/bypass module and continuously recorded.
i. No load.
ii. Fifty percent of rated system kW load, balanced.
iii. One hundred percent rated system kW load, balanced.
c. Power Tests: For the transient tests in this paragraph, all voltages
shall be measured with continuous recording instruments at the
output termination of the system output/bypass module.
i. 0 to 50 percent load addition.
ii. 50 to 100 percent load rejection.
iii. Manually initiated transfer.
iv. Manually initiated retransfer.
v. 125 percent of rated system load, balanced.
vi. 150 percent of rated system load, balanced.
vii. Automatic transfer.
viii.Automatic retransfer.
3. Execution
3.1. Installation
A. Install in accordance with manufacturer’s instructions.
B. Include services of technician to supervise adjustments, final connection,

and system energization.
3.2. Field Quality Control
A. Field Testing and Startup:

1) After completion of the UPS installation, but prior to final output connections,
tests shall be conducted on the UPS and associated accessories, complete with
the battery banks.
2) Initial energization of the UPS and all onsite testing shall be provided by the UPS
vendor.
3) Any load banks required or a dummy load equal to the rated UPS output shall be
furnished by the UPS vendor.
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4) All instruments, equipment, materials, and associated devices for proper

performance of these onsite tests shall be included in the Bid.
5) Onsite tests shall preferably be performed under ambient temperature
conditions of a minimum of 25 degrees C.
6) An on-site written test procedure shall be submitted to the Contractor by the
UPS vendor at least 2 weeks prior to the start of any field testing. This test
procedure shall include, but not be limited to, the following:
a. Visual Inspection:
i. Inspect equipment for signs of damage.
ii. Verify installation per the Drawings.
iii. Inspect cabinets for foreign objects.
iv. Verify neutral and ground conductors are properly sized and
configured.
v. Inspect all battery cell cases and interconnections.
vi. Inspect all battery cells for proper polarity.
vii. Verify all printed circuit boards are configured properly.
b. Electrical Inspection:
i. Check all power and control wiring connections for tightness.
ii. Check all terminal screws, nuts, and/or spade lugs for
tightness.
iii. Check all fuses for continuity.
iv. Check all breakers for proper settings.
v. Confirm input and bypass voltage and phase rotation is correct.
vi. Verify control transformer connections are correct for voltage
being used.
vii. Ensure battery connection and voltage of the battery strings.
c. Unit Startup:
i. Perform control/logic checks and adjust to meet specifications.
ii. Verify dc float and equalize voltage levels.
iii. Verify dc voltage clamp and overvoltage shutdown levels.
iv. Verify battery discharge, low-battery warning, and low-battery
shutdown levels.
v. Verify fuse monitor alarms and system shutdown.
vi. Verify inverter voltages and regulation circuits.
vii. Verify inverter bypass sync circuits and set overlap time.
viii.Perform manual transfers and returns.
ix. Simulate utility outage.
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x. Verify proper battery operation by measuring and continuously

recording the battery discharge and recharge rate.
xi. Transient tests as per Section 2.4 (Factory Testing) of this
specification, all voltages shall be measured with continuous
recording instruments at the output termination of the system
output/bypass module.
xii. Zero to 50 percent load addition.
xiii.50 to 100 percent load rejection.
xiv.Full system rated load test for 8 hours.
3.3. Test results shall be documented, signed, and dated for

future reference and shall be submitted to the main
contractor.
3.4. Demonstration
A. Provide a factory-trained field representative to instruct concerned

personnel/main contractor in maintenance and operation of the
equipment.
The below data sheet/specifications to be filled in by the supplier/Sub-contractor.

UPS Schedule
1 UPS identifier
2 Input voltage level
3 Output voltage level
4 Battery autonomy
5 UPS size
1 UPS identifier
2 Input voltage level
3 Output voltage level
4 Battery autonomy
5 UPS size
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.
CABLE TRAYS
1.0 General Requirements
Cable Trays
Cable trays shall be manufactured from hot dipped galvanized sheet steel to and
shall comply with the requirements of IS:2062, National Electrical Code (NEC)
and National Electrical Manufacturers Association (NEMA).
Galvanizing of each element shall be carried out in one complete immersion. The
galvanizing shall be uniform, clear, smooth, continuous and free from acid spots.
Quality of zinc used for galvanizing shall be of 98.8% purity.
All burs and sharp edges shall be removed/filed smooth to avoid damage to
cables. Testing of uniformity of the galvanizing shall comply with IS:2633 and in
any case the minimum thickness shall be 110microns.
Cable Trays shall be of Standard Sizes:
Length 2500mm
Width 300/400/600/800/1000/1200 mm as required.

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Thickness of Sheet Steel – 2.0mm to 3.0mm as per width of Tray.
All to have double return edge flange.
Grade selections and widths shall be as identified in the schedules.
Cable racks/trays shall be of perforated steel section slotted angles for suitable
purpose. The trays/racks shall be complete with plates, tees, elbows, risers and all
necessary hardware. The steel trays shall be painted. Cable trays shall be erected
properly to present a neat and clean appearance. Suitable cleats or saddles shall
be used for securing the cables to the cable trays. The cable trays shall comply
with the following requirements:
a) The trays shall have suitable strength and rigidity to provide adequate support
for all contained cables The supporting system shall be of approved design
supplied by the tray manufacturer considering the full loading of the cable trays.
b) It shall not present sharp edges, burrs of projections injurious to the insulation of
the wiring/cables.
c) If made of Sheet metal, it shall be adequately strength protected against corrosion

or shall be made of corrosion resistant material.
d) It shall have side rails or equivalent structural members.

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e) It shall include fittings such as horizontal, vertical bends, tie rods, hooks etc., or
other suitable means for changes in direction and elevation of runs, fishplates and
hard ware.
2.0 Installation
a) Cable tray shall only be cut along a line of plain metal, not through perforations.
All cut edges shall be prepared and treated according to the original finish of the
metal. Where tray has been welded and on hot dip pre galvanized tray, 2 coats of
zinc-rich paint shall be used for this treatment.
b) Cable trays shall be installed as a complete system. Trays shall be supported

properly at not more than 1000 mm intervals for trays up to 200 mm wide and at
900 mm for wider trays from the building structure. The entire cable tray system
shall be rigid. Support shall be sufficient to ensure that there is no perceptible
sagging of the trays when all the cables are in position. Trays shall be fixed at both
sides of a change of direction at a maximum distance of 150mm from the change.
b) Each run of the cable tray shall be completed before the installation of cables.
c) In-portions where additional protection is required, non-combustible

covers/enclosure shall be used.
d) Cable trays shall be exposed and accessible.
e) Where cables of different system are installed on the same cable tray, non-
combustible solid barriers shall be used for segregating the cables.
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f) Earth links shall be installed for all joints, and where trays and ladders crossover but are
not continuously connected, they shall be cross bonded with minimum 4mm2 earth
cable.
g) Cable trays shall be grounded by two No’s. Earth continuity wires. Cable trays shall not be
used as equipment grounding conductors.
h) PVC Edge protection shall be used where cables run off tray to avoid any insulation
damage.
i) Mushroom headed steel roofing bolts and nuts shall be used for the installation
And coupling of trays, with domed head presented in the cable tray for ease of
cabling.
j) Drop rod studding support for cable tray shall be cut to allow a maximum of 4 threads
through the nut and locking nut. The cut ends shall be filed and treated with 2 coats of
galvanized paint and then a protective rubber cover fitted to reduce the effect of head
injury.
k) Where Cable Tray crosses an expansion joint in the building a manufactured slip connector
shall be installed with flexible earth braids for continuity.
Cable Ladders:
Cable ladder shall be manufactured with hot dipped hot dip pre galvanized finish to IS
2633.
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Cable ladder shall be made up of the following grades:-
Light Duty 50mm deep
Medium Duty 100mm deep
Heavy Duty 25mm deep
Extra Heavy Duty 150mm deep
Grade selections and widths shall be as identified in the schedules.
Cable ladders fittings and accessories shall be factory formed, of the same
Manufacturer and construction as the ladder. Where cable ladder is cut, filed or
Shaped, the ends shall be given 2 coats of anti-corrosive paint and 2 finishing
galvanized coats to match the ladder finish.
Cable ladders shall be fixed with adequate supports to take the full weight of
finished cables. Supports shall be at no more than 2 meter intervals for ladders up
to 300mm wide and 1.5 meter intervals for larger sizes. There shall be no
perceptible sagging of the ladder when cables are in position. Additional fixings
shall be provided within 150mm of each side of any bend, tee or intersection and
as necessary to ensure no sagging with cables installed.
Cable ladder shall be mechanically and electrically continuous throughout.

Mushroom-headed bolts shall be used on all joints and for fixing. There shall be
not less than two bolts per joint or fixing. Cable ladder shall not be used as the
system earth return path for the electrical installation.
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Earth links shall be installed for all joints, and where ladders and cable trays
crossover but are not continuously connected, they shall be cross bonded with
minimum 4mm2 earth cable.
Only factory supplied accessories will be permitted, this includes bends, tees,
crossovers, reducers and risers, both internal and external, lids, splice plates etc.
to provide a complete installation.
Where cable ladder crosses an expansion joint in the building a manufactured slip
joint shall be installed with flexible earth braids for continuity.
Where cables are taken off the ladder either up or down then manufactured drop
out plates shall be used to avoid point strain in the cables.
Cables shall be tied to the cable ladder using cable cleats /clips/ties dependent on
the cables being installed. All cleats shall be low smoke and zero halogen.
3.0 RACE WAYS
Raceways shall comprise of totally enclosed, ‘C’ type channel made from 1.6mm
thick pre-galvanized sheets and screwed/push to fit type cover fabricated from
2.0mm thick pre-galvanized sheets.
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The complete installation shall be fabricated with proper jigs and fixtures to get
consistent dimensional accuracy.
The sheet steel shall be properly pretreated with 7-tank process prior to
galvanizing.
The height of the raceway shall not be more than 50mm and widths of 100,200,300
& 450mm shall be supplied dependent on the number of cables required.
Raceways up to 150mm width shall not have any internal barriers. Race ways of
200mm width shall have a central barrier of 1.6mm thickness and 300mm shall
have 2 barriers. Wherever the width required is more than 300mm, two separate
raceways shall be used side by side.
The raceways shall be suitable for installation in floor screed, supporting from
ceiling above false ceiling. The joining accessories shall be of same material and
manufacturer and shall be supplied with the main lengths of raceway.
Junction boxes shall be fabricated from the same material and manufacturer as
raceways with 2.0mm thick screwed covers. All four sides of junction box shall be
fitted with removal covers. The junction box sizes shall be suitable to receive
100/200, 300 & 450mm raceways. The height & width of the JBs shall be slightly
more than the raceway size so as to insert raceway from all sides. Heights of JB
shall be 60mm (height variable between 40mm to 80mm) or as specified in the
drawing.
Raceway shall be firmly attached to its associated equipment, either by bolted

flanges or by hexagonal male bushes, couplings and compression washers,
according to the direction of run in relation to the equipment.
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Where raceway does not terminated in equipment, the open end shall be capped
with a flanged cover.
Before any cabling is commenced, the trunking installation shall be completely free
from debris and be complete in its construction.
Where holes or cut outs are made in the trunking for connection to a distribution
board or other electrical switchgear, the cut out shall ensure continuity of the
trunking capacity and have cut out protected with edge trim to ensure no damage
to cables during installation. An insulating material such as Paxolin shall be
inserted between the trunking and board or other switchgear so the insulator is
cut slightly smaller than the trunking cut out.
Connections between service outlet units shall be made using flexible non-metallic
/ metallic conduits of suitable length. An equipotential bonding conductor shall be
provided between each service outlet and the cavity of trunking.
4.0 UNDERFLOOR TRUNKING SYSTEM
Under floor raceways shall be of readymade type closed rectangular section made
out of 1.6mm thick CRCA sheet duly coated with rust free coating and may be
sourced from Tata Steel or equivalent. The raceways will be embedded in floor
screeding with allowance for screed covering of depth to avoid cracking after
installation or mounted under the raised floor surface. Overall under floor
trunking dimensions, compartmentation and service outlet arrangements shall be
as indicated in the schedules/drawing.
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Junction boxes for under floor systems shall be of similar material with 2mm thick
removable counter sunk screw top cover shall be supplied. The height of these
junction box shall not be more than 60mm & widths of 10mm higher than
raceway sizes shall be supplied. These junction boxes shall be placed right below
the workstation partitions. Careful coordination with other services will be
required to ensure positioning.
Installation
Final finished floor levels and confirmation of the finishes shall be established prior to the
installation of the trunking system.
Under floor trunking systems shall be fully re-wireable to final circuit outlets.
Conduits shall be connected at inspection joints or points of easy access. The
leveling and alignment of the trunking shall be carefully carried out with respect
to the finished floor level.
Under floor trunking shall have a minimum screed thickness of 25mm to provide
cover. The screed shall be reinforced with expanded metal mesh. All lids shall be
suitably sealed to prevent the ingress of grout during the floor screeding
operation.
The trunking shall be properly packed underneath with screed to ensure that no
voids exist to allow the trunking to collapse when any weight is applied to the
surface.
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Due allowance shall be made in long runs of trunking for expansion and contraction
of the supporting structure. A suitable flexible coupling shall be provided in all
instances where the trunking crosses an expansion joint in the building structure.
Cable crossovers shall be designed to maintain segregation of services. Where

space permits, crossover shall be of the double height type to maintain the
trunking system capacity.
Cable crossovers shall only take place at inspection points. Where trunking does
not terminated in equipment, the open end shall be capped with a flanged cover.
Earth continuity shall be maintained throughout both the floor service boxes and
the trunking system using copper earth links across each joint.
Before any cabling is commenced, the trunking installation shall be completely free
from debris and be complete in its construction.
III CONDUTING:
Unless otherwise specified all concealed conduits should be of PVC FRLS of

2.0mm wall thickness and exposed conduits in indoor locations (Factory Area)
shall be of Black enameled MS of 1.78mm wall thickness. For indoor office
building, PVC FRLS conduits shall be used. In exposed areas, MS/GI conduits/ 2.0
mm thick rigid heavy duty PVC FRLS conduits and accessories shall be used.
Conduit, trunking, cable tray, ladder rack and cables shall be installed to give the
following minimum clearances to mechanical services pipework:
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Pipe Clearance
Type
Insulated 50 mm for
Pipes conduit or
trunking
Un 100 mm for
Insulated conduit or
Pipes trunking
Insulated 50 mm for
Pipes cables not
enclosed
Un 150 mm for
Insulated cables not
Pipes enclosed
Any system of containment that shall be used is to be complete with all

accessories to provide a complete system that uses all components from a single
manufacturer.
Containment systems shall be erected complete with all accessories connected.

They shall then be offered to the Engineer for inspection before any cables are
installed.
No lubricants, apart from the French chalk, shall be used to assist when pulling
wires/cables into or onto any containment system. Adequate draw-wires shall be
provided where conduit systems are not to be wired on completion or are to be
wired by others.
Where containment systems have been suspended using drop rods or studding,
these shall be cut and sealed after completion to avoid excessive rod below the
containment installed. No more than four threads should appear through fixing
nuts and washers. Ends shall be sealed with galvanized paint and rubber / plastic
caps fitted to avoid head injuries.
2.0 PVC FRLS CONDUIT SYSTEM
PVC FRLS conduit and accessories shall be super high impact, heavy gauge,
complying with IS 9537, IS 3419 and IS 14930. The minimum diameter shall be
20mm and maximum 32mm unless otherwise specified. Inspection bends, solid
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bends, elbows, tees or normal bends shall be installed.
PVC FRLS conduit and fittings shall bear the ISI Mark and be colored black or
white as indicated on the drawings/schedule.
The temperature range shall be -5● C to + 100●C.
Inspection / Pull box / Junction boxes, where used, with relevant PVC FRLS
conduit installation shall be of heavy gauge PVC FRLS and conform to IS
specification and shall match with the conduit sizes. The box shall be
round/square rectangular with conduit stub projection for termination of
conduit. The box shall be of minimum 50mm deep and the size of box shall be
suitable to pull/make necessary joints of wires inside the boxes. The boxes shall
have flush type cover.
Box lids shall make good contact with the boxes. For flush work the lids shall
overlap the box adequately on all side. Screws shall secure all lids.
Wall thickness shall be minimum 2.0mm for 20mm conduit, 2.0mm for 25mm
conduit and 2.0mm for 32mm conduit, 2.2mm for 40mm conduit.
All accessories associated with the PVC FRLS conduit installation including all
adaptable boxes, conduit boxes, runners, couplers etc. shall be by the same
manufacturer as the main conduit tubes, with matching color and finish. All
accessory boxes and fittings to have M4 brass inserts for lid fixing and brass earth
terminals.
3.0 General Installation Requirements
PVC FRLS conduits shall only be installed where described within the
Specification. PVC FRLS conduits shall be installed in accordance with the
latestIS 732. PVC FRLS installations shall be free from kinks or buckling or
deformation.
Conduit shall be mechanically continuous throughout so that cables are fully

protected. Joints and connections shall be made with an adhesive recommended
by the manufacturer of the conduit.
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Where a number of conduits converge, large adaptable PVC FRLS boxes shall be
employed to avoid the conduits crossing. Conduits shall be connected to the boxes
by means of male bushes and couplers.
Conduits shall be saddled to the structure of the building within 150mm of each
box or fitting and at intervals not greater than 900 mm on horizontal runs and
1200mm on vertical runs. For higher ambient temperatures and areas where
rapid air temperature occurs, this distance shall be reduced by 300mm in each
direction. Saddles shall be a sliding fit around conduits to allow for movement due
to expansion.
For concealed conduit installations the conduit in ceiling slab shall be straight as
far as possible. Before the conduits are laid in the ceiling, the position of the outlet
points, controls, and junction boxes shall be set out clearly as per the dimensions
and to minimize off-sets and bends. Before the reinforcement rods are kept in
position electrical contractor shall mark in paint the position of outlet points and
conduit drop on the shuttering. When the outlet boxes are kept in position and
before pouring the concrete, all outlet boxes shall be filled with thermo coal to
avoid entry of concrete into the box. Conduits in ceiling shall be bonded to the
reinforcement rods with G.I. bonding wire at intervals not more than 1000mm, to
secure them in position. PVC deep light outlet / pull boxes shall be provided as
required. The conduit in the ceiling slab shall be laid above the first layer of
reinforcement rods to avoid cracks in the ceiling surface. In general the conduit
shall not be laid directly on the shuttering surface to avoid cracks in the ceiling
surface.
Conduits concealed in the wall shall be secured rigidly by means of steel hooks /
staples at min. 600 mm intervals. Before conduit is concealed in the walls, all
chases shall be made to the required depth which shall ensure the cover of 20mm
over the conduit using electrically operated groove cutting tools to accommodate
the relevant number of conduits in that location.
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The outlet boxes for control switches, inspection and draw boxes shall be fixed as
and when conduits are being fixed. The recessing of conduits in walls shall be so
arranged as to allow at least 12mm plaster cover on the same. All grooves, chases
etc. shall be rough plastered using cement mortar of appropriate specification up
to the original surface. Chicken mesh cover shall be used over the concealed
conduits. Surface conduits wherever specified shall be fixed to the surface over
spacing bars or suspended on supports.
Where conduits pass through expansion joints in the building, adequate

expansion fitting or other approved devices shall be used to take care of the
relative movement.
After conduits, junction boxes, outlet boxes etc. are fixed in position, their outlets
shall be properly plugged with PVC stoppers or any other suitable materials, so
that water, mortar, vermin or any other foreign materials do not enter into the
conduit system. All conduit ends terminating into an outlet shall be provided with
bushes of PVC or rubber after the conduit ends are properly filed to remove
burrs and sharp edges.
Necessary G.I. pull wires shall be inserted into the conduit for drawing wires
before concreting. Insulated earth wires shall be run in each conduit originating
from the panel board up to the Light, Socket and Switch boxes. If the Electrical
Contractor forgets to install any conduit/boxes etc., before the
plastering/painting work is done by other agencies, he may be permitted to
install the same with prior permission of owners/ consultant and he shall be
liable to make good the wall, floor, ceiling etc. at his own cost.
Conduits shall be so arranged as to facilitate easy drawing of wires through them.

The entire conduit layout shall be completed in such a way as to avoid additional
junction boxes other than light points. The wiring shall be done in a looping
manner. All the looping shall be done in either switch boxes or outlet boxes. Joints
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in junction or pull boxes are strictly not allowed.
All conduits shall be installed so as to avoid touching of steam and hot water
pipes.
Conduits shall be installed in such a way that the junction and pull boxes shall
always be accessible for repairs and maintenance work. The location of
junction/pull boxes shall be marked on the shop drawings and approved by the
owner/consultant.
A minimum separation of 200mm shall be maintained between electrical conduits

and hot water lines in the building.
Caution shall be exercised in using the PVC conduits in locations where ambient
temperature is 50 degree Celsius or above. Use of PVC conduits in places where
ambient temperature is more than 60 degree C is prohibited.
The entire conduit system including boxes shall be thoroughly cleaned after
completion of installations and before drawing of wires.
Conduit system shall be erect and straight as far as possible. Traps where water
may accumulate from condensation are to be avoided and if unavoidable, suitable
provision for draining the water shall be made.
All jointing methods shall be subject to the approval of the owner/consultant.
Separate conduits shall be provided for the following system.

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 Lighting wiring
 16 Amp power outlets.
 6 Amp outlets and lighting system.
 24 Volt supply system.
 Telephone/intercom system,
 Fire Alarm system,
 Computer data cabling system.
 Equipment wiring.
Where a conduit terminates at a main switch, distribution board, sub-switch or

other metal clad accessory, a half-screwed socket shall be employed. It shall be so
arranged as to be in good mechanical contact with the metal case. An internal
bush shall be screwed into the socket from inside the case and the two locked
together.
Any PVC FRLS conduit sections that have been installed with scratches,
discoloration, manufacturer’s marks, general marks or burrs shall be replaced
with new undamaged sections at no cost to the Contract.
PVC FRLS joints shall be made using either permanent as manufactured adhesive
for rigid sealed connections, or a non-hardening as manufactured flexible
adhesive for connections where movement is required such as expansion joints or
timber framed buildings. Adhesives shall be supplied by the conduit manufacturer
to ensure compatibility.
MAXIMUM PERMISSIBLE NUMBER OF 650/1100 VOLT GRADE WIRES THAT MAY

BE DRAWN IN TO RIGID PVC CONDUITS.
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Nominal
Cross
20mm 25mm 32mm 40mm
Sectional
Area of
Conduct S B S B S B S B
1 2 3 4 5 6 7 8 9
1.5 5 4 8 6 15 10 - -
2.5 4 2 6 4 10 8 - -
4 2 - 4 4 8 6 - -
6 2 - 4 3 6 5 - -
10 - - 3 2 5 4 6 5
16 - - 2 2 3 3 5 4
25 - - - - 3 2 5 3
Note:
1) COMPLIED WITH IS 694-1990
2) THE ABOVE TABLE SHOWS THE MAXIMUM CAPACITY OF CONDUITS FOR A

SIMULTANEOUS DRAWING OF WIRES.
3) THE COLUMNS HEADED ‘S’ APPLY TO RUNS OF CONDUITS WHICH HAVE

DISTANCE NOT EXCEEDING 4.25M BETWEEN DRAW IN BOXES AND WHICH DO
NOT DEFLECT FROM THE STRAIGHT BY AN ANGLE OF MORE THAN 15
DEGREES. THE COLUMNS HEADED ‘B’ APPLY TO RUNS OF CONDUITS WHICH
DEFLECT FROM STRAIGHT BY AN ANGLE OF MORE THAN 15 DEGREES.
Wires carrying current shall be so installed in the conduit that the outgoing and
return wires are drawn into the same conduit.
4.0FLEXIBLE CONDUIT SYSTEM
General Requirements
Flexible conduit systems shall comply with IS 9537, IS 3480, IS 14930 and IS
3419.
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The choice of material for final connection shall depend on the environment in
which the connection is to be made. Where the flexible connection is
manufactured the conformity to the standards above shall be proven by the
manufacturer.
For final connection to plant and equipment where the fixed wire installation has
been installed to a point adjacent the plant or equipment then sufficient length of
cabling shall be left to allow the final containment section to be flexible to allow
movement. The flexible element shall be limited in length to generally 600mm,
longer sections shall be advised to the Engineer for agreement before installation.
Longer runs will be accepted for modular lighting installations and under floor
wiring systems of up to 3 meters.
To facilitate the connection of the flexible conduit to the rigid hot dip pre
galvanized installation, a hot dip pre galvanized through box shall be connected to
the rigid system with the other outlet connected to the flexible system. For larger
cables an adaptable hot dip pre galvanized box will be required. In all cases that
box shall be used to allow some slack before cables are pulled through the flexible
section.
Where the final connection is flexible from an isolator or other switchgear then
manufactured cable glands and bushes shall be used to ensure an effective seal to
IP65. Earth tags should be included where metallic connections are made with
brass nut and bolt utilized.
Unless specified differently elsewhere the flexible conduit system shall be one of
the following types :-
Uncovered flexible constructed from helically wound hot dip pre galvanized steel
with an operating temperature range from -50ºC to 300 ºC
Hot dip pre galvanized steel conduit with flame retardant low acid PVC covering
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Hot dip pre galvanized steel conduit with flame retardant low acid PVC covering
The choice of flexible conduit will depend on the application and working
temperature within the area where the plant and equipment is installed, in any
event the connections shall utilize glands that give protection to IP65.
Connections to small motors, such as in small ventilating fans, shall be made by

means of multi-core PVC cable with brass packing gland type adaptors at each
end.
Flexible conduit will not be permitted in lieu of sets and bends in the rigid conduit
system.
5.0 STEEL CONDUIT SYSTEM
Steel conduit shall be welded seam and the installation shall meet the
requirements of IS 9537, IS 14768, IS 3480, IS 3837, IS 14763, IS 14930, IS 4649
either black enamel, or hot dipped galvanized inside and out to IS 2633.
Conduits less than 20mm diameter or greater than 32mm diameter shall not be
used.
All conduit fittings and accessories including boxes, couplings etc. shall be
supplied by the same manufacturer and of the same material finish as the main
tubes.
Unless specified elsewhere, the use of black enamel conduit and fittings will be
acceptable for all internal dry areas where the installation is not visible after
completion, note, this does not include Plant Rooms in any location where
galvanized conduit shall be used. For any damp/wet internal areas and external
areas or buried installations, galvanized conduit and fittings shall be used and be
complete with neoprene gaskets for all conduit lids.
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Where a number of conduits converge they shall terminate in a metal box so as to

prevent bunching. Draw boxes and junction boxes shall be of ample size to permit
cables being drawn in and out. Unless otherwise described, boxes shall generally
be at least 100 x 100 x 75 mm for cables up to 6 mm² or conduits up to 25 mm
diameter. They shall be at least 150 x 150 x 75 mm for larger cables or conduits.
Trifoliate bolted labels shall be affixed to the box lid with clear indication of
jointing and warning of highest voltage that is anticipated.
Any exposed threads, including runners formed when joining lengths of conduit
that are visible shall be treated with galvanized paint to ensure avoidance of
rusting.
Boxes shall be manufactured from the same grade of material and finish as the
main conduit tubes and shall have welded corners not folded. Lids shall be made
of the same material as the box. For flush work, lids shall overlap the box
adequately on all sides. For surface work the lids shall make good contact with the
box. Fixing screws shall be mushroom head of the same finish as the lid.
Conduit boxes and extension rings shall be constructed of same grade and finish
of steel as the conduit tubes. Boxes shall be complete with an earth terminal and
be of the same class of finish as the conduit. Where loop-in pattern boxes are
required, they shall be of the same circular pattern with back outlets of the
appropriate number.
Deep boxes or extension rings on standard circular conduit boxes shall be used,
where necessary, in order to bring boxes flush with the surface of the ceiling or
wall.
Circular boxes shall be provided with long spouts, internally threaded, with a
shoulder for the proper butting of the conduit. Conduit boxes mounted outside
the building or in damp areas shall have external fixing lugs. Each such box shall
include a neoprene gasket between the lid and the box.
Box lids shall be made of sheet steel for surface work. They shall make good
contact with the box. Brass screws shall secure all lids. Lids on external boxes
shall have machined joint faces mating to machined faces on the box.
Adaptable boxes shall be grey iron pattern unless otherwise specified. Where
adaptable boxes are fitted flush, the cover plates shall be heavy gauge metal with
12 mm overlap on all sides. The internal depth of the box shall not be less than 40
mm. Covers shall be secured by a screw at each corner and by additional screws,
as necessary, to provide a maximum spacing of 300 mm between adjacent screws.
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Fixing screws shall be brass with round or cheese heads. Weatherproof boxes and
covers shall have machined mating faces complete with a neoprene gasket
Flush outlet boxes to which a pull switch or similar is to be fitted shall be

provided with a break joint ring.
Where hot dip pre galvanized conduit has been specified, all accessories, switch
boxes and associated apparatus shall also be hot dip pre galvanized unless
otherwise directed by the Engineer.
5.1 General Installation Requirements
Where a conduit run passes from a concealed area to an area requiring hot dip pre
galvanized conduit, then the whole of the conduit run shall be hot dip pre
galvanized. Any conduit external to a building shall be weatherproof.
Conduit runs shall, wherever possible, be concealed in ceilings, voids, walls,

chases, etc. Where exposure of conduits in rooms is necessary they shall be
routed through rooms of secondary importance such as stores and risers, using
back outlets to switch boxes, etc.
Particular care shall be taken when setting out conduit runs to outlet points,
which are to be fitted to furniture, kitchen fittings, worktops, island units etc.
Exact details of furniture and fittings construction shall be ascertained in order
that all conduit work shall, wherever possible, be concealed and in any event be
set out in a fully coordinated way taking into account all other affected trades.
Conduits and fittings shall be free from internal burrs and other defects.
Precautions shall be taken to prevent the ingress of silt or moisture into the
conduit system by the use of screwed metal caps and plugs to protect open ends.
If fouling should occur, the affected conduit shall immediately be swabbed clean
and where this cannot be effectively achieved, the conduit shall be replaced.
Where the finish of the conduit is damaged or suffers from the effects of
corrosion, the surface shall be wire brushed and painted with rust-inhibiting
paint to the same standard as the normal surface.
Exposed threads shall be protected by rust-inhibiting paint immediately after

erection. Any conduit shall be treated with zinc-rich paint. The conduits shall be
maintained in good condition throughout the duration of the Works.
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Conduit runs shall be so arranged that any condensed moisture can drain to the
lowest point, where a screwed plug shall be provided for the purpose of
draining off. The conduit routes shall be arranged to avoid traps or low-level
pockets.
Bends shall be made on site to suit conditions. Not more than two right-angled
bends will be permitted without the interposition of a draw box. Generally, long
straight conduit runs shall have draw boxes installed at maximum intervals of 8
meters.
Bends shall be made using a standard type of bending machine. The radius of any
bend shall not be less than four times the outside diameter of the conduit. Care
shall be taken to prevent conduit deformation. Conduit sets through walls will not
be permitted.
Where running couplers are essential and at any other position where hexagonal
locknuts are not practicable, circular locknuts with knurled edges shall be
utilized. They shall seat firmly and evenly onto mating faces of couplings or other
accessories. Any exposed threads shall be treated as previously specified.
Conduit joints shall butt solidly to boxes, couplings, etc., with no exposed threads
except at running couplings. Full use shall be made of the total length of threads.
Where a conduit is exposed to different temperatures, the section of the conduit

at the higher temperature shall be isolated from that at the lower temperature.
(The temperature difference may be due to either surrounding air conditions or
the medium with which the cable is in contact, such as conduit running from a
warmed building to exterior points.) The isolation shall be provided by a conduit
box filled with a permanently plastic compound, after completion and testing of
all wiring.
Conduit shall not be mounted directly on the surface of walls or ceilings. A

minimum spacing of 6 mm to the back of the conduit shall be maintained. This is
to be achieved by the use of spacer saddles.
Where conduit terminates at a main switch, distribution board, sub-switch or

other metal clad accessory, a screwed socket shall be provided. It shall be
arranged to be in good mechanical and electrical contact with the metal case. A
brass bush shall be screwed into the socket from inside the case and the two
locked together with a compression washer.
Boxes with tapped entries and where internal space permits, shall be provided
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with a ring bush as a locknut. Where the space is insufficient a knurled locknut
shall be used on the outside of the box.
Where conduits cross expansion joints in the building structure, special expansion
couplings shall be used, or such other methods as are agreed, in writing, by the
Engineer shall be adopted. Continuity and earth integrity through all such joints
shall be maintained.
6.0 Conduit Fixings

Holes for fixings shall not be drilled in any structural steelwork, pre-stressed
concrete or waterproof finishes such as Sika, without first obtaining the
agreement of the Structural Engineer.
The agreement of the Architect and the Structural Engineer shall be obtained
for any use of cartridge-fired bolts for fixing into brickwork or pre-cast planks
of concrete. Such agreement shall also be obtained where it is proposed to
weld fixings onto steel structure.
Conduit boxes shall be fixed to the structure of the building independently of

the conduit, except where this fixing would breakdown any provision for
weatherproofing. Conduits shall be fixed to the structure of the building
within 150 mm of each box or bend and at centers not exceeding 1000 mm on
straight runs.
Conduit boxes shall be fixed to walls, ceilings and the like by countersunk
woodscrews of appropriate size. Where walls are plugged, special plugs or
plugging materials shall be used. Wooden plugs will not be permitted. Holes in
boxes shall be adequately countersunk to ensure complete recession of the
fixing screws.
Where required, purpose-made clips shall be fabricated from strip iron or mild
steel flat bar, these shall generally be as manufactured products. They shall
receive one coat of protective paint after fabrication with a further coat after
erection. Details of proposed clips and brackets shall be submitted to the
Engineer for comment prior to manufacturer being commenced.
7.0 Surface Conduit
Surface conduit runs shall be planned and shown on the Contractor ’s Working
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Drawings. Surface conduits shall be installed vertically, horizontally or parallel with

features of the building to ensure a discrete installation.
Where the appearance of the conduit runs would be improved by the introduction
of dummy lengths of conduit, or where a more secure fixing for the suspension of
fittings would be obtained, such dummy conduits and continuations shall be
provided.
Where conduits pass directly through floors where washing down is likely to
occur, the conduits shall be sleeved. The sleeve shall be flush with the underside
of the floor, extend 75 mm above the top surface and be secured to the wall by
means of a heavy gauge saddle. Any holes shall be effectively sealed using
approved waterproof seals to ensure no water ingress.
Unless otherwise specified, surface conduits shall be fixed by means of distance

spacing saddles or purpose-made clips, manufactured from the same
manufacturer, material and with the same finish as the conduit tubes.
The saddles or clips shall allow the conduits to be taken directly into the
accessories without sets or bends. They shall be fixed using non-ferrous screws.
8.0Concealed Conduit
Concealed conduits shall be securely fixed to prevent movement during building

operations. Fixing shall be by means of purpose-made clips or other means, so as
to ensure that there is no conduit deformation.
Where conduits are installed in multi-story buildings, a substantial right-angle

shall be interposed at every third story to ensure adequate support of the
installed cabling and to prevent undue stress on the terminal connections.
Where conduits are installed in ducts or voids, fixing shall be in the manner
specified for surface conduits. Conduits in ceiling cavities shall be supported
independent of the suspended ceilings.
Recessed conduit boxes buried in plaster shall permit a full 12 mm depth of cover
over its entire length. These conduits shall be mechanically and electrically
continuous throughout so that cables are fully protected.
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Conduits installed in chases of walls or floors shall be firmly secured by wrought

iron pipe hooks or cram pets. These fixings shall be sufficient to hold the
conduits in place. Conduits mechanically damaged by the installation of cram pets
will be rejected and shall be replaced.
Conduits installed in chases shall be painted with one coat of rust-inhibiting paint
before erection. A further coat shall be applied to all accessible surfaces, including
the hooks and cram pets, after erection.
Conduit boxes and draw boxes cast into concrete walls or floors shall be held in
place so that they are absolutely rigid until and while the concrete is poured and
vibrated. The depth of such boxes shall be such that the open side is flush with the
finished surface of the concrete.
Where conduits are laid direct on the shuttering of reinforced slab construction,
conduit extension rings or deep boxes shall be used to raise the conduit to run
between the top and bottom reinforcing. PVC tape shall be wrapped round butt
joints on extension rings to prevent the ingress of moisture/ wet concrete.
Where conduits are laid in concrete slabs or screeds and the like, a competent
person shall be in attendance while the concrete pouring or screeding operation
is being carried out. This person shall ensure that damage to the conduit is
avoided and that the conduit work is in sound condition, properly and efficiently
maintained, during this work element period.
Conduit buried in the ground shall be wrapped with PVC self-adhesive tape, half
lapped. The taping shall extend for a distance of 150 mm beyond the point where
the conduit emerges from the ground. Joints in the conduit system shall be made
watertight using aluminum paint and sealant at each connection. Joints shall be
partially screwed up before the paint and sealant are applied to maintain
electrical continuity.
There shall be no joints or connections underground. If required the conduits

shall be run above surface to make these connections in approved boxes fitted
with neoprene gaskets. Labels shall be applied with engraved trifoliate screw
fixed to the box lid.
Wiring for Lighting & Small Power

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WIRES (FRLS GRADE/PVC )
Wires shall be of 660V grade, FRLS grade/PVC, flexible single core, multi strand
copper.
CONDUCTORS
All PVC insulated FRLS copper conductor wires shall conform in all respects to
Standards as listed under sub-head Regulations and Standards and shall be IS
approved and ISI marked.
BUNCHING OF WIRES
Wires carrying current shall be so bunched that the outgoing and return wires are
drawn into the same conduit. Wires originating from two different phases shall
not run in the same conduit. All wires shall have ferrules for identification.
Lighting and power circuits shall be in separate conduits.
DRAWING CONDUCTORS
The drawing and jointing of PVC insulated copper conductor wires shall be
executed with due regard to the following precautions. While drawing wires
through conduits, care shall be taken to avoid scratches and kinks which may
cause breakage of conductors. There shall be no sharp bends. Wire reel stands to
be used for pulling of wires to avoid kinks.
Insulation shall be removed by insulation stripper only. Strands of wires shall not
be cut for connecting terminals. The terminals shall have sufficient cross sectional
area to take all strands and connecting brass screws shall have flats ends. All
looped joints shall be connected through terminal block/ connectors. The
pressure applied to tighten terminal screws shall be just adequate, neither too
much nor too less.
All light points shall be terminated through connectors. Conductors having

nominal cross sectional areas exceeding 10sq.mm shall always be provided with
cable sockets. At all bolted terminals brass flat washer of large area and approved
steel spring washer shall be used. Brass nuts and bolts shall be used for all
connections.
All wires and cables shall bear the manufacturer’s label and shall be brought to
site in original packing. For all internal wiring. PVC insulated wires of 1100 volts
grade shall be used. The sub-circuit wiring for point shall be carried out in loop
system and no joints shall be allowed in the length of the conductors. No wire
shall be drawn into any conduit until all work of any nature that may cause injury
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to wire is completed. Care shall be taken while pulling the wires so that no
damage occurs to wire, the conduits shall be thoroughly cleaned of moisture,
dust , dirt or any other obstruction. The minimum size of PVC insulated copper
conductor wires for all sub-circuit wiring for light points shall be minimum 2.5 sq.
mm copper conductor wire. Separate neutral shall be provided for each circuit.
JOINTS
Joints shall be made at main switches, distribution boards. socket outlets, lighting
outlets and switch boxes only. No joints shall be made in conduits and in junction
boxes. Conductors shall be continuous from outlet to inlet.
MAINS AND SUB-MAINS

Mains and sub-mains cable or wires where called for shall be of the rated capacity
and approved make. Every main and sub main wires shall be drawn into an
independent adequate size conduit. Earthing shall be in conformity with relevant
IS codes and calculations shall be submitted for verification. An independent earth
wire of the proper rating shall be provided for every single phase sub-main. For
every 3 -phase sub-main, 2 Nos. earth wires of proper rating shall be provided
along with the sub-main. The earth wires shall be fixed to conduits by means of
clips at not more than 1000 mm distance. Where mains and sub-mains cables are
connected to switchgear, sufficient extra lengths of cable shall be provided to
facilitate easy connections and maintenance.
Wiring for lighting shall be carried out using 1100 Volts, 1.5Sq.mm/2.5 Sq.mm FRLS grade PVC
insulated multi strand copper conductor wires.
Sizes lower than 1.5Sq.mm shall not be acceptable except for specified applications.
1.5Sq.mm size shall be used for point wiring and 2.5 Sq.mm wires for circuit wiring.
3c x 2.5Sq.mm copper flexible cable shall be used for high bay luminaire drawn in
conduit.
All end terminations shall be carried out using copper lugs.
Color code shall be adopted. Red, Yellow, Blue for Phases, Black for Neutral and
Green/Yellow green for earth wire.
Each wire shall be ferruled at both ends for identification.
Each of the switchboxes shall carry identification tags and shall be earthed.
All accessories required to complete the wiring shall be included whether specified
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or not.
Each indoor lighting circuit shall have not more than 10 points except for staircase
/ Corridor lighting wherein the circuit shall be sized and controlled by a Single
MCB/Switch.
The wiring of general purpose sockets in corridor, lounge & common areas shall not
be looped with the lighting circuits.
Emergency / Exit lighting backed up by inverter / SLR batteries shall not be looped
with the General lighting circuits.
Timer/Photocell based Lighting control system shall be adopted to separately

control pathway, parking lot, external & Street lighting.
Light control switches shall be of a 240V, 6A rating for controlling light points as
specified. Light control switches shall be of Modular plate type design with metal
or PVC boxes suitable for flush mounting for general lighting as specified.
2.0 Sub-Mains and Circuit Mains
Wiring of sub-mains and circuit mains in concealed or surface conduit systems

shall be with 2mm thick rigid FRLS/ PVC conduits and conduit accessories with
660/1100V grade FRLS PVC insulated multi strand copper flexible wires for phase
neutral and earth from Final Distribution Panel/Lighting Distribution Panel to
First Switch Box and looping between Switch Boxes/ First point of group
controlled light points.
3.0 Point Wiring
Point wiring shall commence from the first switch box for the points connected to
the same circuit. Point wiring for lights, sockets, fan points etc., shall be carried
out with FRLS PVC insulated copper conductor wires of 660/1100V grade. The
point wiring shall be inclusive of MS/PVC Box, Switches, Switch plates, wires in
suitably sized conduits along with all accessories required of approved make and
shall be provided with FRLS PVC insulated copper earth continuity wire for
earthing for all points as specified.
4.0 Installation
All switch connections shall be made only after ensuring the continuity of wires
and terminations. Tapping of wires shall be done only at the terminals of switches,
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sockets and ceiling roofs and terminal blocks. Under joining and extension of
wires in pipes and conduits shall not be carried out under any circumstances.
The arrangement of switches and sockets shall be straight, neat, systematic, and
aesthetic. The Sub-Contractor shall obtain approval from the Consultant / Main
Contractor with regard to the proper location of switches and all outlets.
5.0 SOCKETS:
All decorative modular sockets 6A and 16A ratings shall be of flush mounting type with
control switches of Modular plate type housed in a MS/PVC boxes. The enclosures
of sockets and pin of the sockets shall be connected to the ground through a
proper size insulated earth continuity wire. Hylam phase barriers shall be
interposed between switches located in a common enclosure, when wired on
different phases. The polarity of the socket shall be checked and corrected if
required.
MCBs, RCDs, RCBOs, ISOLATORS(MCB TYPE) AND MCB Distribution Boards.
The Miniature circuit breaker (MCB) shall be moulded type. The MCB’s shall have
inverse time tripping characteristic against overloads and instantaneous trip
against short circuit, ON and OFF position shall be clearly marked on the MCB.
The MCB’s shall be suitable for operation of 50Deg. C ambient without any
duration. The rating and fault level of MCB’s shall be as per specific requirements.
The terminals of the MCB’s shall be suitable for use with Pin / Fork lugs. Tripping
characteristic of the MCB shall be as per specific requirements.
Bus Bars
The busbar and connectors shall be made of high conductivity copper. The bus bar
shall be amply sized to carry the rated continuous current under the specified
ambient temperature without exceeding the total temperature of 90 Deg. C. the
bus bar and their connections shall be capable of withstanding without damages
the thermal and mechanical effects of through fault currents.
The MCBs shall be of the single pole, double pole, triple pole or 4 pole type,
suitable or Din Rail mounting.
The MCBs shall have a minimum short circuit rating of 10KA and type C
characteristics unless otherwise specified.
The MCBs shall be provided with finger touch proof terminals and captive
screws.
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The MCB shall be having protection against short circuit currents.
The MCB shall be having protection against Overload Current.
The MCB shall be suitable for Thermal Release under overload condition the
bimetal strip defects and trips the operating mechanism.
The MCB shall be suitable for Magnetic release in case of Short circuit through the
magnetic coil activates the plunger to strike operating mechanism.
The MCB shall be provided with over voltage trip and an indication after the
BESCOM metering.
Specific Requirements of MCB DB’s
Service (Indoor / Outdoor) : Indoor

Voltage : 415V +/- 10%
Frequency : 50Hz +/- 5%
System Earthing : Solidly Grounded
Fault Level : 10kA
Phase Segregated / Non phase segregated : Phase Segregated
Single / Three Phase Distribution : Single / Three Phase as indicated in the
Distribution diagram
Design Ambient Temperature : 50 Deg. C
Enclosure
Type : Metal clad
Material : CRCA
Thickness (Minimum) : 1.6mm
Single Door / Double Door : Double door with acrylic cover
Hinges : Hidden type
Degree of protections : IP-45/IP54/IP65
Type of Mounting : Wall Mounted type
Wiring
Voltage Rating : 1100V
Conductor : Copper
Minimum area of cross section : 2.5sq mm
Name Plate
Material & thickness : Plastic, 3mm or eq.
Main incomer TP/TP+NL/4P : TP+NL
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Individual Phase Incomer : Double Pole as indicated in the SLD

Individual Phase Outgoings : SP / DP MCB’s as indicated in the SLD
RCD’s
The Residual current device (RCD) shall be suitable to operate on three phase
415V / single phase 240V, 50Hz AC supply.
The sensitivity of the RCD shall be 30/100/300mA as specified in BOQ & the
tripping time not more than 30m secs.
The RCD shall be of DIN rail mounting type and shall be suitable for mounting
inside MCB DBs as main or phase incomer.
The RCD shall have a test button for periodical testing of the operation.
Isolators (MCB Type) shall be similar in appearance and features to the MCB s
except that they shall not have tripping mechanism.
MCB DISTRIBUTION BOARD
The distribution boards shall comprise factory assembled and wired, totally
enclosed metal clad fabricated out of cold rolled steel with minimum thickness
1.6mm with gasket all points and openings including hinged doors with suitable
locking facility. The DB shall be of wall mounted type.
Protect insulated cover plate shall be provided inside the panel to shroud all the
live parts. Only the operating handle of the switch/MCB shall be projecting
outside the cover plate. The incoming switch terminals shall be suitably shrouded
with hylam plate. The incoming and outgoing terminals shall be suitable for
terminating cables.
All the low voltage internal wiring of the distribution boards shall be of 1100V
grade stranded copper conductor of core 2.5sq mm minimum suitable for fault
withstand capacity of the boards.
All the device wiring and terminal block with in the board shall be clearly
identified by durable and legible tags corresponding to those in applicable
drawings. All wiring shall be easily identifiable by ferrules(interlocking type)
accessible for maintenance checks.
The DB shall have nameplate with its designation inscribed on it. Suitable
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nameplate shall be provided for each piece of equipment for easy identification.
The Following colour coding shall be used for identification of busbars and wiring
as per standards.
R Phase Red
Y Phase yellow
B Phase Blue
N Neutral Black
E Earthing Green or Yellow
C Control Grey
Suitable removable gland plates shall be provided for top / bottom cable entry, as
specified.
An each bus of bare copper strip of adequate section shall be provided all along
the length of the DB with two bolted type earthing terminals. All metallic non-
current carrying parts including doors, switches etc. shall be securely connected
to the main earth bus by stranded PVC insulated copper wire of adequate size.
Paint shall be as per specific requirements.

Proper danger plate shall be provided on each board as per relevant standards.
The double door type MCB DBs shall be of the factory assembled three
phase/phase segregated / TPN / Vertical TPN / Horizontal Tier type suitable for
surface/ flush mounting as indicated in the Detailed BOQ.
MCB DBs shall be of the totally enclosed type fabricated out of 1.2mm thick CRCA
sheet. The DB enclosure shall undergo pretreatment followed by powder Coated
finish. The DB shall have glazed lockable door which shall be Reversible.
Gland plates with knockouts shall be provided on the top and bottom. The sides
shall have conduit knockouts.
All 3 Phase shall be housed in a common compartment for 3 phase DB’s and
separate compartment for phase segregated DB’s.
The DB shall have provision for fixing an RCCB/ RCBO in the incoming side for the
vertical DB’s and phase incoming for phase segregated type.
Insulated fork type phase bus bars of requisite length shall be supplied.
A common neutral bus and an earth bus of 100A rating shall be provided in the
DB’s with 3ph. outgoings. In the phase segregated type DB’s independent neutral
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bus shall be provided for each phase and a common earth bus. All bus bars shall
be of copper.
Two earthing studs shall be provided for external earthing.
All outgoing circuits shall have an earth connection from the above mentioned
bus.
Apart from the insulated earth bus, the body of the panel shall have provision
for earthing which will be connected to the general earthing grid.
The MCB DB’s shall be having Cable Ties for better cable Management.
MCB DB shall be having Stoppers on din rail at either end.
MCB DB’s shall be having removable front plate (Without removing door) to
facilitate easy servicing.
LIGHTING DB:
Distribution Boards (10KA) made out of 18SWG CRCA enclosure hinged cover/over
flanged cover with cutouts for operating the MCB knobs and comprising of phase
busbars, neutrals and earth bus with tapped holes, bakelite phase barriors, pvc insulator
shoes for incoming wire etc complete. DBs shall be mounted by grouting in to the
wall/angle to brick wall as required. DBs shall be suitable for single phase loads. Or DBs
shall be mounted on suitable M.S. angle and supporting flat. DBs shall include
termination lugs etc., all complete. All LTG DB are ‘C’ Curve, Distribution Board shall be
IP43 – Metal door unless other standards specified.
RAW POWER DB:
Distribution Boards (10KA) made out of 18 SWG CRCA enclosure hinged cover/over
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termination lugs etc., all complete. All RP DB are ‘C’ Curve, Distribution Board shall be
IP43 – Metal door unless other standards specified.
UPS POWER DB:
Distribution Boards (10KA) made out of 18 SWG CRCA enclosure hinged cover/over
termination lugs etc., all complete.All UPS DB breakers are ‘D’ Curve,
Distribution boards shall be suitable for 415 volts, 3 phase A.C. supply of 230 volts
single phase A.C. supply as required. Distribution board shall generally conform IS:
2675 or BS: 214.
Type & Construction:
Distribution boards shall be of totally enclosed dead front safety type. The
enclosures shall be factory made/ approved make. The sheet steel not less than
2mm thick shall be treated with a rigorous rust inhibition process before
fabrication. The distribution boards shall comprise of circuit breakers as specified
incoming and required number of circuit breakers as out goings. The main and
out goings shall have rating as specified in the drawings and schedule. The
distribution board shall be provided with suitable earthing lug.
Bus Bars:
Suitable bus bars made of high conductivity copper strips and mounted on non-hydro
scopic insulating supports shall be provided. Separate earth line will be provided.
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Circuit Breakers:
Miniature circuit breakers shall be of approved make/design. Circuit breakers shall be

equipped with individually insulated, braced and protected connectors. The front face of
all the breakers shall be flush and in line with each other.
Safety & Interlocks:
All the live parts shall be shrouded such that accidental contacts with live parts are
totally avoided. Distribution boards shall be provided with a front hinged door.
Distribution boards interior assembly shall be dead front with the front cover removed.
Main lugs shall be shrouded. Suitable insulating barrier made of arc resistant material
shall be provided for phase separation. Ends of the bus structures shall also be
shrouded.
Cabinet design :
The distribution board cabinet shall be totally enclosed type with dust and vermin proof
construction. The cabinet shall be stove enamelled. The interior surface shall finished to
a off-white shade. The interior components shall be mounted and locked on to the study
provided inside the cabinet. Over this, a cover made of hilum sheet or stove enamelled
sheet shall be provided with slots for operating handle of breakers. The cabinet shall be
equipped with a front door having a spring latch and vault lock. Cabinets shall have
detachable gland plates at both top and bottom.
Terminals:
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Distribution boards shall be provided with a terminal block of adequate size to receive
mains and outgoing circuits. The location of the terminal block shall be so located that
crowding of wires in the proximity of live parts is avoided. A neutral link having rating
equal to that phase bus shall be provided.
Distribution SLD:
Distribution boards shall be provided with a SLD indicating the area or loads served by
each circuit breaker, the rating of breakers, size of conductors, etc. The SLD shall be
mounted in metal holder with a clear plastic sheet on inside surface of the front door.
Installation:
Distribution boards shall be surface mounted / recessed mounted as required/specified

and at the locations shown on the drawings. The boards shall be fixed with suitable
angle iron clamps and bolts. All the cables / conduits shall be properly terminated using
gland / grips / check nuts etc., Wiring shall be terminated properly using crimping
lugs/sockets & PVC identification ferrules. The necessary DB mounting frame shall be
included for taking incoming and outgoing cables with neat finishes complete.
CEILING FANS
The ceiling fan shall be supplied with 300mm long down rod.
The Ceiling fans and Regulators shall be designed, manufactured and tested as per
IS-374-1966.
The fan shall have a totally enclosed capacitor start and run motor suitable for
operating on 240V single phase, 50 Hz AC supply system.
The fan shall be of the double ball bearing type, having 3 blades with a sweep of
1200mm complete with suspension rod, canopies and mounting roller.
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The regulator shall be of the electronic type and suitable for surface/flush
mounting on the switch box.
The regulator shall facilitate step less variation of speed and shall not cause
interference, humming noise and bearing failure.
The ceiling fan shall be supplied with standard 300mm long down rod
EXHAUST FANS
The exhaust fans shall be of 300mm dia, 960 RPM heavy continuous duty, single
phase type suitable for operation on 240V, 1 phase supply.
All the exhaust fans shall be complete with mounting ring, finger touch proof
wire guard for the blades on both sides.
The fans shall be supplied with 1 meter long wire chord and 3 pin top.
The noise level of the fans shall be less than 70 dBA.
Decorative models shall be supplied for the Office area toilet blocks.
5.1 Industrial Type Sockets
Industrial type sockets shall be provided wherever specifically called for on the
drawings. Industrial sockets shall be rated as specified. Plugs and sockets shall
have 3 pins for single phase applications and 5 pins for 3 phase applications. The
sockets shall be provided with suitable plug top and cable entry device and shall
be controlled by a suitably rated rotary switch. The sockets shall be housed in
suitable PVC housings of IP 54 protection class.
5.2 LOCAL ISOLATORS:
This shall be of load break type.
Suitable size enclosure duly painted shall be provided.
All live parts shall be shrouded.

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6.0 Labeling
The Contractor shall provide labeling for all light control switches, industrial-type
sockets, socket outlets, permanently connected devices, etc., identifying the
distribution board and circuit breaker number, in an approved manner, acceptable
to the Consultant / Main Contractor, to provide ready identification.
Hand painted labels are not acceptable.
18.2 MCBs, RCDs, RCBOs, ISOLATORS(MCB TYPE) AND SURGE SUPPRESSORS.
The Miniature circuit breaker (MCB) shall be moulded type. The MCB’s shall
have inverse time tripping characteristic against overloads and instantaneous
trip against short circuit, ON and OFF position shall be clearly marked on the
MCB. The MCB’s shall be suitable for operation of 50Deg. C ambient without any
duration. The rating and fault level of MCB’s shall be as per specific
requirements. The terminals of the MCB’s shall be suitable for use with Pin /
Fork lugs. Tripping characteristic of the MCB shall be as per specific
requirements.
Bus Bars
The busbar and connectors shall be made of high conductivity copper. The bus
bar shall be amply sized to carry the rated continuous current under the
specified ambient temperature without exceeding the total temperature of 90
Deg. C. the bus bar and their connections shall be capable of withstanding
without damages the thermal and mechanical effects of through fault currents.
The MCBs shall be of the single pole, double pole, triple pole or 4 pole type,
suitable or Din Rail mounting.
The MCBs shall have a minimum short circuit rating of 10KA and type C
characteristics unless otherwise specified.
The MCBs shall be provided with finger touch proof terminals and captive
screws.
The MCB shall be having protection against short circuit currents.
The MCB shall be having protection against Overload Current.
The MCB shall be suitable for Thermal Release under overload condition the
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bimetal strip defects and trips the operating mechanism.
The MCB shall be suitable for Magnetic release in case of Short circuit through
the magnetic coil activates the plunger to strike operating mechanism.
The MCB shall be provided with over voltage trip and an indication after the
BESCOM metering.
Specific Requirements of MCB DB’s

Service (Indoor / Outdoor) : Indoor
Voltage : 415V +/- 10%
Frequency : 50Hz +/- 5%
System Earthing : Solidly Grounded
Fault Level : 10kA
Phase Segregated / Non phase segregated : Phase Segregated
Single / Three Phase Distribution : Single / Three Phase as
indicated in the
Distribution diagram
Design Ambient Temperature : 50 Deg. C
Enclosure
Type : Metal clad
Material : CRCA
Thickness (Minimum) : 1.6mm
Single Door / Double Door : Double door with acrylic
cover
Hinges : Hidden type
Degree of protections : IP-45
Type of Mounting : Wall Mounted type
Wiring
Voltage Rating : 1100V
Conductor : Copper
Minimum area of cross section : 2.5sq mm
Name Plate
Material & thickness : Plastic, 3mm or eq.
Main incomer TP/TP+NL/4P : TP+NL
Individual Phase Incomer : Double Pole as indicated in the SLD
Individual Phase Outgoings : SP / DP MCB’s as indicated in
the SLD
RCD’s
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The Residual current device (RCD) shall be suitable to operate on three phase
415V / single phase 240V, 50Hz AC supply.
The sensitivity of the RCD shall be 30/100/300mA as specified in BOQ & the
tripping time not more than 30m secs.
The RCD shall be of DIN rail mounting type and shall be suitable for
mounting inside MCB DBs as main or phase incomer.
The RCD shall have a test button for periodical testing of the operation.
Isolators (MCB Type) shall be similar in appearance and features to the MCB s
except that they shall not have tripping mechanism.
SURGE PROTECTIVE DEVICES
The surge suppressors shall be of the double pole type identical in size to the
double pole MCB and shall protect the downstream equipment against
switching/ lightning surges with a wave front of 8/20 seconds. The surge
suppressor shall provide protection up to 8kA and shall withstand peak voltages
up to 1.5 kV. Replacement cartridges shall be available.
Surge suppressors of 35/40/60KA rating, having protection against phase to

phase, phase to neutral and phase to earth surges will be provided in the Main
Distribution Boards.
The Surge protection devices shall be designed manufactured and tested in

compliance with the Following Codes of Standards:
American National Standards institute and institute of Electrical and electronic

engineers (ANSI / IEEE C62. 11, C-62.41, C-62.45)
National Electrical Manufacturer Association (NEMA LS-1 1992)
National Fire protection Association (NFPA-20, 70 )
National Electrical Code 75 & 780,
International Electro technical Commission (IEC-801, IEC-1000)
The Maximum continuous operating voltage of the complete Surge protective

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Devices as well as all components in the suppression path shall be greater than
115% of the normal system operating voltage to ensure the ability of the system
to withstand temporary RMS over voltage (Swell condition)
The Operating Frequency range of the Surge protective Device shall be 47 to 63

Hz.
The Surge Protective device shall be having 70% capability for Under voltage
detection capability.
The Surge Protective Device shall be equipped with Phase loss monitoring.
The Unit is suitable for terminating up to 10sq mm cable.
The Surge Protective Device shall have following Environmental requirements.
Storage Temperature : -55 deg. To + 85 deg C. (-87deg to + 187 deg C)
Operating Temperature : -40deg. To +50 deg C(-40deg. To 122 deg. C)
Relative Humidity : 0% to 95%
Audible Noise : The unit shall not generate any appreciable noise.
Magnetic Fields : The unit shall not generate any appreciable magnetic
fields.
18.6 MCB DISTRIBUTION BOARD
The distribution boards shall comprise factory assembled and wired, totally
enclosed metal clad fabricated out of cold rolled steel with minimum thickness
1.6mm with gasket all points and openings including hinged doors with suitable
locking facility. The DB shall be of wall mounted type.
Protect insulated cover plate shall be provided inside the panel to shroud all the
live parts. Only the operating handle of the switch/MCB shall be projecting
outside the cover plate. The incoming switch terminals shall be suitably
shrouded with hylam plate. The incoming and outgoing terminals shall be
suitable for terminating cables.
All the low voltage internal wiring of the distribution boards shall be of 1100V
grade stranded copper conductor of core 2.5sq mm minimum suitable for fault
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withstand capacity of the boards.
All the device wiring and terminal block with in the board shall be clearly
identified by durable and legible tags corresponding to those in applicable
drawings. All wiring shall be easily identifiable by ferrules(interlocking type)
accessible for maintenance checks.
The DB shall have nameplate with its designation inscribed on it. Suitable
nameplate shall be provided for each piece of equipment for easy identification.
The Following colour coding shall be used for identification of busbars and
wiring as per standards.
R Phase Red
Y Phase yellow
B Phase Blue
N Neutral Black
E Earthing Green or Yellow
C Control Grey
Suitable removable gland plates shall be provided for top / bottom cable entry,
as specified.
An each bus of bare copper strip of adequate section shall be provided all along
the length of the DB with two bolted type earthing terminals. All metallic non-
current carrying parts including doors, switches etc. shall be securely connected
to the main earth bus by stranded PVC insulated copper wire of adequate size.
Paint shall be as per specific requirements.

Proper danger plate shall be provided on each board as per relevant standards.
The double door type MCB DBs shall be of the factory assembled three
phase/phase segregated / TPN / Vertical TPN / Horizontal Tier type suitable
for surface/ flush mounting as indicated in the Detailed BOQ.
MCB DBs shall be of the totally enclosed type fabricated out of 1.2mm thick
CRCA sheet. The DB enclosure shall undergo pretreatment followed by powder
Coated finish. The DB shall have glazed lockable door which shall be Reversible.
Gland plates with knockouts shall be provided on the top and bottom. The sides
shall have conduit knockouts.
All 3 Phase shall be housed in a common compartment for 3 phase DB’s and
separate compartment for phase segregated DB’s.
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The DB shall have provision for fixing an RCCB/ RCBO in the incoming side for
the vertical DB’s and phase incoming for phase segregated type.
Insulated fork type phase bus bars of requisite length shall be supplied.
A common neutral bus and an earth bus of 100A rating shall be provided in the
DB’s with 3ph. outgoings. In the phase segregated type DB’s independent
neutral bus shall be provided for each phase and a common earth bus. All bus
bars shall be of copper.
Two earthing studs shall be provided for external earthing.
All outgoing circuits shall have an earth connection from the above mentioned
bus.
Apart from the insulated earth bus, the body of the panel shall have provision
for earthing which will be connected to the general earthing grid.
The MCB DB’s shall be having Cable Ties for better cable Management.
MCB DB shall be having Stoppers on din rail at either end.
MCB DB’s shall be having removable front plate (Without removing door) to
facilitate easy servicing.
IV Luminaries
1.0General
 Luminaries shall be installed as indicated in the approved drawing and Luminaire

samples approval shall be obtained from Main Contractor for each type of Luminaire.
 The fixture shall be complete with the required lamp / fluorescent tube and the
starting inductor.
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 The fixture shall be high P.F correction type.
 All this shall have proper earthing facility to take care for eddy currents.
 The fluorescent tubes shall be TL-5 high efficiency with minimum color rendering
index of 84 & Lamp temperature 4000K.
 Where electromagnetic chokes are used shall be with low loss copper polyester
make.
 STROBOSCOPIC EFFECT : The fixture shall have no stroboscopic effect under

normal voltage conditions.
 The normal life of fluorescent lamps shall not be less than 7500 Hours.
 The IP classifications shall be as per IEC-529 and as follows.
 Office interiors / corridors - IP-20.
 The outdoor streetlights - IP-43.
 Underwater fitting - IP-67.
 The fixture shall be class 1 safety level as per IEC.
 The fixture shall be suitable for an atmospheric temperature of 35 degree

centigrade.
 The 600mm x 600mm fittings shall be of Category III optics.
 The fixtures to be fixed to the false ceiling shall have a clip-on mechanism for
fixing.
 The fittings shall be mounted with G.I chain fixed with anchor bolt to the ceiling.
 It shall never be fixed resting on to the grid of false ceiling or on the AC ducting.
 All the fixtures shall be with loop in or loop out wiring facility.
 The inter wiring of fixtures shall be with class –H insulation.

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Installation of Luminaries
General
All Luminaries shall be assembled and tested before installation.
Suitable anchor fasteners, GI chain / GI brackets of required length and accessories

shall be used in the installation.
Where painted surfaces are damaged, they shall be made good by painting to the
same standard as the original paintwork.
Fittings are to be installed subject to the approval of the Consultant / Main

Contractor.
All luminaries shall be effectively earthed.
The Luminaries shall be covered with polythene cover immediately after

installation to avoid dust accumulation and all louvers should be cleaned before
commissioning.
Fluorescent Luminaries
Luminaries shall be supported by two fixings at each end. One fixing at each end
of a narrow fitting will be accepted where a 1.6 mm thick back plate reinforces
each fixing screw.
End to end luminaries shall be correctly aligned using packing strips where
necessary.
Luminaries shall not be supported or suspended from plastic boxes or fittings.
Plastic boxes attached to luminaries or cable protection shall not be used as part
of the fixing method.
Where a PVC conduit enters a luminary, a screwed PVC adaptor with circular lock
nuts shall be used to secure the conduit to the luminary. Lock nuts are not
required for luminaries with screwed conduit entries.
Where indicated, luminaries shall be suspended level with electroplated welded

link chains at each end.
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Surface Mounted Luminaries
Luminaries shall be securely fixed to structural members of the ceilings or walls,

or fixed by hangers or brackets, which are securely fixed to structural members.
The minimum size of fixing for luminaries, hangers, or brackets for various
surfaces shall be as follows:
(a) Fixing to timber: steel wood screw No.10 x 25, round head, cadmium
plated.
(b) Fixing to concrete: approved screw expanding bolts M5 x 40.
(c) Fixing to hollow blocks: M5 electro-galvanized, round head screws with

spring loaded butterfly toggles. Where a deep cast iron junction box is provided in
the center, M5 metal screws shall be used with approved expanding fixings at each
end.
(d) Fixing to suspended ceilings shall be as indicated.
All fixings shall be fitted with large diameter (minimum 3 mm screw dia.)
cadmium plated washers under the heads of each screw.
2.4 Recessed Luminaries
Recessed luminaries shall be fitted with flexible cords and 3 pin plugs. The flexible
cord shall be PVC insulated, 3 core with 1.5 mm 2 conductors, and shall comply
with the relevant IS. It shall be of suitable length not greater than 1500 mm.
A plug socket shall be located within 500 mm from the edge of the access aperture
to allow the luminary to be plugged-in prior to fixing.
Recessed luminaries installed in timber-framed ceiling shall be fixed to the ceiling

members and noggins using the proprietary fixings supplied by the luminary
manufacturer, subject to the approval of the Consultant / Main Contractor.
Recessed luminaries using incandescent or discharge, lamps and installed in a

confined space (e.g. covered way, counter canopy, integrated ceiling or roof) shall
be wired to a near-by junction box using cable having insulation at least rated to
200 deg.C maximum operating temperature.
Recessed luminaries for suspended or modular ceilings shall be attached to

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suspended ceilings with proprietary mounting brackets supplied by the luminary

manufacturer.
2.5 Post Top Luminaries
Unless otherwise indicated, post-top luminaries shall be mounted on tapered

steel lighting columns.
Unless otherwise indicated, lighting columns shall consist of proprietary brand

steel poles, hot dipped galvanized and suitable for base plate mounting on
galvanized rag bolt assembly set in a concrete pad. The poles shall be adequately
drained and shall be fitted with an approved weatherproof lockable enclosure to
house the control gear and fuse(s), in the lower section of the pole, within 1000
mm of the ground.
5001.1. BALLASTS DETAILS:
The Electronic ballast shall be :
I. Suitable for linear fluorescent and CFL lamps.
II. Poly carbonate housing shall be used with earth spring facility.
III. RFI generated shall be as per EL-55015 norms.
The Electromagnetic ballast shall be as per :
I. Suitable for linear fluorescent and CFL lamp.
II. With coil core assembly low less silicon steel lamination super enameled
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copper wire with class – H insulation. Vacuum impregnation method shall be used.
III. Confirm to IS 1543 - part-1 -1972 and IS – 2418 – 1977.
IV. The metal halide ballast invert confirm to IS 9974 – 1981.
OTHER DETAILS:
The contractor shall supply all the luminaries as per the specifications/ type reference
specified in the Bill of Quantities as per the approved sample or make/model. The
luminaries should have following minimum requirements.
All Fluorescent luminaries should be provided with electronic ballast. The fluorescent
tubes shall be of high efficiency type. CFL luminaries shall have low loss copper ballast.
Flood light, Street lighting luminaries complete with CG box and mounting brackets shall
be supplied.
The contractor shall install the luminaries as per the drawing. All luminaries shall be
tested before installation.
Suitable anchor fasteners, GI chain of required length and all required accessories should
be used in the installation. The cost of these shall be included in the installation rate of
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luminaries. The luminaire shall be covered with polythene cover immediately after
installation to avoid dust accumulation and all louvers to be cleaned with proper cleaner
once after the interior works are over such that no damages occur and any such damages
occur during cleaning the fixture shall be replaced at own risk, cost.
Detail Specifications for Designer Street Light Pole
 STREET LIGHT POLE FOR SMALL ROADS : POST TOP LANTERN: 4 Mtr. height,
straight Colombia Musical pole suitable for mounting 150W CDMT post top
luminaire. The pole shall be made of 80 mm dia galvanized steel pipe of 3.8mm
thick with built-in control box prewired. suitable for 240V, single phase AC.
Galvanized steel tubular pole with 300 x 300 x 10 mm thick base plate welded at
the bottom of the pole, flexible PVC pipe of 1 mts. length fitted to the 18 guage GI
weather proof control gear box of size 450mm length and 150mm width
including enclosures with front opening cover with locking arrangements
including suitably sized Elmex connectors for looping in and looping out of 3C x
2.5 Sq.mm Armoured Aluminium cable and a 10A SP MCB for controlling the lamp
and including the wiring for lamp from the control gear box with 2Rx2.5 + 1Rx2.5
Sq.mm FRLS Cu wires and including the spiral earthing with 10SWG for each pole.
The pole shall be erected with RCC coping in cement concrete.
 HIGH MAST: High Mast is the combination of swaged tubular mast with a lantern
carriage and typical winching system for manual operation. The mast is split in
two lengths for easy of transport and handling. The lantern carriage
accommodate 6 flood lighting luminaires. The luminarie are wide spread /
directional flood light and can be rotated on its own axis and can also be tilted for
aiming at different angles. The luminaire is designed for single 250W Metal halide
lamps. Suitable for 240V, single phase, AC. Control panel and discrete control,
photosensitive switching, etc Pole integral part suitable for 6 x 250W MH tubular
lamp. Galvanized steel. tubular pole with 300 x 300 x 10 mm thick base plate
welded at the bottom of the pole, flexible PVC pipe of 1 mts .length fitted to the 18
guage GI weather proof control gear box of size 450mm length and 150mm width
including enclosures with front opening cover with locking arrangements
including suitably sized Elmex connectors for looping in and looping out of 3C x 6
Sq.mm Armoured Aluminium cable and a 10A SP MCB for controlling the lamp
and including the wiring for lamp from the control gear box with 2Rx2.5 + 1Rx2.5
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Sq.mm FRLS Cu wires and including the spiral earthing with 10SWG for each pole.
The pole shall be erected with RCC coping in cement concrete.
Street Light Fixture.
 Street light luminaire with aesthetically designed die cast aluminium housing,
POT optics reflector and toughened flat glass (IP65 protection) with Textured
Silver colour, with required control gear box and all accessories as as required,
complete enclosed suitable to mount specified tubular Pole
 Post top lantern luminaire with aesthetically designed die cast aluminium
housing, POT optics reflector and toughened flat glass (IP65 protection) with
specified light fixture including all accessories as as required, complete enclosed
suitable to mount.
 Integral type, flood light luminaire with pressure die cast aluminium housing with
IP 66 protection with required control gear box and all accessories as per dwg.
enclosed suitable to mount on high Mast for High mast
 Outdoor type flood light recessed in-ground drive, housing in die cast aluminium,
toughened glass protector, integral control gear, stainless steel rapid closing
mechanisms, protected to IP67 with load bearing capacity of 3000kg.
 Heavy duty copper wound ballast, PF capacitor and electronic ignitor shall be
pre-wired upto terminal block.
 Lamp holder confirming to IS specification.
 Earthling terminal and fuse contact shall be provided.
 Conform to IS 10322 Part 5 / Sec 1 : 1987.
Other Accessories:
Pole mounted boxes.
The box should be manufactured from FRP/metal boxes. The box shall be provided with
hinged door for locking arrangements. The box shall be with 16 AMP Kit-Kat fuses
including 4 way connector strip. The box shall be of a size 250 x 200 x 100 mm., 2.7 mm.
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thick approximately. Hinged cover shall be a proper locking arrangements and shall be
erected on the street light pole at a specified height from ground level by means of
clamps specifies in item. The FRP/metal box shall have provision for incoming, outgoing
cables and box shall be provided with the necessary fixing arrangements..
GI Pipe ‘A’ Class 40mm dia
This item includes supplying ISI mark, approved make, G.I. pipe and it should be
erected for enclosing cable on pole. ‘A’ Class GI Pipe – 40mm dia.
Galvanized Steel tubular Poles
The poles are to be made of specified thickness and shall be of galvanized steel and have
to be of specified height for specific light fixtures. The tubular poles design have to be
approved by the main contractor before fabrication/installation.
AVAITION LIGHT.
The obstruction lighting shall be suitable for safety of any tall structures, buildings and
airports. The obstacle light marking shall be suitable to notice the presence of all tall
structures that may be hazard to air navigation at night and meet the legal requirement.
The lighting system must be designed to meet International Civil Aviation Organization
(ICAO) standards for product specification and placement to provide for a high level of
safety and visibility.
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The Aviation light shall be new and improved maintenance free obstacle light for
aviation warning purpose. It shall be advanced high power LED with optimized optical
design and shall be able to create a reliable system based on only one single LED. It shall
be suitable to be used as a Low Intensity, Type A obstacle light according to ICAO
standards.
Shall meet the following Features and Benefits:
Innovative and Advance –
 IEC protection class II (double insulation) offering extra safety, IP66.

 Surge protection integrated: IEEE C62.41 – 1991, IEEE C62.45 – 1992.
Flexible and easy to install –
 Easy to install.
 Shall have long life time 50,000 hours (at 70% lumen depreciation)
 Plug and play, operated directly under line voltage (90 – 265VAC 50/60 HZ.
 Exceptional energy efficiency <5W.
Technical Specification: Light source High power LED’s with superior packaging and
low thermal resistance. Light color Aviation Red (ICAO).
EARTHING IS:3048 1987
All earthing systems for:
i) System earthing with TN -S System to IEC 60364

ii) Equipotential protection to IEC 1024 -1-1
iii) Supplementary bonding to BS7671
a) The source neutral is connected directly to earth and all exposed conductive parts
on installation are connected to this earth. All insulation faults will convert into
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phase-earth faults and causes a high fault current (only limited by earth loop
impedance). The automatic disconnection is achieved by over current protective
device or Residual current Devices (RCD).
b) For Main Feeder system: using main grounding wire then tapping to looping to
local panels. In this case earth loop impedance should be low to operate CB
( Magnetic tripping threshold <Isc), otherwise ( Ex. Local panels for from MDB)
RCD should be used.
c) Selecting the grounding wire size for TN-S system is based on thermal protection
and earth loop impedance ( For operating protective device).
Scope of work
The scope of work shall include all civil works, preparation of masonry chamber and
covering with cast iron hinged covers.
Supply and installation of all Earth Electrodes as enumerated in earthing

schematic.
Supply installation of earthing conductors for the electrical works covered under
this scope of work.
The minimum thickness of the strips shall be 3mm. The galvanizing coating shall not
be less than 700 gms / Sq.mtr. Joints in the GI strip shall be bolted and welded.
Joints in the run of the copper conductor shall be Brazed / bolted. All brazed /
welded joints shall be protected with black bituminous paint & Hessian tape.
Supply and installation of Rigid PVC pipes up to the nearest shaft or cut in
building or the cable trench in the vicinity to enable laying of earth strips by other
agencies at a later date.
The sizes of earth conductors shall be as indicated in the drawing.
1.0 Earthing Electrodes
Earthing electrodes shall be designed as per the requirements of IS: 3083-47.

Earth electrode shall be of the GI pipe type for safety earthing complete with
50mm class B GI pipe up to 3M long. The number and size of earth electrodes
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shall be calculated so that under fault conditions no electrode is loaded above its
maximum permissible current density.
Earthing electrodes of plate type shall be used. The choice of pipe or plate
electrode shall be decided according to the anticipated fault level of the network
and local soil conditions.
The earth conductor shall be laid in trench/cable tray/along walls and neatly
clamped. Outside the buildings an earth grid shall be formed and the same shall
be buried at a depth of not less than 600mm from the finished ground level.
All grounding electrodes shall be tested with earth meggers and grounding
resistances are recorded.
2.0 Plate Electrode
Plate electrodes shall be made of copper plate of 3.15 mm thick and 60 x 60 cm

size. The plate shall be buried vertically in ground at a depth of not less than 2
meters to the top of the plate, the plate being encased in salt and charcoal to a
thickness of 15 cm all around. It is preferable to bury the electrode to a depth
where subsoil water is present. Earth leads to the electrode shall be of copper and
shall be laid in a GI pipe and connected to the plate electrode with brass, bolts,
nuts and washers. A GI pipe of not less than 25 mm dia. shall be placed vertically
over the plate and terminated in a funnel at 5 cms above the ground. The funnel
shall be provided with a wire mesh. The funnel shall be enclosed in masonry
chamber of 45 cm x 45 cm x 30 cm dimensions. The chamber shall be provided
with GI frame and GI cover. The earth station shall also be provided with a
suitable permanent identification using painting.
3.0 Maintenance free grounding electrodes.
Characteristics
Shall have good Electrical conductivity.
 Shall high Corrosion Resistance.
 Shall be mechanically robust and reliable.
 Maintenance free Earthing System shall consist
a. Copper bonded Earth Rod at a depth of minimum 3 meters (3 rod per pit)
b. Ground Enhancing Material (GEM).
c. Earth Rod Clamps.
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3.1 Copper bonded Steel Earth Rods:
Copper bonded Steel Earth Rods shall have the UL certification, which calls for a
minimum molecular bonding of 250 microns. These Coppers bonded rods are
provided with a Nickel bonding interface to avoid galvanic corrosion.
3.2 Ground Enhancing Material:
Earth Enhancing Material shall be supplied in bags consists of Earth Enhancing

chemical for good conductivity.
3.3 Method of Installation:
One number or three numbers as per Bill of material, Copper bonded Earth Rod
shall be placed in an Earth Pit of 10-inch diameter. The earth pit has to be
connected by means of Copper Earth Rod Clamp. The whole setup is treated by
Ground Enhancing Material (GEM).
The resistance of earth electrodes shall not exceed one Ohm.
4.0 Precautions
Earthing system shall be mechanically robust and the joints shall be capable of
retaining low resistance, even after passage of fault currents.
Joints shall be welded, bolted or double-riveted. All welded joints are painted with
cold zinc galvanizing paint. All the joints shall be mechanically and electrically,
continuous and effective. Joints shall be protected against corrosion.
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4.0 Testing
On the completion of the entire installation, tests on the earth resistance of the
electrodes shall be conducted using an earth-testing Megger and recorded.
All meters, instruments and labor required for the tests shall be provided by the
Contractor. The test results shall be submitted in triplicate to the Main contractor
for approval. Tests shall be conducted in the presence of Engineer.
Ground resistance test shall be conducted to verify impedance of the electrical

ground systems.
For sizes of conductors of earthing refer to earthing schematic.
VI LIGHTNING PROTECTION SYSTEM

5001.2.
5001.3. 1.0 GENERAL
The lightning protection system should be in full compliance with Indian Standard
IS 2309 : 1989. To ensure an effective system and satisfactory long-term
performance, all fittings need to be mechanically sound and provide good corrosion
resistance in conditions of 50° C and 95% relative humidity. All materials used
should be suitable for lightning protection installations.
2.0 COMONENT PARTS

The principal components of a Lightning Protective system are:
a) Air Terminations
b) Down Conductors
c) Joints and bonds
d) Testing Joints
e) Earth Terminations
f) Earth Electrodes.
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The component parts of lightning protective systems should have dimensions

not less than those given in the table.
Minimum Dimensions Component Parts
Component Dimensions Area
mm Sq. mm
Air terminations:
Alumininium, copper
& galvanized steel strip 20 x 3 60.00
Aluminum, Aluminum alloy
or, Phosphor bronze &
Galvanized steel rods 10.0 dia 78.54
Suspended conductors:
Stranded aluminum 19/2.14 70.00
Stranded Copper 19/2.14 70.00
Stranded aluminum/
Steel reinforced
Stranded galvanized steel 6/4.72 100.00

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Down Conductors:
Aluminum, Copper or
Galvanized steel strip 20 x 3 60.00
Aluminum, aluminum
Alloy Galvanized steel rods 10.0 dia 78.54
Earth terminations
Hard-drawn copper rods for
Direct driving into soft
Ground 12.0 dia 113.00
Hard-drawn or annealed
Copper rods for indirect
Driving or laying
Under ground 10.0 dia 78.54
Phosphor bronze for hard
Ground 12.0 dia 113.00
Copper-clad or galvanized
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Steel rods 10.0 dia 78.54
Fixed connection(s) in aluminum,
Aluminum alloy, copper,
Galvanized steel
External
Strip 20 x 3 60.00
Rods 10.0 dia 78.54
Internal
Strip 20 x 1.5 30.00
Rods 6.5 dia 33.00
Stranded flexible connection(bonds)
External, Aluminum 560/0.5 70.0
External, annealed copper 990/0.3 70.00
Internal, aluminum 276/0.4 35.0

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Internal, annealed copper 107/0.2 35.0
4.02. 3.0 AIR TERMINATIONS
Air termination networks may consist of vertical or horizontal conductors or

combinations of both.
No part of the roof should be more than 9 m from the nearest horizontal protective
conductor.
All metallic projections, including reinforcement, on or above the main surface of

the roof which are connected, intentionally or fortuitously, to the general mass of
the earth,
Should be bonded to, and form part of, the air termination network.
Metallic coping, roof coverings, handrails and window washing equipment and
metallic screens around play areas should be considered for inclusion as part of the
air termination network.
If portions of a structure vary considerably in height, any necessary air

terminations or air termination networks for the lower portions should be bonded
to the design conductors of the taller portions in addition to their own down
conductors.
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4.03. 4.0 DOWN CONDUCTOR
The function of a down conductor is to provide a low impedance path from the air
termination to the earth electrode so that the lightning current can be safely
conducted to earth. The down conductor{s) should be high conductivity round or flat
solid bare Aluminum, copper or galvanized steel strip conductor with a minimum
size mentioned in the table. For steel framed building NO added down conductors
are required but earthing is essential in accordance with this code. They should be
fixed to the structure steel column to the earth rod by means of fasteners. The strips
should be buried beneath structure or laid in trenches at depths unlikely to be
affected by seasonal drying out.
5.0EARTH TERMINATION SYSTEM
The earthing to be done as per code of practice for earthing IS 3043 : 1987.
The resistance value of each earth termination system should be 10 Ohms or less.
When earth rods are used they should be driven into the ground beneath. Earth
Electrodes should be capable of being isolated and a reference earth point should
be provided for testing purposes. This connection should beequipped with
adisconnecting clamp housed in a concrete or inspection pit.
6.0 INSPECTION
All lightning protective systems should be visually inspected during installation, after
completion and after alteration or extension, in order to verify that they are in
accordance with the recommendations. In addition the mechanical condition of all
conductors, bonds, joints and earth electrodes (including reference electrodes )
should be checked and the observations noted.
7.0 TESTING
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On the completion of the installation, or any modification to it, the following

measurements should be made and the results recorded.
a) The resistance to earth of the whole installation and of each earth

termination.
b) The electrical continuity of all conductors, bonds and joints.
The method of testing shall be that recommended in IS 3043 : 1987
8.0 RECORDS
The following records should be kept on site or by the person responsible for the
installation:
a) Drawing Showing the nature, dimensions, materials and position of all

component parts of the lightning protective system.
b) The nature of the soil and any special earthing arrangements.
c) The type and position of the earth electrodes, including ‘ reference

electrodes’
d) The test conditions and results obtained.
e) Any alterations, additions, or repairs to the system.

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FIRE BARRIERS:
Fire barriers shall be provided at all electrical & communication shafts /cutouts.
The fire barriers have a 2 hours fire rating shall comprise the following.
Non-combustible support Frame of 20mm thick glass reinforced panel without

paper lamination.
The infill insulation shall comprise of homogenous slabs of 100mm thick, RT

grade ceramic wool impregnated and coated with intumescent compound.
The Fire seal shall be of non-chlorinated and fire retardant rubber.
The fire barriers shall be rodent and termite proof and it shall be possible to
rework on the same to introduce additional cables at a later date.
The installation shall be carried out by trained personnel and the entire
installation shall carry the manufacturer’s guarantee.
The fire barriers may be of "Hilti" brand or approved equivalent. Alternate fire
service approved barriers such as 3M may also be offered.
MISCELLANEOUS ITEMS:
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The contractor shall be required to supply several miscellaneous items such as

supporting brackets/ structures for cable trays, switch boards etc., sheet steel
enclosures, Anchor fasteners, Pipe sleeves, cable/earth pit markers etc. required
to complete the installation. All such items shall be subject to consultants/clients
approval.
Copies of A1 sized single line and substation layout drawings duly approved by
CEIG duly laminated shall be displayed in the electrical rooms.
Junction boxes with terminals of requisite capacity shall be installed to terminate

control cables.
SAFETY ACCESSORIES
Following safety accessories shall be supplied and installed.
Rubber mats duly certified for the voltage grade on the front & rear of all 11kV/
415V switchboards included in the scope.
Pair of rubber gloves duly certified for the voltage grade.
Shock treatment chart in English/ Hindi/ Kannada in electrical room.
A first aid box in the main electrical room.
A pair of sand buckets in each of the switch/ transformer/ HV switchgear rooms.

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Danger boards.
PERFORMANCE TESTS
The commissioning and testing procedure shall generally be as per IS-732-1989

and shall include the following:
f) Visual inspection: This shall be carried out by the site engineer on items to
ensure that the equipment meets the dimensional and quality requirements laid
down in the specification and to ensure that the equipment is not visibly
damaged during transportation to the site.
g) All tests as specified shall be conducted and test results shall be recorded. These
shall include but not be limited to the following:
h) Continuity tests on circuit conductors including main supplementary equi-
potential bonding conductors.
i) Earth electrodes resistance.
j) Insulation resistance and High voltage Tests.
k) Polarity checks.
l) Earth loop impedance.
m) Operation of RCD’s and over current devices.
n) Functional tests as per design requirements.
o) Checks on controls and interlocks.
p) The Testing shall be witnessed by the site engineer and the contractor’s
representative.
q) A check list of all Defects, balance work mal-functioning of devices etc., shall be
tabulated. Such work shall be attended before the final commissioning is carried
out.
r) All testing instruments required to carry out the work shall be arranged by the
contractors. These shall be calibrated at standards lab and certificates shall be
produced.
GENERAL
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At the completion of the work, the entire installation shall be subject to the
following tests in the presence of the Owner’s site representative.
o Wiring continuity test.

o Insulation resistance test.
o Earth continuity test.
o Earth resistivity test.
o Test as per Appendix È' of IS:732 -1989
Besides the above, any other test specified by the local authority shall also be
carried out. All tested and calibrated instruments for testing, labor, materials and
incidentals necessary to conduct the above tests shall be provided by the
Contractor at his own cost.
TESTING OF WIRING
All wiring systems shall be tested for continuity of circuits, and earthing after
wiring is completed and before installation is energized.
INSULATION RESISTANCE TEST
The insulation resistance shall be measured between earth and the whole
system of conductors, or any section thereof, with all switches closed and except
in concentric wiring all lamps in position of both poles of the installation
otherwise electrically connected together, a direct current pressure of not less
than twice the working pressure provided that it does not exceed 660 volts for
medium voltage circuits. Where the supply is derived from AC three phase
system, the neutral pole of which is connected to earth, either direct or
through added resistance, pressure shall be deemed to be that which is
maintained between the phase conductor and the neutral. The insulation
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resistance measured as above shall not be less than 50 divided by the number of
points provided on the circuit, the whole installation shall have an insulation
resistance greater than one megaohms. The insulation resistance between the
frame work of housing of power appliances and all live parts of each appliance
shall not be less than that specified in the relevant standard specification or
where there is no such specification, shall not be less than one a megaohms. All
equipments, cables shall be inspected at works by the Architect as per relevant
IS and testing commissioning of installation as per Appendix È' of IS:732-1989
shall be done and all record to be maintained.
TESTING OF EARTH CONTINUITY PATH
The earth continuity conductor metallic envelopes of cables shall be tested

for electric continuity and the electrical resistance of the same, along with the
earthing lead but excluding any added resistance or earth leakage circuit
breaker, measured from the connection with the earth electrode to any point in
the earth continuity conductor in the completed installation, shall not exceed one
ohm.
TESTING OF POLARITY OF NON-LINKED SINGLE POLE SWITCH
In a two wire installation a test shall be made to verify that all non-lined single
pole switches have been connected to the same conductor throughout, and such
conductor shall be labeled or marked for connection to an outer or phase
conductor or to the non-earthed conductor of the supply. In the three or four wire
installation, a test shall be made to verify that every non-linked single pole switch
is fitted to one of the outer or phase conductor of the supply. The entire electrical
installation shall be subject to the final acceptance of the Owner’s site
representative as well as the local authorities.
24.0 LIAISON WORKS

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The contractor shall be responsible for all liaison work relating to the above
work as required. The contractor’s scope shall include the following:
a) Preparation of approval drawings and documentation and obtaining approval of
the same from the Electrical Inspectorate for the M.S Building/Commercial
Building/Industrial Building etc.
b) Power sanction for the entire facility from the LOCAL STATUTORY AUTHORITY
with submission of required drawings and the documents.
APPROVAL OF SAMPLES:
The Contractor shall submit samples of all discrete components, like luminaires/
MCB DBs, conduits, switches, wires, cables, luminaires raceways & earthing
materials etc., for the approval.
The samples submitted shall conform to the relevant specifications and makes
specified. After the approval, sample of each item shall be displayed on a
wooden board at the site office till the end of the project.
SAFETY PRECAUTIONS:
The electrical contractor shall ensure that all Safety norms are strictly adhered to
throughout the installation period. The following points should be specifically
noted and complied with.
All Electrically operated hand tools shall be of the double insulated type.
All workmen should be provided with tools having insulated handles.

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All workmen operating at heights of more than 2.5M above floor level shall use
safety belts.
Properly designed ladders or scaffolding shall be used while working at heights.
All workmen shall be provided with Rubber / Safety shoes & Helmets.
The welding sets to be used shall have proper terminal box for cable termination
and earthing.
No joints shall be allowed in the cabling.
Necessary safeguards shall be taken to protect the wooden and other combustible
equipment in the site during welding.
23.0 INSPECTION
The responsibility of inspection of all the materials before delivery shall rest with
the contractor.
However the Client/Consultant shall have full authority to inspect the materials
and accept/reject the same on receipt at site. Any material rejected shall be
replaced free of cost by the Contractor.
COMMISSIONING CHECKLIST
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LT SWITCHBOARDS / MCCs / CONTROL PANELS
a. Check for physical damage to the enclosure, meters, relays and other
components.
b. Check all bus bar joints and tighten with torque wrench.
c. Check wiring.
d. Carryout functional tests on all switchgear components and relays..
e. Check all interlocks- Mechanical & Electrical
f. Megger & continuity checks on all circuits.
g. Checks relay grading & make the settings.
h. Check and ensure that all unused entries into the switchboards are closed.
INSTALLATION
a. All 11 KV cables to be high voltage tested (Not applicable).

b. All 1.1KV, 660V grade power cables to be meggered.
c. Check Crimping of all Main Cables.
d. Measure resistance of each earth station/Mat by isolating the same from
station grid.
e. Check all MCB DBs for dressing of wires, ferruling, tagging and earthing.
f. Test all RCDs.
g. Check all socket points for polarity, earthing and loose connections.
h. Check all Luminaires and Lamps.
i. Check illumination level and compare with specifications.
j. Check emergency lighting inverter for Automatic operation and duration of
Battery backup.
k. Check overall earth grid resistance & oil bonded points
l. Check equipotential bonding.
m. Check earth loop impedance.
n. Check sealing of all sleeves at entry points.
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o. Check fire barriers.

p. Check cable dressing and tagging.
All commissioning tests shall be carried out in the presence of Main Contractor
Engineer in charge and test reports duly signed by all the participants shall be
submitted as a part of the final documentation.
PREFERED MAKES
The equipment/installation materials to be supplied shall be selected from

among the following makes only. In case any make other than the ones
specified below are to be procured, the Main Contractor’s prior approval
shall be obtained. Tick the selected Make for quote.
S
l
.
Items Description Make of the Components
N
o
.
XLPE Insulated Aluminum conductor
1 Polycab / KEI/ Havell’s
HT / LT cables
2 HT Cable Termination Kit Raychem
Unarmored / Armored – LT Copper
3 Polycab / KEI/ Havell’s
Cables
Decorative Luminaires Philips / Bajaj / Thorn
Outdoor Light Fittings Philips / Bajaj / Thorn
4
Explosion / Flame Proof Light NITEL /SCG / Bajaj / CG /
Fittings Baliga.
5 High efficiency fluorescent lamp Osram / Philips / Bajaj
MCB / B,C & D Curve/ RCDs/Surge
6 Schneider/ABB/Legrand
suppressors /Isolators
7 MCB DBs Schneider/ABB/Legrand
8 MCCB’s Schneider/ABB/Legrand
Decorative type modular Switches & Anchor Roma / Siemens /
9
Sockets Legrand
1 Dowels / SMI / Joint well/
Heavy duty cable Lugs/ Cable glands
0 Comet
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Neptune/Scame
Industrial Switch & sockets
1 /Gewiss/Schneider
Moulded Industrial Switches &
1 Neptune/Scame/
Sockets
Gewiss/Schneider
1 MS Conduits GB / Bharat / Tata
2 FRLS PVC Conduits National / VIP / Universal
1
Wires FRLS / PVC Polycab /Anchor / Havell’s
3
1 CROMPTON / Bajaj /
Ceiling / Wall Fans
4 Havell’s
1
Cable/Earth pit markers Suraba / SMI
5
1
Terminals Wago / Phoenix
6
1
Rubber Mat Jyothi or Eq.
7
1 Siemens / Schneider / ABB
Push Button Station
8 / L&T
1 Siemens / Schneider /ABB
DOL/Star Delta Starter(if applicable)
9 /L&T
2
Earth pit marker SMI or Eq.
0
2
Fire Barriers 3M / VIPER / Hilti
1
Power Pack / MAA/
2
Cable Trays
2
2 Fabricated Wire ways / Raceways Power Pack Bangalore /

3 Readymade Wire ways / Raceways
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LKPace / Classic
2
UPS / Inverter APC / Numeric /Delta
4
2
Emergency Lighting Luminaries Prolite / MDS Legrand
5
2
CAT-6 Cable AMP Net Connect
6
2
Co-Axial Cable Comescope / LAPP
7
Anchor Roma / Siemens /
2
TV / Telephone Outlets
8
2
Telephone Cable Delton / Finolex / LAPP
9
3
Telephone TAG Block Krone
0
Elmex / Connectwell /
3
Terminal Block
1
3
Isolators MCB Type (Trip Free ) Legrand / MK / Hager
2
3
Isolators MCCB Type (Trip Free ) Legrand / MK / Hager
3
3 Anchor Roma / Siemens /
Metal and Surface Boxes
4
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3
ESE Type Lightining Arestor Nimbus / Indolec / Franklin
5
Nitel / SCG / Bajaj / CG /
3 Explosion / Flame Proof Socket

6 Outlets
3
Advanced Earthing System Ashlok / JEF Eco Safe
7
STANDARD TECHNICAL SPECIFICATION
HVAC WORKS
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STANDARD HVAC TECHNICAL SPECIFICATION
INDEX
Section-01 : Chillers
1 Air cooled water chilling machine
a) Air cooled outdoor water chilling machine P

a
g
e
2 Water cooled water chilling machine.
a) Centrifugal water chilling machine Page

11
b) Screw water chilling machine. Page

18
3 Technical data sheet
a) Air cooled water chilling machine. Page

24
b) Water cooled water chilling machine. Page

32
4 Test report
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a) Air cooled water chilling machine. Page3

7
b) Water cooled water chilling machine Page3

9
Section-02 : Pumps
1 Split Casing Pumps. Page

41
2 Mono-block End Suction Pumps. Page

41
3 Closed / Long Coupled Vertical Inline Pumps. Page

43
4 Variable Speed Pumping System Page

44
5 Technical data sheet& Test Report Page

52
Section-03 : Cooling Tower
1 Induced Draft Cooling Tower. Page

58
2 Forced Draft Cooling Tower. Page

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59
3 Technical data sheet& Test Report Page

62
Section-04 : Air Conditioning Equipment’s
1 Air Handling Units (AHU) Page

66
2 Air Washer Units. Page

77
3 Fan Coil Units –Chilled water type. Page

78
4 Air-cooled Packaged Units & Split Air Conditioning Units. Page

82
5 Precision Air Conditioning units
a) Air-cooled DX type Page

85
b) Chilled Water type Page

94
6 Variable Air Volume (VAV) units Page

99
7 Automatic Controls & Instruments. Page

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100
Section-05: Variable Refrigerant Volume (VRV) System. Page

104
Section-06 : Ventilation Fans
a) Centrifugal fans Page 115
b) Axial fan Page 116
c) Propeller fan Page 117
d) Roof mounted fan Page 117
e) Jet fan Page 118
Section-07: Air distribution works.
a) Ducting. Page 127
b) Dampers. Page 130
c) Fire & Smoke Dampers. Page 131
d) Fire Dampers. Page 132
e) Supply & Return Air Registers. Page 132

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f) Supply & return air Diffusers Page 133
Section-08: Thermal& Acoustic Insulation. Page 139
Section-09: Piping Works for Chilled water. Page 145
Section-10: Standards for Measurement. Page 162
Section-11: HVAC System Testing & Balancing. Page 165
Section-12: Commissioning Requirements. Page 180
Section-13: Codes & Standards. Page 186
Section-14 : List of Approved Makes Page 191

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SECTION-01
CHILLERS
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1. AIRCOOLED WATER CHILLING MACHINE
A. AIRCOOLED OUTDOOR WATER CHILLING MACHINE
Water chiller packages shall comprise of Compressor, Drive motor, Condenser coils,
fans, Evaporator, refrigerant pipes and fittings, electronic expansion valves, controls,
water pressure failure/flow switch, Microprocessor Control Panel, suction line and
evaporator insulation, first charge of refrigerant gas, oil, flexible rubber bellows, anti-
vibration mounts etc. All the equipment shall be mounted on Galvanized iron or MS
powder coated mounting frame fabricated out of channels, angles and other
sections. The frames shall be powder coated or hot dip galvanized.
The chiller packages shall be mounted on vibration isolation mounting. The chiller
packages shall be suitable for outdoor installation and as such no weather protection by
way of plant room is envisaged. The chiller packages shall be factory fabricated and
tested. The noise level of the chiller shall not exceed 65 dBA at 1m from the chiller or
lower as specified for all loads including part loads. Wherever required provide
attenuators for the compressors to meet the noise criteria.
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The chiller package shall have casing fabricated out of heavy Gauge hot dip
galvanized steel sheets and plasticized mesh protection for the condenser coils and
shall be fixed rigidly. The fasteners used shall be of stainless steel. The chiller
package shall be provided with suitable access doors for easy service of various
equipment’s.
1.1 COMPRESSOR
The compressors shall be of screw type in multiple numbers with independent
circuits as specified. The refrigerant shall be of HFC134a.
The screw compressor shall of semi-hermetic/hermetic type. The compressor

speed shall not exceed 2900 RPM. The compressor rotor shall have less tip
clearances so that the leakage between high and low pressure side is minimized
during compression. The compressor shall unload from full load to the minimum
capacity preferably without steps by means of a slide valve. The slide valve shall be
positioned over both the male and female rotors. The chiller shall have an electronic
expansion valve. The compressor shall be provided with phase loss, phase reversal,
phase imbalance and incorrect phase sequence apart from overload and under load
protection.
1.2 DRIVE MOTOR

The compressor drive motor shall be of TEFC squirrel cage type with class F insulation.
The speed of the compressor motor shall not exceed 3000 RPM. The motor shall
be of energy efficient type with a high and flat efficiency curve from 50 to 100%. The
starter shall be of soft type or closed transition star delta type with less starting
current. Test certificates shall be produced for the motors & shall meeting IEC/NEMA
specification.
1.3 CONDENSER
The air-cooled condenser coils shall have multi row configuration with copper
tubes and Aluminium fins. The design shall permit better performance with optimum
air flow, lower pressure drop and lower condensing temperatures. The condenser
coils shall have sub-cooling circuits. The number of fins shall be between 3-5 per cm.
The coils shall be factory tested for a minimum pressure of 30 KSC. Separate receiver
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shall be provided if the condenser does not have adequate capacity to hold the entire
refrigerant charge in the system.
The receiver shall also be tested with the same pressures as that of the condensers. The
condenser shall be provided with purge and relief valves. The air cooled
condensers shall work in conjunction with adequate number of propeller fans.
The fan speed shall not exceed 960 rpm and the noise level of the fan shall not exceed
78dBA at 1m. Provide fans having a speed not exceeding 750 rpm for
lower noise applications as specified. It is preferred that the required
numbers of fans only come into operation based on the ambient conditions using
automatic controls. The fan shall be statically and dynamically balanced. The fan motor
shall be suitable for outdoor installation and shall have minimum IP-55 protection.
The fan shall be suitable for mounting vertically and should withstand higher
temperatures. The fan shall be provided with bird screen.
1.4 EVAPORATOR
The evaporator shall be of shell and tube horizontal direct expansion type with carbon
steel shell and seamless copper tubes. The tubes shall have a minimum diameter of 16
mm. Adequate number of properly spaced baffles shall be provided for maintaining
optimum water velocity and heat transfer. Tubes shall be adequately supported. The
evaporator shall have a fouling factor of 0.0005 (in British units). The evaporator
shall be provided with electronic expansion valves, solenoid valves for each
refrigerant circuit, drain and vent valves, antifreeze thermostat fixed into water passage
having direct contact with water, water pressure failure switch, pressure gauges and
thermometers. The chiller shall be designed for a working pressure of 14 KSC for the
tube side and 7 KSC for the water side. The chiller shall be tested in the
factory for a minimum pressure of 21 KSC for both the tube and water
sides. Test certificates shall be produced for the chillers.
The chiller shall be site or factory insulated using 2 layers of 19 mm thick Nitrile rubber
insulation after pressure testing. For smaller capacity chillers plate type heat
exchangers may be considered. The plate heat exchanger shall consist of a pack of
corrugated stainless steel plates with portholes for the passage of the refrigerant and
water. The plate back shall be assembled between a frame plate and pressure
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plate and compressed by tightening bolts. The plates shall be fitted with a gasket,
which seals the channel and directs the fluids into alternate channels. The plate
corrugations shall promote fluid turbulence and support the plates against differential
pressure. Provide rubber isolation bellows for chilled water lines and water
pressure failure switch/flow switch. The chiller shall be provided with flanged
connection for the water lines. Victaulic connections shall be converted to flanged
connections at field. Alternatively flooded evaporators are acceptable.
1.5 CONTROLS
The refrigerant flow control shall use an electronic expansion valve. The chiller shall
have factory installed microprocessor control for various control functions. The control
center shall have a 40 character alphanumeric Liquid Crystal display. The screen shall
indicate chiller operating hours, entering and leaving chilled water temperatures,
condenser entering air temperature, evaporating and condensing temperature of the
refrigerant, oil pressure and temperature and motor current.
Digital programming of various set points such as leaving chilled water

temperature, percent current limit, pull down demand limiting, seven day time
clock for starting and stopping. All safeties shall be annunciated through
alphanumeric display. The safeties shall include high condenser pressure,
low oil pressure, high oil temperature, compressor thrust bearing oil
temperature, low evaporator pressure, high motor winding temperature, motor over
current, over voltage, under voltage etc.
The chiller shall be offered with factory built Plant Manager as specified. The
plant manager shall be able to compute the capacity in TR using the water flow
(measured by external gadgets), entering and leaving chilled water
temperatures and entering condenser air temperatures and power consumed using the
voltage, current, and power factor for various compressor loads. The results are to
be logged in the form of a table. The capacity obtained and power consumed
shall be compared with the performance charts for performance evaluation. The chiller
shall have provision to hook up with building automation system and shall be
compatible with Bacnet, Modbus, and Profibus protocols. Necessary hardware
shall be included as a part of the plant manager in this regard. Cabling interconnecting
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the chillers with plant manager and BAS panel is in the purview of the HVAC agency. The
chiller shall be provided with a single incoming MCCB, ACB interconnecting the entire
sub MCCB/ACB for various circuits. The electrical panel shall have IP 55 protection.
1.6 MICROPROCESSOR PANEL
The following system protection shall automatically act through micro computer control
to ensure system reliability depending upon the machine design:
- Low suction pressure
- High discharge pressure
- High oil temperature
- Freeze protection
- High ambient air temperature
- Low oil level
- Compressor run error
- Power loss
- Chilled water flow loss
- Sensor error
- Compressor over current
- Anti recycle
- Motor current signal loss
- Under/over voltage
- Low evaporator refrigerant temp
- High compressor discharge temp

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- Low oil pressure
- Loss of condenser air flow
- Starter fault
- High oil pressure
- Excessive starter transition time
- Motor current signal loss
- Motor power supply, Phase reversal, phase imbalance, incorrect phase sequence
- Temp. Sensor & transducer fault
- Motor wiring protection
- Single cycle dropout
If the abnormal operation condition continues and protective limit in reached, the
machine shall be shut down.
The 40/80 character Alpha numeric liquid crystal display utilizing menu
driven software shall obtain information/measurements on the display screen.
- A chiller report
- A refrigerant report
- Compressor report
- An operating configurable custom report
- Evaporator pressure
- Condenser pressure
- System voltage
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- Compressor Amps drawn each compressor/phase
- Compressor elapsed run time for each compressor
- Compressor contactor status
- Optical oil float switch status.
- Water temperature reset value.
- Water flow switch status
- External start/stop command status.
- An operator configurable custom report.
- Operator settings.
- Service tests and diagnostics message display in clear language by pressing

the appropriate button.
The unit control module, utilizing the adaptive control microprocessor shall
automatically take action to prevent unit shut down due to abnormal
operating conditions associated with low evaporator refrigerant temperature,
high condensing temperature, pressure and motor current, over load, high motor
amps. The operating program shall eliminate chiller failure due to failure of AC power
supply.
1.7 QUALITY ASSURANCE
(a) Chiller performance should be rated in accordance with ARI standard 550 (latest
addition)
(b) Equipment and installation shall be in compliance with ANSI/ASHRAE 15 (latest

addition)
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(c) Cooler shall include ASME - U Stamp & name plate certifying compliance with ASME
section VIII Design I code for unfired pressure vessels.
(d) Chiller shall be manufactured in a facility that has been registered by UL

to the ISO 9000 standards for quality.
(e) Chiller shall be designed and constructed to meet UL & CSA requirement
and shall have labels appropriately affixed.
(f) Each compressor assembly shall undergo a mechanical run in test to check proper
operation of components and to verify that vibration level, oil pressure/temperature
and efficiencies within acceptable limits at the manufacturing unit. Each
compressor shall be pneumatically pressure tested at 405 Psig or (2792 KPa) and
leak tested with a tracer gas at 225 Psig or (1551 Kpa).
(g) Both cooler and condenser shall be pressure tested on the refrigerant side and leak
tested with Refrigerant tracer gas. The water side of each heat exchanger shall be
hydrostatically tested at 1.5 times rated working pressure.
(h) The entire chiller assembly shall be leak tested with a refrigerant tracer gas at 450
Psig.
(i) Prior to shipment the chiller packages shall be tested for proper operation of controls.
(j) Unit shall be supplied charged with refrigerant gas or nitrogen holding
charge and oil and
refrigerant gas in separate cylinders for charging in the field.

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(k) Unit shall be supplied with all refrigerant piping and control wiring factory installed.
Wherever specified, Microprocessor controlled Plant Manager shall be provided

for controlling multiple chillers. The plant manager shall sequence chillers for uniform
wear and tear and shall select and run compressors efficiently resulting in power saving.
The plant manager shall have ASHRAE BACNET, Modbus or Profibus protocol for
hooking to BAS. The chiller shall be provided with cable entry and earth terminal bolts. If
so desired the Owners may depute their representatives to the manufacturer’s unit
to visualize the tests. Before inspection the manufacturers shall send a
format of the test report on which readings will be taken. In the absence of
factory inspection the manufacturer shall perform the test and send the test report to
the Owners and obtain clearance before dispatch of the chillers.
Part load performance charts indicating the capacity and power consumed
(with and without condenser fans) for constant ambient temperature and for various
ambient temperatures as per ARI relief shall be submitted along with the chiller
technical specifications. Computer selection of the chiller with various parameters
pertaining to compressor, condenser, and evaporator shall also be submitted.
Necessary terminal box for termination of cables to the chiller shall be a part of the
chiller panel.
2. WATERCOOLED WATER CHILLING MACHINE
A. CENTRIFUGAL WATER CHILLING MACHINE
2.1 SCOPE
The scope of this section consists of but is not necessarily limited to the following:
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a. Manufacture and supply of centrifugal liquid chillers with associated motors,

starter and accessories.
b. All associated items herein to be supplied delivered and installed.
c. In case of multiple compressors, distribution panel having one incoming and

multiple outgoings (equal to number of compressors) along with cabling from
panel to compressor motors.
d. Assembly of chiller components including connection of cooler, condenser,

motor, compressor, purge system for low pressure machine etc. into complete
refrigeration machine.
e. Provide manufacturer’s factory representative’s services, including coordination,

and start-up and testing supervision.
f. Testing (factory and field), start-up supervision, training and providing

necessary documentation and tools for operation.
g. Carry out performance test run at site.
2.2 QUALITY ASSURANCE PROGRAMME
a. Chiller shall be rated in accordance with Parameters indicated in Schedule of

Quantities. Pressure vessels shall be designed, constructed, tested, stamped
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and shall be complete with safety devices in accordance with ANSI/ASHRAE

15-1989 Safety Code and ASME Code.
b. Chiller shall be the product of a manufacturer / license normally supplying this

type of equipment and who can show evidence, having completed five
installations of approximately the same capacity that have been in successful
operation for at least five years.
c. The chiller shall be designed/manufactured and tested in accordance with the

applicable portions of the latest revisions of the following Standards and Codes.
ARI 550 / 590 – - Performance rating of water chilling packages

2003 using the vapor compression cycle.
ARI 575 - Air Conditioning and Refrigeration Institute.

Standard Method of Measuring Machinery
Sound Within Equipment Rooms ( Basis of all
data presented or field testing of equipment,
with relation to sound requirements).
ASME CODE - American Society of Mechanical Engineers.

(Div. 1 Code for Unfired Pressure Vessels -
Section VIII, Design, construction, testing and
certification of pressure vessels).
ANSI-B9.1 - American National Standards Institute. Safety

Code for Mechanical Refrigeration (overall
general safety requirements, relief device sizing,
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etc.)
ANSI-B31.5 - American National Standards Institute. Code for

Refrigerant Piping.
TEMA - Tubular Exchanger Manufacturer’s Association.
ISO R281 - Rolling Bearings – Dynamic Load Ratings and

Rating Life
2.3 CAPACITY
Actual refrigeration capacity of chilling machine shall be as shown on Drawings and in

Schedule of Quantities.
2. 4 CENTRIFUGAL COMPRESSOR
a. The compressor shall be single / multiple stage, open / hermetic type, using
Refrigerant- HFC 134 a. The impeller shaft shall be either direct driven or
connected to the speed increasing gear. It shall be self-aligned and balanced
and shall be assembled in the compressor casing. The driven end of the gear
shaft shall be connected with the motor through a flexible coupling. The
impeller shall be cast from alloy steel / aluminum alloy. This shall be
statically and dynamically balanced to ensure vibration free operation.
Casing design shall ensure that major wearing parts, bearings thrust bearings are
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accessible for maintenance and replacement. Condensed liquid refrigerant shall

be injected in to the compressor discharge to reduce discharge gas temperature
and to reduce sound level of the compressor.
b. Bearings
The compressor shall incorporate the necessary design features which eliminate
both the axial and radial thrust. Bearings shall be fabricated of aluminium
alloy/white metal and precision bored and axially grooved. The bearings
shall be pressure lubricated during operation and shall be completely
sequenced and interlocked with the start up of the machine in such a way that
the oil pump should start earlier than the machine and the machine should
automatically start after some time provided the oil temperature and pressure is
maintained during the start-up period. On stopping the machine, oil pump
should stop only after the machine has completely stopped.
c. Lubrication System
The lubrication system shall form one integral part of the compressor assembly
and shall enforce complete force feed lubrication (at a controlled pressure and
controlled temperature) to all bearing surfaces under any speed conditions, at
start-up, at shut down and during operation at various loads. Provision shall
also be made to take care of lubrication during coast down cycle upon
intermittent failure of power. Thus full lubrication must be available to the
machine during acceleration and deceleration periods. Further it should
include the following :
i. High efficiency oil filters.

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ii. Low oil pressure cutout.
iii. Oil coolers and oil heaters (with built-in-thermostat) to aid maintaining
constant temperature.
iv. Oil level indicator.
v. Oil pressure control with pressure gauges and thermometer.
The compressor shaft seal shall consist of a spring loaded precision carbon
ring high temperature elastomer “O” ring static seal and stress relieved precision
lapped collars. The seal must effectively prevent the leakage of refrigerant along
the shaft during shut down periods. During operation an oil film under
pressure should prevent outward leakage of refrigerant.
Oil cooler shall be in built part of chiller package. Oil cooler shall be shell & tube /
PHE type. Condensed liquid refrigerant shall be used for oil cooling purpose.
d. Capacity Control
The compressor shall be equipped with an automatic suction damper or

inlet guide vanes control for regulating its capacity. The positioning of the
damper shall be done by means of thermostatically actuated electronic
temperature-controller differential-type with its sensing element or elements in
the outgoing chilled water lines. The automatic damper will maintain the
constant temperature of chilled water. It should be possible to go down to
30% of full load as per ARI 550/590-2003, with linear reduction in power input
to the chilling machine.
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Compressor and motor sole plates, anchor bolts and sleeves and necessary
vibration isolation pads shall be included.
e. Microprocessor Control Centre
Each unit shall be furnished with microprocessor control centre in a locked

enclosure, factory mounted, wired and tested. The control center shall include a
40-character alphanumeric display showing all system parameters in English
language with numeric data in English (FPS) units.
Digital programming of essential set points through a color coded, tactile-feel

keypad shall include: entering and leaving chilled water temperature and
condensing water temperature; percent loading: pulldown demand limiting;
seven-day time clock for starting and stopping chiller (complete with local
holiday schedule): and remote reset temperature range.
All safety and cycling shutdowns shall be annunciated through the

alphanumeric display and consist of day, time, cause of shutdown, and type of
restart required. Safety shutdowns shall include: high oil pressure; high
compressor discharge temperature: low evaporator pressure: motor controller
fault: and sensor malfunction. Cycling shutdowns shall include: low water
temperature; low oil temperature: chiller/condenser water flow interruption;
power fault; internal time clock; and anti-recycle.
System operating information shall include: return/leaving chilled water

temperatures; return/leaving condenser water temperatures; evaporator
/condenser refrigerant pressure; differential oil pressure; percent motor
current; evaporator/condenser saturation temperatures; guide vane position,
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operating hours(Hours Run) and number of compressor starts, purge unit

operation, compressor motor current and fault history.
Security access shall be provided to prevent unauthorized change of

setpoints to allow local or remote control of the chiller, and to allow manual
operation of the prerotation vanes and oil pump.
The chiller shall be provided with an RS-232/485 port to output all system
operating data, shutdown/cycling messages and a record of the last four cycling
or safety shutdowns to a remote printer or Building Automation System (BAS).
The control centre shall be programmable to provide data logs to the
BAS/printer at a set time interval.
The chiller control panel shall be able to interface with the Building
Automation System (BAS) to provide remote chiller start/stop, reset of
chilled water temperature, reset of current limit; and status messages
indicating chillier is ready to start, chiller is operating, chiller is shut down
on a safety requiring reset, and chiller is shut down on a recycling safety.
Control panel should be with open protocol like Modbus RTU/ Bacnet/ Lon
work for integrating with BAS.
2.5 INTERFACE WITH BUILDING AUTOMATION SYSTEM
All necessary hardwares / softwares to integrate the chiller panel to BAS

system shall be provided free of cost by chiller manufacturer / supplier.
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For the integration of Microprocessor Panel of the chilling machine with the Building
Automation System, an Interface Control Document shall be developed by BAS
Subcontractor. It shall be responsibility of HVAC Subcontractor to provide following to
BAS Subcontractor for preparing the interface.
a. Hardware Protocol of Chiller Microprocessor panel.
b. Software Protocol of Chiller Microprocessor panel.
c. Communication structure relating to collection of message / event information.
d. Description of the formatted packets / blocks of data which construct controller

commands / responses.
e. Written permission to BAS Subcontractor to develop the interface without any

financial implication.
2.6 ELECTRIC MOTOR
a. The main electric motor and drive shall be furnished by chilling machine
manufacturer in order to ensure system compatibility and drive train
optimisation. Motor system shall be suitable for 415±10% volts, 3 phase, 50
cycles AC supply. Motor shall be squirrel cage induction type. The motor shall be
suitable for load characteristics and the operational duty of the driven
equipment, and comply with these specifications and latest NEMA / IEC codes.
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The efficiency and power factor shall be not less than the following values, at
rated voltage and frequency and at the specified loads.
Load Efficiency Power Factor
Full Load 96% 0.95
3/4 96% 0.92
1/2 96% 0.88
Starting current at rated voltage and frequency shall not exceed 2 times the full
load current at the rated voltage and frequency. The total efficiency shall include
losses of the auxiliaries such as independent excitation, motor-driven fans, lube-
oil pumps etc. Over voltage surge protection shall be provided to protect motor.
The motor shall be capable of successful operation when running at rated load
with variations in voltage and frequency as follows :
i. Within ± 10% of rated voltage with rated frequency.
ii. Within ± 5% of rated frequency with rated voltage.
iii. Combination variation in voltage and frequency of 10% (sum of absolute

values) of the rated values, the frequency variation not exceeding ± 5% of
rated frequency.
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Terminal box of sturdy construction shall provide enough space for terminating,
connecting and earthing of PVC/XLPE - insulated aluminium conductor cable. All
terminal boxes shall be located at the same side of the motor and have terminal
and cable glands suitable for cables specified.
b. Motor shall include following accessories and features :
i. Temperature detector in stator windings.
ii. Platinum resistance temperature detector for bearing temperature.
2.7 DRIVE :
The compressor shall be driven directly or through speed increasing gears as required.
The gears and pinions shall be pressure lubricated. The gears shall be provided with oil
filter and submerged oil pump. The gears should be of helical type with crown teeth
designed such that more than one tooth is in contact at all times to provide even
distribution of compressor load and quiet operation. Gears should be integrally
assembled in the compressor rotor support and be film lubricated. Each gear should be
individually mounted in its own journal and thrust bearings to isolate it from impeller
and motor shafts.
2.8 ECONOMISER SUBCOOLER
Each chiller shall be provided with shell and tube / PHE / flash chamber type
economizer. Condensed liquid in condenser shall be taped off and shall be expanded at
intermediate pressure with expansion valve. Value of intermediate pressure (Pi) shall be
as follows.
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Pi = (Pc Pe)0.5
Where Pc = saturated condensing pressure (abs)
Pe = Saturated Evaporation Pressure (abs)
The liquid expanded to intermediate pressure shall be used to absorb enthalpy from
remaining liquid refrigerant in order to provide subcooling. Vapor refrigerants due to
above heat transfer shall again be admitted to compressor at intermediate pressure port.
2.9 EVAPORATOR AND CONDENSER
a. Shells and Water Boxes
The evaporator and condenser shells shall be of rolled carbon steel plate with
fusion welded seams. Removable compact water boxes of cast iron or welded
steel with stub-out water connections shall be provided to permit access for
tube cleaning and replacement. Water boxes shall be designed for 150 psig
working pressure and hydraulically tested at 225 psig. The tubes shall be
finned from outside having spiral ridges from inside, roller expanded into the
tube sheets providing a leakproof seal. The tube material will be copper.
Intermediate steel tube supports should be provided at intervals not
exceeding 1200 mm.
b. Evaporator (Chiller)
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Chiller shall be provided with eliminator to prevent liquid carry over to the
compressor. The chiller shall be provided with liquid level sight glass and a
relief valve or repture disc of the bursting type to prevent excess pressure in
the heat exchanger. The chiller shall be horizontal, shell and tube type,
provided with the following connections and accessories, as separately identified
in the Schedule of Quantities :
i. Refrigerant inlet and outlet pressure gauges.
ii. Water inlet and outlet connections.
iii. Drain and vent connections with stop valves.
iv. Pressure gauges on water inlet and outlet connections.
v. Descaling valves.
Chiller shall be factory insulated with 25 mm thick nitrile rubber / or equivalent

thermal insulation as per manufacturers standard with vapour barrier,
thermal insulation material. The insulation shall be applied in such a manner
that water boxes and covers shall be removable without damaging it.
c. Condenser
The condenser shall be horizontal, shell and tube type. The condenser shall be
complete with the following accessories, as separately defined in the
Schedule of Quantities :

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vi. Centrifugal Machine with Refrigerant 123 shall include compressor less
purge unit using high pressure oil as a fluid piston to compress non-
condensable gases.
INSTALLATION
The chilling machine shall be installed over a cement concrete platform and shall be
adequately isolated as per manufacturers recommendations against transmission of
vibrations to the building structure. For open type, special attention shall be paid to the
alignment of the drive and driven shafts; final alignment shall be checked at site in
presence of the Owner’s site representative, using a dial indicator. Compressor and
motor sole plates, anchor bolts and sleeves and necessary vibration isolation pads
shall be included.
PAINTING
Centrifugal water chilling machine shall be finished with durable enamel paint. Shop
coats of paint that have become marred during shipment or erection, shall be cleaned
off with mineral spirits, wire brushed and spot primed over the affected areas, then
coated with enamel paint to match the finish over the adjoining shop-painted surface.
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PERFORMANCE RATING
The unit shall be selected for the lowest operating noise level. Capacity ratings, and
power consumption with operating points clearly indicated, shall be submitted and
verified at the time of testing and commissioning of the installation. Capacity
shall be ascertained by measurements of chilled water flow rate and temperature of
chilled water in and out of the chilling unit. Power consumption shall be computed
from measurements of incoming voltage & input current to the chilling machine.
WITNESS TEST
Prior to shipment, chilling machines shall be subjected to inspection and witness of

performance tests by Owner’s representative to verify various performance parameters
as confirmed by vendor earlier at the time of award of contract. Performance test shall
be carried out as per procedure laid down by ARI / EUROVENT and as per Employer
specified parameter, at 100%, 75%, 50% and 25% loading. Chilled water leaving
temperature shall be kept constant to design value for partial load testing.
Fouling factor simulation for condenser and evaporator shall be done as per ARI-
550/590-2003.Incremental temperature difference ( to be calculated based on
Normative appendix-C of ARI-550/590-2003) on account of designed fouling factors
shall be added in condenser water entering temperature and shall be subtracted for
leaving chilled water temperature. Chiller shall produce design refrigeration capacity
and guaranteed power consumption at these corrected set of entering condenser water
and leaving chilled water temperature. Outside tube surface area (for condenser and
flooded evaporators) and inside tube surface area (for DX-Evaporator), being inputs for
ARI mathematical model for fouling, shall be submitted along with the offer.
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All expenses inclusive of business class airfare, boarding lodging etc. relating to the
witness test will be borne by the vendor / Subcontractor.
2. WATERCOOLED WATER CHILLING MACHINE
B. SCREW WATER CHILLING MACHINE

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2.1 SCOPE
The scope of this consists of but is not necessarily limited to the following:
a. Manufacture and supply of screw liquid chillers with associated motors, soft
starter and accessories.
b. All associated items herein to be supplied delivered and installed.
c. In case of multiple compressors, distribution panel having one incoming and

multiple outgoings (equal to number of compressors) along with cabling from
panel to compressor motors.
d. Assembly of chiller components including connection of coolers, condensers,

motors, compressors, purge system for low pressure machine etc. into complete
refrigeration machines.
e. Provide manufacturer’s factory representative’s services, including coordination,

and start-up and testing supervision.
f. Testing (factory and field), start-up supervision, training and providing

necessary documentation and tools for operation.
g. Carry out performance test run at site.

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2.2 QUALITY ASSURANCE PROGRAM
a. Chillers shall be rated in accordance with Parameters indicated in Schedule of

Quantities. Pressure vessels shall be designed, constructed, tested, stamped
and complete with devices in accordance with ANSI/ASHRAE 15-1989 Safety
Code and ASME Code.
b. Chillers shall be the product of a manufacturer normally supplying this type of

equipment.
c. The chiller shall be designed/manufactured and tested in accordance with the

applicable portions of the latest revisions of the following Standards and Codes.
ARI 550 / - Performance rating of water chilling

590 - 2003 packages using the vapor compression cycle.
ARI 575 - Air Conditioning and Refrigeration Institute.

Standard Method of Measuring Machinery
Sound Within Equipment Rooms (Base of all
data presented or field testing of equipment
with relation to sound requirements).
ASME CODE - American Society of Mechanical

Engineers Code for Unfired Pressure
Vessels - Section VIII (Design, construction,
testing and certification of pressure vessels).
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ANSI-B9.1 - American National Standards Institute.

Safety Code for Mechanical Refrigeration
(overall general safety requirements, relief
device sizing, etc.)
ANSI-B31.5 - American National Standards Institute.

Code for Refrigerant Piping.
ISO R281 - Rolling Bearings – Dynamic Load Ratings

and Rating for Life.
2.3 CAPACITY
Actual refrigeration capacity of chilling machine shall be as shown on Drawings and

indicated in Schedule of Quantities.
2.4 COMPRESSOR
Compressor shall have a open / semi-hermetic direct / gear drive with integrate
lubrication system utilizing compressor pressure differential / oil pump. Refrigerant
shall be HFC-134a. Compressor casing shall be constructed from a high strength iron
casting, having reinforced double wall construction to provide a rigid structure and
minimize the transmission of noise. Multiple pressure lubricated rolling element
bearing shall be used to absorb axial thrust as well as radial load. Minimum 80 mesh
reinforced SS strainer shall be provided at the suction of compressor for protection.
Rotors shall be precision made from ductile iron.
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Oil separator shall be provided at discharge side of compressor. Oil separator can be an
integral part of compressor of alternatively, it could be separate pressure vessel. Oil
separator shall contain impingement plate, removable SS oil strainer and electrical oil
heater. Drained oil from oil separator shall be piped back to the compressor.
Step-less capacity control to exactly match system load shall be provided. A

microprocessor based controller shall modulate slide valve in response to chilled water
outlet temp. controller shall be programmed for PID&T logic. Compressor shall be able
to unloaded upto 10% of load with stable running.
2.5 MICRO PROCESSOR CONTROL CENTRE
Each unit shall be furnished with microprocessor control centre in a locked enclosure,
factory mounted, wired and tested. The control centre shall include a 40-character
alphanumeric display showing all system parameters in English language with numeric
data in English (FPS) units.
Digital programming of essential setpoints through a colour coded, tactile-feel keypad

shall include: entering and leaving chilled water temperature and condensing water
temperature; percent loading: pull down demand limiting; seven-day time clock for
starting and stopping chiller (complete with local holiday schedule); and remote reset
temperature range.
All safety and cycling shutdowns shall be annunciated through the alphanumeric
display and consist of day, time, cause of shutdown, and type of restart required.
Safety shutdowns shall include: high oil pressure; high compressor discharge
temperature: low evaporator pressure: motor controller fault: and sensor malfunction.
Cycling shutdowns shall include: low water temperature; low oil temperature:
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chiller/condenser water flow interruption; power fault; internal time clock; and entire
cycle.
System operating information shall include: return/leaving chilled water temperatures;

return/leaving condenser water temperatures; evaporator /condenser refrigerant
pressure; differential oil pressure; percent motor current; evaporator/condenser
saturation temperatures; guide vane position, operating hours(Hours Run) and number
of compressor starts, purge unit operation, compressor motor current and fault history.
Security access shall be provided to prevent unauthorized change of setpoints to

allow local or remote control of the chiller, and to allow manual operation of the
prerotation vanes and oil pump.
The chiller shall be provided with an RS-232 port to output all system operating
data, shutdown/cycling messages and a record of the last four cycling or safety
shutdowns to a remote printer or Building Automation System (BAS). The control
center shall be programmable to provide data logs to the BAS/printer at a set time
interval.
Control center shall be able to interface with the Building Automation

System (BAS) to provide remote chiller start/stop reset of chilled water
temperature reset of current limit; and status messages indicating chiller
is ready to start, chiller is operating, chiller is shut down on a safety
requiring reset, and chiller is shut down on a recycling safety.
2.6 INTERFACE WITH BUILDING AUTOMATION SYSTEM
All necessary hardwares / softwares to integrate the chiller panel to BAS

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system shall be provided free of cost by chiller manufacturer / supplier.
For the integration of Microprocessor Panel of the chilling machine with the Building
Automation System, an Interface Control Document shall be developed by BAS
Subcontractor. It shall be responsibility of HVAC Contractor to provide following to BAS
Subcontractor for preparing the interface.
a. Hardware Protocol of Chiller Microprocessor panel.
b. Software Protocol of Chiller Microprocessor panel.
c. Communication structure relating to collection of message / event information.
d. Description of the formatted packets / blocks of data which construct controller

commands / responses.
e. Written permission to BAS Subcontractor to develop the interface without any

financial implication.
2.7 ELECTRIC MOTOR
Motor shall be energy efficient and suitable for 415±10% volts, 3 phase, 50 cycles AC
supply. Hermetic/semi hermetic motors shall be suction gas cooled ,two pole, squirrel
cage induction types. In case of open compressor type motors shall be screen protected
drip proof squirrel cage induction type. Motor shall be designed and guaranteed
for continuous operation. Insulation of motors shall be F class. Temperature rise of
motor under rated service conditions shall not exceed 80 Deg C (by resistance method
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of measurement) over an ambient of 40 Deg C. the motor shall be provided with a

combination of ball and roller bearing & shall meeting IEC/ NEMA specification.
Starting current at rated voltage and frequency shall not exceed 2 times of full load
current at rated voltage and frequency.
Terminal box of sturdy construction shall provide enough space for terminating,
connecting and earthing of PVC - insulated aluminium conductor cable. All terminal
boxes shall be located at the same side of the motor and have terminal and cable glands
suitable for the specified cables.
The efficiency and power factor shall be not less than the following values, at rated
voltage and frequency and at the specified loads.
Load Efficiency Power Factor
Full Load 96% 0.86
3/4 96% 0.8
1/2 96% 0.8
Starting current at rated voltage and frequency shall not exceed 2 times the full load
current at the rated voltage and frequency. The total efficiency shall include losses of the
auxiliaries such as independent excitation, motor-driven fans, lube-oil pumps etc. Over
voltage surge protection shall be provided to protect motor.
2.8 STARTER
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Shall be close transition star delta starter or soft starter to ensure starting current at
rated voltage & frequency does not exceed 2 times full load current.
All components of starter shall be housed in dust proof enclosure and suitable for 415 ±
10% volts 50 cycles 3 phase AC power supply.
2.9 EVAPORATOR AND CONDENSER
a. Shells and Water Boxes :
The evaporator and condenser shells will be of rolled carbon steel plate with
fusion welded seams. Removable compact water boxes of cast iron or welded
steel with stub-out water connections shall be provided to permit access for
tube cleaning and replacement. Water boxes shall be designed for 150 psig
working pressure and hydraulically tested at 225 psig. The tubes shall be
finned from outside having spiral ridges from inside, roller expanded into the
tube sheets providing a leakproof seal. The tube material will be copper,
intermediate steel tube supports should be provided at intervals not
exceeding 1200 mm.
b. Evaporator (Chiller) :
Chiller shall be provided with eliminator to prevent liquid carry over to the
compressor. The chiller shall be provided with liquid level sight glass and a
relief device (of the bursting type) to prevent excess pressure in the heat
exchanger. The chiller shall be horizontal, shell and tube type, provided with
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the following connections and accessories, as separately identified in the

schedule of quantities :
Chiller shall be insulated with 25 mm thick nitrile rubber. The insulation shall be
set with compound recommended by the insulation manufacturer and shall be
applied sealing the joints. The insulation shall be applied in such a manner that
water boxes and covers shall be removable without damaging it.
c. Water cooled Condenser :
The condenser shall be of same construction as for chiller above (without

insulation). It shall be complete with the accessories as separately defined in
the schedule of quantities . Shell side volume of the condenser shall be high
enough to contain complete refrigerant charge in case of pump-down. In case of
chiller with de-superheater, main condenser shall be sized for 100% heat
rejection duty.
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3. 0 ECONOMISER SUBCOOLER
Each chiller shall be provided with shell and tube / PHE / flash chamber type
economizer. Condensed liquid in condenser shall be taped off and shall be expanded at
intermediate pressure with expansion valve. Value of intermediate pressure (Pi) shall be
as follows.
Pi = (Pc Pe)0.5
Where Pc = saturated condensing pressure (abs)
Pe = Saturated Evaporation Pressure (abs)
The liquid expanded to intermediate pressure shall be used to absorb enthalpy from
remaining liquid refrigerant in order to provide subcooling. Vapor refrigerants due to
above heat transfer shall again be admitted to compressor at intermediate pressure port.
INSTALLATION
The chilling machine shall be installed over a cement concrete platform and shall be
adequately isolated as per manufacturers recommendations against transmission of
vibrations to the building structure.
PAINTING
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Screw water chilling machine shall be finished with durable enamel paint. Shop coats
of paint that have become marred during shipment or erection, shall be cleaned off
with mineral spirits, wire brushed and spot primed over the affected areas, then
coated with enamel paint to match the finish over the adjoining shop-painted surfaces.
PERFORMANCE RATING :
The unit shall be selected for the lowest operating noise level Capacity ratings, and
power consumption with operating points clearly indicated, shall be submitted and
verified at the time of testing and commissioning of the installation. Capacity
shall be ascertained by measurements of chilled water flow rate and temperature of
chilled water in and out of the chilling unit.
Power consumption shall be computed from measurements of incoming voltage &

input current to the chilling machine.
Sound Pressure level for Air cooled chillers shall not exceed 75dBA at 1m distance from
chiller.
WITNESS TEST
Prior to shipment, chilling machines shall be subjected to inspection and witness of

performance tests by Owner’s representative to verify various performance parameters
as confirmed by vendor earlier at the time of award of contract. Performance test shall
be carried out as per procedure laid down by ARI / EUROVENT and as per Employer
specified parameter, at 100%, 75%, 50% & 25% loading. Temp. of leaving chilled water
shall be kept constant during part load testing.
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Fouling factor simulation for condenser and evaporator shall be done as per ARI-
550/590-2003.Incremental temperature difference ( to be calculated based on
Normative appendix-C of ARI-550/590-2003) on account of designed fouling factors
shall be added in condenser water entering temperature and shall be subtracted for
leaving chilled water temperature. Chiller shall produce design refrigeration capacity
and guaranteed power consumption at these corrected set of entering condenser water
and leaving chilled water temperature. Outside tube surface area (for condenser and
flooded evaporators) and inside tube surface area (for DX-Evaporator), being inputs for
ARI mathematical model for fouling, shall be submitted along with the offer.
All expenses inclusive of business class airfare, boarding lodging etc. relating to the
witness test will be borne by the vendor / contract.
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TECHNICAL DATA FOR AIR COOLED TECHNICAL DATA FOR AIR COOLED WATER
CHILLING MACHINES
(IMPORTANT: ALL DATA TO BE FURNISHED ONLY IN THE UNITS INDICATED WATER

CHILLING MACHINES)
SCHEDULE OF TECHNICAL DATA FOR WATER CHILLING MACHINES

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1.COMPRESSOR
a. Manufacturer (Make)
b. Country of Origin
c. Model and type (Open / Semi-hermetic)
d. No. of compressors per chiller and compressor RPM
e. Refrigerant
f. Saturated evaporating temperature (0C)
g. Saturated condensing temperature (0C)
h. Discharge gas temperature (0C)
i Cooling capacity at above condition (TR)
j. Compressor shell test pressure (Kg/cm2)

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k. Method of oil cooling
l. Quantity of refrigerant in the chiller (Kg)
Load IkW/TR at tender IkW/TR at ARI IkW/TR at tender

design conditions 550/590 design conditions &
& with ARI relief conditions constant condenser
water entering temp
100%
75%
50%
25%
Part load value NPLV = IPLV = PLV =
m. Recommended range of capacity control without

surging (%)
n. HP/LP/OP cutout set points (Kg/cm2)
o. Capacity variation step-less (Yes / No)
p. Type of bearings
Note: In case of machines containing multiple compressors, power consumption of each

compressor shall be indicated.
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2.COMPRESSOR MOTOR
a. Motor manufacturer
b. Type
c. K W Rating / Power factor
d. Electrical Characteristics (±10% voltage variation)
e. Motor RPM.
f. Insulation class.
g. Enclosure/protection class.
h. Efficiency.
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i. Starter manufacturer & mode of start.
j. Starting current (Amps)
k. Full load current FLA (Amps)
l. Locked rotor current (Amps)
m. Type of vibration isolation forcompressor and motor
3. CONDENSER
a. Manufacturer (Make) Model
b. Shell Material
c. Tube material / No. of tubes / Tube OD (mm)
d. Number of passes
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e. Fouling factor (FPS)
f. Water Flow (USGPM)
g. Water velocity in tubes (m/s)
h. Water side pressure drop (Kg/cm2)
i. Water temperature In/Out (0F/0C)
j. Design degree of subcooling (0F/0C)
k. Shell side design pressure (Kg/cm2)
l. Tube side design pressure (Kg/cm2)
m. Shell side test pressure (Kg/cm2)
n. Pressure relief valve set pressure (Kg/cm2)
o. ACTUAL capacity of condenser at above conditions(TR)

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4. CHILLER
a. Manufacturer (Make) Model
b. Shell Material
c. Type (DX / Flooded)
d. Tube material / No of tubes / Tube OD
e. Fouling factor (FPS)
f. Number of circuits
g. Water Flow (USGPM)
h. Water velocity in tubes in case of flooded coolers (m/s)
Pressure
i. drop of chilled water (Kg/cm2)
Shell
j. side design pressure (Kg/cm2)
Tube
k. side design pressure (Kg/cm2)
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Shell
l. side test pressure (Kg/cm2)
Tube
m. side test pressure (Kg/cm2)
Pressure
n. relief valve set pressure (Kg/cm2)
o. Shell insulation at MFR works material & thickness (mm)
p. Water temperature, IN/OUT (0F/0C)
q. ACTUAL capacity of cooler at above conditions (TR)
5.MICROPROCESSOR CONTROL CENTRE
a. Indicate point wise display system, set points etc.
b. Interface with BAS (Confirm provided)
6. GENERAL
a. Original computer selection printout from manufacturer to be

attached with the offer (confirm)
b. ARI / Eurovent certification (Confirm)

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c. Overall Dimension(M)
Length
Breadth
Height
d. Operating weight (kg) / shipping weight
e. Service clearance required (M) L x B x H
f. Sound power level (dB) in each octave band
Mid freq 63Hz 125Hz 250Hz 500Hz 1000Hz 2000Hz 400 8000Hz
0Hz
SWL(dB)*
* SPL ref to 10-12W
Sound pressure level at 3m horizontal distance (dBA)

g.
Type of vibration isolators

h.
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INSTRUMENT CALIBRATION REPORT
PROJECT _____________________________________________________________________
INSTRUMENT / SERIAL NO. APPLICATION DATES OF CALIBRATION TEST

USE DATE.
REMARKS.
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TEST DATE __________________________READINGS BY _______________________
TESTS FOR AIR COOLED WATER CHILLING MACHINES
The following readings shall be taken (and results computed) during the performance tests on
the plant.
I AIR COOLED WATER CHILLING MACHINE :
A. COMPRESSOR :
1. Suction Pressure - Kg/sqcm
2. Suction temperature - deg C
3. Discharge pressure - Kg/sqcm
4. Condensing temperature - deg C
5. Oil Pressure - Kg/sqcm
6. Control oil pressure - Kg/sqcm `
7. Compressor speed – rpm
8. Compressor motor current – amps
9. Compressor motor speed – rpm
10.Voltage – Volts
11. Compressor power input – IKW
12. Power consumption – IKW/TR
13. Starting Current - Amps
14.Running Current - Amps

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15. Vibration level - microns
16. Noise level - db
B. AIR COOLED CONDENSER :
1. Entering air temperature - deg C
2. Leaving air temperature - deg C
3. Condensing temperature - deg C
4. Temperature of liquid refrigerant

leaving the condenser - deg C
5. Temperature of liquid refrigerant at

Inlet to the expansion valve - deg C
6. Fan speed - rpm
7. Fan static pressure - mm wg
8. Fan delivery - m3/hr.
9. Fan motor current - Amps
10. Noise level - db
11. Vibration level - microns
C. CHILLER :
1. Water Flow Rate - LPs
2. Entering water temperature - deg C
3. Leaving water temperature - deg C
4. Evaporating temperature - deg C

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5. Pressure drop - Kg/Sqcm
CHILLER TEST REPORT FOR WATER CHILLING MACHINES
(TO BE FURNISHED BY INSTALLER)
PROJECT _______________________________ UNIT____________________________
LOCATION________________________________________________________________
MANUF.______________________ MODEL ____________ SERIAL NO. ____________
CAPACITY ___________ REFRIG__________ STARTER_________ HEATER SIZE _______
COMPRESSOR DESIGN ACTUAL MOTOR STARTER DESIGN ACTUAL
Make / Model Make / Model

Serial No. Type
Type (Reciprocating, Voltas
Centrifugal Sealed, Semi
Sealed, Screw Rotary)
Piping Material Amps
Suction Pr / Tem. O/L Release Range
Discharge Pr/Temp
Refrigerant EVAPORATOR DESIGN ACTUAL
Oil Pump Type Make / Model
Oil Pressure No. of Passes
Oil Failure Switch Ref : Level
Pressure
Unload Arrangement Ref : Pressure /
Temperature
Unload Set Points Ent. Water
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Temp/Pressure
Drive LeavingWaterTemp
/Pressre
Compressor Speed Temperature
Difference
Oil Level Pressure Difference
Oil Temperature Water Quantity CPM
L P Setting Relief Valve Setting
H P Setting I KW / Ton
Anti Freeze Setting
Purge Unit Type
Purge Operation Checked CONDENSER DESIGN ACTUAL
Make/Model
No. of Passes
Ref : Pressure /
Temp
COMPRESSOR MOTOR DESIGN ACTUAL Ent. Water Temp /
Pressure
Make / Model Leaving Water
Temp/Pressure
Type Temperature
Difference
Voltage I1 Ie I2 I3 I3 I1 Pressure Difference
Motor Rated Current Water Quantity CPM
Motor F L Current Relief Valve Setting
REMARKS
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TEST DATE _____________________________ READINGS BY ______________________
SECTION-02
PUMPS
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PUMPS
SCOPE
The scope of this section comprises the supply, erection, testing and commissioning of
water pumps conforming to these Specifications and in accordance with
requirements of Schedule of Quantities.
TYPE
The type and size of all chilled water, condensing water, cold water and condensate
drain pumps for air conditioning applications shall be in accordance with
requirement of Drawings and Schedule of Quantities.
CAPACITY
Water flow rates and head of the pumps shall be in accordance with the requirements of
1.0 SPLIT CASING PUMPS
a. Pump casing shall be close-grained cast iron of heavy section,

horizontally/vertically split, making possible complete servicing of rotating
parts without breaking piping or motor connections. Motor to pump connection
shall be of the flexible coupling type. Suction passages shall be volute in form,
promoting smooth entry to impeller and increased efficiency. Impeller shall be
bronze or gun metal, double suction, enclosed type, hydraulically balanced
and passages smooth-finished for minimum friction and maximum efficiency.
Impeller rings shall be secured from relative movement by tongue and groove
fittings. Shaft shall be steel, protected by gunmetal sleeves extending through
stuffing boxes. Stuffing boxes shall be extra deep, water sealed with renewable
bushes. Shaft shall be supported in ball /journal bearings, grease lubricated,
contained in easily removable housing. Pumps shall be fitted with mechanical
seals, an air valve, two grease lubricators, drain plug and water seal drain
connections.
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b. Motor shall be energy efficient, totally enclosed, fan-cooled, class-F insulation.

Motor shall be specially designed for quiet operation and its speed shall not
exceed 1440 rpm. The motor rating shall be such as to ensure non overloading
of the motor throughout its capacity range. Motor shall be suitable for
415±10% volts, 3 phase, 50 cycles AC, power supply & shall meeting IEC/NEMA
specification.
c. Base shall be of a size suitable for the pump, motor and shaft and shall be
constructed of cast iron or welded steel. Flexible coupling shall be protected by
a guard mounted on the common base.
d. Installation : The pump shall be installed on a concrete foundation with

vibration isolators as per Approved-for-Construction shop drawings/Schedule of
Quantities.
2.0 MONOBLOC END SUCTION PUMPS
a. The pump set shall be of non priming single stage centrifugal volute with axial
suction port and radial discharge port, horizontal shaft components with
horizontal coupled motor. Pump casing shall be of close grained cast iron. The
pump shall be complete with bronze impeller, mechanical seal, air cock, base
frame, anti vibration mounts and drive motor. The impeller shall be statically and
dynamically balanced. Suction passages shall be volute in form, promoting
smooth entry to impeller and increasing the efficiencies. The drive shaft shall be
of high tensile steel and the shaft sleeve shall be of bronze or gunmetal. All
outside surfaces shall be machined and water passages finished to
reduce friction loss. The bearing assembly shall be with single row
antifriction ball/roller type bearing lubricated for life contained in
separate easily removable housing. A thrower on the shaft shall prevent water
entering the bearing assembly. The pump and motor shall be mounted on a
common base frame.
The coupling shall be of flexible type with steel pin and rubber bushing. The
motor shall remain in position during dismantling of the pump set so as to avoid
subsequent alignment. The complete bearing assembly including impeller and
shaft seal shall be dismantled without removing the volute casing from the
piping. The shaft seal shall be of mechanical type. The pump shall be mounted on
factory made inertia frames with anti vibration mounts and placed over
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concrete foundation blocks with nosing frames. The nosing frames are to
be provided by the air-conditioning Subcontractor. The fixing bolts shall
be of stainless steel. Cushy foot isolators shall be used and rubber pads
are not permitted. The speed of the pumps shall not exceed 1450/2900
rpm as specified. The pump shall be suitable for flange connections.
Pressure gauges with needle valves shall be installed at the suction and discharge
lines as shown in the drawings. The vibration of the pump sets on the bearing
shall not exceed a peak-to-peak displacement of 100 microns. Provide rubber
bellows at the inlet and outlet pipelines of the pump sets. The noise level of the
pump shall not exceed 65 dBA at a distance of 1 m from the pump. Provide
canopy for the motor when exposed to weather.
b. The motor for the pump sets shall be squirrel cage totally enclosed and fan cooled
type with class F insulation and IP 55 Protection. The motor shall be high energy
efficiency type – EFF 1 and having a high and flat efficiency curve for 50%
to100% loads. The frame shall be of close grained cast iron and the stator and
rotor cores shall be built of low loss high permeability sheet steel
laminations.Windings shall be of high conductivity copper bars with both ends
braced to heavy shorting rings. The shaft shall be of precision-machined high
tensile mild steel bars and have sufficient margin for shock loads.The motor
shall be statically and dynamically balanced & shall meeting IEC/NEMA
specification.
Bearings shall be combination of ball and roller type with readily

accessible grease nipples. Terminals shall be amply sized and housed in a
terminal box, which shall be suitable for cable or conduit entry. Two earth
terminals shall be provided. The starting torque shall match with the load torque.
Unless otherwise specified the motors shall be suitable for 415 V 3 phase, 50
cycles AC supply and shall conform to IS: 325. The continuous BHP rating of the
motor shall be at least 110% of the maximum power requirement to allow for
voltage fluctuations and drive losses as per NEMA standards. The vibration of
the motors on the bearing shall not exceed a peak-to-peak displacement
of 100 microns. Provide Special cable terminal boxes suitable for aluminium
cable termination as a part of the motor.
c. Installation : The pump base shall be mounted on a concrete foundation as

per on Approved-for-Construction shop drawings.
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3.0 CLOSE / LONG COUPLED VERTICAL IN-LINE Pumps

Pump shall be single stage, single suction Vertical In-Line type , with rising head to shut
off pump characteristics. Refer to the schedule for pump flows and heads and motor
speed, efficiency, enclosure and power requirements.
Pump casing shall be cast iron, suitable for 175 psig working pressure at 140°F. The
casing shall be hydrostatically tested to 150% maximum working pressure. The casing
shall be radially split to allow removal of the rotating element without disturbing the
pipe connections. The casing shall be provided with NPT threaded companion flanges,
for the appropriate pump size, with gaskets and hardware.
Pump impeller shall be fully enclosed type. The impeller shall be keyed and secured to
the pump shaft by stainless steel fittings.
The pump shaft shall be a stainless steel stub shaft for frame 56 motors. The steel motor
shaft shall be enclosed by a bronze shaft sleeve, on other motor frame sizes.
Mechanical Seal shall be single spring inside type in close couple pump and outer side of
pump casing in case of long coupled pump (for easy replacement) with Carbon and Ni-
Resist faces, EPDM elastomer, stainless steel spring and hardware. (Carbon and Ceramic
faces, with Buna elastomer and brass hardware, on frame 56 motor units). Provide
factory installed seal vent line, piped from the seal area to the pump suction connection.
LUBRICATION
Upon installation of the complete system and before testing, the pump shall be
lubricated in strict accordance with the manufacturer’s instructions.
PUMP ALIGNMENT
Split casing pumps, prior to testing, shall be aligned with a dial indicator within 0.05
mm.
PAINTING
All pumps, motors and bases shall be supplied with approved finish. Shop coat of paint
that have become marred during shipment or erection shall be cleaned off with
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mineral spirits, wire brushed and spot primed over the affected areas, then coated
with enamel paint to match the adjoining areas.
PERFORMANCE DATA
Pump performance curves and power consumption with operating points clearly
indicated shall be submitted and verified at the time of testing and commissioning of the
installation.
TESTING
Pump performance shall be computed from the pump curves provided by

manufacturer. All pumps shall be tested at factory as per relevant BIS codes.
4. VARIABLE SPEED PUMPING SYSTEM
SCOPE
The scope of this section comprise the supply, erection, testing and commissioning of
variable speed pumping package consisting of following :
a. Individual Components
b. Pump Control Panel
c. Adjustable Frequency Drive
d. Different pressure transmitted
e. Logic Programming for sequence of Operation
f. Power wiring and control wiring shall be carried out by installation

Subcontractor as shown on the field connection drawings and wiring diagrams
supplied with the pumping package.
REFERENCES
a. ANSI - American National Standards Institute
b. NEMA - National Electrical Manufacturers Association

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c. UL - Underwriters Laboratories Inc.
d. ETL - Electrical Testing Laboratories
e. CSA - Canadian Standards Association
f. NEC - National Electrical Code
g. ISO - International Standards Organization
h. IEC - International Electrochemical Commission
SUBMITTALS
Submittals shall include the following and shall be specific to this project. General
Submittals shall not be accepted.
a. System summary sheet.
b. Sequence of operation
c. Shop drawing indicating dimensions, required clearances and location and size of
each field connection.
d. Power and control wiring diagrams.
e. System profile analysis including variable speed pump curves and system curve.
The analysis shall also include pump, motor and Adjustable Frequency Drive
(AFD) efficiencies, job specific load profile, staging points, horse power and
kilowatt/hour consumption.
f. Pump data sheets.
QUALITY ASSURANCE
a. The pumping package shall be assembled by the pump manufacturer. An

assembler of pumping systems not actively engaged in the design and
construction of centrifugal pumps shall not be considered a pump manufacturer.
The manufacturer shall assume “Unit Responsibility” for the complete pumping
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package. Unit responsibility shall be defined as responsibility for interface and

successful operation of all system components supplied by the pumping system
manufacturer.
b. The manufacturer shall have a minimum of 20 years experience in the design and
construction of variable speed pumping systems.
c. The local supplier of Chilled Water Variable Speed Pumping System (VSPS) shall
have relevant expertise in all aspects of design, application engineering,
installation, programming, interfacing, commissioning and after sales service.
Supplier must have commissioned minimum 25 sets of chilled water VSPS in
India.
d. All functions of the variable speed pump control system shall be tested at the
factory prior to shipment. This test shall be conducted with motors connected to
AFD output and it shall test all inputs, outputs and program execution specific to
this application.
e. The manufacturer shall be fully certified by the International Standards

Organization per ISO 9001. Proof of this certification shall be furnished at time of
submittal.
f. Manufacturer shall be listed by Underwrite’s Laboratories as manufacturer of

packaged pumping systems.
g. Tenderer shall comply with all sections of this specification relating to packaged
pumping systems. Any deviations from this specifications shall be clearly defined
in writing at time of bid. If no exceptions are taken at time of bid, the supplier
shall be bound by these specifications.
MANUFACTURED UNITS
a. Furnish and install as shown on the plans a Variable Speed Pumping System as
per approved manufacturers.
b. The control system shall include as, a minimum, the programmable logic pump
controller, adjustable frequency drive(s) and remote sensor / transmitters as
indicated in the drawings and schedule of quantities on the plans. Additional
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items shall be included as specified or as required to properly execute the

sequence of operation.
c. The variable speed pump logic controller, adjustable frequency drives, AFD
bypass if indicated in schedule of quantities, and remote sensor / transmitters
shall be shipped as individual components to the job site.
d. Pump logic controller, adjustable frequency drives, sensor / transmitters and

related equipment shall be installed by the mechanical Subcontractor as shown
on the plans.
e. Power wiring shall be installed by the mechanical Subcontractor as shown on the

field connection drawings and wiring diagrams supplied with the pumping
package.
f. Low voltage wiring shall be installed by the mechanical controls Subcontractor as

shown on the field connection drawings and wiring diagrams supplied with the
pumping package.
4.1 PUMP LOGIC CONTROLLER
a. The pump logic controller assembly shall be listed by and bear the label of
Underwriter’s Laboratory INC. (UL). The controller shall meet Part 15 of FCC
regulations pertaining to class A computing devices. The controller shall
specifically designed for variable speed pumping applications.
b. The controller shall function to a proven program that safeguards against

hydraulic conditions including :
i. Pump flow surges
ii. Hunting
iii. End of curve
iv. System over pressure.
v. NPSHR above NPSHA
vi. Motor overload

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c. The pump logic controller shall be capable of receiving up to two discrete analog
inputs from zone sensor / transmitter as indicated on the plans. It will then
select the analogue signal that has deviated the greatest amount from its setpoint.
This selected signal shall be used as the command feedback input for a hydraulic
stabilization function to minimize hunting. Each input signal shall be capable of
maintaining a different set point value. Controller shall be capable of controlling
upto three pumps in parallel.
d. The pump logic controller shall have an additional analog input for a flow sensor.
This input shall serve as the criteria for the end of curve protection algorithm.
e. The hydraulic stabilization program shall utilize a proportional-integral-

derivative control function. The proportional, integral and derivative values shall
be user adjustable over an infinite range.
f. The pump logic controller shall be self prompting. All messages shall be displayed
in plain English. The operator interface shall have the following features :
i. Multi-fault memory and recall last 10 faults and related operational data
ii. Red fault light, Yellow warning light and Green power on light.
iii. Soft-touch membrane keypad switches.
g. The display shall have four lines, with 20 characters on three lines and eight large
characters on one line. Actual pump information shall be displayed indicating
pump status.
h. Controller shall be capable performing the following pressure booster function :
i. Low suction pressure cut-out to protect the pumps against operating with
insufficient suction pressure.
ii. High system pressure cut-out to protect the piping system against high
pressure conditions.
iii. No flow shut down to turn the pumps off automatically when system
demand is low enough to be supplied by hydropneumatic tank. No flow
shutdown shall require any external flow meters, flow switches, nor
pressure switches to determine when a No Flow condition exists.
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j. The following communication features shall be provided to BAS :
i. Remote system start / stop non-powered digital input.
ii. Failure of any system component. Output closes to indicate alarm

condition.
iii. One 4-20 mA output with selectable output of :
 Frequency
 Process Variable
 Output Current
 Output power.
k. The following communication features shall be provided to the building

automation system via an RS-485 port utilizing Johnson Controls Metasys N2
protocol or equivalent protocol.
i. Individual Analog Input
ii. Individual Zone Set Points.
iii. Individual Pump / AFD on/off status.
iv. System percent speed.
v. System Start / Stop command
vi. System operation mode.
vii. Individual KW signals.
viii. System flow, when optional flow sensor is provided.
l. The pump logic controller shall be a ITT industries technologic 500 or approved
equal housed in a NEMA 1 Enclosure.
4.2 ADJUSTABLE FREQUENCY DRIVE
a. The adjustable frequency drives shall be Pulse Width Modulation (PWM) type,
microprocessor controlled design.
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b. The Adjustable Frequency Drive (AFD), including all factory installed option, be
tested to UL standard 508. The AFD shall also meet C-UL and be CE marked and
built to ISO 9001 standards.
c. The AFD shall be housed in a NEMA 1 enclosure. AFF with plastic enclosure shall
not be acceptable.
d. The AFD shall employ and advanced sine wave approximation and voltage vector
control to allow operation at rated motor shaft output speed with no derating.
This voltage vector control shall minimize harmonics to the motor to increase
motor efficiency and lift. Power factor shall be near unity regardless of speed or
load.
e. The AFD shall have balanced DC link reactors to minimize power line harmonics
AFDs without a DC link reactor shall provide a 3% impedance line reactor.
f. Input and output power circuit switching can be done without interlocks or
damage to the AFD.
g. The following customer modifiable adjustments shall be provided :
i. Accel time.
ii. Decel time.
iii. Minimum Frequency.
iv. Maximum Frequency.
h. RS-485 communication for Johnson Controls N2 shall be available and provided

as an option.
i. An automatic energy optimization selection feature shall be provided. This

feature shall reduce voltage when lightly loaded and provide a 3% to 10%
additional energy savings.
j. The AFD shall be suitable for upto 3300 feet elevation above sea level without
derating. Maximum operating ambient temperature shall not less than 104
degrees F. AFD shall be suitable for operation in environments upto to 955 non-
condensing humidity.
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k. The AFD shall be capable of displaying the following information in plain English
via an alphanumeric display :
i. Frequency.
ii. Voltage
i. Current
ii. Kilowatts per hour
iii. Fault Identification.
iii. Percent Torque.
iv. Percent Power
viii. RPM
4.3 AUTOMATIC AFD BYPASS
a. Variable speed pumping system shall be equipped with an automatic bypass in

accordance with requirement of Schedule of Quantities.
b. Bypass shall consist of a main power disconnect with ground fault protection, a
pair of interlocked Subcontractors and a motor overload relay. All are to be
mounted in a NEMA 1 enclosure.
c. Automatic bypass shall operate as shown in schematic drawings described in the

sequence of operation.
4.4 SENSOR / TRANSMITTERS
a. Provide field mounted differential pressure sensor transmitters as indicated in BOQ

or on the plans. Unit shall transmit an isolated 4-20mA dc signal indicative of
process variable to the pump logic controller via standard two wire 24 DC system.
Unit shall have a corrosion resistant steel body with 1/8” NPT process connection. It
shall have a NEMA 1 electrical enclosure capable of withstanding 450 PSI static
pressure. Accuracy shall be within 0.5% of full span. The installation Subcontractor
shall ensure that these differential pressure sensor are enclosed within pilfer proof
housing such MS plate housing with lockable access panel.
4.5 SECONDARY PUMPS
a. SCOPE
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The scope of this section comprise the supply, erection, testing and
commissioning of water pumps conforming to these specifications and in
accordance with requirements of Schedule of Quantities.
b. TYPE
The type and size of secondary chilled/hot water, and pumps for air
conditioning applications shall be in accordance with requirement of
Drawings and Schedule of Quantities.
c. CAPACITY
Water flow rates and head of the pumps shall be in accordance with the
d. SPLIT CASING PUMPS
i. Pump casing shall be close-grained cast iron of heavy section,

horizontally/vertically split, making possible complete servicing of
rotating parts without breaking piping or motor connections. Motor to
pump connection shall be of the flexible coupling type. Suction passages
shall be volute in form, promoting smooth entry to impeller and
increased efficiency. Impeller shall be bronze or gun metal, double
suction, enclosed type, hydraulically balanced and passages smooth-
finished for minimum friction and maximum efficiency. Impeller rings
shall be secured from relative movement by tongue and groove fittings.
Shaft shall be steel, protected by gunmetal sleeves extending through
stuffing boxes. Stuffing boxes shall be extra deep, water sealed with
renewable bushes. Shaft shall be supported in ball /journal bearings,
grease lubricated, contained in easily removable housing. Pumps shall
be fitted with mechanical seals, an air valve, two grease lubricators, drain
plug and water seal connections.
ii. Motor shall be energy efficient, totally enclosed, fan-cooled, class-F

insulation and suitable for operation on Adjustable Frequency Drive
(AFD). Motor shall be specially designed for quiet operation and its
speed shall not exceed 1440 rpm. The motor rating shall be such as to
ensure non overloading of the motor throughout its capacity range.
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Motor shall be suitable for 415 ± 10% volts, 3 phase, 50 cycles AC, power
supply.
iii. Base shall be of a size suitable for the pump, motor and shaft and shall be
constructed of cast iron or welded steel. Flexible coupling shall be
protected by a guard mounted on the common base.
iv. Installation : The pump shall be installed on a concrete foundation as

shown in Approved-for-Construction shop drawings.
v. Each pumps shall be provided with certified performance curves showing

power absorbed and corresponding flow rates by varying the speed. Tests
shall be done at factory and may be witnessed by Owner’s site
representative.
e. PUMP ALIGNMENT
Split casing pumps, prior to testing shall be aligned with a dial indicator within
0.05 mm. Monobloc pumps shall be factory aligned with motor on common
base, and need not be realigned at site.
f. PERFORMANCE DATA
Pump performance curves and power consumption with operating points clearly
indicated shall be submitted and verified at the time of testing and
commissioning of the installation.
g. TESTING
Pump performance at site shall be computed from the pump curves provided
by manufacturer.
PAINTING
All variable pumping system, pumps, motors and bases shall be supplied with approved
finish. Shop coat of paint that have become marred during shipment or erection shall
be cleaned off with mineral spirits, wire brushed and spot primed over the affected
areas, then coated with enamel paint to match the adjoining areas.
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SEQUENCE OF OPERATION
a. The system shall consist of a pump logic controller, multiple pump / AFD sets,
with manual and automatic alternation and pump staging.
b. The pumping system shall start upon the closure of customer’s contact when the
pump logic controller Mode of Operation selector switch is in the REMOTE
position.
c. When the pump logic controller selector switch is in the LOCAL position, and
start command on Tech 500 is given via operator interface, the pumping system
shall operate automatically.
d. Sensor / transmitters shall be provided as indicated on the plans.
e. Each sensor / transmitter shall send a 4-20 mA signal to the pump logic
controller, indicative of process variable condition.
f. The pump logic controller shall compare each signal to the independent, engineer
/ user determined set points.
g. When all set points are satisfied by the process variable, the pump speed shall
remain Constant at the optimum energy consumption level.
h. The pump logic controller shall continuously scan and compare each process
variable to its individual set point and control to the least satisfied zone.
i. If the set point can not be satisfied by the designated lead pump, the pump logic
controller shall initiate a timed sequence of operation to stage a lag pump.
j. The lag pump shall accelerate resulting in the lead pump(s) decelerating until
they equalize in speed.
k. Further change in process variable shall cause the pumps to change speed
together.
l. When the set point criteria can be safely satisfied with fewer pumps, the
Technologic pump logic controller shall initiate a timed destage sequence and
continue variable speed operation.
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m. As the worst case zone deviates from set point, the pump logic controller shall
send the appropriate analog signal to the AFD to speed up or slow down the
pump / motor.
n. In the event of a AFD fault, the pump logic controller automatically initiates a
times sequence of events to start the redundant pump / AFD set in the variable
speed mode. The redundant variable speed system shall be started through the
pump logic controller.
o. Upon AFD fault(s), the pump controller shall display an alarm condition through
a plain english message.
p. AFD fault indication shall be continuously displayed on the operator interface of

the pump until the fault has been corrected and the controller has been manually
reset.
q. In the event of the failure of a zone sensor / transmitter, its process variable
signal shall be removed from the scan / compare program. Alternative zone
sensor / transmitters, if available, shall remain in the scan / compare program for
control.
r. Upon sensor failure a plain english warning message shall be displayed on the
operator interface of the pump logic controller.
s. In the event of failure to receive all zone process variable signals, a user
selectable number of AFDs shall maintain a user adjustable speed, reset shall be
automatic upon correction of the zone failure.
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TECHNICAL DATA FORVARIABLE SPEED PRIMARY PUMPING SYSTEM
4.1 ADJUSTABLE FREQUENCY DRIVE
a. Make / Country of Origin
b. Model No.
c. Type
d. Motor Rating
e. Rated Current
f. Maximum Output
g. PID Controller
h. Interface with BAS.
j. Fault Indication.
k. Dimensions (mm)
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l. No. of Steps
m. Operating Weight
4.2 AUTOMATIC AFD BY PASS
b. Model No.
c. Type
d. Motor Rating
e. Rated Current
f. Rating of Power disconnect switch.
g. Type of Enclosure
4.3 PUMP LOGIC CONTROLLER
b. Model No.
c. Microprocessor
d. No. of Bits.
e. Clock Frequency
f. RAM Memory
g. Power supply
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4.4 DIFFERENTIAL TRANSMITTER/SENSOR
a. Make/ Country of Origin.
b. Model No.
c. Type
d. Constructional Material
Sensing Element Material for pressure &

e.
flow rate.
f. Maximum Static pressure
g. Power supply
h. Degree of Protection
4.5 SECONDARY PUMP (CHILLED WATER)
a. Manufacturer & Model
b. Type
c. Capacity (USGPM)
For SCHWP indicate
capacity at varying speed.
d. Head (ft.)
e. Efficiency (%)
f. Pump (RPM)
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g. B.H.P
h. Motor (HP)
j. Motor make.
Electrical characteristics (±10% voltage

k.
variation)
l. Motor efficiency and class of insulation.
m Full load current (Amps)
n Starting current (Amps)
p Locked rotor current on full load (Amps)
m. Impeller material
n. Type of water seals.
o. Vibration isolation
p. Operating weight (Kg)
q. Overall dimensions (M)(LxWxH)
NOTE : Performance curves for each pump shall be submitted alongwith the technical
submittal.
4.6. PRIMARY PUMPS CHWPUMP CDWPUMP
a. Manufacturer & Model.

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b. Type
c. Capacity (USGPM)
d. Head (ft.)
e. Efficiency (%)
f. Pump (RPM)
g. B.H.P
h. Motor (HP)
j. Motor make.
Electrical characteristics (±10% voltage

k.
variation).
l. Motor efficiency and class of insulation.
m Full load current (Amps)
n Starting current (Amps)
o Locked rotor current on full load (Amps)
p. Impeller material
q. Type of water seals.
r. Vibration isolation
s. Operating weight (Kg)
t. Overall dimensions (M)(LxWxH)

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Note :
Performance curves for each pump shall be submitted alongwith the technical submittal.
PUMP TEST REPORT
PROJECT _______________________________________________
DATA PUMP NO. PUMP NO. PUMP NO. PUMP NO. PUMP NO.
Location
Service
Manufacturer
Model Number
Serial Number
GPM/Head
Req. NPSH
Pump RPM
Impeller Diam.
Motor Mfr. /
Frame
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Motor HP/RPM
Volts/Phase/Hertz
F.L Amps
Seal Type
Pump Off-Press.
Valve Shut Diff.
Act.Impeller Diam.
Valve Open diff.
Valve Open GPM

Final Dischg.
Press.
Final Suction
Press.
Final Ap
Final GPM
Voltage T1 T2 T2 T3
T3 T1
Amperage T1 T2
T3
REMARKS
TEST DATE _____________________ READINGS BY __________________________

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SECTION-03
COOLING TOWER
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3. COOLING TOWERS
3.1 SCOPE
The scope of this section comprises the supply, erection, testing and commissioning
of cooling towers in accordance with requirements of Drawings and of the Schedule
of Quantities.
3.2 TYPE
Cooling Towers shall be induced draft /forced draft in accordance with requirement of
Drawings and of the Schedule of Quantities. Cooling towers shall be as per CTI (for
green buildings only). In case of multiple fans in cooling tower, HVAC Subcontractor to
provide a electrical panel for one incoming and multiple outgoings/ ( including starters
DOL/ Star delta / VFD as required) equal to number cooling tower fans. This panel shall
be included in cooling tower rate.
3.3 INDUCED DRAFT COOLING TOWER
Cooling Towers shall be suitable for outdoor use. Tower shall be vertical, induced draft,
counter/cross flow type. FRP construction, in rectangular/ square /octagonal profile,
complete with fan, motor, diffusion deck spray section, eliminators, steel supports, and
sound attenuation equipment where called for in Schedule of Quantities.
a. Capacity
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The cooling tower capacities shall be as per the Drawings and Schedule of
Quantities.
b. Side Casing
This shall be made out of FRP construction of minimum 5 mm thick and UV

stabilized with smooth surface on both sides for minimum resistance to air flow.
It shall have sufficient structural strength to adequately withstand high
wind velocities and vibration. The casing may be installed in the reinforced
cement concrete basin if so identified in drawings, or in Schedule of Quantities.
The tower supporting structure shall be made out of hot dipped galvanized
tubular frame. Air intake shall be all along the sides so that tower can be
installed quite independent of prevailing wind direction. Anodized aluminium or
PVC louvers integrated with fill UV stabilized PVC fill and backed up by
galvanized bird screen / FRP Louvers shall be provided at air intake. Sufficient
clearance between casing and adjoining structures shall be provided to enable
servicing and periodic cleaning.
c. Cold Water Basin
Cold water basin shall be a minimum 600 mm deep sump and made out of 5 mm
thick FRP construction and UV stabilized on which cooling tower super
structure shall be supported. RCC suction tank with easily removable double
brass strainers may be provided with this basin, if separately identified in
drawings or in Schedule of Quantities.
Basin fittings shall include the following :
i. Bottom outlet.
ii. Screened suction assembly.
iii. Drain connected to the side / underside of basin.
iv. Overflow connected to the side of basin.
v. Built-in bleed off attached to inlet header discharging through

polyethylene tube into overflow pipe.
vi. Ball type automatic make up water valve.

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vii. Quickfill connected to the side of basin.
viii. Equalizing connection and balancing valve for multiple CTs.
d. Distribution System
Hot water distribution system shall comprise of header and branch arms
system or open pan gravity flow system.
e. Filling
Fillings shall be made of corrosion proof and rigid PVC film in honey comb
design and arranged in square / rectangular form. Fill sheets shall be
suspended from H.D.G steel structural tubing supported from the lower
structure & shall be elevated above the floor of the cold water basin to facilitate
cleaning and easy replacement. They shall be arranged in such a manner to
ensure negligible resistance to air flow and to eliminate back water spots and
prevent fouling through scales that may form. In order to reduce carry-over
losses through entrainment of moisture drops in air stream, PVC drift
eliminator shall be installed.
f. Mechanical Equipment
The tower shall be provided with low speed fan running at less that 360 RPM
through gear reducer. Direct driven fan speed shall not exceed 700 RPM. Fan
shall be of the propeller type light-weight rotor fitted with multiple aerofoil
blades. The entire fan assembly shall be statically and dynamically balanced.
Fan shall be driven by 415±8% volts, 3 phase, 50 cycles, AC supply, energy
efficient motor totally-enclosed, fan-cooled, weather-proof construction,
designed and selected to operate in humid air stream. Fan shall be protected by
a fan guard and bird screen of galvanized steel construction to prevent birds from
nesting during idling period & shall be easily accessible for inspection and
maintenance. A service ladder (Aluminium construction) shall also be
provided for greater convenience. The mechanical equipment assembly shall be
adequately supported on a rugged steel base welded to tubular support
assuring vibration-free support. Fan guard and bird screen (of galvanized steel
construction) shall be provided to prevent birds from nesting during idling
periods. Gear-reducer shall be of spiral bevel type. G.S.S canopy shall be
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provided over the fan motor for protection against rain water. Care shall be
taken that fan air is not restricted. Motor terminal box shall be made water tight.
3.4 FORCED DRAFT COOLING TOWER
Forced draft cooling tower shall be FRP construction of minimum 5 mm thick and UV
stabilized and structural framed, cross-flow forced draft type, suitable for outdoor use.
Tower shall be complete with fan, motor, diffusion deck, spray section and eliminator
plate. Tower shall be selected for low height and lowest possible noise level as defined in
a. Capacity
The cooling tower capacity shall be as per the Drawings and Schedule of
Quantities.
b. Casing
Casing and basin shall be of FRP of minimum 3 mm / 5 mm thick respectively

and sealed for water tightness. All joints and corners shall be sealed and an
aluminium ladder shall be provided to reach upto the top of cooling tower.
c. Cold Water Basin
Cold water basin shall be a with deep sump in which cooling tower
superstructure shall be supported. Easily removable brass-strainers shall be
provided with the basin and pump suction shall be provided after strainers.
Basin fittings shall include the following :
i. Side outlet.
ii. Screened suction assembly with openable cover of steel sheet.
iii. Drain connected to the side / underside of basin.
iv. Overflow connected to the side of basin.
v. Built-in bleed off attached to inlet header discharging through

polyethylene tube into overflow pipe.
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vi. Ball type automatic make up water valve.
vii. Quickfill connected to the side of basin.
viii. Equalizing connection/balancing valve for multiple cooling towers.
ix. Bird screen at air inlet/outlet of the fan.
d. Distribution System
Hot water distribution system shall be comprising of header and branch arm
system or open pan gravity flow system suitable for high pressure.
e. Filling
Fillings shall be made of corrosion proof and rigid UV stabilized PVC film in
honey comb / modular design and arranged in square / rectangular form. Fill
sheets shall be suspended from H.D.G steel structural tubing supported from the
lower structure & shall be elevated above the floor of the cold water basin to
facilitate cleaning and easy replacement. They shall be arranged in such a
manner to ensure negligible resistance to air flow and to eliminate back water
spots and prevent fouling through scales that may form. In order to reduce
carry-over losses through entrainment of moisture drops in air stream, PVC
drift eliminator shall be installed.
f. Mechanical Equipment
Fan shall be centrifugal/axial fan, aluminium alloy aerofoil construction. The

entire fan assembly shall be statically and dynamically balanced. Fan motor shall
be low RPM, suitable for 415±8% volts, 3 phase, 50 cycles AC supply, energy
efficient electric motor, totally enclosed, fan-cooled, weather-proof
construction. The noise level from cooling tower shall be less than 65 DB from 3
meter distance all around the cooling tower. The mechanical equipment
assembly shall be adequately supported through galvanized steel angle frame
work. The hot and humid air shall be discharged at the top level. Galvanized
steel construction bird screen at outlet shall be provided to prevent birds from
nesting during idling period.
PERFORMANCE DATA
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Complete performance ratings and power consumption at varying loads and outdoor
wet bulb temperatures, shall be submitted and verified at the time of testing and
TESTING
Capacity of the cooling tower shall be computed from the measurements of water
flow, incoming/outgoing water temperatures and ambient air wet bulb temperature
using accurately calibrated mercury-in-glass thermometers. Computed ratings shall
conform to the specified capacities and quoted ratings. Power consumption for
cooling towers shall be computed from measurements of incoming voltage and input
current.
TECH DATA SHEET - COOLING TOWER

a. Manufacturer
b. Type (Induced/Forced draft)
c. Model
d. Capacity TR
e. Water flow rate (US GPM)
f. Range Deg. F
g. Approach Deg F
h. Casing Material
j. Basin Material
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k. Eliminators Material
l. Piping Material and size.
m. Mechanical equipment supports material
n. Fill Material
o. Ladder Material
p. Fan dia and RPM
q. Fan Motor
i. Make
ii. Type
iii. HP
iv. RPM
v. Efficiency and class of insulation.
Electrical Characteristics (±10% voltage
vi.
variation)
vii Full load / current
viii Type of starter & manufacturer
Noise level (DB) at following distance from
r.
cooling tower
10 metre
15 metre
20 metre
s. Drift Loss % of water flow.
t. Evaporative Loss %
u. Total makeup water required (US Gallons/Hr)
v. Water equalizing connection for multiple cooling

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towers
w. Operating weight Kg.
x. Overall dimensions (M)(LxWxH)
COOLING TOWER TEST REPORT
PROJECT____________________________SYSTEM___________________________
LOCATION______________________________________________________________
MANUF.__________________MODEL_______________SERIAL NO.________________
NOM. CAPACITY____________________________WATER TREAT__________________
COOLING TOWER / AIR DATA DESIGN ACTUAL

MOTOR / WATER DATA
Make / Model Fan CFM

Type Outlet S.P.
Tons Avg. Ent. W.B.
No. of Fan Motors Avg. Lvg. W.B.
Motor HP / RPM Ambient W.B.
Motor / Drive Fan RPM
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Motor Speed Voltage I1 Ie I2 I3 I3 I1

Motor Rated Current Amps T1 Te T21
Motor FL Current
O/L Release Setting
CT Range
CT Approach
COOLING TOWER FAN /

DESIGN ACTUAL WATER DATA DESIGN ACTUAL
AIR DATA
Ent//Lvg./Water
No. of Fans
Pressure
Ent//Lvg./Water
Type/ Drive of Fan
Temperature
Water Temperature
Fan Dia
–T
Fan Speed GPM
Air Inlet Temperature Bleed GPM
Air Outlet Temperature Voltage I1 Ie I2 I3 I3 I1
Fan Air Quantity Amps T1 Te T21
Water Bleed GPM
REMARKS
TEST DATE ______________________ READINGS BY___________________________

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SECTION-04
AIR CONDITIONING EQUIPMENTS

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1.0 AIR HANDLING UNITS
1.1 GENERAL
a) Work included
This section specifies the requirements necessary to furnish and install, complete
commercial-type air handlers serving comfort air conditioning areas.
b) Design Criteria
i) All fans shall be rated, tested and certified in accordance with AMCA standards.
ii) All coils shall be rated, tested and certified in accordance with ARI standards.
iii) Use dielectric unions or flange kits for dissimilar metal connections capable of
galvanic corrosion.
iv) Buna-N seals are not allowed on hot water systems, use EPDM or Viton.
i) Filters shall be tested and certified in accordance with ASHRAE standard 52.
ii) Units shall be designed in accordance with seismic requirements.
iii) All instrumentation and controls shall be commercial quality.
iv)
c) Submittals
In addition to the standard requirements, provide the following with the Bid:
a) Estimates of inlet and outlet sound power levels (in dB re 10(-12) watt) in each
octave band from 63Hz to 4,000 Hz. These estimates shall take into account the
attenuation provided by the cabinet of the air handler, which shall be acoustically
lined as described in this specification.
ii) Provide fan performance curves showing static pressure, rpm and motor
horsepower requirements versus air quantity handled over full range of fan
capacity.
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iii) Complete ARI certified performance data at standard design conditions for all coils
with performance at actual site conditions listed on the data sheets. Complete coil
dimensional data and installation requirements.
iv) Data for each fitter type: complete certified performance data at design conditions,
including volumetric flow rate and air pressure drop.
v) Seismic design calculations shall be submitted and certified with bid.
i) Provide proposed tie-down details with equipment submittals.
d) Factory vibration balance report
i) Certificate of compliance papers shall be attached to each fan at shipment, and signed by
the fan manufacturer’s quality control inspector. An additional copy shall be sent to
Owner / Project Managers.
ii) All factory balancing test results shall be furnished to certify the fan vibration does not
exceed 50 mils per second rms for belt-driven units. Measurements shall be taken in a
direction parallel to the shaft in a horizontal plane. And in a direction perpendicular to
the shaft in both the horizontal and the vertical planes.
iii) During balancing tests, the fan shall be operating at rated volume flow against the design
external static pressure.
The scope of this section comprises of supply and installation of double skin cabinet type
air handling unit with all its accessories conforming to this specification and in
accordance with the relevant drawings.
The air handling units shall be constructed using double skinned acoustic panels with
minimum 0.40 mm thick pre-coated GSS sheet for outer skin and & 0.4mm plain GSS
sheet for inner skin of the unit. All the panels shall incorporate 25mm thick and
minimum 40 kg/cum density PUF insulation sandwiched in between inner & outer skin;
the inner skins can be of perforated sheet in the case of fan sections to bring down the
noise level.
The air handling unit’s capacities, fan motor HP, fan static pressure & all other details are
furnished in the equipment schedule & relevant drawings.
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All the panels shall be assembled on a supporting frame of anodized hollow aluminium
sections. Panel – to frame joints shall be provided with EPDM gaskets. Only stain less
steel screws shall be used for fastening panels to the supporting frame. The inside of the
unit shall give clear surfaces free from bolt & bolt – head projections.
The entire unit shall be of study construction to ensure freedom from vibration while
running. All sections shall incorporate access doors / panels. The hinges shall be of cast
aluminium & handles shall be of pressed steel. Self – lubricated Nylon sleeves shall be
provided. The entire housing shall be mounted on extruded aluminium channel frame
work having pressure die cast aluminium jointers. All access doors, coil connections etc,
shall be provided on one side of the unit. In other words, access to the other side of the
unit should not be necessary for any purpose what so ever.
Special care shall be taken to ensure that doors, handles, hinges, etc. shall be robust
enough to with stand heavy industrial usage. The vibration of the AHU fans (as measured
on the bearing block after assembly) shall not exceed a peak-to-peak displacement of
100 microns. For all AHUs, serrated rubber pads shall be provided for vibration
isolation.
1.2 COMPONENTS OF THE AIR HANDLING UNITS
i) SCOPE
The scope of this section, comprises the supply, erection, testing and commissioning of
double skin construction air handling units, conforming to these Specifications and in
accordance with requirements of drawings and of the Schedule of Quantities.
ii) TYPE
The air handling units shall be double skin construction, draw-thru type comprising of
various sections, filter section, coil section and fan section, mixing box, (wherever the
return air and fresh air are ducted) as shown on drawings and included in schedule of
quantities.
iii) CAPACITY
The air handling capacities, maximum motor horse power and static pressure shall be
as shown on Drawings and in Schedule of Quantities.
iv) CASING
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Double skinned panels shall be 23 mm thick made of galvanized steel, pressure

injected with foam insulation (density 40 kg/m3) with K factor not exceeding 0.02
Watt/Mc shall be fixed to 1.5 mm thick aluminium alloy twin box section structural
framework with stainless steel screws. Outer sheet of panels shall be made of
galvanised preplasticised sheet of 0.63 mm thick, and inner sheet of 24 Gauge plain
G.I.Sheet.
The entire framework shall be mounted on an aluminium alloy or galvanized steel

(depending on size) channel base as per manufacturer’s recommendation. The panels
shall be sealed to the framework by heavy duty gaskets held captive in the framed
extrusion. All panels shall be detachable or hinged. Hinges shall be made of die cast
aluminum / hard nylon with stainless steel pivots, handles shall be made of hard
nylon and be operational from both inside and outside of the unit. Units supplied with
various sections shall be suitable for on site assembly with continuous foam gasket. All
fixing and gaskets shall be concealed.
Units shall have hinged, quick opening access door in the fan section and also in filter
section where filters are not accessible from outside. Access doors shall be double skin
type. The unit shall be provided with maintenance door airtight type for Inspection & at
coil section.
Condensate drain pan shall be fabricated from 18 gauge stainless steel sheet with all
corners welded. It shall be isolated from bottom floor panel with 19 mm elastomeric
nitrile rubber.
v) MIXING BOX
AHU’s requiring mixing boxes as specified in Schedule of Quantities shall be complete

with fresh and return air dampers.
vi) THERMAL BREAK PROFILE
AHU’s such as TFA units, AHU with mixing box having return air ducted shall be
provided with thermal break profile as indicated in schedule of quantities. Also these
AHU’s shall be provided with 46 mm thick panel.
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vii) DAMPER
Dampers shall be opposed blade type. Blades shall be made of double skinned aerofoil
aluminium sections with integral gasket and assembled within a rigid extruded
aluminium alloy frame. All linkages and supporting spindles shall be made of
aluminium or nylon, turning in teflon bushes. Manual dampers shall be provided with
a bakelite knob for locking the damper blades in position. Linkages shall be extended
wherever specified for motorised operation. Damper frames shall be sectionalised to
minimise blade warping. Air leakage through dampers when in the closed position shall
not exceed 1.5% of the maximum design air volume flow rate at the maximum design air
total pressure.
viii) MOTOR AND DRIVE
Fan motors shall be energy efficient (EFF-1) and shall be 415±10% volts, 50 cycles,
three phase, totally enclosed fan-cooled (TEFC) squirrel cage class F, with IP-55
protection & shall be meeting IEC/NEMA specification. Motors shall be especially
designed for quiet operation and motor speed shall not exceed 1440 rpm. Drive to fan
shall be provided through belt-drive arrangement. Belts shall be of the oil-resistant
type.
ix) FAN
Fans shall be centrifugal, forward curved / backward curved / aerofoil so as to give

maximum efficiency for given duty condition.. Fans driven by variable frequency drive
shall be backward inclined irrespective of static pressure value. Fans shall be selected
for minimum efficiency of 75% Fan casing shall be made of galvanised steel sheet. Fan
wheels shall be made of galvanised steel. Fan shaft shall be grounded C40 carbon
steel and supported in self-aligning plummer block operating less than 75% of first
critical speed, grease lubricated bearings. Fan wheels and pulleys shall be
individually tested and precision balanced dynamically. Fan motor assembly shall be
statically and dynamically balanced to G6.3 grade as per relevant ISO/AMCA standard.
Computerized fan selection print outs shall be submitted along with the offer.
Motors shall be mounted inside the AHU casing on slide rails for easy belt tensioning,
and be totally enclosed, fan cooled, to be class `F’ insulation. Motors shall drive heavy
duty V-belt, constant pitch, drive selected at 110% of motor horsepower.
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Both fan and motors assemblies shall be mounted on a deep section aluminium alloy
or galvanised steel (depending on size) base frame.
Combination spring and rubber anti vibration mounts shall be provided for isolating the
unit casing. Frame retardant, waterproof silicone rubber impregnated flexible
connection shall be provided at the fan discharge.
x) COOLING COILS
Chilled water coils shall have 12.5 to 15 mm dia (O.D )tubes minimum 0.4 mm thick
with sine wave aluminium fins firmly bonded to copper tubes assembled in zinc
coated steel frame. Face and surface areas shall be such as to ensure rated capacity
from each unit and such that the air velocity across the coil shall not exceed 150
meters per minute. The coil shall be pitched in the unit casing for proper drainage. The
coil shall have copper header with chilled water supply & return connections protruding
out of AHU casing by minimum 150 mm and fitted with dielectric coupling for
connection with Chilled water pipes. Each coil shall be factory-tested at 21 kg per sq.
m air pressure under water. Tube shall be hydraulically / mechanically expanded
for minimum thermal contact resistance with fins. Copper tubes shall be as per latest
ASTM standards. Fin spacing shall be 4 - 5 fins per cm. Water pressure drop in coil shall
not exceed 10 PSIG.
All public area AHU’s shall be provided with minimum 6 Row Cooling Coil. All TFA
AHU’s shall be provided with minimum 8 row cooling coil.
Computerized cooling coil selection output shall be submitted. Coil rating shall be as per
ARI-410/2006.
xi) FILTERS
Each unit shall be provided with a factory assembled filter section containing
washable synthetic type air filters having anodised aluminium frame. The filter shall
have minimum 90% efficiency down to 10 microns . The media shall be supported with
HDP mesh on one side and aluminium mesh on other side. Filter banks shall be
easily accessible and designed for easy withdrawal and renewal of filter cells. Filter
framework shall be fully sealed and constructed from aluminium alloy. All filters shall
have pressure gauge.
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xii) ACCESSORIES
Each air handling unit shall be provided with manual air vent at high point in the cooling
coil and drain plug in the bottom of the coil. In addition, the following accessories may
be required at air handling units, their detailed specifications are given in individual
sections, & quantities separately identified in schedule of Quantities.
a. Insulated butterfly valves, balancing valves, `Y’ strainer, union & condensate
drain piping with ‘U’ trap up to sump or floor drain in air handling unit room, as
described in section “Piping”.
b. Thermometers in the thermometer wells & pressure gauge (with cocks) within
gauge ports in chilled water supply and return lines as per the section
“Instruments”.
c. Water resistance marine light shall be provided at each section of the unit with
power cabling.
xiii) ISOLATORS
Vibration isolators shall be provided with all air handling units. Vibration isolators shall
be cushyfoot mounting type. Minimum vibration isolation efficiency shall be 90%.
xiv) FRESH AIR INTAKES
Extruded aluminium construction duly anodized (20 microns and above) fresh air
louvers with birdscreen and dampers shall be provided in the clear openings in
masonry walls of the air handling unit rooms having atleast one external wall.
Louvers, damper, pre-filters, ducts and fresh air fan with speed regulator shall be
provided as shown on Drawings and in Schedule of Quantities. Fresh air dampers shall
be of the interlocking, opposed-blade louver type. Blades shall be made of extruded
aluminium construction and shall be rattle-free. Dampers shall be similar to those
specified in “Air Distribution”. Fresh air fans and fresh air intakes shall be as per the
xv) PAINTING
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Shop coats of paint that have become marred during shipment or erection shall be
cleaned off with mineral spirits, wire brushed and spot primed over the affected areas,
then coated with paint to match the finish over the adjoining shop painted surface.
xvi) PERFORMANCE DATA
Air handling unit shall be selected for the lowest operating noise level of the
equipment. Fan performance rating and power consumption data, with operating
points clearly indicated shall be submitted and verified at the time of testing and
xvii) TESTING
Cooling capacity of various air handling unit models be computed from the
measurements of air flow and dry and wet bulb temperatures of air entering and
leaving the coil. Flow measurements shall be by an anemometer and temperature
measurements by accurately calibrated mercury-in-glass thermometers. Computed
results shall conform to the specified capacities and quoted ratings. Power
consumption shall be computed from measurements of incoming voltage and input
current.
Data to be furnished by the Subcontractor
AIR HANDLING UNITS
Description
(Please furnish)
a) leaflet and
b) details noted below for all AHUs
c) Noise spectrum from at various. frequencies from 16 Hz to 8000 Hz
A General
1 Manufacturers name
2 Whether medium pressure unit?

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3 State nature of machinery used for manufacture
4 Whether motor is within the unit?
5 Model & size
6 Overall dimensions – mm x mm x mm
7 Overall weight (including cooling coil & fan
8 Is AHU suitable for outdoor installation? If so weather proof canopy

is considered (please refer where ever it is called)?
B Casing
1 Panels
2 Material of outer skin
3 Material of inner skin
4 Thickness of outer skin
5 Thickness of inner skin
6 Finish of outer skin
7 Finish of inner skin
8 Panel thickness
C Frame
1 Description
2 Material pf frame
3 Describe frame – panel joints
D Panel Insulation
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1 Material
2 K value – W/m. ºC
3 Density –Kg/cum
E Access Doors
1 List sections for which Access doors are included
2 Door material
3 Construction details
4 Type of hinges
5 Type of handle
F FAN AND FAN MOTOR:
1 Type of fan
2 Number of fan drums
3 Diameter of fan drum –mm
4 Length of fan drum –mm
5 Number of blades
6 Type of blades (i.e., whether forward curved or backward curved or

of aerofoil section)
7 Delivery –cmh
8 Total Static Pressure –mm wg (to be considered at dirty condition)?

Please give details for pressure drop for various sections like
a) Mixing Box
b) Pre filter Section

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c) Bag Filter Section
d) Moisture Eliminator
e) Cooling Coil
f) A/W Section
g) Fan Section
h) Plenum for SA
i) Dampers at inlet & outlet
j) Others
9 Maximum static pressure capability –mm wg
10 Speed – rpm
11 Critical speed – rpm
12 BKW
13 Motor selected
14 Type of motor
15 Motor speed – rpm
16 Type of starter
17 Fan noise level?
Please ensure that noise levels at various frequencies are attached

along with quote (starting from Hz to 8 K Hz)
18 Whether impellor and shaft dynamically (and statically) balanced?
19 Vibration level
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G FILTER SECTION
1 Overall dimensions – mm x mm x mm
2 Number of filters – Nos
3 Nominal dimensions of each filter –mm
4 Type of filter
5 Media used
6 Efficiency of filter (State the test method)
7 Manufacturer’s name
8 Resistance of filter when clean-mm wg
9 Maximum resistance of filter –mm wg
10 Dust Holding Capacity (Per & bag filter) – gms
11 Is the media cleanable?
12 Is 2 sets of spare filters considered in the quote apart from one set in
the AHU
13 Is one set of commissioning filters considered in the quote?
H VARIABLE FREQUENCY DRIVE
1 Is VFD with control panel considered in the quote?
2 Is necessary software & hardware required for BMS integration /

functioning possible to draw the information to BMS without any
additional hardware & software
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3 Harmonic suppression; filtration considered in the scope?
H COOLING COIL / DX COIL
1 Please specify the type of coils considered in the scope
2 Material of construction for coil /tubes
3 Material of construction for fins
4 Is special quoting specified in the Specs for fins considered in the

cope
5 Is moisture eliminator considered after coil section?
6 What is the material of construction for moisture eliminator
7 No of Rows
8 Bypass factor
I MIXING CHAMBER
1 Is mixing box considered in the Scope?
2 Is it with dampered outlets ? If yes is it considered for 2 return air
3 Is material of construction in terms of thickness & material same as

other panels.?
4 Is AHU is of thermal Break construction?
J SAFETY FEATURES
Please specify safety features considered in AHU?

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AIR HANDLING EQUIPMENT TEST REPORT
PROJECT___________________________SYSTEM / UNIT________________________
LOCATION_______________________________________________________________
UNIT DATA MOTOR DATA
Make/Model No. Make / Frame

Type/Size H.P / RPM
Serial Number Volts/Phase/cycles
Arr./Class F.L amps.
Discharge Pully Diam/Bore
Pully diam/Bore Pully /Distance.
No.
Belts/make/size
No.Filters/type.size
(Pre.)
No.Filters/type/size
(secondary)
TEST DATA DESIGN ACTUAL TEST DATA DESIGN ACTUAL
Total Cfm Discharge S.P
Total S.P
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Fan RPM Cooling Coil S.P
Motor Volts. T1 T2 T2 Filters S.P

T3
T3 T1
Outside air Cfm
Return air Cfm
REMARKS.
TEST DATE__________________________ READINGS BY _______________________

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COOLING / HEATING TEST REPORT (AHU)
PROJECT________________________________________________________________
COIL DATA COIL NO. COIL NO. COIL NO. COIL NO.
System Number
Location
Coil Type
No. Rows
Fins/In
Manufacturer
Model Number
Face Area, Sq.Ft.
TEST DATA DESIGN ACTUAL DESIGN ACTUAL DESIGN ACTUAL DESIGN ACTUAL
Air Qty. CFM
Air Vel.FPM
Press.Drop
In.
Out.Air
DB/WB
Ret. Air
DB/WB
Ent.Air
DB/WB
Lvg.Air
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DB/WB
Air AT
Water flow.
GPM
Press.Drop.P
SI
Ent.Water
Temp
Lvg .Water
Temp
Water AT
Exp.Valve/Re
frig
Refrig.Suctio
n Pr.
Refrig.Suct.T
emp
Inlet Steam
press.
REMARKS.
TEST DATE ___________________________READINGS BY ______________________
2. AIR WASHER
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Evaporative cooling systems provide effective air Temperature cooling to meet temperature
requirements. The units are designed in such a manner that it gives maximum efficiency,
consumes less energy & delivers the comfort air as per requirement. These units are available
in Single/ Double modular, Draw type comprising various sections such as Spray section, Filter
sections, Fan section, mist eliminator etc. Framework for each section shall be joined together
with soft neoprene gasket to make the joint airtight. The panel shall be 25 mm thick. These
panels shall be joined together in the frame work. In case of Double Skin, the Panels are puff
injected.
Imported Cellulose Pads having 200 mm thickness & 90% efficiency are used in the Evaporative
units. The velocity across the pads is considered as 500fpm. Stainless Steel distributors are
provided above the pads so that proper Spray of water is provided on the pads. GI/ Stainless
Steel Pipes are used for Headers.
Wet Section comprises of Stainless Steel Sump of 18G thickness complete with float connections
for Drain, quick fill up, Makeup & Overflow.
The Fans are imported forward/ backward curved DIDW type duly statically & dynamically
balanced along with TEFC sq. Cage induction motor & with drive arrangements. The fan &
motor shall be placed on common channel base with spring isolators/ cushy foot mounts to
eliminate the vibration.
All Fans & Motors are carefully selected so as to give maximum efficiency, low noise, consumes
less energy.
All Evaporative cooling units are complete with Eliminators to avoid the carryover of water
from the wet section to the fan sections.
Pre Filters with Aluminium Frame, HDPE media and washable type having efficiency of 90%
down to 10 microns are provided in cooling units.
3. FAN COIL UNITS – CHILLED WATER TYPE
3.1 SCOPE
of fan coil units conforming to these Specifications and in accordance with the
requirements of the Drawings and Schedule of Quantities.
3.2 TYPE
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The fan coil units shall be vertical type for floor mounting, horizontal type for ceiling-
suspended. Floor-mounted vertical units shall have vertical top discharge; and
horizontal units mounted within ceiling space shall have horizontal discharge and
shall be ductable. All units shall be complete with chilled water coil, one or more
centrifugal fans and motor, cleanable fabric filters, double-wall insulated
condensate drain pan.
3.3 CAPACITY
The air moving and coil capacities shall be as shown on Drawings and indicated in
3.4 CABINETS
Cabinets for floor mounted exposed FCU shall be constructed of 17 gauge die-formed
cold-rolled galvanized sheet steel, bonderized and painted with approved shade of
powder coating finish. The cabinets shall be of sufficient size to enclose all piping and
control valves, and shall have access doors to piping and controls. Access panels shall
have positive locking fasteners for easy removal. Horizontal furred-in type units
mounted within ceiling space shall be provided with GI casing of 18 Gauge, the coil
and fan section with provision to mount filters within the fan section.
3.5 INTERIOR CHASSIS
The interior chassis shall be constructed of not less than 16 gauge cold rolled
galvanized sheet steel bonderized and painted with approved shade of powder coating
finish. All ceiling suspended vertical fan coil units shall be securely mounted from the
building structure with top panel set dead level in both directions. In case of ceiling
suspended horizontal units fan deck and cooling coil shall be easily removable from
FCU without lowering down of the FCU or disturbing the other installation.
3.6 DRAIN PAN
Primary drain pan shall be prepressed 22 gauge SS-304, and an additional inner
bottom panel of 18 gauge SS-304 shall be provided to prevent damage to, and
floatation of the bottom panel insulation. The pan shall be insulated with not less than
6 mm thick nitrile rubber (class O as per BS 476) insulation shall be effective to prevent
condensation. The pan shall be of sufficient size to catch all drippage of condensation
from any part of the unit. In all cases pan shall be large enough to cover cooling coil
supply and return water headers and bends, control valves and ball valves with copper
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pipes. A secondary (auxiliary) condensate pan similar to primary drain pan may be
provided by the manufacturer of these units which are so identified in Schedule of
Quantities. All drain pans shall be with powder coating finish as per interior chassis
defined above.
3.7 COOLING COIL
All cooling coils shall be standard three-row staggered seamless copper tube with
aluminium sine wave fins. The coil shall be fitted with dielectric coupling for connection
with Chilled water pipes by HVAC Subcontractor. Tubes shall be minimum 7 mm OD and
wall thickness shall be minimum 0.41 mm. Fin spacing shall be 12 fins per inch. All
bends and joints shall be enclosed within insulated end sections of the base unit for
protection against sweating. Tubes shall be mechanically expanded for minimum
thermal contact resistance with fins. Air vent shall be provided in headers at a level
higher than coils. The cooling coil shall be easily removable from back side of FCU along
with fan section without disturbing the other Installations. All coils shall be factory
tested at 21 KG per sq. cm (300 psig) air pressure while submerged in water. The
copper tube shall be latest ASTM standards.
3.8 FANS
Fans shall be centrifugal forward curve DIDW, direct driven by a fractional horse
power shaded-pole motor.
3.9 MOTOR
Motor shall be TEFC squirrel gauge 220 ± 6% volts, 50 cycles single phase, energy
efficient, six pole, shaded pole type, speed not exceeding 700 rpm at maximum
airflow. Motors shall have three speed windings and shall be factory wired to a terminal
block mounted within the fan section. Motors shall have extended shaft on both sides.
Motor shall meet IEC/NEMA specifications.
INSTALLATION
Ceiling suspended horizontal units and units mounted within the ceiling space shall be
hung through rubber-in-shear vibration isolator suspenders.
ACCESSORIES
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All fan coil units shall be equipped with copper piping connections, dielectric union
and manual air vent at the cooling coil outlet header. In addition, the following
accessories may be required at fan coil units; their detailed Specifications are given
in individual sections and quantities separately identified in Schedule of Quantities.
a. Imported fan coil units as specified in Schedule of Quantities shall be factory

fitted with Ball valves at inlet and outlet. Ball valve with `Y’ strainer shall be
installed in the tapping of the chilled water pipe installed in riser/shaft or as
shown on Drawings and in Schedule of Quantities.
b. ALTERNATELY Ball valve with ‘Y’ strainer, and ball valve as shown on Drawings
and in Schedule of Quantities.
c. Adjustable discharge air grille as shown on Drawings and in Schedule of
Quantities.
PAINTING
Shop coats of paints that have become marred during shipment or erection shall be
cleaned off with mineral spirits, wire brushed and spot primed over the affected areas,
then coated with enamel paint to match the finish over the adjoining shop painted
surfaces.
PERFORMANCE DATA
Fan coil units shall be selected for the lowest operating noise level having standard
sound level rating of NC 30 at low speed and NC 35 at medium/high speed. Fan
performance rating and power consumption data, with operating points clearly
indicated, shall be submitted by the Subcontractor and verified at the time of testing
and commissioning of the installation.
TESTING
Cooling capacity of various fan coil unit models shall be computed from the
measurements of air flow and dry and wet bulb temperatures of air entering and
leaving the coil. Flow measurements shall be by anemometer and temperature
measurements by accurately calibrated mercury-in-glass thermometers. Computed
ratings shall conform to the specified capacities and quoted ratings. Power
current.
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FAN COIL TEST REPORT
PROJECT__________________________________________DATE_________________
LOCATION_______________________________________________________________
MANUFACTURER_________________________________________________________
TEMPERATURE DEG. F
AREA SERVED FCU MAKE CAPACITY TR
GRILLE ROOM
REMARKS.
TEST DATE _____________________ READINGS BY ___________________________
4. AIR COOLED PACKAGED AND SPLIT AIR CONDITIONING UNITS
4.1 SCOPE
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The scope of this section comprise the supply, erection, testing and commissioning of Air
Cooled Packaged and Split Units conforming to these specifications and in accordance
with the requirements of Drawings and Schedule of Quantities.
4.2 TYPE
The Split Units shall consist of hermetically sealed Scroll compressor, motor, air cooled
condenser, strip heaters (if required), integral refrigerant piping and wiring, all mounted
on a steel frame.
Indoor unit to be installed for Split Unit within building, shall be housed in insulated
cabinet consisting of cooling coil, blower with motor, filter & insulated drain pan.
The Air Cooled Packaged Unit shall consist of hermetically sealed Scroll compressor,
motor, strip heaters, integral refrigerant piping and control panel duly wired to
compressor and air cooled condenser all mounted on a steel frame. The Air cooled
condenser with fan duly mounted on a common frame shall be installed on the wall
openings with suitable angle iron / channel frame to be provided by Subcontractor. The
suitable starters, switches, power control cabling between Air Cooled Packaged Unit and
Air Cooled Condenser shall be included by the Subcontractor.
4.3 CAPACITY
The refrigeration capacity of Packaged Unit and Room Air Conditioners, split unit shall
be as shown on Drawings and in Schedule of Quantities.
4.4 COMPRESSOR AND MOTOR
Compressor shall be hermetic reciprocating / Scroll, serviceable type and shall have dual
pressure stat, and an operating oil charge. The motor shall be suction gas cooled and
shall be sealed against dirt and moisture. The motor shall be suitable for 415±10% /
volts or 230±10 % volts, 50 Hz, A.C. supply.
4.5 REFRIGERANT PIPING AND CONTROLS
Refrigerant piping and fittings interconnecting compressor condenser shall be all copper
and valves shall be brass / gunmetal construction. The copper pipe shall be as per latest
ASTM standards.
4.6 CASING
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The indoor & outdoor units shall be sectionalised / cabinet construction. Indoor units
shall be consisting of fan section, coil section, filter section, and drain pan. Outdoor unit
shall consist of condenser coil, fan & compressor. In case of package units, the
compressor shall be mounted within the indoor units and in case of split unit, the
compressor shall be mounted with the outdoor units. Each section shall be constructed
of thick sheet steel all welded / bolted construction, adequately reinforced with
structural members and provided with sufficient access panels for proper lubrication
and maintenance. Base panel shall be constructed of fabricated steel structure provided
with an under frame suitably braced. Each unit shall include one piece drain pan
constructed of 20 gauge galvanised sheet steel plate. Drain pan shall extend under coil
and fan sections with drain connections. Removable panels in fan and coil sections shall
provide access to all internal parts. Panels shall be internally lined with 2.5 cm thick
fibreglass as per section “Insulation” for the thermal insulation and acoustic lining.
4.7 FAN MOTOR AND DRIVE
Fan motor shall beTEFC squirrel gauge suitable for 415 ± 10% volts or 230±10% volts,
50 Hz, A.C.Supply, Single phase, motors shall be provided with permanent capacitor.
Motors shall be especially designed for quite operation and motor speed shall not exceed
1440 rpm. Motor shall meet IEC/NEMA specifications.
4.8 FAN
Fan wheels and housing shall be fabricated from heavy gauge steel. Fan wheels shall be
of double-width, double inlet forward-curve, multi-blade type enclosed in a housing and
mounted on a common shaft. Fan housing shall be made of die-formed steel sheets with
stream-lined inlets to ensure smooth air flow into the fans, fan shaft bearing shall be
oil/grease lubricated. All rotating parts shall be dynamically balanced individually, and
the complete assembly shall be statically and hydraulically balanced. Fan speed shall not
exceed 1000 rpm and maximum fan outlet velocity shall be 550 meters per minute.
4.9 COOLING COIL
Cooling coils shall be of fin and tube type having aluminium fins firmly bonded to copper
tubes assembled in zinc coated steel frame. Face and surface areas shall be such as to
ensure rated capacity from each unit and air velocity across each coil shall not exceed
100 meters per minute. The coil shall be pitched in the unit casing for proper drainage.
Each coil shall be factory-tested at 21 Kg. per sq.cm air pressure under water. Tube shall
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be mechanically / hydraulically expanded for minimum thermal contract resistance with

fins. The number of fins per cm. shall be 4 to 5.
4.10 VIBRATION ISOLATORS
The indoor and outdoor units shall be provided with ribbed rubber pad vibration
isolators.
PAINTING
Split units shall be factory finished with durable alkyd spray enamel. Shop coats of paint
that have become marred during shipment or erection shall be cleaned off with mineral
spirits, then coated with enamel paint to match the finish over the adjoining shop-
painted surface.
PERFORMANCE RATING
The unit shall be selected for the lowest operating noise level. Capacity rating and power
consumption with operating points clearly indicated shall be submitted with the tenders
and verified at the time of testing and commissioning of the installation.
4.04.
FAN COIL UNITS/HIWALL/CASSETTE
Capacity (TR)
a. Manufacturer
b. Model Type
c. Actual Capacity (TR) at
HI Speed.
MED Speed
LOW speed.
d. Actual Air Quantity (CFM) at

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HI Speed.
MED Speed
LOW speed.
e. Coil face area (ft2)
f. Unit size : L (mm)

W (mm)
H (mm)
g. Material/Gauge
i. Casing
ii. Blowers
iii. Drain pan with sandwitch insulation .
iv. Copper Tubes dia & wall thickness
v. Fins/inch
h. Rows of cooling coil, air side & water side

pressure drops
i. Type of filter
j. Motor make
k. Motor HP/RPM
l. Electrical characteristics. (230 ± 6% volts)

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m. Material of flexible connection
n. Type of vibration isolators

4.05. 5. PRECISION AIR CONDITIONING (PAC) UNITS –DX TYPE AIRCOOLED
A. AIRCOOLED DX TYPE
5.1 The room air-conditioning system shall be Floor discharge type (Down Flow) / Ductable
Top dischargedesigned specifically for high sensible heat ratio applications such as
Special Equipment labs.
Each unit shall be capable of providing sensible cooling capacities at rated ambient
temperatures with adequate airflow. Each unit shall be capable of providing
cooling capacity as mentioned in the schedule of quantities.
The system shall contain Scroll compressor, Evaporator, Humidifier, Condenser Thermostatic /
Electronic Expansion valve, all of which shall be contained within the cabinet of
the unit.
5.2 Cabinet Construction
The frame shall be constructed of Galva bond steel & shall be Single/double skin type. Frame
should be design in such a way that Noise level will be in the given range and panel are
fitted in such a way to service from the front would be easy for the service point.
5.3 Filtration
The filter chamber shall be an integral part of the system and withdraw able from front of the
unit. The filter should be of 5 micron filtration Capacity & efficiency level
should be above 90%.
5.4 Fans
The fan section shall be designed for an external static pressure of 25 Pa. The fans shall be
located downstream of the evaporator coil and be of the forward /backward curved
centrifugal type, double width, double inlet and statically and dynamically
balanced to G6.3DIN ISO 1940 part I. Each fan shall be separately driven by
a high efficiency electric motor. The assembly of the whole fan section has been
designed to facilitate all servicing requirement.
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5.5 Humidifier
Humidification shall be provided by boiling water in a high temperature

polypropylene steam generator. The steam shall be distributed evenly into the bypass
airstreams of the environment control system to ensure full integration of the water
vapor into the supply air without condensation. The humidifier shall have an
efficiency of not less the 1.3 kg/kw and be fitted with an auto flush
cycle activated on demand from the microprocessor control system. The
humidifier shall be fully serviceable with replacement electrodes. Wastewater
shall be flushed from the humidifier by the initiation of the water supply solenoid water
valve via a U-pipe overflow system. Drain solenoid valves will not be used.
5.6 Electrical Heating
The electric heating elements shall operate at a heat density level not exceeding
60 kW/m2 . The low watt density elements shall be of finned tubular steel
construction finished in high temperature paint. The heating circuit shall include dual
safety protection through loss of air and manual reset high temperature controls.
5.7 Scroll Compressor
The compressor shall be of the high efficiency complaint scroll design with an
E.E.R. (energy efficiency ratio) of not less than 3.25) at ARI rating conditions. The
compressor shall be charged with mineral oil and designed for operation on
R407c. Each compressor shall have internal motor protection and be mounted on
vibration isolators.
5.8 Refrigeration Circuit
The refrigeration system shall be of the Single circuit direct expansion type and
incorporate hermetic scroll compressors, complete with crankcase heaters.
Cooling steps shall be a maximum of 50% of total unit cooling capacity for
one and two compressor models. The system shall include a manual reset high
pressure control; auto reset low temperature switch, thermostatic / electronic
expansion valve, high sensitivity refrigerant sight glass, large capacity filter drier
and charging/access ports in each circuit. Each refrigeration circuit shall
include rigidly mounted isolation valves in the discharge and liquid lines to aid
servicing and installation (air cooled units only).
5.9 Evaporator Coil

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The evaporator coil shall be A-shape coil (for down flow) incorporating draw-through air
design for uniform air distribution. The coil shall be constructed of rifled
bore copper tubes and louvered aluminum fins, with the frame and drip tray fabricated
from heavy gauge aluminum. All metal parts in contacts with condensate shall be the
same material to prevent electrolytic corrosion. The drip trays shall ensure the
collection of condensate and be accessible for cleaning .
5.10 Dehumidification
Dehumidification function shall operate only when actually required, without reduction in the
airflow rate and ensure uniform air distribution & Avoids sudden variation in supply air
& room air temperature.
5.11 Remote Air Cooled Condenser
The air-cooled condenser shall be the low profile, weatherproof type incorporating high
efficiency, direct drive,external rotor motors with axial blade fans. The condenser shall
be constructed from heavy-duty aluminums and corrosion resistant components. Heavy
duty mounting legs and all assembly hardware shall be included. Condensers shall be
suitable for 24-hour operation and be capable of providing vertical or horizontal
discharge. The condenser shall be fully factory wired and require a 230-volt I phase 50
Hz electrical services.
5.12 Fan Speed Control Condenser
The condenser fans shall be directly driven by 4 pole 1210 rpm 230 volt 50 hz electric motors
with an IP54 enclosure rating and class F insulation. The motor shall be equipped with
permanently sealed ball bearing and high temperature grease. The motors shall be speed
controlled to ensure stable operating conditions from –50DegC to 45 DegC ambient by a
factory fitted, direct acting pressure actuated fan speed controller. The control system
shall be complete with input isolation switch, transducers and pressure switches.
The high performance heat exchanger shall include mechanically expanded crosshatched
copper tubes and louvered aluminum form maximum heat transfer. The coil shall be
finished in a high temperature modified epoxy coating (kirbykote) to offer increased
protection in aggressive environments. The coil shall be have maximum of 3 rows and
472 fins per meter and the face velocity shall not be more than 2.91 m/s.
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5.13. Unit Size
The unit shall require front access (600 mm) only for routine service and installation work.
5.14. Unit Controller
The unit controller shall be microprocessor based and include a large .LCD backlit graphic
display for clear visibility of text and graphics. The display and control buttons shall be
accessible from the unit front without removing any external panels. The controller shall
feature ISP (In-system-Programming) technology to support program upload via a PC.
Control strategies shall be P-I-D with dew point compensation for accurate temperature
and humidity control. A selection of return or supply air control shall be provided to suit
the application. The controller shall have a user-friendly menu driven interface with
supporting help screens and shall use multi-protocol data communications. Access to the
controller settings to prevent against unauthorized access. In normal operating mode
screen shall display unit number, temperature and relative humidity set points and
actuals, graphs, time, date and operating status. Dynamic icons identify the system-
operating mode. A 48-hour real time log of temperature and humidity data shall be
retained by the control system. All parameters and data shall be protected in memory by
an onboard battery. An EIA-232 communications interface shall provide the capability of
remote monitoring with the option of EIA-485 interface on 2 or 4 wire connection.
5.15. Control
The control system shall allow programming of the following con
• Temperature set point
• Humidity Set point
• High Temperature Alarm
• Low temperature Alarm
• High Humidity Alarm
• Low Humidity Alarm
The control system shall include the following settable features:
• Unit identification number.

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• Startup Delay, Cold start Delay and Fan Run on timers
• Sensor Calibration.
• Remote shutdown & general Alarm management
• Compressor Sequencing.
• Return temperature control.
• Choice of Modulating output types.
5.16. Alarms
The microprocessor shall activate an audible, visual and general any of the following
conditions:
• High Temperature
• Low Temperature
• High Humidity
• Low Humidity
• Loss of Air
• High Pressure
• Low Pressure
• Humidifier Low Water
• Water Under Floor
• Spare Alarm 1 and 2 (Customized text)
The unit shall also incorporate the following protections:
• Single phasing preventors.
• Reverse phasing
• Phase imbalancing
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• Phase failure
• Overload tripping (MPCB) of all components
TECHNICAL DATA FOR PRECISION AIR CONDITIONING – AIRCOOLED DX TYPE
INDOOR UNIT
Description Unit
Number of bay --
Number of circuit’s --
Casing material --
Skin --
TYPE OF UNIT:
Floor Unit FA/RA/DA
COMPRESSOR:
Make --
Type --
Model No. --
No of Compressor / unit nos.
Power supply V / Ph / Hz
Capacity Control Arrangement %
Method of Lubrication --
Grade of Lubrication Oil --
Starting & unloading
arrangement --
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Motor rpm rpm
Motor class of insulation --
Motor protection --
EVAPORATOR COIL:
Make --
Type --
No of Coil / unit --
Rows deep nos.
Face area m2
Fins per Inch nos.
Tube Material / Size / Thick -- / mm /

mm
Fin Material / Thick -- / mm
REFRIGERANT CONNECTIONS
Gas Connection (OD) mm
Liquid Connection (OD) mm
EVAPORATOR FAN:
Make --
Type of Fan --
Material Fan / Frame --
Type of Drive --
Fan diameter mm
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No of Fan / unit nos.
Motor rpm rpm
Motor protection --
Type of Bearing --
Bearing Lubrication --
EXPANSION VALVE:
Make -- Type --
Model No. --
No of Compressor / unit nos.
Capacity Control Arrangement %
Method of Lubrication --
Grade of Lubrication Oil --
Starting & unloading arrangement --
Motor rpm rpm
Motor protection --
EVAPORATOR COIL:
Make --
Type --
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No of Coil / unit --
Rows deep nos.
Face area m2
Fins per Inch nos.

mm
Fin Material / Thick -- / mm
REFRIGERANT CONNECTIONS
Gas Connection (OD) mm
Liquid Connection (OD) mm
EVAPORATOR FAN:
Make --
Type of Fan --
Material Fan / Frame --
Type of Drive --
Fan diameter mm
No of Fan / unit nos.
Motor rpm rpm
Motor protection --
Type of Bearing --
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Bearing Lubrication --
EXPANSION VALVE:
Make --

mm
Fin Material / Size / Thick -- / mm /

mm
CONDENSER FAN:
Make --
Type of Fan --
Fan Material --
Type of Drive --
No of Fan / Condenser nos.
Impeller Diameter mm
Motor Rated KW kW
Full Load Amps (FLA) amps.
Motor rpm rpm
Motor protection --
DIMENSION AND WEIGHT:
Casing Material --
Vertical Discharge
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Width mm
Depth mm
Height mm
Horizontal Discharge
Width mm
Depth mm
Height mm
Weight kg
4.06. 5.PRECISION AIR CONDITIONING (PAC) UNITS – CHILLED WATER TYPE
B. CHILLED WATER TYPE

Modular type construction Floor discharge type (Down Flow) / Ductable Top discharge type
PAC Units.
PAC units shall comprise pre filters, blow through direct driven Electronically communicated
Motors with Plug fans to deliver air quantity as indicated in the Design Parameters ( 4.0 ), 4/ 6
row chilled water fed cooling water coil, insulated condensate drain pan made of stainless steel
( SS304 ) construction, heater banks to maintain humidity inside the room, Microprocessor
control panel with power and control switchgears for fan motors, heaters, etc., with graphical
display ,programmable control & recording unit complete with intelligent alpha numeric
display, function keys, cursor keys, free programmable keys, multi color LEDS, inscription fields
with integrated battery backup supply at 24 V AC 50 Hz. The unit shall be suitable for operation
on 415 V 50 Hz AC supply. The Display panel shall display date, time, actual & set values,
operating conditions, signal faults, collective faults limiting values. Each unit shall comprise of
various sections as listed above & particular specifications capable of delivering Actual cooling
capacity as mentioned in this specification under scope of works or schedule of equipment. It is
preferable for microprocessor to have programming with RS 485 communication port &
communication with BACNET /IP protocol for hookup to BMS for monitoring of all parameters.
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The Cooling capacity shall meet ARI standards for units offered from USA and units offered
from Europe shall have Euro vent Certification.
The unit should be rated for continuous duty application.
The units should be fully assembled and tested at the factory as per design parameters and to
cooling capacities.
Factory Performance Test certificates should furnished for Owner approval prior to dispatch of
units from factory.
5.1 General
These specifications describe requirements for a precision environmental control system. The
system shall be designed to maintain temperature and relative humidity conditions comprising
critical equipment of the Building.
The manufacturer shall design and furnish all equipment to be fully compatible with heat
dissipation requirements of the Technical Assistance Centre Lab and Building Distributor Room
Provide packaged Chilled water Coil Precision Air Conditioning units, factory assembled, pre-
wired and pre-piped, each consisting of cabinet, fans, coils, filters, return air plenum and all
controls necessary for complete operation. Units offered must have VDE and CE / ISO 9000
conformity for electrical safety and quality norms.
5.2 Cabinet and Frame
The frame and panel shall be constructed of heavy gauge (1.2mm) Zinc- anneal corrosion
resistant sheet steel.
The front, rear and end panels shall be acoustically insulated internally with 25 mm thick Class ‘
O ’open cell elastomeric insulation material of 144 Kg/ cum density and insulating material
shall meet the requirements of FM global.
Cabinet shall be powder coated and have a textured finish.
Structural Frame of PAC units shall be of 14-gauge welded steel suitably braced for rigidity.
Welded tubular steel floor stand with adjustable legs and vibration isolation pads and shall
meet the requirements, Mechanical Sound And Vibration Control Codes.
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Doors and Access Panels: Heavy-gauge steel with polyurethane gaskets, hinges to allow
removal of panels, and concealed fastening devices.
Filtration: The Filter Section shall be an integral part of the system and withdrawable from the
front of the Unit. Filtration shall be provided by deep V form G 4 performance dry disposable
media to AS1324.
Factory fabricated and factory assembled Return Air plenum connecting the PAC unit upto
False ceiling should be supplied as an integral part of the PAC unit.
Pre fabricated panel for covering chilled water pipes being installed at the side of the PAC unit
with access panel to be provided along with PAC Units.
5.3 Fan and Motor:ELECTRONICALLY COMMUNICATED MOTORS.
Plug fan shall be supplied along with the unit and fans shall be statically and dynamically
balanced.
Plug Fans: Plug fans must be provided with direct drive each running with DC drive
electronically communicated motors.
The fan speed must be controlled based on the room return air temperatures and also must
have automatic speed control without manual intervention.
USE OF AUTOMATIC TRANSFORMER for speed control is not acceptable, also during
dehumidification mode the controller must give an output to the fans to operate at lower
speeds thus reducing the airflow and enhancing the latent cooling capacity of the units.
Units shall be factory balanced in accordance with Euro vent, Mechanical Sound And Vibration
Control.
(FAN CURVES SHOWING OPERATING PARAMETERS TO BE ATTACHED WITH QUOTE)

Noise Level of the PAC unit should not exceed 60dbA at 1.5 m from the machine in all
directions.
5.4 Chilled Water Coil
Seamless copper tubes expanded into aluminium fins with necessary 2 way Chilled water flow
control valve with actuator & related accessories. Copper pipe dia shall be 9.5 mm and
thickness not less than 0.4 mm and aluminium fins shall be not less than 0.16 mm thickness.
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Distance between fins shall not be less than 1.8 mm and the face velocity of the coils should not
exceed 2.0 m / sec. Coil pressure drop should not exceed 25 Kpa and the pressure drop across 2
way valves should not exceed 22 kpa and the total pressure drop shall not exceed 50 Kpa Coil
selection to be suitable for SHF > 0.95 and provided with hydrophilic coating to minimize /
eliminate water carrying in the airflow stream.
PAC units to be supplied with two way chilled water flow control valves with actuators.
PAC units should be supplied with Chilled water pipe flanges for connecting chilled water pipes
to the unit.
PAC unit supplier shall provide dielectric union for connecting dis – similar metals and the
union shall be made of Bronze and brazing of this joint shall be carried out by using silver
brazing rods with silver flux.
Cooling coils to be hydraulically pressure tested for 10 Kg/ cm2.
Cooling coils shall be designed for 14° F temperature differential ( ∆ T )
5.5 Filters
Filters shall be meet the requirements EU 4 ( G4 ) standards and the efficiency levels shall be
90% down to 10 microns.
Resistance of clean filters shall not exceed 7 mm and at clogged conditions shall not exceed 10
mm with dusting holding capacity as per EU 4 ( G 4) standards.
The filters shall be disposable pleated type filters.
Filters mounting frame should have access from the front
Pre commissioning filter to be provided and also a spare set of filters to be supplied along with
the units.
Filter – Dry media disposable Type I Class A 20% efficiency to AS1324
Filter clog pressure switch to be supplied as an integral part of the PAC unit.
5.6 HUMIDIFIER ( Optional )

Humidification shall be provided by boiling water in a polypropylene steam generator.
The steam shall be distributed uniformly into the by pass air stream of the precision air
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conditioning unit. The humidifier shall be capable of providing minimum 10 kg of steam

per hour. The humidifier shall have an efficiency of not less than 1.3 Kg/ per kW and be
fitted with auto flush cycle activated on demand from the unit’s control system. The
humidifier shall be fully serviceable with replaceable electrodes. Waste water shall be
flushed from the humidifier by initiation of water supply solenoid valve via a U pipe
system
5.7 ELECTRIC HEATERS
The electrical heating elements shall operate at a heat density level not exceeding 60
kW/m2. The low watt density elements shall be of finned tubular steel construction
finished with high temperature paint.
The heating circuit shall include dual safety protection through loss of air and manual
rest high temperature controls.
5.8 Electrical Panel
Control cabinet to be NEMA 250; Type 2 enclosure, UL Listed/ VDE Certified, with piano
hinged door, grounding lug, combination magnetic starters with over load relays, circuit
breakers and interlock, and control circuit transformer protected by MCB
Panel to include 230 V/ 24 V step-down transformer of requisite capacity to provide

control supply to the microprocessor. The Switch gear shall consist of MCCB / MPCB
with all protections and shall have terminals suitable for copper cable termination.
Unit to be earthed at two points and necessary termination provisions to be made in the
PAC unit being supplied.
5.9 Controls
The standard controls shall be of microprocessor based programmable PID logic
controller , that monitors, displays and operates the PAC cooling units, so that the
environment is held within desired specifications.. The controller shall have a LCD alpha
numeric display screen, which shall be visible from the front of the unit without
removing any covers/external panels.
The controls shall have separate indications for

Various modes of operation (cooling, heating, humidifying and de-humidifying),
Alarm conditions (temperature high, wet floor and loss of air flow, filter clog, high
humidity and fire alarm)
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In the event of wet floor alarm the unit should trip and alarm shall be displayed as wet
floor.
Healthy conditions of the above alarm conditions to be indicated in the display panel.
Graphical displays of set temperature & humidity and achieved temperature & humidity
of return air.
Date, time and unit identification display

Back up battery charge status display on the controller screen
Visual system alarm indication (along with mutable audio alarm as well)
48 hrs temperature and humidity graph display menu
Programmable services interval indication display
The system shall have a menu driven interface with supporting help screens and shall
use multi-protocol data communications. Access to the controller settings shall be
protected with passwords to prevent against unauthorized access.
The unit shall be capable of communicating through an RS-232/ RS-485 communication
support to link upto 99 units for monitoring and control purposes. The controller should
also incorporate 2 additional spare alarm inputs for customer interface (e.g.
Unauthorized entry alarm, building fire alarm etc) manual override switches &
selectable alarms. Local & remote alarms will be triggered in case of any alarm
conditions being reached. Unit should have auto restart facility to ensure automatic
starting of the PAC unit on the resumption of power supply.
Units to be supplied with third party interfacing communication card for control and
monitoring of PAC units through BMS and should be IP addressable.
Mapping points to be provided along with tender submittals.
The unit shall also incorporate the following protections:
Single phasing preventors.
Phase reversal
Phase imbalance
Overload tripping ( MPCB ) of all components

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One Moisture detection sensors to be provided along with PAC units.
TESTS
The following readings shall be taken (and results computed) during the performance tests of
the PAC units at site.
PRECISION AC UNITS ( CHILLED WATER TYPE )
1 COOLING COIL
1. Entering Water temperature - deg F
2 .Leaving water Temperature- deg F
3 .Pressure drop across cooling coil - psi
4. Chilled water flow rate - USGPM
5. Air Flow rate across filter - CFM
6. Entering Air temperature- deg F
( Dry bulb & Wet bulb )
7. Leaving Air temperature - deg F

( Dry bulb & Wet bulb )
8. Air temperature at first grille - deg F

9. Air temperature at last grille - deg F
10. Temperature rise - deg F
11. Supply air quantity - CFM
12. Supply air quantity at first grille- CFM
13. Supply air quantity at last grille- CFM

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14. Noise level inside the PAC unit room -

dbA
15. Noise level inside the conditioned space -

dbA
16. Speed of the fan- rpm
17. Current drawn by the fan
across all the three phase- Amps
18. Voltage across all the three
Phase- V
19. Heaters power consumption/bank- Kw
6. VARIABLE AIR VOLUME UNITS (VAV) :
6.1. Variable Air Volume (VAV) Units are of double skin construction, fabricated out of pre
coated sheet steel, mechanically sealed with gasketed & leak resistance construction.
Both supply & discharge shall be suitable for duct connections.
6.2. VAV Unit shall be ceiling suspended with hanger brackets & vibration isolators. VAV
Units shall be complete with following accessories:
a. Temperature Sensor:
Wall / Ceiling mounting type with stepless temperature setting, ON/OFF switch and digital LCD
display. Sample shall be approved by the Owner.
b. Microprocessor Controller:
Unit shall be suitable for transferring data & operating through master controller and
BAS System.
c. Damper Actuator
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d. 24 Volts Control Transformer
e. 25 mm thick Insulated double skin panel
f. Hanger Bracket
g. Disconnecting Switch
6.3. Pressure independent Sheet metal VAV Units with low leakage, damper, actuator,
microprocessor unit, wall mounted remote temperature sensors, set point adjustment,
ON/OFF switch, control transformer, unit hanger brackets, etc. The Microprocessor Unit shall
be suitable for transferring data through RS485 MODBUS/Bacnet over IP interface at the
integrator (which networks all VAV controllers). The vendor to map details and ID Setting in
the VAV and show the parameters of the VAV on the MODSCAN/ Bacstack/ Cimetrics
software before integrating to the IBMS. It shall also be possible to monitor and log the
following values from each VAV controller on the BMS. The set and actual temperature, air
flow, damper position and control etc.. The VAV controller shall be capable of providing
write function from BMS so that any control and over riding function on VAVs can be
performed by BMS. The VAV supplied shall include 2 Core Flexible Cord with
International 3-Pin Plug, make and model shall match the socket provided by the Electrical
Subcontractor.
6.4 Network controllers for the pressure independent sheet metal VAV units for networking
the VAV's to the respective AHUs. The price quoted shall include the required hardware
for the integrator / router and necessary cabling between the VAV controllers and the
routers / integrator for integrating with the BMS System.
The integrator / router will be located in the Ground Floor, BMS Room.
Cabling between VAV Controller and Router/ Integrator with 2/3 Core 1.5 sqmm
unarmoured FRLS ATC conductor multistranded twisted, overall PVC sheathed mylar taped
signal cable.
7. AUTOMATIC CONTROLS AND INSTRUMENTS

7.1 SCOPE
of automatic controls and instruments conforming to these Specifications and in
accordance with the requirements of Drawings and Schedule of Quantities.
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7.2 TYPE
All automatic controls shall be electric controls as described in the various sections
of these Specifications. All instruments shall be as described in the various sections of
these Specifications.
7.3 AUTOMATIC CONTROLS
Automatic controls required for various types of machines have been described in the
various sections of these specifications and shown on the Drawings. The individual
safety controls and selected automatic controls, may be installed within the machines by
the manufacturers before shipment. However, the following automatic controls, if not
already installed on the machines, may be installed at site by the Subcontractor, as
indicated in Schedule of Quantities.
a. Two way or Three-way modulating valve for each air handling units shall be
provided in chilled water line at each air handling unit as shown on the Drawings
and included in Schedule of Quantities. Each valve shall be actuated by a space
thermostat. Constant space condition shall be maintained by continuous
proportional modulation of the chilled water through the coil. The valve shall be
provided with spring return function so that it reverts to fully by pass position
when fan is shut off. Valves for 2.5 to 5 cm pipe sizes shall be similar to
Honeywell model V 5013A three-way mixing valve with two inlets and one
outlet.
For pipe sizes larger than 5 cm, valves shall be similar to Honeywell Model V
5013 B three way mixing valve with two inlets and one outlet.
Motor shall be similar to Honeywell model M 944 A proportional modutrol

motor. Motor shall be suitable for 24 volts supply and shall have a cover mounted
220/24 volts transformer factory-installed.
b. Two way or Three -way diverting Valve for each fan coil unit shall be provided in
chilled water lines at each fan coil unit as shown on Drawings and included in
Schedule of Quantities. The valve shall be actuated by space thermostat. Constant
space conditions shall be maintained by allowing all of chilled water to either
pass through the coil or bypass the coil and mix with the chilled water return.
The valve shall be provided with spring return function so that it reverts to fully
bypass position when fan is shut off.
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Valve shall be similar to Honeywell two position diverting valves 15 cm (1/2

inch) diameter with flare connection. Valve shall be selected for water flow rate
of 5-6 USGPM. Pressure drop across the valve shall not exceed 2 psi. Valve shall
have the facility to replace motor & actuator without removing the valve body.
c. Flow Switch shall be provided in condensing water outlet and chilled water outlet
at each water chilling machine, and at each water-cooled condensing unit for
refrigeration system in cold stores, as shown on Drawings and included in
Schedule of Quantities. Flow switch shall prevent the compressor from starting
unless the cooling water flow is established in condensing water lines, and chilled
water flow is established in chilled water lines.
d. Thermostat shall be electric, fixed differential cooling / heating type as specified

herein, with sensing element located in the return air stream. All thermostats
shall be supplied with the standard mounting boxes, as recommend by the
manufacturer. The profiles, mounting arrangement and exact location of
thermostats shall be approved at site. Requirement of thermostats shall be as
shown on Drawings and included in Schedule of Quantities.
i. Proportional control thermostats for air conditioning application for

actuating the two way or three way modulating valve at each air handling
unit, as shown on Drawings and included in Schedule of Quantities.
Thermostat shall be similar to Honeywell model T921B/T92A or
equivalent, line voltage cooling thermostat. Range shall be 56-84 degree F,
differential shall be 3 degree F.
ii. Proportionate type thermostat for air conditioning applications for

modulation of two way or three-way diverting valve at each fan coil unit
as shown on Drawings and included in Schedule of Quantities.
Thermostat shall be similar to Honeywell model T694A or T4039 cooling

thermostat, for range 56-84 degree F, differential 3 degree F, with OFF-HI-
MED-LO fan switch, temperature adjustment NORMAL-COOL setting.
Switching off must break fan circuit.
iii. Snap acting fixed differential heating thermostat for electric reheat
applications for putting on/off power supply to electric reheat coil in air
handling unit as shown on Drawings and included in Schedule of
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Quantities. Thermostat shall be similar to Honeywell; model T451A, two

stage thermostat.
iv. Safety thermostat for electric reheat application for cutting off power
supply to tubular heaters in case air flow across tubular heater is not
established. Thermostat shall be similar to Varma Trafag model MS 95R.
e. Humidistat may be provided with air handling unit for areas which require
constant indoor humidity or humidity control with reheat, as shown on Drawings
and included in Schedule of Quantities. One humidistat shall activate the reheat
coils in case the space humidity rises beyond the preset limit, another humidistat
shall energize the humidifier when the humidity falls below the preset limit.
These humidistats shall also de-energize these devices when the desired
humidity is reached.
Humidistat shall be snap acting or modulating type as per the requirement, 20-80
percent relative humidity range with differential of 5 percent. Humidistat shall
have removable knob to prevent tempering of set point.
f. Airstat and Safety thermostat may be provided as shown on Drawings and

included in Schedule of Quantities, within air handling units containing electric
heating or reheat coils to prevent heaters from energizing unless the air flow is
established.
7.4 INSTRUMENTS
Instruments required for different types of machines have been described in the various
sections of these Specifications and shown on the Drawings. Following instruments
may be provided as per the requirements indicated in the Schedule of Quantities.
a. Thermometers : shall be dial type 80 mm dia or V form industrial type. Body shall
be aluminium alloy, anodised gold-coloured surface. The casing shall be
adjustable side ways for reading from the front. The glass capillary shall be
triangular in shape with blue mercury filled in glass for better visibility. Scale of
reading shall be of the range 0°C to 60°C & +32°F to 150°F. Graduation of scale
shall be 1° in both readings. Range of scales shall be 30-120 degree F (0-50
degree C) for air conditioning applications of cooling only. Quality has been
included in Schedule of Quantities.
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Thermometer shall be suitable for 15 mm connections. Thermometer for chilled

water shall be with long stem, so that thermometer is removable without
damaging the insulation. M S socket to be welded on pipes shall be provided with
thermometer. Thermometers shall be installed on chilled water supply and
return at each air handling unit, supply and return at each chiller and
condenser as shown on the Drawings and included in Schedule of Quantities.
b. Pressure Gauges : shall be 80 mm dia & casing made out of SS 304 installed on
suction header and at discharge side of each pump, in the chilled water supply
and return at each air handling unit, at inlet and outlet of each chiller and
condenser, as shown on the Drawings and included in Schedule of Quantities.
Suction side gauge at pump suction header shall be compound gauge with 80
mm dia, range 75 cm vacuum to 8 kg (30 inch vacuum to 150 psi) pressure.
Discharge sides gauge at pumps and at all other locations shall be 80 mm range
0-8 kg per sq. cm (0-150 psi) pressure. Gauges shall be connected to the pipes
by 6 mm diameter Stainless Steel Syphon tube through a ball valve, required for
gauge protection.
c. Room Thermometer : shall be dial type, wall-hung temperature indicator, of

appropriate range for cold stores and deep freezers, in accordance with the
requirements of Drawings and Schedule of Quantities.
d. Room RH Indicator : shall be dial type, wall hung, relative humidity indicator
of appropriate range, for special areas, in accordance with the requirements of
Drawings and Schedule of Quantities.
e. Electronic Thermometer : shall be electronically operated Digital

Temperature Indicator in accordance with requirement of Drawings and as
included in Schedule of Quantities. The display shall be 3-5 digit Liquid Crystal
Display. The thermometer shall consist of fully solid state integrated circuit.
The thermometer shall have front LED òn’ indication and automatic low
battery indication. The resolution shall be 1° centigrade. Thermometer shall
be complete with suitable electronic sensor to accurately sense the
temperature with sensor housed in suitable airwell / thermowell for air
temperature / water temperature measurement. The thermometer shall be
suitable for operation on 9V DC / 230V AC. The display unit shall be housed in
attractive sheet metal cabinet with prominent display of conversion charts of °F
& °C on front plate. Thermometer shall be complete with separable socket type
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interconnecting cables of 2 m length suitable for installation within a radius of 2

m of the thermowell or air sensing point.
Electronic thermometer may be installed at chilled water supply and return at

selected air handling units as shown on Drawings and included in Schedule of
Quantities. Range of scale shall be 30 degree F - 120 degree F (0-50 degree C)
for air conditioning application.
7.5 CALIBRATION AND TESTING
All automatic controls and instruments shall be factory calibrated and provided with
necessary instructions for site calibration and testing. Various items of the same type
shall be completely interchangeable and their accuracy shall be guaranteed by the
manufacturer. All automatic controls and instruments shall be tested at site for
accuracy and reliability before commissioning the installation.
SECTION-05
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VARIABLE REFRIGERANT VOLUME SYSTEM (VRV)
5. VARIABLE REFRIGERANT VOLUME SYSTEM
5.1 SCOPE
The scope of this section comprises the supply, erection testing and commissioning of
Variable Refrigerant Volume System conforming to these specifications and in
accordance with the requirements of Drawing and Schedule of Quantities
5.2 TYPE
Units shall be air cooled, variable refrigerant volume air conditioner consisting of one
outdoor unit and multiple indoor units, each indoor unit having capability to cool
independently for the requirement of the rooms.
It shall be possible to connect multiple indoor units on one refrigerant circuit. The
indoor units on any circuit can be of different type and also controlled individually.
Following type of indoor units shall be connected to the system:
 Ceiling mounted cassette type (Double flow)

 Ceiling mounted cassette type (Round flow )
 Slim Ceiling mounted duct type
 Ceiling mounted built-in type
 Ceiling mounted duct type
 Ceiling suspended type
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 Wall mounted type

 Floor standing type
 Concealed floor standing type
 Ceiling mounted cassette corner type
Compressor installed in outdoor unit shall be equipped with at least one inverter
compressor up to 18HP, two inverter compressors up to 36 HP and above this, three
inverter compressors. The system shall be capable of changing the rotating speed of
inverter compressor by inverter controller in proportion to variations in cooling load.
Outdoor unit shall be suitable for mix match connection of all type of indoor units.
The refrigerant piping between indoor units and outdoor unit shall be extended up to
165m with maximum 50m level difference without any oil traps.
Both indoor units and outdoor unit shall be factory assembled, tested and outdoor units
filled with first charge of refrigerant before delivering at site.
5.3 OUTDOOR UNIT
The outdoor unit shall be factory assembled, weather proof casing, constructed from
heavy gauge mild steel panels and coated with baked enamel finish. The unit should be
completely factory wired tested with all necessary controls and switch gears:
 All outdoor units above 8HP shall have minimum two scroll compressors and be able
to operate even in case one of compressor is out of order.
 In case of outdoor units above 18HP (MULTI MODULAR), the outdoor unit shall have
at least 2 inverter compressor so that the operation is not disrupted with failure of
any compressor.
 It should also be provided with duty cycling for automatically switching starting
sequence of multiple outdoor units/compressors.
 The noise level shall not be more than 60-65 dB (A) at normal operation measured
horizontally 1m away and 1.5m above ground level.
 The outdoor unit shall be modular in design and should be allowed for side by side
installation
 The unit shall be provided with its own microprocessor control panel.
The outdoor unit should be fitted with low noise, aero spiral design fan with large
airflow and should be designed to operate compressor-linking technology. The outdoor
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unit fan should also be capable to deliver 70 Pa or external static pressure to meet long
exhaust duct connection requirement.
The condensing unit shall be designed to operate safely when connected to multiple fan
coil units, which have a combined operating nominal capacity up to 130 % of indoor
units.
5.4 COMPRESSOR
The compressor shall be highly efficient scroll type operating on R410a environmental
friendly refrigerant and capable of control with single inverter & other constant speed
type compressor(s). It shall change the speed in accordance to the variation in cooling
load requirement:
 The inverter shall be IGBT type for efficient and quiet operation.
 All outdoor units shall be designed for automatic capacity control to meet load
fluctuation and indoor unit individual control. All parts of compressor shall be
sufficiently lubricated stock. Forced lubrication may also be employed.
 Oil heater shall be provided in the compressor casing.
*: IGBT represents Insulated Gate Bipolar Transistor.
5.5 HEAT EXCHANGER

The e-Pass heat exchanger shall be constructed with copper tubes mechanically bonded
to aluminum fins to form a cross fin coil.
 The aluminum fins shall be provided with special coating.

 The unit shall be provided with necessary number of direct driven low noise level
propeller type Aero spiral fans with DC motor arranged for vertical discharge. Each
fan shall have a Aero fitting grille resulting in reduced pressure loss.
5.6 REFRIGERANT CIRCUIT

The refrigerant circuit shall include liquid & gas shut-off valves and a solenoid valves at
condenser end.
All necessary safety devices shall be provided to ensure the safely operation of the
system.
The new SCe-bridge Circuit (sub-cool) feature prevents the flash gas from long piping
and reducing the refrigerant volume required and there by reduction in piping size.
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5.7 SAFETY DEVICES

All necessary safety devices shall be provided to ensure safe operation of the system.
Following safety devices shall be part of outdoor unit; high pressure switch, fuse,
crankcase heater, fusible plug, over load relay, protection for inverter, and short
recycling guard timer.
5.8 OIL RECOVERY SYSTEM

Unit shall be equipped with an oil recovery system to ensure stable operation with long
refrigeration piping lengths.
5.9 ENVIRONMENTALLY AWARE

R410A is a new mixed refrigerant that exhibits superior safety characteristics .Even with
zero coefficient of ozone layer depletion; R410A offers a better performance to the
conventional R22.
Further lead free PC Boards making its use even more environmentally conscious.
Galbarium a material that requires no coating is used for the bottom plate for easy
recycling.
5.10 - INDOOR UNIT

This section deals with supply, installation, testing, commissioning of various type of indoor
units confirming to general specification and suitable for the duty selected. The type,
capacity and size of indoor units shall be as specified in detailed Bill of Quantities
GENERAL
Indoor units shall be either ceiling mounted cassette type, or ceiling mounted ductable type
or floor standing type or wall mounted type or other as specified in BOQ. These units shall
have electronic control valve to control refrigerant flow rate respond to lead variations of
the room.
a) The address of the indoor unit shall be set automatically in case of individual and
group control
b) In case of centralized control, it shall be set by liquid crystal remote controller
The fan shall be dual suction, aerodynamically designed turbo, multi blade type, statically &
dynamically balanced to ensure low noise and vibration free operation of the system. The
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fan shall be direct driven type, mounted directly on motor shaft having supported from
housing.
The cooling coil shall be made out of seamless copper tubes and have continuous aluminum
fins. The fins shall be spaced by collars forming an integral part. The tubes shall be
staggered in the direction of airflow. The tubes shall be hydraulically/ mechanically
expanded for minimum thermal contact resistance with fins. Each coil shall be factory tested
at 21kg/sqm air pressure under water.
Unit shall have cleanable type filter fixed to an integrally molded plastic frame. The filter
shall be slide away type and neatly inserted.
Each indoor unit shall have computerized PID control for maintaining design room
temperature. Each unit shall be provided with electronic expansion valve & should have
microprocessor thermostat for cooling.
Each unit shall be with wired LCD type remote controller. The remote controller shall
memorize the latest malfunction code for easy maintenance. The controller shall have self-
diagnostic features for easy and quick maintenance and service. The controller shall be able
to change fan speed and angle of swing flat individually as per requirement
5.11 CEILING MOUNTED CASSETTE TYPE UNIT (ROUND FLOW TYPE)
The unit shall be ceiling mounted type. The unit shall include pre-filter, fan section and
DX-coil section. The housing of the unit shall be powder coated Galvanized steel. The
body shall be light in weight and shall be able to suspend from four corners.
Unit shall have an external attractive panel for supply and return air. Unit shall
have four way supply air grilles on sides and return air grille in center. Each unit shall
have high lift drain pump, fresh air intake provision (if specified) Low gas detection
system and very low operating sound.
All the indoor units regardless of their difference in capacity should have same
decorative panel size for harmonious aesthetic point of view. It should have provision
of connecting branch ducts.
5.12 CEILING MOUNTED DUCTABLE TYPE UNIT

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Unit shall be suitable for ceiling mounted type. The unit shall include pre filter, fan
section & DX coil section .The housing of unit shall be light weight powder coated
galvanized steel. The unit shall have high static fan for Ductable arrangement.
5.13 CEILING SUSPENDED TYPE
Unit shall be suitable for ceiling suspended arrangement below false ceiling. The unit
include pre filter , fan section & DX coil section . The housing of unit shall be light weight
powder coated galvanized steel.
5.14 HIGH WALL MOUNTED UNITS
The units shall be wall-mounted type. The unit includes pre filter, fan section & DX coil
section. The housing of unit shall be light weight powder coated galvanized steel.
Unit shall have an attractive external casing with sophisticated design and compact
casing harmonized in any interior décor.
5.15 CEILING MOUNTED BUILT-IN TYPE
Unit shall be suitable for Highly flexible for various arrangement with complete line-up
of optional kits to satisfy various needs such as design concept ,interior decoration and
so on . The unit includes pre filter, fan section & DX coil section. The housing of unit shall
be light weight powder coated galvanized steel.
Each unit shall have optional high lift drain pump.
5.16 CENTRALIZED TYPE REMOTE (TOUCH SCREEN TYPE) CONTROLLER (Optional)
A multifunctional compact centralized controller shall be provided with the system.
The Graphic Controller must act as an advanced air-conditioning management system to

give complete control of VRV air-conditioning Equipment, It should have ease of use for
the user through its touch screen, icon display and color LCD display.
It shall be able to control up to 64 groups of indoor units with the following functions:-
a) Starting/stopping of Airconditioners as a zone or group or individual unit.

b) Temperature settling for each indoor unit or zone.
c) Switching between temperature control modes, switching of fan speed and
direction of airflow, enabling/disabling of individual remote controller operation.
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d) Monitoring of operation status such as operation mode & temperature setting of

individual indoor units, maintenance information and troubleshooting
information.
e) Display of air conditioner operation history.
f) Daily management automation through yearly schedule function with possibility
of various schedules.
The controller shall have wide screen user friendly color LCD display and can be wired
by a non polar 2 wire transmission cable to a distance of 1 km. away from indoor unit.
5.17 UNIFIED ON/OFF CONTROLLER
Unified ON/OFF controller shall be supplied as optional accessory.

The controller shall be able to control minimum 15 groups ( each group containing
maximum 16 indoor units) or 128 nos. of indoor units with the following
functions:
a) On/Off as a zone or individual unit.
b) Indication of operation condition of each group.
c) Select one of 4 operation modes.
5.18 SCHEDULE TIMER
A schedule timer shall be supplied as an optional accessory.
a) The timer shall be able to set operation schedule for all indoor units.
b) The timer shall be able to set 8 pattern of schedule combined with centralized
controller.
5.19 REFRIGERANT PIPING
All refrigerant piping for the air conditioning system shall be constructed from soft
seamless up to 19.1mm and hard drawn copper refrigerant pipes for above 19.1mm
with copper fittings and silver-soldered joints. The refrigerant piping arrangements shall
be in accordance with good practice within the air conditioning industry, and are to
include charging connections, suction line insulation and all other items normally
forming part of proper refrigerant circuits.
All joints in copper piping shall be sweat joints using low temperature brazing and or
silver solder. Before joining any copper pipe or fittings, its interiors shall be thoroughly
cleaned by passing a clean cloth via wire or cable through its entire length. The piping
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shall be continuously kept clean of dirt etc. while constructing the joints through
nitrogen bleeding at 1.0kg/sqcm and subsequently, it shall be thoroughly blown
out using nitrogen.
After the refrigerant piping installation has been completed, the refrigerant piping
system shall be pressure tested using nitrogen at pressure of 30Kg per sq. cm. Pressure
shall be maintained in the system for 24 hours. The system shall then be evacuated to
minimum vacuum if 700mm hg.
The air-conditioning system supplier shall be design s izes and erect proper
interconnections of the complete refrigerant circuit.
The thickness of copper piping shall not be less than 20gauge for pipes up to
19.1mm and 18gauge for bigger sizes
The suction line pipe size and the liquid line pipe size shall be selected according to the
manufacturers specified outside diameter. All refrigerant pipes shall be properly
supported and anchored to the building structure using steel hangers, anchors, brackets
and supports which shall be fixed to the building structure by means of inserts or
expansion shields of adequate size and number to support the load imposed
thereon.
To protect Nitrile rubber insulation of exposed copper piping from degrading due
ultra violet rays & atmospheric condition, it shall be covered with M.S Type / G.I.
Type protection tray.
5.20 PIPE INSULATION
a. Refrigerant Pipe Insulation
The whole of the liquid and suction refrigerant lines including all fittings, valves
and strainer bodies, etc. shall be insulated with 19mm /13 mm thick elastomeric
Nitrile rubber as specified in BOQ.
b. PVC Drain Pipe Insulation
Drain pipes carrying condensate water shall be insulated with 6 mm thick

elastomeric Nitrile rubber insulation.
For proper drainage of condensate, U Trap shall be provided in the drain piping (wherever
required). All pipe supports shall be of pre fabricated & pre painted slotted angle supports
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Data Sheet- For Ducting
CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER

INSTALLATION
Needs Not
Description Remarks
No O.K Attention Applicable
Duct Work clean ?

1.
Smoke test Report.
2.
Fire Dampers open ?
3.
Access doors closed ?
4.
Lined ducts ?
5.
Flexible duct connected, ok
6.
System balanced
7.
Short circuiting or other
8. a Air Distribution problems ?
b Note locations.
9. VCD provided as per spec.
VCD all open and adjusted ?

10.
Supply / Return / Exhaust
11. outlets / Inlets balanced ?
Noticeable flow of Air

12.
Air balance report details
13.
VAV Box
a. Minimum stops - %
14.
b. Maximum opening - %
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Controls working ?
15.
Thermostats
16.
Type
a.
Properly located
b.
Working
c.
Set point - °C
d.
Space temperature - °C
e.
Duct insulation checked
17.
Supports and hangers
18. checked including spacing
Turning vanes provided in

19. elbows.
Test witnessed and

20. certified
DETAILS TO BE FURNISHED BY TENDERER ALONG WITH OFFER

CASSETTE UNITS / HIWALL UNIT / VRV DUCTABLE UNITS
(To be filled up and submitted for all models and sizes.)
Sl. No. Description Tenderer To Furnish
1. CONDENSER (OUTDOOR UNIT)
1.1 Model No.
1.2 Power Supply
1.3 Cooling Capacity (Kw) at Normal Condition
1.4 Cooling Capacity (Kw) at Design Conditions

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1.5 Capacity Control
1.6 Compressor Type / Motor Output (Kw)
1.7 Overall Dimension (HxWxD) mm
1.8 Machine weight (kg)
1.9 Refrigerant
1.10 Refrigerant Charge (Kg)
1.11 Piping Connection Liquid, Gas (mm)
1.12 Air entering coil temperature (TE – DB deg.C)
1.12 Air entering coil temperature (TE – WB deg.C)
2. INDOOR UNIT
2.1 Type of Unit
2.2 Model Nos.
2.3 Power Supply
2.4 Cooling Capacity (Kw) at Normal Condition
2.6 Air Flow (L/s)
Noise level of the package unit at dBA) at 1.5 m

2.7
distance
2.8. Overall Dimension (HxWxD) mm
2.10 Piping Connection Liquid, Gas (mm)

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Date:-
Place:- Authorised Signatory of the Tenderer
With Seal
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CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER

INSTALLATION
Date:
Sl. No. Description Tenderer To Furnish
1. CONDENSER (OUTDOOR UNIT)
1.1 Model No.
1.2 Power Supply
1.5 Capacity Control
1.6 Compressor Type / Motor Output (Kw)
1.9 Refrigerant
1.12 Air entering coil temperature (TE – DB deg.C)
1.12 Air entering coil temperature (TE – WB deg.C)
2. INDOOR UNIT
2.1 Type of Unit
2.2 Model Nos.
2.3 Power Supply
2.6 Air Flow (L/s)
Noise level of the package unit at dBA) at 1.5 m

2.7
distance
Date:-
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Place:- Authorised Signatory of the site in charge
With Seal
DETAILS TO BE FURNISHED BY TENDERER ALONG WITH OFFER
OUTDOOR UNITS
(To be filled up and submitted for all models and sizes.)
1.0 Unit Detail
Rated Capacity at specified Outdoor & Indoor

1.1
condition
Minimum Cooling capacity – TR at design

1.2
conditions
Total Power Consumption at 100% rated

1.3
condition
1.4 COP at above condition
1.5 Physical size (LxBxH)
1.6 Operating weight – Kgs
1.7 Noise Level at Full Load condition
1.8 Type of Refrigerant
1.9 Refrigerant connection size: In / Out (mm)
1.10 Data Communication Included
1.11 Local Isolating Switch Included
2.0 Compressor Details
2.1 Type of compressor

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2.2 Nos. of Compressors
2.3 Nos. of Inverter Driven Compressors
2.4 Compressor Max speed (rpm)
2.5 Compressor suction pressure and temperature
Compressor discharge pressure and

2.6
temperature
2.7 Type of starter
2.8 Motor Voltage
2.9 Type of capacity control
3.0 CONDENSER
3.1 Coil Face area – Sq.mt / Sq.ft.
3.2 Temperature of air at Inlet DB °C / °F
3.3 Temperature of air at outlet DB °C / °F
3.4 Fan Type (Variable Speed)
3.5 Fan Input Power -kw

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SECTION-06
VENTILATION FANS
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6. VENTILATION FANS
SCOPE
of centrifugal, in-line and propeller type fans and roof mounted units conforming to
these Specifications and in accordance with the requirement of Drawings and Schedule
of Quantities.
TYPE
Centrifugal, in-line propeller fans and roof mounted units shall be of the type as
indicated on Drawings and identified in Schedule of Quantities.
CAPACITY
The air-moving capacity of fans shall be as shown on Drawings and in Schedule of

Quantities.
6.1 CENTRIFUGAL FAN
Centrifugal fan shall be DWDI / SWSI Class I construction arrangement 3 (i.e. bearings
on both the sides) for DWDI fans complete with access door, squirrel-cage induction
motor, V-belt drive, belt guard and vibration isolators, direction of discharge /
rotation, and motor position shall be as per the Approved-for-Construction shop
drawings.
a. Housing shall be constructed of 14 gauge sheet steel welded construction. It

shall be rigidly reinforced and supported by structural angles. Split casing shall
be provided on larger sizes of fans, however neoprene / asbestos packing
should be provided throughout split joints to make it air-tight.
18 gauge galvanized wire mesh inlet guards of 5 cm sieves shall be provided on

both inlets. Housing shall be provided with standard cleanout door with handles
and neoprene gasket. Rotation arrow shall be clearly marked on the housing.
b. Fan Wheel shall be backward-curved non-over loading type. Fan wheel and
housing shall be statically and dynamically balanced. For fans upto 450 mm dia,
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fan outlet velocity shall not exceed 550 meter/minute and maximum fan speed
shall not exceed 1450 rpm. For fans above 450 mm dia, the outlet velocity shall
be within 700 meter/minute and maximum fan speed shall not exceed 800 RPM.
High static pressure fan speed shall be as per manufacturer.
c. Shaft shall be constructed of steel, turned, ground and polished.
d. Bearings : shall be of the sleeve / ball-bearing type mounted directly on the fan
housing. Bearings shall be designed especially for quiet operation and shall be
of the self-aligning, oil / grease pack pillow block type.
e. Motor : Fan motor shall be energy efficient and suitable for 415±8% volts, 50
cycles, 3 phase AC power supply, squirrel-cage, totally enclosed, fan-cooled
motor, provided with class F insulation, and of approved make. Motor name
plate horsepower shall exceed brake horsepower by a minimum of 8%. Motor
shall be designed specially for quiet operation and motor speed shall not
exceed 1440 rpm. The fan and motor combination selected for the particular
required performance shall be of the most efficient (smallest horse power), so
that sound level is lowest. The motor shall meet IEC/NEMA specification.
f. Drive to fan shall be provided through belt with adjustable motor sheave and
a standard belt guard. Belts shall be of the oil-resistant type.
g. Vibration Isolation : MS base shall be provided for both fan and motor, built as
an integral part, and shall be mounted on a concrete foundation through
resistoflex vibration isolators. The concrete foundation shall be atleast 15 cm
above the finished floor level, or as shown in approved-for-construction shop
drawings.
6.2 AXIAL FLOW FAN
Fan shall be complete with motor, motor mount, belt driven (or direct driven) and
vibration isolation type, suspension arrangement as per approved for construction shop
drawings.
a. Casing : shall be constructed of heavy gauge sheet steel. Fan casing, motor
mount and straightening vane shall be of welded steel construction. Motor
mounting plate shall be minimum 15 mm thick and machined to receive motor
flange.
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An inspection door with handle and neoprene gasket shall be provided. Casing
shall have flanged connection on both ends for ducted applications. Support
brackets for ceiling suspension shall be welded to the casing for connection to
hanger bolts. Straightening vanes shall be aerodynamically designed for
maximum efficiency by converting velocity pressure to static pressure
potential and minimizing turbulence. Casing shall be bonderized, primed and
finish coated with enamel paint.
b. Rotor : hub and blades shall be cast aluminium or cast steel construction.
Blades shall be die-formed aerofoil shaped for maximum efficiency and shall vary
in twist and width from hub to tip to effect equal air distribution along the
blade length. Fan blades mounting on the hub shall be statically and
dynamically balanced. Extended grease leads for external lubrication shall be
provided. The fan pitch control may be manually readjusted at site upon
installation, for obtaining actual air flow values, as specified and quoted.
c. Motor: shall be energy efficient squirrel-cage, totally-enclosed, fan cooled,

standard frame, constant speed, continuous duty, single winding, suitable for
415±8% volts, 50 cycles, 3 phase AC power supply, provided with class `F’
insulation. Motor shall be specially designed for quiet operation. The speed of
the fans shall not exceed 800 RPM for fans with impeller diameter above 450
mm, and 1440 RPM for fans with impeller diameter 450 mm and less. For
lowest sound level, fan shall be selected for maximum efficiency or
minimum horsepower. Motor conduit box shall be mounted on exterior of fan
casing, and lead wires from the motor to the conduit box shall be protected from
the air stream by enclosing in a flexible metal conduit. The motor shall meet
IEC/NEMA specification.
d. Drive : to fan shall be provided through belt drive with adjustable motor sheave
and standard sheet steel belt guard with vented front for heat dissipation. Belts
shall be of oil-resistant type.
e. Vibration Isolation : The assembly of fan and motor shall be suspended from the
slab by vibration isolation suspension of rubber-in-shear type.
f. Accessories : The following accessories shall be provided with all fans :
i. Outlet cone for static pressure regain.

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ii. Inlet cone.
Fan silencers may be provided where specifically called for in Schedule of

Quantities. Fans shall be factory assembled and shipped with all accessories
factory-mounted.
6.3 PROPELLER FAN
Propeller fan shall be direct-driven, three or four blade type, mounted on a steel
mounting plate with orifice ring.
a. Mounting Plate shall be of steel construction, square with streamlined venturi

inlet (reversed for supply applications) coated with baked enamel paint.
Mounting plate shall be of standard size, constructed of 9 to 16 gauge sheet steel
depending upon the fan size. Orifice ring shall be correctly formed by spinning
or stamping to provide easy passage of air without turbulence and to direct the
air stream.
b. Fan Blades shall be constructed of aluminium or steel. Fan hub shall be of heavy
welded steel construction with blades bolted to the hub. Fan blades and hub
assembly shall be statically and dynamically balanced at the manufacturer’s
works.
c. Shaft shall be of steel, accurately ground and shall be of ample size for the load
transmitted and shall not pass through first critical speed thru the full range of
specified fan speeds.
d. Motor shall be standard (easily replaceable) permanent split capacitor or

shaded pole for small sizes, totally enclosed with prelubricated sleeve or ball
bearings, designed for quiet operation with a maximum speed of 800 rpm for fans
60 cm dia or larger and 1440 rpm for fans 45 cm dia and smaller. Motors for
larger fans shall be suitable for 415±6% volts, 50 cycles 3 phase power
supply, and for smaller fans shall be suitable for 220 ± 6% volts, 50 cycles single
phase power supply. Motors shall be suitable for either horizontal or vertical
service as indicated on Drawings and in Schedule of Quantities. The motor
shall meet IEC/NEMA specification.
e. Accessories : The following accessories shall be provided with propeller fans :
i. Wire guard on inlet side and birdscreen at the outlet.

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ii. Fixed or gravity louvers built into a steel frame at the outlet.
iii. Regulator for controlling fan speed for single phase fan motor.
iv. Single phase preventors for 3 phase fans.
6.4 ROOF MOUNTED FAN
Roof mounted fan shall be propeller type or centrifugal fans, direct driven or belt driven
as shown on drawing and in Schedule of Quantities complete with motor drive, and
housing with weather-proof cowl.
a. Housing:
Shall be constructed of 16 gauge steel sheet. The housing shall have an adjustable
flange to facilitate installation and shall be especially adapted to receive fan,
motor and drive. The housing shall have a low silhouette. For belt driven units,
motor shall be installed in ventilated water proof housing outside the air stream.
The discharge cowl shall be hinged along one edge for easy access to motor and
drive, for inspection and maintenance. The entire assembly shall be
weatherproof and raised from the roof terrace sufficiently to prevent
downflow of rain water accumulated on the terrace. 18 gauge
galvanized steel mesh birdscreen shall be provided on all discharge cowls
around the outlet area.
b. Fans :
Shall be backwardly inclined centrifugal wheel or propeller type as required,

designed for maximum efficiency, minimum turbulence and quiet operation.
Fan shall be statically and dynamically balanced.
c. Motor :
Shall be shaded pole, of split capacitor type with lubricated sleeve or ball
bearings, designed for quiet operation. Bearings shall be designed for vertical
mounting. Motor name-plate horse-power shall be such that the motor shall
not be overloaded in the entire range of rated speed. Motor and fan assembly
shall be easily removable. Motor power supply characteristic and maximum
speed shall be as specified for propeller fans and as indicated in the Schedule of
Quantities. The motor shall meet IEC/NEMA specification.
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d. Fan Bearings :
Shall be heavy duty, self aligning sleeve/ball bearings designed for thrust load
and sealed for grease retention.
e. Backdraft Damper :
Where called for in the Schedule of Quantities, roof-mounted fan shall be

equipped with a rattle-free backdraft damper to prevent air from re-entering
the fan when fan is not in operation, thus sealing completely in closed position.
Damper shall be chatterproof under all conditions.
f. Vibration Isolation :
The motor and fan assembly shall be isolated from the base with vibration
isolators.
PERFORMANCE DATA
All fans shall be selected for the lowest operating noise level. Capacity ratings, power
consumption, with operating points clearly indicated, shall be submitted and verified
at the time of testing and commissioning of the installation.
TESTING
Capacity of all fans shall be measured by an anemometer. Measured air flow

capacities shall conform to the specified capacities and quoted ratings. Power
current.
DUCTLESS VENTILATION SYSTEM
6. 5 JET VENT FAN
Jet Fans shall be completely assembled at factory and then supplied to the site. These
fans shall have characteristics as of high performance ventilation with small air volume.
Each jet vent fan unit shall consist of fan having inlet cones, protective screen, silencer at
both inlet and outlet discharge nozzle, terminal box & mounting arms or brackets.
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Fan shall be axial flow type balanced dynamically and statically. The impellers shall be of
precision die-cast to offer thin Aerofoil sections for low generation of noise levels.
Aerofoil Fan impellers shall have a unique aerodynamic section blade to optimize the
efficiency of performance and minimize the generation of noise .The complete fan
assembly with its Casing, impeller & motor (not only the motor or one of the item) shall
be sourced from one manufacturer and certified as tested for 300 Deg C for minimum 2
hours operation.
The fans shall have a non-overloading characteristic; the peak power input occurs within
the range of normal operating pressures and is always exceeded by the motor rating.
6.6 CASING
The casing shall be either a long cased form complete with an externally mounted pre-
wired electrical terminal box, or short cased for duct or plate installation.
Casings shall be spun from sheet steel with integral pre-drilled flanges, fully welded
seams and hot-dipped galvanised after fabrication.
6.7 MOTOR
The Motor shall be high efficiency Squirrel cage type, class H insulation, lubricated
bearings with wide temperature grease and keyed shaft. The motor shall comply with
BS5000 Part 99 (or equivalent) and IEC 34-a/NEMA (or equivalent), and IP55 housing.
(Overheat protection shall be provided on single phase motors). Motor shall be suitable
for power supply of 415 volts + 10%, 50 Hz AC. The Type of motor shall be suitable for
two speed or single speed as specified in the BOQ.
6.8 PROTECTIVE GUARDS
The fans shall have protection guards at inlet side.
6.9 SILENCERS
The noise level from fan shall not exceed 52 DB at 1.5 meter distance. In case silencers
are required for achieving the performance then same shall be of following specification:
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Silencer casing shall be of minimum 1.0 mm thick cold mill steel sheet with baked
enamel coated on outside. Inside of casing shall be contained 25 mm thickness glass
wool and finish with punched stainless steel sheet.
The sound levels quoted shall be based on tests carried out by the manufacturer at
third part laboratory and duly certified test results shall be submitted prior to supply of
equipment at site.
6.10 INLET CONE
Jet fans shall have Inlet cone constructed of Aluminum 3003 and transparent paint
coated. It shall be designed to reduce air turbulence at inlet of the fan
6.11 DISCHARGE NOZZLE
The nozzle shall be made of aluminum round shaped aerodynamically and finished with
polishing coat.
6.12 TERMINAL BOX
The pre-wired Terminal box shall be mounted at the outer fan Casing.The box shall be
equipped with high temperature type indication lamp The wire to the motor shall be
enclosed with fiberglass tube for fire protection. It shall be sealed with fire rated sealant
and all internal wiring and components tested by PSB to BS 7346 Part2.
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6.13 MOUNTING ARMS / BRACKETS
The unit shall be furnished with mounting brackets for ceiling suspension. Mounting arm
shall permit adjustment of the air stream.
6.14 ANCILLARIES
Following accessories shall be supplied as part of Jet Fan installation by the

Subcontractor:
Mounting Feet
Impeller and Motor Side Guards
Two Silencers with or without pod
2 speed switch
Air Operated Dampers
Matching Flanges
Bellmouth Inlets
Flexible Connectors
Vibration Isolators
CENTRIFUGAL / AXIAL FLOW FANS
GENERAL Centrifugal Fans Axial Flow Fan

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Manufacturer
Type
Bearings
Casing Material
Impeller Material
Shaft Material
Vibration Isolators
Fan Size and Model
Fan speed
Fan efficiency
Noise level
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Noise attenuator
Manufacturers
Type
DB reduction guaranteed at 2 M & 3 M distance
from Noise attenuator
length (Metre)
Motor
manufacturer
type
operating speed
motor efficiency and class of insulation.
Electrical Characteristics (±10% voltage variation).
Type of starter & manufacturer
Type of drive
Material of flexible connection
Type of vibration isolators

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Motor operated through VFD, confirm following
Motors do not get derated
Higher size motor is not required.
OPERATING DATA Centrifugal Axial Flow
Fan model
Fan CFM
Fan Outlet Velocity (FPM)
SP (MM)
Fan RPM
Noise Level
DB Reduction BY Attenuator
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Resultant Noise Level (DB)
BHP
Limit Load HP
Motor (HP)
Full Load Current (AMPS)
Starting Current(AMPS)
PROPELLER FANS
Manufacturer
Motor HP
Capacitors provided.
Speed Regulator for single phase fans

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Gravity louvers
Single phase preventor for 3 phase fans
Back draft damper.
Bird Screen
Wire guard
JET VENT FAN
Manufacturer
Type
Model
I. High Speed
Capacity (CFM)
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Fan Speed (RPM)
Power Input (kW)
Current (Amps).
II.Low Speed
Capacity (CFM)
Fan Speed (RPM)
Power Input (kW)
Current (Amps)
Sound Level (dB(A))
Casing Material
Impeller Material
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Impeller Diameter (mm).
Whether Adjustable Blades
Max. Temperature rating
Type of Drive
Silencers
Electrical Characteristics
Weight (KG)
FAN TEST REPORT
PROJECT_______________________________________________________________________________
FAN DATA FAN NO. FAN NO. FAN NO.
Location
Service
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Manufacturer
Model No.
Serial No.
Type / Class
Motor Make / Style
Motor H.P/RPM/ Frame
Volts/Phase/Cycles
F.L Amps.
Motor pully Diam./Bore
Fan pully Diam./Bore
No. Belts/ Make/Size
Pully Distance.
TEST DATA DESIGN ACTUAL DESIGN ACTUAL DESIGN ACTUAL
CFM
FAN RPM
S.P IN/OUT
TOTAL S.P
Voltage T1 T2 T2
T3
T3 T1
Amperage T1 T2 T3
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REMARKS:
TEST DATE:_________________________________ READINGS BY _____________________

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4.07.
4.08.
4.09. SECTION-07
AIR DISTRIBUTION SYSTEM

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7. AIR DISTRIBUTION SYSTEM
SCOPE
The scope of this section comprises supply fabrication, installation and testing of all
sheet metal / aluminum ducts, supply, installation, testing and balancing of all grilles,
registers and diffusers. All to be in accordance with these specifications and the general
arrangement shown on the Drawings.
7.1 DUCT MATERIALS
RAW MATERIALS
Galvanizing shall be Class VIII – light coating of zinc, nominal 120gm/sq.m surface area
and Lock Forming Quality prime material along with mill test certificates. In addition, if
deemed necessary, samples of raw material, selected at random by owner’s site
representative shall be subject to approval and tested for thickness and zinc coating at
Subcontractor's expense.
GAUGES, BRACING BY SIZE OF DUCTS
All ducts shall be fabricated from galvanized steel / aluminum of the following thickness,
as indicated as below :
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For Ducts with external SP upto 250 Pa (25mmWg)
Rectangular Pressure 250 Pa
Ducts G. S. Duct Section Length 1.2 m (4 ft)
Maximum Gaug Joint Type Bracing

Duct Size e Spacing
1–750 mm 26 C & SS Nil
751 – 1000 26 4 Bolt Transverse Duct Nil

mm Connector-E (TDC) with built
in sealant
1001 – 1200 24 4 Bolt TDC –E Nil

mm
1201 – 1500 24 4 Bolt TDC-H Nil

mm
1501 – 1800 22 4 Bolt TDC-H Nil

mm
1801 – 2100 20 4 Bolt TDC-J Zeebar

mm stiffener 1-S
2101 – 2700 18 4 Bolt TDC-J Zeebar

mm stiffener 1-S
For Ducts with External SP upto 500 Pa (50mmWg)
Rectangular External Pressure 500 Pa

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Ducts G. S. Duct Section Length
1.2 m (4 ft)
Maximum Gaug Joint Type Bracing

Duct Size e Spacing
1–600 mm 26 C & SS Nil
601-750 26 4 Bolt Transverse Duct Nil

mm Connector-E (TDC) with built
in sealant
751-1000 24 4 Bolt TDC-E Nil

mm
1001-1200 22 4 Bolt TDC-H Nil

mm
1201-1300 20 4 Bolt TDC-J Nil

mm
1301-1500 18 4 Bolt TDC-J Zeebar

mm stiffener 1-S

mm stiffener 1-S

mm stiffener 1-S

mm stiffener 1-S

mm stiffener 1-S
2401-2700 18 4 Bolt TDC-J 600

mm
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'C'-cleat; 'S'-S cleat; 'SS'-Standing S cleat; 'AI' -Angle Iron in mm
*Distance of reinforcement/bracing from each joint. Bracing material to be same as of

material used for joining of duct sections.
FOR ALUMINUM DUCTS MATERIAL SHALL BE ONE COMMERCIAL GAUGE HIGHER

WITH 22 G AS MINIMUM
For Round Ducts
Duct Upto 50 mm Wg 51 – 250 mm Wg Upto 50 mm Wg

diameter static pressure (+ve) static pressure (+ve) static pressure (-ve)
mm
Spiral Longitudinal Spiral Longitudinal Spiral Longitudinal
seam seam gauge seam seam gauge seam seam gauge
gauge gauge gauge
Upto 650 26 24 24 22 24 22
651-900 24 22 22 20 22 20
901 – 22 20 20 20 20 18
1250
1251 – 20 18 18 18 18 16
1500
1501 – 18 16 18 16 16 14
2100
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FABRICATION STANDARDS & EQUIPMENT
All duct construction and installation shall be in accordance with SMACNA standards. In
addition ducts shall be factory fabricated utilizing the following machines to provide the
requisite quality of ducts.
a. Coil (Sheet metal in Roll Form) lines to facilitate location of longitudinal seams at
corners/folded edges only, for required duct rigidity and leakage free
characteristics. No longitudinal seams permitted along any face side of the duct.
b. All ducts, transformation pieces and fittings to be made on CNC profile cutter for
requisite accuracy of dimensions, location and dimensions of notches at the
folding lines.
c. All edges to be machine treated using lockformers, flangers and rollers for
turning up edges.
d. Kitchen exhaust ducting shall be with 16 G MS. Suitable access doors shall be
provided at every 3m. Provision shall be made for fire fighting agency to install
duct mounted sprinklers at every 3m. Generally exhaust ducts shall have slope
towards kitchen hood.
DUCT CONSTRUCTION
All ducts shall be fabricated and installed in workmanlike manner, conforming to

relevant SMACNA codes.
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a. Ducts so identified on the Drawings shall be acoustically lined and insulated from
outside as described in the section “Insulation” and as indicated in schedule of
Quantities. Duct dimensions shown on drawings, are overall sheet metal
dimensions inclusive of the acoustic lining where required and indicated in
Schedule of quantities. The fabricated duct dimensions should be as per
approved drawings and care should be taken to ensure that all connecting
sections are dimensionally matched to avoid any gaps.
b. Ducts shall be straight and smooth on the inside with longitudinal seams shall be
airtight and at corners only which shall be either Pittsburgh or snap button as per
SMACNA practice, to ensure airtightness.
c. All ducts up to 75cms width within conditioned spaces shall have slip and drive
(C & S/SS) joints. The internal ends of slip joints shall be in the direction of
airflow. Care should be taken to ensure that S/SS Cleats are mounted on the
longer side of the duct and Cleats on the shorter side. Ducts and accessories
within ceiling spaces, visible from air-conditioned areas shall be provided with
two coats of mat black finish paint.
d. Changes in dimensions and shape of ducts shall be gradual (between 1:4 and 1:7).
Air-turns (vanes) shall be installed in all bends and duct collars designed to
permit the air to make the turn without appreciable turbulence.
e. Ducts shall be fabricated as per details shown on Drawings. All ducts shall be
rigid and shall be adequately supported and braced where required with standing
seams, tees, or angles, of ample size to keep the ducts true to shape and to
prevent buckling, vibration or breathing.
f. All sheet metal connection, partitions and plenums, required to confine the flow
of air to and through the filters and fans, shall be constructed of 18 gauge GSS /
16gauge aluminum, thoroughly stiffened with 25mm x 25mm x 3mm galvanized
steel angle braces and fitted with all necessary inspection doors as required, to
give access to all parts of the apparatus. Access doors shall be not less than 45cm
x 45cm in size.
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g. Plenums shall be shop/factory fabricated panel type and assembled at site.

Fixing of galvanized angle flanges on duct pieces shall be with rivets heads inside
i.e. towards GS sheet and riveting shall be done from outside.
h. Self adhesive Neoprene rubber / UV resistant PVC foam lining 5mm nominal
thickness instead of felt, shall be used between duct flanges and between duct
supports in all ducting installation.
INSTALLATION PRACTICE
All ducts shall be installed generally as per tender drawings, and in strict accordance
with approved shop drawings to be prepared by the Subcontractor:
a. The Subcontractor shall provide and neatly erect all sheet metal work as may be
required to carry out the intent of these Specifications and Drawings. The work
shall meet with the approval of Owner’s site representative in all its parts and
details
b. All necessary allowances and provisions shall be made by the Subcontractor for
beams, pipes, or other obstructions in the building, whether or not the same are
shown on the drawings. Where necessary to avoid beams or other structural
work, plumbing or other pipes, and conduits, the ducts shall be transformed,
divided or curved to one side (the required area being maintained) all as per the
site requirements.
c. If a duct cannot be run as shown on the drawings, the Subcontractor shall install
the duct between the required points by any path available in accordance with
other services and as per approval of owner’s site representative.
d. All ductwork shall be independently supported from building construction. All

horizontal ducts shall be rigidly and securely supported, in an approved manner,
with trapeze hangers formed of galvanized steel rods and galvanized steel
angle/channel or a pair of brackets, connected by galvanized steel rod under
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ducts. The spacing between supports should be not greater than 2.0 meter. All
vertical ductwork shall be supported by structural members on each floor slab/
Porlin for PEB structure buildings/Factory buildings . Duct supports may be
through galvanized steel insert plates left in slab at the time of slab casting.
Galvanized steel cleat with a hole for passing the hanger rods shall be welded to
the plates. Trapeze hanger formed of galvanized steel rods shall be hung through
these cleats. Wherever use of metal insert plates is not feasible, duct support
shall be through dash/anchor fastener driven into the concrete slab by
electrically operated gun. Hanger rods shall then hang through the cleats or fully
threaded galvanized rods can be screwed into the anchor fasteners.
e. Ducting over furred ceiling shall be supported from the slab above, or from
beams after obtaining approval of Owner’s site representative. In no case shall
any duct be supported from false ceiling hangers or be permitted to rest on false
ceiling. All metal work in dead or furred down spaces shall be erected in time to
occasion no delay to other Subcontractor’s work in the building.
f. Where ducts pass through brick or masonry openings, it shall be provided with
25mm thick TF quality expanded polystyrene around the duct and totally covered
with fire barrier mortar for complete sealing.
g. All ducts shall be totally free from vibration under all conditions of operation.
Whenever ductwork is connected to fans, air handling units or blower coil units
that may cause vibration in the ducts, ducts shall be provided with a flexible
connection, located at the unit discharge. Flexible connections shall be
constructed of fire retarding flexible heavy canvas sleeve at least 8cm long
securely bonded and bolted on both sides. Sleeve shall be made smooth and the
connecting ductwork rigidly held by independent supports on both sides of the
flexible connection. The flexible connection shall be suitable for pressure at the
point of installation.
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h. Duct shall not rest on false ceiling and shall be in level from bottom. Taper pieces
shall taper from top.
7.2 DAMPERS
a. Dampers : All duct dampers shall be opposed blade louver dampers of robust 16
G GSS construction and tight fitting. The design, method of handling and control
shall be suitable for the location and service required.
b. Dampers shall be provided with suitable links levers and quadrants as required
for their proper operation. Control or setting device shall be made robust, easily
operable and accessible through suitable access door in the duct. Every
damper shall have an indicating device clearly showing the damper position at
all times.
c. Dampers shall be placed in ducts at every branch supply or return air duct
connection, whether or not indicated on the Drawings, for the proper volume
control and balancing of the air distribution system (If necessary)
7.3 FIRE & SMOKE DAMPERS
a. All supply and return air ducts at AHU room crossings and at all floor crossings
shall be provided with Motor operated Fire & smoke damper of atleast 90
minutes rating as per UL555/1995 tested by CBRI. These shall be of multi-leaf
type and provided with Spring Return electrical actuator having its own thermal
trip for ambient air temperature outside the duct and air temperature inside the
duct. Actuator shall have Form fit type of mounting, metal enclosure and
guaranteed long life span.
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b. Fire damper blades and outer frames shall be of 16G galvanised steel
construction fitted with 18 gauge extended sleeves on both sides. The damper
blade shall be pivoted on both ends using chrome plated spindles in self
lubricated bronze bushes. Stop seals shall be provided on top and bottom of the
damper housing made of 16G galvanised sheet steel. For preventing smoke
leakage metallic compression seals will be provided.
c. The electric actuator shall be energised either upon receiving a signal from
smoke detector installed in AHU room supply air duct / return air duct or
temperature sensor. The fire damper shall also close upon sensing temperature
rise in supply air ducts thru the electronic temperature sensor.
d. Each damper shall be provided with its own control panel, mounted on the wall
and suitable for 240 VAC supply. This control panel shall be suitable for spring
return actuator and shall have atleast the following features:
 Potential free contacts for AHU fan ON/ Off and remote alarm indication.
 Accept signal from external smoke / fire detection system for tripping the
electrical actuator.
 Test and reset facility.
 Indicating lights / contacts to indicate the following status:
 Power Supply On
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 Alarm
 Damper open and close position.
e. Actuators shall be mounted on the sleeve by the damper supplier in his shop and
shall furnish test certificate for satisfactory operation of each Motor Operated
Damper in conjunction with it’s control panel. Control panel shall be wall
mounted type.
f. It shall be HVAC Subcontractor’s responsibility to co-ordinate with the Fire Alarm

System Subcontractor for correctly hooking up the Motor Operated Damper to
Fire Detection / Fire Management System. All necessary materials for hooking up
shall be supplied and installed by HVAC Subcontractor under close co-ordination
with the fire protection system Subcontractor.
g. HVAC Subcontractor shall demonstrate the testing of all Dampers and its control
panel after necessary hook up with the fire protection / fire management system
is carried out by energising all the smoke detectors with the help of smoke.
h. HVAC Subcontractor shall provide Fire retardant cables wherever required for
satisfactory operation and control of the Damper.
j. HVAC Subcontractor shall strictly follow the instructions of the Damper Supplier
or avail his services at site before carrying out testing at site.
k. Fire/smoke damper shall be provided with factory fitted sleeves; however,

access doors shall be provided in the ducts within AHU room in accordance
with the manufacturer’s recommendations.
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l. The Subcontractor shall also furnish to the Owner, the necessary additional
spare actuators and temperature sensor ( a minimum of 5% of the total
number installed) at the time of commissioning of the installation.
7.4 FIRE DAMPERS
a. Whenever a supply/return duct crosses from one fire zone to another, it shall be
provided with approved fire damper of at least 1½ hour fire rating as per
UL555/1995 tested by CBRI. This shall be curtain type fire damper.
b. Fire damper blades shall be one piece folded high strength 16 gauge galvanised
steel construction. In normal position, these blades shall be gathered and stacked
at the frame head providing maximum air passage and preventing passing air
currents from creating noise or chatter. The blades shall be held in position
through fusible link of temp 70o C.
c. In case of fire, the intrinsic energy of the folded blades shall be utilized to close
the opening. The thrust of the suddenly released tension shall instantly drive the
blades down and keep it down without the use of springs, weights or other
devices subject to failure.
d. Fire damper sleeves and access doors shall be provided within the duct in
accordance with the manufacturer’s recommendation.
e. The Subcontractor shall also furnish to the Owner, the necessary additional
fusible links (spares), as recommended by the manufacturer, at the time of
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7.5 SUPPLY AND RETURN AIR REGISTERS
Supply & return air registers shall be of either steel or aluminium sections as specified
in schedule of quantities. Steel construction registers shall have primer Coat finish
whereas extruded aluminium registers shall be either Anodised or Powder Coated as
specified in Schedule of Quantities. These registers shall have individually adjustable
louvers both horizontal and vertical. Supply air registers shall be provided with key
operated opposed blade extruded aluminium volume control damper anodised in matt
black shade.
The registers shall be suitable for fixing arrangement having concealed screws as
approved by Owner. Linear continuous supply cum return air register shall be
extruded aluminium construction with fixed horizontal bars at 15 Deg. inclination &
flange on both sides only (none on top & bottom). The thickness of the fixed bar louvers
shall be minimum 5.5 mm in front and 3.8 mm in rear with rounded edges. Flanges on
the two sides shall be 20 mm/30 mm wide as approved by Owner. The grilles shall be
suitable for concealed fixing. Volume control dampers of extruded aluminium
anodised in black colour shall be provided in supply air duct collars. For fan coil
units horizontal fixed bar grilles as described above shall be provided with flanges on
four sides, and the core shall be & suitable for clip fixing, permitting its removal without
disturbing the flanges.
a. All registers shall be selected in consultation with the Owner. Different spaces
shall require horizontal or vertical face bars, and different width of margin
frames. These shall be procured only after obtaining written approval from
Owner for each type of register.
b. All registers shall have a soft continuous rubber/foam gasket between the
periphery of the register and the surface on which it has to be mounted. The
effective area of the registers for air flow shall not be less than 66 percent of
gross face area.
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c. Registers specified with individually adjustable bars shall have adjustable pattern
as each grille bar shall be pivotable to provide pattern with 0 to +45° horizontal
arc and upto 30° deflection downwards. Bars shall hold deflection settings under
all conditions of velocity and pressure.
d. Bar longer than 45 cm shall be reinforced by set-back vertical members of

approved thickness.
e. All volume control dampers shall be anodised aluminium in mat black shade.
7.6 SUPPLY AND RETURN AIR DIFFUSERS
Supply and return air diffusers shall be as shown on the Drawings and indicated in
Schedule of Quantities. Mild steel diffusers/dampers shall be factory coated with rust-
resistant primer. Aluminium diffusers shall be powder coated & made from extruded
aluminium section as specified in schedule of quantities.
a. Rectangular Diffusers shall be steel / extruded aluminium construction,

square & rectangular diffusers with flush fixed pattern for different spaces as
per schedule of quantities These shall be selected in consultation with the
owner. These shall be procured only after obtaining written approval from
owner for each type of diffuser.
b. Supply air diffusers shall be equipped with fixed air distribution grids,
removable key-operated volume control dampers, and anti-smudge rings as
required in specific applications, and as per requirements of schedule of
quantities. All extruded aluminium diffusers shall be provided with removable
central core and concealed key operation for volume control damper.
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c. Linear Diffuser shall be extruded aluminium construction with

removable core, one or two way blow type. Supply air diffusers shall be
provided with volume control/ balancing dampers within the supply air collar.
Diffusers for different spaces shall be selected in consultation with the owner,
and provided as per requirements of schedule of quantities. All diffusers shall
have volume control dampers of extruded aluminium construction anodised in
mat black shade.
d. Slot Diffuser shall be extruded aluminium construction multislot type with air
pattern controller provided in each slot. Supply air diffusers shall be provided
with Hit & Miss volume control dampers in each slot of the supply air
diffusers. Diffusers for different spaces shall be selected in consultation with the
owner and provided as per requirement of Schedule of Quantities.
DOCUMENTATION & MEASUREMENTS FOR DUCTING
All ducts fabricated and installed should be accompanied and supported by proper
documentation viz:
a. Bill of material/Packing list for every duct section supplied.
Measurement sheet covering each fabricated duct piece showing dimensions and
external surface area along with summary of external surface area of duct gauge-
wise.
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Each and every duct piece to have a tag number, which should correspond to the
serial number, assigned to it in the measurement sheet. The above system will
ensure speedy and proper site measurement and verification.
Unless otherwise specified, measurements for ducting for the project shall be on
the basis of centerline measurements described herewith
Ductwork shall be measured on the basis of external surface area of ducts. Duct
measurements shall be taken before application of the insulation. The external
surface area shall be calculated by measuring the perimeter comprising overall
width and depth, including the corner joints, in the center of each duct section,
multiplying with the overall length from flange face to flange face of each duct
section and adding up areas of all duct sections. Plenums shall also be measured
in a similar manner.
 For tapered rectangular ducts, the average width and depth shall be considered
for perimeter, whereas for tapered circular ducts, the diameter of the section
midway between large and small diameter shall be adopted, the length of tapered
duct section shall be the centerline distance between the flanges of the duct
section.
For special pieces like bends, tees, reducers, branches and collars, mode of
measurement shall be identical to that described above using the length along the
centerline.
The quoted unit rate for external surface of ducts shall include all wastage
allowances, flanges and gaskets for joints, nuts and bolts, hangers and angles with
double nuts for supports, rubber strip 5mm thick between duct and support,
vibration isolator suspension where specified or required, inspection
chamber/access panel, splitter damper with quadrant and lever for position
indication, turning vanes, straightening vanes, and all other accessories required
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to complete the duct installation as per the specifications. These accessories shall
NOT be separately measured nor paid for.
b. Special Items for Air Distribution shall be measured by the cross-section area
perpendicular to air flow, as identified herewith :
i. Grilles and registers - width multiplied by height, excluding flanges.

Volume control dampers shall form part of the unit rate for registers and
shall not be separately accounted.
ii. Diffusers - cross section area for air flow at discharge area, excluding
flanges. Volume control dampers shall form part of unit rate for supply air
diffusers and shall not be separately accounted.
iii. Linear diffusers - shall be measured by cross-sectional areas and shall

exclude flanges for mounting of linear diffusers. The supply air plenum
for linear diffusers shall be measured with ducting as described earlier.
iv. Fire dampers - shall be measured by their cross sectional area

perpendicular to the direction of air flow. Quoted rates shall include the
necessary collars and flanges for mounting, inspection pieces with access
door, electrical actuators and panel. No special allowance shall be payable
for extension of cross section outside the air stream.
v. Flexible connection - shall be measured by their cross sectional area

perpendicular to the direction of air flow. Quoted rates shall include
the necessary mounting arrangement, flanges, nuts and bolts and
treated-for-fire requisite length of canvas cloth.
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vi. Kitchen Hoods - shall be measured by their cross sectional area at the
capture point of fumes, parallel to the surface of kitchen equipment.
Quoted rates shall include the grease filters, provision for hood light,
suspension arrangement for the hood, profile to direct the air to
ventilation ducts and provision for removable drip tray.
RECTANGULAR DUCT
TRAVERSE REPORT
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PROJECT______________________________SYSTEM______________________________________
LOCATION / ZONE_____________________ACTUAL AIR TEMP. ________________DUCT S.P_________
DUCT REQUIRED ACTUAL
SIZE___________SQ.FT._________ FPM_________________CFM______ FPM_________________CFM______

_________ _________ _________
POSITION 1 2 3 4 5 6 7 8 9 8 9 12 13 12 15
9
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12
13
VELOCITY
SUBTOTAL
REMARKS.
TEST DATE________________________________READINGS BY ______________________________

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GRILLES AND DIFFUSERS
TEST REPORT.
PROJECT____________________________________ SYSTEM __________________________________
OUTLET MANUFACTURER________________________TEST APPARATUS____________________
PRELIMI
AREA OUT LET DESIGN FINAL
NARY
VE
VEL L.
SERVE
NO TYPE SIZE CFM VEL OR OR VEL CFM
D
CFM CF
M
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REMARKS.
TEST DATE______________________ READINGS BY _________________________

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SECTION-08
THERMAL & ACOUSTIC INSULATION

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8. SCOPE
The scope of this section comprises the supply and application of insulation conforming to
these specifications.
8.1 DUCT THERMAL INSULATION
MATERIAL
 Insulation material shall be Closed Cell Elastomeric Rubber

 Density of Material shall be between 40 to 60 Kg/m3
 Thermal conductivity of elastomeric Closed Cell Elastomeric Rubber shall not exceed 0.033
W/m.K at mean temperature of 0C
 Insulation material shall have anti-microbial product, which is EPA (Environmental
Protection Agency), USA approved, as an integral part of insulation that can not be washed
off or worn off.
 It shall give enhanced level of protection against harmful Microbes such as bacteria, mold,
mildew and fungi and should confirm to following standards: Fungi Resistance – ASTM G21
and Bacterial resistance – ASTM G 22 / ASTM 2180.
 The insulation shall have fire performance such that it passes Class 1 as per BS476 Part 7 for
surface spread of flame as per BS 476 and also pass Fire Propagation requirement as per
BS476 Part 6 to meet the Class ‘O’ Fire category as per 1991 Building Regulations (England
& Wales) and the Building Standards (Scotland) Regulations 1990
 Material should be FM (Factory Mutual), USA approved.
 Water vapour permeability shall not exceed 1.74 x 10-14 Kg / (m.s.Pa), i.e. Moisture Diffusion
Resistance Factor or ‘µ’ value should be minimum 10000.
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Thickness of the insulation shall be as specified for the individual application.
THICKNESS SELECTION CHART FOR CLOSED CELL ELASTOMERIC NITRILE

RUBBER INSULATION
Design Basis: Condensation Control
Non-Coastal Areas Pune, Delhi, Hyderabad, Bangalore etc.
(OUTDOOR & INDOOR)
Design Conditions: 30 Deg .C & 82% RH
DUCT INSULATION
Required
Thickness (mm)
Supply Air Duct (Line 18

Temperature 14 Deg. C)
Return Air Duct (Line 8

Supply Air Duct in Return 8

Air Path (Line Temp. 14
Deg.C)

RUBBER INSULATION
Coastal Areas Mumbai, Chennai, Kochi, Goa etc.
(OUTDOOR, ATTIC & UNCONDITIONED SPACES VENTED TO OUTDOOR)

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Design Conditions: 28.3 Deg .C & 90% RH (As per ASHRAE guidelines)
DUCT INSULATION
Required
Thickness (mm)



RUBBER INSULATION
Coastal Areas Mumbai, Chennai, Kochi, Goa etc.
INDOOR (CONDITIONED/ SEMICONDITIONED AREAS)
Design Conditions: 26.8 Deg .C & 85% RH
DUCT INSULATION
Required
Thickness (mm)


Supply Air Duct in Return 8

Air Path (Line Temp. 14
Deg.C)
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External thermal insulation installation procedure:
 Duct surfaces shall be cleaned to remove all grease, oil, dirt, etc. prior to carrying out
insulation work.
 Measurement of surface dimensions shall be taken properly to cut closed cell elastomeric
rubbers sheets to size with sufficient allowance in dimension.
 Material shall be fitted under compression and no stretching of material should be allowed.
 A thin film of adhesive shall be applied on the back of the insulating material sheet and then
on to the metal surface.
 When adhesive is tack dry, insulating material sheet shall be placed in position and pressed
firmly to achieve a good bond.
 All longitudinal and transverse joints shall be sealed as per manufacturer recommendations.
 The adhesive shall be strictly as recommended by the manufacturer.
 The detailed Application specifications are as per the manufacturer’s recommendation.
INSTALLATION OF DUCTS EXPOSED DIRECTLY TO SUNLIGHT:
For installations exposed to sunlight, after giving 36 hours curing time for the adhesive
apply manufacturer’s recommended UV/Mechanical Protection. Please refer the separate
detailed guidelines on UV/Mechanical Protection.
For the Under deck insulation, 13mm thk closed cell elastomeric nitrile rubber insulation has to
be used.
8.2 DUCT ACOUSTIC INSULATION
 Material shall be engineered Open Cell Elastomeric Rubber foam

 The Random Incidence Sound Absorption Coefficient (RISAC); tested as per ISO 354,
should be minimum as per enclosed chart

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Freq 125 250 500 1000 2000 4000 NRC

(Hz)
10 mm 0.03 0.04 0.14 0.04 0.88 1.00 0.35
15mm 0.01 0.09 0.29 0.74 1.08 0.83 0.55
20mm 0.04 0.13 0.4 0.9 1.04 0.90 0.6
25mm 0.02 0.25 0.86 1.14 0.88 0.99 0.8
30mm 0.07 0.32 0.99 1.16 0.93 1.08 0.85
50mm 0.23 0.73 1.29 0.99 1.09 1.11 1.05
 The material should be fibre free

 The density of the same shall be within 140-180 Kg/m3
 It should have antimicrobial product protection, and should pass Fungi Resistance as per
ASTM G 21 and Bacterial Resistance as per ASTM E 2180.
 The material should have a thermal conductivity not exceeding 0.047 W/m.K @ 20 Deg.
C
 The material should withstand maximum surface temperature of +850C and minimum
surface temperature of -200C
 The material should conform to Class 1 rating for surface spread of Flame in accordance
to BS 476 Part 7 & UL 94 (HBF, HF 1 & HF 2) in accordance to UL 94, 1996.
 The insulation should pass Air Erosion Resistance Test in accordance to ASTM Standard
C 1071-05 (section 12.7).
DUCT ACOUSTIC LINING
Material shall be processed Open Cell Nitrile Rubber foam. The material should be fibre
free. The density of the same shall be within 140-180 Kg/m3.The material should have a
thermal conductivity not exceeding 0.048 W/mK @ 20 deg C. The maximum surface
temperature the material should withstand is 1050 C and minimum temperature should be -
200C. Thickness of the material shall be as specified for the individual application. The
material should conform to Class 1 rating for surface spread of Flame as per BS 476 Part 7 and
UL94 (HBF,HF1 & HF2) in accordance to UL94,1996.The material shall have anti-
microbial resistance properties – Fungi resistance in accordance to ASTM G21 and
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Bacterial resistance in accordance to ASTM E2180.The Tensile strength shall be 100 – 125 kPa
in accordance to DIN EN ISO 1798.
The recommended thickness is 15mm
Ducts so identified and marked on Drawings and included in Schedule of Quantities shall be
provided with acoustic lining of thermal insulation material for a distance of minimum 5 meters
(or 30% of the duct length whichever is more) as follows:
INSTALLATION PROCEDURE
The inside surface for the ducts shall be covered with adhesive. Cut Foamed sheets into
required sizes apply adhesive on the foam and stick it to the duct surface
8.3 ACOUSTIC LINING OF MECHANICAL ROOMS
Two walls and ceiling of air conditioning plant room and air handling unit rooms may
be provided with acoustic lining. Material shall be processed Open Cell Nitrile Rubber
foam. The material should be fibre free. The density of the same shall be within 140-180
Kg/m3.The material should have a thermal conductivity not exceeding 0.048 W/mK @ 20
deg C. The maximum surface temperature the material should withstand is 1050 C and
minimum temperature should be -200C. Thickness of the material shall be as specified for the
individual application. The material should conform to Class 1 rating for surface spread of
Flame as per BS 476 Part 7 and UL94 (HBF,HF1 & HF2) in accordance to UL94,1996.The
material shall have anti-microbial resistance properties – Fungi resistance in accordance to
ASTM G21 and Bacterial resistance in accordance to ASTM E2180.The Tensile strength shall be
100 – 125 kPa in accordance to DIN EN ISO 1798.
The recommended thickness is 20/25 mm
Installation Method -1
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Thoroughly cleaned wall surface should be applied with a layer of adhesive recommended by
the manufacturer. A layer of Adhesive also to be applied to Precut 1mtx1 mt foam sheet and
stuck the same to the adhesive applied wall surface when the adhesive on both surfaces are
tack dry. The whole acoustic foam area can be covered with one layer of glass cloth to
give additional mechanical protection.
Acoustic lining of walls shall be terminated approximately 15 cm above the finished floor to
prevent damage to insulation due to accidental water-logging in plant/AHU rooms.
Installation method 2
Precut 0.5x0.5mt Acoustic foam material should be inserted in to the prefabricated

aluminum channel grid of 0.5x5mt as per the manufacturer’s recommendation.
Prefabricated to aluminum channel size mentioned above would be riveted to the wall
surface as per the manufacturer’s recommendations. The whole grid area can be covered with
either one layer of glass cloth or aluminum perforated sheet to give addition mechanical
protection. Aluminum perforated sheet also can be painted to suit the aesthetic
requirement of the building.
8.4 PIPING INSULATION
For chilled water piping Rigid Polyurethane Foam (RPUF) meeting the following requirement
shall be used as insulation material:
a) Density : Not less than 34.36 Kg/cum
b) Compressive Strength : Not less that 1.7 Kg/Sqm
c) Water Vapour : Not more that 13 Mg/Nh (2.5 per in)
d) 'K' Value : Not greater than 0.02 W/m2. Deg C
at 10 deg C.
The RPUF used shall be in the form of pre-formed cylindrical sections

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All insulation on equipment, piping, etc., shall be applied only after the system has been
pressure tested satisfactorily.
Chilled water piping and condensate drain piping shall be insulated to the following thickness.
------------------------------------------------------------------------
Description Pipe sizes Thickness of
mm -- dia mm -- dia Insulation- mm
------------------------------------------------------------------------
a) Chilled water piping Upto 65 30
b) Chilled water piping 65 & above 50
c) Condensate All sizes 25
Drain Piping
---------------------------------------------------------------------
The insulation shall be applied as follows:
a) Clean the piping surface with wire brush to remove dirt and rust.
b) Apply a thick coat of bituminous primer uniformly over the surface, Bitumen used shall
be R 85/25.
c) Apply pre-formed rigid pipe sections of appropriate thickness taking care to see that
circumferential joints are staggered longitudinally.
Insulation over all cold piping (laid above ground) shall be covered with aluminium cladding
using 24 G sheets, the joints being formed with proper grooves, and over laps and secured in
position with self-tapping screws. For bends/elbows and such other fittings, the cladding shall
be in multi-piece construction, the thickness of sheet employed being 22 G.
For piping laid underground, a layer of bitumen shall be applied on the insulation. This shall be
followed by application of 24 G x 19 mm hexagonal GI wire by netting, butting all joints and
tying together with 20 G GI lacing wire. Two layers of cement and sand plaster shall be applied
thereon, the thickness of each layer being not less than 10 mm. The proportion of cement to
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sand shall be not less that 1:3. Water proofing shall be provided over the plastered surface by
applying two layers of fiber glass tissue set in air blown grade bitumen.
SECTION-09
PIPING WORKS
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9. PIPING
9.1 SCOPE
The scope of this section comprises the supply and laying of pipes, pipe fittings and
valves, testing and balancing of all water and refrigerant piping required for the
complete installation as shown on the Drawings. All piping inclusive of fittings and
valves shall follow the applicable Indian Standards.
9.2 PIPE SIZES
Pipe sizes shall be as required for the individual fluid flows. Various pipe sizes have
been indicated on the Drawings, these are for Subcontractor’s guidance only and shall
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not relieve Subcontractor of responsibility for providing smooth noiseless balanced

circulation of fluids.
9.3 CHILLED, HOT AND CONDENSING WATER PIPING
Following material shall be used for pipes and fittings.
Pipes Nominal size (mm) Material Specification
<150 IS 1239 Part-1
200 and above IS 3589 Gr. FE 48 (8mm thick)
Fittings Nominal size (mm) Material Specification
<40 Socket welded, ASTM A85 as per ANSI B16.9
50-150 Butt welded, ASTM A234 Gr. WPB as per ANSI

B16.9
>200 Site fabricated from IS 3589 Gr. FE 48 (8mm)
Flanges Nominal size (mm) Material Specification

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< 150 IS 2062 Gr.Aas per ANSI B16.5 (#150 class)
>200 IS 2062 Gr.A, as per ANSI B16.5 (#150 class)
All jointing in the pipe system shall generally be by welding, unless otherwise
mentioned, or directed at site. All welding shall be done by qualified welders and shall
strictly conform to BIS Code of practice for manual metal arc, welding of Mild Steel.
Out of three weld one butt weld of each welder shall be fully radiographed for testing
purposes. Upon approval of welding joints the concerned welder shall be allowed to
carry further welding of pipes. Rest of the welds shall have 80% visual inspection.
a. All welded joints (except pipe welded end-to-end) shall be made by use of one-
piece welding flanges, caps, nozzles, elbows, branch outlets and tees of approved
make. Cut samples shall be submitted for approval, if directed. All such fittings
etc., shall be of a type which maintain full wall-thickness at all points, simple
radius and fillets, and proper bevels or shoulders at ends. All job welding shall be
done by the electric arc welding process in accordance with the following :
 All joints shall have 45 degree bevel type, pipe mill-bevelled or machine-
bevelled by the Subcontractor.
 All scale and oxide shall be removed with hammer, chisel or file and bevel
left smooth and clean.
 Pipe lengths shall line up straight with abutting pipe ends concentric.
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 Both conductors from the welding machine shall be extended to locations

at which welding work is being done. The leads from welding machine to
location of welding work shall be held together with tape or other
approved means so as to prevent induced current in structural steel, in
piping or in other metals within the building. The ground lead shall be
connected to length of pipe through joints in pipe, structural steel of
building or steel pipe supports.
b. All pipes and their steel supports shall be thoroughly cleaned and given one
primary coat of red oxide paint before being installed. For vibration isolators
premoulded polyurethane pipe sections of 160 Kg/m3 density with adhesive
shall be fixed between pipe and MS support. 8 mm thick MS ‘U’ clamp with
resistoflex shall be fixed on the pipe so that the pipe is kept in position. All
welded piping shall be subject to the approval at site.
c. Fittings shall be malleable casting of pressure rating suitable for the piping
system. Fittings used on welded piping shall be of the weldable type. These shall
form part of piping and are not separately identified in Schedule of Quantities.
d. Tee-off connections shall be through equal or reducing tees, otherwise ferrules

welded to the main pipe shall be used. Drilling and tapping of the walls of the
main pipe shall not be resorted to.
e. Ball and butterfly valves conforming to the following specifications shall be

provided as shown on Drawings :
------------------------------------------------------------------------------------------------------
------
Size Construction Ends Type
------------------------------------------------------------------------------------------------------
------
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15 to 25 mm Bronze ASTM B62/ Screwed Ball
Cast Steel
30 mm and over Body Cast iron, Wafer Butterfly
Type and requirements shall be as indicated in Schedule of Quantities. Valves

shall have non-rising spindles unless specified otherwise and shall be suitable
for PN16 rating. Butterfly valve should be of wafer type long neck construction
single stem design with centre lugs to ensure proper alignment of pipe flanges.
Mount valve on to flanges only after flanges have been welded to pipes using a
tool piece and cooled down to room temperature to prevent damage to resilient
seat. The rubber liner should be fully supported by the valve flanges. Appropriate
dimensions and thickness of Flanges and Bolts, as per the Flange Tables ANSI
B16.5 (#150 class), should be used. The flanges should be properly aligned with
each other so that bolts are exactly perpendicular to the flanges.Evenly tighten
the flange bolts to secure the valves. Counter flanges with nut-bolts and gaskets
shall be provided by valve manufacturer.
f. Butterfly valves shall perform the function of isolating valves and shall be
suitable for PN16 rating. Butterfly valves shall have Epoxy Coated cast iron body
with Integrally moulded EPDM liner of replaceable type. The liner shall be
integrally moulded on hard backup ring and shall be suitable for PN16 rating
unless specified otherwise. All butterfly valves shall be provided with locking
devices. Valves 250 mm and above dia shall be gear driven.
g. Automatic balancing valves shall automatically control flow rates with + 5%

accuracy. Valve control mechanism shall consist of a stainless steel cartridge
with a ported cup and coil / helical spring to avoid corrosion. Four operating
ranges shall be available with the minimum range requiring less than 14 kPa to
actuate the mechanism. Manufacturer shall provide independent laboratory tests
verifying assurance of performance.
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h. Manual double regulating balancing valves shall be provided at chiller, condenser,

various tapp-offs and each AHU outlet line as indicated in Schedule of Quantities.
These valves shall have built-in pressure-drop measuring facility to compute
flow rate across the valve. The test cocks shall be long enough to protrude out of
pipe insulation. To enable accurate and practical operation, measurement of flow
and differential pressure shall be made with a computerised balancing
instrument which shall enable the operator to read the flow directly without the
use of diagrams or tables. In addition to measuring flowrate, differential pressure
and temperature, computerised balancing instrument shall have a computer
programme to provide the following functions:
i. To balance the HVAC installation and calculate the necessary valve

settings, based on system measurements.
ii. To store the results of balancing.
iii. To log measured values from a valve (differential pressure, flowrate or

temperature).
iv. To printout saved data in computerised measurement protocol (CMP)

consisting of:
- Name and size of Balancing Valve (BV)
- Presetting position of BV
- P at BV
- Flow at BV
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- Design Flow
j. Flanges shall be of approved make. The supply of flanges shall form part of
piping (not separately identified in Schedule of Quantities) and shall also include
supply of bolts, washers, nuts and suitable asbestos fibre / rubber insertion
gaskets (minimum 3 mm thick).
k. All ball valves and ball valves with Y strainer shall be bronze forged body
construction with chrome plated bronze ball and handle of stainless steel
constructions. These are separately identified in Schedule of Quantities.
l. Non return valves shall be dual plate check valve provided as shown on the
Drawings, and identified in Schedule of Quantities conforming to relevant Codes
and in accordance with the following Specifications :
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Size Construction Ends
-------------------------------------------------------------------------------------------------------
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40 to 300 mm Body: Grey Cast iron Flanged
(Epoxy Coated),
CI IS 210 Gr. FG 260
Plates: CF-8 (SS-304),
Hinge/Stop Pin: SS-410
Spring(s): SS-316.
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Seal: EPDM
350 mm to 500 mm Body: Grey Cast iron Flanged
(Epoxy Coated),
CI IS 210 Gr. FG 260
Plates: SS-409.
Hinge/Stop Pin: SS-410
Spring(s): SS-316.
Seal: EPDM
The spring and hinge/stop pin shall be SS304 and bearing PTFE material.
Valves shall be PN 16 rating.
m. Strainers shall be ‘Y’ type or Pot Strainer suitable for PN 16 rating as shown on
drawings and included in BOQ. ‘Y’ Strainer shall be fabricated out of MS ‘C’ class
pipe two sizes higher than that of Strainer pipe size. Flanges as per ANSI B16.5
(#150 class)shall be provided at inlet and outlet connectors. The body shall be
hot dip galvanized. Permanent magnet shall be provided in the body of the
Strainer to arrest MS particles. Filter element shall be of non magnetic 20 gauge
SS sheet with 3 mm perforation. Strainers shall be provided at in let of each Air
Handling Unit and Pump as shown in drawings and included in BOQ.
Pot Strainers body shall be fabricated out of MS plate IS 226. Thickness of sheet
shall be as per size of the strainer chamfered pipes with flanges shall be provided
at inlet /outlet connections of the strainer. The tangential entry of water shall
create a centrifugal action and due to velocity shall separate sediments and
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deposit on the inner surface of Filter Element and at bottom of the Strainer.
Butterfly valves shall be provided at inlet / outlet connections as shown in
drawing and included in BOQ. The strainer body shall have two separate
chambers properly sealed to avoid mixing of filtered and unfiltered water. A
powerful magnet shall be provided in the body to arrest MS particles. Filter
element of Pot Strainer shall be of non magnetic 18 gauge SS sheet properly
reinforced to avoid damage of the element. A cone with sufficiently large drain
pipe with butterfly valve shall be provided at the bottom chamber to flush-out
foreign particles. This arrangement shall avoid frequent opening of Pot Strainer
for cleaning of filter element. Gauge connection shall be provided at inlet and
outlet connection.
A set of MS flanges with tongue and groove arrangement and neoprene rubber
gasket shall be provided on the top cover and Pot Strainer flange with sufficient
bolts and nuts to make the joint water light. Bearing loaded tope cover lifting and
swinging arrangement shall be provided. The Pot strainer body shall be properly
de-rusted and epoxy coated from inside and outside. Manufacturers Test
Certificate shall be provided with each Pot Strainer..
Size of various Pot Strainer, Filter Element and Thickness of MS sheet shall be as
under:
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Pipe size Pot Dia Pot HT Element Dia Element HT MS Plate

Thickness
(mm) (mm) (mm) (mm) (mm) (mm)
--------------------------------------------------------------------------------------------------------
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50 300 400 200 240 6

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80 350 450 250 250 6
80 450 500 300 280 6
125 500 600 330 340 8
150 540 700 360 390 8
200 68 815 400 470 8
250 800 955 550 58 8
300 800 185 750 580 8
350 990 1100 895 678 12
400 1150 1500 820 785 12
450 1518 1700 860 890 12
500 1690 1800 180 900 12
600 2000 2200 1500 960 12
Each Port strainer shall be provided with a Test Certificate.
n. All chilled water piping and fittings shall be pressure tested, painted and then
insulated as described under the section “Insulation”.
o. Grooved coupling : Grooved coupling shall have 3 main parts viz. Housing, Gasket
and bolting arrangement. Housing shall be made out of ASTM-A 536 Grade 65-45-
9. The housing key shall engage into the grooves around the full pipe
circumference, securing the pipe ends together with positive grip. Housing shall
be designed to provide optimum combination of pressure, stress relief and end
load conditions while maintaining reasonable weight. Gasket shall be of high
sealing efficiency and shall be able to withstand upto (-) 0.35 Bar pressure. Bolt
shall confirm to ASTM A183, while nut shall confirm to ASTM A194. Nut-bolt shall
be electro-galvanized.
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9.4 GROOVED PIPE JOINTING SYSTEM
A. References:
1. American Society for Testing Materials (ASTM)
a. ASTM A-53 – Pipe, Steel, Black and Hot-Dipped Zinc Coated, Welded
and Seamless.
b. ASTM A-183 – Carbon Steel Track Bolts and Nuts
c. ASTM A-234 – Standard Specification For Piping Fittings or

Wrought Carbon Steel and Alloy Steel.
d. ASTM A-449 – Quenched and Tempered Steel Bolts and Studs
e. ASTM A-536 – Ductile Iron Castings
f. ASTM F-1476 - Standard Specification for Performance of Gasketed

Mechanical Couplings for Use in Piping Applications
2. American Society of Mechanical Engineers
a. ASME B16.9 – Factory Made Wrought Butt Welded Fittings
b. ASME B31.1 – Chemical Plant and Petroleum Refining Piping

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c. ASME B31.9 – Building Services Piping
3. American Water Works Association
a. AWWA C-606 – Grooved and Shouldered Joints
B. Quality Assurance
All grooved components (including couplings, fittings, valves and accessories) to

be supplied by one manufacturer. Grooving tools shall be of the same
manufacturer as the grooved components.
C. Grooved Mechanical Couplings for Joining Carbon Steel Pipe
a. Grooved Mechanical Couplings: Manufactured in two segments of cast

ductile iron, conforming to ASTM A-536, Grade 65-45-12. Gaskets shall be
pressure-responsive synthetic rubber, grade to suit the intended service,
conforming to ASTM D-2000. (Gaskets used for potable water applications
shall be UL classified in accordance with ANSI/NSF-61 for potable water
service.) Mechanical Coupling bolts shall be zinc plated (ASTM B-633) heat
treated carbon steel track head conforming to ASTM A-449 and ASTM A-
183, minimum tensile strength 18,000 psi (758450 kPa) as provided
standard Victaulic.
i. Rigid Type: Coupling housings with offsetting, angle-pattern bolt pads

shall be used to provide system rigidity and support and hanging in
accordance with ANSI B31.1, B31.9, and NFPA 11.
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ii. Flexible Type: Use in locations where vibration attenuation and stress
relief are required. Flexible couplings may be used in lieu of flexible
connectors at equipment connections. Three Couplings shall be placed
in close proximity to the vibration source.
b. Flange Adapters: For use with grooved end pipe and fittings, for mating to
ANSI Class 150 flanges.
c. Grooved couplings shall meet the requirements of ASTM F-1476.
d. Gasket: Synthetic rubber, wide width, conforming to steel pipe outside

diameter and coupling housing, manufactured of elastomers as designated
in ASTM D-2000.
D. Grooved End Fittings: Fittings shall be cast of ductile iron conforming to ASTM A-
536, Grade 65-45-12, forged steel conforming to ASTM A-234, Grade WPB 0.375"
wall (9,53 mm wall), or fabricated from Std. Wt. Carbon Steel pipe conforming to
ASTM A-53, Type F, E or S, Grade B. Fittings provided with an alkyd enamel finish
or hot dip galvanized to ASTM A-153. Zinc electroplated fittings and couplings
conform to ASTM B633.
a. Grooved Hole-Cut Branch Outlets:
i. Bolted Branch Outlet: Branch reductions on 2"(DN50) through

8"(DN200) header piping. Bolted branch outlets shall be manufactured
from ductile iron conforming to ASTM A-536, Grade 65-45-12, with
synthetic rubber gasket, and heat treated carbon steel zinc plated bolts
and nuts conforming to physical properties of ASTM A-183.
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ii. Strapless Outlet: 1/2"(DN15) or 3/4"(DN20) NPT outlet on 4" (DN80)

and larger header sizes rated for 300 PSI (2065 kPa).
iii. Strapless Thermometer Outlet: To accommodate industrial glass bulb

thermometers with standard 1-1/4"-18 NEF 2B extra fine thread and
6" (152mm) nominal bulb length on 4" (DN80) and larger header sizes
rated for 300 PSI (2065 kPa).
9.5 Pressure independent balancing cum control valves
Each Air Handling Unit / Fan Coil Unit shall be provided with 2/3Way Pressure
Independent Balancing Cum Control Valve with Integrated in a single Body with Globe
Type in Construction.
Control - Valve should be equipped with electronic modulating actuator which can
accept either 4(0)-20 mA / 2(0)-10 V DC signals. Operating voltage for actuator shall be
24V AC. Delta p controller should ensure 100% valve authority at all loads (part load
Actuator shall be able to work against maximum closing pressure of 6 Bar at full load).
With feedback signal to Control system. 230/24V transformer shall be included.
Balancing – Each Valve should have steeples adjustable maximum flow limitation as per
the designed flow rate of coils. Balancing should be done only in Valve not in actuator so
that at any given condition of failure balancing is not lost and easily accessible.
All Valve actuator shall be microprocessor based with self calibrating feature.
Valve should be of linear control characteristics with stepless characteristics.

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9.6 VALVE SPECIFICATIONS
Description For 15 to 32 mm For 40 to 150 mm
Diff Pressure (P1-P3) 16 To 400 kPa 20 To 400 kPa
Media Temperature 5 ° to 120 °C 5 ° to 120 °C
Ambient Temperature 10 ° to 54 °C 10 ° to 54 °C
Body Material Brass (CuZn40Pb2 - CW 617N) Grey iron EN-GJL-250(GG25)
Internal Components 316 Stainless Steel 316 Stainless Steel
Test Ports Needle measuring nipple Needle measuring nipple
Leakage acc. to standard max.0,01 - 0.05% of kv at

max.0,01 - 0.05% of kv at 650N
IEC 534 650N
Stem Seals EPDM - CuZn40Pb2 - CW 617N EPDM -NBR
Maximum Close Off Pr 600 kPaD 600 kPaD
Maximum Operational Pr 400 kPaD 400 kPaD
Control Range Standard IEC 534 Since CV Characteristic is Linear Control Range is
Infinity
Control Valve Character Linear Characteristic with the help of Actuator in equal Ratio
Percentage
9.7 ACTUATOR SPECIFICATIONS FOR ALL SIZES
Supply Voltage : 24V AC (230/24 Transformer shall be included)
Power Consumption : 10V AC Max.

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Frequency : 50 HZ
Control Input : 2-10V DC, 4-20mA, 3-point Selection.
Position Output : 2-10V DC 4-20mA
Body Housing Insulation : Non Corrosive - IP 42 Till DN 40 & IP 54 Till DN 50 To 150.
Valve Body and Characteristics:-
1. Pressure Controller Device should maintain the Pressure irrespective of Fluctuation with
the help of Diaphragm self adjusting type and should not be in contact with each other.
2. Control valve shall accurately control the flow, with help of Modulating Actuator
3. All Valve Sizes should have a Testing Port Device for verifying accuracy of flow performance
with respective of Differential Pressure.
4. Flow regulation unit shall consist of stainless steel Material 316.
Valve Actuator and Housing:-
5. The Valve + Actuator must have ability to undertake both Logarithmic Control
Characteristics and Linear Control Characteristics. This shall ensures compatibility for both
Water/Air and Water/Water Heat Exchange.
6. Valve Actuator housing shall made of non Corrosive (Aluminum) Material. Valve actuator
housing shall be IP Protection (Weather Proof: Dust & Water Protected). Valve actuator
housing shall be acceptable to IP 42 Till 40MM and above should be IP54.
7. Control/Dip Switch Setting should be easy to Manual Access to avoid Manual Contact to
directly with Integrated IC Circuit of the system.
8. Actuator should not play a part in balancing process.
Valve Flow Balancing :
9. Balancing & Control : Balancing should be accomplished by the Diaphragm and Control
should be taken care by Actuator receiving signals from Room Thermostats or BMS.
10. Manual Override Flow Balancing should only be done in Valve , not in actuator and should
not involve opening of actuator Body.
 Flow Setting Balancing (Commissioning) for the Valves should be simple and fool proof.
 Should not involve opening of the actuator.
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 Should not need compulsory involvement of high end technicians.

 Should avoid direct Manual Contact with Integrated Circuit (IC) of the actuators.
9.8DRAIN PIPING
a. All pipes to be used for condensate drain and fittings shall be HDPE conforming
to relevant BIS Codes.
HDPE Pipes and Fittings
i) All AHU / FCU / HVAC equipment condensate drains
HDPE Pipes and fittings:-
General Specifications for Execution
i) High Density Polyethylene (HDPE) pipes and fittings confirming to ISO 8770 / 8772; BS
5572 / 6367; EN 1519-1; DIN 8075 / DIN 8074 / EN12666-1 and pressure classified as
PE80 in accordance with DIN 8075 shall be used throughout the project.
ii) The density of the material shall be 0.95 g/cm3 and shall have melting Index MFI: 190/5
<=1.1 g/10min.
iii) All pipes must be black in colour with a minimum of 2% carbon black to prevent UV
degradation.
iv) The pipes and fittings shall be of uniform material throughout and shall be free from all
manufacturing defects.
v) G.I. Heavy class pipe sleeves of specified diameter corresponding to the pipe size shall be
provided wherever the pipes are crossing the fire rated walls/floors slab and sealing the
sleeves with glasswool in between and fire sealant compound on either end, all as per E-
I-C's requirement.
vi) Rubber lined stainless steel clamps and brackets, legend boards shall be used for the
installation in the vertical shafts.
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vii) All pipes and fittings for the entire project shall be sourced from the single reputed
vendor.
viii) Installation shall be to the satisfaction of Engineer in charge.
HDPE Fittings
i) Fittings shall be moulded and absolutely tight. They shall be flexible so to prevent the
cracks and breaks.
ii) The fittings shall be free of blisters, bubbles and sink marks. The end must be cut
vertically to the fitting axis and free of burr.
iii) The fittings must have a smooth inner and outer surface. Insignificant wavy grooves and
irregularities in wall thickness caused by these are only allowed, if they do not fall short
of the minimum thickness. Not allowed are in any case sharp-edged grooves.
iv) The deviation between the largest and smallest diameter of the fitting may not exceed
the following values:
 Ø 32 - 50: max. 1 mm
 Ø 56 and above max. 2 %
HDPE Pipes
i) The pipes must be free of blisters, bubbles and sink marks.

ii) The end must be cut vertically to the pipe axis and free of burr.
iii) The pipe must have a smooth inner and outer surface. Insignificant wavy grooves and
irregularities in wall thickness caused by these are only allowed, if they do not fall short
of the minimum thickness. Not allowed are in any case sharp-edged grooves.
iv) The inner and outer diameter of pipes along with the allowable weight and operation
pressure for different pipe sizes shall be as below table
EN 1519-
Outside Actuall Inside 1 Weight Max. Series
Dia wall Dia wall empty allowable (ISO)
d(mm) thickness di(mm) thickness kg/m operation S

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s (mm) (s) mm pressure
32 3 26 3 0.259 10 5
40 3 34 3 0.331 7.9 6.3
50 3 44 3 0.42 6.2 8
56 3 50 3 0.471 5.5 -
63 3 57 3 0.536 5 10
75 3 69 3 0.644 4 12.5
90 3.5 83 3.5 0.903 4 12.5
v) EN 1519-1 wall thickness must be printed on pipes

vi) Max. allowable operation pressure conditions shall be: max. 20°C for 50 years, with a
security factor 1.6 (SF 1.6)
vii) Standard length of HDPE pipes shall be minimum 5 meters
viii) The maximum allowed deviation from straightness of a pipe 1 meter long resting on a
flat surface shall not be more than 2 mm.
ix) The pipe shall be permanently marked with the following information:
 Licence and logo of the selected company

 Outer diameter and wall thickness 110 x 4.2 (wall thickness according EN 1519-
1)
 Material: PE 80
 Week/year of manufacturing: xx/yyyy
 Supervisor mark: A
x) The pipes are to be tempered in such a way, that when tested according DIN 8075, 6.5,
the heat reversion does not exceed the following values:
Change in: radial dimension: < 0.6 %
axial dimension: < 1.0 %
Jointing method
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The HDPE drainage system jointing system shall depend on the method of construction. Any of
the following joining methods shall be used:
 Butt welding,
 electroweld sleeve coupling,
 ring seal socket,
 linear expansion socket,
 screw-threaded joint or
 flange joint.
Installation method
i) All pipe and fitting joints including the joint to the outlet will be fusion welded either
electro sleeve coupling or butt weld.
ii) Expansion joints must be provided at a maximum of 5 metre intervals and / or changes
in direction more than a metre apart unless clipping are positioned to allow movement.
iii) Intermediate sliding supports must be provided in accordance with the manufacgturer’s
application technique manual.
iv) Alternative fixing of horizontal pipes in excess of 1m in length may be made using the
pipe bracket to a square rail immediately above the pipe.
v) Fixed points must be provided at 5m intervals by a means of a welded sleeve on the pipe
and a bracket between the sleeve and the square rail. The rail shall be fixed to the roof
structure at maximum intervals of 2.5m. The contractor / installer should allow for some
secondary bracketing as a result of the height from fixing rail to roof structure.
vi) Intermediate sliding supports to fasten the pipe to the rail shall be at the following
intervals:
Pipe 40mm to 75mm diameter : 0.8m.
Pipe 90mm diameter and above : 10 x overall pipe diameter.
Inspection and Testing
The work shall be inspected and tested during installation at agreed stages. All work which will
be concealed shall be tested before it is finally enclosed. A final test shall be made upon
completion for soundness and performance in accordance with BS EN 12056 Code of Practice
for Sanitary Pipe work.
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All completed soil & waste systems to be air tested to a minimum of 38mm water gauge over 3
minutes. There will be no drop in pressure during this period in time.
Storage of material
i) Pipes stored in the exposed shall be protected against deformation by covering.

ii) Pipes may not be stacked to heights that could result in deformations exceeding the
allowed tolerances.
iii) All other care shall be taken for the storage of pipes and fittings as per the above
description for HDPE pipes
9.9 REFRIGERANT PIPING
a. All refrigerant pipes and fittings shall be hard drawn copper tubes and
wrought copper / brass fittings suitable for connection with silver solder / phos-
copper.
b. All joints in copper piping shall be sweat joints using low temperature brazing
and / or silver solder. Before jointing any copper pipe or fittings, its interiors
shall be thoroughly cleaned by passing a clean cloth via wire or cable through its
entire length. The piping shall be continuously kept clean of dirt etc. while
constructing the joints. Subsequently, it shall be thoroughly blown out using
carbon dioxide / nitrogen.
c. Refrigerant lines shall be sized to limit pressure drop between the evaporator
and condensing unit to less than 0.2 kg per sq.cm.
d. Sight glass with moisture indicator and removable type combination dryer cum
filter with GI/ MS housing and brass wire mesh / punched brass sheet shall be
installed in liquid line of the refrigeration system incorporating a three valve by
pass. After ninety days of operation, liquid line drier cartridges shall be replaced.
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e. Heat exchanger shall be GI/ MS heavy duty pipe in pipe type and without any
joint in the inner pipe.
f. Horizontal suction line shall be pitched towards the compressor and no reducers
shall be provided for proper oil return.
g. After the refrigerant piping installation has been completed, the refrigerant
piping system shall be pressure tested using Freon mixed with nitrogen /
carbondioxide at a pressure of 20 kg per sq. cm (high side) and 8 kg per sq. cm
(low side). Pressure shall be maintained in the system for a minimum of 12
hours. The system shall then be evacuated to a minimum vacuum of 70 cm of
mercury and held for 24 hours. Vacuum shall be checked with a vacuum gauge.
h. All refrigeration piping shall be installed strictly as per the instructions and
recommendations of air conditioning equipment manufacturer.
PIPING INSTALLATION
a. Design Drawings indicate schematically the size and location of pipes. The
Subcontractor, on award of the work, shall prepare detailed shop drawings,
showing the cross-section, longitudinal sections, details of fittings, locations of
isolating and control valves, drain and air valves, and all pipe supports. He must
keep in view the specific openings in the building through which pipes are
designed to pass.
b. Piping shall be properly supported on, or suspended from, stands, clamps,

hangers as specified and as required. The Subcontractor shall adequately design
all the brackets, saddles, anchors, clamps and hangers and be responsible for
their structural sufficiency. All pipes in HVAC plant room shall be supported with
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pipes and channels from floor only with necessary PUF pipe supports and
resistoflex sheet.
c. Pipe supports shall be of steel, adjustable for height and primer coated with
rust preventive paint and finish coated black. Where pipe and clamps are of
dissimilar materials, a gasket shall be provided in between. Spacing of pipe
supports shall not exceed the following :
_____________________________________________________________________
Pipe size Spacing between supports Rod Size
_____________________________________________________________________
Upto 12 mm 1.5 Meter 8 mm
15 to 25 mm 2.0 meter 8 mm
30 to 150 mm 2.0 meter 8 mm
Over 150 mm 2.5 meter 12.5 mm
d. Vertical pipes passing through floors shall be plumb and parallel to wall. Pipes
shall be supported on alternate floor. MS cleats shall be welded on pipes and rest
on MS channel placed on the floor with 15 mm thick resistoflex pads between the
cleat and channel. U clamps with resistoflex sheet shall be provided to keep the
pipe in position.
e. Bull heading in water/refrigerant piping shall be avoided.
f. Pipe sleeves atleast 3 mm thick, 50 mm / 80 mm larger in diameter than

condenser / chilled water pipes respectively shall be provided wherever
pipes pass through retaining wall and slab. Annular space shall be filled with
fibreglass and finished with retainer rings welded on the ends of the sleeve.
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g. Wherever pipes pass through the brick or masonry / slab openings, the gaps shall
be sealed with fire sealant such as fire barrier caulks.
h. Insulated piping shall be supported in such a manner as not to put under

pressure on the insulation. 20 gauge metal sheet shall be provided between the
insulation and the clamp, saddle or roller, extending atleast 15 cm on both sides
of the clamp, saddles or roller.
j. All piping work shall be carried out in a workmen like manner, causing
minimum disturbance to the existing services, buildings and structure. The
entire piping work shall be organized, in consultation with other agencies work,
so that laying of pipes, supports, and pressure testing for each area shall be
carried out in one stretch.
k. Cut-outs in the floor slabs for installing the various pipes are indicated in the
Drawings. Subcontractor shall carefully examine the cut-outs provided and
clearly point out where the cut-outs shown in the Drawings do not meet with the
requirements. Also point out where PEB cut-outs are required & seek approval
from Owner & to make PEB cutout from Specialised Subcontractor.
l. The Subcontractor shall make sure that the clamps, brackets, clamp saddles and
hangers provided for pipe supports are adequate. Piping layout shall take due
care for expansion and contraction in pipes and include expansion joints where
required.
m. All pipes shall be accurately cut to the required size in accordance with relevant
BIS Codes, edges bevelled and burrs removed before laying. Open ends of the
piping shall be closed as the pipe is installed to avoid entrance of foreign
matter. Where reducers are to be made in horizontal runs, eccentric reducers
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shall be used for the piping to drain freely. In other locations, concentric
reducers may be used.
n. Flanged inspection pieces 1.5 meters long, with bolted flanges on both ends,
shall be provided no more than 30 meters centres, or where-ever shown in
Approved-for-Construction shop drawings, to facilitate future cleaning of all
welded pipes.
o. All buried pipes shall be cleaned and coated with zinc chromate primer and
bitumen paint, and placed on concrete blocks with PUF saddles dipped in
bitumen at every 2 meters and wrapped with three layers of fibre glass tissue,
each layer laid in bitumen.
p. Insulated buried pipes shall be cleaned, derusted, then coated with rust-
resistant primer and placed on concrete blocks with PUF saddles dipped in
bitumen at every 2 meters. Insulation shall be applied as per the section
“Insulation”, wrapped with GI wire and covered with polyethylene sheet. Two
coats (each 6 mm thick) of cement plaster shall be applied over chicken wire
mesh lath. Where indicated in Schedule of Quantities, buried insulated pipes
shall be water-proofed using coat of Shalibond, or approved adhesive, over the
plastered surface; wrapping one layer of fibre glass RP tissue and one layer of
roofing tarfelt with sufficient overlaps, set and sealed with the adhesive, held
in position by 16 gauge G.I wire tied at 15 cm intervals.
q. Auto purge valves shall be provided at all highest points in the piping system for
venting air. Air valves shall be 15 mm pipe size with screwed joints.
Discharge from the air valves shall be piped through an equal sized mild steel or
galvanized steel pipe to the nearest drain or sump. These pipes shall be
pitched towards drain points.
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9.10 PRESSURE GAUGES AND THERMOMETERS
a. Pressure gauges as specified under section “Automatic Controls and

Instruments” shall be provided at suction and at discharge of each pump, at
chilled water supply and return at each air handling unit, at each chillers and
condenser, and as shown on the Drawings and included in Schedule of
Quantities. Care shall be taken to protect pressure gauges during testing.
Pressure gauge sockets on insulated pipes and accessories shall be extended upto
insulation to avoid damage of insulation for replacement of gauges.
b. Thermometers as specified under section “Automatic Controls and

Instruments” shall be provided at chilled water supply and return at each air
handling unit, at each chiller and condenser, and as shown on Drawings and
included in Schedule of Quantities.
c. Thermometers on CHW lines shall be with long stem. Thermometer socket shall
be extended upto insulation thickness so that the thermometer shall be
removable without damaging the insulation.
TESTING
a. During construction , the Subcontractor shall properly cap all lines, so as to

prevent the entrance of sand, dirt, etc. Each system of piping shall be flushed
thoroughly after completion (for the purpose of removing dirt, grit, sand etc. from
the piping and fittings) for as long a time as is required to thoroughly clean the
system.
b. All piping shall be tested to hydrostatic test pressure of atleast two times the
maximum operating pressure, but not less than 8 kg per sq. cm gauge for a
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period of not less than 24 hours. All leaks and defects in joints revealed during
the testing shall be rectified, retested and gotten approved
c. Piping repaired subsequent to the above pressure test shall be re-tested in the
same manner.
d. Piping may be tested in sections and such sections shall be securely capped, then
re-tested for the entire system.
e. The Subcontractor shall give sufficient notice to all other agencies at site, of his
intention to test a section or sections of piping and all testing shall be witnessed
and recorded by Owner’s site representative.
f. The Subcontractors shall provide temporary pipe connections to initially by-pass

condenser/chiller and circulate water through condenser/chilled water pipe
lines for minimum 8 hours. Water should be drained out from the lowest point.
The temporary lines shall be removed and blanked with dead flanges. Pot
strainers and Y strainers shall be cleaned and fresh water filled in the circuits.
g. The Subcontractor shall make sure that proper noiseless circulation of fluid is
achieved through all coils and other heat exchange equipment in the system
concerned. If proper circulation is not achieved due to air bound connection,
the Subcontractor shall rectify the defective connections. He shall bear all
expenses for carrying out the above rectifications including the tearing up and
re-finishing of floors and walls if required.
h. After the piping has been installed, tested and run for atleast three days of
eight hours each, all insulated exposed piping in plant room shall be given
two finish coats, 3 mils each of approved colour, conforming to relevant BIS
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Codes. The direction of flow of fluid in the pipes shall be visibly marked with
identifying arrows. For painting of insulated and clad pipes refer to Insulation
section.
j. After testing, all systems shall be chemically cleaned. After cleaning, the pipe
work should be rinsed multiples times until the system is neutral. Chemical
cleaning shall be carried out in 3 stages. In first stage biological cleaning shall be
done to remove algae, bacteria, SRB etc which produces slimes. Second stage is
pre-cleaning in which loose rust, oil, and debris are removed. Chemical addition
and hold up time shall be as per chemical supply agencies recommendations.
Third stage is passivation, in which chemicals will be added and passivation film
will be formed over inside surfaces of piping system. Type of chemical used and
quantity of the same along with detailed method statement shall be submitted by
Subcontractor before starting this activity.
Before handover Owner’s site representative shall be provided with certificate of

cleaning of pipe systems, signed by the Subcontractor.
k. The Subcontractor shall provide all materials, tools, equipment, instruments,

services and labour required to perform the test and to remove water
resulting from cleaning and after testing.
BALANCING
a. After completion of the installation, all water system shall be adjusted and
balanced to deliver the water quantities as specified, quoted, or as directed.
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b. All balancing valves, Automatic control valves and two-way diverting valves
shall be set for full flow condition during balancing procedure. Each water
circuit shall be adjusted thru balancing valves provided for this purpose; these
shall be permanently marked after balancing is completed, so that they can be
restored to their correct positions, if disturbed.
c. Complete certified balancing report shall be submitted for evaluation and

approval by Owner’s site representative. Upon approval, four copies of the
balancing report shall be submitted with the as-installed drawings and
completion documents.
VALVE IDENTIFICATION
Provide 30 mm dia brass valve tag, with embossed letters and number for each valve
and attach the tag to valve handle by “S” hook or by suitable means. Subcontractor shall
provide valve tag schedule and valve chart for each piping system, consisting of
schematic drawing of piping layout, along with a valve list, showing and identifying each
valve by number, service and location and describing its function.
The Subcontractor shall frame under glass in the airconditioning plant room or as
directed by Owner’s site representative two copies of valve chart. Two additional
unmounted copies shall be supplied to the Owner’s site representative.
Tags shall correspond with the valve schedule and record drawings. In back of house
areas, where ceilings are installed and the valve or valve tag is not visible, a self adhering
tag with the valve number shall be installed on the wall or directly under the ceiling. For
public area ceiling valves, these tags are to be installed in the service corridor, leading to
the public areas.
MEASUREMENT FOR PIPING

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Unless specified otherwise, measurement for piping for the project shall be on the
basis of centre line measurements described herewith.
Piping shall be measured in units of length along the centre line of installed pipes
including all pipe fittings, flanges (with gaskets, nuts, and bolts for jointing), unions,
bends, elbows, tees, concentric and / or eccentric reducers, inspection pieces,
expansion loops etc. The above accessories shall be measured as part of piping length
along the centre line of installed pipes, and no special multiples of pipe lengths for
accessories shall be permitted.
The quoted rates for centre line linear measurements of piping shall include all
wastage allowances, pipe supports including hangers, MS channel, PUF supports, nuts,
check nuts, vibration isolator suspension where specified or required, and any other
item required to complete the piping installation as per the Specifications. None of
these items will be separately measured nor paid for.
However, all valves (gate / globe / check / balancing / purge / butterfly / drain etc),
strainers, thermometers, pressure gauges shall be separately counted and paid as
per their individual unit rates, which shall also include their insulation as per
Specifications. Piping measurements shall be taken before application of the insulation.
Subcontractor shall get pressure testing of pipes/measurements etc verified by the

Owners representative at site.
9.11 NITRIBLE RUBBER INSULATION FOR REFRIGERANT PIPES

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The material used shall Closed cell elastomeric nitrile rubber for copper pipes, suction & liquid
lines, condensate drain pipes, sheet metal ducting for both thermal & acoustic purpose
The material used shall conform to the following requirements:
 Density : Not less than 60 kg/cum

 Thermal conductivity : Not less than 0.035 W /m K
 Water Vapour : greater than 7000
Permeability
 Fire propogation : total Index performance less than 12

Sub index less than 6
Conforms to BS 476 P 6/7
 Reaction to Fire : Self-extinguishing. Does not drip
 Fire Performance : Class ‘O’

 Health aspects : CFC /HCFC free
Dust & Fire Free
 Corrosion risk : PH neutral

 Resistance to : Building Material: Very good
Ozone : Very good
The owner reserves the right to require that the weights, dimensions, etc., of the
materials supplied be measured and shown to conform to the values specified.
a. Refrigerant Pipe Insulation

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The whole of the liquid and suction refrigerant lines including all fittings, valves
and strainer bodies, etc. shall be insulated with 19mm /13 mm thick elastomeric
nitrile rubber as specified in BOQ.
b. Drain Pipe Insulation
Drain pipes carrying condensate water shall be insulated with 6 mm thick

elastomeric nitrile rubber insulation.
For proper drainage of condensate, U Trap shall be provided in the drain piping
(wherever required). All pipe supports shall be of prefabricated & pre painted
slotted angle supports, properly installed with clamps etc.
To protect nitrile rubber insulation of exposed copper piping from degrading due to
ultra violet rays & atmospheric condition, it shall be covered with Aluminum foil for
above nitrile rubber insulation. Fiberglass tape shall be helically wound & coated with
painted two coats of resin with hardener to give smooth & plain finish.
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SECTION-10
STANDARDS FOR MEASUREMENT

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10. MEASUREMENTS
The following procedure for measurement shall be followed for purpose of billing in case
of items subject to variation in quantities.
Ducting:
10.1 Payment for ducting shall be on the basis of the external surface area of the ducting.
10.2 The rate per square meter of the external surface shall include flanges, gaskets for joints,
bolts and nuts, duct supports and hangers, vibration isolation pads or suspenders,
flexible connections, inspection doors, dampers, turning vanes, straightening vanes, and
any other item which will be required to complete the duct installation except external
insulation and finish thereon.
10.3 The external area shall be calculated by measuring the over-all width and depth
(including the corner joints) in the centre of the duct section and over-all length of each
duct section from flange face to flange face in case of duct lengths with uniform cross
section. Total area will be arrived at by adding up the areas of all duct sections.
10.4 In case of taper pieces average width and depth will be worked out as follows:
W1 = Width of small cross section
W2 = Width of large cross section
D1 = Depth of small cross section
D2 = Depth of large cross sectio

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Average Width = W1 + W2
Average Depth = D1 + D2
Width and depth in the case of taper pieces shall be measured at the edge of the collar of
the flange for duct / sections fitted with angle iron flanges; otherwise at the bottom of
the flange where the flanges are of GSS. Face to face length for taper piece shall be the
mean of the lengths measured face to face from the centre of width and depth flanges.
10.5 For special pieces like bends, branches, and tees, etc., the same principal of area
measurement as for linear lengths shall be adopted, except for bends and elbows, the
length of which shall be the average of the lengths of inner and outer periphery along the
curvature of angle of the piece.
10.6 Duct measurements for calculation of area shall be taken before application of
insulation.
Uninsulated Piping:
10.7 Payment for uninsulated piping shall be on the basis of linear measurement including all
material and labour for installed pipe.
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10.8 The linear rate per meter for each nominal diameter shall include all pipe fittings,
flanges, unions, gaskets for joints, bolts and nuts, pipe supports and hangers, vibration
isolation devices or suspenders, flexible connections and any other item required to
complete the pipe installation except valves of any kind and strainers. The rate for
underground piping shall also include cost of excavations and back filling and finishing
the surface. The length of the pipe sections with flanges shall be from flange face to
flange face.
10.9 For fittings like bends, elbows, and tees etc., same principal of linear measurements as
for pipe sections shall be adopted except for bends, the length of which shall be the
average of the lengths of inner and outer periphery along the curvature.
10.10 Payment for valves and strainers will be on unit basis. Where they are insulated
the cost shall include cost of insulation.
10.11 The linear measurement shall be taken before the application of insulation.
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SECTION-11
HVAC SYSTEM TESTING & BALANCING

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11. Air Systems Testing, Adjusting, And Balancing
A) General
i) Work Included
This section specifies the requirements necessary for services required to

measure, test and adjust, and record, complete, the air system capacities to match
design conditions for airflow capacity and space pressurization. The air systems
to be tested, adjusted, and balanced include but are not limited to:
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a) General purpose and comfort air handling systems.

b) General purpose and building exhaust systems.
ii) Qualifications
a) All air systems shall be tested and adjusted under the direct supervision of
a qualified registered professional engineer, or an independent firm
specializing in air system testing and balancing.
b) The Subcontractor’s Project Manager shall have a minimum of 5 years of
experience testing and adjusting building air handling systems. He shall
supervise all aspects of field measurements, select appropriate tests,
consult with Subcontractor and Owner on technical matters, and approve
the test report.
c) The Subcontractors Field Engineer shall have a minimum of 2 years of
experience testing and adjusting air handling systems as a field engineer
or field technician. He shall supervise all field technicians assigned to
complete the testing and adjusting of the work covered by this section, and
shall be responsible for all onsite testing and data acquisition. No field
tests shall be taken without Owner / Project Managers presence.
d) All field technicians shall have completed previous training in building
mechanical systems and air balancing procedures, shall have worked in
this capacity on at least one other similar project, and shall only work
under direct supervision of the Field Engineer.
iii) Submittals
Provide the following in addition to the standard requirements with the Bid:
a) Qualifications of all field technicians, the Field Engineer, the Project

Manager, Pertaining to execution of HVAC system
A list shall be available upon request of projects similar in size and

complexity to this project that the firm has completed. Include the project
name, description of mechanical system, range of services provided, and
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the name and phone number of the Owner who had responsibility for final
inspection and acceptance of the service.
A list shall be available upon request of projects similar to this project that the
Field Supervisor or project Manager has managed and/or adjusted.
b) Written presentation outlining the testing, adjusting, and balancing

procedures to be performed.
c) Description of all instrumentation and test equipment to be used, as well
as calibration documentation.
d) Samples of all field reports, charts and forms proposed to document
measured conditions. A sample test report for a similar project shall be
available for inspection by Subcontractor and Owner to verify the
Subcontractors expertise is data collection and interpretation.
iv) Required at completion of Balancing Work:
a) Orderly computerized field reports, charts, and forms completed with all
measured data.
b) Description of operating condition of all general purpose and clean areas.
c) Reduced set of owner floor plan drawings, maximum size 11 by 17 inches,
showing all sample points referred to on other field data sheets.
d) Separate section in the report outlining any operating or balancing
problems remaining at the end of the testing and adjusting procedures.
Describe the condition and its effect on the room pressurization levels and
the recommended remedies.
e) A list of all instrumentation and test equipment actually used in the
balancing process, including manufacturer, model and has calibration
date.
f) Description of all tests performed, including the purpose, instrumentation,
procedure, results and analysis of the data. All data shall be properly
presented and graphically displayed to permit full understanding of all
tests. Include the date test were taken and the field technicians performing
the tests.
g) Six copies of the completed Air Balancing Report shall be submitted by
Subcontractor for Owner review and acceptance.
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v) Products
Authorized Balancing Agencies
Materials and Testing Equipment
a) The Subcontractor shall supply all materials, tools, equipment, and

Instrumentation required to perform the air system balancing as described in
this section.
b) All test equipment used in the testing and balancing procedure shall be
precision instruments recognized by the industry as being applicable for the
intended use. Coordinate work with section 15951, piping systems Adjusting
and Balancing. Calibration of equipment shall be traceable to NBS Standards
within the previous 12 months.
c) Air velocity measurements shall be taken with a calibrated air measuring
cone. In areas where in air measuring cone is not practical, a Velgrid velocity
instrument, registered by Short ridge instruments, Will be accepted to take
direct velocity measurements at the face of the ceiling outlet.
d) Pressure differential measurements shall be taken with a portable liquid-filled
inclined manometer or a magnahelic gauge, or equivalent calibrated
instrument
e) Noise Level Tests shall be taken with precision sound level meters recording
data in all eight octave bands as well as the third level band. Sound meter shall
be Bruel and Kjaer, or similar, by General Radio.
f) Airflow in ducts shall be measured with a pilot tube, if sample ports are
specifically provided. (Do not drill coated stainless steel exhaust ducts.)Drill
and plug duct at sample point. Sample in center of equal areas of ducts.
Execution
Preparation
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a) Pre-balancing Conference: Prior to commencing with balancing, the

Subcontractor shall meet with Project Managers and Owner and Certification
Agency to review the systems and the balancing procedures, and to ensure
that the Subcontractor has a full understanding of the requirements.
Equipment Verification:
a) Identify all equipment to be tested.

b) Verify that the equipment installed corresponds with the latest shop drawings
and that ducting and piping correspond with the latest plans. Notify
Subcontractor of any deviations that may cause under performance.
c) Record the installed size, type, manufacturer, rating and capacity of all
equipment to be tested, including air outlets and inlets.
vi) General Air Balancing Procedures
General:
Adjust air systems in accordance with standard procedures and recognized practices
of the Associated Air Balance Council.
Fan and airflow adjustments have been corrected for the jobsite elevation airflow
values shown are the actual air quantities necessary for proper heat transfer. The
Balance Logs shall indicate the recorded jobsite values, and all velocity and mass
correction factors used to provide equivalent standard air quantities.
Outlets and Inlets:

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Adjust diffusers, registers, and grilles for proper deflection, throw and coverage.
Check for drafts and noise, and eliminate where possible. Adjust diffusers installed as
four-way blow to three-way or two-way blow if required to eliminate collision of
airstreams.
Adjust air volumes for supply diffusers and grilles, and for return and exhaust grilles
to the quantities shown , with allowable variation of plus 10, minus 0 percent.
Mark final positions of all balancing dampers with felt pen. Recommend addition or
replacement of dampers as necessary to obtain proper air control. When major
adjustments are made to a portion of any fan system, all other portions of that same
system must be re- read to determine the effects imposed by the adjustments.
vii) Equipment:
Air Moving Equipment:
Adjust fan speeds, active wheel widths, or blade settings to obtain required
equipment air volumes, with allowable variation of plus 10, minus 0 percent. After
final adjustment, motor amp draw shall not exceed nameplate amperage on any
phase, and fan must not exceed ist maximum rated RPM. Perform airflow test
readings under simulated or actual conditions of maximum cooling maximum
heating minimum outside air, maximum outside air and exhaust, and maximum
return air.
When directed, make all drive and belt changes, furnishing belts and sheaves to
adjust equipment to the specified conditions. Provide written notice to all air handler
manufacturers if any drive or belt changes were made.
Adjust all outside air dampers, supply dampers, return air dampers, bleed off air
dampers, and exhaust air dampers for air requirements.
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Record static pressure readings at each unit inlet and discharge, and on inlets and
outlets of filters, coils, dampers and plenums for every supply, return and exhaust
fan, and for all air handlers.
Record equipment nameplate data on all fans, motors, heaters, coils etc., indicating
equipment identification, motor and drive data, and starter and heater data.
Air Terminal Units:
Measure the difference between inlet and discharge static pressures to ensure that
sufficient pressure differential exists for the terminal unit to operate in control.
Verify that terminal unit controls are operating properly, that stroke is from full open
to full close, and that operation is smooth and without binding. If corrective
measures are required, notify the controls installer.
Verify that sensors are free of blockage and sensing a fully developed air flow profile.
Set air terminal unit volumes using the inlet velocity probe when provided with unit.
Where upstream conditions prevent accurate readings, measure the air volume using
a pilot traverse at an alternate location where accurate readings may be taken. Only
in the absence of an acceptable traverse point may methods such as controller set
point, sums of the outlets, down streams pitot traverse, and mixed temperature be
used to determine terminal unit air volume. Two confirming readings using different
methods shall be taken.
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Record inlet and outlet static pressures with terminal units set to design maximum
air volume.
11. Systems Startup And Commissioning
B) General
a) Work Included
This section specifies the requirements for pre-balance, start-up, and

commissioning of mechanical systems, including, but not limited to:
i) General purpose and comfort air handling systems.

ii) General purpose and building exhaust systems.
iii) Chilled water systems.
Requirements for the following are included:
i) HVAC systems pre-balancing.

ii) HVAC systems manual run.
iii) HVAC systems balancing.
iv) HVAC control system testing.
v) HVAC systems commissioning.
vi) HVAC systems 72-hour acceptance test.
b) Related Work:
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This section shall be used in conjunction with the following other specifications
and related Contract Documents to establish the total standard requirements for
HVAC systems startup and commissioning.
i) Provide services described in this section and in accordance with Owner startup
Program see the Systems Startup and commissioning Appendix, at the end of this
section. Contact Owner for a copy of this document.
c) Quality Assurance
i) ASHRAE Project Managers Guideline 1, The HVAC Commissioning Process.
d) Definitions
HVAC systems commissioning consists of the following:
i) Verify operation and functional performance of HVAC systems for compliance

with design documents.
ii) Document HVAC test inspections.
iii) Verify application of operation and maintenance manuals, as-built (record)
documents, spare parts listing, special tools listing, and other items as may be
specified herein for support of HVAC systems and equipment.
iv) Coordinate and direct training to personnel for operation and maintenance of
HVAC equipment and systems.
e) Documentation
The Subcontractor shall prepare and have ready the following documents at
the start of commissioning:
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i) Project plans and specifications (Subcontract documents), authorized

revisions, HVAC shop drawings and submittals (approved), test and balance
reports, equipment startup and certification reports etc.
ii) Records of required code authority inspections documentation signoff, etc.,
f) Submittals
Submit the following for approval prior to starting the commissioning process:
i) Commissioning plan (Scheduling, sequence, documentation requirements,

verification procedures, staffing requirements, etc.,)
ii) Training plan (scheduling, sequence of training personnel involved, etc.,)
iii) Tool list.
After commissioning is complete, the subcontractor shall submit all

documentation obtained during the commissioning process to Owner.
B) Products
Instrumentation
Instrumentation shall be provided by the Subcontractor or agency performing prior

tests. Instruments shall be operated by individual Subcontractor or agency as
requested by Subcontractor.
C) Execution
i) General
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a) Subcontractor personnel involved in commissioning (commissioning

team) shall actively participate in construction phase of the project to
ensure compliance with HVAC commissioning requirements.
ii) Procedure
a) Commissioning team shall attend pre-construction meeting and establish

requirements for HVAC commissioning authority process throughout
construction phase.
b) Commissioning team shall prepare and submit to Subcontractor and
Owner an HVAC commissioning outline which shall include:
aa) Responsibility of each trade affected by HVAC commissioning, as

required by appropriate paragraph of this section.
bb) Requirement for documentation of commissioning process.
cc) Requirements for documentation of HVAC test and inspections
required by code authorities.
dd) Format for training program for operation and maintenance personnel.
ee) Commissioning team shall periodically attend construction and

coordination meetings.
iii) HVAC systems Pre-Balance
Subcontractor shall perform the following work for pre-balancing of all air and hydraulic
systems:
A. Prior to completion of the duct and piping systems, the mechanical subcontractor
shall coordinate and fully cooperate with the balancing subcontractor. All
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drawings shall be checked and any dampers, balancing valves, or devices not
shown on the drawings, but necessary for proper balance as determine by the
balancing subcontractor, shall be added or relocated at no additional cost. After
completion of the duct and piping systems, the mechanical and balancing
subcontractors shall both certify, in writing, to Owner that the systems have been
checked and that all devices are installed to facilitate the balancing work.
B. Complete all duct and piping pressure testing as specified.
C. Complete all punch list items which may affect balancing.
D. Remove all shipping and storage protection; remove shipping locks from
vibration isolators and clean debris from under all isolated equipment.
E. Check all motors for rotation. Log RPM, voltage, and amps.
F. Check starter heater size for conformance with motor nameplate data.
G. Adjust and align all sheaves and belts; set all adjustable sheaves to provide
specified RPM. Ensure all rotating components turn freely without interference
or binding.
H. Install temporary construction filters or media as required.
I. Set all dampers, diffusers, grilles, extractors, inlet vanes, valves and balance
valves to the full open position.
J. The controls subcontractor shall, either via the control system or manually at
each device, fully open all automatic control valves and dampers.
K. Drill all probe holes required for static pressure readings, pitot tube traverse
readings, and temperature readings. Coordinate locations with balancing
subcontractor. Install plastic plugs in all such holes.
L. Clean interior of all plenums, casings, and ducts and install all specified filters.
M. Lubricate all equipment per manufacturer’s recommendations and provide
access to lubrication fittings as required.
N. Align all pumps and ensure that bases are grouted as required; check alignment
of all flexible pump connectors.
O. Flush clean all piping systems from debris. Treat piping systems with chemicals,
if required.
P. Fill, bleed and charge with chemicals all piping systems.
iv) HVAC Systems Manual Run
Upon the completion of above and the submission of the documentation required for
above items, the subcontractors shall perform the following:
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a) Charge and start chillers, boilers, cooling towers, pumps, and all other major
pieces of equipment. Manufacturers representatives shall perform the startup of
all major equipment. Setting of all operating and limit equipment controls shall
also be by manufacturers representative. Log all settings and furnish a startup
report for each piece of equipment.
b) Check all systems and equipment for excessive noise and vibration. Check and
adjust all spring isolators and replace any that are “bottomed out”. Any problem
area shall be reported to Subcontractor and Owner for corrective action.
c) Perform final vibration balance and testing for equipment requiring vibration
balancing after installation as specified.
d) Operate all equipment manually (in the LOCAL or HAND mode) for a minimum of
5 consecutive 8-hour days. All variable frequency drives shall be set to HAND or
MANUAL (not BYPASS) with the output set at 100 percent. Repair or replace any
piece of equipment which fails during this period and restart the test for that
machine.
e) After such time as all systems have been successfully operated for the
aforementioned 5-day period, the mechanical subcontractor shall so notify
Owner so that the balancing subcontractor may begin his work.
f) At the completion of the above test run, remove all startup strainers. Clean all
permanent strainers. Replace temporary filters and/or clean permanent filters.
Generally make all systems ready for full time operation.
v) HVAC Systems Balancing
a) Air and water balancing have been specified under separate paragraphs of this
section. The Subcontractors shall provide the following support during balancing:
b) Make available a qualified technician for 10 man-hours to assist and instruct the
balancing subcontractor. The Subcontractor shall document (via daily time
vouchers signed by Subcontractor) any labour thus expended. At the completion
of the project the Subcontractor shall credit to Owner any unused labour at
standard hourly rates per the BID Form.
c) The mechanical subcontractor shall operate and maintain all equipment and
systems for the use of the balancing and controls subcontractors from the time of
initial startup until the successful completion of the final 72-hour test, Owner
acceptance, and start of the warranty period.
d) It shall be the responsibility of the balancing subcontractor to determine and
convey to the mechanical subcontractor to determine and convey to the
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mechanical subcontractor the sizes of any required fan sheave changes. Any
sheave replacements shall be the responsibility of the balancing subcontractor
and will be treated as a change order for this project.
vi) HVAC Control System Testing
a) The control system testing phase required that the controls subcontractor, with
assistance from the mechanical subcontractor as necessary, perform a complete
checkout and verification of the proper operation and calibration of all system
points, sequences , interlocks with associated systems (e.g., fire alarm and
equipment switchover for backup), and loop functions. The purpose of this phase
of work is to place the system into automatic operation in preparation for
verification of the mechanical and controls system operation by the 72-hour
system acceptance test.
b) The testing phase will consist of the following steps:
aa) Field testing and verification (loop checks).
bb) Performance Verification.
c) Test 1 is conducted by the controls subcontractor. This portion of the test verifies
accurate wiring and pneumatic connections from control devices i.e., sensors,
valves, thermostats, damper actuators, switches, relays and control panels.
d) All sequences of operation specified and identified in the drawings and
specifications shall be tested. Calibration of sensors, transmitters, controllers, and
actuators to achieve set point tolerance for all control loops shall be
accomplished during this test.
e) The controls subcontractors shall submit checklist forms to owner for approval at
least 2 weeks prior to beginning Test 1. These forms shall identify all devices,
sequences, set points, etc., which are to be tested as part of Test 1.
f) Project Managers and Owner may choose to observe any or all of the testing
performed for Test 1.
g) Test 2 is the demonstration by the controls subcontractor to Owner that all
equipment is tested and ready for final system commissioning.
h) Test 2 will be started after three prerequisites are met:
aa) Test 1 must be completed by the subcontractor.

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bb) The completed Test 1 checklist have been submitted to and approved
by Project Managers and Owner.
cc) The controls subcontractor shall certify in writing that each wiring and
pneumatic connection has been checked, the operation and calibration
of each device has been verified, all sequence have been observed, and
all have been found to be complete and operational.
i)
vii) HVAC Systems Commissioning
aa) HVAC systems commissioning shall begin after the pre-balance, manual run, air
and water balancing, and control system testing phases are completed.
bb) Owner and Project Managers shall be included in the commissioning process.
cc) Verify air and water balancing readings, such as supply and return air quantities,
fan performance, hydraulic performance, branch duct readings, boiler
performance, chiller performance etc.,
dd) Verify calibration of temperature sensors, relative humidity sensors, dew point
sensors, pressure transmitters, and related controls, such as damper settings,
valve positions, VAV boxes, etc.,
ee) Verify readings of remote data and control systems, such as temperature, relative
humidity, dew point, pressure, damper positions, variable frequency drive
settings etc.,
ff) Verify operation of system modes, such as humidification / dehumidification,
smoke purge system operation, equipment failure and backup unit start up etc.,
gg) Verify that total HVAC systems are performing to provide conditions outlined in
design documents such as temperature control, humidity control, pressurization
control, control system response, etc.,
viii) Mechanical and Electrical 72-Hour Systems Acceptance Test
a) The purpose of the 72-Hour systems test is to demonstrate that the overall
system will function reliably and in accordance with the design documents.
b) Systems that are capable of producing trend logs for control points shall be
utilized to produce these logs to record the status of temperature, pressure,
humidity, et., during the test. The points to be mentioned will be determined by
SubContractor and Owner.
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c) The 72-hour test is a prerequisite to obtaining a notice of Substantial Completion

for the mechanical, electrical and control systems. Equipment and systems
warranties shall begin with Substantial Completion and acceptance by owner.
d) Successful completion of the 72-hour test is a prerequisite to obtaining a notice
of substantial completion for the mechanical, electrical and control systems.
Equipment and systems warranties shall begin with substantial completion and
acceptance by Owner.
e) All HVAC systems and associated control and alarm interlocks shall be operated
for a period of 72 consecutive hours. During the 72-hour period, all systems shall
function in a completely automatic mode without any equipment shutdown of
malfunction. All system shall operate to maintain design sequences and
conditions.
f) Any system shutdown, malfunction, or deviation from design sequences during
the 72-hour test will be cause to discontinue the test and restart after faults are
corrected. Owner will determine if a failure is severe enough to discontinue the
test.
Appendix
Package________
TAG NO. REV.
Owner Startup Program

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11. Piping Systems Adjusting and Balancing
C) General
i) Work Included
This section specifies the requirements necessary to measure, adjust, and record
the piping systems capacities to match design conditions. The systems are listed
below:
a) Primary Chilled water.

b) Secondary chilled water.
c) Condenser water.
ii) Quality Assurance
Firms proposing on this service shall have NEBB, AABC, or equivalent

certification or an equivalent amount of experience. A list shall be available upon
request of projects similar in size and complexity to the work that the firm has
completed. Include the project name, description of mechanical system, range of
services provided, and the name and phone number of the engineer or Owner
who had responsibility for final inspection of the services.
iii) Submittals
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Provide the following in addition to the standard requirements with the

Bid:
a) Written presentation outlining the adjusting and balancing procedures to

be performed.
b) Description of all instrumentation to be used, as well as calibration
documentation.
c) Samples of all field reports, charts, and forms proposed to document
measured conditions. A sample report for a similar project shall be
available for inspection by Subcontractor and Owner to verify the
Subcontractor’s expertise in data collection and interpretation
Provide the following within 1 week of their completion:
a) Orderly handwritten or computerized field reports, charts, and forms

completed with all measured data. Five copies of the report shall be
submitted to Owner for review.
b) Reduced set of mechanical drawings showing the final flow readings for
each system.
c) Separate section in the report, if necessary, that describes any operating
difficulties in any of the piping systems that could not be eliminated by the
procedures described herein. These problems shall be specifically
identified by system and location within the building, a summary of the
condition and its effect on the building shall be outlined, and all corrective
action attempted shall be described.
d) A list of all instrumentation and test equipment actually used in the
balancing process, including manufacturer, model, and last calibration
date.
B) Products
i) General
a) The testing and balancing firm shall supply all materials, tools equipment, and
instrumentation required to perform the piping system balancing.
C) Execution
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Piping Systems Balancing Services
a) Provide equipment nameplate data on all pumps, chillers, coils, etc., indicating
equipment identification, motor and drive data, and starter and heater data.
b) Adjust cooling tower water and chilled water, systems for the required water
flows at each coil, connection, terminal device. Final flow volumes to be minus
5/plus 10 percent of design volumes. Provide proper flow through individual
evaporator and condenser circuits, each tower cell, each pump, all water coils
and all recirculation loops. Measure and adjust flow through all valves and
valve bypass lines, and mark final position of all balancing cocks, valves, and
operations with a center punch. Coordinate work with Section Air systems
Testing, Adjusting, And Balancing.
Field Quality Control
a) After all adjustments on a system have been completed and the balance logs
submitted, the balancing firm shall demonstrate the water procedures to
Owner to verify the test results.
b) All test result and any adjustments or rebalancing procedures shall be
submitted to Owner to be included with the balance logs.
SYSTEM READY TO BALANCE CHECK LIST
Ready Date Ready Date
1. HVAC Units Ye No. Corr Ye No. Corrected

(AHU) s ecte s
d
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a) General e) Vibration isolation
Louvers installed Springs and compression
Manual dampers Base level and free

open & locked
Automatic dampers
set properly
Housing 2. Duct systems

Construction-leakage
Access doors-leakage a) General
Condensate drain Manual dampers open &

piping and pan locked
Free from dirt and Access doors closed and

debris tight
Nameplate data Fire dampers open and

accessible
b) Filters Terminal units open and

set
Type and size Registers and diffusers

open and set
Number Turning vanes in square

elbows
Clean Provisions made for TAB

measurements.
Frame-Leakage Systems installed as per

plans.
c) Coils (Hydronic) Ductwork sealed as

required
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Size and rows b) Owner
Fin spacing and Windows installed and

condition closed.
Obstructions and / Doors closed as required.

or debris
Airflow and direction Ceiling plenums installed

and sealed.
Piping leakage Access doors closed and

tight
Correct piping Air shafts and openings

Connections and flow as required
Valves open or set
Airvents or steam 3. Pumps.

traps
Provisions made for a) Motors.

TAB measurements
d) Fans. Rotation
Rotation. Lubrication
Wheel clearance and Alignment

balance
Bearing and motor Set screws tight

lubrication
Drive alignment Guards in place
Belt t tension. Tank level and controls.
Drive set screws tight Starters and disconnect

switches
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Belt guard in place Electrical service &

connections.
Flexible duct Nameplate data.

connector alignment
Starters and
disconnect switches
Electrical service &

connections.
Nameplate data
Ready Date Ready Date
b) Piping 5. Refrigeration
Equipment
Correct flow Crankcase heaters

energized
Correct connections Operating controls and

devices.
Leakage Safety controls and

devices.
Valves open or set Valves open
Strainer clean Piping connections and

flow
Air vented Flexible connectors
Flexible connectors Oil level and lubrication
Provisions made for Alignment and drives.

TAB measurements
c) Bases Guards in place.

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Vibration isolation. Vibration isolation.
Grouting Starters, contactors and

disconnect switches.
Leveling. Electrical connectors.
Nameplate data.
4. Hydronic
equipment.
a) Heat 6. Hydronic Piping

Exchangers/HW systems.
coil
Correct flow and Leak tested.

connections
Valves open or set Fluid levels and make-up
Airvents or steam Relief or safety valves.

traps
Leakage Compression tanks and

air vents.
Provisions made for Steam traps and

TAB measurements connections.
Nameplate data. Strainers clean
b) Cooling towers valves open or set
Correct flow and Provisions made for TAB

connections. measurements.
Valves open or set Systems installed as per

plans.
Leakage
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Provisions made for 7. Controls System

TAB measurements
Sump water level. Data centers.
Spray nozzles. Outdoor return air reset
Fan/pump rotation. Economizer
Motor/fan Static pressure

lubrication.
Drives and alignment Room controls.
Guards in place. 8. Other Checks.
a) Other trades or
personnel notified of
TAB work requirements.
b) Preliminary data
complete
c) Test report forms

prepared.
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4.10. SECTION-12
COMMISSIONING REQUIREMENTS
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12. INTRODUCTION:
A. COMMISSIONING REQUIREMENT FOR CHILLERS
This document provides the commissioning requirements for commissioning of Chillers as per
Owner requirements.
Scope of Works
The scope of works for the successful vendor / contractor:
1. To provide complete testing & commissioning of Chillers at site testing.

2. To arrange for all necessary equipments & instruments required for testing. All
the instruments to be calibrated and calibration certificates to be produced at
site.
Pressure Test DX - gas lines:
This test is to be conducted on Dx - pipes before connecting them to the PAC / Spilt
units/indoor units. Pressurize the pipeline with nitrogen of 1.5 times the operating pressure &
hold for 24 hours. Pressure measurement would reflect whether there are any leakages or not.
START END
AHU
SR NO CAPACITY TIME TIME
PRESSURE PRESSURE
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KEPT ON KEPT ON
HOLD HOLD
12.1 Heat load testing of the PAC Units:
Heat load test shall be conducted at site for the PAC units installed.
Air balancing and chilled water balancing shall be completed and agreed by the Owner
with the balancing results achieved, before the start of Heat Load Testing.
Artificial heat loads, measuring instruments i.e. data loggers, air flow meters, meters for
power measurement, static measurement needs to be arranged by the vendor /
Subcontractor for site testing along with all the latest Owner approved good for
construction (GFC) drawings, red line drawings & sufficient technical manpower. The
data hall heat load test will be carried out for design heat load.
Following measurements shall be carried out during site testing at rated capacity of the
units:
 Air flow measurements

 Temperature measurements
 Fan speed measurement
 Unit cooling capacity.
 Water side pressure drop
 Water flow rate
 Electrical control, interlocks, functions and alarms
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 Power Measurements
 Power failure shut down and automatic re-start
 Failure scenarios & Alarms
 BMS interface verification
A site test method statement shall be issued prior to the test, the test to be carried out as
per the method statement.
CHILLED WATER BALANCING:
Prior to start of chilled water balancing below detailed checks to be completed –
 Operation of balancing valves.

 100% Open status of all the isolation/butterfly valves.
 100% Open status of all the modulating valves.
 Performance testing of pumps.
After the completion of above listed requirements the commissioning of balancing shall be as
per the sequence mentioned below –
1. Balancing valves installed across the chillers.

2. Valves installed in the headers (supply/return/ comfort/critical).
3. Valves installed in the subsequent branches and risers floor wise.
At the completion of the valves located at the farthest equipment the position of all the
balancing valves shall be re-verified for appropriate balancing.
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12. INTRODUCTION:
B. COMMISSIONING REQUIREMENT FOR HVAC SYSTEMS
This document provides the commissioning requirements for commissioning HVAC Systems as
per Owner requirements.
Scope of Works
The scope of works for the successful vendor / contractor:

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1. To provide complete testing & commissioning of the HVAC package at site testing.
2. To arrange for all necessary equipments & instruments required for testing. All
the instruments to be calibrated and calibration certificates to be produced at
site.
12.1 TESTING & COMMISSIONING REQUIREMENTS OF HVAC SYSTEM:
12.2 Site Testing:
After installation of chilled water pipelines pressure testing & flush out of the chilled
water pipes to be carried out as follows:
12.3 AIR HANDLING UNITS PERFORMANCE TESTING:
Prior to the performance testing of the AHU, AHU shall exhibit satisfactory results of the below
listed testes
 Duct pressure testing

 HVAC piping pressure test
 HVAC piping Flush out
 HVAC water balance
 Air Balancing.
Air handling unit shall be run on VFD mode @ 50Hz with all the VAVs 100% open and all the
dampers locked in their positions as determined during air balancing. All the door of the space
conditioned by the AHU shall be closed during measurements.
Power consumption (V, I, kW, power factor) shall be noted.
Temperature in the conditioned space shall be measured and recorded.
Pressure drop and temperature of chilled water shall be recorded.
The above explained measurements shall be repeated for three or four trials over 2 or 3 hour
intervals.
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Measuring Equipments:
1. Sling Psychrometer.
2. Calibrated Pressure gauges,
3. Calibrated Temperature gauges,
4. kW meter and multimeter.
12.4 DUCT PRESSURE/LEAK TESTING
Standard procedure of duct leak/pressure testing to be mentioned by the Subcontractor.
12.5 AIR BALANCING
AIR SIDE TESTING AND BALANCING:
The Air Distribution System shall be inspected for the Preliminary test as tabulated below -
LEGEND:
A – Acceptable
NA – Not Acceptable
PRELIMINARY CHECKLIST:
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STATUS COMMENTS /
DUCT SYSTEM
REMARKS
A / NA
Are the volume control dampers open & locked?
Access doors closed and tight?
Fire dampers open and Accessible?
Registers and diffusers open & set?
Turning vanes in square elbows?
Provisions made for TAB measurements?
Systems installed as per plans?
Ductwork sealed as required?
Are fans ready to run?
Rotation of fans in correct direction?
Impellor clearance and balance?
Motor & Fan impellor pulleys aligned?
Belt tension?
Belt guard in place?
Flexible duct connector alignment?
Starters and disconnect switches?
Electrical service & connections?
Nameplate details?
Vibration isolation pads in place?

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The Air System shall be tested and balanced as under, only after the above tabulated checks are
found acceptable:
1. Test and adjust fan RPM to design requirements.

2. Test and record motor full load amperes.
3. Obtain design CFM at fans.
4. Test and record system static pressures, suction, discharge and total.
5. Test and adjust system for design re-circulated air.
6. Test and adjust system for design outside air.
7. Test and record entering air temperatures DB/WB.
8. Test and record leaving air temperature DB/WB.
9. Adjust all main supply and return air ducts to proper design CFM.
10. Adjust all zones to proper design CFM (supply and return).
11. Test and adjust each diffuser, grille and register to within 10% of design requirements.
12. Each grille, diffuser, register shall be identified as to location and area.
13. Size, type and manufacturer of diffusers, grilles, registers, and all tested equipment shall
be identified and listed. Manufacturer's ratings on all equipment shall be used to make
required calculations.
14. Readings and tests of diffusers, grilles and registers shall include required velocity and
test resultant velocity. Required CFM and test resultant CFM after adjustments.
15. In co-operation with control manufacturer's representative, set adjustments of
automatically operated dampers to operate as specified, indicated and/or noted.
16. All diffusers, grilles, and registers shall be adjusted to minimize drafts in all areas.
OBSERVATIONS:
1. Fan speed (rpm):

2. Motor full load consumption (A):
3. Measured flow (cfm):
Measuring Equipments:
1. Flow Hood,
2. Torch,
3. Measuring tape.
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Training & Documentation:
Post commissioning training to be provided for the operations staff at site for operation &
maintenance of the Split units.
Vendor / Subcontractor to issue following documents to the project team post commissioning:
 All as-built drawings

 GA Drawings
 Power & Control layouts
 Operation & Maintenance manual.
 Warranty certificates
 Factory certificates & site testing reports.
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4.11. SECTION-13
CODES AND STANDARDS
13. Codes, Regulations and Standards

The installation shall conform in all respects to ASHRAE / Indian Standard Code of Practice for Air
conditioning Installation, tender specifications and drawings.
In case of discrepancy among specifications, drawings and other documents, the specifications
take precedence over all other documents. In case of discrepancy between specification, drawings
etc AND Codes & Standards, the tenderer shall assume the more stringent of the two.
Air Conditioning Equipment
IS 659 Safety Code for air conditioning

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IS 660 Safety Code for mechanical refrigeration
IS 3615 Glossary of terms used in refrigeration & air conditioning
IS 5111 Testing of refrigeration compressors
IS 7896 Data for outside design conditions for air conditioning
IS 10617 Hermetic Compressors (Part-I, II & III)
IS 11338 Thermostats for use in refrigeration, air conditioners etc.
SP 7 National Building Code (Group 4)
IS 3615 Glossary of terms used in refrigeration and air conditioning
IS 7896 Data for outside design conditions for air conditioning for summer
months
Noise & Vibration
IS 2264 Preferred frequencies for acoustical measurements.
IS 3483 Code of practice for noise reduction
IS 3932 Sound level meter for general purpose use.
IS 9736 Glossary of terms applicable to acoustics in buildings.
IS 9901 Measurement of sound insulation in buildings & building elements
IS 9876 Guide to the measurement of air borne acoustical noise &

evaluation of its effects on man.
IS 10423 Personal sound exposure meter.

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IS 11446 Measurement of air borne noise emitted by compressors units

intended for outdoor use.
IS 12710 Glossary of terms used in acoustic emission testing.
IS 4758 Methods of measurement of noise emitted by machines
IS 14280 mechanical vibrations – balancing – shaft and fitment key

convention
IS 12065 Permissible limits of noise level for rotating electrical machines.
Pipe & Fittings
IS 638 Gaskets
IS 1239 Mild steel tubes & fittings
IS 5822 Code of practice laying of electrically welded steel pipes for water
supply.
Pump & Valves
IS 778 Copper alloy gate, globe & check valves for water works purposes.
IS 4854 Glossary of terms for valves and their parts.
IS 5312 Swing check type non return valves.
IS 8092 Code for inspection of surface quality of steel castings for valves,
fittings & other piping components.
IS 12969 Method of test for quality characteristic of valves.

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IS 13095 Butterfly valves for general purposes.
Refrigerant Gas & Lubricants
IS 1447 Method of sampling and test for lubricants.
IS 4578 Lubricating oils for refrigeration machinery
IS 10609 Refrigerants – Number – Designation
Sheet Metal Works
IS 277 Galvanized Steel sheet
IS 513 Cold rolled low carbon steel sheets.
Thermal Insulation
IS 334 Glossary of terms relating to bitumen & tar
IS 3069 Glossary of terms, symbols & units relating to thermal insulation

materials
IS 3144 Mineral wool thermal insulation – Methods of tests
IS 3346 Method of determination of thermal conductivity of thermal

insulation materials
IS 4671 Expanded polystyrene for thermal insulation purposes

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International Standards
SMACNA HVAC Systems – Duct Design
SMACNA HVAC Air duct leakage test manual
SMACNA HVAC duct construction standards – Metal & flexible
SMACNA Rectangular duct construction
SMACNA Round duct construction
SMACNA Energy conservation guidelines.
SMACNA Energy recovery equipment and systems, air to air
ANSI-UL-555-1985 Fire dampers
ANSI Scheme for identification of piping system
SMACNA HVAC Systems – Testing, adjusting & balancing
CTI Acceptance test code for water cooling towers, mechanical draft,
natural draft, fan assistant type evaluation of results and thermal testing of wet and dry cooling
towers as per CTI-ATC-105-1990
CTI Code of measurement of sound from cooling towers as per CTI-

ATC-128
ANSI / AMCA Laboratory methods for testing fans for rating as per ANSI / AMCA
210
UL Fire dampers as per ANSI-UL-555
ASME Scheme for identification of piping system as per ANSI / ASME A-

13.1
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13.1 Drawings, Specifications and deviations
The drawings and specifications lay down minimum standards of equipment and workmanship.
Should the tenderer wish to depart from the provisions of the specifications and drawings either
on account of manufacturing practice or for any other reasons, he should clearly draw attention in
his tender to the proposed points of departures and submit such complete information, Drawings
and specifications will enable the merits of the deviations to be fully appreciated. In the absence of
any such deviation list, it will be deemed that the tenderer is fully satisfied with the intents of the
specifications and the drawings and their compliance with the statutory provisions and local
codes. All deviations or departures not brought out to the notice shall be disregarded.
13.2 Tools and Spare parts
All the tools and tackles, scaffolding and staging required for erection and assembly of the
installation covered by the contract shall be obtained by the Subcontractor himself and shall meet
the EHS requirement.
All other material such as foundation bolts, nuts etc, required for the installation of the plant shall
be supplied and included in the contract.
Tenderer shall include spares recommended by him for two years operation for each type of
equipment covered by the specification.
13.3 Shop drawing, Inspection and testing,
13.4 Working and construction drawings

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The Subcontractor shall prepare shop drawings and all work shall be
according to approved working drawings. Shop drawings shall give all
dimensions and shall incorporate the requirements of the
Owner/Project Managers. Approval of drawings does not relieve the
Subcontractor of his responsibility to meet the intents of the
specifications. All such drawings for approval shall be submitted in 6
copies for Owner/ Project Managers team. In addition, the Subcontractor
shall submit manufacturer’s details and get them approved before
ordering. This has to be done whether the materials / equipment are one
of the approved makes or not.
13.5 Testing and Inspection
The Subcontractor shall carry out tests on different equipment and system in total as specified in
various sections of the tender in the presence of Owner/ Project Managers in order to enable
them to determine whether the plant, equipment and installation in general comply with the
specifications. All equipment shall be tested after carrying out the necessary adjustments and
balancing to establish equipment ratings and all other design conditions. The test data shall be
submitted in Acceptance Test Form.
13.6 Calibration of instruments and meters
Instruments required for testing shall be furnished by the Subcontractor for testing with initial
requirements of all consumables. All the instruments, meters etc to be used at site and on the
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system shall have a valid calibration certificate issued by the competent authority. The
Subcontractor shall maintain and make available all such calibration certificates.
13.7 Handing over requirements
The plant shall be handed over after satisfactory testing along with following documents.
1. Detailed equipment data in the approved proforma

2. Manufacture’s maintenance and operating instructions
3. Set of as built drawings, layouts, piping, ducting, cable routing, cable schedules etc
4. Approved test readings of all equipment and installations
5. Inspection certificates
6. Certificates of approval from statutory or Local Authorities for the operation and
maintenance of the installations, wherever such approval or certification is required. This shall
include Application filed along with enclosures and receipts of fees paid and deposits made.
7. List of recommended spares
8. Certificate from the Subcontractor that he has cleared the site of all debris and litter caused
by him with out violating the EHS norms during the construction. However, Subcontractor has
also to periodically clear the site from all the debris which is generated from his part of scope.
9. Undertaking that all the materials supplied by him at site are fully tax paid and shall produce
all documentation for satisfaction of Owner / Project Managers or taxation authorities.
Submission of the above documentation shall form a precondition for final acceptance of the plant
and installation and final payments.
13.8 Statutory approvals inspection

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The Subcontractor shall be fully responsible for meeting all the statutory obligations and local
inspectorates wherever applicable to the works carried out by them. The Subcontractor should
prepare all working drawings and obtain approval of competent authorities and also have the
equipment and installation inspected and got approved. All the original receipts of official fees
paid and deposits made against the demand in writing from the appropriate authority shall be
submitted to the Owner.
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4.12. SECTION-14
4.13. LIST OF APPROVED MAKES
LIST OF APPROVED MANUFACTURER / VENDOR
The equipment/installation materials to be supplied shall be selected from among the

following makes only. In case any make other than the ones specified below are to be
procured, the Owner / Main Contractor prior approval shall be essential. The Owner / Main
Contractor reserves the right to select any one of the makes at the time of procurement.
1 Air Cooled Water Chilling Machines : Daikin-McQuay / York/ Carrier / Trane
2 Water Cooled Water Chilling Machines : Daikin-McQuay / York/ Carrier / Trane

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3 Pumpsets : Grundfos / Kirloskar/ KSB
4 Cooling Towers Advance/ Bell/ Paharpur/ Protech
5 Air Handling Units(AHU) : Zeco/ Bluestar / Citizen / Trane
6 Air Washer : Zeco/ Root cooling / Humidin
7 Fan Coil unit -Factory fitted valves : Sinko/Midea
8 Precision Air Conditioning : Emerson / Stulz / Bluebox / Uniflair
9 Air Cooled Packaged Air Conditioner : Daikin / Toshiba
10 Variable Refrigerant Volume (VRV) : Daikin / Toshiba

System
11 Ventilation Fans : Kruger / Greenheck /Nicotra
12 Jet Fans : Systemair

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13 CO Sensor : Honeywell
14 Variable Air Volume (VAV) units : Trane / Siemens / Johnson Controls

/Trox
15 Motors : ABB / Siemens/ Kirloskar
16 Variable Frequency Drives : ABB/ Danfoss / Siemens
17. Combined Smoke & Fire Damper : Caryaire/ Greenheck/ Ruskin /

Equivalent
18 Grilles & diffusers : Ravistar/ Air Master / Caryaire
19 Galvanised Sheet Steel : Jindal / TATA/ SAIL
20 Duct Supports : Hi Tech or Equivalent
21 GI / MS Pipes : Jindal / TATA/ SAIL
22 HDPE Pipes : Prince / Supreme/ Rishi
23 Copper Pipes : Rajco / Nippon

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24 Balancing Valve : TA / Flowcon / Advance/ Danfoss
25 Butterfly Valves / Check Valves : Audco / Advance /KITZ
26 Ball Valves & Ball valves with Y-Strainer : Audco /Advance/ KITZ
27 Pumps Suction Guide Anergy / ITT Industries
28 Mechanical Seal for Pumpsets Bergman / Duro / Leak - Proof / Sealol
29 Y-Strainer : Emerald / Sant
30 Duct Insulation / Acoustic Lining / : Armacell / K- Flex/ Equivalent

Under Deck Insulation
31 Rigid PUF Insulation for pipes : Lloyds/ UP Twiga/ Insulation India
32 AHU Room Panel Type Acoustic Lining : KIMMCO, /UP Twiga / Owenscorning.
using Fiber Glass Insulation
33 Factory Fabricated Ducting : Zeco/ Rolastar / Camduct

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Site Address :-
34 Volume Control Damper, Butterfly : Ravistar /Airmaster/ Caryaire

damper and Fire damper
35 Fire Damper Actuators : Belimo / Honeywell/ Johnson

Controls
36 Closed Loop Expansion Tank : Anergy / ITT Industries
37 Air Seperators : Anergy / ITT Industries
38 Automatic Air Vents : Anergy /Itap/ Eqvt
39 Thermometer/ Pressure Gauges : H Guru / Warree
40 Insulated Flexible Ducting : ATCO / Supaflex/ Polyaire
41 Factory Fabricated Perforated Cable : Indiana/ Eqvnt.

tray
42 Sand Media Filters : Coron India / Eqvt
43 Round Ducting : Zeco/ Rolastar / Camduct

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44 Vibration isolators : Dunlop / Resistoflex
45 DDC Controller : Honeywell/ Siemens/Trane /Sauter
46 Interfaces / Gateways / Network : Honeywell/ Siemens/Trane /Sauter

Controllers
47 2-way & 3-way control valves & : Belimo / Honeywell / Sauter / Siemens
actuators
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TECHNICAL SPECIFICATIONS
FIRE PROTECTION SYSTEM

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Table Of Contents
SECTION 1
...................................................................................................................................................................
SCOPE OF WORK
...................................................................................................................................................................
594
SECTION 2
...................................................................................................................................................................
DESIGN
...................................................................................................................................................................
596
2.1 Codes and standards
.....................................................................................................................................................
596
2.2 Classification
.....................................................................................................................................................
596
2.3 Type of systems
.....................................................................................................................................................
596
2.4 Fire water storage tanks
.....................................................................................................................................................
597
2.5 Fire water pumps
.....................................................................................................................................................
597
2.6 Fire hydrant system
.....................................................................................................................................................
597
2.7 Wet riser cum down comer system
.....................................................................................................................................................
598
2.8 Yard hydrants
.....................................................................................................................................................
598
2.9 Automatic sprinkler system
.....................................................................................................................................................
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598
2.10 Portable fire extinguishers
.....................................................................................................................................................
599
SECTION 3
...................................................................................................................................................................
GENERAL PROVISIONS FOR FIRE FIGHTING SYSTEM
...................................................................................................................................................................
601
3.1 Scope of work & special conditions
.....................................................................................................................................................
601
3.2 Application codes and standards
.....................................................................................................................................................
601
3.3 Shop drawings and design calculations
.....................................................................................................................................................
603
3.4 Inspection and approval
.....................................................................................................................................................
603
3.5 Painting
.....................................................................................................................................................
603
3.6 Instruction manual / completion drawing / training
.....................................................................................................................................................
603
3.7 Documents to be submitted after award of contract
.....................................................................................................................................................
604
3.8 Instruction manual/completion drawing/training
.....................................................................................................................................................
604
SECTION 4
...................................................................................................................................................................
FIRE HYDRANT SYSTEM
...................................................................................................................................................................
605
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4.1 Piping
.....................................................................................................................................................
606
4.2 Piping installation & support
.....................................................................................................................................................
608
4.3 Excavation
.....................................................................................................................................................
616
4.4 Thrust blocks
.....................................................................................................................................................
616
4.5 Valves
.....................................................................................................................................................
617
4.6 Rubber hose reel
.....................................................................................................................................................
618
4.7 Hydrant valve and rrl type hose pipe
.....................................................................................................................................................
618
4.8 Internal hose cabinet
.....................................................................................................................................................
619
4.9 External hose cabinet
.....................................................................................................................................................
619
4.10 Fire brigade connection
.....................................................................................................................................................
620
4.11 Air release valves
.....................................................................................................................................................
620
4.12 Drain valves
.....................................................................................................................................................
621
4.13 Hydrant valve chambers
.....................................................................................................................................................
621
4.14 Pipe protection
.....................................................................................................................................................
621
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4.15 Testing
.....................................................................................................................................................
622
4.16 Pumps and accessories
.....................................................................................................................................................
622
SECTION 5
...................................................................................................................................................................
DIESEL ENGINE
...................................................................................................................................................................
627
5.1 General
.....................................................................................................................................................
627
5.2 Starting
.....................................................................................................................................................
627
5.3 Governing system
.....................................................................................................................................................
628
5.4 Fuel system
.....................................................................................................................................................
629
5.5 Cooling water system
.....................................................................................................................................................
629
5.6 Accessories
.....................................................................................................................................................
629
5.7 Instrumentation
.....................................................................................................................................................
630
SECTION 6
...................................................................................................................................................................
LT SWITCH BOARDS/FIRE PANELS.
...................................................................................................................................................................
631
6.1 General specification of equipment
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.....................................................................................................................................................
631
6.2 Standards
.....................................................................................................................................................
631
6.3 Construction
.....................................................................................................................................................
632
6.2 MCCB moulded case circuit breaker
.....................................................................................................................................................
636
6.3 Contactors
.....................................................................................................................................................
639
6.4 Current transformers
.....................................................................................................................................................
640
6.5 Potential transformer
.....................................................................................................................................................
642
6.6 Instruments & meters
.....................................................................................................................................................
643
6.7 Indicating instruments
.....................................................................................................................................................
643
6.8 Push buttons
.....................................................................................................................................................
646
6.9 Control wiring
.....................................................................................................................................................
647
6.10 General specifications for medium voltage cables
.....................................................................................................................................................
653
6.11 Storing, laying, jointing and terminations
.....................................................................................................................................................
653
6.12 Cables in outdoor trenches
.....................................................................................................................................................
654
4.3 Cable in indoor trenches
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.....................................................................................................................................................
654
4.3.1 Cable on trays / racks
.....................................................................................................................................................
654
SECTION 5 SRINKLER SYSTEM

...................................................................................................................................................................
658
5.1 Scope of work
.....................................................................................................................................................
658
5.2 Sprinkler heads
.....................................................................................................................................................
659
5.3 Pipes and fittings
.....................................................................................................................................................
660
5.4 Orifice plates
.....................................................................................................................................................
660
5.5 Installation control valves
.....................................................................................................................................................
661
5.6 Inspection and test valve assembly
.....................................................................................................................................................
662
5.7 Flow switch
.....................................................................................................................................................
662
5.8 The main stop valve
.....................................................................................................................................................
662
.....................................................................................................................................................
663
5.10 Signage
.....................................................................................................................................................
664
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SECTION 7 GAS SUPPRESSION SYSTEM (FM200-HFC-227ea chemical agent)

...................................................................................................................................................................
664
6.1 Design
.....................................................................................................................................................
666
6.2 Control panel
.....................................................................................................................................................
667
6.3 Accessories
.....................................................................................................................................................
668
SECTION 8
...................................................................................................................................................................
LIST OF RECOMMENDED MAKES
...................................................................................................................................................................
669
8.1 Recommended make of fire hydrant and sprinkler system
.....................................................................................................................................................
669
8.2 Recommended make of electrical materials
.....................................................................................................................................................
675
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SECTION 1 SCOPE OF WORK
This specification is intended and not limited to cover design, engineering, manufacture,
test and inspection at works, delivery of materials to site properly packed for
transportation, supply, erection, testing, commissioning, performance demonstration at
site and handing over to purchaser of Fire Protection System as indicated in the schedule
of Requirement and scope of work and as required for reliable and effective fire
protection.
1.1 This specification also includes complete earthwork, i.e. excavation and back filling for
the entire buried piping for hydrant and sprinkler system.
1.2 The specification also includes the supply of erection and commissioning of spares as
specified and special tools and tackles.
1.3 This specification also makes it obligatory for the contractor for arranging and obtaining
necessary clearance / approval from all Local / statutory authorities.
1.4 It is not the intent to completely specify all the details of design and construction herein.
Never the less the equipment and installation shall confirm to high standard of
engineering, design, and workmanship in all respect and shall be capable of performing
continuous satisfactory operation and acceptable to the main contractor as well as to the
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various statutory authorities. In case of any violation of the above contract, the main
contractor reserves the right to change / reject / modify the equipment / system during
detail engineering.
1.5 Wherever material or article is specified or described by the name of particular brand,
manufacturer or vendor, the specific item mentioned shall be understood as established
type function and quality desired. Other manufacturer’s product will be considered
provided sufficient information is furnished to allow the purchaser to determine that the
product proposed is equivalent to those brands.
1.6 The entire system shall be designed and engineered by the main contractor based on the
guidelines furnished in the specification, various codes / standards. Main contractor’s
experience and also good engineering practice. Items and quantities, which have been
furnished in this specification, are tentative and indicative only. During quoting, the
contractor shall vet the design by reviewing it and confirm the same w.r.t. the local
statutory authority requirements. Also shall confirm the Bill of Material and may furnish
additional items necessary for satisfactory operation of the system before awarding of
the contract during the tendering stage.
1.7 Supplies and services to be covered under this tender specification and the conditions
thereof are detailed in the subsequent sections of the specifications. In case of conflict
among various sections, subsections, documents, drawings the same shall be referred to
main contractor whose decision shall be final and binding to the contractor. In all cases,
the best advantages will go to the main contractor.
1.8 The Contractor to note that no technical deviation shall be permitted for the system.
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SECTION 2 DESIGN
2.1 Codes and standards
The Fire protection system shall be designed and installed as per National Building Code (NBC)
of India 2005, part -4, Fire and Life safety and as per recommendations of local fire norms.
2.2 Classification
The Building/facility has been classified, as _____________ building,
2.3 Type of systems
Following are the various Fire Protection systems which shall be proposed,
 Centralized Firewater tank and Fire pump room equipment.

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 Wet riser cum down comer system
 Yard Hydrants
 Automatic Sprinkler System
 Fire extinguishers and Signage (Fire safety plans).
2.4 Fire water storage tanks
 As per National Building Code( NBC) of India clause No. 6.0 and Table 23 /
Local norms.
2.5 Fire water pumps
 Electrically driven main pumps for each system.
 Electrically driven standby pumps for both systems fed from standby DG sets.
 Electrically driven common Jockey pump.
 All pumps are connected to IBMS through Fire alarm system for monitoring.
2.6 Fire hydrant system

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iii) A main header in the Basement floor ceiling with isolation valves.
iv) Main header on Terrace level for inter connecting all Wet risers.
v) Wet risers cum down comers for buildings.
vi) Landing Hydrants on all floors near Staircases inside the dedicated Shaft.
vii) Fire Brigade Inlet connection for filling the Firewater tank as well as wet riser
system.
2.7 Wet riser cum down comer system
 Wet riser cum down comer for every 1000 sq.mts floor area for all buildings.
 Landing Hydrants on all floors with Single-headed hydrant valve, 1 x 15Mts. of
fire hoses, Hose reel with 36.5 Mts. Rubber hose and nozzle.
2.8 Yard hydrants
 Yard Hydrants at every 45m of periphery of the Building with Single headed
Hydrant valve, 1 x 15 Mts. long fire hoses and Branch pipe with Nozzle.
2.9 Automatic sprinkler system
viii) Sprinklers at the ceiling level.

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ix) Design density is 6.1 LPM / sq.mts for Assumed area of Operation of 272 Sq.
Mts. as per NBC Ordinary Hazard, curve II.
x) Coverage per Sprinkler is 9 – 12 sq.mts and Sprinklers are Pendant / sidewall
/ upright (as suitable at site) type with 68 deg. Temperature rating.
xi) Flow switches provided on the Sprinkler mains at all floor levels for
Supervising at Fire alarm Panel.
xii) All glass façade elements are provided with window sprinklers at specified
spacing.
Portable fire extinguishers are provided at locations mentioned below,
 ABC type fire extinguisher of capacity 2/4/6/9 kg fitted with gun metal cap, high
pressure carbon-dioxide cartridge, with suitable mounting brackets conforming
to IS 2171 near main switch board room, transformer, generator room, pump
room & wherever suitable.,
 Water expelled carbon-dioxide type fire extinguisher of capacity 9 liters fitted

with gun metal cap, high pressure carbon-dioxide gas cartridge, with brackets,
conforming to IS 940 located near each staircase landing on every floor and office
areas, wherever suitable.
 Carbon dioxide type fire extinguishers of capacity 2 / 4.5 kilograms fitted with
valve, discharge hose, conforming to IS 2878, located in electrical panel room,
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pump room, STP, lift machine room, AHU and office areas and 22.5 kg Co2 in
Pump room, DG room, Transformer yard, LPG storage yard, Electrical panel room
at Terrace level
 Mechanical foam type fire extinguishers of 9 lts. Capacity fitted with all
accessories shall be provided at D.G. Rooms and Firewater pump house and near
oil filled Transformers.
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SECTION 3 GENERAL PROVISIONS FOR FIRE FIGHTING SYSTEM
3.1 Scope of work & special conditions
The scope of work includes design/design review, supply, installation, erection, testing,
commissioning the fire Hydrant system, Sprinkler system & and First aid fire
extinguishers with all necessary accessories.
3.2 Application codes and standards
The work shall be carried out in accordance with the regulations of local bodies, if any, and
the following specifications and codes which may govern the requirements of the system.
IS 5290 Specification for single headed hydrant valve.
IS 902 - 1992 Specification for suction hose coupling for fire fighting purposes.
IS - 13039 Butterfly valve for water works purposes.
IS - 3589 Mild steel tube, tubular and other wrought steel fittings ,
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IS-1239 Specification for G.I pipes
IS - 8423-1977 Controlled percolating hose for firefighting.
IS - 5290-1983 landing valves
IS - 2871-1983 Branch pipe, universal for firefighting purposes.
IS - 884 First aid hose reel for fire fighting
IS – 2190 -1992 Code of practice for selection, installation and maintenance of

portable first aid fire extinguishers.
IS – 934-1989 Specification for portable fire extinguisher water type (Soda acid)
IS – 937-1981 Specification of washers for water fittings for firefighting system.
IS – 2871-1983 Specification for branch pipe
IS - 1091-1984 Specification for extended branch pipe for fire brigade use.
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3.3 Shop drawings and design calculations
The drawings enclosed herewith are for the general guidance to the tender. The sub
contractor shall upon the award of the work, furnish detailed working drawings necessary
to carry out the work at site. These shall be submitted to the main contractor for the
approval and the work shall be commenced only after the approved drawing is issued by
the main contractor.
3.4 Inspection and approval
The sub-contractor shall arrange all necessary inspection by Fire Brigade Authority if
applicable. He shall also arrange for the tests and obtain and deliver to the Employer any
approval required as per local by-laws / statutory requirements.
3.5 Painting
All piping equipment’s, cabinets etc., shall be properly painted with two coats of synthetic
enamel paint over a coat of primer of approved color and make.
The sub-contractor shall guarantee both the material and works man ship of first class
quality corresponding to standard engineering practice. Any defective materials / works
man ship shall be rejected which has to rectified / replaced at his own cost. Guarantee
certificate of the materials supplied shall be handed over to the main contractor.
3.6 Instruction manual / completion drawing / training

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The sub-contractor shall furnish detailed instruction manuals and operation manuals in
triplicate including detailed completion drawings & Fire Safety Plans on a tracing sheet to
approved scale. It is also the responsibility of the sub-contractor to train the concerned
personnel in the operation and maintenance of the system and conduct Fire drill in the
presence of the main contractor.
3.7 Documents to be submitted after award of contract
List of data/document/drawings to be submitted after the award of contract. The list shall
essentially contain the following:
1 Design and operation manual of the complete firefighting system

2 Piping layout.
3 Schematic drawings,
4 Data sheets of all the equipment envisaged
5 Detailed Hydraulic calculation
6 Bar chart/network schedule covering all milestone activities.
3.8 Instruction manual/completion drawing/training
The Sub-contractor shall be responsible for training of all the concerned personnel
(minimum 6 rounds) in the period of operation and maintenance of the system and conduct
Fire drill. The rates quoted shall inclusive of submitting 6 sets of the following documents
(HARD COPIES) along with CDs (Soft copy) and the following,
d). Detailed equipment data in the approved proforma.

e). Manufacture’s maintenance and operating instructions manuals.
f). Set of as built drawings, layouts, piping, ducting, cable routing, cable schedules etc
g). Approved test readings of all equipment and installations.
h). Inspection certificates.
i). Certificates of approval from statutory or Local Authorities for the operation
and maintenance of the installations, wherever such approval or certification is
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required. This shall include Application filed along with enclosures and receipts of
fees paid and deposits made.
j). Warranty / guaranty certificate for all the equipment installed.

k). List of recommended spares together with list of suppliers and their contact
details.
l). Certificate from the main civil contractor that he has cleared the site of all debris
and
Litter caused by him.
m). Undertaking that all the materials supplied by him at site are fully tax paid and
shall produce all documentation for satisfaction of the main contractor/approved make of
materials list and statutory authorities.
Submission of the above documentation shall form a precondition for final acceptance of
the building, the installation and final payments.
SECTION 4 FIRE HYDRANT SYSTEM
Without restricting to the generality of the foregoing, the fire hydrant system shall include the
following:
 Galvanized Iron /MS Class "C" fire riser main within the building and as well outside the
building.
 Landing valves, hose reels, hose cabinets, fire brigade connections and connections to
pumps and appliances.
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 Hydrant pump and its accessories.
 All materials shall be of the best quality conforming to these specifications and subject to
the approval of the Client.
 Pipes shall be fixed in a manner as to provide easy accessibility for repair and
maintenance and shall not cause obstruction in shafts, passages etc.,
 Pipes and fittings shall be fixed to walls and ceilings by suitable clamps at intervals
specified. Only approved types of anchor fasteners shall be used for RCC ceilings and walls.
 Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required in a neat
manner.
 Valves and other appurtenances shall be as located that they are easily accessible for
operation, repairs and maintenance.
 Pipes for wet risers within the Building shall be GI/MS tubes conforming to IS 1239
(heavy duty 'C' class) with flanged / welded joints.
 Fittings for black steel pipes shall be malleable iron or approved type cast iron fittings
with screwed / welded joints.
 Joints for black steel pipes and fittings shall be metal to metal thread joints. A small
amount of red lead may be used for lubrication and rust prevention. Joints shall be welded
when approved by the Client.
 Stand pipe (80mm dia) shall be of GI class 'C' as per IS 1239 PI-90 and FBA approved
make.
4.1 Piping
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All pipes inside the building and where specified, outside the building shall be GI tubes
conforming to IS: 1239 - heavy duty.
Fittings for GI pipes installed above ground shall be malleable iron or approved type
cast-iron fittings with screwed threads welded or flanged to IS 1554 or as per IS: 1239,
Part II (heavy grade) pipes above 150 mm diameter shall be fabricated as per IS: 3589.
Pipes shall be carefully laid to the alignment, levels and gradients shown on the plan and
sections and great care shall be taken to prevent any sand, earth or other matter from
entering the pipes during laying.
Pipes shall be kept thoroughly clean during the course of laying. The ends of pipes shall be
blocked with wooden plugs wedged home, at the end of each day work to prevent dirt and
rodents, insects etc., entering the pipe.
For GI pipes up to 50mm diameter, socket welding type jointing shall be adopted, while for
pipes above 50mm diameter welded or flanged connections shall be used. A small amount
of red lead may be used for lubrication and rust prevention. Joints shall be welded when
asked for, by the main contractor/any authorized personnel. Flanged joints shall be made
with 3 mm thick insertion rubber washer. All bolt holes in flanges shall be drilled. The
drilling of each flange shall be in accordance with relevant Bureau Indian Standards.
Flanged joints shall be used for connections to vessel equipment, flanged valves and also
on suitable straight lengths of pipeline at strategic points to facilitate erection and
subsequent maintenance work.
The Bolts /Nuts / Washers used in the system shall be Galvanized as per IS 1367 and
suitable length & not more than 15mm beyond the Nut.
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4.2 Piping installation & support
Tender drawings indicate schematically the size and location of pipes. The Contractor,
on the award of the work, shall prepare detailed working drawings, showing the cross-
sections, longitudinal sections, details of fittings, locations of isolating and control
valves, drain and air valves, and all pipe supports. He must keep in view the specific
openings in buildings and other structure through which pipes are designed to pass.
Piping shall be properly supported on , or suspended from , on stands, clamps, hangers

as specified and as required. The Contractor shall adequately design all the brackets,
saddles, anchor, clamps and hangers, and be responsible for their structural stability.
Pipe work and fittings shall be supported by hangers or brackets so as to permit free
expansion and contraction. Risers shall be supported at each floor with Galvanised steel
clamps. To permit free movement of common piping support shall be from a common
hanger bar fabricated from Galvanised steel sections.
Pipe hangers shall be provided at the following maximum spacings:
Pipe Dia Hanger Rod Dia Spacing between Supports
(mm) (mm) (m)
Up to 25 6 2
32 to 50 6 2.5
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65 to 80 8 2.5
80 to 100 10 2.5
125 to 150 10 3.0
200 to 300 12 3.5
The end of the steel rods shall be threaded and not welded to the threaded bolt.
All pipe work shall be carried out in a proper workman like manner, causing minimum
disturbance to the existing services, buildings, roads and structure. The entire piping
work shall be organized in consultation with other agencies work, so that area can be
Cut-outs in the floor slab for installing the various pipes area are indicated in the
drawings. Contractor shall carefully examine the cut-outs provided and clearly point out
wherever the cut-outs shown in the drawings, do not meet with the requirements.
Pipe sleeves, larger diameter than pipes, shall be provided wherever pipes pass through
walls and slab and annular space filled with fiberglass and finished with retainer rings.
The contractor shall make sure that the clamps, brackets, saddles and hangers provided
for pipe supports are adequate or as specified / approved by Consultants. Piping layout
shall take due care for expansion and contraction in pipes and include expansion joints
where required.
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All pipes shall be accurately cut to the required sizes in accordance with relevant BIS
codes and burrs removed before laying. Open ends of the piping shall be closed as the
pipe is installed to avoid entrance of foreign matter. Where reducers are to be made in
horizontal runs, eccentric reduces shall be used for the piping to drain freely. In other
locations, concentric reduces may be used.
Automatic air valves shall be provided at all high points in the piping system for venting.
All valves shall be of 15mm pipe size and shall be associated with an equal size gate
valves. Automatic air valves shall be provided on hot water risers.
Discharge from the air valves shall be piped through a pipe to the nearest drain
or sump. All pipes shall be pitched towards drain points.
Pressure gauges shall be provided as shown on the approved drawings. Care shall be
taken to protect pressure gauges during pressure testing.
4.2.2 Pipe fittings
Pipe fittings mean tees, elbows, couplings, unions, flanges, reducers etc and all such
connecting devices that are needed to complete the piping work in its totality.
Mild Steel / Galvanised Iron / Ductile Iron / Cast Iron / Forged steel screwed type fitting
shall be used for pipes of 50 mm dia & below.
Fabricated fittings shall not be permitted for pipes diameters 50mm and below.
Fabricated fittings used on pipe size 65 mm & above shall be fabricated , welded in
workshops. They shall be inspected by Project Manager before dispatch from the
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workshop. The welding procedures of the workshop should have been approved by the
rules for sprinkler system and applicable to hydrant and sprinkler system. For “T”
connection, pipes shall be drilled and reamed. Cutting by gas or electrical welding shall
not be permitted.
4.2.3 Procedure for pipe protection application
a) Surface Preparation - The pipe surface shall be cleaned by a wire brush.
b) Application of Primer - Primer is to be applied on pipes immediately after cleaning.

This is to prevent any further accumulation of rust on the pipe. This is a cold
applied primer and is applied by brush.
c) Application of 4 mm bitumastic Tape - After the primer is applied on the pipe, it is

allowed to dry for about 30 min. till it becomes touch dry. Before adhering the tape
to the pipe, it is advisable to gently heat the primer coated pipe by a run of LPG
torch. Remove the bottom polyethylene from the tape & then heat bottom surface
of the tape by LPG torch or any heat source & start wrapping the tape to the pipe
by heating the primer coated pipe & by removing the bottom polyethylene from
the tape before wrapping better adhesion between the tape & pipe is obtained.
Overlaps are maintained with a minimum of 15.0 mm.
d) Tape coating of weld joints - The tape is applied over the weld joints after the
necessary welding & testing methods of the joints is completed. The procedure for
application of tape shall be the same as bare pipe procedure. Overlaps on each side
of the weld joints shall be 50 mm.
e) A final coat of White wash with water based cement paint is done immediately
over the entire coated pipe.
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4.2.4 Jointing
Welded joints :
Joints between MS pipes and fittings shall be butt joint made with the pipes and
fittings having “V” groove and welded with electrical resistance welding in an
approved manner. But welding without “V” groove shall not be permitted.
Grooved joints:
Remove all loose dirt scale & grease from the pipe surface.
Wrap the tape around the pipe, make sure the take is not twist & make the groove by
machine as per the requirement of coupling manufacturer.
Joints between the pipes and grooved fitting shall be made with the pipe by making
square groove by grooving machine without reducing the thickness of pipe wall and
fixed with the help of grooved coupling, nut, bolts & gasket etc.
Grooved Mechanical Couplings for Joining Carbon Steel Pipe :
Grooved Mechanical Couplings: Manufactured in two segments of cast ductile iron,

conforming to ASTM A-536, Grade 65-45-12. Gaskets shall be pressure-responsive
synthetic rubber, grade to suit the intended service, conforming to ASTM D-2000.
(Gaskets used for potable water applications shall be UL classified in accordance with
ANSI/NSF-61 for potable water service.) Mechanical Coupling bolts shall be zinc plated
(ASTM B-633) heat treated carbon steel track head conforming to ASTM A-449 and
ASTM A-183, minimum tensile strength 110,000 psi (758450 kPa) as provided standard.
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a. Rigid Type: Coupling housings with offsetting, angle-pattern bolt pads

shall be used to provide system rigidity and support and hanging in
accordance with ANSI B31.1, B31.9, and NFPA 13.
b. Flexible Type: Use in locations where vibration attenuation and stress

relief are required. Flexible couplings may be used in lieu of flexible
connectors at equipment connections. Three Couplings shall be placed in
close proximity to the vibration source.
Flange adapters: For use with grooved end pipe and fittings, for mating to ANSI Class
125 / 150 flanges.
Grooved couplings shall meet the requirements of ASTM F-1476.
Gasket: Synthetic rubber, wide width, conforming to steel pipe outside diameter
and coupling housing, manufactured of elastomers as designated in ASTM D-
2000.
Grooved end fittings
Fittings shall be cast of ductile iron conforming to ASTM A-536, Grade 65-45-12, with
grooved ends for direct connection into grooved piping systems with steel forged steel
conforming to ASTM A-234, Grade WPB 0.375" wall (9,53 mm wall), or fabricated from
Std. Wt. Carbon Steel pipe conforming to ASTM A-53, Type F, E or S, Grade B. Fittings
provided with an alkyd enamel finish or hot dip galvanized to ASTM A-153 with fire lock
arrangement. Zinc electroplated fittings and couplings conform to ASTM B633.
Grooved Hole-Cut Branch Outlets:

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a. Bolted Branch Outlet: Branch reductions on 21/2"(DN65) through

6"(DN150) header piping. Bolted branch outlets shall be manufactured
from ductile iron conforming to ASTM A-536, Grade 65-45-12, with fire
lock type synthetic rubber gasket, and heat treated carbon steel zinc
plated bolts and nuts conforming to physical properties of ASTM A-183.
b. Strapless Outlet: 1/2"(DN15) or 3/4"(DN20) NPT outlet on 4" (DN100)

and larger header sizes rated for 300 PSI (2065 kPa).
c. Strapless Thermometer Outlet: To accommodate industrial glass bulb

thermometers with standard 1-1/4"-18 NEF 2B extra fine thread and 6"
(152mm) nominal bulb length on 4" (DN100) and larger header sizes
rated for 300 PSI (2065 kPa).
Lubricant for fixing the Gasket on pipe should be oil free by manufacture and
capable to give the as required.
Flanged joints (65 mm dia and above)
Flanged joints with flanges conforming to IS: 6392 shall be provided on
a. Straight runs at intervals not exceeding 25-30m on pipe lines of 50 mm dia and
above and as directed by the Project Manager.
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b. For jointing all types of valves, appurtenances, pumps, connections with other
type of pipes, to water tanks and other places necessary and as required for good
engineering practice and as shown/noted on the drawings.
c. Flanges shall be with GI bolts and nuts and 3mm insertion gasket of natural
rubber conforming to IS: 11149.
Unions (up to 50 mm dia)
Approved type of dismountable unions shall be provided on pipe lines of 40 mm dia and
smaller dia, in locations similar to those specified for flanges.
Air vessel/pressure vessel
The air vessel shall be provided to compensate for slight loss of pressure in the system
and to provide an air cushion for counter-acting pressure, surges, whenever the
pumping sets come into operation. Air vessel shall conform to IS:3844. It shall be
normally half full of water, when the system is in normal operation. Air vessel shall be
fabricated with 8 mm thick M.S. plate with dished ends and suitable supporting legs. It
shall be provided with one 100 mm dia flanged connection from pump, one 25 mm drain
with valve, one water level gauge and 25 mm sockets for pressure switches. The air
vessel shall be tested to pressure for 12 hours at 2 times the operating pressure or 1.5
times the shut-off.
Air cushion tank

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Every wet riser shall be provided with an air cushion tank at its top most point. The air
cushion shall be provided with an automatic air release cock, 20 mm dia drain pipe,
drain valve and shut off valve.
4.3 Excavation
Excavation for pipelines shall be in open trenches to line and grade shown on the
drawings or as required at site. Pipelines shall be buried to a minimum depth of 1M until
and unless specified.
The sub-contractor shall support all trenches or adjoining structures with adequate
timber supports wherever required during excavation to avoid safety hazards.
On completion of testing and painting of the pipelines, trenches shall be refilled with
excavated earth in 20cms.Layers and consolidated.
4.4 Thrust blocks
Contractor shall provide suitable Burnt Brick Masonry blocks/construct pedestals of

suitable dimensions at regular intervals of 3 meters to support the pipes. Masonry shall
be of Table Molded Class I Bricks in CM 1:6 and plastered in CM 1:3, finished with a neat
smooth coat of cement. Size of Blocks shall be 600mm x 600mm x 450mm and such
pedestals and supports shall be made over suitable grade of PCC.
Pipe supports
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Supports for above ground pipes of 50 mm diameter and above shall be fabricated by
using structural steel of suitable sections with suitable fasteners. The spacing of supports
shall be 3mts minimum and painted two coats of enamel paint of approved color over a
coat of primer.
Suitable type hangers shall support pipes below 50 mm diameter with clamps, anchor
fasteners and suspended rods etc. In any case fasteners shall not be less than 12 mm
diameter in size.
4.5 Valves
Butterfly valves shall be provided for pipes 50mm diameter and above. The valves shall
conform to IS 13039 and shall be CI construction. The valves shall be tested to a minimum
pressure of 16 Kg/sq.cm.
a. Gate valve
The primary function of a gate valve is for starting and stopping of flow. It has a disc
actuated by a stem screw and hand wheel, moves up and down at right angles to the path
of flow of fluid and seats against two faces to shut of flow. As the disc of the gate valve
presents a flat surface to the direction of flow, this valve is only for starting and shutting
the flow in the pipe.
These valves are of Gun Metal (GM) make. Supplying, fixing and testing correspond to IS
778-1984, Specifications for Copper Alloy Gate, Globe and Check Valves for Water Works.
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All globe and check valves shall have working parts suitable for hot and cold water, as
required. Valves shall be tagged with permanent label under hand wheel indicating type
or duty.
All valves should have manufacturer test certificate indicating the date of shop test and
other quality control tests with the material used for the same.
b. Check valves
Check valves are designed to prevent reversal of flow. These are also called Non-return
valves or reflux valves to avoid reversal of flow. Check valves shall be Dual Plate check
valves with CI body, aluminum bronze plate SS 316 hinge pins and springs and Buna-N
seals to ANSI series 125. They can also conform to IS 778-1984, Specifications for Copper
Alloy Gate, Globe and Check Valves for Water Works.
4.6 Rubber hose reel
Contractor shall provide standard fire hose reels with 19mm dia high pressure Dunlop
rubber hose of 36.5m length with gunmetal nozzles and control valve, shut off valve, all
mounted on a circular hose reel drum of mild steel construction and cast-iron bracket.
The hose reel along with 63mm dia landing valve and 2 nos 15M long 63mm dia hose pipe
shall be installed in fire hose cabinet inside the building.
4.7 Hydrant valve and rrl type hose pipe
The landing valve (internal) shall be gunmetal single / Single headed type conforming to
IS: 5290, complete with hand wheel, quick coupling, spring and blank cap.
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Heavy duty hose pipe 63mm dia (2 nos 15M. length in FHC and 2nos. of 15 mts. length in
external hose cabinet) with 63mm dia. Instantaneous pattern single / Single headed
hydrant valve, branch pipe and nozzle to be provided in the fire hose cabinet. The branch
pipe shall be gunmetal and conform to IS: 903.
4.8 Internal hose cabinet
Hose cabinet shall be of glass fronted with hinged door & lock. The cabinet shall be made
of 16 gauge thick MS/SS (as per SOQ) sheet and spray painted to shade No. 536 of IS:5.
The hose cabinet shall be of size to accommodate the following:
i. Landing Valves (Single/double headed)
ii. Hose pipe (2 or 4 length of 15M)
iii. Hose reel (36.0 mts.)
iv. Branch pipes, nozzles (1/2 sets)
v. Fire man's axe and hand appliances
4.9 External hose cabinet
The hose cabinet shall be of size to accommodate the following:

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i. Single/Double headed yard hydrant valve
ii. Hose pipe (2 length of 15 m)
iii. Branch pipes, nozzles (1/2 sets)
iv. Fire man's axe
4.10 Fire brigade connection
Provide as shown on drawings gunmetal four connecting head with 4 x 63mm dia
instantaneous type inlets with built in check valve and 150mm dia outlet connection to the
fire main grid with 150mm dia Butterfly valve.
Provide as shown on drawings gunmetal two connection head with 2 x63mm dia
instantaneous type inlet with built in check valve and 150mm dia outlet connection to U.G
sump.
4.11 Air release valves
Provide 20mm screwed inlet GM single acting air release valve on all high points in the
system or as shown on drawings.
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4.12 Drain valves
Provide 50mm dia GI pipe conforming to IS 1239 heavy class with 50mm butterfly valve
for draining any water in the system in low pockets.
4.13 Hydrant valve chambers
Sub-contractor shall provide suitable brick masonry chambers in cement mortar 1:5 (1
cement: 5 Coarse sand) on cement concrete foundations 150mm thick 1:5:10 mix (1
cement :5 fine sand : 10 graded stone aggregate 40mm nominal size) 15mm thick
cement plaster inside and outside finished with a floating coat of neat cement inside
with cast iron surface box approved by local fire brigade including excavation, back filling
complete.
Valve chambers shall be of following sizes:
For depths up to 1M 750mm X 750mm
For depths up to 1M. & beyond 1000mm X 1000mm
All pipes above ground and in exposed locations shall be painted with one coat of red
oxide primer and two or more coats of synthetic enamel paint of approved shade after
testing of the pipe for no leakages. The below ground pipes shall be coated protected using
polymer based material to avoid corrosion of the under/below ground pipes. The pipe
(buried) should be initially brushed to remove all foreign matter, testing shall be done and
two coats of primer shall be applied over the pipe. Primer is allowed to dry until the
solvent evaporates and surface becomes tacky. The tape with 4mm thick and 150 /
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250mm wide shall then be wound in a spiral fashion and bonded completely to pipe by
thermo fusion process. The overlap to be maintained at 15mm uniformly.
4.15 Testing
All piping in the system shall be tested to hydrostatic pressure of 1.5 times the system
pressure without drop in pressure for at least 2 hours. Each welding joint, fittings, valves
to be witnessed for leakages, rectify all leakage, make adjustment and retest as required
and directed to the satisfaction of the local Fire authorities and the main contractor.
4.16 Pumps and accessories
The pumps shall be exclusively used for firefighting purposes and shall be approved by
the Local Fire Authority. Two set of electrical motor driven direct coupled centrifugal
pump of adequate discharge and additional stand by Diesel engine driven direct coupled
centrifugal pump of adequate discharge and head shall also be provided. The pumping
capacity of main hydrant pump shall be as per the specifications.
4.17.1 General requirement
The electrical pump shall be horizontal centrifugal pump designed for continuous
operation and shall have a continuously dropping head characteristic without any zone
of instability. The power capacity characteristic shall be non over loading type.
The head vs. capacity, input power vs. capacity characteristics, etc., shall match to ensure
load sharing and trouble free operation throughout the range.
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In case of accidental reverse flow through the pump the driver shall be capable of
bringing the pump to its rated speed in the normal direction from the point of maximum
possible reverse speed.
The contractor under this specification shall assume full responsibility in the operation
of the pump and the drive as one unit.
The capacity of pump shall be a minimum of 150 percent of rated capacity at a total head
of not less than 65 percent of the total rated head. The total shut off head shall not
exceed 120 percent of total rated head on the pump.
An automatic air release valve shall be provided to vent air from the pump discharge and
also to admit to the pump to dissipate the vacuum there, upon stopping of the pump.
This valve shall be located at the highest point in the discharge line between the pump
and the discharge check valve.
Pump coupled with motor or engine on a common platform shall perform smoothly
without any excessive noise or vibration.
4.17.2 Pump casing
The casing shall be capable of withstanding to the maximum pressure developed by the
pump at the pumping temperature.
4.17.3 Impeller
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The impeller shall be of standard bronze.
The impeller shall be secured to the shaft and shall be retained against circumferential
movement by keying, pinning or lock rings.
All screwed fasteners shall tighten in the direction of normal rotation.
4.17.4 Shaft
Shaft size shall be selected on the basis of maximum combined shear stress.
The shaft shall be of stainless steel AISI-410 (ASTM – A – 276 Type 410) (BS 970 410 S
21) ground and polished to final dimensions and shall be adequately sized to withstand
all stresses from motor weight, hydraulic loads, vibrations and torque’s coming in during
operation.
Pump Shaft-Motor Shaft Coupling
All shafts shall be connected with adequately sized flexible couplings with spacer of
suitable approved design. Necessary guards shall be provided for couplings.
4.17.5 Base plate
A common base plate mounting both for the pump and drive shall be provided. The base
plate shall be of rigid construction, suitably ribbed and reinforced.
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Base plate and pump supports shall be so constructed and the pumping unit so mounted
as to minimize misalignment caused by mechanical forces such as normal piping strain,
hydraulic piping thrust etc.,
4.17.6 Vibration and balancing
The rotating elements shall be so designed to ensure least vibration during start and
throughout the operation of the equipment. All rotating components shall be statically
and dynamically balanced at workshop.
All the components of pumps of identical parameters supplied under these specifications
shall be interchangeable.
4.17.7 Instruction manual and tools/spares
A comprehensive instruction manual shall be provided by the sub-contractor indicating

detailed requirements for operation, dismantling and periodic operation and
maintenance procedures.
Recommended tools / spares shall be provided and their unit rate breakup shall be
provided by the sub-contractor.
4.17.8 Electric motors
The motor shall be rated not to draw starting current more than 6 times normal running
current. Motor shall be capable of driving the pumps at 150% of its rated discharge and
shall be designed for continuous full load duty. The motor shall be capable of handling
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the required starting torque of the pumps. Speed of motor shall be compatible with the
speed of the pump.
The cooling fans shall be directly driven from motor shaft.
Motor situated out doors or exposed to the weather shall be weather protected.
Motors shall be enclosed type and shall have dust tight construction with suitable means
of breathing and of drainage to prevent accumulation of water from condensation. Drain
holes shall exclude bodies greater than 6mm diameter.
All components shall be of adequate mechanical strength and robustness and shall be
constructed of metal unless otherwise approved.
All motors shall be dynamically balanced.
The enclosure shall be designed to provide an affective sealing between the primary and
secondary air circuits.
Winding insulation shall be class B 415V AC motor and winding shall be vacuum
impregnated with heat and moisture resistant varnish glass fiber insulated.
Two independent earthling points shall be provided in accordance with IS: 3043 on
opposite sides of the motor for bolted connection.
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The cable boxes and termination shall be designed to enable easy disconnection and
replacement of cables.
SECTION 5 DIESEL ENGINE
5.1 General
The diesel engine shall be of multi cylinder type four stroke cycle with mechanical
(airless) injection, cold starting type.
The engine shall be designed with regard to ease of maintenance, repair, cleaning and
inspection. This will also provide interchangeability of parts.
All parts susceptible to temperature changes shall have tolerance for expansion and
contraction without resulting in leakage, misalignment of parts or injury to parts.
5.2 Starting
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The engine shall be capable of both automatic and manual start. Generally the engine
shall start automatically but in case of the auto-start system failure the engine shall be
capable of manual start. Engine shall be able to start without any preliminary heating of
combustion chamber; cranking mechanism shall also be provided. All controls /
mechanism which have to be operated in the starting process, shall be within easy reach
of the operator.
A high DC motor charged by battery shall initiate automatic start of diesel engine. The
battery shall hold adequate retainable charge to provide the starting of the diesel engine.
Starting power will be supplied from two sets of storage batteries. One set of battery is
for automatic starting of the engine and the other provided for manual starting. A
selector switch will be provided at automatic starting control panel to select any of the
two sets of battery for manual / auto starting of the engine. The battery capacity shall be
adequate for ten consecutive starts without recharging with a cold engine under full
compression.
The battery banks shall be used for no other purpose other than starting of the engine
and shall be fully charged at all times with provision for trickle and boost charges. After
start of the engine the charger shall be disconnected, the battery being fed from the
engine dynamo. The two-battery charger of air-cooled type shall be able to charge on
battery bank at a time.
The D/E starting panel along with the battery chargers should be approved by local fire
authority.
5.3 Governing system
The engine shall have a speed control device, which will control the speed under all
conditions of load; the governor shall be suitable for operation without external power
supply.
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The Governor shall offer following features:
An adjustable governor to regulate engine speed within a range of 10% between shut-off
and maximum load conditions of the pumps. The governor shall be set to maintain rated
pump speed at maximum pump load.
5.4 Fuel system
The diesel engine is to run on high speed diesel, the tank provided being enough to hold
the volume required for 6 hours (minimum) continuous operation.
5.5 Cooling water system
Direct cooling system shall be employed for the diesel engine. Water shall be tapped
from the fire pump discharge. This water shall be led through duplex strainer, pressure
breakdown orifice and then after passing through the engine, the outlet water shall be
taken directly to the sump through an elevated funnel.
Recirculating thermo syphon system of cooling using a fan cooled radiator or indirect
cooling system using head exchange shall not be accepted.
5.6 Accessories
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The engine shall be mounted on a base plate of fabricated steel construction. Adequate
access shall be provided for the big end and main bearings, camshaft and governor
drives, water jackets etc.,
The engine shall have a base plate made from MS sections. There shall be reasonable
space at the big end, camshaft, water jackets, governor drives and main bearings.
The engine shall be provided with intake and discharge duct work, inlet filter and
silencer, outlet muffler, expansion joints, dampers etc., as necessary for efficient
operation. Intake air should be taken from inside the building in which the engine is
located, but the exhaust should be discharged outside the building and exhaust duct shall
be adequately sized for minimum pressure drop as per relevant code / standard, and
shall be housed clearing man height.
The flywheel shall have graduated marking around the periphery to facilitate checking of
valve and fuel pump timings.
Full set of diesel engine spares as per Standard requirement to be provided along with
tool kit.
5.7 Instrumentation
The diesel engine shall be provided with adequate instrumentation. The gauge etc., as
required are provided for in the Engine Panel.
Operating Condition for Pumps
Start Stop
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Operating Pressure 14.0 kg/sq.cm.
Jockey Pump both automatic 13.0 kg/sq.cm 14.0 kg/sq.cm.
Main Pump 12.0 kg/sq.cm Manual
SECTION 6 LT SWITCH BOARDS/FIRE PANELS.
6.1 General specification of equipment
The switchboard shall be metal clad, totally enclosed, rigid, compartmentalized/modular

design, floor mounting, air insulated, extensible cubicle type for use on 415v, 3 phases 4
wire 50 Hz system. The degree of protection shall be of IP52 in case of indoor
application as detailed in BOQ.
The equipment shall be designed for operation in rated ambient temperature and rated
humidity tropical atmospheric conditions. Means shall be provided to facilitate ease of
inspection, cleaning and repairs for use in installations where continuity of operation is
of prime importance.
6.2 Standards
Following equipment shall conform to the requirements of :

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Air Circuit Breaker (ACB) - IS 13947 - 1,2 / IEC 947 - 1,2
Moulded Case Circuit Breaker (MCCB) - IS 13947 - 1,2/ IEC 947 - 1&2
Contactors - IS 13947 - 1,4
Miniature Circuit Breaker (MCB) - IS 8828 – 1996 / IEC 898 - 1995
Residual Current Circuit Breaker (RCCB) - IS 12640 - 1988 / IEC 1008
HRC fuse link - IS 13703 and BS 8 :8
Current Transformer - IS 2705 and IEC 60044
Potential Transformer - IS 60044
Relay - IS 3231 & IS 8686 (For Static Relays)
Indicating Instrument - IS 1248
6.3 Construction
The switchboard shall be Sheet steel enclosed, indoor floor mounted freestanding
cubicle type.
Made up of the requisite vertical sections modular type which when coupled together
shall form continuous dead front switchboards.
Dust, vermin and damp proof and ingress protection not less than IP 52, enclosure
suitable for expandable section by addition for vertical section.
Each feeder / instrument compartment shall be provided with a hinged door interlocked
with MCCB inside the compartment such that door can only be opened when MCCB in off
position.
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Switchboards shall have access to the feeders, bus bars, cable termination, cable alley,
etc. as required.
A front framed structure of rolled / folded CRCA sheet steel angle section of minimum 3
mm thickness rigidly bolted together. This structure shall house the equipment such as
circuit breaker, fuse switch units, main horizontal bus bars, vertical risers and other
front mounted accessories.
The structure shall be mounted on a rigid base frame of ISMC of minimum 6 mm

thickness and 75 mm height. The mounting arrangement shall ensure uniform load
sharing and alignment of shipping section.
A cable chamber housing the cable end connections and power / control cable
terminations. The design shall ensure generous availability of space for ease of
installation and maintenance of cabling and adequate safety for working in one vertical
/ horizontal section without coming into accidental contact with live parts of the
adjacent section.
A cover plate at the top / bottom of the vertical section to facilitate glanding cables.
Front and rear doors fitted with dust excluding neoprene gaskets with fasteners
designed to ensure proper compression of the gaskets. When covers are provided in
place of doors generous overlap shall be ensured between sheet steel surfaces with
closely spaced fasteners to preclude the entry of dust.
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The height of the panel shall not be more than 2200 mm unless otherwise specified and
maximum height of operating handle shall not be more than 1800mm from FFL. The
total depth of the panel shall be adequate to cater to proper cabling space.
Doors shall be of minimum 14 gauge sheet steel and covers / partitions of 16G sheet
steel. All sheet steel work forming the exterior of switchboards shall be smoothly
finished, leveled and free from flaws. The corners should be rounded.
The bus bar chamber cover shall be provided with louvers. The louvers shall be covered
with perforated sheet to prevent vertical extension. The Components in the
switchboards shall be so arranged as to facilitate ease of operation and maintenance and
at the same time to ensure necessary degree of safety.
Components forming part of the switchboards shall have the following minimum
clearances:
Between phases - 25mm
Between phases and neutral - 25mm
Between phases and earth - 25mm
Between neutral and earth - 19mm
When, for any reason, the above clearances are not available, suitable insulation barrier
/ shielding shall be provided. Clearances shall be maintained during normal service
conditions.
Creep age distances shall comply with those specified in relevant standards.
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All insulating material used in the construction of the equipment shall be of non-
hydroscopic material treated to withstand the effects of high humidity, high temperature
and tropical ambient service conditions.
Functional units such as circuit breakers, fuse switches, MCCBs, etc. shall be arranged in
multitier formation except that not more than two air circuit breakers shall be housed in
a single vertical section.
Painting: Painting shall confirm to relevant IS standards.
Primer: Primer coating with a coat of corrosion resistant primer applied on wet surface.
Finish coat: Two finishing coats of stoving synthetic enamel paint to the specified shade
of IS: 5. Both the finish shall be only powder coating.
For outdoor units the finishing coat shall be of weather resistant stoving epoxy paint of
specified shade of IS5.
6.3.1 Bus bars
The bus bars shall be made of high conductivity high strength E91E Aluminum alloy
suitable for 415 volts, 3phase 4 wires 50 Hz 50KA unless otherwise specified.
The bus bars shall be suitably supported with non-hygroscopic supports to provide
a fault withstand capacity as specified.
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High tensile bolts and spring washers shall be provided at all bus bar joints.
Fish plates of equal type and size shall be used at all joints.
The bus bars shall have uniform cross section throughout and shall be capable of
carrying the rated current at 415V continuously. The bus bars shall be designed to
withstand a temperature rise of 45 Deg C above the ambient.
The neutral bus bars shall have a continuous rating of at least 50% of the phase bus bars,
unless mentioned otherwise.
Bus bars shall be fully sleeved using heat shrunk PVC sleeves appropriately colour
coded to identify different phases and neutral bar.
An earth bus of size not less than 40 x 6 mm Aluminum / GI shall run throughout the
length of switchboard at top or bottom as required.
The earth bus lead shall be brought for connecting the external earthing.
All the doors shall be provided with flexible earthling links.
6.2 MCCB moulded case circuit breaker

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The Moulded Case Circuit Breaker shall be incorporated in the switchboard wherever
specified and shall be of the current limiting type. MCCB shall conform to IS 13947-1/
IEC 60947-1 (part I & II / section 1) 1977 for general rules. It should be suitable for
Horizontal and Vertical mounting and line load reversibility. MCCB shall be suitable
either for Single Phase AC 230V On Three Phase 415V. The MCCB shall be available in
four pole versions for neutral isolation. It shall have tropicalization as standard feature.
The MCCB cover and case shall be made of high strength heat-resistant and flame-
retardant thermosetting insulating material. The operating handle shall be quick make,
quick break and trip - free type. The operating handle shall have suitable ÒN' ÒFF'
`TRIPPED' indicators and in order to ensure suitability for isolation complying with IS
13947-2/IEC60947-2, the operating mechanism shall be designed such that the toggle or
the handle can only be in ÒFF' position: if the main contacts are actually separated.
6.2.1 Accessories
MCCB shall be designed to have following accessories and it shall be fitted at site.
Under voltage trip
Shunt trip
Alarm switch
Auxiliary switch
Remote operation using motor mechanism with facility of using the same in
auto/manual mode.
6.2.2 Interlocking
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MCCB shall be provided with following interlocking devices for interlocking the door of a
switchboard.
Handle interlock to prevent unnecessary manipulations of the breaker.
Door interlock to prevent door being opened when breaker is in ON position.
The interlocking device to open the door even if the breaker is in ON position.
In addition to the above, any other features indicated in the Schedule of Quantities shall
also be provided.
6.2.3 Breaking capacity
Short time with standing capacities different ratings of MCCB’s shall be as follows:
Short time with standing capacities for short circuit current ratings for MCCB’s shall
be as per SLD or as mentioned below.
Ratings Breaking capacity
[Amps] [KA]
01. Up to 200 20
02. 250 to 400 35
03. 630 to 800 50

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6.2.4 Cable terminations
Cable risers shall be adequately supported to withstand the effects of rated short circuit
currents without damage and without causing secondary faults.
The cable gland supplied shall be single compression.
Earthing plate shall be provided in the gland for gland earthing.
Gland hole made for the gland plates the panel shall be without rough surface ( burrs )
Cable lengths shall be of tinned copper and of the crimping type.
6.3 Contactors
Contactor shall comply with IS 13947-1 for general rules and IS 13947 - 4.1 for
Standards pertaining to Contactor and Motor Starter.
The Contactors shall be capable of withstanding breaking and making capacities impulse
voltage confirming to IS.
Contactor shall be suitable for aluminium termination with a maximum permissible

temperature rise of 55 degree Centigrade at the terminals with an ambient temperature
of 40 degree Centigrade.
The coils shall have three terminals and the insulation class as per IS.
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The auxiliary contact block shall have a switching capacity of 220V, 2A.
Contactor shall have built in auxiliary contacts and provision for add contacts in steps of
two.
Miniature Circuit Breakers [MCB]:
MCB shall comply with IS 8828-1996/IEC 898-1995. It shall be suitable for use in
frequency range 40Hz to 60Hz and shall accommodate AC / DC supply according to
requirements. It shall have a trip-free mechanism and toggle shall give a positive contact
indication. It shall be suitable for mounting on 35mm DIN rail/surface mounting. It may
be installed horizontally, vertically on the ceiling in any place without any change in
electrical performance.
There shall not be line-load restriction. Degree of protection when the MCB is flush
mounted shall be IP40. MCB shall be supplied with clamping terminals fully open.
Contact closing shall be independent of the speed of operator. The breaking capacity of
the MCB shall be 9KA / 10KA. The MCB shall be capable of being used as Incomer Circuit
Breaker and shall be suitable for use as isolator. In case of multiple MCBs in a single
location (DB), it should be possible to remove any MCB without having to disturb other
MCB in the vicinity. The MCB with suitable curve ‘B’ ‘C’ & ‘D’ shall be selected to suit the
application.
6.4 Current transformers
Current transformer shall comply with the requirements of IS 2705. They shall have
ratios, outputs and accuracy as specified / required. All CT's shall be of resin cast type
unless otherwise specifically called for.
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All CT's shall be of bar type primary or suitable for the cable given type and size and the
CT’s shall be provided with shorting links irrespective of the CT’s ratio’s preferably with
ELMEX / PHOENIX
For all the CT's suitable type and size clamps are to be supplied for mounting in the
switchboards.
Polarities and terminal markings of primary and secondary shall be clearly marked on
all CT's.
Specifications for CT’s:
a.Current Ratios
i. Primary : As per feeder ratings
ii. Secondary : 5A
b.Type : Resin Cast
c.Class : 5P10
Protection : 5P10-O/C,E/F, RPR
Class 1 for metering
d. System Voltage
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i. LT : 415V 3Ph 50Hz
6.5 Potential transformer
All the Potential Transformers shall comply with the requirements of IS 3156 latest
edition. All PT's shall be resin cast type and shall have Voltage ratios, output and
accuracy class as specified in Data Sheet.
All PT's shall be single phase / 3 phase dry type suitable for mounting inside the panel /
cubicles. Clamps / brackets / supports required for the mounting shall be supplied along
with PT.
Polarities and Terminal markings shall be clearly marked in all PT's and shall be
visible during inspection.
Nameplate indicating, voltage ratio, burden, accuracy class and type, Sl.No. Make and
model etc., shall be provided on the front side.
A common earth terminal for earthing of core, bolts, clamps (non-current carrying metal
parts) etc., shall be provided.
a. Voltage ratio : As detailed in drawing or in spec.
b. Type : Resin cast

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c. Burden : Refer drawing or spec.
d. Class (Metering/
Protection) : Clause 1
6.6 Instruments & meters
All instruments and meters shall be enclosed in dust proof, moisture resistant, black
finished cases and shall be suitable for tropical use. They shall be calibrated to read
directly the primary quantities. They shall be accurately adjusted and calibrated at
Works and shall have means of calibration, check and adjustment at site.
6.7 Indicating instruments
All indicating instruments shall be digital LED type display. The number of digits of
display shall as per requirement only.
The indicating instruments shall conform to IS: 1248 and shall have an accuracy class of
1.
The Ammeter and Wattmeter current coils shall withstand 200% of rated current
continuously and 10 times the rated current for 0.5 seconds without loss of accuracy.
Voltmeter and Wattmeter potential coils shall withstand 120% of rated voltage
continuously and twice the rated voltage for 0.5 sec. without loss of accuracy.
6.7.1 Voltmeter
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Voltmeter shall be suitable for operating directly on LT supply voltage 415V, 50Hz or
with a PT as per the requirements.
All the Voltmeters used for rated operating Voltage of 415 / 110V as required at 50Hz
AC. With a scale as required at site.
The display shall read the actual voltage and not the PT voltage.
All Voltmeters are 95 x 95mm, suitable for mounting on the panel.
Type Sl.No. Accuracy class and borders of the Voltmeter shall be indicated on the
Rear side.
6.7.2 Ammeter
All the Ammeters shall be CT operated (5A).
Type, Sl.No. Accuracy class, Operating Current, Burden etc., shall be indicated on the rear
side.
All Ammeters shall be of panel mounting type and shall be provided.

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6.7.3 Energy meters
WATT HOUR AND VAR HOUR METERS shall be of the three-phase two-element type
suitable for measurement of unbalanced loads in three phase four wire circuits. They
shall be of draw out type and suitable for flush mounting with back connecting
terminals. The meter shall have glass covers removable from the front of the panel,
without dismantling the meter from the panel. All permanent magnets shall of the non-
ageing type. The meter shall be fitted with a separate test block for testing of the reverse
direction. They shall be provided with a separate test block for testing of the meters
without disturbing the CT and PT secondary connections. They shall have cyclometer
type of register. At least two sealing studs for sealing purposes shall be provided.
They Energy Meter shall be connected to the secondary of potential transformers and
current transformers respectively. These meters shall conform to IS : 13010 and have
an accuracy of class 1.0 or better for KWH meter and 3.0 or better for KVARH meters.
Meters shall be compensated for temperature errors and factory calibrated to directly
read the primary quantities without the use of additional multiplying factor. Multiplying
factor, if unavoidable shall be a multiple of 10. Number of digits provided shall be
adequate to cover at least 1000hrs. of operations.
The current coil of the meters shall have a continuous overload capacity of 200% for
both accuracy and thermal limits. Also the current coils shall withstand at least 10 times
the rated current for 0.5 seconds without loss of accuracy.
6.7.4 Digital load monitor
Digital Load Monitor shall be capable of displaying the following parameters:

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Line and Phase Voltages, Current, Active and Reactive Power, Power Factor, Frequency,
Active and Reactive Energies. Maximum Demand etc.
The Digital Monitor shall have capability to measure both power and energy. It shall
serve as data logger for all Electrical Parameter as and when scanned, displayed and
stored.
The Digital Monitor shall have RS 232/RS 485 Port for PC interface for remote data
acquisition, telemetering capability, analysis and graph plotting.
It shall be capable of operating an Low Voltage networks with a input voltage 110V to
600V and on a CT either 1A or 5A.
Shall be mechanically robust, LED display, suitable for mounting an Electrical panels,
capable of operating on 3Ph, 4Wire, balanced / unbalanced load, continuously on
environmental condition such as temperature 0 to + 50Deg.C, Relative humidity 100%.
Display LED shall be 3 digits / 4 digits as per the number requirement.
6.8 Push buttons
Push buttons shall be of momentary contact type with rear terminal connection. These
shall be suitably shrouded to prevent inadvertent operation. Integral inscription plates
engraved with their functions shall be provided. All push buttons shall have two
Normally Closed and two Normally Open contacts comprising rivets of pure silver. The
contacts shall be able to make and carry 5 A and break up one amp inductive load at
250V DC.
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6.9 Control wiring
All control wiring shall be carried out with 1100/660 V grade single core PVC cable
having stranded copper conductors with minimum cross section of 1.5 Sq mm for
potential circuits and 2.5 Sq mm for current transformer circuits.
Wiring shall be neatly bunched, adequately supported and properly routed to allow for
easy access and maintenance.
Wires shall be identified by numbered ferrules at each end. The ferrules shall be of ring
type and of non-deteriorating material. They shall be firmly located on each
termination so as to prevent free movement.
All control circuit fuses shall be mounted in front of the panel and shall be easily
accessible.
6.9.1 Terminal blocks
Terminal blocks shall be of 500 Volts grade and of stud/screw less type.
Terminal blocks shall have a minimum current rating of 10Amps and shall be shrouded.
Provisions shall be made for label inscriptions. At least 20% spare terminals shall be
provided on each panel and these spare terminals shall be uniformly distributed on all
terminal blocks.
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Terminal blocks for current transformer and voltage transformer secondary leads shall
be provided with test links and isolating facilities. Also current transformer secondary
leads shall be provided with short-circuiting and earthing facilities.
There shall be a minimum clearance of 250mm between the first row of terminal blocks
and the associated cable gland plate. Also, the clearance between two rows of terminal
blocks shall be a minimum of 150mm.
6.9.2 Relays
All Relays shall conform to the requirement of IS: 3231/IS 8686 or other applicable
approved standards Relays shall be suitable for flush and Semi-flush mounting on front
At with connections from the rear.
All Protective Relays shall be of draw out or plug in type/Modular cases with proper
built in test facilities. Test blocks and switches shall be located immediately below each
relay for testing. The auxiliary relays shall be self reset type.
All AC Relays shall be suitable for operation at 50Hz. AC Voltage operated relays shall be
suitable for 230 Volts PT secondary and Current operated relays for 5Amp. CT.
primary as specified in this specification. Voltage operated relays shall have adequate
thermal capacity for continuous operation.
Auxiliary Relays and Timers shall have pairs of contacts as required to complete the
scheme. Contacts shall be silver faced with spring action.
All Protective Relays, Auxiliary Relays and Timers except the lockout relays and
interlocking relays specified shall be provided with self-reset type contacts. All, Trip
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and Timers shall be provided with externally hand reset positive action provided with
inscription subject to /Consultant approval. Timers shall be of the electromagnetic or
solid-state type.
Wherever solid-state relays are used the following requirement shall be met with:
All Relays shall be designed for operating under or ambient temperature 55.C and 100%
relative humidity. Electronic type timers shall be as far as possible avoided.
All accessories required for correct operation of each relay shall be supported by the
Contractor without any extra cost.
The solid state relays shall be stable and suitably protected against transient / induced
over voltages. The bidder shall state clearly in his list special requirements, if any, for
DC input arrangement or cabling considered necessary for satisfactory operation of
solid state relays quoted by him.
6.9.3 Name plate
The panel as well as feeder compartments shall be provided with name plate of anodized
aluminium with white engraving on black background. They shall be properly secured
with fasteners / rivets. The panel / feeder descriptions shall be as indicated in the
drawings / by the contractor.
6.9.4 Tests
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The routine tests shall be conducted as per IS standards on each Power Control Center
and shall comprise:
Inspection of the Switch Boards including inspection of wiring and electrical operational
/ functional tests where necessary.
6.9.5 Dielectric tests
Insulation resistance of the power circuit between each pole and the earth and that
between the poles shall be measured.
Insulation resistance of all secondary wiring between phase and earth shall be
measured. Insulation test shall be carried out both before and after high voltage test.
Checking of protective measures and electrical continuity of the protective circuits.
6.9.6 High voltage test
A high voltage test with 2.5 KV for power circuit and 1.5KV for Control Circuit, Duration
one minute shall be applied between each pole and earth and between poles. Test
certificate shall be submitted along with panel.
6.9.7 Storing, erection and commissioning

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Storing
The panels shall be stored in a well-ventilated dry place. Suitable polythene covers
shall be provided for necessary protection against moisture, dust and vermin.
Erection
Switch boards shall be installed over trench/floor as required. Suitable grouting holes
shall be provided in the flooring. Suitable MS base channel shall be embedded in the
flooring on which the panel can directly be installed. The switch boards shall be
properly aligned and bolted to the flooring by at least four bolts. Cables shall be
terminated on the bottom plate or top plate as the case may be, by using brass
compression glands. The individual cables shall then be led through the panel to the
required feeder compartments for necessary terminations. The cables shall be
clamped to the supporting arrangement. Either side, the switch board earth bus shall be
connected to the local earth grid.
The base channel used for erection of panels shall form part of the cost of the panel and
shall not be measured or paid separately.
6.9.8 Precommission tests
The panels shall be commissioned only after successful completion of the following tests.
The test shall be carried in the presence of main contractor & the client as classified in
the scope.
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All main and auxiliary bus bar connections shall be checked and tightened.
All wiring terminations and bus bar joints shall be checked and tightened.
Wiring shall be checked to ensure that it is according to the approved drawing.
All wiring shall be tested for insulation resistance by a 500 volt megger.
Phase sequence test to be conducted on grid power and DG backup power.
Suitable injection tests shall be applied to all the measuring instruments to establish the
correctness and accuracy of calibration and working order if required by the
Employer.
All relays and protective devices shall be tested for correctness of settings and
operation by introducing a current generator and an ammeter in the circuit or shall
produce calibration / test certificate as required by the Employer / Inspectorate /
consultant.
Functional tests on all feeders.
Makes, type and ratings of all components shall be checked/verified as per approved
drawings.
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6.10 General specifications for medium voltage cables
Type
Medium voltage cables shall be Aluminum conductor, XLPE insulated, PVC sheathed
and steel wire armoured or steel tape armoured construction. The cables shall conform
to IS 7098 for xlpe cables & IS 1554 for Pvc insulated cables Part I in all respects.
Cables shall be laid in tray / Hume pipe / In readymade trenches etc., as required.
Rating
Power cable shall be rated for a voltage of 1100 Volts.
Core identifications
Cores shall be provided with the following color scheme of PVC insulation:
1 core : Red/Black/Yellow/Blue
2 core : Red and Black
3 core : Red, Yellow and Blue
3 1/2 / 4 core : Red, Yellow, Blue & Black
6.11 Storing, laying, jointing and terminations
Storing
On receipt of cables at site the cables shall be inspected and stored in a safe place.
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Laying
Cables shall be laid as per the specifications given below:
6.12 Cables in outdoor trenches
Cables shall be laid in outdoor trenches wherever called for. The depth of the trenches
shall not be less than 75 cm from the final ground level. The width of the trenches shall
suit easy laying of cable. Where more than one cable has to be laid in the same trench,
all attempts shall be made to keep the axial distance between successive cables to be
at least 1d where 'd' is the diameter of the bigger cable. The trenches shall be cut square
with vertical side walls and with uniform depth. Wherever cables are bent, the
minimum bending radius shall not be less than 12 times the diameter of the cable.
After the cable is laid and straightened, it shall be covered with sand cushion. Over this a
course of cable protection tiles or burnt brick shall be provided on either sides and
above. Trench shall be back filled with earth and consolidated. Cables shall be laid in
hume pipes / stoneware pipes at all road crossings & wall entries shall in closed for
water entry. Approved cable markers made of CI indicating the voltage, no. of cables
and the direction of run of the cables shall be installed at regular intervals.
4.3 Cable in indoor trenches
Cables shall be laid in indoor trenches wherever specified. Suitable angle iron brackets,
clamps, hoods and saddles shall be used for securing the cable in position.
4.3.1 Cable on trays / racks

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Cables shall be laid on cable trays/racks wherever specified. Cable racks / trays shall be
of perforated steel section / slotted angles suitable for the purpose. The trays / racks
shall be complete with plates, tees, elbows, risers and all necessary hardware. The steel
trays shall be painted. Cable trays shall be erected properly to present a neat and clean
appearance. Suitable cleats or saddles shall be used for securing the cables to the cable
trays. The cable trays shall comply with the following requirements:
The trays are ladder type and shall have suitable strength and rigidity to provide
adequate support for all contained cables.
It shall not present sharp edges, burrs of projections injurious to the insulation of the
wiring / cables.
If made of Sheet metal, it shall be adequately protected against corrosion or shall be

made of corrosion resistant material.
It shall include fittings such as horizontal, vertical bends, tie rods, hooks etc., or other
suitable means for changes in direction and elevation of runs, fishplates and hard ware.
4.3.2 Installation
Cable trays shall be installed as a complete system. Trays shall be supported properly
from the building structure. The entire cable tray system shall be rigid.
Each run of the cable tray shall be completed before the installation of cables.
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In-portions where additional protection is required, non-combustible covers / enclosure

shall be used.
Cable trays shall be exposed and accessible.
Where cables of different system are installed on the same cable tray, non-combustible
solid barriers shall be used for segregating the cables.
Cable trays shall be grounded by two nos. earth continuity wires. Cable trays shall not
be used as equipment grounding conductors.
4.3.3 Jointing and terminations
Generally cable jointing is not recommended, however in case un avoidable due to long
length Cable jointing shall be done as per the recommendations of the cable
manufacturer. Jointing shall be done by qualified cable jointers. The cable joints to be
carried with due approval from main contractor.
Each terminations shall be carried out using brass compression glands and cable
sockets. Hydraulic crimping tool shall be used for making the end terminations. Cable
gland shall be bonded to the earth by suing suitable size G.I. wire/tape.
Suitable identification tags with the feeder designation inscribed on an Aluminum / G.I.
sheet shall be tied to either ends of each cable.
4.3.4 Testing
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Cables shall be tested at factory as per the requirements of IS 7098 Part I. The tests
shall incorporate routine tests, type tests and acceptance tests. Copy of such test
certificates shall be furnished to the Employer prior to dispatch.
4.3.5 Commissioning of cables
1.Phase sequence of the cable to be tested and confirmed.
2. The continuity test to carried out and crosschecked with the
3. The cable shall be tested with loading in steps for main incoming cables.
4. The temperature rise to be observed on the surface of cables near the load and at
the panel.
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SECTION 5 SRINKLER SYSTEM
5.1 Scope of work
The sprinkler system shall include the following:
Sprinkler main, branch and internal piping complete with valves, alarms and supporting
arrangements.
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Sprinkler heads with spare sprinklers. Connections to risers/mains etc.
All material shall be of the best quality conforming to specifications and subject to the
approval of the main contractor.
Pipes and fittings shall be fixed truly vertical/horizontal or on slopes required in a neat
manner.
Pipes shall be fixed in such a manner so as to provide easy accessibility for repair and
maintenance and shall not cause obstruction in shafts, passages etc.
Pipes shall be securely fixed to walls and ceilings by suitable clamps at intervals
specified.
Only approved types of anchor fasteners shall be used for RCC ceilings and walls. Valves
and other equipment shall be so located that they are easily accessible for operation,
repairs and maintenance.
5.2 Sprinkler heads
The sprinkler heads shall be UL listed/FM approved typefixed temperature type with a
quartzoid bulb containing liquid having high vapour pressure held in position by a
forged GM yoke and deflector. The rated temperature of quartzoid bulb shall be 68 deg.
C. Coverage area per sprinkler to cover 9 to 12 sq. m each and design density of water is
5.0 LPM / sq. m for assumed area of 360 sq.m. For building pendent type/side throw
sprinklers with 68°C rated and shall be provided with a density of 4 mm/min over
hydraulically most remote 140 sq.m . The spacing shall however conform to the detailed
drawing, in Co-ordination with electrical and other allied services at the ceiling level.
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Sub-contractor shall supply 90 spare sprinkler heads and 2 nos. spans neatly installed in
a steel box with glass shutter at an appropriate position approved by the Engineer-in-
Charge.
A water motor gong and an inspection test connection shall be provided on the
downstream side of the system.
5.3 Pipes and fittings
Pipes for the sprinkler system shall be GI/MS “C” Class pipes conforming to IS 1239
(heavy class) fittings for GI pipes shall be of approved make with flanged fittings. For
jointing of pipes, butterfly valves, check valves etc., please refer to the specifications
given for Fire Hydrant System.
Holes for the Sprinkler system, pipes should be drilled to suit the size of the collar, and
also suitable size of T or collar to be provided for the below false ceiling pendent
sprinklers while quoting pipes this should be considered.
5.4 Orifice plates
For restricting pressure at lower levels in the sprinkler system, orifice plates of
appropriate sizes shall be fitted at different floor levels, at the branching points from
Riser Main.
The Diameter of such orifice shall not be less than 50% of the dia of pipe into which it is
to be fitted, which shall not be less than 50mm dia. These orifice plates must be of
stainless steel with plain central hole without burrs, and the thickness shall be 3mm for
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pipe size upto 80 mm, 6 mm for pipes from 80 to 125 mm dia and 9 mm for pipes
greater than 125 mm dia. Such orifice plate must have a projecting identification tag.
The orifice plate shall fitted not less than two pipe internal diameters down stream of
the outlet from any elbow or brand.
Contractor shall submit the design and identify location on drawing before installation.
5.5 Installation control valves
Each installation shall be provided with a set of installation control valves comprising:-
a. An Alarm Valve.
b. A Water Motor Alarm & Gong.
c. Installation valves shall be installed on the sprinkler circuits as shown on the

drawings.
d. Contractor shall submit detailed shop drawings showing the exact location,
details of installation of the valves/alarm in all respects.
e. Installation valve shall comprise of a cast iron / ductile iron body with gunmetal
trim, and double seated clapper check valves, pressure gauges, test valve and
orifice assembly and drain valve with pressure gauges, turbine water gong
including all accessories necessary and required and as supplied by original
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equipment manufacturer and required for full and satisfactory performance of

the system. A cast iron isolation valve with lock and chain at the inlet of the
installation valve shall be provided.
5.6 Inspection and test valve assembly
Inspection and testing of the automatic starting of the sprinkler system shall be done by
providing an assembly consisting of gunmetal valves, gunmetal sight glass, bye-pass
valve and orifice assembly as per approved drawing.
5.7 Flow switch
Flow switch shall have a paddle made of flexible and sturdy material of the width to fit
within the pipe bore. The terminal box shall be mounted over the paddle/ pipe through
a connecting socket. The Switch shall be potential free in either N O or N C position as
required. The switch shall be able to trip and make / break contact on the operation of a
single sprinkler head. The terminal box shall have connections for wiring to the
Annunciation Panel. The flow switch shall have connections for wiring the seat shall be
of S.S to the Annunciation Panel. The flow switch shall have IP: 55 protection.
The flow switch work at a triggering threshold bandwidth (flow rate) of 4 to 10 GPM.
Further, it shall have a ‘Retard’ to compensate for line leakage or intermitted flows.
5.8 The main stop valve
These shall be of cast iron body of requisite size. When closed, these will shut off supply
of water to the installation.
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A location plate must be fixed on the outside or an external wall, as near to the main
stop valve as possible, bearing the following words on raised letters or other approved
type letter.
i Sprinkler Stop Valve Inside : The word `sprinkler stop valve' shall be in letters
of at least 35mm and the word "INSIDE" at least25mm in height. The words shall
be painted white on black back ground.
ii All stop valves shall be right handed i.e. they shall be so constructed that in order
to shut the valve the spindle shall turn from left to right. There shall be an
indicator which will show whether the valve is open or shut.
Portable fire extinguishers are provided at locations mentioned below,
 ABC type fire extinguisher of capacity 2/4/6/9 kilograms fitted with gun metal cap,
high pressure carbon-dioxide cartridge, with suitable mounting brackets
conforming to IS 2171 near main switch board room, transformer, generator room,
pump room, AHU rooms, for every 8 car park and lift machine room.
 Water expelled carbon-dioxide type fire extinguisher conforming to IS 940 located

near each staircase landing on every floor and office areas.
 Carbon dioxide type fire extinguishers conforming to IS 2878, located in electrical

panel room, pump room, lift machine room.
 Mechanical foam type fire extinguishers at, D.G. Rooms, pump house and near oil
filled Transformers.
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5.10 Signage
 Required, as per Local fire force like exit signs & Floor indication (eg Ground floor,
1st floor/ Production area, paint shop, welding shop etc..), size shall 200mm x
500mm & action chart ( size shall be 600mm x 1000mm) in case of fire /
emergency, Staircase location indication etc. The location / quantity shall be on
each landing of every staircase on each floor.
 Signs shall be made out of 3mm thick PVC foam board with PVC non – reflective self
adhesive vinyl foam board OR equivalent material with Mirror fasteners for fixing
complete.
SECTION 7 GAS SUPPRESSION SYSTEM (FM200-HFC-227ea chemical agent)
The bidder shall supply, install, test and put in operation Gas suppression system (FM 200) fire
Suppression system. The fire suppression system shall include and not be limited to gas
release control panel, CCE approved seamless cylinders, discharge valve (with solenoid or
pneumatic actuator) as the case may be, discharge pipe, non-return valve and all other
accessories required to provide a complete operation system meeting applicable requirements
of NFPA 2001 or ISO standards and installed in compliance with all applicable requirements of
the local codes and standards.
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The system design should be based on the specifications contained herein, NFPA 2001 & in
accordance with the requirements specified in the design manual of the agent. Thebidder,
shall confirm compliance to the above along with their bid.
The system shall be properly filled and supplied by an approved OEM (Original Equipment
Manufacturer)
The systems should offer fire suppression in accordance with the National Fire Protection
Association (NFPA).
NFPA 2001 - Standard on Clean Agent Fire Extinguishing Systems, NFPA 70 - National
Electrical Code,
NFPA 72 - National Fire Alarm Code, and the guidelines contained in this manual. The system
and
its components should only be used for total flooding applications, not local application
protection.
The design of such the system requires that the FM-200 chemical agent be discharged from its
container within 10 seconds and be thoroughly mixed throughout the room or area, reaching a
minimum concentration level of 6.25% but not exceeding 9% in normally occupied spaces.
FM-200 gas suppression system should be used for suppressing fires in specific equipment or
hazards requiring an electrically non-conductive agent and that may be occupied. FM-200 may
be
used in the protection of the following types of facilities:

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 Data processing facilities.

 Process control rooms
 Telecommunications facilities
 High value assets/facilities.
6.1 Design
A minimum 6.25% volumetric concentration is required for Class A surface burning type fires,
such as wood or other cellulose type materials. The Class B flammable liquid type fires require a
minimum design
concentration at 30% above the extinguishing concentration of the fuel or 30% above the cup
burner
value established for the fuel. Design values for particular fuels are given in the Appendix of this
manual.
The minimum design concentration for Class C hazards shall be at least that for Class A surface
fires and the minimum design concentration for a manually actuated system shall be the
extinguishing concentration times for safety factor. The agent concentration should be based on
the lowest ambient temperature expected within the area. When calculating the concentration
levels for normally occupied spaces, care must be taken to insure that at its highest expected
ambient temperature, the space does not exceed the NOAEL value of FM-200 of 9% as stated in
National Fire Protection Association Standard 2001.
The specific concentration shall be in line with the volume of the area specified or to be
known. Any environmental factors that require additional agent for compensation, such as
temperature and leakage, also must be known.
The design and offered price of the system should consist of selection and proper placement of
the following equipment:
 Container(s)
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 Mounting bracket(s)
 Nozzle(s)
 Pipe and fittings
 Control panel(s)
 Detection
 Optional accessories
However, the location of placement, area of the facility to install the system shall be
confirmed by the main contractor by issuing the GFC drawing or in the BOQ.
6.2 Control panel
The control panel offered shall be listed and/or approved for Releasing Device Service and
compatible with Chemetron FM-200 equipment. Mounting location for the control panel will be
a shock and vibration free area. If the panel has a hinged door, allowances shall be made for it to
swing completely open for service. The standards of the National Electrical Code (NFPA 70),
Local Protection Signaling (NFPA 72), and any state and local codes shall be followed for
detection and visual and audible alarms. The control equipment shall supervise the actuating
devices and associated wiring. Also it should be provided with a reliable 24-hour minimum
standby source of energy.
Automatic detection
The automatic detection devices used shall be capable of detecting and indicating heat, smoke,
flame or combustible vapors that are likely to produce a fire. When choosing detectors, the four
fire stages should be considered. The stages are incipient, smoldering, flame, and heat.
1. Incipient Stage - This stage is when visible products of combustion are present without
smoke,
flame, or heat.
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2. Smoldering Stage - During this stage, visible products of combustion and smoke are present;
how-ever flame and heat are still not present.
3. Flame Stage - When this stage is reached, an actual fire is present but without appreciable
heat,
which will follow very quickly.
4. Heat Stage - This is the final stage, with rapidly expanding gasses and uncontrollable heat
present.
The consideration in choosing detector type should be based on vibration, response time, and
the amount
of dirt or corrosive products in the environment. Ionization (smoke) detectors respond best
during the
incipient stage and decrease in effectiveness during the smoldering, flame and heat stages.
Photoelectric
detectors respond best during the early smoldering stage. A thermal type detector gives the
best response
during the later flame and heat stages of a fire. They are selected by temperature range in
conjunction
to the area being protected.
6.3 Accessories
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The system shall be including all accessories for installation including audible or visual devices
used to indicate the operation of the system, hazards to personnel, or failure of supervised
devices.
SECTION 8 LIST OF RECOMMENDED MAKES
8.1 Recommended make of fire hydrant and sprinkler system
“In the list of recommended below, out of two-three makes mentioned in the list, only 1st make
shall be quoted for and used. However if due to non-availability or any other technical reasons,
the alternative make is allowed, it shall be subject to price adjustment as approved by main
contractor.
No Name of Meterial / Equipment Name of Reference Remar

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. Supplier/Manufacturer ks
C FIRE PROTECTION
1 Fire Pumps Kirloskar / Grundfos / KSB
2 Diesel Engine Kirloskar / Greaves / Cummins India
3 GI Pipes / MS Pipes TATA / Jindal
4 GI/MS Pipe Fittings MS Fittings / VS Brand / Bharat Forge
5 Butterfly Valves Audco / Intervalve / Keystone
6 Check Valves Advance/ H. Sarker / Hawa
7 Gate Valves / Ball valves Leader / Zoloto / I tap
8 Strainers Kirlosker / Audco / Grandfix
9 Foot Valves Normex / H. Sarker

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10 Flow meter Forbes Marshall / Eureka
11 Pressure Switch Indfos / Switzer / Delta Control
12 Pressure Gauge H. Guru / Fiebig / Prico
13 Hydrant Valves Newage / Winco / Minimax
14 Branch Pipe with Nozzle Newage / Winco / Minimax
15 Fire Hoses Newage / CRC
16 Hose Couplings Newage / Winco / Minimax
17 Hose Reel Eversafe / Tyco / Minimax
18 Hose Box / Fire Duct Eversafe / Tyco / Minimax
19 Fire Extinguisher Safex / Minimax / Eversafe/Ceasefire.
20 Sprinklers Tyco / Viking / Kidde

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21 Sprinkler Alarm Valve Tyco / Viking / Kidde
22 Flow Switch System Sensor / Switzer / Levcon
23 Paint Asian / Berger
24 Air release Valves Leader / HAWA
25 Welding Electrodes Esab 28 / Advani
26 Heat Detectors Aqua Inteltech / Filpro / Digitech
27 Main Control Panel Notifier / Honeywell / Siemens
28 Manual Pull Stations Notifier / Honeywell / Siemens
29 Hooters / Stations Notifier / Honeywell / Siemens
30 Modules Notifier / Honeywell / Siemens
31 Battery HitachiI / Johnson / Exide

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32 Copper Conductor Control Polycab / Shakthcab / Finecore
33 Manual Pull Stations Notifier / Honeywell / Siemens
34 Hooters / Stations Notifier / Honeywell / Siemens
35 Modules Notifier / Honeywell / Siemens
36 Battery HitachiI / Johnson / Exide
37 Copper Conductor Control Polycab / Shakthcab / Finecore
38 Communication Wires Polycab / Shakthcab / Finecore
39 M S Conduits Bharath / GB / Prince
40 PVC Conduits VIP / Precision / Nelco
41 Public Address Speakers Toa / Philips / Ahuja / Bosch
42 Public Address Console Tyco / Fire Pro / Bosch

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Public Address
43 Toa / Philips / Ahuja / Bosch
Amplifiers/Equipment
44 CCTV/ACCESS/AV System Panasonic / Bosch/ Honeywell
45 Recorder Bosch / Honeywell
46 projector Epson
47 Ceiling Mounted Kit Actis
48 Video / Audio Conferencing system Polycom
49 HDMI Patch card MX
Microphones for Audioconferencing

50 Polycom
system
51 Ceiling Speaker JBL
52 Wireless Lapel mic Shure

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8.2 Recommended make of electrical materials
Name of Meterial /
No. Name of Reference Supplier/Manufacturer Remarks
Equipment
D ELECTRICAL
XLPE Insulated,
Aluminum conductor
1 Polycab / Gloster/ Havell’s
HT/ LT
cables
Unarmored and
Armored – LT -Copper
2 Polycab / Havell’s / Gems Cab
conductor
Cables
Decorative Luminaires
3 Philips
/ Light Fittings
High efficiency
4 Osram / Philips
fluorescent lamp
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MCB/B,C & D Curve/

RCDs/Surge
5 Schneider/ABB/Legrand
suppressors
/Isolators
6 MCB DBs Schneider/ABB/Legrand
7 MCCB’s Schneider/ABB/Legrand
Decorative type
8 modular switches & Anchor Roma / Crabtree / Clipsal/MK
Sockets
Heavy duty cable Lugs/

9 Dowels / SMI
Cable glands
Industrial Switch &

10 Neptune/Scame /Gewiss/Schneider
sockets
Moulded Industrial
11 Neptune/Scame/ Gewiss/Schneider
Switches & Sockets
12 MS Conduits BEC/GB / Bharat
13 FRLS PVC Conduits VIP / Precision

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14 Wires(FRLS) RR Kable / Rajaniganda / Havell’s
Cable/Earth pit
15 Suraba / SMI
markers
16 Terminals Elmex / Connectwell /wago
17 Rubber Mat Jyothi or Eq.
18 Push Button Station Siemens / Schneider / ABB / L&T
DOL/Star Delta
19 Siemens / Schneider / ABB / L&T
Starter(if applicable)
20 Earth pit marker SMI or Eq.
21 Fire Barriers 3M / VIPER / Hilti
22 Cable Trays Power Pack / MAA/ Patney
Fabricated Wire ways /

23 Power Pack Bangalore / Patney /LKPace/Equivalent
Raceways
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Readymade Wire ways

24 Power Pack Bangalore / Patney /LKPace/Equivalent
/ Raceways
25 UPS / Inverter APC / Numeric /Dubas
Fabricated Wire ways /

26 Pushpak/Storac/Innospacer
Raceways
Emergency Lighting
27 Prolite / MDS Legrand
Luminaries
28 CAT-6 Cable AMP Net Connect
29 Co-Axial Cable Comescope / LAPP
30 TV / Telephone Outlets Anchor Roma / Clipsal /Crab Tree
31 Telephone Cable Delton / Finolex / LAPP
32 Telephone TAG Block Krone
33 Terminal Block Elmex / Connectwell /wago

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FIRE ALARM, PUBLIC ADDRESS SYSTEM, ACCESS CONTROL SYSTEM AND CC TV

SYSTEM.
General
This specification covers the requirements of design, supply of components, installation, testing,
commissioning intelligent analog addressable Fire Detection - Alarm & Public address systems,
Access control, CCTV systems as required by the main contractor.
1. STANDARDS :
The equipment and installation work shall conform to latest editions of applicable Indian /
International Standards. The standards shall include but not be limited to the following:
a. Applicable NFPA Standards.
b. BIS code of practice for Fire Detection and Alarm System -IS 2189:1999.
c. All the products shall have UL listing & CE Marking.

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d. NFPA Standard No-72 the National Fire Alarm Code.
The installation shall be carried out in conformity with the stipulations of local fire authority.
2. DRAWINGS
The typical drawings/details indicating the locations of Smoke Detectors, speakers, Fire Alarm control
panel with scheme of system architecture proposed etc are being issued to the subcontractor for the
general guidance.
Detailed working (shop) drawings shall be prepared by the sub-contractor and submitted for approval
before taking up the work.
The sub-contractor shall examine all drawings before starting the work and report to the site engineer
any discrepancies which in his opinion will hamper the work and obtain the clarifications from the
consultant.
3. PROJECT PARTICULARS
This project is proposed industrial/commercial building project ________________________at

______________________________.
4. SCOPE OF WORK :
The following systems are part of the specifications. However, the scope of works or the works to be
executed will be a part of the BOQ.
a. Analog addressable fire detection & alarm system across the facility
b. Public Address system
c. Two way communication system.
d. Access control system
e. CCTV system
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7.0 EXCLUSIONS:
The works which do not form a part of the scope mentioned in these specifications, should be
highlighted and clarifications to be obtained from the main contractor.
8.0 SITE FACILITIES:
8.1 The main contractor will make available an open area to the contractor to put up the site office and
stores. The contractor shall do so at his cost.
8.2 The following shall be made available:
c). Temporary power at one point shall be made available by the main contractor. Further
extension of the power supply to specific locations in the project for execution of works shall
be included in the sub-contractors offer.
d). Security / watch & ward for the stored materials at site shall be organized by the vendor, the
main contractor shall not be responsible for the materials before handing over the assigned
work in complete working conditions, adhering to the general conditions of the contract
documents.
9.0 SITE REPRESENTATIVE:
The sub-contractor shall appoint a full time site engineer and he should not be transferred /
Relocated till the completion/handover of the Project. Any transfer of the site Engineer should be
done only with the consent from the Client / PMC.
The Sub-contractor shall ensure that all Safety norms are strictly adhered to throughout the installation
period. The following points should be specifically noted and complied with.
10.1 All electrically operated hand tools shall be of the double insulated type.
10.2 All lifting tackles shall have valid capacity certification.

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10.3 All workmen should be provided with electrically operated tools having insulated handles.
10.4 All workmen operating at heights of more than 3 M above floor level shall use safety belts.
10.5 Properly designed ladders or scaffolding shall be used while working at heights. Wooden ladders &
scaffolding will not be permitted.
10.6 All workmen shall be provided with rubber gloves, helmets & safety shoes.
10.7 Proper safety Signage must be displayed at selected places and all the safety norms to be followed
as per the main contractor’s guidance.
10.8 The welding sets to be used shall have proper terminal box for cable termination and earthing.
10.9 No intermediate joints shall be allowed in any cables or wiring.
10.10 Welding shall be carried only by the trained / certified welders.
11.0 DESIGN PARAMETERS
a. FIRE DETECTION & ALARM (FDA) SYSTEM
All the FDA devices shall be of the analogue addressable type only.
A Fire Alarm Panel shall be installed as per the design/drawings/details/conforming to the local
statutory authorities
.
Fire alarm control panel shall be extendable type and shall be communicable with repeater panels and
suitable for integration through TCP / IP protocol for PA system and BMS system.
Smoke detectors shall be provided at ceiling level as per the drawings/details and The below false
ceiling detectors will be provided where ever false ceiling is provided or as per the drawing. For all the
areas high sensitivity Addressable optical detectors and for Pantry / kitchen / Electrical rooms, multi
sensor Detectors shall be provided.
The area coverage of each detector shall be limited to 400sqft, in open plan areas & 600sqft for above
False-ceiling. Control module shall be provided in the electrical rooms and for the VRV outdoor unit
locations if specified in the drawings/details.
Addressable Manual call points/stations shall be provided at all exit points and at emergency exit
points or as specified in the drawings. The exact location shall be decided at site. Addressable
electronic Hooters with a sound level of 85 –90 dBA shall be provided. The manual call points shall be
housed in dust proof and moisture proof enclosure properly sealed with rubber lining. The manual call
point glass thickness should not be exceeding 12 mm.
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The detectors, manual call points/stations and other devices except Hooters shall be wired in a 2/4
wire loop using FRLS grade PVC insulated, 2 core 1.5 Sqmm Copper conductor cable in FRLS
conduits as per specification and connected to the control panel. Each loop shall have up to 150
devices of which the detectors shall not exceed 80% of the capacity. In case where the vendor is unable
to offer the system with the said detectors, the additional loops as required shall be included by the
vendor in the BOQ separately. The other devices shall include control modules, manual call points and
fault isolation modules.
Repeater Panel:-
Active Repeater Panel shall be provided if specified in the BOQ. The Repeater panel shall be
connected to the FACP through RS485 communication. It shall be powered from the FACP & shall be
supplied with necessary interface cards for connecting to FACP. The panel shall have minimum 2x40
characters back lit LCD display which will repeat all the events, alarms, messages displayed by the
FACP. LCD display annunciators shall mimic the main control panel 80 character display and shall not
require special programming. The Repeater Panel shall have the following LEDs for displaying
System Status: DC Power, Fault, Fire.
b. PA SYSTEM
The PA system is generally installed for paging or for any announcements. The system supplied shall
be capable of receiving signal from fire alarm panel & automatically announce in the event of fire in
the building. This system shall cover open areas, entrance lobby, toilets & closed cabins. The system
also should be suitable for playing music from separate cassette or CD player.
The PA system for general area shall comprise of 5 / 6 / 15-Watt ceiling/wall mounted speakers,
amplifiers and microphones. The amplifiers shall have a bandwidth of 50-15000Hz, Frequency
response of 45-16000Hz 5-band equalizer, bass and treble tone controls and shall have provision
connect both wired and wireless microphones up to 8 numbers. The units shall be suitable for
operation on 240V 1Phase AC supply. Microphones shall be provided at the security control room and
reception desk. Handheld cordless mike shall be supplied as per the BOQ. Console for PA system shall
be made of CRCA sheet of 1.6mm thick. Proper ventilation to be taken care with the louvers.
Integration modules have to be provided to make the required communication to the fire dept and also
to provide the mass notification and emergency communication.
2. EQUIPMENT / COMPONENT SPECIFICATIONS
AUTOMATIC FIRE DETECTION & ALARM SYSTEM

FIRE ALARM CONTROL PANEL
Type : Analog addressable
No. of detectors per loop : Up to 120

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No. of all devices per loop : Not more than 150
Type of devices : Analog addressable
Type of construction : Made out of 2mm thick CRCA sheet steel

Duly painted / powder coated with Fire Red
shade.
Hinged door with glazed window & pad

locking facility
Suitable for concealed / surface mounting
Suitable Conduit / cable entry and wiring

space to be provided
Cable entry should be preferably at the top
Degree of protection shall be not less than

IP-54
Specific requirements : Panel shall support the device network and

shall be able to communicate with the
addressable devices and the central P.C
station loaded with graphical illustration
software.
The panel shall be compatible to facilitate

overall system supervision general
diagnostics, sensitivity settings testing and
fault clearing from the central monitoring
station
It shall be possible to identify each of the

devices, their status and set values from the
PC and change the settings
Modularity in design to be adopted for easy

addition of address identification modules.
At least 6 Nos. Relay modules shall be

provided for external connectivity.
System features : Printer / PC interface
Minimum 500 event non-volatile memory

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Real time clock and calendar. Key board for

Menu driven programming
Intelligent alarm verification.
Polling time shall not be more than 300 mS
Response time shall be 300mS to 3

Seconds
Regulated power supply & power supply

monitoring
Local and remote diagnostics
Time/event based scheduling
Lightning/ EMI protection
Short circuit protection
80 character LCD display
Programming : Each addressable device shall be

programmable for ON time, OFF time.
Display ON/OFF when a device is activated
Audible Alarm ON/OFF when a device is

activated
Device bypass ON/OFF
Activation of relay modules with respect

device activation
Fire threshold
Sensitivity of devices
Response time of device
Time delay in alarm activation
Protection against unauthorized access : 3-6 digit pass code
Up to 99 different pass codes for various

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authority levels
Display and Reports : Fire alarm.
Trouble alarm.
Test/Status reports.
Diagnostics.
Output relay status.
Power supply status.
Opening & closing reports
80 characters display
Power supply
a. Primary Input : 240V, 50Hz, Single phase.

b. Secondary Input : 24V DC, maintenance free batteries
c. Battery Capacity : Battery backup shall be for minimum 8
Hours normal operation & 30 min. alarm
condition.
d. Power Supervision : In case of primary power failure indication
should be provided
In case secondary source capacity
diminishes below 85% of its rated capacity
indication for low battery to be provided
e. Wiring : Internal wiring with 660V grade FRLS

wires of 1.5 Sq.mm is to be carried out
Wiring shall be neatly bunched and
terminated using suitable cable lugs
Identification tag shall be provided at
both the ends
Suitable terminals shall be provided for
input and output
DEVICES
Type : Analog Addressable

The following devices will be required
a. Smoke Detectors
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b. Thermal detectors
c. Control Modules
d. Multi Sensor Detectors
e. Fault isolation modules
f. Addressable manual call points
g. Response indicators
h. Strobe type Hooters
a. Hermetically sealed solid state design
b. Self diagnostic features
c. Programmable address setting facility
d. Plug-in type common base suitable for
ceiling mounting
e. Suitable for air velocities between
0 to 5000 ft/min
f. Terminal size shall be not less than
1.5Sq.mm
g. Flashing LEDs with 360 degree
viewing
Protection
a. Against Voltage surges
b. Against polarity reversal
c. Against Faulty wiring
d. E.M.I suppression
Make : Specified as per the approved makes
SMOKE DETECTORS:
Voltage : 24V DC
Type : 2/4 wire High sensitivity optical type
Sensitivity : 0.67 to 3.77% obsc / ft.
Temperature range : 0º to 45º C
Humidity : 0 to 90% non condensing
Compensation : Automatic
Shade : Half- white
Wind velocity : Up to 1500 ft./ min
Integrated Fault isolation Required
ADDRESSABLE HEAT DETECTOR

Voltage : 24V DC
Temperature range : -20 deg.C to +80 deg.C
Type : Rate of rise type heat detector.
Shade : Half- white
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MANUAL CALL POINT

Voltage : 24V DC
Type : Break glass
Accessories : Push button ‘NO’ contact
FAULT ISOLATION MODULES

Purpose : To protect system against wire to wire short
circuit
Voltage : 24V DC
Operation : Shall automatically open the circuit when
system
Voltage goes below 4V and isolate a group
of
Detectors. Shall reset automatically reset
when
Fault is cleared.
SOUNDER CUM HOOTER

Type : Strobes shall be of the wall/ceiling
mounting electronic type with inbuilt
flasher and audible alarm.
: It shall be possible to vary the volume with
at least 11 different settings. The decibel
level shall not be lower than 110dBA in the
frequency range of 400 to 2800Hz
CONTROL MODULES
Voltage : 24V DC
Temperature : 0º to 45º C
Humidity : 0 to 90% non condensing
End of line device : 10 kΩ
Shade : Half- white
Contacts : 1 NO + 1 NC potential free contacts
Note – The Fresh air fans, VRV outdoor units shall be interlocked with FDA System such that
these units will be switched off automatically when the fire is detected in that particular area.
ADRESSABLE MANUAL CALLPOINT
Type : Break glass.

Voltage : 24V D.C
Accessories : Push button 'NO' contact for both types
RESPONSE INDICATOR
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Type : LED type

Voltage : 24V D.C
These shall be provided for all detectors
located above the false ceiling and detectors
in full height cabins.
HOOTER : The hooter shall be of the electronic strobe

type.
EXIT SIGNAGE : Self reflected type exit signage

shall be installed indicating the exit route
Fire Alarm System Software:
All necessary software to form a complete operating system as described in this specification shall be
provided as specified.
The software programs specified in this section shall be provided as an integral part of the unit and
shall not be dependent upon any higher level computer for execution.
Status Change Report: All alarm or point change reports shall include the point's English language
description, and the time and date of occurrence.
Report Routing: Alarm reports shall be archived for future recall.
Alarm Messages: In addition to the point's description and the time and date, the user shall be able to
print, display or store a custom alarm message to more fully describe the alarm condition or direct
operator response.
Each control unit shall be capable of storing a library of at least 1000 events. The event log shall have
the ability to be printed via a parallel printer port built-into the FACP.
The FACP shall have a parallel printer port which allows the internal software the ability to print the
following reports:
Alarm Verification: The alarm verification feature shall be used to delay acceptance of alarms until
they can be confirmed, and shall meet all applicable code requirements and standards. Any or all
circuits may be selected for verification through field configuration, which shall be done without
removal of an EPROM. If a circuit is selected for alarm verification, it will only verify two-wire
smoke detectors. Contact devices, such as manual stations, connected to a verified circuit will be
discriminated and will not be verified.
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When the unit detects an alarm on an initiating circuit programmed for alarm verification, the unit
shall automatically reset the power to that circuit. If the alarm condition is still present after a pre-set
time period of 30 seconds, then the system will automatically enter the Alarm mode.
History Mode: The system shall be able to store and display at least 1000 system events that have
occurred in a non-volatile buffer memory. Display of these events shall be accomplished on-site
through the use of the front control panel indicators and switches.
Field Configurable: The system shall be fully configurable and expandable at the owner's site without
the need for EPROM programmers. All configurations shall be accomplished through downloading of
programs from a computer. Reconfiguration shall not require knowledge of any programming
languages or require any special training. All programs shall be stored in non-volatile memory. Entry
into program mode shall require a special key and a special password entered into the front panel.
ADDRESSABLE MULTI SENSOR SMOKE DETECTORS
a. Voltage : 24V DC
b. Type : 2 wire type.
c. Sensitivity : 0.67 to 3.77% obsc/ft & rate of rise of temp.
d. Temperature range : 0 to 45 Deg.C
e. Humidity : 0 to 90% non condensing.
f. Compensation : Automatic.
g. Shade : Off white.
h. Wind velocity : Upto 1500 ft./ min.
i. Addressing method : Through software or switch at the detector base.
Workstation :
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a. The workstation shall be provided with 17-inch color monitor, standard 101-key
Keyboard and two-button mouse. The computer system shall be constructed from
commercially available computer hardware. The client workstation shall utilize a minimum
Intel Pentium 4 processor supporting true multi-user, multi-tasking capabilities with a
minimum of 1GB of RAM. The system shall be capable of supporting up to two serial I/O
ports (expandable to four or more). Each client workstation shall be capable of supporting at
least one printer.
b. The workstation shall utilize Microsoft Windows XP Professional with Service Pack 2 or the
latest Microsoft operating system available at the time of installation operating system which
shall be confirmed by the main contractor.
c. The workstation shall be supplied with Ethernet network interface card that supports
10/100 topology.
d. Each workstation shall be capable of supporting color graphics display facilities. The
workstation shall be equipped with the standard ACS Client software package, and shall be
provided with USB connection to support the local Card Management system.
3. PA SYSTEM
This system shall comprise the following
i. 5W/ 6W, round recessed / surface mounting speakers
ii. 4W, round wall mounting speakers
iii. 15W, cone type weather proof Speakers.
iv. Amplifier with zone selector
v. Microphones at the security desk.
vi. Handheld cordless Mike
vii. PA amplifier shall have USB port facility and PC connectivity for any pre-recorded
messages.
The complete wiring required shall be carried out as specified.
4.0 ACCESS CONTROL SYSTEM
5.0 Reader Interface Module – Proximity Reader:-

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Overview:-
The Proximity Reader shall be Slim, attractive design, ideal for indoor or outdoor mounting.
Smart Card Reader
The contact less Smart Card Reader shall operate at 13.56MHz. The reader shall have a minimum read
range of 3.75 cms
The Smart Card Reader shall connect to the door controller via a serial data network. The Smart Card
Reader shall be capable of reading data from multiple sectors from a contact less smart card. Apart
from reading the standard access data - passed on to the controller for validation, the Smart Card
Reader shall also read the card holder's name or employee code and such other specified data from the
designated sectors within the smart card.
Smart Reader Terminal - SRT

The Smart Card Reader shall be powered from the door controller and shall be fully supervised. Soft
keys and navigation keys on the reader shall allow the user to access user defined prompts and assist
messages.
Contactless smart card readers shall output credential data in compliance with the SIA AC-01 Wiegand
standard with configurable outputs as 26-bit, 32-bit, 34-bit, 40-bit, or 56-bit.
Data security with smart cards shall use 64-bit authentication keys to reduce the risk of compromised
data or duplicate cards. The contactless smart card reader and smart cards shall require matching keys
in order to function together. All RF data transmission between the card and the reader shall be
encrypted, using a secure algorithm. Card readers shall be provided with keys that are compatible with
the cards.
Contactless smart card readers shall meet the following certifications as minimum : UL 294, CE Mark,
FCC, RoHS Compliant & IP65 Rated
Smart Card Reader versions shall support 13.56 MHz Mifare smart cards and shall have IP 50 rating.
General Features:-
The access card reader shall have the following features
 Accepts 5 to 16 volts, meeting most voltage requirements

 Available with Wiegand or Clock-and-data interface
 Allows easy upgrade from magstripe to a proximity reader; no rewiring or pulling of new cable
 Offer high reliability, consistent read-range and low power consumption in an easy to install
package
 Mounts directly onto metal with no change in read range performance
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 Provides multicolor LED, compatibility with all standard access control systems and internal or
host control of LED & beeper
System Architecture:
General
The Access Control System Management System (ACS Software) shall use a Client Server architecture
based around a modular PC network, utilizing industry standard operating systems, networks and
protocols. The system shall allow the distribution of system functions such as monitoring and control
and graphical user interface etc. across the network to allow maximum flexibility and performance.
The architecture shall include support native Ethernet LAN / WAN using standard hardware and
software to link nodes into a single integrated system. The network protocol used shall be industry
standard TCP-IP / UDP.
Access Software Module features
The features of the access software shall be specified however, the sub-contractor shall have a
software which has the capacity to accommodate the following based on licensing Unlimited number
of card profiles which shall be specified:
 Unlimited number of operators.
 Central on-line data storage of historical transactions, expandable as system resources allow.
 levels of alarm priority.
 Multiple badge numbers per cardholder. Each badge can be tracked separately.
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 Multiple issue levels per card, only one of which shall be active at any given time.
 Fifty user-defined cardholder fields. The system shall be capable of reporting on any or all of the
user-defined fields. Each user-defined field may be defined by the user as alphanumeric, numeric,
or Text List.
 Support a minimum of 99 time zones with 2 on & 2 off periods. And 3 set of times corresponding to
3 security levels..
 Anti-pass back feature support.
 Door open time set for each door.
 The time in and time out is calculated on the first in and last out basis.
 Supports day and overnight shifts.
 Overtime calculations.
 Detailed data entry fields in employee master.
 Employee master maintained for various locations/branches.
 Employee code up to 8 digits.
 Employee master maintained for old employees on location basis.
 Photographs can be stored for each employee.

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 Manual Entries
 Out door duty entries
 Tour entries
 Department types, employee types, grades, locations maintained.
 Grace time for different grade types.
 Backup and restoration facilities for employee master and swipe data.
 Reports on employee master and time and attendance.
 Login and authority rights to the software can be set for each user.
 Leave system set on calendar or financial year or any month of the year.
 Pro-rata calculation of leaves.
 Leave register maintained for CL, SL, PL and other leaves.
 Maternity and marriage leave setup.
 Carry forward of previous years leave.
 Leave encashment facility.
 Various leave related reports.

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 Employee Leave card status.
 Backend Database: ODBC compliant
 Data can be stored on a central database server.
 Front end: GUI based user-friendly interface based on client server technology for Windows
2000/XP/2003 Server environment.
 Third party interface: ASCII flat files with coma separated values as per requirement .
 Architecture: 3 Tier (User, Business & Data services) to ensure scalability
 Operators: Unlimited
 Configuration: Full set up & programming of all door controller functions
 Card Database: To contain Photo image of cardholder along with other relevant data. Card
database – 100,000 cards numbers expandable up to 10, 00, 000
 Card profiles: Unlimited with respect to single card or batch of cards. Shall define valid doors, 3
time zones per card applicable to weekday, off day & holiday
 Archival: Daily automatic archival based on defined time.
 Reports: User definable access reports with respect to time, Date, door & card. Daily Attendance
reports based on 1st IN & last OUT. Reports should also include archived data.
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 Door Control: Each Door individually or all door simultaneously may be locked / unlocked or
normalised from the PC.
 Roll call: The software shall be able to provide the no. of list of card holders in the premises. It shall
also be capable locating an user based on the last transaction.
Operator Interface Characteristics
ACS Software shall provide a Windows operator interface as standard. No custom programming or
scripting shall be necessary to produce the following:
 Window re-size,
 Dedicated icons and Pull Down Menus to perform the following:
 Associated Alarm Display
 Alarm Summary
 Alarm Acknowledgement
 Graphic Call-up
 Card Holder Detail
 Alarm Banner showing priority
 System Date
 Current Operator
Operator Functions
The following functions shall be performed through the operator interface:
 Display and control of door control units

 Acknowledge alarms on a priority basis
 Initiate printing of reports
 Archive and retrieve event logs
 Change own password
 Monitoring of data communications channels
 Configure system parameters
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Operator Security:
Security
Each operator shall be assigned a user profile that defines the following:
 Operator Identifier or User Name

 Unique Password
 Partition
 Workstation Access
 Password expiry parameters
Any actions initiated by the operator shall be logged in the Event database by operator identifier.
Area Assignment / Area Profile
Each operator shall be assigned a specific area of the building with the appropriate monitoring and
control responsibility (no view, view only, alarm acknowledge only or full control). An area shall be
defined in this context as a Partition. This in turn may represent a physical space in the building. This can
be used to partition the database in such a way as to assign operators control over certain areas and
prevent unauthorized access to other areas.
Standard System Displays
The ACS software shall be capable of storing a number of graphic displays (maps). The quantity of such
maps shall be limited by available hard disk storage space only. Display maps) are layered i.e. lower level
maps associated with the top layer map existing in the system. It should be possible to navigate through
the displays (maps) layers by clicking on the sections of a map layer. The following displays shall be
included as part of the system:
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 Alarm Display
 Alarm Count
 Event Display
System Status Displays
System status shall be displayed on all UWS and show the following parameters :
 Recent alarms pending ACKNOWLEDGE

 Alarms ACKNOWLEDGED but not PROCESSED
 Communication failures
 Communication links status
 Controller status
Administration Displays
The system shall provide the following consoles:
 Global Settings Console

 ACS Software Management Console – architectural and logical views
 User Management Console
 Operator Management Console
 Graphics Management Console
Creating Custom Displays
Graphic Display Builder
The ACS Software shall provide a Graphics Console for the creation of site-specific graphic displays. It
shall allow one-step online building of display static objects. It is a WYSIWYG editor (what you see is what
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you get) allowing the displays drawn using an external editor to appear exactly, the same when viewed
from an Operator Workstation.
Monitoring And Control
Audit trail:
ACS Software shall maintain an audit trail file of operator activity, and shall provide the ability to
generate a report by operator, time and date, and type of activity (audit code). The system shall allow
the operator to direct the audit trail report to screen, printer, or file. The audit trail feature records:
 Site parameters modified.

 System login or logout.
 Cardholder added, deleted, or changed.
 Alarm message added, deleted, or changed.
 Communications initiated or terminated.
 Access privileges added, deleted, or changed.
It shall include comprehensive report facilities of on line activities and a permanent record of cardholder
activity. The vendor shall provide the required audit trail facility in their reports and software. This audit
trail shall be possible for all programs, event & alarms
Cardholder Management System
The ACS Software shall store security related cardholder/pass holder information in a relational database
Microsoft SQL Server.
The access matrix shall be defined in the Card Profile. Unlimited such profiles can be created. Each profile
shall also be assigned User Defined Fields.
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Badges shall be created in the Card Settings where each card behavior is defined. Card Profile is also
associated to the card to create the access profile for each card. Card Holders are then created and card
associated to them.
Multi-Selection
It shall be possible for multiple cardholders to be selected and a single edit to be performed on all of
these cardholders selected.
Alarm Management
ACS Software shall report alarms to the Alarm Window in the Event screen. Alarms are grouped
according to the priority assigned to it.
In the case where over 1000 alarms are in unprocessed state, they are not automatically retrieved.
This will enable the user to attend to any fresh alarm easily. History alarms can be fetched by a manual
command.
Alarm Priorities
Each alarm shall be set one of the up to 255 available priority levels.
 Alarm Annunciation
 Alarms shall be annunciated by:
 Alarm message appearing on alarm display.
 Available Tone - based on a “*.wav” or other sound file for each alarm priority
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 Alarm message printed on the alarm printer

 Alarm indicator flashing on the operator interface
Alarm Processing
It shall be possible for the operator to click on the alarm window and process each alarm. The following
information shall be made available in the alarm details window:
 Date and Time Stamp

 Description of the point in alarm
 Location of the alarm
 Alarm Priority with total count
 Response Text
 History of last 10 alarms from that location. It shall enable the operator to choose to bulk process
all alarms in a priority.
 It shall also be possible to perform a multi select and process more than one alarm.
 Alarm Filtering
The Software shall enable each operator to select the alarms that he/she needs to view and the system
will annunciate only those alarms. It shall also be possible to set if the operator can acknowledge and/or
process such alarms. Alarms that occur within an operator’s Partition shall only be reported.
Reporting
The system shall support a flexible reporting package to allow easy generation of report data. The reports
provided shall include pre-configured standard reports for common requirements such as Alarm Event
reports and custom report generation facilities that are configurable by the user.
It shall be possible to define SQL queries in an easy to understand screen.
Historical Data Archiving

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The system shall support archiving of historical data to allow a continuous record of history to be
built up over a period of time. Archived data shall be stored on the hard disk of the system or a
remote network drive or moved off-line to removable media such as floppy disk, cartridge tape, DAT
tape, or optical disk. Once archived, the data shall be made available for reporting.
INTRUSION/PANIC ALARM SYSTEM:
The intrusion or panic alarm system shall offer a highly reliable, round-the-clock vigilance system
that not only detects would-be intruders through discharge of signals as assigned in the specification and
denies entry to and exit from the protected area as specified.
The system shall include PIR/motion/vibration detectors. The range of detection or suitable diameter to be
covered shall be indicated in the specifications/drawings. The panic button shall be fixed at the specified
location as per the drawing/will be instructed at site by the main contractor.
The intrusion or panic alarm system shall be able to easily fix at the specified location. It shall also be installed
as a stand-alone system at specified locations which shall be integrated with auto dialer if specified .
Zone Configuration:
The intrusion alarm system shall be integrated from 8 zones which shall be extendible to 32 zones. Zone
feeding shall be through lead out cables drawn underground wherever necessary for integrating the system
to function which shall be confirmed by the main contractor and accordingly the zone panel shall be selected
or will be specified in the BOQ.
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CCTV SYSTEM:
All cameras shall be IP based. Each camera shall be provided with 1 no of RJ45 information outlet which will
be connected to network switch (Layer-2) floor wise. These network switches will be interlinked and finally
connected to main network switch (Layer-3). This Layer-3 main network switch will be connected to Network
Video Recorder and main application server.
 For every 40 Cameras there shall be one network video recorder.

 There shall be 2 nos racks to mount NVR and main application server. This shall be integrated with
Access control system.
 The monitoring and recording shall be based on Trigger/Motion.
 For very critical areas analytic type camera with intelligent software shall be provided.
 For peripheral compound walls power fencing zone wise shall be interlinked with CCTV and any
intrusion in particular zone, that particular zone camera will trigger and capture the image and gives
alarm.
 Each camera will consume 1.5-2 mbps of bandwidth which shall be taken care by networking
contractor.
If the main contractor confirms that they are going ahead with POE (Power Over Ethernet) network
system then Cat6 cable itself will take care of both power and network system for each camera then no
need of providing power cabling for each camera.
For every 10 cameras there shall be wall mounted power supply unit with an adapter of 230V/24V/12V.
This power supply unit will have 1 no of 6A UPS socket. The data sheet of the CCTV camera and its
features with manual/catalogue to be furnished by the subcontractor.
VIDEO RECORDING MODULE:
The IP CCTV system must be a module in the ISMS. Video recording module without integration with access
control system (as per the specification given by the main contractor) and perimeter fence system (as per the
specification given in the enquiry) is not acceptable. All video transmission shall be on the IP network and
recording shall be at a central location.
It shall have the facility to pop up live video from various devices.
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It shall have the facility to program video motion detection of cameras
Recording shall be through a recording software and scheduled for each day of the week. Each day shall have
at least 4 sessions of recording with 1 on time and 1 off time for each session.
It shall be possible to configure the following recording modes:
 Alarm Recording .
 Motion Detection/Alarm Recording .
 Motion Detection and Alarm Recording
 Command Trigger
 Manual Recording
It shall be possible to select layout for Multi-viewer. There shall be a minimum of 8 different formats of
layouts to select. A minimum of 64 cameras shall be viewed on a multi-viewer in the required layout.
It shall be possible to have more than one multi-viewer for an operator. Each operator shall also save his
layout setting. Each pane in multi-viewer shall have tools in the form of icons for Lock/Unlock :
 Video Stream Selection

 2 Way Audio Enable / Disable
 Record
 Capture
 Maximize / Minimize
 Close
Alarm Spotting: It shall be possible to select a pane in multi-viewer layout and link the same to Alarm
Spotting. If an alarm occurs and if it has a camera linked to the alarm, then the camera shall be played live in
the selected pane.
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Playback Spotting: It shall be possible to select a pane in multi-viewer layout and link the same for playback.
In case if the operator wants to play video linked to an event, then the camera shall be played back in the
selected panel.
It shall be possible to perform PTZ functions with PTZ tool as well as with mouse. In case of Variable Speed
PTZ Units, the speed of the PTZ shall be controlled.
The PTZ tool bar shall have the following controls
 Focus
 Iris
 Cruise
 Preset
 Operator PTZ Priority
The ISMS application shall support a minimum of 5 levels of priority to be set for each operator on the PTZ
camera. The priorities shall be
 Highest
 High
 Medium
 Low
 Lowest
There shall be provision in the system to have a visual indication if a PTZ camera is locked by an operator. The
ISMS shall give the name of the operator, priority level of the operator who has locked the PTZ camera.
The ISMS shall allow the operator of a higher priority to control the PTZ camera at any point of time. If
operator chose not to lock it or set the operator PTZ priority then the system shall work as is currently
implemented.
The Multi-viewer shall support Single Panel Sequence as well as Page Sequence.
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Sequence shall save and share among operators
GENERAL
The system shall consist of design, supply, installation, testing, training & handing over of all materials,
equipment’s and appliances and labor necessary to commission the said system, complete with fixed dome
Cameras, C/CS mount cameras and Digital Video Server Transmitter. It shall also include laying of cabling,
necessary for installation of the system as indicated in the specification and Bill of Quantities. Any
openings/chasing in the wall/ceiling required for the installation shall be made good in appropriate manner.
EQUIPMENT
The CCTV System shall comprise of Dome Cameras, C/CS mount camera and Digital Video Recorders,
recording device and viewing software if any as applicable and wherein used.
Dome Camera
The Dome camera unit shall be 1/3” or ¼” CCD type Color and shall provide a minimum of 480 TV lines
resolution. The lens for fixed domes shall be 3.6~3.7 mm focal length. The complete unit shall be housed in a
dome and base unit, both preferably made from injection moulded plastic. It shall be possible to adjust the
camera head inside the dome in both the planes so that it can be wall or ceiling mounted. The camera shall
operate on 12 vdc.
Fixed Color Camera - ‘C/CS’ Mount
The camera shall be of 1/3” format CCD type, compact of rugged design and shall employ solid-state circuitry.
The camera shall deliver clear, high-resolution color picture without geometric distortion.
The Camera shall comply with the enclosed datasheet.
Technical Specifications for ‘C/CS’ Mount Camera
Pick up Element : 1/3 inch Colour CCD image

Sensor (interline)
Power supply : 230VAC
Scanning System : 2:1 interlace
Resolution : 480 TV lines
Sensitivity : 0.06 lux
S/N Ratio : less than 50 db
Electronic shutter : Auto:1/50 (60) to 1/1,00,000sec
Output : 1Vp-p Composite video output,75 Ohm
Lens mount : CS Mount
IP rating for Housing : IP 67
Operating Temperature : 10 to 50° C / 30 – 90% RH
Data Sheet For 1/3” OR 1/4” Colour Dome Camera

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Pick-up device : ¼ format, interline transfer, CCD image sensor

Horizontal resolution : 470 TVL.
Sensitivity
(Usable video) : 0.5 lx
Signal to noise ratio : ≥ 50dB
White balance : 2000 k to 10,000 k
Gain control : off/Auto
Aperture correction : Horizontal & Vertical
Operating Temperature : -40 °C to +50 °C
Humidity : 0 to 90 % relative, non-condensing.
EMC : UL , Immunity: UL , Emission: UL , Safety: CE,
Housing : Indoor, pendant-mounted dome housing,
Mount : Wall or in ceiling mount (same make as that of the
camera)
Digital Video Recorder
The DVR shall be a 8 / 16 channel, high-performance IP video encoder to encode video and control
data for transmission over an IP network to remote CCTV monitors and PCs.
The DVR shall be capable of producing MPEG-4 video at 25 images per second (PAL Mode) per
channel at ½ DI resolution and shall also support 25 images per second if one channel is used giving
DVD-quality 4CIF resolution.
The encoder shall accept analog video input from fixed cameras and then provides MPEG-4 IP video
to the network.
The encoder shall support NTSC, PAL, EIA, and CCIR camera sources.
The DVR specified shall be capable of functioning on data networks, such as Ethernet LANs and the
Internet, using a standard web browser (such as Microsoft Internet Explorer Version 6.0 or later) as the
receiver, the encoder shall function as a server to provide MPEG-4 or JPEG video via the network to a
PC workstation. The web browser may also be used to configure the settings of the encoder using the
local network or via the Internet.
The DVR shall be capable of transmitting video that can be viewed over an IP network using the
software running on a network workstation.
The DVR shall provide dual streaming capability that simultaneously creates two data streams at
different rates and resolution where one stream may be used for local recording and the second stream
may be transmitted over the network for live viewing.
The MPEG-4 encoder shall allow selection of the following resolutions per channel:
Resolution Frame-rate
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QCIF 30fields/sec
CIF 30fields/sec
2CIF 25fields/sec
25
½ D1 Frames/sec
12
4CIF / D1 frames/sec
An RS-232 bidirectional serial communications port shall be provided to allow configuration of the
encoder settings for network
Individual snapshots from a video sequence of the encoder currently being displayed on the browser
may be saved as JPEG images and stored on the PC hard drive.
Video clips from the video sequence of the encoder currently being displayed on the browser may be
saved on the PC hard drive.
The DVR encoder shall provide more than three levels of password protection to prevent unauthorized
connection or configuration changes to the unit.
The DVR shall provide a standard BNC connector for connection of the video input source.
The DVR shall be compatible with NTSC, PAL, EIA, and CCIR video sources.
The DVR shall be capable of sending images to a network video recorder for long term archiving.
The internal time/date clocks of the specified product shall be synchronized from the system computer
or every two hours from a network time server (NTP server). The time synchronization capability
ensures that simultaneously occurring events will display the correct time and date when multiple
specified devices are connected to the same network.
The DVR specified shall be provided by the manufacturer complete with configuration cables,
Installation and Operations Manuals, and a CD containing all the required software for the unit’s
operation such as MPEG Active X control, an MPEG viewer, DirectX viewer, etc.
The DVR shall provide four alarm inputs for external sensors such as door contacts or PIRs. These
alarm inputs can trigger an automatic connection between the encoder and a remote workstation. A
relay shall be provided that may be automatically or manually activated.
The DVR shall trigger an alarm upon video loss.
The DVR shall be capable of establishing a connection to a predefined IP address upon an alarm. Up
to ten IP addresses may be programmed where each location is contacted until a connection is
established. Automatic reconnection to one of the specified IP addresses shall be established after each
restart caused by a connection or network failure.
The DVR shall provide a normally open or normally closed relay output function. The relay may be
configured to turn on and stay on until manually reset, or, the relay may be activated for a specific
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period of time. Alarm conditions such as video loss or an external contact input may activate the relay
output.
The relay output may be activated remotely via a standard web browser or an optionally available
video management software program. The relay may be programmed to remain in its active state when
switched, or, revert to the inactive state after a specific time interval. The relay may be configured to
activate if a connection is established to the unit, there is a loss of video signal, or an via an external
alarm sensor.
INSTALLATION MATERIALS AND INSTALLATION WORK
CONDUITING
Conduiting shall be surface type and shall be with FRLS PVC. MS conduits to be used in shafts.
Minimum size of conduit shall be 20mm. The conduit accessories may be of socketed type. All
accessories such as junction boxes, bends, etc. shall be of the approved type. Samples shall be
produced for consultant's/clients approval before installation. Elbows shall not be used in the
installation. Only bends shall be permitted.
Suitable colour identification shall be provided on the conduits to distinguish the type of service.
WIRING
Wiring for FDA system shall be with 660V grade, copper conductor FRLS insulated wires. 2C
shielded 14/36 size PVC insulated FRLS copper conductor wires shall be used. PA system will be
wired using twisted pair copper conductor 14/36 size wire. All the above wiring shall be drawn in
FRLS grade PVC conduits.
The cross sectional area of the conductor in each of the cases shall be selected as per standard practice
and shall be as indicated in the price schedule.
TESTING
The Fire Detection & Alarm and Public addressing systems shall be tested and commissioned as per
the relevant standards. The tests shall include but not be limited to the following. The test shall be
conducted in the presence of client's engineer and the test results should be recorded in an agreed
format.
FDA SYSTEM
Visual Inspection:
 All the detectors shall be visually inspected after installation to ensure that they are properly
sited, properly mounted on the base and connected.
 All the detectors shall be individually tested taking adequate precaution not to damage the
detectors during the testing. The detector should be reset after the test.
 The addresses of all analogue addressable detectors shall be verified.
 Each smoke detector should be tested to initiate the alarm at the installed location with smoke.
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 The safety interlocks between the detector and the VRV outdoor unit should be ensured by
testing.
 The operation of hooters and response indicators should be checked.
Verification Testing
Provide the service of a factory-trained technician authorized by the manufacturer of the system to
technically supervise and participate during all of the adjustments and tests for the system. All testing
shall be in accordance with NFPA and the manufacturer.
 Check for correct connections and test for short circuits, ground faults, continuity, and
insulation.
 Close each sprinkler system flow valve and verify supervisory alarm at the FACP.
 Verify activation of all flow switches.
 Open initiating and indicating device circuits and verify trouble signal activation.
 Ground all circuits and verify response of trouble signals.
 Check for audibility of tone at all alarm notification devices.
 Check installation, supervision, and operation of all smoke and duct smoke detectors.
 Verify the proper alarm and trouble receipt and processing of signals at the FACP and any
remote annunciators.
 Perform all tests in accordance with the manufacturer’s testing procedures.
 Correct any deficiencies discovered as a result of the testing and retest the work affected by
such corrections.
 Final inspection and instruction
A factory trained representative of the manufacturer shall demonstrate that the system functions
properly.
Instructions for operating the system shall be provided in a hands-on demonstration as stated
elsewhere in the specification or as indicated on the drawings. Written operating instructions shall be
provided.
Record of Completion indicating certification of the fire alarm system installation and testing shall be
submitted to the Consultant at completion in accordance with Tender Requirements. A copy of all
Record of Completion certificates together with Inspections and Testing Forms shall be delivered to
the Owner’s Representative. Photocopies shall be included in the Operating and Maintenance Manuals.
P.A SYSTEM
The installation should be as specified in the drawing and BOQ it shall be visually inspected and all
connections should be checked before energization.
Individual amplifier shall be tested and the speaker matching should be carried out.
The microphone should be tested.
The volume control should be adjusted and clarity of the system should be verified.
All the system will be accepted only after the tests are conducted successfully in the presence of
client’s representative.
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MAINTENANCE
The contractor shall maintain the systems for a period of TWO YEARS from the date of handing over.
Any defects noticed during this period shall be set right at no extra cost to the client.
TRAINING
The client's representative shall be trained on the operation, trouble shooting and maintenance of the
system so that they can operate the system independently.
DOCUMENTATION
Following documents shall be furnished as a part of handing over procedure.

 Test certificates for all the above specified systems.
 Floor layouts showing all the components of the total installation.
 Schematic/ wiring diagrams.
 Maintenance manual with trouble shooting chart.
 Display of FIRE ORDER in every floor as per statutory requirement.
 As built layout & schematic drawings for all the systems as detailed below.
 Two sets of soft copies in Latest Version of Auto CAD
 One set of reproduceable tracing sheets.
 Six sets of white prints.
QUANTITY
An estimated quantity of all components required for each of the system has been indicated in the Bill
of Quantities. Wiring system with different types and sizes of wires required for each of the systems
along with the conduits/pipes should be indicated for each of the systems and the unit rates for all
items of wiring shall be quoted.
GUARANTEE
All the systems covered by these specifications shall be guaranteed for trouble-free operation for a
period of minimum 24 months from the date of commissioning. Vendor shall furnish the guarantee
period of equipment supplied to the contractor. Any defects noticed during this period shall be
rectified free of charge at the shortest possible time.
APPROVED MAKE OF COMPONENTS

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Fire control panel and Repeater : Notifier / Edwards / Bosch

Panel
Detectors and associated : Notifier / Edwards / Bosch

devices
Wires : LAPP/ Polycab
PA systems with speakers, : Philips / Bosch

Amplifiers
MS Conduits and Accessories : GB / Bharath / AKJ Industries.
PVC Conduits and Accessories : Universal / VIP / National
Response indicator : Indigineous
Batteries : Panasonic / Amco / Amaron
Junction boxes : National / ISI approved
Panic bar : Dorma / Europlex
LCD Monitor : Panasonic/Viewsonic
Digital video recorder : Panasonic / Bosch
Cameras : Panasonic / Samsung / GE /

Honeywell / Axis
Power Supply Units : Indigenous
BNC Connectors : PPC

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COMPRESSED AIR SYSTEM
1.0 SCOPE
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1.1 This specification covers the design, manufacture, shop testing, packing,
forwarding, delivery to site, supervision of erection, testing and commissioning of
the Rotary Screw Air Compressors and its associated accessories.
2.0 QUALIFICATION CRITERIA
The bidder for the supplier shall be an established manufacturer of Rotary Screw
air compressor . The vendor must have supplied at least 5 identical units in the last
5 years and out of this at least 2 must have crossed 30000 hours. In case the
supplier does not have the requisite experience he is allowed to quote his
collaborators machine. However in such a case the machine must be manufactured
in the collaborators shop.
3.0 DESIGN AND CONSTRUCTIONAL DETAILS
3.1 Duty and Capacity
3.1.1 Type : Screw type Indoor, stationary, electric
motor driven Aircooled rotary screw

compressor
3.1.2 Duty
To be designed for continuous, load-unload,

and on-off mode & VSD operation to deliver
required air capacity air at 0.75 MPa. working
pressure.
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3.1.3 Quantity : In Nos as specified in BOQ
Standby In Nos as specified in BOQ
3.1.4 Design condition for : ___ degC, ___% RH at MSL of ___m
compressor sizing to deliver
free air
3.1.5 Capacity per each : __ Nm3/min , Fixed speed __ nos & VSD __nos
compressor
1.1.6 Normal working pressure : 0.75 MPa

discharge pressure at
outlet (min)
1.1. Drive motor rating (kw) with service factor & make : ABB / Siemens
1.1.8 Noise level : Not to exceed 78 dBA to a reference level of

0.0002 microbar when measured at a distance
of 1.5 metre above the floor under free field
conditions
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1.1.9 Cooling medium : Air cooled
2.0 Compressor
2.1 The compressor models available should be Air Cooled with silenced canopied rotary
screw compressors. The compressor packages are completely wired and equipped with
all accesories. They include gear-driven compressor elements, a totally enclosed fan-
cooled electric motor, together with lubrication / lubrication free, cooling and regulation
systems. Built as a complete, stationary unit providing the highest efficiency and
reliability within the range. The oil –injected / Oil free rotary screw compressors,
combine a smart design, innovative technology and the lowest cost compressed air.
2.2 REGULATION SYSTEM
Compressors should be equipped with the power conscious, efficient, automatic full-
load/no-load regulation system. The system should regulate the compressor capacity
within a fully adjustable pressure range. The regulation should be equipped with the
delayed second stop feature (DSS) which significantly cuts the energy requirements by
reducing idling time to a minimum in a fixed speed compressors.
The variable speed compressors should not use an unloader valve as the wastage of energy
in no load operation should be eliminated.
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DRIVE ARRANGEMENT
The fixed speed compressors should be driven by TEFC, IP 55, Class F insulation squirrel
cage induction motors. The motor power is transmitted to the compressor elements via
a flexible coupling and step-up gears.
For Variable speed compressors the motors should be Inverter Duty IP 55 motor with
following protections / advantages.
1) Elimination of Speed windows

2) Mechnical enhancements for proper bearing lubrication
3) Elimination of Bearing currents
4) Turn down > = 77%
5) Maximum torque without starvation.
6) Harmonics control
COOLING FAN ARRANGEMENT
 Pulling fans for optimal cooling.

 Fans, fan motors cowls should be hinged for easy cleaning of coolers
 Axial cooling fans driven by separate TEFC electric motors for fixed speed compressors
(IP55 protection)
 For VSD compressors the cooling fans should also be variable speed type with IP55
protection.
AIR SYSTEM
Components of the air system should include:
 Dry-type air intake filter with electronic Vacuum sensor.

 Unloader assembly with pneumatically operated piston type inlet valve.
 Air / oil separation tank with air / oil separator element.
 Minimum pressure valve with non-return valve.
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 Aluminium block type air aftercooler for the air-cooled models or alternatively a shell
and tube heat exchanger for the water-cooled models
 High-efficiency moisture separator with both automatic level sensor based and manual
drain.
LUBRICATION SYSTEM
The lubrication system should be of the differential pressure type & should include the
following components:
 Air-oil separation tank with air-oil separator element, oil sump, oil level indicator, safety
valve, minimum pressure valve, drain tube and filing plug.
 Aluminium block type oil cooler for the air-cooler models or alternatively a shell and
tube heat exchanger for the water-cooled models.- Spin-on type oil filters, with
electronic sensor.
CONTROL MODULE
The regulating system should include & regulate, control and monitor compressor
operation. The control modules should display and monitor the following:
1. Compressor Status Indication

 Voltage on
 Automatic operation
 Compressor loaded
 Compressor unloaded
 Maximum allowed unload pressure compressor
2. Temperature, numerical readouts
 Delivery air
 Element outlet
 Cooling medium
3. Pressure, numerical readouts

 Delivery air
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Air filter pressure differential

 Oil separator pressure differential
 Oil element in
4. Compressor Control
 Start / Stop
 Load / unload
 Emergency stop
 Reset / Test
 Key switch for local/remote compressor control
5. Hour meters
 Total running hours
 Total loading hours
6. Timers
 Programming compressor time-based start/stop commands
7. Service requirement indications
 Air filter
 Oil filter
 Oil lifetime
 Oil separator
 Regreasing of motor
 Sensor error
8. Compressor safety - warning indications
 High element outlet temp
9. Compressor safety - shutdown indications
 High element outlet temp
 Drive motor/fan motor overload
 Emergency Stop
REMOTE CONTROL/MONITORING
10. Digital input commands

 Start
 Programmed stop
 Load / unload
 Emergency stop
11. Digital output compressor status
 Unit running
 Load / unload
 Automatic operation
 General warning
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 General shutdown
All instruments as specified in general; protection & interlock system; and as required
during detailed engineering for completeness of the system shall be provided by
contractor to facilitate safe, reliable and efficient operation of the offered compressed air
system. All pressure & temperature conditions used for tripping the compressor shall be
provided with pre-trip annunciation in the control panel
Overall Operation , Control & Instrumentation
Overall monitoring shall be through a separate centralized PLC/microprocessor based

control system.
Overall monitoring of all the compressors from a single location.
The above controller should be able to sequence the Instrument Air Compressor Group.
Due to this feature in case of increase in air demand, the unit which has clocked least no. of
running hours shall be started and loaded. Similarly when the air demand goes down, the
unit which has clocked most no. of running hours shall be unloaded and stopped.
The above is envisaged to avoid pressure cascading .
At the same time all the parameters appearing in the individual panel shall be
1985displayed on the above common control panel. This would include the following
parameter.
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Hard Wired Signals for Communication to plant DCS
In addition to above, following HW signals shall also be provided by the bidder for
Purchaser’s use for the following:-
i. Compressor status (for each compressor)

ii. Instrument air header pressure
iii. Plant air header pressure
All initiating devices, relays and other hardware required for achieving the above
annunciation, control and interlock system shall be provided by the bidder.
5.5 Control Philosophy
In “Standby” duty, the compressor shall automatically assist base load compressors
during periods of peak air demand. When air pressure in the system reaches a pre-set
lower limit, compressor shall be started to unloaded condition. After a suitable time delay;
the compressor shall be fully loaded.
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When the pressure in the system rises to pre-set high value, the compressor shall be
unloaded and shall run in idling mode for a specific period (set by a time); the compressor
may be loaded to full load in case of drop in system pressure or compressor may be
stopped in case the system pressure does not drop and compressor continues to idle for
more than a preset time.
The pressure and duration of time to be set shall be adjustable at site from the panel.
Further all interlocks for safe and proper operation of the compressors shall be provided.
All pressure and temperature conditions used for tripping the compressor shall be
provided with pre-trip annunciation in the control panel. Independent switches shall be
used for alarms (annunciations) and tripping or interlock.
11.0 MATERIALS, WORKMANSHIP AND TESTS
11.1 Materials & Workmanship
11.1.1 All materials used in the manufacture of the equipment shall be high grade, free
from defects and imperfections and of recent manufacture and unused.. Liberal
factors of safety shall be used throughout the design for all parts of the equipment
when subject to the most severe operating conditions.
11.1.2 All work shall be performed and completed in accordance with the best modern
shop practice in the manufacture of high grade equipment.
11.1.3 Castings shall be free from blow holes, flaws, cracks or other defects and shall be
smooth, close-grained and of true form and dimensions. No plugged or filled up
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holes or other defects will be accepted. No casting shall be burned, plugged,

patched or welded and no repairs of defects will be accepted.
11.1.4 All materials, supplies, parts and assemblies supplied under this specification shall
be tested as far as reasonably practical.
11.2 Shop-Assembly
The bidder shall assemble various components/parts of the compressors along

with the accessories to ensure that all parts are properly fitted or can offer the
complete unit from its principals with service availability in India.
11.4 Shop Tests
11.4.1 During the manufacture of the compressors, manufacturer's performance tests

shall be performed in accordance with IS0 1217, Annex C, Ed 3 latest edition and
requisite number of copies of test certificates shall be furnished as per the enclosed
distribution schedule.
11.4.2 Tests at shop include but not be limited to the following:

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a. Performance tests routine tests for capacity for compressors.
b. Hydrostatic tests on after coolers and inter-coolers as per applicable codes.
11.5 Test at Site
11.5.1 After the compressors along with all accessories are installed at site, the following
tests shall be conducted at site by the bidder with his own calibrated testing
equipment:
a. To check proper and continuously reliable operation of the control/

regulation / unloading equipment furnished.
b.. To check the temperature of the compressed air at the outlet of the
compressor.
c. To check proper operation, freedom from excessive temperature rise,

unsatisfactory vibration noise, freedom from moisture of compressed air.
11.6 Test Reports

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11.6.1 Six (6) copies of test results shall be supplied for approval prior to dispatch of the
compressors along with accessories. Final copies of complete test results shall be
furnished later, as per the attached distribution schedule.
11.6.2 Test reports of factory tests carried out on the compressors along with accessories
shall furnish the following information:
a. Complete identification data including serial number.
b. Method of application and duration of tests.
12.0 PACKING AND TRANSPORTATION
12.1 Each assembly of compressors with all accessories where needed shall be
adequately packed and dispatched separately.
12.2 Packing shall be sturdy / seaworthy and adequate to protect assemblies,

components and accessories from injury by corrosion, dampness, heavy rains,
breakage and vibration encountered during transportation, handling and storage
at the plant site.
12.3 Spare parts shall be packed separately and clearly marked. They shall be specially
packed for long storage without injury.
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13.0 SUPERVISON OF ERECTION, COMMISSIONING (OPTIONAL)
13.1 The bidder shall include in his scope of work and quote per day price for complete
supervision of erection, commissioning of compressor.
13.2 The bidder’s supervision cost shall cover competent supervision while needed
tools, tackles and consumables, like gas, electrodes, etc will be furnished by
erection contractor. Initial fill of lubricants (and refilling where required) shall be
included in the bidder's scope.
13.4 The work shall be governed by the Purchaser's General Conditions of Contract.
Supervision of erection and satisfactory operation of the plant covered by this
specification shall be of the supplier. Purchasers Engineer(s) will do co-ordination
work, laydown priorities supervise the quality of the work, stipulate norms &
standards to which the work covered by the specification must conform during the
course of erection
14.0 BID DATA & DRAWINGS
14.1 Drawings and technical schedule incorporating the following particulars shall be
submitted with the proposal:
14.1.1 General and other technical particulars shall be furnished in the bid.
14.1.2 Ex-works prices shall be furnished in the bid.

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14.1.3 Dimensioned outline drawings for compressors with auxiliaries and air receivers,
air driers etc showing plan, elevation, including net weights, shipping dimensions &
weights and loads on the foundations.
14.1.5 The following data/drawings/documents shall be furnished alongwith the bid:
a. P&I diagram demarking scope of supply.
b. GA drawing of compressor.
c. Schematic wiring drawings
14.1.6 List of users for the offered models with the year in which the compressors were
put into service.
14.1.7 The deviations from this specification with justifications shall be clearly indicated
in deviation sheet otherwise the bid shall be deemed to comply completely with
specification.
14.1.8 A bar chart of design, engineering, procurement, manufacture, testing and delivery
of the compressors along with all accessories.
15.0 POST CONTRACT DATA AND DRAWINGS

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15.1 Bidder shall submit within two (2) weeks from the date of Letter of Acceptance (or
as may be agreed upon by the Purchaser), technical details of the offered
equipment. General Arrangement drawings; wiring diagram; civil drawings with
foundation loads etc to enable Purchaser to proceed with civil works; equipment
detailed drawings incorporating sectional details, constructional features; terminal
connection details incorporating Purchaser's obligations; and other details as
required to satisfactorily coordinate the work.
15.2 After the details and data have been approved, the contractor shall submit for
approval, detailed drawings showing compliance with the requirements of the
specification.
15.3 Any other drawings and details not specified herein and required by the Engineer
to correctly co-ordinate the equipment supplied under this specification with
others work shall be furnished.
15.4 All instructions, notes and legends on the drawings shall be in English language and
all units shall be expressed in metric system.
16.0 INSTRUCTION MANUALS
16.1 Two (2) copies of installation, testing and adjustments after installation, operation
and maintenance manuals shall be furnished. These manuals shall contain every
drawing and information required for installation, operation and maintenance of
offered equipment and all its components. Separate tabs shall be used for such
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instructions concerning each equipment. The data shall include the particulars
needed for servicing the components and ordering their spare parts. The
lubrication schedule should also be included in the manual.
17.0 WARANTEE
17.1 The bidder shall undertake to remedy any defect resulting from faulty design,
materials or workmanship.
17.2 In fixing this period due account shall be taken of the time normally required for
transport as agreed in the purchase order.
17.3 In respect of component parts (whether of the contractor's own manufacture or

not) of the offered equipment as are, expressly mentioned in the PO the warrantee
period shall be same as is specified in respect of each of the equipment.
17.4 The warrantee period shall be twelve (12) months from the date of commissioning
OR 18 months from the date of Receipt of dispatch at the site, whichever is earlier.
17.7 In order to be able to avail himself of his rights under this clause, the Purchaser
shall notify the contractor in writing without delay of any defects that have
appeared and shall give him every opportunity of inspecting and remedying them.
17.8 On receipt of such notification the bidder shall remedy the defect forthwith at his
own expense.
Defective parts replaced in accordance with this clause shall be placed at the
disposal of the bidder.
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OF
Piping system for Air Compressor

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A. GENERAL SPECIFICATIONS FOR FABRICATON ERECTION

AND TESTING OF PIPING
1.0 SCOPE:
This specification covers the technical requirement and essential particulars for the
supply, fabrication, inspection, erection, testing and cleaning of piping systems
observed in the specification documents and drawing, the SUB
CONTRACTOR shall demonstrate that the piping satisfies the requirements of the
specification and applicable codes. All materials, tools, tackles, specials, erection and
testing equipment etc., are all in SUB CONTRACTOR scope.
2.0 CODES AND STANDARDS:
2.1 All piping systems shall comply with currently applicable statutory,
regulations and safety codes in the locality where the equipment will be
installed. The piping shall also conform to the latest editions of the codes
and standards listed on the clause 2.2 below and other applicable
standards. Nothing in this specification shall be construed to relieve the SUB
CONTRACTOR of this responsibility.
2.2 The equipment and work under the contract conform to the following
Standard/Codes
(a) Indian regulations of Chief Inspector of Explosives.
(b) Applicable standard for structural steel
(i) IS : 800- Code of practice for use of structural steel fitting
(ii) IS ; 2062 - Structural steel
(iii) IS : 1239 - MS Galvanised pipes/ tubes, tubular and rod steel fittings
(iv) IS : 3589 - Seamless or electrically welded steel pipes.

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(v) IS : 4736 – For G.I pipe coating.
(c) American National Standards Institutes (ANSI) code “ power piping” ANSI
B31.1 and all other associated ANSI standards
(d) American National Standard Institute (ANSI) code" chemical plant
and petroleum refinery piping" ANSI b31.3 and all other Associates
ANSI standards: ANSI/ASME: 31.4
(e) Manufacturers standardization society (MMS) USA standard
Practices
(f) American society for testing materials (ASTM) specification
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(g) American society of mechanical engineers (ASME) codes

(h) Pipe fabrication institute (PFI), USA Standards
(i) All applicable state laws
(j) Relevant Indian standards
2.3 In case of conflict between codes and standards referred to herein and
the requirements of this specification, the matter shall be brought to the
Attention of MAIN CONTRACTOR for specification.
3.0 SUB CONTRACTOR'S SCOPE OF WORK:
3.1 SCOPE OF SUPPLY:
System to be erected:
a) COMPRESSED AIR PIPING
The scope under this tender includes complete compressed air piping within the
compressor room housing the air-compressor and also up to the various air outlet
points in the Factory. Supply of compressors not included in the scope.
3.1.1 The scope of work of the SUB CONTRACTOR under this contract is as defined else
where in this specification. For all piping systems included in his scope of work,
SUB CONTRACTOR shall supply all materials other than those items specifically
excluded as required in order to render the piping systems complete. SUB
CONTRACTOR scope of supply shall include but not be limited to:
(a) Complete assemblies of sleeper supports, anchors, guides, restraints, etc.,
including welded attachments, clamps, suspension rods, U-clips, shoes, valve-
pits.
(b) Auxiliary steel for clamps, supports, guides, restraints, anchors, etc.,
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3.1.2 Unless otherwise specified, SUB CONTRACTORS scope of work includes all
instrument impulse piping and fittings up to the last root valve and threaded
connection.
3.1.3 SUB CONTRACTOR shall provide all necessary drains and vents as equipped for the
safe and effective draining/venting of the piping systems. Drains shall be
provided at low points and vents at all high points as per actual layout regardless
of whether the same have been shown in the drawing or not .The drains and
vents indicated shall however be regarded as minimum requirements. The drains
and vents shall be laid as shown on drawings or as directed by
MAIN CONTRACTOR / OWNER.
3.1.4 The SUB CONTRACTOR shall supply and install concrete thrust blocks / supports
from PEB for piping/valves/strainers/etc.
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The valve-pits running below grade level and in piping manifold area and wherever
these are already shown in the drawing. Additional pipe sleepers / clamps / valve
supports shall be provided by the SUB CONTRACTOR as may warranted considering
local situations.
3.2 SCOPE OF ERECTION:
3.2.1 All the systems supplied by SUB CONTRACTOR indicated to be in the
scope of work of piping CONTRACT, defined in scope of work shall be erected by SUB
CONTRACTOR.
3.2.2 If the terminal connections or at connections to in-line specialties, the supply of
counter flanges is by others, the same shall be erected by the SUB CONTRACTOR.
Necessary gaskets and fasteners are included in SUB CONTRACTOR’S scope of
supply, unless otherwise excluded.
3.2.3 All valves, strainers, flow meters and other in-line specialties if warranted or
included at a later date during execution of the contract supplied which form a part
of the piping systems erected by the SUB CONTRACTOR, the same shall be installed
by the SUB CONTRACTOR to render the systems complete within his terminal
points. SUB CONTRACTOR shall perform necessary internal machining of pipe for
installing orifices, flow nozzles, straightening vanes etc., if warranted.
3.2.4 Fabrication and erection of pipe supports including shoes, guides, stops /
anchors, clips, radials, hangers, turn buckles, supporting fixtures brackets,

cantilever struts, etc.
3.2.5 MAIN CONTRACTOR/OWNER piping drawings indicate dimensioned layout of
piping. While these have been laid out taking care to avoid interference with
structural steel, cable trays, sanitary sewers, manholes, etc., and other piping and
equipment, certain interference would still exist, it is expected that these interference
would be minor in nature. The SUB CONTRACTOR shall modify prefabricated
piping and reroute the piping to avoid any field interference. These minor
modifications shall be done at no extra cost to the MAINCONTRACTOR/OWNER.
3.3 SCOPE OF SUPPLY FOR ERECTION & TESTING:

SUB CONTRACTOR'S scope of supply for fabrication, erection, cleaning, testing and
commissioning of the piping systems installed by him shall include the following:
3.3.1 All welding consumable like welding electrodes, filler rods and wires, gases like
oxygen, acetylene dioxide, propane etc.,
3.3.2 Films for dye-penetration test of welds.
3.3.3 Dye penetrates, and other required non-destructive testing materials and
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equipment.
3.3.4 All preheating and stress relieving equipment, thermocouples, asbestos
blankets, cables, heat sensitive chalks and crayons etc.
3.3.5 All machinery, crane, equipment, tools and tackles as required for transportation,
handling, fabrication and erection.
3.3.6 All equipment and materials as required for cleaning, flushing, blowing, out and
testing of the piping systems. These shall include but not be limited to pumps and
compressors with prime movers; instruments; pipe work with supports, valves,
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strainers and other specialties, blanks plugs, spool pieces, dummy plates, electrical
accessories etc.
3.3.7 Services of erection Superintendent, supervisors and foremen, fitters and riggers,
welders, gas cutters, grinder, transport and crane operators and other skilled and
unskilled labour.
4.0 DESIGN REQUIREMENTS:

4.1 The SUB CONTRACTOR’S responsibility to plan suitable layouts for these systems in
site as per the requirements of this specification and in consultation with MAIN
CONTRACTOR/ OWNER. Shop drawings should be prepared by the SUB
CONTRACTOR and got approved from MAIN CONTRACTOR/ OWNER before starting
the works.
4.2 While site routing piping, the following requirements shall be taken into account
by SUB CONTRACTOR.
4.2.1 All piping shall be routed so as to avoid interference with other pipes and their
hangers and supports, electrical cables. Structural members, equipment etc.
Adequate clearances shall be ensured with respect to the above to accommodate
pipe movements.
4.3 Drains, vents, etc. wherever not located on MAIN CONTRACTOR piping layout drawings
shall be suitably located by SUB CONTRACTOR as may be warranted by site conditions.
4.4 At all intersection joints, SUB CONTRACTOR shall provide suitable reinforcements as
per the applicable codes and standards.
4.5 The design, layout and supporting of all temporary pipe work as required for
erection, cleaning, flushing, blowing out, testing and commissioning of the piping
systems installed by the SUB CONTRACTOR is the responsibility of the Sub
CONTRACTOR.
4.6 Drawings in general are made to scale. The SUB CONTRACTOR shall use dimensions
and grades relevant at site based on SURVEY and Site Conditions ground levels
as it exists.
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5.0 PIPE SUPPORTS:
5.1 The materials used in construction of Clamps, supports and accessories shall be
the most suitable for the service intended. Test certificate preferably from third party
shall be furnished. One coat of red oxide zinc chromate primer and two coats of enamel paint
of desired color shall be applied by SUB CONTRACTOR.
5.2 Lugs or other means of welded attachment of pipes shall be welded in the shop
and shall be of the same material as the parent pipes.
5.3 The hangers shall be fabricated and assembled in such a manner that they do not
become disengaged by any movement of the supported pipe.
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5.4 The diameter of the hanger rod for piping 65 mm NPS and larger, shall not be
less than 13mm.
5.5 Bolted pipe clamps, used with rod hangers, shall have a minimum thickness of 5
mm for weather protected locations and 6 mm for places exposed to weather.
5.6 All rigid hangers shall provide a means of vertical adjustment after erection.
5.7 Beams clamps shall be of forged steel, each equipped with a rod to Fix a nut.
Beam clamps shall be such as to avoid torsion loading of beams.
5.8 All supports for piping shall be provided with carbon steel machine bolts, nuts in
accordance with applicable codes. Bolts heads shall be regular square and unfinished.
Nuts shall be cold punched semi-finished, heavy hexagonal type.
5.9 All threaded members shall have a true and complete depth of thread.
5.10 The threads on the threaded parts such as hanger rods, nuts and turn buckles
shall conform to applicable codes for the coarse - thread series with a medium class fit for
locking.
5.11 All hangers shall be furnished with beam clamps, rods, pipe stubs and all other
materials required to make the hanger complete.
5.12 All anchors shall be designed for rigid fastening to the structures either directly or
through a bracket. Anchors and guides shall be capable of withstanding the moments and
forces imposed by thermal expansion.
5.13 If vibration is encountered after a piping system is in operation, appropriate

rectification shall be earned out by the SUBCONTRACTOR at the direction of the
MAIN CONTRACTOR/OWNER.
6.0 MATERIALS:
6.1 All materials supplied by the SUB CONTRACTOR shall comply to piping Material
Specification. All materials shall be new and unused.
6.2 All materials shall be certified by proper material test certificates. All material test
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certificates shall carry proper batch number or other acceptable references to

enable identification of the certificate with the material it purpose to certify. The
batch number shall also be indicated on the material certified. The certificates shall
be compiled in the “handing Over” Documents.
7.0 FABRICATION & ERECTION:

7.1 The SUB CONTRACTOR shall prepare necessary fabrication drawings, based on
layout drawings. These shall be based on site survey and elevations, slopes etc.,
Fabrication and erection of pipe systems shall be as per
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SUB CONTRACTOR'S fabrication drawings and OWNER layout drawings. In case of

systems requiring statutory' clearance, fabrication and erection shall commence only
after the necessary clearance has been obtained from the statutory authorities.
SUB CONTRACTORS' fabrication drawings shall carry all details of fabrication,
welding etc., as may be required.
7.2 SUB CONTRACTOR'S work shall be adequately equipped with the required
machinery, templates, gauges, tools and tackles etc. required for fabrication. The extent
of fabrication at works shall be such as to restrict field welding to
circumferential line joints to be performed in the field shall be held to a minimum
limited by handling considerations and erection constraints. It is the responsibility of
the SUB CONTRACTOR to identify necessary field welds during pre-fabrication in a
manner as to enable him to absorb miss-matching at the final connections to
equipment due to field tolerances in erecting civil structures, foundations,
alignment of equipment, piping fabrication etc., Any modification required to be done
on pre-fabricated piping on account of this shall have to be done by the SUB
CONTRACTOR at no extra cost to the OWNER.
7.3 All welded attachments on pipelines shall be of the same material as the parent
pipeline and shall be subjected to the same fabrication and welding procedures as the
parent, piping.
7.4 The use of companion flanges to connect two pieces of pipe and the use of odd
or short pieces of pipe in making up long runs is prohibited except as noted on
OWNER piping drawings.
7.5 Where welded pipe or fittings are used, longitudinal welds in adjoining sections
shall be staggered to a minimum of 90 degrees during fabrication.
7.6 All piping shall be fabricated true to tines and elevations as indicated on the
piping drawings.
7.7 Bends in seam welded pipe shall be oriented so that the seam is positioned along
the neutral axis.
7.8 Neither butt nor branch joints shall be closer than twice the pipe diameter to any
other joint in the same pipe except where weldolet type fittings are used. In which case
the branch weld must be made to the welddolet unless otherwise mentioned on piping
drawings.
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7.9 All pipes bends shall have a radius specified on the OWNER piping drawings /
Specification. The pipe bends shall be true to angle and radius and shall maintain a true
circular cross-section of pipe without deformity or undue stretching. Crimping of
pipes to form bends is not acceptable.
7.10 All pipe flanges and contact surfaces shall be concentric with the axis of the
piping. All flanges and glanced fittings shall be accurately machined and drilled
true to template. Flange bolt holes shall straddle the normal center lines unless
different orientation is shown on drawing to match equipment connections etc.
7.11 All pipelines shall be fabricated and erected without any stress except where cold
springs are specifically called for in drawings. Flanges must be parallel and
correctly aligned to ensure proper flange gaps. In certain pipelines the last weld
joint shall be carried out with utmost care to avoid stress on equipment.
7.12 All welded branch connections shall be of suitable structural adequacy by virtue
of the intrinsic weld connections, reinforcing plates or rings or material inherent in
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the branch. Welded branch connections are not an acceptable alternative where tees
have been specified unless specific approval of engineer is obtained.
7.13 The first circumferential weld joint after a pipe bend shall be after a minimum
straight length of two times the pipe diameter or 500 mm whichever is more
unless otherwise shown in the piping drawing. Where miter bends have been
specified in the piping materials specification sheets, the miters shall be of three
weld type with inner angle 30 Deg. each and outer angles 15 Deg. each.
7.14 Where fabricated reducers have been specified, they shall be fabricated from
parent pipes by the cut and shut method. However, proper mandrills shall be
used to obtain the best possible profile of the reducer.
7.15 SUB CONTRACTOR shall check the bench marks provided by MAIN CONTRACTOR /
OWNER & it shall be SUB CONTRACTOR'S responsibility to establish all layouts and
levels using his own surveying instruments. SUB CONTRACTOR shall protect the bench
mark and shall not remove or disturb the bench marks without the approval of the
MAIN CONTRACTOR / OWNER.
8. ACCEPTANCE PRESSURE TESTING
1. Perform acceptance pressure testing as follows:
Service Operating Test Type Testing Permissible

Pressure Pressure Press. Drop &
bar
Compressed Air 7.00 Kg/cm2 Pneumatic 10.5 Kg/cm2 No pressure

(g for 2hr) or Air (g for 2hr) drop
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2 For systems not indicated in the above table, the test pressure shall be 1.50 times
the operating pressure or 10.5 Kg/cm2 (g, whichever is greater.
3 Refer to referenced SECTIONS for additional testing requirements.
4 If testing demonstrates leakage, determine the sources(s) of leakage, repair or

replace defective materials and workmanship, and retest the installation to specified
requirements.
5 Remake leaking gasket joints with new gaskets and new flange bolting. Destroy old
bolting where welded joints fail, submit proposed method of repair for approval by the
MAIN CONTRACTOR/ OWNER and authorities having jurisdiction.
8.1 Testing Equipment
Test equipment per manufacturer’s published instructions, ASME/ANSI/NFPA

where applicable and as specified for the system.
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8.2 METHODOLOGY:
I) SUB CONTRACTOR shall divide the pipeline in suitable sections for testing based
on the routing and configuration of the lines in consultation with the MAIN
CONTRACTOR/ OWNER
II) All the sections shall be tested to the testing pressure specified on
the drawings and released for coating.
The line shall be completely flushed by using pressurised air.
The SUB CONTRACTOR shall commission the system in consultation with

MAIN CONTRACTOR/ OWNER
All the tools and tackles, machinery, utilities like air, blinds, pressure
gauges, etc., shall be supplied by the SUB CONTRACTOR.
9.0 CLEANING, FLUSHING AND BLOW-OUT:
9.1 All piping including valves and specialties shall be cleaned by the
SUB CONTRACTOR before and during erection to remove grease, dirt, dust,
scale and welding slag.
9.2 Before erection, all fabricated pipe work, assemblies sub-assemblies, fittings
and components etc., shall be thoroughly cleaned internally and externally
by blast cleaning or by power driven wire brushes. The brushes shall be of
the same or similar material as the metal being cleaned.
10.0 INSPECTION AND TESTING

All the materials supplied under this contract shall be subjected to all shop
tests as per applicable material standards. All the materials supplied are
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subject to source inspection by the MAIN CONTRACTOR/ OWNER to ensure

compliance with the material specifications. SUB CONTRACTOR shall notify MAIN
CONTRACTOR/ OWNER in writing at least two weeks in advance on the availability
of the materials at the manufacturer's works for inspection by MAIN
CONTRACTOR/ OWNER and shall extend all facilities to MAINCONTRACTOR/
OWNER at no extra cost All materials subject to inspection by MAIN
CONTRACTOR/ OWNERshall be offered in one lot for inspection, as far as possible.
10.1 All fabrication / erection work covered by this specification shall be subject
to inspection by the MAINCONTRACTOR/ OWNER at no additional cost to the
MAIN CONTRACTOR/ OWNER and the SUB CONTRACTOR shall advise
the MAIN CONTRACTOR/ OWNER promptly at various stages of erection
for inspection.
10.2 The MAIN CONTRACTOR/ OWNER shall have free access to the
SUB CONTRACTOR'S works at all times when anyfabrication / testing work
is being earned out and the SUB CONTRACTOR shallprovide all necessary
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facilities / co-operation to the MAIN CONTRACTOR/ OWNERin this regard.
10.3 The MAIN CONTRACTOR/ OWNERrepresentatives shall, at all reasonable have

facility to witness the SUB CONTRACTOR'S operator's qualification tests conducted
by the SUB CONTRACTOR.
10.4 Any workmanship by the SUB CONTRACTOR inspected in the field and found
not to comply with this specification or any of its parts thereof shall be repaired at
the SUB CONTRACTORS expense. If the non-compliance is the fault of the SUB
CONTRACTOR the fact that MAIN CONTRACTOR/OWNER has not pointed out
faulty work or work which is not in accordance with drawings and specifications shall
not relieve SUB CONTRACTOR from correcting such work as directed by MAIN
CONTRACTOR/OWNER without additional compensation.
10.5 The SUB CONTRACTOR shall assist MAIN CONTRACTOR /OWNER in ensuring the
alignment of rotary equipment with its drive by disconnecting the pipeline
from rotary equipment when called for the SUB CONTRACTOR shall rectify the
pipe line if any misalignment in rotary equipment is attributed to piping
stress at no additional cost. The SUB CONTRACTOR shall reconnect the piping
with equipment after checking.
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10.6 On completion of erection, the inside of all pipes valves, fittings, etc., shall
be clean and free from loose scale and foreign matter before subjecting the line
to any test / inspection.
10.7 Lines having check valves should have the source of test pressure located
on the upstream side.
10.8 Test pressure readings may be taken at the lowest point of the system
being tested provided the effect of static head- is taken into consideration.
10.9 When conditions require a test pressure to be maintained for a period of

time during which the testing medium in the system might be subject to
thermal expansion, provision shall be made for the relief of excess pressure
thereto.
10.10 After pressure test, any leak joints shall be cut out and repaired or
completely replaced, and test repeated until the test has been satisfactorily
passed.
10.11 The rate of pressure rise in any case must not exceed 7 bars per minute.
10.12 No one should be allowed near piping / equipment under test when the test
pressure is near the yield strength or when test pressures over 35 bars are
being applied. The pressure should be lowered by 10% before inspecting for
leaks.
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11.0 CORROSION PROTECTION:
All pipelines and piping components shall be adequately protected against

corrosion during fabrication, handling and storage by appropriate protective paint. Use
of grease or oil for this purpose is prohibited.
12.0 TEST CERTIFICATES AND REPORTS:
The following test certificates shall be submitted to the MAIN CONTRACTOR/ OWNER
for review.
12.1 For materials supplied by SUB CONTRACTOR
12.1.1 Chemical composition.
12.1.2. Mechanical properties such as tensile flattening harness, bending, impact etc.,
as called for in the respective material specification standards.
12.2 Dimensions
12.3 Pressure test.
12.4 NDT reports.

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12.5 Reports on visual examination.
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MATERIAL SPECIFICATIONS FOR PIPES & FITTINGS Piping
material
• MS Galvanized As per IS 1239 Class C for Sizes up to 150-mm and fittings IS 1239 part 2,GI
(IS 4736 for GI coating)
• Gate valve shall be used for Pipe dia above 200mm & Butterfly valve for pipe dia ranging from
50mm to 150mm.
Ball valve :
• Maximum working pressure:16 Kg/cm2

• Female thread connection comply with ISO 228 (BS2779)
• Lever Handle type
• Provided with Brass Hard Chrome Plated Ball.
• PTFE Body ring and Gland Packing.
• Chrome plated finish.
Butterfly valve /Gate valve
• Maximum working pressure:16 Kg/cm2

• Wafer type
• Cast Iron body with integrally mounted EPDM liner
• Liner with integrally mounted hard backup ring..
Auto Drain valve
• Connection female parallel thread BSPT

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• Working pressure -0 to 16 Kg/cm2

• Working temperature -1º C TO 60º C
• Body- aluminum
Pressure gauge
• Connection male thread BSPT

• Working pressure -0 to 16 BAR
• Working temperature -1º C to 60º C
• Body- stainless steel
•Bourdon tube of SS.316
•Position range 0 to 16 Kg/cm2
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SPECIAL REQUIREMENTS
For galvanized lines, painting shall be applied in locations such as weld joints where the heat
of welding has affected the galvanizing coating. The finish coat colour shall match the parent
pipes in all such cases.
WELDING SPECIFICATIONS
The following specifications outline the requirements for the Utility lines. These have to be
strictly followed. No request for change of specifications will be entertained after award of
contract.
These specifications cover the services like compressed air piping,
Butt welds : Single V with 37 1/2 deg. +/- 2 1/2 deg. Bevel
angle. 1.5 mm land and 1.5 mm root gap.
Alt passes : MMAW (Manual metal arc welding)
Pre heat / Post heat : None
Welder qualifications : The welder shall be qualified by Lloyds & Equivalent.
Welding electrodes : Root Pass: 6010

Fill up passes: 6013
Welding procedure : Shall be developed by SUB CONTRACTOR

& approval by MAIN CONTRACTOR
INSPECTION:
Joint fit-up : Visual inspection

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Root passes : Dye Penetrate test
Finished weld : Dye Penetration test
Pressure test : As specified.
Recommended electrode brands
1. ESAB
2. ADVANI OERLIKON
3. D&H
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SHIMIZU CORPORATION INDIA PVT. LTD DG TECHNICAL SPECIFICATION
LIST OF APPROVED MAKES:
1. GI / MS Pipes : Jindal /TATA/ Zenith

2. Isolation Valves : Audco/ Advance
3. Flow meter : Forbes / Toshiniwala/ Krone Marshall
4. Pipe fittings : Metal Llyods / Jainsons / BM
5. Ball Valves : Leader / Zoloto / ITAP
6. Pressure gauge : H Guru/ Bourdan/ Warree
7. Paint : Nippon/ Asian / Nerolac
8. Welding Rods : Advani / Essab / D&H
9. Gasket: Metallic Spiral : Champion
wound Gasket with
SS internals
Page 761
Page 762
14
Page 763
Page 764
Sr.No. Section No. File description Page No.
A Steam Boiler & Ancillaries
B List of Approved Makes.
Page 765
A – STEAM BOILER & ANCILLARIES
The scope of this section comprises the supply, installation, testing and commissioning
of steam boiler, Feed water tank, Chimney, Steam pipe & Valves for Utility/ Process
application.
Schedule of Rates shall also be read in conjunction with this technical specification so
as to have a complete view of the specifications for the particular item.
1. BASIS OF DESIGN
The steam system for the project is designed to cater for steam requirement for Utility/
Process application.
2. SYSTEM DESCRIPTION
2.1 Extent of Work:-

The boiler shall be complete with all ancillaries as feed water tanks, complete steam
supply and condensate return piping, steam headers etc.
3. SYSTEM COMPONENTS
3.1 PNG FIRED STEAM BOILER & ALLIED EQUIPMENT
3.1.1 SCOPE
The scope of this section comprises the supply, erection, testing and commissioning of
steam boiler with PNG fired burner & allied equipments conforming to these
specifications and in accordance with requirements of schedule of quantities.
3.1.2 STEAM BOILER

The steam boiler with single burner with single fuel at a time, shall have capacity to
generate steam as per BOQ and datasheets at 7.5 to10.5 Kg/Sqcm pressure.
Page 766
Steam boiler shall be horizontal shell and tube design unit robustly constructed with
shell plate as approved and shall be suitable for PNG Firing. The steam boiler shall be
mounted on M.S. structural beam skid base with internal forced draft burner and
burner controls.
The tubes of the steam boiler shall be high temperature resistant as per IBR norms
Steam boiler flue outlet shall be provided with one 25 mm socket duly plugged to
measure flue temperature and percentage of Carbon-di-oxide.
Steam boiler shall be suitable for operation on PNG and shall be suitable for working
pressure as mentioned in the schedule of quantities. Test pressure shall be 1.5times
the working pressure.
Steam boiler shall be as per the purview of IBR & shall consist of following integrated
parts.
Pressure Parts
a) Boiler Shell
b) Tube Plates
c) Furnace Flue
d) Combustion Chamber
e) Boiler Tubes
f) Mud door
g) Man door
h) Stand Pipes for Stop, Feed check, Safety and Blowdown Valves
i) Stand pipes for gauge glass and level
j) Flue gas outlet.
General Construction Parts:
a) Front casing with hinged door

b) Rear casing with removable doors
c) Flue outlet flange
Page 767
d) Insulation and sheeting for boiler shell

e) Rear access door refractory
f) Support base frame
g) Ladder and platform.
Combustion Equipment:
Fully automatic, single block modulated, monobloc pressure jet burner fitted with F. D.
Fan, ducting, air / fuel ratio adjusting damper,pressure gauge, Spark Ignitor and flame
surveillance sensor (UV Cell) and sequence controller
Feed Pumps:
2 nos. electrically driven vertical centrifugal multistage pumps mounted on the boiler
frame itself with motor capable of using feed water at temperature of 120 deg C with
all SS304 internals, interconnected pipework between pumps and feed check valves
3.1.3 ACCESSORIES
All the below mentioned accessories shall be supplied as per the final approved
drawings material submittals:
a) Single fired burner Natural gas, with actual steam production of ----- kg/hr at
maximum steam pressure of 10.54 kg/cm2g, at max. steam temperature of 185
degree, dryness fraction of steam quality of min. 98% and NCV at full load 92%-
+2%
b) Blower coupled with motor mounted on bottom chassis.
c) Water pump assembly with surge suppressor and relief valve mounted on
frame.
d) Dust proof, prewired control panel housing with necessary starter, contactors,
relay flame monitor, timer, overload relays etc.
e) Container with panels enclosing boiler and its accessories.
f) Feed water line between feed pump and boiler.
g) BMS Interface for ON/OFF status.
h) One no. gas train assembly with gas generator, solenoid valves for gas.
Where acoustic treatment is required this shall be advised by the specialist

boiler/burner supplier and shall be incorporated as part of the contract works. All
details shall be issued to the Project Manager/ Engineer for approval.
3.1.4 MOUNTINGS AND FITTINGS
Page 768
All the below mentioned mounting and fittings be supplied as per the final approved
drawings / material submittals:
a) Main steam stop valve – 1 nos

b) Single port spring loaded safety valve – 2 nos
c) Blowdown valve – 1 nos
d) Non-return valve on feed water line – 2 nos
e) Isolating needle valves for indicating instruments – 2 nos
f) ‘Y’ Strainer on feed water– 2 nos
g) Fuel gas pressure guage – 1 nos
h) Complete set of gas piping between burner – 1 set
i) Solenoid valve on fuel gas inlet to burner – 1 nos
j) Water level controllers – 2 nos
k) Water guage glass – 2 nos
l) Inspector’s test guage connection – 1 nos
3.1.5 INSTRUMENTS CONTROLS AND SAFETIES

All the below mentioned control and safeties shall be provided as per the final
approved drawings / material submittals:
a) Steam pressure indicator.

b) Steam pressure switch for ON-OFF combustion control.
c) Steam temperature indicator-cum-controller.
d) Feed water temperature indicator.
e) Feed water pressure indicator.
f) Low level water alarm switch on feed water line; with burner cut-off and boiler
trip interlocking arrangement.
g) Flame failure device (Photo electric cell, built into the burner) for gas.
h) Set of Audio visual alarms for abnormal conditions.
i) Temperature gauges at the outlet of the gas.
j) Programming controller to provide automatic sequence of operation for the
burner operation. However, there shall be a provision for the manual
operation of the burner also by providing a selector switch for auto / manual
operation.
k) Air pressure suitable for combustion as required for gas.
l) Gas pressure switch for proper gas regenerator.
m) Gas leakage detector.
n) U.V cell
In addition each steam boiler shall have an automatic firing control system that
effectively controls the supply of fuel / air, and shuts them off in the event of any one
or more of the following circumstances
a) Flame and/or pilot-flame failure

b) Failure to ignite the fuel within a present time
Page 769
c) First Low Water Level – When water level falls to a preset level below normal
working level
d) Second Low Water Level – This shall be an independent overriding control set
to operate at minimum permitted water level
e) Failure of draught fans and/or automatic air dampers
f) When water reaches a point still visible in the gauge glass above which there is
a risk of carryover of water into the distribution system
g) Electrical fault in any control or associated equipment; i.e. the firing and water
level control systems shall be fail-safe
h) Failure of electrical supply to any part of the firing and/or water level control
systems.
Indicator Lights and Alarms

Steam boiler plant shall be provided with the following state or fault lights (min) as
indicated
a) Equipment (e.g. burner, pumps etc.) on
b) Equipment running
c) Equipment lock-out
d) Flame or pilot-flame failure
e) Ignition failure
f) Fan failure (wherever applicable)
g) Air damper failure (wherever applicable)
h) Control equipment failure
i) First low water level alarm
j) Second low water level lock-out
k) High water level
l) High pressure lock-out
m) High flue gas oxygen content (wherever applicable)
n) Others as indicated
All fault conditions shall give rise to unmistakable audible and visual alarms at the
boiler plant room(s), which is clearly distinguishable against the ambient noise
conditions. The types and precise locations of sounders and beacons shall be as
specified and to the approval of the Project Manager/Engineer. Interface shall be
provided so that the BMS can monitor alarms.
Remote audible and/or visual alarms shall be provided at the locations as specified.
This shall show the technical information and the actions to be taken by remote
station personnel in the event of alarm as specified. Failure of communication links
between the boiler plant and remote station shall cause the alarms at both ends to
operate.
Power and standby power arrangements for the boiler plant and the remote alarm
panels shall be as specified.
Page 770
'Accept Alarm' buttons on the local and remote alarm panels to stop and remain
insensitive to the faults which triggered them for an adjustable period up to 30
minutes before automatically resetting. The alarm system shall otherwise remain
sensitive and sound whenever a new fault occurs.
A control (burner) shall be provided that shall contain as a minimum

a) Sequence Timer
b) Starters
c) Fuses, Relays and Switches
d) Indicator Lights/Alarms
e) Normal Firing Light
f) Lock-Out Light
g) Mute Alarm/Run Switch
h) Burner Switch
i) Fuel Selector Switch
3.1.6 FUEL SUPPLY SYSTEM
Gas Fuel:
One gas train comprising of manual ball valve, safety shut valves, PRV, two solenoid
valves, gas pressure indicator with isolating cock, pressure switch, safety relief valves
and pressure gauge isolating valve (1 set).
One pilot gas train consisting of ball valve, pressure indicator, pressure regulator with
isolating cock, solenoid valve (1 set).
3.1.7 STEAM BOILER PERFORMANCE TEST

Following listed tests shall be conducted after installation of the boiler:
a) Capacity test to confirm the total steam load
b) Dryness fraction test to shall be conducted.
c) All controls and safety test.
d) Efficiency test to shall be conducted.
e) Safety valve blow test.
f) Hydraulic test.
All necessary equipments or instruments required for conducting above tests shall be
arranged by the Equipment supplier. Steam boiler will be approved subject to
clearance of above tests.
3.1.8 STEAM BOILER INSPECTION

Equipment supplier shall arrange the inspection and dry trial at works / factory by
the Main Contractor and Owner, of the Steam boiler prior to despatch. All cost in
travel and stay, to be borne by the Equipment supplier.
Page 771
3.1.9 DRAWINGS
Equipment supplier shall furnish following drawings in triplicate within 10 daysfrom
the date of order to the Main Contractor/ Owner.
a) Foundation details of each Steam Boiler.
b) Dimensional detail of Boiler
c) Steam Boiler electrical wiring diagram.
d) Steam Boiler operation manual.
e) P & I diagram.
f) General arrangement & Terminal point details.
g) Proposed layout of boiler house.
The boiler manufacturer shall supply tube cleaning brushes and rod handles for each
boiler plus a comprehensive set of O&M manuals at the time of delivery of the boilers.
The warranty for the boiler shall be in accordance with as defined within this
specification. Extended warranties shall also be provided. The boiler manufacturer
shall also supply paper and electronic copies of the boiler general arrangement and
wiring drawings. The boiler manufacturer shall fully test and commission the boiler
with the Main Contractor/ Owner in accordance with the specification and to the
approval of the Project Manager / Engineer
3.1.10 GUARANTEE / WARRANTEE

Contractor shall furnish a guaranty / warrantee of 24 months from the date of
obtaining the completion certificate / soft opening of the property, whichever is later,
from the Client / Project Managar/ Engineer – in charge against faulty design,
materials or workmanship. During guaranty / warrantee period supplier is bound to
replace the defective parts free of cost.
The warrantee shall include for repair and / or replacement of any defects that appear
in the supplied equipment / system at no additional expenses to the owner.
Furthermore, the warranty shall also cover the costs incurred in making the defective
work good, including repair or replacement of building finishes, other materials, or
damage to other equipment caused by such defects, or by subsequent replacement
and repairs.
3.1.11 PRECOMMISSIONING
On completion of the entire erection of equipment, piping, connection to the pipe
system and electrical system, Sub Contractor shall fill the entire system with cold
water and test for leakage and other erection defects. All such defects shall be
removed. All motors shall be test started.
3.1.12 COMMISSIONING & TESTING

On completion of all procedures at pre-commissioning stage, Steam Boiler shall be
fired by the respective manufacturer, and all adjustments shall be carried out in
Page 772
valves and other accessories for all related equipments. Steam Boiler shall be
allowed to run till the desired pressure & temperature in the system is obtained. Any
defects noted shall be rectified immediately.
4 FEED WATER TANK
4.1 Feed Water Tank:-

Material of Construction of Feed Water Tank shall be SS304. Pressurized feed water
tank shall be completely preassembled unit with all valves, pumps, instruments are
custom-designed according to steam boiler system.
The feed water deaerating plant, consisting of the feed water tank and the deaerator,
removes dissolved gases such as oxygen, carbondioxide and othe non- condensable
gases from boiler feed water and makeup water.
For the operation of steam boilers with high thermal load on the heating surfaces boiler
feed water must be treated and conditioned.
The boiler feed water must be free of hardening constituents in order to prevent the
formation of scale on the boiler heating surfaces. The presence of dissolved oxygen and
carbondioxide causes severe corrosion of metal boiler parts. The feed water deaerating
plant is custom designed for each application and meets essential thermodynamic
requirements to achieve optimal performance.
4.2 Cost of the tank shall be inclusive of providing the following nozzles:
a) Side mounting type level indicator
b) Drain
c) Overflow
d) Quick Fill
e) Make-up water
f) Nos. outlet
g) Condensate return
h) 600 mm dia manhole cover
i) SS304 Deaerator head
j) Vaccum breaker
k) Safety valve
l) Air Vent, Vent head
m) Level controller probe.
n) Solenoid Valve Control etc.
o) Chemical feed line
5. CHIMNEY - STEEL LINING TYPE

Page 773
The Flues and Chimney shall be constructed as per BS 5854: 1980. However, all other
codes and standards shall also be followed for specific materials as per below:
5.1 Plates and sections :-

5.1.1 Steel plates used in the construction of chimneys shall comply with the requirements for
grade 43A of B.S. 4360:1972. of 6 mm thick minimum.
5.1.2 Supporting steelwork and ancillary fittings shall comply with the requirements of B.S. 4
or B.S. 4848 for dimensions and with not less than grade 43A or 50B in B.S. 4360: 1972
for quality.
5.2 Bolts and nuts :-

5.2.1 Mild steel. All mild steel bolts and nuts shall have a tensile strength of not less than
400 N/mm2 and a minimum elongation of 17%, as defined in B.S. 4190:1967 and B.S.
4395: Part 1: 1969.
5.2.2 High tensile steel : structural quality. The material used for the manufacturer of high
tensile steel bolts, nuts and washers, for which permissible stresses are given in B.S.
449, shall have a minimum tensile strength of 580 N/mm2 and other mechanical
properties appropriate to grade 50B of B.S. 4360: 1972.
5.2.3 Friction grip bolts. Friction grip bolts, nuts and washers shall comply with the
requirements of B.S. 4395 :Part 1, and shall be used in accordance with the
requirements of B.S. 4604: Part 1.
5.2.4 The use of structural steel for the shell and other components of steel chimneys shall be
in accordance with the requirements of the relevant clauses of B.S. 449 and B.S. 4076 :
1978.
5.2.5 The minimum thickness of the load-bearing chimney shell, in single or multiple shell
constructions, shall be the calculated thickness obtained from stress and deflection
considerations plus the corrosion allowance, but shall not be less than 6.0 mm of the
outside diameter of the chimney at the same height.
5.3 Angle flanges. The minimum thickness of jointing angles to chimney flanges shall be
6.0 mm.
5.3.1 Where large apertures are cut in the shell plates, as for inlets or inspection panels, a
structural analysis of the stresses shall be made and compensation material provided, as
required, to ensure that the stresses specified in the standard are not exceeded.
Apertures in the shell plates, other than flue inlets, shall have the corners radius to a
minimum of 10 t, where t is the thickness of the plate.
5.3.2 The base plate and holding-down bolts shall be adequate to take the loads, bending
moments and reactions between the shell and the supporting structure or foundations,
the position of holding-down bolts and base gussets or stools being taken into account.
Page 774
Holding-down bolts shall be adequately tightened, with appropriate precautions to

prevent the stripping of threads, and the baseplate shall be properly grouted.
5.3.3 Where base gussets or stools are used, they should preferably be evenly disposed round
the chimney shell. Smaller secondary gussets may be provided between the main
gussets. Base gussets shall be of ample height and shall extend to the edge of the
baseplate. The angle of the sloping edge of any gusset to the horizontal shall be not less
than 60o. The minimum thickness of the gusset shall be 6.0 mm.
5.3.4 All flange bolts in the structural shell shall be positioned not more than five diameters
between centres, with a maximum of 150 mm. Account shall be taken in the design of
the bolts for the eccentricity due to the bolt positions.
5.4 Where the chimney is mounted against building structure, adequate allowance for
expansion and guide brackets shall be provided.
5.5 Expansion joints in chimney shall be provided to compensate for lateral and vertical
expansion contraction.
5.6 Chimney shall be provided with lighting arrestor
5.7 Chimney shall be provided with a suitable cowl on top.
5.8 Welding joints of chimney shall be carried out in accordance with the requirements of
B.S. 5135:-
5.8.1 Procedure approval test. Before the Sub Contractor is permitted to weld chimneys in
accordance with the requirements of the British Standard, he shall adequately and
successfully test his several procedures, and complete records of such tests shall be
available for the Project Manager/Engineer in charge or his representative as specified
in B.S. 4870: Part1.
5.8.1 The Sub Contractor shall be exempt from making procedure tests in accordance with
the requirements of this clause when he can show that, for the previous three years, he
has successfully undertaken the welding of steel chimneys to a quality equivalent to that
required by B.S. 4870: Part 1 in the procedures from which he seeks exemption.
5.8.2 Welder approval tests. Welders employed in the manufacture and erection of steel
chimneys made in accordance with the requirements shall have been tested using an
approved procedure. Complete records of such tests shall be available for inspection by
the Project Manager or his representative as specified in B.S. 4871 : Part 1. The welder
who completes satisfactorily the procedure approval test is thereby exempt from
further welder approval tests involving the same range of procedures.
5.8.3 An adequate and properly-supported working platform shall be provided to enable the
welder to stand and move comfortably in the position he normally adopts at ground
level to carry out the welding.
Page 775
5.8.4 The welding area and working platform shall be protected adequately from the weather.
5.8.5 Surfaces to be welded shall be free from moisture. Precautions shall be taken to prevent
the descent of moisture (i.e. rain and condensation) on to the welding area from the
structure above the point of welding.
5.8.6 Parts being connected by welding shall be attached firmly to each other by bolting,
clamping or other mechanical means until welding is complete in the area.
5.8.7 All electric welding on site shall be carried out with the minimum practical length of
welding cable between the power source and the working area. The supply of welding
current in respect of voltage and amperage shall be adequate for the welding procedure
being employed.
5.8.8 Protective treatment to boiler flue :-
a) Immediately before applying any protective treatment to the exterior surface of the
chimney shell, the surface shall be cleaned by chipping, scraping and wire brushing,
or by other means, to remove all dirt, loose scale, grease, rust or other deleterious
materials.
b) Immediately after the surface preparation has been completed, the exterior surface
shall be given a coat of suitable priming paint followed by one coat of a special high
temperature resistant paint applied in accordance with the recommendations of the
manufacturers of the particular paints.
5.9 The horizontal flue shall connect to the vertical chimney section at an angle of 15o to 30o
to horizontal, with expansion joint immediately at the entry section of the vertical
chimney. The complete chimney section shall be properly graded to allow free draining
of condensate after boiler shut down.
5.10 Provided with the following accessories :-
5.10.1 A removable flanged tundish piece with drain tap at bottom of vertical chimney;
5.10.2 Hinged access door adjacent to drain;
5.10.3 Connection for temperature and pressure sensors and tap off for smoke sensor.
5.11 The flexible connector shall be:-
5.11.1 Asbestos free construction suitable for the operating temperature.
5.11.2 Constructed of stainless steel reinforced fabrics combined with mineral and ceramic
wools with flange connection.
Page 776
The chimney manufacturer / contractor shall provide detailed calculations to

demonstrate that the chimney / draught stabilisation system is compatible with
the selected boilers and complies with local and international code and
insurance requirements.
5001.4. LIST OF APPROVED MAKES FOR STEAM BOILER SYSTEM
S.No. Details of Materials / Equipment Manufacturer’s Name
1. Steam Boiler Thermax / Forbes Marshall
2. Burner Oilon / J.N. Marshall / Ecoflam / Elco
3. Gas Train Dungs, Krom – Schroder / Vanaz
4. Gas Ancillaries Guillani Anello / Watts
5. Pressure Reducing Valve Thermax / Spirax Marshall
6. Steam Pressure Reducing Station / Valve Thermax / Forbes Marshall
7. Steam / Globe Valve Forbes Marshall / Zoloto / Leader / Sant
8. Steam Trap Module Thermax / Spirax Marshall / / Unison
9. Moisture Separator Thermax / JN Marshal / Spirax
10. Temperature Sensor Danfoss / Forbes Marshall
11. Pressure Control Switches Thermax / Danfoss / Switzer
12. Steam Safety Valves Thermax / / Spirax / Fisher
13. Vacuum Breaker Valve Thermax / Spirax
14. Steam Strainers Thermax / Spirax
15. Pressure Reducing Valve (Water) Honeywell / Fouress / / Marck / Suzhik
Page 777
16. Electronic Flow Meter Steam Krohne (Forbes Marshall) / Rockwin /

Thermax
17. Level Controller & Indicator (Water) Auto Pump / Cirrus Engineering / Technika
Techtrol
18. Insulation for Steam Pipes Lloyd Insulation / UP Twiga
19. Insulation for Hot Water Pipes Thermaflex / Armacell - Armaflex
20. Insulation for Chimney Lloyd Insulation / UP Twiga
21. Steam Hose Padmani / Shanti Industires
22. Three Way Motorized Valve Danfoss / Honeywell / Invensys /

Johnson Control / Sauter / Schneider /
Siemens / Yamataki
23. Air Compressor Ingersol Rand/ Atlas Copco/ ELGI
24. Centrifugal (ID) Fan Kruger/Nicotra/ CMB-Nadi
25. Boiler Scrubber Enhanced Wapp System / Hydrotech

Paryavaran / Mark Engineers / Saitherm
Page 778
Sr.No. Section No. File description Page No.
A Boiler Piping & Accessories
B List of Approved Makes.
Page 779
7 PIPING WORK AND ASSOCIATED ACCESSORIES.
4.1 IBR PIPING:

All IBR steam pipes shall be Carbon Steel seamless pipe schedule 40 conforming to
ASTM A 106 Gr. B with IBR certificates. All elbows / bends shall be made from C.S.
seamless pipe schedule 40 conforming to ASTM A 106 Gr. B with IBR certificates
The pipes shall be properly ground at the ends to make a vee. The two pipes before
being welded shall be placed on the vee block properly aligned. A gap of 2-3 mm shall
be maintained between the two pipes and V butt welding done. All welding flux
material of the root run shall be removed using metal brushes andelectrically
operated grinders. The final welding shall be done over the root run forming a proper
bead of the welding. All IBR Steam piping shall be welded by IBR approved & tested
welder using approved quality welding consumables only. WPS (Welding Procedure
Specification) shall be established and PQR (Procedure Qualification Record) shall be
done.
FLANGES:
All C.S. flanges shall be weldneck type conforming to class ASA 300#.
4.2 GASKETS
The gaskets shall be made out of the fire retardant material. The gasket material shall
preferably be minimum 3 mm thick compressed asbestos capable of with standing
minimum 600 degree centigrade temperature.
4.3 NUTS, BOLTS & WASHERS

All nuts & bolts shall be of high tensile M.S. The length of the bolts shall be such that
about half an inch of bolt shall protude outside the face of nuts. In all nut & bolt joints,
washers of suitable sizes shall be used on the bolts as well as nuts side.
4.4 VALVES
GLOBE VALVE:
All valves used for steam piping shall be globe valves of class 150 & shall be IBR
certified. The valves shall be suitable for 16 Kg/Sqcm. test pressure, straight pattern
Page 780
screwed in bonnet, inside screw, rising spindle with body, bonnet, glond, disc nut of
bronze material and stem, disc, body seat ring of SS material.
All sizes(15 to Cast Steel Socket Welded upto 40mm & Flange
300mm) connection above 40mm
NON-RETURN VALVES:
All non-return valves shall be provided as shown in the drawings conforming to

relevant Indian Standards and in accordance with the following specifications:
Upto 40mm Cast Steel Socked Welded
40mm and above Cast Steel Flange Connection
Non-return valves shall be of IBR certified & should be of approved make. Wafer type
non-return valve shall be used & tested to 16 Kg/Sq.cm pressure.
DRAIN VALVES:
All valves shall be suitable in all respects for the class of service and function.
Drain valves shall be provided at low points of all water risers and mains to ensure
that all sections of pipework and plant can be drained.
Drain valves for piping 50mm or smaller shall be 15mm Globe valve, and for piping 65
mm and above shall be 20mm Globe valve.
Page 781
4.5 STEAM TRAP MODULE

The steam trap module shall be either Thermodynamic, Inverted Bucket or Float type
& depending upon the application and for draining the condensate from the main
steam line or branch line. The cost of trap shall include provision of strainer and
bypass arrangement. The steam trap module assembly shall consist of an isolation
valve at inlet and outlet of steam float trap. Each steam float trap assembly shall
consist of Ball float steam trap, strainer, Side flow indicator, disc check valve, bypass
arrangement and ANSI 150 class interconnecting pipe and fittings
4.6 SAFETY VALVES

Safety valves shall be of high lift type with casing lever,for manual flow. The
material shall be of bronze/cast steel.
4.7 PIPE LINE SUPPORTS & PIPE LAYOUT

Pipe line supports shall be installed in a manner so that the pipe line is free to move as
a result of expansion or contraction. Steam lines should be arranged with a fall in the
direction of flow. A fall of around 40 mm in 10 M shall generally be provided. Drain
points shall be provided at every 30 to 50 M interval. Drain points shall also be
provided at any low points where condensate can collect. Branch connections should
always be taken from the top of any main. Drain points shall preferably be provided
wherever pipe work changes direction, when drainage has to be provided in a straight
length of pipe then a large bore pocket should be provided. Concentric reducers shall
be avoided and eccentric reducers shall be used.
4.8 PIPING INSTALLATION

Tender drawings indicate schematically the size and location of pipes. The Sub
Contractor, on the award of the work, shall prepare detailed working drawings,
showing the cross-sections, longitudinal sections, details of fittings, locations of
isolating and control valves, drain and air valves, and all pipe supports. He must keep
in view the specific openings in buildings and other structure through which pipes are
designed to pass.
Piping shall be properly supported on, or suspended from , on stands, clamps, hangers
as specified and as required. The Sub Contractor shall adequately design all the
Page 782
brackets, saddles, anchor, clamps and hangers, and be responsible for their structural
stability.
Piping supports shall be steel, adjustable for the height and primer coated with rust
preventive paint and finish coated black. Where pipe and clamps are of dissimilar
materials, spacing b/w the supports shall not exceed the following:
Pipe Size Spacing between supports.
Upto 20 mm 1.8 meter
25mm to 40mm 2.0 meter
above 200mm 5.0 meter
Vertical risers shall be parallel to walls and column lines and shall be straight and
plumb. Risers passing from floor to floor shall be supported at each floor by clamps or
collars attached to pipe and with a 15 mm thick rubber pad or any resilient material.
Where pipes pass through the terrace floor, suitable flashing shall be provided to
prevent rain water leakage. Risers shall have a suitable drain out in the valve at the
lowest point and air vent at the highest point.
Pipe sleeves, 50 mm larger diameter than pipes, shall be provided wherever pipes
pass through walls and slabs/ PEB wall and annular space filled with fibreglass and
finished with retainer rings.
Insulated piping shall be supported in such a manner as not to put undue pressure on
the insulation. 14 gauge metal sheet shall be provided between the insulation and the
clamp, saddle or roller, extending atleast 15 cm. on both sides of the clamps, saddles
or roller.
Page 783
All pipe work shall be carried out in a proper workman like manner, causing minimum
disturbance to the existing services, buildings, roads and structure. The entire piping
work shall be organized in consultation with other agencies work, so that area can be
Cut-outs in the floor slab for installing the various pipes area are indicated in the
drawings. Sub Contractor shall carefully examine the cut-outs provided and clearly
point out wherever the cut-outs shown in the drawings, do not meet with the
requirements.
The Sub Contractor shall make sure that the clamps, brackets, saddles and hangers
provided for pipe supports are adequate or as specified by Main Contractor. Piping
layout shall take due care for expansion and contraction in pipes and include
expansion joints where required.
All pipes shall be accurately cut to the required sizes in accordance with relevant BIS
codes and burrs removed before laying. Open ends of the piping shall be closed as the
pipe is installed to avoid entrance of foreign matter. Where reducers are to be made in
horizontal runs, eccentric reduces shall be used for the piping to drain freely. In other
locations, concentric reduces may be used.
Flanged inspection pieces 1.5 meters long, with bolted flanges on both ends, shall be
provided not more than 45 meters centers wherever shown in approved for
construction shop drawings to facilitate future cleaning of all welded pipes.
Automatic air valves shall be provided at all high points in the piping system for
venting. All valves shall be of 15mm pipe size and shall be associated with an equal
size Globe valves. Automatic air valves shall be provided on hot water risers.
Discharge from the air valves shall be piped through an equal sized mild steel ; or
galvanized steel pipe to the nearest drain or sump. All pipes shall be pitched towards
drain points.
Page 784
Pressure gauges as required shall be provided at the discharge of pumps. Care shall be
taken to protect pressure gauges during pressure testing.
Thermometers as specified shall be provided at the hot water supply and return line
wherever applicable.
4.9 PIPE & VALVES INSULATION

Pipe Insulation
All pipes and valves for steam / condensate utility, hot water and other requirement
operating at higher than ambient temperature shall be insulated in the manner
specified hereinafter.
Insulating material shall be LRB / rigid preformed sections of rock wool having
density of 144 Kg/M3 minimum with 'K' value of not more than 0.038 W/MK at 100OC
mean temp. The insulation section shall be split on one end and shall be slip on type.
No insulation shall be applied until the pipe is satisfactorily pressure tested.
Thickness of insulation shall be 50 mm for all steam and hot water pipes and valves
Pipe / Valve insulation shall be applied as follows:

a) Pipes / Valves shall be thoroughly cleaned with a wire brush and rendered free
from all rust and grease and applied with two coats of anti-rust paint.
b) Pipes / valves in false Ceilling / Shaft / Exposed:
i) Rigid pipe sections of insulation shall be fixed tightly to the surface taking
care to seal all joints with 50mm wide aluminium adhesive tape
(transverse and circumferential)
ii) The insulation shall be tied with aluminium band not less then 6mm wide (24
gauge 4 bands per meter) using G.I sheet clamp crimped at the joints.
iii) The insulation shall be covered with 26 gauge aluminium cladding screwed at
the joints with cadium coated self-tapping screws. Joints shall be overlapped
minimum 12mm wide.
All valves, fittings, strainers etc. Shall also be insulated in the same manner as
piping.
8 PRESSURE REDUCING STATION

Pressure reducing station shall consist of:-
Page 785
4.1 Pressure reducing valve of suitable capacity and pressure ratings.
4.2 The MOC shall be CS body with SS parts.
4.3 Complete with individual isolation gate valves, by-pass globe valve, strainer and safety
valve.
4.4 Pressure gauge shall be provided at the inlet and outlet of each pressure reducing
station.
4.5 Provision of separator, Needle valve, NRV, Elbow, Reducer, Tee shall be inclusive in the
cost of the PRS.
4.6 The pressure reducing valve shall be:-

8.6.1 Body and diaphragm chamber of high grade close grain cast steel;
8.6.2 Main and pilot valves plug and seat of hardened stainless steel of type 316 S16;
8.6.3 Diaphragm of phosphor bronze;
8.6.4 Pressure adjusting spring of chrome vanadium steel;
8.6.5 With external pressure adjustment knob, lock nut and cap.
9 WATER TREATMENT
4.1 GENERAL
All chemical, service and equipment shall be provided by a specialist chemical
engineering firm approved by the Project Manager/ Engineer in charge.
The basic treatment required shall be for corrosion inhibition, scale prevention and to
prevent boiler water carry over,
Treatment shall be automatic.
Treatment chemicals shall be compatible and neutral to piping and equipment which
form part of the system treated and shall be selected in accordance with system water
flow rate,
Initial supply of chemicals shall be adequate for one year's consumption from Date of
Practical Completion,
Treatment programme shall include precleaning, pretreatment and maintenance

treatment to attain the required water quality.
Page 786
4.2 PERFORMANCE
Condition for steam boiler shall be as per manufacturers recommendation for standard
boiler operation.
External treatment shall be in the form of sodium zeolite ion-exchange water softener
capable of complete removal of total hardness in raw make up water,
The ion-exchange water softener shall be proprietary type complete with all valve,
connection, container and control panel for the automatic control of normal service,
backwash and regeneration. The final recommended water quality and dosage shall be
analysed and proposed by the specialist chemical firm from whom a report on the
effectiveness of treatment shall be provided.
4.3 TEST KIT

Test kit shall be provided to check water quality which include pH, total dissolved
solids, total alkalinity and total hardness.
10 ACCESSORIES
4.1 Pressure gauges shall be:-

10.1.1 Provided with approved snubbers and shut off valves,
10.1.2 With 102 mm dial face in ranges suitable for the pressure services encountered, with
black steel case and convex non-breakable dial face,
10.1.3 Provided for inlet and outlets of pumps, boiler outlet, inlet and outlet of pressure
reducing station.
4.2 Temperature gauge shall be:-

10.2.1 Liquid in metal type,
10.2.2 With 102 mm dial face in ranges suitable for the pressure services encountered, with
black steel case and convex non-breakable dial face,
10.2.3 Provided for condensate return tanks, boiler in/out, steam header, and boiler flue
connection.
4.3 Thermometers shall be:-

10.3.1 Industrial heavy duty type,
Page 787
10.3.2 Installed in stainless steel immersion wells of approved manufacture and filled with an
approved heat transfer medium and shall be installed in such a manner as to sense the
average medium temperature.
11 BOILER EFFICIENCY ANALYSER (Optional Work)

Boiler efficiency Analyser package shall accept field inputs from flue gas oxygen
analyzer, stack temperature, steam flow meter, steam temperature, feed water
temperature, blow-down monitoring system and will automatically maintain the
optimum TDS. The centralized system shall accept all field parameters and
automatically compute individual losses, boiler efficiency and steam to fuel ratio. The
central computation unit shall interface with proprietary software and / or BMS on
site to indicate all parameters on user friendly screens & shall generate automatic
reports every shift indicating average boiler efficiency, total steam consumption and
product to steam ratio, steam to fuel ratio in addition to trends and alarm summary
and status reports.
Components of Boiler Efficiency Analyser

A. Flue gas oxygen analyser
B. Vortex steam flow meter
C. Automatic blowdown control system Computation unit
D. Temperature Transmitters Stack temperature, Feedwater temperature, steam
temperature & Ambient transmitter
E. Computation unit
F. Data Acquisition & Diagnostic software package
Page 788
A. Flue gas oxygen analyser

Measuring Element 300 mm Zirconia Oxide Probe, Diffusion
Type
Analyser Electronic , Detachable From Sensor
Housing Sheet Metal
Protection Weather Proof, IP 65
Output 4 –20 mA. Dc
Local Display Back Lit Alphanumeric Display
Alarm Output System Fault Alarm 230 V Ac ,1A
Accuracy Of Measurement +/-0.01 % O2
Accuracy of display +/- 0.1 % of excess O2
Response time 0.5 sec
Process connection DN 65 ,PN 6 standard( Others on

request)
Electrical conduit Quick disconnect plug
Power supply 230 V ac, 50 Hz
Material of construction(Wetted parts) SS 316 Ti
Probe Housing Cast Aluminum, powder coated
Power consumption 100 –200 VA
Calibration Through key pad using calibration gas
Analyser Wall mounted housing with 6 m cable &

plug provided
Mounting Accessory Mating flange in our scope of supply
B. Vortex steam flow meter

Size 4“
Page 789
Body (Wetted parts) SS 316 L
End connection Sandwich
Range ability 20 : 1
Accuracy +/- 1 % of measured value
Repeatability +/- 0.5 % of measured value
Temperature compensation Provided for mass flow computation
O ring Metal sealing
Measuring range 1817 to 24941 kg/hr
Ingress protection IP 65
C. Automatic blow down control system

Make Spirax MARSHALL
Isolating valves 15 NB upstream & downstream
Control Valve 15 NB with electro –pneumatic actuator
Non return valve Wafer check type
Sensor range 0 to 9990 ppm
Material of construction SS 316 tip ,PEEK insulation
Max pressure & Temp 32 Bar g ,239 deg C
Upstream –downstream piping IBR Approved
D. Temperature Transmitters Stack temperature, Feedwater temperature, steam

temperature & Ambient transmitter
Sensor PT-100 , 2 wire
Range 0 to 400 deg C
Process connection ½ “ B.S.P (T)
Probe length 15 cm
Page 790
Output 4 to 20 milliamp
Supply 24 V dc
Housing Cast Aluminum
E. Computation unit
Controller Moore 353 E based
Supply 230 V/110 V ac,50Hz
Input Analog/Digital/ Frequency
Output Analog/Digital/Relay contacts
Version Dual microprocessor based
Display 3 ½ digit LED with Bar graph indication
Adjustment Digital pulsar knob
Update time Less than 100 milli second
Software Proprietary
Expandability Modular configuration
Communication protocol Modbus, RS 485 / RS 232
Dimensions 390 mm (W) X 177 mm (H) X 186 mm

(H)
Mounting Wall mounted
F. Data Acquisition & Diagnostic software package

 General mimic screen displaying complete boiler equipment with instantaneous
parameter value
 Parameter screen displays graphical trends for measured parameters , losses &
efficiency calculations
Page 791
 Alarm & diagnostic screen displays all deviations from desired results with diagnostic
tips to resolve the same
 Data log screen indicates all important parameters & trends suitable for hard copy
reports on shift/daily basis.
 PC can be located away from the computation unit in central control room or utility
managers cabin as per user convenience.
Following are the PC specification to run the software :-
CPU: Pentium 133 M Hz or higher
RAM capacity: 32 M byte or higher
Hard disk capacity: 100 M bytes free
Monitor: SVGA color
Communication port: RS 232 serial port
Operating system: Windows 98/Windows XP or higher version
Accessories: Mouse & suitable printer
Page 792
4. CHIMNEY - STEEL LINING TYPE
The Flues and Chimney shall be constructed as per BS 5854: 1980. However, all other
codes and standards shall also be followed for specific materials as per below:
5.9 Plates and sections :-

5.1.3 Steel plates used in the construction of chimneys shall comply with the requirements for
grade 43A of B.S. 4360:1972. of 6 mm thick minimum.
5.1.4 Supporting steelwork and ancillary fittings shall comply with the requirements of B.S. 4
or B.S. 4848 for dimensions and with not less than grade 43A or 50B in B.S. 4360: 1972
for quality.
5.10 Bolts and nuts :-

5.10.1 Mild steel. All mild steel bolts and nuts shall have a tensile strength of not less than
400 N/mm2 and a minimum elongation of 17%, as defined in B.S. 4190:1967 and B.S.
4395: Part 1: 1969.
5.10.2 High tensile steel : structural quality. The material used for the manufacturer of high
tensile steel bolts, nuts and washers, for which permissible stresses are given in B.S.
449, shall have a minimum tensile strength of 580 N/mm2 and other mechanical
properties appropriate to grade 50B of B.S. 4360: 1972.
5.10.3 Friction grip bolts. Friction grip bolts, nuts and washers shall comply with the
requirements of B.S. 4395 :Part 1, and shall be used in accordance with the
requirements of B.S. 4604: Part 1.
1.2.4 The use of structural steel for the shell and other components of steel chimneys shall be
in accordance with the requirements of the relevant clauses of B.S. 449 and B.S. 4076 :
1978.
1.2.5 The minimum thickness of the load-bearing chimney shell, in single or multiple shell
constructions, shall be the calculated thickness obtained from stress and deflection
considerations plus the corrosion allowance, but shall not be less than 6.0 mm of the
outside diameter of the chimney at the same height.
5.11 Angle flanges. The minimum thickness of jointing angles to chimney flanges shall be
6.0 mm.
Page 793
5.3.5 Where large apertures are cut in the shell plates, as for inlets or inspection panels, a
structural analysis of the stresses shall be made and compensation material provided, as
required, to ensure that the stresses specified in the standard are not exceeded.
Apertures in the shell plates, other than flue inlets, shall have the corners radius to a
minimum of 10 t, where t is the thickness of the plate.
5.3.6 The base plate and holding-down bolts shall be adequate to take the loads, bending
moments and reactions between the shell and the supporting structure or foundations,
the position of holding-down bolts and base gussets or stools being taken into account.
Holding-down bolts shall be adequately tightened, with appropriate precautions to
prevent the stripping of threads, and the baseplate shall be properly grouted.
5.3.7 Where base gussets or stools are used, they should preferably be evenly disposed round
the chimney shell. Smaller secondary gussets may be provided between the main
gussets. Base gussets shall be of ample height and shall extend to the edge of the
baseplate. The angle of the sloping edge of any gusset to the horizontal shall be not less
than 60o. The minimum thickness of the gusset shall be 6.0 mm.
5.3.8 All flange bolts in the structural shell shall be positioned not more than five diameters
between centres, with a maximum of 150 mm. Account shall be taken in the design of
the bolts for the eccentricity due to the bolt positions.
5.12 Where the chimney is mounted against building structure, adequate allowance for
expansion and guide brackets shall be provided.
5.13 Expansion joints in chimney shall be provided to compensate for lateral and vertical
expansion contraction.
5.14 Chimney shall be provided with lighting arrestor
5.15 Chimney shall be provided with a suitable cowl on top.
5.16 Welding joints of chimney shall be carried out in accordance with the requirements of
B.S. 5135:-
1.8.1 Procedure approval test. Before the Sub Contractor is permitted to weld chimneys in
accordance with the requirements of the British Standard, he shall adequately and
successfully test his several procedures, and complete records of such tests shall be
available for the Project Manager/Engineer in charge or his representative as specified
in B.S. 4870: Part1.
5.8.9 The Sub Contractor shall be exempt from making procedure tests in accordance with
the requirements of this clause when he can show that, for the previous three years, he
has successfully undertaken the welding of steel chimneys to a quality equivalent to that
required by B.S. 4870: Part 1 in the procedures from which he seeks exemption.
Page 794
5.8.10 Welder approval tests. Welders employed in the manufacture and erection of steel
chimneys made in accordance with the requirements shall have been tested using an
approved procedure. Complete records of such tests shall be available for inspection by
the Project Manager or his representative as specified in B.S. 4871 : Part 1. The welder
who completes satisfactorily the procedure approval test is thereby exempt from
further welder approval tests involving the same range of procedures.
5.8.11 An adequate and properly-supported working platform shall be provided to enable the
welder to stand and move comfortably in the position he normally adopts at ground
level to carry out the welding.
5.8.12 The welding area and working platform shall be protected adequately from the weather.
5.8.13 Surfaces to be welded shall be free from moisture. Precautions shall be taken to prevent
the descent of moisture (i.e. rain and condensation) on to the welding area from the
structure above the point of welding.
5.8.14 Parts being connected by welding shall be attached firmly to each other by bolting,
clamping or other mechanical means until welding is complete in the area.
5.8.15 All electric welding on site shall be carried out with the minimum practical length of
welding cable between the power source and the working area. The supply of welding
current in respect of voltage and amperage shall be adequate for the welding procedure
being employed.
5.8.16 Protective treatment to boiler flue :-
c) Immediately before applying any protective treatment to the exterior surface of the
chimney shell, the surface shall be cleaned by chipping, scraping and wire brushing,
or by other means, to remove all dirt, loose scale, grease, rust or other deleterious
materials.
d) Immediately after the surface preparation has been completed, the exterior surface
shall be given a coat of suitable priming paint followed by one coat of a special high
temperature resistant paint applied in accordance with the recommendations of the
manufacturers of the particular paints.
1.9 The horizontal flue shall connect to the vertical chimney section at an angle of 15o to 30o
to horizontal, with expansion joint immediately at the entry section of the vertical
chimney. The complete chimney section shall be properly graded to allow free draining
of condensate after boiler shut down.
1.10 Provided with the following accessories :-
1.10.1 A removable flanged tundish piece with drain tap at bottom of vertical chimney;
1.10.2 Hinged access door adjacent to drain;
1.10.3 Connection for temperature and pressure sensors and tap off for smoke sensor.
1.11 The flexible connector shall be:-

Page 795
1.11.1 Asbestos free construction suitable for the operating temperature.
1.11.2 Constructed of stainless steel reinforced fabrics combined with mineral and ceramic
wools with flange connection.
The chimney manufacturer / contractor shall provide detailed calculations to

demonstrate that the chimney / draught stabilisation system is compatible with
the selected boilers and complies with local and international code and
insurance requirements.
Page 796
5001.5. LIST OF APPROVED MAKES FOR PIPING WORKS & ACCESSORIES FOR STEAM
BOILER
1. IBR Approved Sch. 40 pipes Tata Steel / Indian Seamless /

Maharashtra Seamless
2. M.S./ GI Pipes Class ‘C’ Tata Steel / Jindal Hissar / Jindal Star
3. M. S. Fitting NV Forge / MS Fitting / True Forge /

Jainsons
4. Pressure Reducing Valve Thermax / Spirax Marshall
5. GI pipes fittings Unik / Zoloto M
6. SS Pipes Remi / Viega / V.S. Metal
7. Pipe clamp & supports Chilly / Euroclamp
8. IBR Flanges IBR Approved Class 150# / 300#
9. Non IBR flanges ASA – 150#
10. Steam Pressure Reducing Station / Thermax / Forbes Marshall

Valve
11. Steam Control / Globe Valve Forbes Marshall / Zoloto / Leader / Sant
12. Steam Trap Module Thermax / Spirax Marshall / / Unison
13. Moisture Separator Thermax / JN Marshal / Spirax
14. Temperature Sensor Danfoss / Forbes Marshall
15. Pressure Control Switches Thermax / Danfoss / Switzer
16. Steam Safety Valves Thermax / / Spirax / Fisher
17. Vacuum Breaker Valve Thermax / Spirax
18. Steam Strainers Thermax / Spirax
19. Pressure Reducing Valve (Water) Honeywell / Fouress / / Marck / Suzhik
20. Check Valve – WaferType Advance / Danfoss / Jayhiwa / Sant /
Page 797
Kirloskar
21. Check Valve – Dual Plate Advance / Sant / Marck / CAIR
22. Solenoid Valve Danfoss / Aira / Avcon
23. Thermostatic valve Danfoss/ Oventrop
24. Plug Valve Audco / Sant
25. Air Release Valve Sant / Arco / Fouress
26. Ball Float Valve Sant / Esseti / Prayag
27. Y Strainer (Water) Emerald / Sant / Kirloskar
28. Pot Strainer Marck / CAIR
29. Mechanical Seal Burgmann / Sealol
30. Anti Vibration Mounting & Flexible Cori / Dunlop / Easyflex / Flexionics /
Connections Resistoflex
31. Pressure Gauge Waree/ H Guru / Emerald
32. Water Meter (Mechanical Type) Actaris / Capstan / Kaycee / Kranti
33. Electronic Flow Meter Steam Krohne (Forbes Marshall) / Rockwin /

Thermax
34. Level Controller & Indicator (Water) Auto Pump / Cirrus Engineering / Technika
Techtrol
35. Paints Asian Paints / Berger / ICI / Shalimar

Paints
36. Water Treatment Plant Ion Exchange (Coron) /Thermax
37. Water Treatment Vessel Pentair / Aventura / Structural
38. Dosing Pumps Heidelberg Prominent Fluid Controls
Grundfos / LMI / Pulser Feeder / Toschon
39. Insulation for Steam Pipes Lloyd Insulation / UP Twiga
Page 798
40. Insulation for Hot Water Pipes Thermaflex / Armacell - Armaflex
41. Insulation for Chimney Lloyd Insulation / UP Twiga
42. Steam Hose Padmani / Shanti Industires
43. Three Way Motorized Valve Danfoss / Honeywell / Johnson Control/

Siemens
44. Centrifugal (ID) Fan Kruger/Nicotra/ CMB-Nadi
45. Motorized Damper Air Master / Caryair / Cosmos / Dynacraft
Geroge Rao / Ravistar
46. Boiler Scrubber Enhanced Wapp System / Hydrotech

Paryavaran / Mark Engineers / Saitherm
47. Welding Rods Advani Orlekon / Esab / Cosmos / Super

Bond (S)
48. Fastner Hilti / Fisher
49. Fire Sealant Hilti / Birla 3 M / Promat / BTMH

Engineering
Page 799
DEISEL GENERATOR
Page 800
INDEX
1. GENERAL CONDIOTION……………………………………………………………………… 4
1.1 Project Particulars

1.2 Scope of Work & Exclusion
1.3Site Facilities
1.4 Safety Precaution
2. TECHNICAL SPECIFICATION……………………………………………………………….. 12
2.1 Diesel Engine & Accessories

2.1.1 Fuel Oil system
2.1.2 Lubricating Oil system
2.1.3 Jacket Water System
2.1.4 Air Intake and Exhaust System
2.1.5 Cooling system
2.1.6 Governing System
2.2 Generator
2.2.1 Alternator
2.2.2 Engine Mounted Control Panel
2.2.3 Batteries
2.2.4 MCC for DG Auxiliaries
2.3 Acoustic Enclosure
2.4 Exhaust System

2.5 HSD Fuel Piping and Associated Works
2.5.1 Pumps
2.5.2 Piping
2.6 Ventilation and Acoustic Treatment

2.6.1 Room Wall and Ceiling Insulation
2.6.2 Sheet Metal Works
2.6.3 Rectangular Ducting
2.6.4 Insulation Work
2.6.5 Sound Attenuator
2.6.6 Tube Axial Fan
3. INSTALLATION………………………………………………………………………………… 29
3.1 Unloading
Page 801
3.2 Diesel Generator Set

3.3 Fuel Piping
3.4 Fuel Handling System
3.5 Exhaust Piping
3.6 Electrical Installation
3.6.1 Cabling and Cable Trays
3.6.2 Busduct
3.7 Earthing
4. TESTING & COMMISSIONING…………………………………………………...................... 36
4.1 At Manufacture’s Work

4.2 Performance at Shop
4.3 Performance at Site
4.4 Testing at ‘OEA's or OEM’s Works
4.5 Site Testing
5. APPROVALS AND NOC……………………………………………………………………… 39
6. DOCUMENTATION…………………………………………………………………………… 39
7. TAKING OVER………………………………………………………………………………… 40
8. WARRANTEE………………………………………………………………………………….. 40
8.1 DG set
9. MAINTENANCE……………………………………………………………………………… 41
10. SPECIAL TOOLS AND TACKLES…………………………………………………………. 41
11. SITE REPRESENTATIVE…………………………………………………………………… 41
12. TRAINING OF CLIENT’s / MAIN CONTRACTOR’S PERSONNEL…………………… 41
13. PREFERRED MAKES………………………………………………………………………… 41
Page 802
GENERAL CONDITION
1.1 PROJECT PARTICULRAS
Project Name: New Factory

Location:
Construction Schedule: Yet to receive from Client
Question acceptance deadline- / /2013
Answer for Questions- / /2013
Dead Line for Date of submission- / /2013, Before-5Pm
Please find few points which need to be considered while estimation:
1. Specification and standard to be followed as per BOQ and Spec Attached.

2. BOQ items to be followed and rates to be provided for all the line items without
changing the BOQ format.
3. Any condition or assumption shall be mentioned or highlighted.
Page 803
4. All tax detail and break up for each item to be shown in BOQ.
1.2 SCOPE OF WORK & EXCLUSIONS
The scope of work shall include but not to be limited to the supply, installation, testing
and commissioning of the following items. The supplier shall study the requirements
stipulated carefully and offer a complete system with guaranteed performance under the
severest operating conditions specified.
This specification covers the requirements of design, manufacture, testing, supply,

delivery, installation, testing and commissioning of ___nos. x ______kVA, high speed,
415V, 3Phase, 4 Wire, 50Hz AT 0.8 PF, Indoor, Prime Rated, Radiator Water cooled
Diesel Generators with Acoustics.
The items covered under this specification are listed in the BOQ and indicated in
theSingle Line diagram if there is any discrepancy found between the BOQ and the SLD,
the contractor shall seek for the clarifications from the main contractor.
a) ____Nos. _________kVA, 415 Volts, 3 phase, Water Cooled radiator type AMF DG sets
b) Fuel day tanks and over flow tank, flow meter, Fuel piping and associated accessories.
c) Exhaust piping & thermal insulation with 48kg/Cu M density mineral wool cladding with
aluminium sheet.
d) DG CP, MCC’s, power, control, signal cabling and earthing between the DG and the
associated Electrical equipment.
e) Miscellaneous items including local safety accessories, installation materials etc.
f) Obtaining NOC from statutory bodies, Pollution Control Board and Electrical Inspectorate
and any other agencies require approval for installing and operation of the DG sets.
a) Obtaining drawings and installation approval of the Nos. x kVA, DG set installation
from CEIG.
h) Preparation of related electrical and any other schematic and GA drawings covering DG
set
Installation, control panel, exhaust / fuel piping, acoustic treatment, ventilation system.
cable laying and earthing.
i) Supply of coolant, Diesel DM water & lube oil for first filling and Testing of the system.
j) Co-ordination with other agencies to ensure timely completion.
k) Arranging temporary power connection for construction purposes.

Page 804
l) Housekeeping during the installation work and removal of debris & unwanted materials on
day to day basis and clearing the site on completion.
m) Exhaust piping including structural supports & thermal insulation to the height
required.
n) Obtaining Diesel Engine manufacturer's approval of the installation with specific

emphasis on alignment, exhaust piping and ventilation before commissioning.
o) Supply of coolant, Diesel, DM water & lube oil for first filling and Testing of the system for
24hrs.
p) A combined electrical control panel with AMF start auto synchronizing and auto load
sharing provision and necessary metering as per statutory requirements.
q) Testing of the installation at Manufacturer’s works and at site.
r) Any related work covering supply of installation materials, consumables, battery

charging, etc whether specified or not, to render the system fully functional and
conforming to the best engineering standards.
s) Major Civil works associated with the foundation and building. However minor civil
works shall be included.
t) PLC controlled electronic control panel with distribution switchgear and MCC for D.G
Aux. Fans.
u) Ventilation and Acoustic treatment for the DG Room.
v) Electrical installation work including supply of cables, earthing, cable trays etc related to
DG works.
w) Installation of all the above systems including electrical cabling and earthing and minor
Builder’s works.
x) Testing of the installation and commissioning.
y) Any related work covering supply of installation materials, consumables etc whether
specified or not, to render the system fully functional and conforming to the best
engineering standards.
z) Supply of all consumables for testing at site.
EXCLUSIONS
Page 805
Following works shall be carried out by other agencies.
a) Preparation of foundations for DG sets and slab cutouts for exhaust pipe.
b) Civil works associated with DG Foundations etc, However minor civil works such as wall
chipping, finishing and allied works related to earthing pits shall be included if
applicable.
1.3 SITE FACILITIES
The main contractor will make available open space in the site to store his materials. The
vendor shall put up his own site office cum stores in the same location (if required).
The sub-contractor shall ensure that all Safety norms are strictly adhered to throughout
the installation period. The following points should be specifically noted and complied
with.
The construction power installation shall be protected by RCCBs at the source as per
statutory regulations.
All electrically operated hand tools shall be of the double insulated type.
All workmen should be provided with tools having insulated handles.
All workmen operating at heights of more than 3M above floor level shall use safety
belts.
Properly designed ladders or scaffolding shall be used while working at heights. All
workmen shall be provided with rubber shoes.
Safety gloves shall be used while operating energized HT equipment.
The welding sets to be used shall have proper terminal box for cable termination and
earthing.
SAFETY RULES AND REGULATIONS:
The following safety rules have been adopted for the protection of the employees
working for the project.
Page 806
 Report all injuries to the first aid office immediately, no matter how trivial they may
seem to be.
 Wear goggles when grinding, welding, cutting or chipping steel or concrete; working in
dusty places or on acid lines, or any other job where eye protection is known to be a
necessity.
 Safety guards removed for repairs or adjustment must be replaced before machine is
started.
 Do not use unsafe tools or ladders. Report on the condition to your foreman or safety
department.
 Do not remove lights or make any kind of electrical repairs unless you are an electrician
working under your foreman’s order.
 Horseplay and playing on the job will not be tolerated.
 Shut down all machinery before cleaning moving parts. Do not wear gloves or loose
clothing while working around moving parts of machinery.
 When you see a warning or danger sign, be sure you are safe before you go ahead. Failure
to do so is to invite injury deliberately.
 Do not go up or down a ladder without the free use of both hands. If material has to be
handled, use a rope to lift it, leaving the hands free.
 Fire-fighting equipment should be used for fire-fighting purposes only, never place
obstructions within 15 ft. or fire plugs or hose houses.
 Before starting work on machinery or equipment, post signs to prevent anyone else’s
starting the equipment while you are working on it.
 Dust and light fume respirators are obtainable at the safety department for use of
workmen working in pot ramming operations.
SAFETY LITERATURE - BULLETINS:
Safety instructions as to safe practices on Mixing & Ramming Machine should be

explained to operators. These should be read thoroughly and filed away in the safety
binder for ready reference.
Page 807
The safe practice rules appearing hereunder shall individually be placed before members
of the committee in session for approval. Upon vote of the majority, the rules may be
amended at any time.
Acceptance of safe practice rules shall be recorded in the Minutes of the meeting. The
number of safe practice rules shall be increased to include every hazard possible. Such
rules as accepted shall be distributed to each member of committee and others to be
read.
Safety rules index
Tools and Equipment
Danger Signs
Reporting Accidents
Safety Code Binder
Safety Helmets
Electrical Safety Codes.
House Keeping Standards.
Cleaning Schedule.
Site Office Cleaning Schedule.
Electric Shock.
Barricades
Scaffolds
Hand Tools
Motor Trucks
Drinking Water
Handling Material
Page 808
TOOLS & EQUIPMENT
Lead site engineer (sub-contractor) is responsible for all endeavors to prevent accidents.
It is the duty of lead site engineer to ensure that tools, equipment and materials used are
in good condition.
DANGER SIGNS
Danger signs will be posted in following conditions:
o Open Trenches
o Men at work overhead
o Special warning for dangerous typical situation.
In typical situation where signs prove insufficient, lead site engineer will station a
watchman to ensure proper protection.
REPORTING ACCIDENTS
Any accident, however trivial, shall be reported to lead site manager. Workmen injured
shall report to the first aid station for treatment.
SAFETY CODE BINDER
The site engineer will keep the safety code binder up to date by filing all bulletins, letters,
minutes of safety meetings.
SAFETY HELMETS
Each workman shall be provided with safety helmet. Individual agency shall have
helmets of different colour for easy identification.
ELECTRICAL SAFETY CODE:
Only certified electricians shall make electrical connections, soldering and taping of coils
and cables shall meet with the requirements of National Building Code.
Wherever possible, all wires shall be placed in conduit and the current-carrying parts of
utilization equipment shall be completely enclosed.
Page 809
Wires not in conduit shall be placed at least 8” above the ordinary working level of
platforms readily accessible to workmen other than qualified electrician.
Where electrical equipment cannot be isolated by being placed in special rooms, it

should, wherever practicable, be provided with suitable enclosure, cabinets so as to
prevent persons or objects from coming into direct contact with live electrical parts.
Do not depend on insulation to protect you from injury from electrical shock. Insulation
goes bad with age, chemical fumes, acid, etc. Consider every wire a bare wire.
Tapping live wires is dangerous. Never do it without the express permission of your
foreman. Remove insulation from only one line at a time, and do not expose the second
wire until the first is soldered and taped.
Never over fuse a circuit under any circumstances. This rule must be rigidly adhered to.
Before working on any circuit sees that the switches are in off position and wherever
working facility is provided, the same is locked.
Use of tools with metallic handles in the electrical department is forbidden.
Do not take hot solder in buildings without first obtaining permission from the shift
foreman or operators in charge.
Do not connect extension cords unless they have vapor-proof globes.
Do not connect extension cords to inside lights, always connect them to outside lights or
lighting panels.
Extension cords for temporary lights and motors should be supported from steel or
pipes. Do not let them lie on the ground to be cut by something
MEDICAL SERVICE – FIRST AID & CASUALITY TREATMENT
BASIC FIRST AID RULES
Do not move an injured person unless absolutely necessary to prevent further injury.
Act fast if the victim is bleeding severely, appears to have stopped breathing, or has
swallowed poison.
Keep the person lying down, if he has vomited – and you are sure his neck is not broken –
turn body and head to one side. Keep him warm.
Get medical help as early as possible.
Page 810
Examine the person gently. Loosen or cut away clothing to lessen pain – but do not pull
clothing from burns.
Reassure the person, and stay calm yourself.
Always expect and be ready to treat shock.
Do not give fluids or alcohol and do not try to rouse an unconscious person before
getting medical advice.
SERIOUS EMERGENCIES
BLEEDING
Stop bleeding by pressing a pad over the wound. If this is ineffective, press on nearest
pressure point – just below armpit for the arm, below groin for leg. Or apply a
tourniquet, loosen it for one minute in every ten.
BREATHING STOPPAGE
Mouth-to-mouth artificial respiration is easiest and best. First, with the victim on his
back, tilt his head back so the chin points upward. Make sure nothing is blocking air
passage. With your fingers, pull person’s tongue forward, if necessary, and remove any
loose objects from mouth. Then place your mouth over the victim’s mouth and pinch his
nostrils shut. (With a small child, you may need to pinch the nostrils shut if you can cover
both his nose and mouth with your own mouth.) Blow 12 times a minute for an adult –
20 for a child – letting the air return each time.
The heart may be re-started by closed-chest heart massage. Press firmly and relax 60
times a minute on the lower part of the chest. Place hands one on top of the other, and
with heel of bottom hand, press downward about two inches at bottom of breastbone.
Page 811
Emergency Telephone Numbers
Doctor
Alternative Doctor
Hospital
Police
Fire Department
Poison Control
Friend or relative
Other important numbers
SHOCK
Shock may follow any serious, sudden injury. Danger signals are clammy skin, rapid
breathing and rapid pulse. Keep person quiet and warm with feet higher than head –
except in head injury. Effects of shock can be lessened by stopping bleeding, relieving
pain and talking reassuringly to victim.
ELECTRIC SHOCK
Immediately break the body contact with the electric current. Use dry board to remove
the wire, or hook an article of your clothing around the person to pull him away from it.
Be sure that you are standing on a dry surface. If you can’t feel the person’s pulse, mouth-
to-mouth resuscitation in combination with Cardio-Pulmonary Resuscitation (CPR)
should be used.
BARRICADES
Page 812
Substantial railings shall be erected around all floor openings. All floor opening shall be
protected by toe-boards.
SCAFFOLDS
The inspection committee shall make it a point to inspect all scaffolds in use and report
any defect to the lead site engineer and also report at the next meeting of the safety
committee.
Safety checklist: Scaffold
Survey the condition under which scaffolding will be erected.
Prepare scaffolding design under direction of engineer.
Check scaffolding height, height should be sufficient.
As scaffolding goes up, check braces.
Safety factor must be 4 to 1.
Scaffold should be anchored every 30’ of length and 25’ of height.
Working platform should be properly hand-railed.
Check elements for soundness.
Check tower for plumb.
Check plank for permissible span.
Cross-bracing must be installed across the width of scaffold at least every third set of
posts horizontally and every fourth runner vertically.
HAND TOOLS
The site engineer will ensure that all tools are in good operating condition. Tool man in
each workstation will be held responsible for the inspection and care of all tools. He will
also ensure that no defective tools are given out.
Safety checklist: hand tools
Do not use defective tools
Do not keep defective tools on the job.
Do not use the tools with mushroom heads.
Page 813
Reprimand the workman who is continually dropping tools
Do not let small tools lie around the work area. So anyone can fall over them or so they
will fall on men below.
Do not use tools with split ends or loose handles. Handles of all tools should be of the
best straight grained materials and should be fitted to the tool by experienced men.
Ensure that the faces of hammers are in good condition.
MOTOR TRUCKS
Workmen shall ride inside, not on running boards, fenders, or edges or trucks.
Responsibility for the condition of the truck rests upon the operator.
DRINKING WATER
All workmen shall ensure that the drinking water fountain is kept in clean and sanitary
conditions.
HANDLING MATERIAL
Material of all kinds must be piled or stored in an orderly manner and secured so as not
to fall over. Material must be guarded so it will not be knocked down by teams of trucks.
Ensure that material place in main roads is well guarded and place red lights at night.
Supervisor mixing room will be individually responsible for piling and removing of
material.
DG SPECIFICATION
2.1 DIESEL ENGINE & ACCESSORIES
ENGINE
The Engine shall be complete in all respects but not limited to the following:
Diesel engine shall be complete with all the standard accessories. The diesel engine shall
be suitable for radiator type cooling system (Primary jacket cooling in closed circuit with
water and in turn same water cooled in radiator with air)
The diesel engines shall be of the direct injection, four stroke multi cylinder, water cooled
Page 814
through Radiator, turbo charged & after cooled type operating at a nominal speed of the
specified RPM and capable of developing requisite BHP to drive the specified Alternator
(Prime Rating).
The DG sets shall be capable of starting from cold condition on loss of normal A.C supply
and coming up to rated speed and Voltage within the minimum time as specified
elsewhere.
The diesel engine shall be capable of starting and operating for a few minutes without
supply of cooling water at the time of start-up.
The Diesel engine shall be equipped with suitable battery operated starting system
consisting of a starting motor, Batteries, charging generator, regulator and starting
device. The system shall be sized to provide three successive starts without the
availability of electric power.
The Diesel Engine shall consist of a single engine directly coupled to the generator, all
mounted on the same rigid base. The radiators shall be locally located near the engine.
The radiator fans shall be powered directly by the engine. The Diesel engine intake and
exhaust systems shall have silencers. The rpm of the DG set shall not exceed the specified
speed.
The DG set shall be capable of simultaneous starting of connected motors with the
voltage dip not exceeding 20% and frequency drop not exceeding 10% during its starting
period.
The DG set shall be capable of safe, proper and continuous operation at all loads.
Vibration, noise, mechanical and thermal stress shall be properly taken care of in the
design of the equipment.
The continuous engine break horse power (BHP) rating at the site condition shall be at
least 15% greater than the maximum shaft horse power requirement of the generator at
the rated KVA at the specified power factor.
The DG sets shall be suitable for operation with High Speed Diesel oil. All statutory
regulation for firing and storing of high speed diesel oil shall be observed in preparing
and locating the diesel generator sets and necessary approvals / clearance from the
statutory authority regarding the above shall be arranged by the contractor.
The primary cooling of Engine shall be by coolant. The coolant & the Lube oil shall be
circulated through the Radiator by Engine driven pump.
The engine and the governing system shall conform to class-A1 governing as per BS 5514
and shall be suitable for continuous and AMF duty power generating application. The
unit shall be suitable for operation on High Speed Diesel Oil.
The engine start up shall be with battery assisted manual/auto starting. The design shall
Page 815
ensure that the starter will be automatically released when the engine picks up speed
beyond 60% of the rated speed.
The governing system of the engine shall be suitable to control frequency variation
within +/-4% whenever a load up to 70% of its prime rating is switched in or thrown off.
The engine shall meet the current emission norms Engine control system having
provision to alter the emissions to meet more stringent norms that may be enforced in
future will be preferred.
Integral Base frame for the engine and alternator with lifting hooks & built in fuel tank of
500 liters capacity. The fuel tank shall be complete with fuel gauge, inlet & outlet
connections & inspection cover.
CPCB approved acoustic enclosure as per specification covered separately. The height of
the enclosure shall not exceed 2.5mtrs.
Residential grade silencer to limit the exhaust noise to 75dBA at 1M from the enclosure.
Spillage oil collection trays beneath the engine.
The Engine shall be having Electronic Governor and Suitable for AMF, Operating
with Auto and manual synchronizing, Load Sharing, load Balancing, Load
dependant starting/stopping etc. with EGCP/Easygen-3500 or Equivalent relays &
shall be Suitable for Manual Synchronization with Dark lamp Method.
The engine fitments shall include but not be limited to the following:-
i. Flexible coupling and flywheel with guard.
ii. Air inlet system with Dry type air filter with clogged condition indicator and turbo
charger.
iii. Fuel system complete with Fuel Pump, flexible hoses, primary and secondary fuel filters
with service indicator and manual priming pump.
iv. Electronic governor with control module.
v. Exhaust system with dry manifold and residential Grade silencer.
vi. Lube oil system with gear type oil pump, oil cooler, filter and crank case breather.
Page 816
vii. Cooling system with engine coolant, fan with guard and radiator.
viii. 24V D.C. Starter & battery charging alternator with auto cut off.
ix. Hydraulic governor/electronic governor. As an alternative to the conventional engine

governing system, a combined engine governing and alternator voltage regulator unit
may also be offered with all protective, auto synchronizing & auto load sharing
capabilities.
x. An engine cum alternator instrument panel (EGCP) complete with digital display, Engine
alternator protection, modbus compatibility and RS 485 output for remote Monitoring
& control through BMS.
The protections shall include the following:
 Low lube oil pressure alarm & trip.

 Over speed alarm & trip
 Coolant temperature high alarm & trip.
 Coolant level low alarm & trip.
 Magnetic pick up in operative trip.
The panel shall have record of the last 20 events in memory.
The EGCP shall in additional shall have provision to monitor following electrical
parameters.
 Voltage
 Current.
 Frequency.
The electrical protections shall include.
 Voltage restrained over current.

 Over load.
 Short circuit.
 High water temperature.
 Over voltage.
 Under voltage.
 Under frequency.
 Current limit feature on fault.
Page 817
xi. Electronic Instrument Panel comprising
a) Lube oil pressure indicator.

b) Tachometer for speed indication with hour meter
c) The battery charging ammeter and engine control switch with key.
d) Water temperature gauge.
e) Display of electrical parameters such as Amps, Volts, frequency.
f) Emergency stop button.
g) Low lube oil pressure switch and high water temperature thermostat with contacts
wired to terminals.
h) Over speed stop switch.
i) Low coolant level alarm.
j) Over crank protection.
k) RS-485 Communication port for extracting Engine Parameters through mod bus
communication.
xii. Wiring harness using temperature resistant insulation and flexible copper conductor
wires. The wiring should be clamped at regular intervals and terminated using lugs.
xiii. Stainless steel flexible for engine exhaust.

All moving parts of the engine and other associated equipment shall be provided with
guards to prevent accidental contact. The guard shall be designed to facilitate easy
removal and reinstallation.
xiv. The engine speed shall be regulated through an electronic governing system which shall
also provide the over speed protection. The governor shall ensure that the speed of the
set is regulated within 1% of the nominal speed under normal operating conditions.
xv. The DG set shall be capable of handling step (Block) loads up to 60% of the capacity
without dropping other loads due to voltage dips. Further the engine shall be capable
of taking full load within 60 seconds of starting.
xvi. All moving parts of the engine and other associated equipment shall be provided with
guards to prevent accidental contact. The guard shall be designed to facilitate easy
removal and reinstallation.
ENGINE ACCESSORIES.
The following accessories shall be supplied with the DG set.
a) Common base frame for the Engine and Alternator.
b) Anti-vibration mounts of GERB make in requisite quantity.
Page 818
c) Residential Grade silencers.
d) Protective guards for all rotating parts.
e) Day tanks of suitable/applicable capacity fabricated out of 4mm thick sheet steel.
The day tanks shall be complete with inlet breather, fuel filter, overflow pipe, drain
pipe, fuel level indicator, flame proof level control switches with contacts for very low,
low, high and very high level indication, valves & man hole with cover.
The tanks shall be painted with two coats of primer and a finishing coat of synthetic
enamel paint of gray color.
One Fuel flow meter with electronic output shall be supplied for measuring the fuel
delivered to each day tank.
f) 18 SWG galvanized sheet steel trays beneath the engine, day tank and over flow
collection tank to collect the oil leakage.
g) A common tank of suitable/applicable capacity with level switch and other fitments as
above shall be supplied to collect the fuel over flow from the day tank.
h) Batteries and Accessories
i) Oil Leakage Collection Trays of GI
Auxiliary Equipments
The following equipments shall be supplied

Flywheel with Guard
Fuel Piping
RPM Indicator
Lubricating oil cooler (if applicable)
Exhaust silencer & Piping.
Fuel & lubricating oil filters, air filters.
Temperature gauge for water.
Pressure gauge for lubricating oil.
Hand barring gear
Common base frame for the engine & alternator
Foundation bolts and base channels.
Starting and protective equipments.
Lifting arrangements.
Radiator
Any other equipments necessary for proper operation, Maintenance and operating
personnel safety.
2.1.1 Fuel Oil system
Diesel Fuel oil system shall be complete in all respects but not limited to the following:
Page 819
Individual diesel oil day storage tank (Day tank) for the engine of suitable/applicable
capacity with a mechanical oil level indicator, a low oil level switch, a very low oil level
switch and high level switch with contact output for alarm / annunciation.
Engine driven diesel oil booster pump, injectors etc for the engine.
Secondary Containment Diesel storage tank shall be provided.
Oil containment tank below the tanks shall be provided.
Thermostatically controlled electric heaters for diesel oil if ambient conditions warrant
the same.
Sufficient length of flexible hosepipe for the diesel oil transfer pump suction on order to
enable transfer of diesel oil from barrels to the day tank.
The fuel system shall be designed to remain primed with diesel oil at all times. If
required, an AC motor driven priming pump for intermittent operation with timer
operated on auto starting facility shall be provided.
Complete interconnecting piping between diesel oil transfer pump and day tank, and day
tank and engine along with all necessary valves, fittings, instrumentation and supports
shall be provided.
The system shall be complete with simplex type filters, hoses, piping fittings valves
supports. Control & instrumentation and all other accessories to complete the
installation work.
The fuel tank shall be painted with oil resistant paint.
All pipe joints shall be properly brazed / welded.
Galvanized sheet steel trays beneath the engine & day tank to be provided to collect
leakage oil.
2.1.2 Lubricating Oil system
Diesel Engine lube oil system shall be complete in all respects but not limited to the
following:
Engine driven gear type pump.
Water cooled lube oil cooler.
Thermostatically controlled electric heater for lube oil, if ambient conditions warrant the
same.
Page 820
A priming system with one auto AC priming pump and one DC priming pump shall be
provided for the DG sets.
Automatic pressure lubrication shall be provided by a shaft driven gear type pump
through an oil cooler and fin mesh filters to the bearings, drives, governor etc.
If lubricating oil pump is used for intermittent priming one hand driven and one electric
motor driven oil priming pump shall be provided for each DG set a suitable starter shall
be provided in control panel.
Lubricating fuel oil filters shall be provided for operation under normal conditions of a
more than 250 hours without necessity of its replacement or cleaning.
All necessary accessories like Pressure gauge, temperature and oil level indicators,
valves, pressure switches for alarm and control shall be furnished.
2.1.3 Jacket Water System
Diesel Engine Jacket water system shall be complete but not limited to the following:
Jacket suitable for closed cooling water system. The quality of the cooling water shall be
either service water or passivated DM water available in the plant with suitable make-up
arrangement.
Engine driven pump.
Thermostatically controlled jacket water pre heater to enable quick starting and loading
of the engine.
All necessary piping, valves, fittings, instrumentation and supports.
2.1.4 Air Intake and Exhaust System
The air intake and exhaust system shall be provided with:
Air intake silencer and filters.
Exhaust gas driven turbo charger
Charge air cooler
Exhaust gas silencers as specified.
Necessary air inlet and exhaust pipe, supports, thermal insulation for the entire exhaust
pipe for personnel safety, flexible / expansion joints to avoid transmission of vibrations
from the engine to the structures.
Page 821
2.1.5 Cooling system
The system shall be closed cycle and shall have radiator in front of the engine with a fan
driven mechanically from the engine shaft.
Forced water circulation shall be by means of pump driven by engine shaft.
The radiator tubes shall be of copper with sufficient heat transfer area.
2.1.6 Governing System
The governing system of engine shall be electronic type of class A1 type as per BS-5514.
The governor shall ensure that the speed of the set is regulated within 1% of nominal
speed under normal operating conditions.
It shall be suitable to control frequency variation within +/- 3% whenever a load of

200kW is switched in or thrown off.
The governor shall be suitable for operation without external power supply and shall
provide adequate speed control in the event of failure of electrical governor circuitry.
A mechanical over speed trip device shall be provided to automatically shut off fuel in
case of speed exceeds 110% of the rated value.
Critical speed of the machine shall not be lesser than 120% of normal speed.
2.2 GENERATOR
The generator and all necessary operating equipment shall be mounted on the same skid
as the diesel engine. The degree of protection of the generator shall be IP-23, generator
shall be directly coupled to the diesel engines and complete with brushless (rotating
diode type) excitation system, automatic voltage regulator (AVR) control and interlocking
systems, manual starting / tripping system, control panel and other accessories as
requirements as per this specifications.
The Generator shall be provided with an Auto – On – Mains Failure (AMF) panel, time
delayed No-Volt relay contact shall be provided to give an impulse for DG set to start. The
D G shall be capable of starting and developing rated voltage and speed automatically
without any manual intervention.
Alternator shall be provided with an integral speed indicator. Speed transducers shall be
Page 822
provided with output of 4 – 20mA for remote monitoring of speeds.
The DG set shall be capable of Three (3) start in quick succession. A hand reset lockout
relay shall be provided with suitably wired contacts such that it prevents starts in excess
of five (5) in quick succession. Stopping of DG for a normal shut down shall be done
manually by means of push button locally as well as from remote.
The line and neutral end of each phase winding of the generator shall be brought out on
six (6) suitably located terminals. Suitable clamping arrangement shall be provided for
connecting the cables to the machine terminals. The terminals shall be suitably enclosed
to prevent short circuits by rodents. Etc. suitable cable glands shall be provided on the
enclosure to facilitate entry of the cables.
240V single phase space anti-condensation heaters of adequate ratings shall be provided
in the lower part of stator frame. The kW rating of the space heaters shall be indicated.
The response ratio of the excitation system shall not be less than 1.50
The excitation system shall be so designed and / or protected, that harmful over – voltage
cannot occur at the main commutator due to combined effect of maximum exciter field
current and machine over – speed.
Each generator shall be sized for 24 Hours of operation according to the demands.
2.2.1 Alternator
The specified DG set/s has to be star connected, horizontal foot mounted, single bearing,
separately excited, brush-less, screen protected drip proof, continuous duty alternator
with Class "H" insulation in IP-23 enclosure incorporating the following.
a) Stator winding with 2/3 pitch.
b) Continuous damper winding fitted on each pole.
c) PMG Pilot exciter or separate excitation winding.
d) Thermisters for Hot spot detection with control unit for mounting in the control panel.
e) 3 phase sensing AVR incorporating engine load relief features and +/- 0.5% voltage
regulation and capable of operating at lagging P.F range of 0.1 to 1.0.
f) As an alternative to the independent Electronic Engine governor and alternator AVR, a

combined engine governing cum alternator voltage governor may also be offered with all
protective synchronizing and load sharing facility.
g) Quadrature droop kit with C.T for paralleling.
Page 823
h) Terminal box suitable to receive.
i) Separately mounted adopter box with bus bars & flexible uninyvin wiring between
Alternator terminals and adopter box drawn in PVC covered metallic flexible conduit.
The adopter box shall be suitable for terminating up to 7 / 8 runs of 3.5C
300/240/185 sq. mm PVC insulated, Aluminium conductor cables.
The Alternator shall further meet the following specification.
a) The alternator shall conform to IS 4722/BS 2613.
b) The alternator shall be suitable for 20% over speed for two minutes.
c) The alternator terminal voltage for any load variation should be maintained within +/-
2%.
d) The transient and steady state frequency variation should be limited to +/-4% for
sudden load variation up to 70%. The generator TVD for sudden load variation of 100%
shall not be more than 15%.
e) Both ends of each phase winding shall be brought to the terminal box.
f) The alternator shall be capable of carrying 50% overload for a duration of one minute.
g) The alternator shall withstand a 3 phase short circuit at the terminals for a period of 3
seconds.
h) The total harmonic distortion shall not exceed 3% and the design shall permit up to
30% unbalance between phases while in operation.
i) The efficiency shall not be less than 95% in the normal operating range of 50% to
100% loading.
The performance criteria shall be as follows:
The temperature rise while operating at rated load continuously shall not exceed the
limits specified for Class “H” insulation.
The alternator shall be capable of delivering the rated output at rated power factor as per
specific requirements.
General Requirements.
The alternator shall be capable of carrying 10% overloading for 1hour in any period of
12hours running.
Page 824
The terminal voltage for any variation should be maintained within +/- 5%
The prime mover response should be such that with 200kW load throw off/on for the
alternator both transient and steady state frequency variation should be within +/-3%.
The field coil terminal shall be wired to terminal box for external speed control. Both
ends of each phase winding shall be brought to terminal box.
The total harmonic distortion shall not exceed 3% and the design shall permit up to 3%
unbalance between phases while in operation.
Windings
The conductors shall be of high electrolytic grade of copper.
The alternator winding shall have class of insulation class-H with temperature rise
limited to class-B.
The winding shall be given power house treatment i.e two coats of varnish and final coat
of resin.
The total insulation shall be non hygroscopic.
Temperature Detectors
Six nos. of RTD shall be suitably located in stator winding where highest temperature
may be expected and one element in each bearing.
RTD shall be connected to thermistor relay in the panel which shall have contacts for
alarm and trip.
Excitation System
The excitation system shall be a brush less system with all accessories and shall be
capable of supplying the excitation current of the alternator under all conditions of
output from no load to full load and capable of maintaining voltage within +/-1% of the
set value.
The voltage setting range shall be -10% to + 10% of rated voltage. It shall be possible to
set from remote also.
The exciter shall have class-F insulation with temperature rise limited to class-B.
Automatic Voltage Regulators (AVR)
The voltage regulator shall be digital type supplied complete with cross current
Page 825
compensation. The regulator shall be supplied complete with voltage setting device, all
accessories and alarm contacts.
The AVR shall regulate the output voltage from alternator current / Voltage signals. The
regulation system shall be follow up the provided with equipment for automatic and
manual control. Necessary motorized potentiometer for manual control raise / lower
PB’s shall be provided.
When there is a failure of AVR the alternators excitation control is transferred

immediately to manual control without any change in excitation current.
Necessary equipment for field suppression and surge protection shall be provided.
The response time of exciter and the alternator shall be matched to avoid hunting.
Suitable measures shall be taken for field failure protection. The manufacturer should
specify the method adopted for the same with proper equipment specification and
schemes.
Terminal Box
The line and neutral leads of phase windings of the Alternators shall be brought to six
terminals in two separate cable boxes.
The terminal box shall be of adequate size to terminate cables as specified in specific
requirements. Terminal box shall be mounted on top of the alternator or side of the
alternator as per DG Manufacturers requirements.
For single phase cables gland plate shall be of non magnetic material.
Space Heater
It shall be located in lower part of alternator to maintain internal temperature above dew
point to prevent moisture condition when set is not running.
These heaters shall be switched ON automatically when set is running.
Supply shall be 240V single phase 50Hz.
Tripping Conditions
The DG shall be tripped under the following abnormal conditions:
 Over – speed of DG as sensed by over speed trip device
 Low lubricating oil pressure after the DG has attained 90% speed.
Page 826
 High jacket water temperature.
 Incomplete start after a preset time.
 DC control supply failure
 Excitation failure due to tripping of field breaker or failure to build up voltage.
 Engine trip due to generator fault.
All the above sensing devices shall be provided on the DG and accessory relays on the
control panel to achieve the above tripping conditions. These devices shall be suitable for
operation on ungrounded DC System.
Annunciators
Window type annunciators shall be supplied and mounted on each DG control panel to
give visual and audible indication for the following conditions. The annunciation list shall
be subject to approval of Purchaser.
High jacket water temperature.
High lubricating oil temperature.
Low lubricating oil pressure and trip of the engine.
Low and high fuel oil tank level.
Engine over speed and trip
Starting air pressure low, if applicable.
Failure to start
High differential pressure across lube oil filter.
Lubricating oil priming pump in operation
Voltage out of limit.
Excitation failure.
Generator fault.
Ground fault on the system.
Page 827
DC control supply failure.
Four spare windows.
The annunciation system shall be microprocessor based complete with facilities like
‘Acknowledge’ ‘Reset’ ‘ ‘Test’, ‘Audible Alarm’ etc.
2.2.2 Engine Mounted Control Panel
Microprocessor based control panel shall be mounted on engine to display the following
engine and electrical parameters.
 Lube oil pressure and Temperature indicator.
 Tachometer for speed indication with hour meter.
 Battery charging ammeter.
 Starting switch with key.
 Over speed stop switch with contacts.
 Low lube oil pressure switch.
 High water temperature alarm & Trip.
The panel shall be suitable for display the faults and keep a record of faults. an
emergency stop push button will be provided to stop the DG during emergency. For
engine faults the set will be stopped in emergency mode and for electrical faults it shall
be stopped with a time delay for cooling down.
Audible alarm shall be provided in the main panel to announce tripping of DG. The panel
shall have output port for BMS Connectivity.
2.2.3 Batteries
The batteries shall be of heavy duty, high performance, SMF of Exide / Equivalent make
for starting the engine.
Each battery shall be rated 12V. The number and AH capacity shall be selected to suit the
engine requirements.
Battery shall be suitable for six successive starting attempts each of 10 seconds duration
with a gap of 5 seconds between successive starts.
The battery shall be supplied complete with electrolyte and accessories. The accessories
shall include battery stand, battery leads with terminal ends, acrylic top cover & inter
battery connectors. First charging of the batteries including supply of electrolyte.
Each battery is provided with a charger to charge the batteries within ten hours when the
set is running. The charger shall get disconnected while DG set is running.
The charger shall be provided with DC Voltmeter, DC Ammeter and Automatic Voltage
stabilizer.
Page 828
The charger shall work satisfactory for supply voltage variation +10% it shall have
necessary filters to reduce the ripple factor less than 3.
2.2.4 MCC for DG Auxiliaries
Motor control center with requisite number of starter feeders for all the cooling fans shall
be supplied with thermostatic control. All power and control components such as MPCBs,
Starters, auxiliary relays, time switches and thermostatic control of fans shall be
included. This panel is of compartmentalized design.
2.3 ACOUSTIC ENCLOSURE
The acoustic enclosure shall carry CPCB approval.
The acoustic enclosure shall be pre-fabricated to CPCB approved drawing & shall be
modular in construction, free standing, floor mounting type. The sides shall have
sliding doors to facilitate maintenance work.
The design shall be modular and bolted type construction so that the enclosure can be
easily assembled at site.
The enclosure shall be provided with Sliding / hinged doors. The doors shall have pad
locking facility. A view panel with double glass shall be provided on the acoustic
enclosure opposite the engine gauge panel to read the gauges from outside the
enclosure.
The acoustic enclosure shall have louvered openings on the front and rear fitted with
sound absorbing attenuators to limit the noise level.
The design of the enclosure shall ensure that the temperature rise inside shall not exceed
5Deg. C above the ambient while operating at rated load.
Sound attenuating panels shall be fabricated out of corrugated 18G CRCA sheet steel
and filled with mineral wool of not less than 50mm thickness and not more than 64
Kgs/m3 density. The panels shall be covered by GI perforated sheet of 0.8mm thickness.
These panels shall be bolted on all sides and the roof of the frame work. Alternately
Page 829
other approved make of sound attenuating materials may also be offered.
If required, a supply air fan of adequate capacity and static shall be provided to supply
requisite quantity of cooling air
Suitable entries shall be provided for the fuel oil inlet, outlet, exhaust pipe outlet, cable &
earthing conductor entry. Provision shall be made for topping up the radiator.
A fuel gauge shall be provided with lockable covers.
All the joints in the enclosure shall be sealed to limit the noise transmission.
The exhaust gas silencer shall be located outside the enclosure and separately insulated.
The enclosure shall be painted after the trail runs with two coats of finishing paint. The
colour shall be indicated at the time of installation. The colour should be as per the
Architects approvals.
Duct entries if any into the enclosure shall be sealed after installation to avoid key hole
effect.
A light point shall be provided over the gauge panel. 2 additional light points shall be
provided in the enclosure and controlled from outside. All wiring shall be through M.S
conduits.
Provision shall be made for oil & coolant drain. Fuel tank should have provision for
cleaning.
Performance Criteria
The noise level measured at 1M from the acoustic enclosure at any point shall not exceed
75dBA or the level provided by PVB whichever is lower.
Page 830
There shall be no de-rating of the D.G Set while operating in the enclosure. The
maximum temperature of oil and water shall not exceed the limits prescribed by the
manufacturer of the diesel engine. The D.G set shall give rated output continuously.
2.4 EXHAUST SYSTEM
A suitable residential grade quality silencer / including flexible exhaust fitting and
exhaust piping, properly sized to the manufacturers recommendations shall be provided.
The silencer shall be mounted in such a way that the weight is not supported by the
engine.
Exhaust pipe size shall be sufficient to ensure that the exhaust back pressure does not
exceed the maximum limitations specified by the DG set Manufacturer.
Higherbackpressureleadsto
- Lowerfueleconomy
- Highexhausttemperaturesandrelatedfailures
- Poorperformanceoftheengine
- Lessdurabilityoftheengine
Useofthimbleismustwhilepassingthepipethrough
concretewall.Theclearancearoundthepipeinwallis
mustforfreemovementandexpansion/contractionof piping.
Exhaustpipinginsidethegensetroomshouldbelagged
alongwithaluminumsheetcladdingtoavoidheatinputto
theroom.Typicalthicknessoflaggingis50mm.
Itisrecommendedtouse‘ScheduleB’MSpipesand longbendelbows.
Theexhaustoutletshouldbeinthedirectionofprevailing
windsandshouldnotallowexhaustgasestoenterair inlet/windowsetc.
Page 831
OptimumSilencerLocation:Locationofthesilencerin exhaust system has very definite

influence on both silencingandbackpressureimposedonthesystem.
Careshouldbetakentoensurethatnocarbonparticlesemittedduetoexhaustleakageentersa
nddepositson alternatorwindingsandopenconnections
Commonexhaustsystemformultipleengines
Common exhaust system for multiple sets is not recommended due to condensation,
excessive suction pressure, entry of exhaust gases in non working engine, increased back
pressure and lack of failsafe system availability. However exhaust of two banks of V-
engines can be connected, after silencer. Ensure that area of common pipe is greater than
sum of the areas of individual pipes.
The exhaust system shall be such that the exhaust revise level shall not be greater than
70dbA at one meter from the Exhaust outlet.
All indoor exhaust piping shall include lagging to maximization a surface temperature
not exceeding 65Deg. C. the insulation shall be insulated so that it does not interface with
the flexible exhaust piping.
The exhaust piping and silencer shall be wrapped with rack wool / calcium silicate and
supported from the roof / wall. The outside shall be neatly wrapped with aluminium
cladding. Exhaust system with vertical shall have rain lord to prevent rain water entry.
2.5 HSD FUEL PIPING AND ASSOCIATED WORKS
2.5.1 Pumps
The pumps for HSD shall be of Rotary Gear type to work on 3 Phase 400/440V 50 cycles
with necessary flame proof motor, flame proof outdoor isolator with starter and all
electrical protection, flame proof glands, suction and delivery outlets, companion flanges,
nuts, bolts, gaskets, non-return valves etc.,
2.5.2 Piping
Page 832
Pipes shall be of heavy quality MS ERW screwed socket type and shall conform to IS
1239. All fittings shall be malleable fittings of approved best Indian make. The thickness
of pipes shall conform to the table given below.
a) Tube
Thickness
i) Medium tubes butt welded : + Not limited - 10 percent

ii) Medium tubes seamless : + Not limited - 12.5 percent
Weight
i) For quantities of 150 and over, (one size) : +/- 4 percent
ii) Single tube : + 10 percent
- 3 percent
Sockets
Outside diameter : +/- 2.5 percent
The manufacturing tolerance shall be permitted on tubes and sockets in addition to those
indicated in the table above.
2.6 VENTILATION AND ACOUSTIC TREATMENT-(Room Acoustics -If applicable)

The ventilation and acoustic treatment/room acoustics shall be required if the DG sets
are installed in a closed room or in the basement.
Scope of Work
The scope of work involves the Design, Fabrication, Supply, Installation and testing
and commissioning of Noise reduction Acoustic treatment on the four sides of the
DG Room Walls, Ceiling and ventilation system, primarily consisting of the
attenuators and secondarily the fans will be provided for optimum heat transfer
and sound attenuation.
100mm thick insulated panels shall be installed on the wall and the ceiling for
acoustic treatment, there shall be fresh and hot air attenuators on either side of
the DG sets for fresh air entry and hot air exit. The openings shall be provided for
easy hot air transfer system without effecting the performance of the DG sets.
Ducting shall be provided from the engine radiator to hot air chamber which the
hot air will be dissipated outside the room. Sufficient hot air opening shall be
provided to ensure that the outgoing of hot air velocity.
Page 833
Acoustic doors shall be provided in lieu of the normal doors for DG Room access
with glass viewing window. All the openings shall be thoroughly sealed for
obtaining maximum performance.
The scope of work covers fabrication, supply, erection, testing and commissioning
of ventilation, exhaust and acoustics systems for the DG room comprising of fresh /
exhaust air fans, GI ducts, fresh / exhaust fan attenuators, acoustic panels for the
walls / ceiling and acoustic doors.
The acoustic system design shall ensure a noise level of not more than 70dBA at
1m from the exterior wall of the DG room.
Fresh air / Exhaust air sound attenuators shall be installed at the locations
indicated. The doors for the DG room shall be acoustically treated. The fresh air
opening / exhaust fan attenuator shall be provided with aluminium powder coated
storm louvers to prevent water entry into the room.
Supply air fans (if required) shall be installed at the locations indicated on the
drawing. Calculations shall be produced to prove the adequacy of the fan size and
capacity selected. The fans shall be thermostatically controlled using a
temperature controller such that they operate automatically when required and
the maximum temperature in the DG room does not exceed 45C.
The ceiling shall be covered with acoustic panels having mineral wool filling and
perforated aluminium sheet.
Civil works such as opening in the walls, foundation works etc. will be organized
through other agencies. However minor civil works, MS frame work for the fans
and attenuators will be in the scope of the DG contractor.
Wiring for the supply and exhaust fans shall also be carried out.
2.6.1ROOM WALL AND CEILING INSULATION

The acoustic panels are made out of honeycomb-boxed structure of 100mm deep.
Each panel is fabricated out of 20SWG formed C/U pre galvanized at the intervals
of 600x600mm. the panels shall be filled with 2 layers of 50mm thick, 64kg/cu.
Mtr., resin bonded rock wool slabs which shall be protected from mechanical
damage by using 24SWG GI perforated sheet of grade IV having minimum free area
of 33%, which will be secured in place via aluminium rivets at every intervals of
approximately 100 to 125mm pitch and cover with insulation material.
The panels shall be fixed on the wall with perforated sheet facing the room on one
side and the wall on the other side by means of special anchor fasteners and a air
gap of 60mm to 80mm will be maintained between the masonry wall / concrete
wall surface and the acoustic panels. To camouflage the spacing between panel to
panel special type U formed pre galvanized beading shall be provided on the joints
of the panels for the walls and ceiling respectively.
2.6.2 SHEET METAL WORK
All ducts shall be fabricated from galvanized sheet steel conforming to IS:277. The
coating of zinc shall conform to Class VIII. Flanges and stiffeners used in duct sections
shall be rolled steel angles. All nuts, bolts and washers shall be of zinc plated steel and all
Page 834
rivets shall be galvanized or made of aluminium alloy. Self tapping screws need not be
used. Gaskets shall be of 3mm neoprene rubber and shall be leak proof.
Only new, clean and bright sheets without water marks shall be used. The
Consultants/Owners reserve the right to reject the sheets not meeting the requirements.
2.6.3 RECTANGULAR DUCTING
a) Duct construction shall follow IS:655. Thickness of sheets for rectangular duct shall be as
follows:
Maximum size of the Minimum Sheet

Duct in mm Thickness in mm
750 mm and below 0.63
752 mm to 1500 mm 0.80
1501 mm to 2250 mm 1.00
2251 mm and above 1.25
b) The fabrication of the ducting including details of transverse joint connections, bracing,
seams etc., for longitudinal joints etc., will be generally as per IS:655. The ducts should
be rigid and should have very minimum leakages.
c) Only angle iron flanges shall be used for all transverse joints and GS sheet flanges are not
acceptable. The angle iron flanges shall be painted with two coats of primer and black
enamel paint.
d) All ducts shall be supported on Factory made GI supports using threaded rods and
slotted channels using anchor fasteners. The span of the supports shall not exceed 2m.
All civil works including drilling, chipping, grip bolting and other related works shall be
within the scope of the DG contractor.
e) Stiffening angles shall be fixed to the sides of the duct by riveting. Flanged joints shall be
used at intervals not exceeding 1800 mm using angle iron of size not less than 40 x 40 x 3
mm. Flanges shall be welded at corners first and then riveted to duct. All flanged joints
must have 6 mm felt lining between flanges.
f) All joints shall be made air tight with proper packing gaskets and all interior surfaces
shall be smooth. Bends shall be made with radius not less than one half the width of the
duct or with properly designed inside curved vanes.
Page 835
g) Duct connections to the radiator shall be made by inserting a heavy duty fire resistant
flexible double canvas sleeve connection of 300 mm length. The sleeve shall be securely
banded and bolted to the duct and radiator casing.
h) All ducts shall be totally free from vibration under all conditions of operation.
All exposed ducting inside the DG room shall be painted with primer followed by 2 coats
of synthetic enamel paint of approved color.
2.6.4 INSULATION WORK
a) Resin bonded fiber glass mat or mineral wool shall be used for insulation in the
attenuators and the wall panels. The fiber glass shall have a density not less than 24
kg/cum and a thermal conductivity not greater than 0.029 k-cal hr/sq. m/deg. c/m at 20
deg. c. Fiber glass shall be in the form of blankets. Alternatively rock wool of density 64
kg/cum can be used. GI frame work shall be supplied in which the acoustic material will
be filled. Samples of all insulation material specified shall be submitted by the successful
contractor.
b) The consultants/owners or their authorized representatives reserve the right to check

the weights, dimensions etc., of the insulation material supplied. The samples not
confirming to the specifications shall be rejected.
2.6.5 SOUND ATTENUATOR
The attenuator shall be fabricated using 18 G(1.25mm) thick galvanized steel sheet as
per the sizes indicated. The flanges shall be fabricated out of 50 x 50 x 6mm thick MS
angles. The attenuator duct and the angle frame shall be treated with Zinc chromate
primer and painted with two coats of approved synthetic enamel paint. The attenuator
leaves shall be fabricated using GI sheet metal frames fabricated again out of 18 G sheet.
The 100mm thick leaves shall be packed with 2 layers of 50mm thick fiber glass of
density 24kg/cum. or rock wool of 64kg/cum density. The insulation shall be covered
with RP tissue and sandwiched between 1mm thick GI perforated sheets. The sheet shall
have minimum 20% free area. Only pop rivets shall be used for joining the perforated
sheet to the frames. The spacing of the leaves shall be as indicated in the drawings and
shall be rigidly supported. Whenever the height exceeds 1500mm intermediate support
has to be provided at the middle. The attenuator leaves shall also be in two layers and
the height of each attenuator leaf shall not exceed 1500mm. The sound attenuator shall
be factory fabricated and offered for inspection prior to dispatch.
The design of acoustic system shall ensure that the noise level at 1M from the DG room
shall not be more than 70dBA.
Page 836
Fresh Air and Hot Air Attenuators
The extensive range of attenuators shall be used for pass air through the external wall of
the building and maintain a high overall level of sound reduction and efficient
aerodynamic performance and least self generated noise.
The attenuator casings shall be fabricated out of 18G (1.25mm) thick CRCA sheet steel.
The casing shall be formed from top, bottom and side tray sections. The flanges shall be
fabricated out of 50x50x6mm thick M.S angles.
The semi aerofoil acoustic attenuator blade elements shall be fabricated from 1.0mm
thick CRCA sheet steel. The blades are filled with 64Kg. / cu. Mtr. Acoustic media namely
the rock wool slabs, which shall be RP tissue, faced to prevent fiber erosion into the air
system and shall be further protected from mechanical damage by 0.6mm thick grade IV
pre-galvanized perforated sheet steel of 20% minimum free area and secured in place via
aluminium rivets. The resin bond acoustic media is completely inert, does not harbor
bacteriological growth and non-combustible and fire retardant and tested in accordance
with BS and IS standards.
The attenuator box will be treated with anti corrosive zinc chromate primer and painted
with 2 coats of approved synthetic enamel on the exterior surface and aluminium paint
on the inner wall side.
Acoustic Door
Double leaf Acoustic sound resistant door in lieu of the normal door will be provided for
access to the DG Room. The outer wall of the door is made out of 1.6mm thick CRCA sheet
steel and inner wall out of 1.0mm thick GI perforated sheet steel and insulated with 2
layers of 50mm thick 64 kg / cu. Mtr. Density rock wool slabs. It will be of a double skin
construction, supported by three point heavy-duty hinges and five fold formed structural
frame. The main door is provided with double glazed viewing window with 15mm
beading with lockable fasteners.
Hot Air Duct
The hot air ducts will be provided to guide the hot air from the radiator till the hot air
attenuator through which, the hot air is thrown out of the room. It is made out of 1.25mm
thick CRCA sheet steel with supports and flanges. The duct will be insulated with 50mm
thick 48kg / Cu. Mtr. Rock wool slabs and covered layer flexible SWG GI perforated sheet.
In addition to the metal ducting double layer flexible canvass material will be used
between the radiator and the duct for isolating the vibrations.
The duct shall be treated with anticorrosive zinc primer and two coats of approved
synthetic enamel.
Page 837
2.6.6 TUBE AXIAL FANS
The specified tube axial fans shall be installed in case the DG is installed in a closed area
or in a basement.
a) Tube axial fans shall have MS power coated or epoxy coated diaphragm. The impellers
shall be die cast aluminium or MS power coated epoxy coated with adequate gauge sheet.
The fan shall be statically and dynamically balanced. The fan motor shall be suitable for
outdoor installation and shall have minimum IP-55 protection. The fan shall be suitable
for mounting vertically and should withstand higher temperatures. The fan shall be
suitable for three phase operation.
In case of deviation the Bidders shall fill in the following technical data:
a) Make of Tube axial fans :
b) Diameter (mm) :
c) Speed in RPM :
d) Power in watts :
e) Whether single/three phase :
f) Make of fiber glass :
g) Density Kg/cum :
h) Thermal conductivity :
i) Make of GI sheet :
j) Class of GI sheet :
k) Diameter of perforations and

free area in case of perforated sheet :
Page 838
3.0 INSTALLATION
The bidder shall undertake the installation work at site. All statutory requirements
governing labour shall be fulfilled by the contractor before taking up the work. The
general scope of installation work shall include but not be limited to the following.
3.1 UNLOADING
a) Provision for genset lifting is provided on base-rails. Unload the genset from base rail by
lifting with proper genset lifting tackle or nylon sling / steel rope of suitable capacity
and crane so as to ensure no damage to oil sump, air cleaner, radiator pipes etc.
b) Donotliftthegensetfromengineandalternatorhooks.
Thesearedesignedforliftingindividualitemsonly.
c) Keepthegensetcoveredwithpolyethyleneortarpaulin during installationto ensure thatwater

does not enter inside.
d) Spreaderbar/spacerplateofsuitablesizemaybe
requiredtoavoiddamagestogensetcomponents.
3.2 DIESEL GENERATOR SET
The Diesel Generator Set shall be installed over the foundation prepared by other
agencies on anti-vibration mounts. The unit shall be visually inspected for any transit
damage.
All accessories sent loose shall be assembled as per manufacturer's recommendations.

The electronic governors shall be mounted on a separate stand to avoid excessive
vibration.
The contractor shall after the installation arrange for the inspection of the set by the
diesel engine manufacturer's authorized representative and obtain his approval before
rolling the set.
Drip trays shall be provided below the engine Crank case, Fuel filters and any other
locations susceptible to oil leakage to ensure that the oil will not spill on the floor.
The batteries shall be charged, installed on stands and inter connected.
3.3 FUEL PIPING
The inlet fuel piping from the bulk storage yard up to individual day tanks will be
Page 839
installed.
The D.G supplier shall supply and install the following on the inlet line of each unit.
 A flame proof valve to shutoff the fuel.

 A fuel flow meter to record the quantity of fuel delivered to each tank.
 Flame proof level switches to provide following indication shall be supplied and installed
on the fuel day tanks and over flow collection tank.
 Over flow indication on the control panel in the event of accumulation of fuel in the over
flow tank.
 The fuel piping shall include supply and installation of 25/50mm dia, Class "B" MS
pipes with necessary valves and accessories required for the supply , return and over
flow lines.
 The joints in the line shall be properly sealed to avoid any leakage of fuel.
 The fuel piping shall be painted and labeled as per standards.
LAYING AND FIXING
Where pipes have to be cut or re-threaded, ends shall be carefully filed so that no
obstruction to the bore is offered. For internal work all pipes and fittings shall be fixed
truly vertical and horizontal, either by means of standard pattern holder-bat clamps
keeping the pipes 1/2” (12mm) clear of the wall everywhere or concealed as directed. For
external work, MS pipes and fittings shall be laid in trenches. The width of the trench shall
be the minimum width required for working. The pipes laid underground shall be not less
than 60cm. from the finished ground level and a minimum horizontal distance of 100cm
shall be maintained between other services lines.
WRAPPING OF CONCEALED MS PIPES
CLEANING
Pipe surfaces shall be thoroughly cleaned and dried before tape is applied and shall be free
of dirt, grease and rust scale or other foreign matter. The pipe shall be cleaned
mechanically.
Oil and grease, if present on the pipe surface should be removed by using a suitable solvent
and clean rags. The use of dirty, oily rags should not be permitted.
FIELD APPLICATION OF TAPE
The tape shall be wrapped in accordance with the manufacturers recommendations in a

manner that shall meet the adhesion requirement. During application, care shall be taken
to ensure that there are no air pockets or bubbles beneath the tape.
Page 840
The tape should be wrapped with an overlap of 50% for TEES. The first wrapping shall be
done individually. The tape may be cut if required to suit the profile. There shall be two
layers of tape wrappings. The first layer is to be wrapped on the pipe directly after
cleaning the pipe surface. The second layer is to be applied over the first layer. The second
layer should also be wrapped with 50% overlap.
VALVES
Carbon steel single piece ball valve antistatic and fire safe AF51/52 confirming to IS
Standards.
Valves shall be provided on branch pipe connections to mains and at connection to

equipment where indicated. All valves are to be located for easy access and are to be full
bore of pipe connected together. All valves shall be supported wherever necessary.
FLANGES
Mild Steel MS flanges Table-E on pipelines with welding, gaskets, bolts and washers.
Basic Equipment
 Flame proof Electric drive motor

 Flame proof D.O.L starter for motor
 Additional recommended spare parts.
 Liquid seal breakage alarm device
 Flexible connection
 Base frame (Trolley or standard fixed type)
LEVEL SENSORS
Float type level sensors shall be used
3.4 FUEL HANDLING SYSTEM
The outdoor bulk fuel storage system will be installed by other agencies.
a) Intermediate fuel tank (Day Tank) of 990 ltrs Capacity fabricated out of 4 mm thick sheet
steel with fitments as specified shall be installed in the DG yard area.
b) Fuel-bulk storage tank and associated works will be installed by other agencies. Fuel
piping from the outdoor bulk fuel storage tanks to the intermediate tank located in the
DG Yard will be installed by DG Vendor scope of works including necessary Supply/
return fuel pipes/connectivity auto shut off valves and flame proof Pumps /starter etc.
c) The supply and installation of intermediate tank of 990 liters capacity and the pipe
Page 841
connections shall be included in the DG vendor’s scope. The fitments on each of the tanks
shall be as specified. Oil will flow by gravity from intermediate tank to in built day tanks
and from these DG Set-in built day tanks to the bulk storage tank.
d) 18 SWG galvanized sheet steel trays beneath the engine to collect the leakage oil.
e) The following specific requirements shall be included in the DG Vendor’s scope.
f) The intermediate oil tank which receives oil from the bulk storage will have level
switches with 2 level points for low & high levels. These shall be connected to initiate
starting/ stopping of fuel oil pump in bulk storage area and audible alarm at a manned
location to be identified. The bulk storage tank-fuel transfer pump shall operate
automatically based on fuel requirement in the intermediate tank. The necessary auto–
manual components shall be supplied along with starter panel.
g) Each day tank shall have level switches with 2 level points for low & high level.
i) Level indicators, manhole and vent shall be provided on each of the tanks.
j) Each tank shall have oil containment provision to hold the full capacity of the tank in the
event of leakage.
k) The total volume of fuel oil in any single enclosure/ room shall not exceed 2500 ltrs.
m) The supply & return oil piping from each tank to the engine shall be carried out by double
wall MS piping of appropriate size including piping from bulk storage tank. The outer
pipe shall collect the leakage and drain the same into the containment provided for the
main tank.
3.5 EXHAUST PIPING
a) The exhaust piping shall be fabricated from 10/12/14”dia or as specified, 5mm thick MS
pipes.
b) The horizontal run of exhaust piping shall be supported on spring supports fixed to the
ceiling. The vertical run shall have expansion bellows where the length exceeds 25M.
c) A weather cowl shall be provided at the top.
d) The pipe shall be painted after fabrication with heat resistant paint.
e) Sampling point and a 15A universal socket in weather proof box as required by Pollution
Control Authorities shall be provided at appropriate location.
f) The exhaust piping and the silencers shall be insulated using 50mm thick mineral
wool all along the length. The insulation shall be cladded with 24 G aluminium sheet.
Page 842
g) The exhaust pipe shall be lead up to a height of 3M above the highest point.
h) All lifting tools and tackles used for the erection shall have valid safety certification.
3.6 ELECTRICAL INSTALLATION
The electrical connection between DG & DG Control panel, main LT panel, covering the
power & control cables shall be executed as per the I.E. rules and the stipulations of local
authorities.
The wiring between the alternator & terminals in adopter box shall be carried out using
copper conductor Uninivyn cables of an aggregate rating of 3200A/ phase under the site
conditions. A non-canvass type flexible connection shall be provided between alternator
& the adopter box.
The earth conductors from the earth mats for DG body & DG neutral will be extended up
to the DG room. The DG contractor shall extend the same to earth the DG set, DG CP, and
all other equipment in the DG room.
The DG contractor shall co-ordinate his work with all other agencies working at site.
The contractor shall arrange all approvals from CEIG.
3.6.1 CABLING & CABLE TRAYS
A. L.T POWER CABLES
a) The wiring between the alternator & cable terminals in adopter box shall be carried out
using copper conductor Uninivyn wires of a suitable rating under the site conditions.
b) The connection between the alternator terminal box and the control panel shall be
carried out using 1.1kV grade, 3.5C, Aluminium conductor XLPE insulated armoured and
FRLS grade PVC sheathed cables.
c) The design of XLPE cables shall permit continuous operation of the cable at a conductor
temperature up to 90deg.C under normal conditions and 250 Deg. C during faults without
causing any permanent damage.
d) The cables shall be designed to allow a bending radius of not less than 12 times the
diameter or lower as per manufacturer's instructions.
B. L.T.CONTROL CABLES
The L.T control cables shall be with electrolytic grade copper conductor only. The control
Page 843
cables shall be PVC Insulated, GI wire Armoured & FRLS sheathed type.
C. CONDUCTOR
a. The aluminum conductor for the Cables shall be of Electrolytic grade, 99% purity & 3/4 H
Hardness.
b. The Copper Conductor for Control cables shall be of the Electrolytic grade and 99.9%
purity.
c. The conductor shall be of circular/sector shaped type and insulation of phase and
neutral shall be color coded.
d. All sizes of conductors above 6sq.mm shall be of the stranded type.
e. The Conductor shall conform to IS-8130 – 1984.
D. TERMINATION
a. The cables shall be terminated using cable glands of cadmium plated brass & tinned
Copper heavy duty cable lugs.
b. The cable glands shall be of the double compression type for the main cable & single
c. compression type for all other control/power cables.
E. CABLE TRAYS
The cable trays from outdoor DG yard to the DG panel room shall be made for taking the
power cables from DG set to DG control panel. The data / control cables shall be either
laid in black enameled MS conduits or in covered wire way channels fabricated out of pre-
galvanised sheets in the trays. All bends, accessories & supports shall be from the same
source.
3.6.2 B
USDUCT
General
Thebusbartrunkingsystem(800Aandabove),both feederandplug-in,shall be
sandwichconstruction.All busbartrunkingproductsandfittings (straightlength,
elbow,tees,flangedends,cabletapbox andcircuitbreaker,etc.)shallbein
Page 844
accordancewithIS8623(1&2)andIEC60439:2005 orUL857 andfrom the same

manufacturerasthebusbartrunkingsystem. The degree ofprotectionofthe busbar
trunkingsystemshould be IP54/55in accordance to IEC 60529.
Ratedoperationvoltageofthebusbartrunkingis660V 3–Phase,4.Theneutral
conductorshouldhavethe samecross-sectional area as the phase conductor. External
CopperEarthingstrip ofadequate size shall beprovided.
Theampereratings,approximatefootage,fitting,plug-inunitsetc.areshownonthe
plan.Theelectricalcontractorshallberesponsiblefor routingthe busbar trunkingto
coordinatewiththeothertrades.Finalfieldmeasurementsshallbemadeby the
contractorpriorto release to thebusbartrunking forfabrication bythe manufacturer.
Certificate
Thebusbar,offullrangeandeachrating,shouldpassfulltypetestsspecifiedin
IEC60439:2005.Thecertificateshallbeissuedby aninternationalindependent
testingauthority(e.g.ASTA,KEMA,UL).
The busbar trunking system should pass seismic tests with actual physical
productandbeingcertifiedcomplyingwithUBCseismicZone4conditionbyaninternationalre
cognizedearthquakeresearchbodye.g.AsianPacificNetworkof
CentersforEarthquake EngineeringResearch (ANCER).
ShortCircuitRatings andTests
Thewholebusbartrunkingsystemshallbecapableofwithstandingtheshort
circuitoftheelectricalinstallationwithoutdamagingtheelectrical,mechanical
andthermalstress underfaultcondition The minimum ratedinsulation voltage shall
be1000V.
Theminimumcertifiedshortcircuitratingsofthebusbartrunkingshallbeas follows:
Rating KA/1 sec. KAPeak Rating KA/1 sec. KAPeak

800A 40 84 2500A 75 165
Page 845
1000A 50 105 3200A 90 198

1250A 50 105 4000A 100 220
1600A 60 132 5000A 120 264
2000A 60 132 6000A 120 264
Basic Construction
Housing:
The busbar trunking housing shall beconstructedof code gauge steeland

aluminumtoreducehysteresisandeddycurrentlosesandshallbeprovided with a suitable
protective finish ofANSI49greyepoxypaint.
The busbartrunking housing shall be totally enclosed non-ventilated for

protectionagainstmechanicaldamageanddustaccumulation.Anditshallpass atleast500
hourssaltspraytestto ensure theanticorrosionability.
Thetotallyenclosedhousingshallbemanufacturedby thebusbartrunking
manufacturer.Modificationsofbusbartrunkingtomakeittotallyenclosedby
otherthanthebusbartrunkingmanufacturervoids the manufacturer’s warranty. Busbar
trunkingso modified isunacceptable without the written consentofthe manufacturer.
Busbars
Busbarsshallbeofharddrawnsilver-platedhighconductivityAluminumwith
coppercladdingutilizedMolecularFusion technology.
There shall benoboltspassingthrough thebusbarsofthebusway.
EachbusbarshallbeinsulatedwithClassBwith(130degreecelsius)multiple
layersofpolyesterfilminsulation.
Thetemperatureriseatanypointofthebusbartrunkingenclosureshallnot
exceed55degreeCentigraderiseaboveambienttemperaturewhen operationat
ratedcurrent.
Joint
Page 846
Thebusbartrunkingjointshallbeoftheone-bolttypewhichutilizesahigh strengthsteel
bolt(s)andBellevillewashers to maintainproperpressureovera large contactsurfacearea.
Theboltshall be torqueindicatingand atearth potential.
Theboltshallbetwo-headeddesigntoindicatewhenpropertorquehasbeen appliedand require

onlya standard longhandle wrench to beproperlyactivated.
Accessshallberequiredtoonlyonesideofthebusbartrunkingfortighteningjointbolts.
Itshallbepossibletoremoveany jointconnectionassembly toallow electrical

isolationorphysicalremovalofabusbartrunkinglength withoutdisturbing
adjacentbusbartrunkinglengths.
Plug-in Opening
Theconnectingjawoftheplug-inunitshallplugdirectlyontothebusbarand have full

contactwith busbaritself.Welded tabatplug-in busbarisnotallowed. All contacton
jointand plug-in openingshould besilverplatedcopper.
Onplug-inbusbartrunkingthereshallbethreedeadfront,hingedcovertype plug-in
openingsoneach side.
All openingsshall beusable simultaneously.
Busbartrunkingshallbeinstalledsothatplugsaresidemountedtopermit practical useofall

plug-in openings.
It shallbepossibletoinspecttheplug-inopeningandbusbarspriortothe installation
oftheplug-in units.
SupportofBusbarTrunking
Hanger spacing shall be noted on layout drawings and shall not exceedmanufacturer’s
recommendations.
Indoorfeederandplug-inbusbartrunkingshallbeapprovedforhangerspacing of
upto3metersforhorizontallymountedrunand4.88metersforvertically
mountedruns.Outdoorfeederbusbartrunkingshallbeapprovedforspacingof up to 1.5
metersforhorizontallyorverticallymounted runs.
Page 847
Voltage drop
Thevoltagedrop(inputvoltageminusoutputvoltage)specifiedshallbebased on the busway

operating at full rated current and at stabilized operating
temperaturein 30℃ambient.
Thethree-phase,linetolinevoltagedropshallnotexceed3.4voltsperhundredfeet at 40%
power factor concentrated load which may exist during motor starting.
Theline-tolinevoltagedropshallnotexceed4.1voltsperhundredfeetatthe load
powerfactorwhich produces maximumvoltage dropin thebusway.
Plug-in Units
Theplug-injawshallbespringdesigncomposedofdifferentmetaltoensurethe firmand
tightcontactwith thebusbar.
Theearthingcontactoftheplug-inunitshallalwaysbemadebeforethatofthe
liveconductorsandthelasttobreakduringremoval.Anditmustconnecttothe earth
barofbuswayto ensure thesafety.
Coversofallplug-inunitsmusthaveinterlockstopreventthecoverfrombeing openedwhen
theswitchisin the ON position.
Plug-inunits(circuitbreakertypeorfusibleswitchtype)shallbeoperatedwith visible blade
quick-make and quick-breakmechanism
PresenceofTransparentshield shall beinside to avoid directcontactofhuman. Theplug-
inunitsshallbeequippedwithinternalbarrierstopreventaccidental contact of fish tape and
conductors with live parts on the line side of the protective device duringtime ofwire
pulling.
Type Test
Page 848
Sand witch Type Bus Bar Trunkings shall comply with the following Type Test as perIEC
60439.
Verification ofTemperature rise limit.
Verification ofDielectricproperties.
Verification ofshort-circuitstrength.
Verification oftheeffectiveness oftheprotective circuit
Verification ofclearances and creepage distances.
Verification ofmechanical operation.
Verification ofthedegreeofprotection.
EMC tests
Verification ofresistance ofinsulatingmaterial to abnormal heatand fire.
Verification oftheelectrical characteristicsofthebusbartrunkingsystem
Verification ofstructural strength.
Verification oftheendurance oftrunkingsystemwith trollytype tap-offfacilities
Verification ofcrushingresistance
Verification ofresistance to flamepropagation
Verification ofFire resistance inBuildingpenetration
3.7 EARTHING
 The earthing shall conform to TNS category to IS-3043.

 The DG neutrals will be solidly earthed by two connections to the earth mat installed by
others.
 The DG bodies shall also be connected at two points to the earth mat installed by others.
 The size of earth conductors shall be as indicated below:
 DG body, DG CP - 2 nos. 50x6mm GI
DG neutral - 2 nos., PVC Sleeved 50X6mm / 40X6mm Copper Strips or 1Cx120
sq. mm. XLPE copper cable.
Page 849
Fuel tanks - 7/16 SWG GI
f) When the two DG sets operate in parallel only one neutral will remain closed.
g) GI earth pits for safety earthing and copper earth pits for neutral earthing will be
installed by the electrical contractor who will lay two earth conductors of the size
specified into the outdoor DG yard. From this point all earthing conductors to the DG set
& accessories shall be supplied & installed by the DG Vendor.
h) All joints in the run of GI strips shall be welded and copper conductor brazed/
riveted/bolted
4.0 TESTING & COMMISSIONING
The individual components of the DG sets shall be tested at Manufacturer’s Works before
delivery and necessary Test Certificates shall be submitted for approval of Client /
Consultants.
The Contractor shall carry out all performance tests after installation, in the presence
of the main contractor, as per specification. The Contractor shall bear all expenses for
such tests.
Load test shall be carried out site. All test equipment and dummy loads shall be arranged
by the Contractor. The contractor has also to furnish the list of tests to be carried out
prior to handing over at site.
The Contractor shall be responsible for executing the contract as per Indian Electricity
Rules, Rules and Regulations of supply authorities and the Rules of the local Electrical
Inspectorate. Any changes/ modifications pointed out by the authorities shall be carried
out at no extra cost. The works shall be deemed to be complete only if all authorities have
approved the same in writing.
4.1 AT MANUFACTURER'S WORKS
The routine tests and full load test on Engine, Alternator shall be carried out at
manufacturer's works in accordance with applicable Indian standards and test
certificates shall be submitted in six copies.
H.V Test.
Insulation resistance test.
Interlock and automatic start up
Trip test through protection
Auto / Manual synchronizing test
Page 850
4.2 PERFORMANCE AT SHOP
The DG shall be capable of starting from cold condition, reaching synchronous speed and
taking up load within the period specified from the “start” impulse and shall be capable
of delivering continuously at the generator terminals rated output, with invisible
exhaust.
With the DG running at no – load, rated voltage and speed, the transient voltage drop at
its terminals shall not exceed specified percentage of rated voltage, on starting a
maximum capacity induction motor direct on-line required to be started during this
period.
4.3 PERFORMANCE AT SITE
The site performance test shall be carried out for the DG and its auxiliaries. The following
items of performance shall be guaranteed during site performance tests in respect of DG
and the auxiliaries for the specified site conditions:
Net electrical output at generator terminal.
Fuel oil consumption at 25%, 50%, 75% and 100% load.
Lube oil consumption at full load.
Jacket water temperature to and from engine
Lubricating oil temperature to and from engine.
Freedom from vibration and noise.
Governor response, over-speed trip and speeder gear capability.
Voltage regulator response and excitation at full load and under specified variation of
voltage and speed.
After completion of the installation, the contractors shall perform a test and take various
readings as follows and submit the same to the consultants/owners for formal approval.
a) Noise level (dB A) at 1m from:
The fresh air attenuator :
The exhaust air attenuator :
The fresh air fan attenuator :
The exhaust air fan attenuator :
Page 851
b) Velocity (fpm)/air flow (cfm) through:
The fresh air attenuator :
The exhaust air attenuator :
The fresh air fan attenuator :
The exhaust air fan attenuator :
4.4 TESTING AT ‘OEA's or OEM’s WORKS
Following tests shall be conducted at the assembler's works in the presence of main
client’s representatives.
a) Load testing for ½ hours at 25% load, ½ hours at 50% load, ½ hours at 75% load and 1
hour at 100% load and 10% over load for one hour immediately after the full load test.
b) Full load testing for 8 hours with load bank.
c) Overload testing at 10% overload for one hour immediately after the full load test.
Operation of protective devices shall be checked by simulation.
d) All the readings shall be logged to evaluate the fuel consumption, lube oil pressure. Water
and oil temperature vis-a-vis the electrical load.
e) The guaranteed specific fuel consumption shall not exceed 150 grams/BHP.HR with a
tolerance of +2.5%. The noise level at 1Meter from the enclosure shall be checked. Noise
level at any point should not be more than 75dBA.
f) Operation of protective devices except the RTDs, thermistors.
4.5 SITE TESTING
Following tests shall be conducted at site in the presence of the main contractor’s
representative before energization. The contractor shall provide all testing equipment,
labor and consumables required for the testing.
Page 852
a) Checking the alignment by engine manufacturer's representative and obtaining approval.
b) Insulation resistance test on alternator, control panel and cabling.
c) Testing of earth resistance of individual earth electrodes and combined system.
d) Checking the AMF operation both on auto and manual mode.
e) Checking engine safeties for satisfactory operation.
f) Checking vibration levels by specialist agency and noting the readings.
g) Testing of individual protective devices on engine and alternator and ensuring that
the wiring is carried out properly.
h) Running each DG for 2 hours continuously with the available load at site. All the readings
shall be logged to evaluate the fuel consumption, lube oil pressure, water & oil
temperature vis-a-vis the electrical load. All these values shall be within the guaranteed
limits.
i) After running each DG as mentioned above, all the DGs shall be switched on with AMF
logic and auto synchronized. Minimum load required for synchronizing operation shall
be specified by the DG vendor. In the event such amount of load is not available at site
after conducting the tests mentioned in h) above, then this test shall be done by DG
vendor as soon as required quantum of load is made available at site. Duration of this
test shall be 2 hours.
j) The guaranteed specific fuel consumption shall not exceed 150grams/BHP.HR with a
tolerance of +2.5%. The same shall be proved during the load trial.
k) The noise level at 1M from the D.G room and the temperature rise inside the room at the
end of the load trial shall be measured. The same shall be within the limits specified.
l) The installation is liable for rejection if the noise level is found to be higher than 70dBA
or CPCB guidelines.
m) The temperature rise in the room while all the DG sets are in operation shall not exceed 5
Degree Centigrade above ambient.
n) Any deviation from the guaranteed parameters shall be made good and these
performance parameters should be measured once again till the required results are
achieved.
o) The DG set shall be deemed to be commissioned after satisfactory performance of all

associated equipment, successful conduct of the tests and demonstration of successful
Page 853
PLC operation for monitoring and control of all parameters/logic as required and after
submission of performance test reports.
p) Hydraulic pressure testing of all pressure parts.
q) Static and dynamic balance test of rotating parts of applicable over speed and
determination of vibration level.
r) Radiography and magna flux examination of materials and welds.
s) Ultrasonic testing of casting and forgings.
t) Calibration tests of fuel pumps, injectors, standard orifices, nozzles, instruments etc.
u) Check for noise level.
v) Performance of all interlocks and protection circuits associated with DG sets and DG
Panel shall have to be tested.
w) All tests for all items as per relevant codes and standards and as per approved quality
assurance plan.
5.0 APPROVALS AND NOC
Following approvals / NOC shall be obtained by the contractor:
a) NOC and approval from Pollution Control Board for the installation of the unit.
b) NOC from Concerned local authorities for the installation of DG sets.
c) Approval for the chief electrical inspectorate.
6.0 DOCUMENTATION
As a part of the equipment supply, following documentation shall be furnished.
---------------------------------------------------------------------------------------------------------------------
------------------------
With For For
tender approval records
---------------------------------------------------------------------------------------------------------------------
------------------------
Page 854
a. General arrangement and 1 6 6

foundation plan of DG set in encl.
b. Layout of DG room - 6 6
c. Engine wiring diagram - 6 6
d. Control schematic GA for - 6 6

Engine control panel
e. Exhaust piping, routing and - 6

6
supporting details
f. GA and schematic drawings

for the DG control panel - 6 6
g. Test certificates for engine,

Alternator, remote radiator, Pumps & ECP - 6 6
h. Installation, operation &

maintenance instructions of diesel engine,
alternator - - 2set
scanned
copied to
be submit
i. Spare parts list - 2 -
j. Approval from statutory

Authorities - - 1 Each
Page 855
7.0 TAKING OVER
Client will take over the DG set for operation on completion of the following:
a) DG sets are installed, tested and commissioned as per the specifications.
b) Original test certificates are furnished for engine, alternator, centrifuge and other bought
out items.
c) Load trials are successfully conducted including the performance of room acoustic
treatment and ventilation fan.
d) Approvals are obtained from Pollution Control Board and CEIG.
e) AS BUILT documentation, spare parts list, maintenance chart and operation and
maintenance instruction booklet are submitted.
8.0 WARRANTEE
8.1 DG SET
The DG set, control panel, other sub systems and accessories shall be guaranteed for
satisfactory operation for a period of 24 months from the date of commissioning or 5000
running hours from the date of supply whichever is earlier. Any defects noticed during
this period shall be rectified free of cost.
The supplier shall indicate the type of records to be maintained so that the warranty
claims if any are honored by the manufacturer without hesitation.
The design and installation of acoustic treatment shall ensure that the noise level at
1M from the D.G room at any point shall not exceed 70dBA while operating the sets at
rated load.
9.0 MAINTENANCE
a) The contractor shall be required to maintain the installation at no extra cost to the
owner for a period of one year from the date of commissioning. During this period, the
contractor shall make good any defects caused due to faulty design, bad workmanship
and poor quality of materials.
b) The response time for any break down call shall not be more than 4 hours.
Page 856
c) During the warrantee period, the bidder shall carry out regular servicing of the unit
every three months or 250 hours whichever is earlier. The consumables required for this
will be made available by the owners.
d) The contractor shall train the client's operating personnel on operation and
maintenance of sets as per manufacturer's recommendations.
10.0 SPECIAL TOOLS AND TACKLES
One set of special tools and tackles required for the routine operation and maintenance
shall be supplied with the DG Set.
11.0 SITE REPRESENTATIVE
The contractor shall appoint a full time site engineer holding valid supervisory permit
issued by the state government and he should not be transferred / relocated till the
completion / handover of the Project. Any transfer of the site Engineer should be done
only with the consent from the Client /Main contractor.
12.0 TRAINING OF CLIENT’s / MAIN CONTRACTOR’S PERSONNEL
The bidder shall include in his scope the training of concerned Maintenance personnel on
operation and maintenance of the equipment.
13.0 PREFERRED MAKES
Diesel engine with Residential Grade : Cummins/ MTU / Kohlar DG

silencer Sets
Alternator : Stamford with PMG exciter /

MARATHON AVK-SEGC / Leroy
Somer
Ant vibration mounts : Dunlop / Gerb / Approved

Equivalent.
Battery : Exide – SMF Type, Amaron
Acoustic Enclosure : CPCB Approved from reputed

Manufacturer.
Page 857
TECHNICALDATASHEET
ENGINE
Sl.No. Description Units BiddertoIndicate
1. Nameofmanufacturer :
2. No. ofDieselEngine :
3. Power rating ofthe engine@1500rpm. EkW

4. Engineratingatsitecondition KW
5. ModelofEngine
6. StandardRatingtype
7. GrossEngineBHP BHP
8. GrossEngineKW KW
9. Length(EngineAlone) mm
10. Width(EngineAlone) mm
11. ArrangementofCylinder
12. Height(EngineAlone) mm
13. No.ofCylinders No.
Page 858
14.a Bore mm
b. 15. No.ofStrokes.
Displacement L
16. Compressionratio No
17. BMEPoftheengine KPa
18. Directionofrotation
19. OperatingSpeed
20. ‘V’angle Deg.
21. Firingorder
32. Heightofbaserailusedfortheengine M
22. Aspirationofengine ExhaustSystem
1. Exhaustsystembackpressurepermitted K
23. Pistonspeedofengine M/Sec.
24. Max.overspeedallowed(Tripsetat) rpm

2. (max.)
Diameterofengineexhaustoutlet m
25. Max.Engineratingatsitewith10% KW
3. (inside)
No.ofexhaustoutletsrequired N
26. Overload
Totaldryweightofengine 4. Kg No.ofsilencerssuppliedwitheachengine N
27. Totalwetweightofengine 5. Kg Noisereductionprovidedbythesilencers DB
horsepowerconsumedbyenginedriven 6. Restrictionofferedbysilencers In.H

28. accessories KW/HP
7. Exhaustgasflowrate CP
29. Mechanicalefficiencyoftheengine %
8. Exhaustgasflowrate M3
30. Thermal efficiencyoftheengine %
9. Exhaustgastemp(stack) Deg
31. Ref.standardsfortheseengines
10. Exhaustsilencertype
11. Heightofeachchimney M
Page 859
Heatexchangers(Shell&TubeType) LubeOil
JacketWaterSystem
1. No.ofheatexchangerperDGset Nos.
System
ConstructionFeatures
1. Type
Shellside
1. Fluidcirculated LubeOil
2. Quantityoffluidcirculated M3/hr JacketWater

3. Temperature–inlet
C
4. Temperature–outlet
C
TubeSide
1. Fluidcirculated Raw
Cooling
water
2. Quantityoffluidcirculated M3/hr
3. Temperature–inlet
C
4. Temperature–outlet
C
MaterialSpecification
1. Shell
2. Tubes
3. Tubesheet
Page 860

4. Gaskets
PositionofCenterof
1. Forwardfromrearfaceoftheblock mm
Gravity(Approx.)
2. Abovecrankshaftcenterline mm
3. Rightofcrankshaftcenterline mm
SpecificFuelConsumption
1. SpecificFuelConsumption @100%load g/bkW
- Hr
- Hr
- Hr
5. Tolerance g/bkW
- Hr
FuelConsumption inLiters
1. FuelConsumptionin Liters@100%load L/Hr
5. Toleranceconsidered
6. Densityoffuelconsidered Kg/L
7. AlternatorEfficiencyconsidered %
LubeoilConsumptionoftheEngine
Page 861
1. LubeoilConsumption@100%load L/Hr
Page 862

5. Recommendedlubeoil
6. LubeOilchangeperiod Hrs.
7. Minimumacceptablelubeoiltemperature
atstartup C
8. Lubeoilprimingpump Yes/No
9. Lubeoilprimingpump EngineDriven/AC
motordriven/DC
motordriven
10. ACmotordrivenstandbypumpifany Included/excluded
11. DCmotordrivenstandbypumpifany Included/excluded
HeatRejectionDetails
1. HeatRejectiontocoolant kW
2. HeatRejectiontoexhaust kW
3. HeatRejectiontoatmosphere kW
6. Heatthatcanberecoveredfromexhaust kW
DerationDetails
1. Derationoftheengine–Altitude(normal M
temp)
2. Derationoftheengine–Altitude(@50 M
degC)
3. Derationoftheengine–Temperature Deg.C
4. Derationoftheengine–Humidity
5. Inletairtemperature %
Page 863
Page 864

6. Overallde-ratingfactor %
AirIntake System
1. Intakefiltertype
2. Airintakerestriction–withcleanelement kPa
3. Airintakerestriction–withdirtyelement kPa
4. Filtrationcapacityinmicrons Microns
5. Intakemanifoldpressure kPa
6. Max.intakemanifoldtemperature Deg.C
7. Combustionairinletflowrate CFM
8. Combustionairinletflowrate M3/Min
FuelSystem
1. FuelSystemtype
2. Filtertype&No.
3. Filtrationcapacity(particlesize) Microns
4. Full oilsuction filters
5. Primingpumptype AC/DCmotordriven/
EngineDriven
6. Fuelsupplylinerestrictionmax.allowable kPa
7. Fuelreturnlinerestrictionmin.allowable kPa
8. Normalfuelpressure kPa
9. Fuelflowtotransferpump(max.) L/Hr.
10. Max.headontransferpump–static/
dynamic
Page 865

11. Fuelfilterchangerecommended Hrs.
FuelOilSystem
1. Daytanksize Litres
2. FuelOilsuction filters
Type and Number
Engine Construction Future

1. Turbo charger/Supercharger Included/excluded
2. Nameofthemanufacture
3. Number
4. Speed RPM
5. Aftercooler Included/excluded
6. Intercooler Included/excluded
LubeOilSystem
1. Enginelubeoilcapacity L
2. Refillvolumewithfilter L
3. Sumpcapacity–lowmarklevel L
4. Sumpcapacity–highmarklevel L
5. Oiltemp.–max. Deg.C
6. Oilpressure–normalrange kPa
7. Oilpressure–low oil kPa
8. Filtertype&No.
9. Filtrationcapacityinmicrons Microns
10. Crankcaseventilationtype
Page 866
Units BiddertoIndicate
Sl.No Description
11. Oilcoolertype
.
12. Pre-lubprimingpumprating
13. Connectinghosedetails
14. Max.flowoflubeoilprimingpump
15. Mountingdetailsforthepre-lubpump
16. Lubeoilheaterconnectiondetails
StartingSystem
1. Systemvoltage VDC
2. No.motorsprovided&ratingofmotors No.
3. Batterychargingalternatorcapacity Amps.
4. Min.RecommendedBatteryCapacity
Jacket WaterSystem
1. Enginejacketwatercoolantcapacity L
2. Enginejacketwatercoolantflowrate LPM
4. Coolantoutlettemp.max.allowed Deg.C
5. Coolantinlettemp.min.allowed Deg.C
6. Systempressuremin.recommended kPa
7. Starttoopentemp.–thermostat Deg.C
8. Fullyopentemp.–thermostat Deg.C
9. Min.coolantfillrate(ifapplicable)
10. Min.coolantexpansionspaceas%of %
systemcapacity
EngineMountedRadiatorDetails
Page 867

1. Coolantcapacityofradiator Litres
2. Ambientcapacityoftheradiator DegC.
3. Radiatordriveratio
4. SizeofRadiator(HeightxWidthx mm
5. Length)
Diameterofradiatorfan mm
6. Powerof radiatorfan kw
7. Min.radiatorcappressure PSI
8. Weightofradiator(Dry) kg
9. Weightofradiator(Wet) kg
NoiseLevelDetails
Mechanicalnoise(allloads)
1. @1Meter dB(A)
2. @7Meters dB(A)
Exhaustnoise@1.5Meters
3. @100%load dB(A)
4. @90%load dB(A)
5. @80%load dB(A)
6. @75%load dB(A)
7. @70%load dB(A)
8. @50%load dB(A)
9. @25%load dB(A)
Exhaustnoise@7Meters
10. @100%load dB(A)
11. @90%load dB(A)
Page 868

12. @80%load dB(A)
13. @75%load dB(A)
14. @70%load dB(A)
15. @50%load dB(A)
16. @25%load dB(A)
EmissionDetails@100%Load
1. NOXlevelasNO2 gm/hr
2. CO gm/hr
3. TotalHC gm/hr
4. SoxasSO2 gm/hr
5. Particulatematter gm/hr
6. Oxygendry %
7. SmokeOpacity %
8. BoschsmokeNo.
MOUNTINGSYSTEM
1. SAENo.oftheflywheelhousing
2. Flywheeldimension
-Diameter mm
-Width mm
-No.ofteeth No.
3. Typeofcoupling(for2bearing)
4. Whethercomeswithabaseframe
GOVERNINGSYSTEM
1. Typeofgovernor(Digital–PCC)
Page 869

Make
Model
2. ClassofGovernor
3. Steadystatebandofregulation %
4. Drooprange %
5. Recoverytime
6. Temporaryvariation
7. Permanentvariation
ALTERNATOR
Description Units BiddertoIndicate
Nameofmanufacturer
Type
DesignRating(Maximum) KVA
KW
Continuousoutputrating KW
PowerFactor PU(Lag)
No.ofPhase/Current
Frequency HZ
Speed RPM
RatedVoltage(RV) V
VoltageVariation %RV
RatedFLC AMP
Enclosureasper IS:4691
Coolingasper IS:6362
Page 870
Mountingasper IS:2253
Page 871
Altitude MSL
Ambient DEGC
Insulation Class
Stator
Rotor
Temp.Rise(Deg.C)
IS:12802
Above40Deg.CAMB
a. Stator
C
b. Rotor
C
c. Core
C
GoverningStandards
Resistance MainStator
InOHMSat20Deg.C MainRotor
Ex.Stator
Ex.Rotor
WR2 of rotating mass in diesel
engine,generatorexciteretc.
MainExciter
Ratedvoltage Volts
Ratedcurrent Amps
Excitationsystemresponseratio
Page 872

Insulation class
Stator
Rotor
ExcitationType
RectifierBridgeType
Rt.FieldCurrent NoLoad
InADC FullLoad
Exciteroverload Capacity
Excitation Current NoLoad
InADC FullLoad
Automatic Voltage
AVRType/DVRType
Regulator/DVR
BurdenofAVR/DVRonCT’s&PT
’s
CT’s Va
PT’s Va
Deadband(ifany)
VoltageRegulation
SystemResponseTime MS
WaveFormDistortion THF
Winding.No.
Rating KVA/KW
ShortCircuitRatio SCR
SynchronousReactance XD
TransientReactance XD’
Page 873
SubtransientReactance’s(Full XD”
Voltage)
(PerUnit)
Negativesequencereactance X2
Zerosequencereactance X0
Opencircuitfieldtimeconstant Sec.
Spaceheaterrating No.x
Efficiencyat0.8PF(Lag) Watts
a. ½Load %
b. ¾Load %
c. FullLoad %
StatorWinding&Connection
Terminals&Marking
DamperWinding
Overloadcapacity
SustainedShortCircuit
Unbalancedloadpermit
Impregnation
ProtectionAgainstmoisturedust
Painting
Bearings DE
NDE
Lubrication
OverSpeed
Page 874
DirectionofRotation
CoolingAir M3/Min
MomentofInertia KG-M2
General Dimensionarrangement
Weight KG
Page 875
DataSheetforD.GandAuxiliaries
Netelectricaloutput ofDGsetat kW
siteafter de-ratingfactors and
auxiliarypowerrequirement have
beentakenintoaccount.
Fueloil consumption
a.Fullload gms/kwh
b.75%load gms/kwh
c.50%load gms/kwh
Lubeoilconsumption
a.Fullload gms/kwh
b.75%load gms/kwh
c.50%load gms/kwh
Jacket water temperature ‘IN’ to

C
engine.water temperature ‘OUT’

Jacket
C
fromengine.
Overloadof10%foronehour
Guarantee emissionsat theoutlet

ofstackat100% loadoftheDG set.
Description Units a)NoxBiddertoIndicate ppm
Voltageregulatorresponse b)Sox ppm
c)Particulatematters ppm
Page 876
WeightSchedule
Weight of engine, less flywheel Kg.
includingstandardaccessories.
Weightofflywheel Kg.
Totalshippingweight Kg.
Weightofgenerator Kg.
Weightofcontrolpanel Kg.
Heaviest singlepiecetobe handled

during:
Erection/itsweight
Maintenance/itsweight
Dimensions
Shippingdimensions
Engine
Generator
Page 877
DataSheetforControlCabinets
Manufacturer’sname
Indoor/Outdoorapplication
Thicknessofsteelsheet Mm
Degreeofprotectionprovided(as
perIS:2147orequivalent)
BillofMaterialforthe various Yes/No.
equipmentgivingmake, type,
ratingsetc.enclosed.
Colouroffinishpaint
Outside
Busbarsforpowerdevices(when
applicable)
Inside
a)Material (Insulated/Bare)
b)Continuouscurrentrating
ControlWiring/PowerWiring
a) Materialofconductorandsize (Insulated/Bare)
b) Conductor–Solid/Stranded
DataSheetsforMotors
Application/Designation
Manufacturer
ApplicableStandards
Page 878
Rated
Output kW
RP
M
Speed
Page 879
TypeofDuty(IS325or equivalent)
DutyDesignation(IS325or
equivalent)
SupplyConditions
a) i) RatedVoltage V
ii)No.ofPhases
Hz
i) Voltage %
iii)Frequency
ii) %
b)AllowableVariationsin
Frequenc
c) PermissibleUnbalance
y iii) Combined
inSupplyVoltage %
Current
a)Fullload Amps
b)Starting %FL
FullloadEfficiency %
FullloadPowerfactor
MethodofStarting
Torque
a)Starting %FLT
b)Maximum %FLT
ClassofInsulation
a)Ref.AmbientTemperature
C
b)Temp.risebyRes.Method
C
Page 880
Project Name : -
Site Address :-
TypeofEnclosure
DegreeofProtection(IS13947or
equivalent)
SuitableforOutdoorOperation Yes/No
NormalWindingConnection Star/Delta
Type&No.ofTerminalsbrought out
ShaftOrientation
DimensionalDrwg.Enclosed. Yes/No
Project Name : -
Site Address :-
FOR
PUBLIC HEALTH ENGINEERING (PHE)
WORKS
Project Name : -
Site Address :-
TABLE OF CONTENTS
SECTION 1:- 887
GENERAL PROVISIONS 887
1.1 Scope 887
1.2 Licensed Plumber 888
1.3 Regulations and Standards 888
1.4 Fees, Permits and Notices 891
1.5 Introduction to the Project 892
1.6 Water storage & distribution system 893
1.7 As Built Drawings 897
1.8 Manufacturers’ Instructions 897
1.9 Materials 898
1.10 Guarantee 898
SECTION 2:- 899
SOIL,WASTE & VENT WATER PIPES 899
2.1 Scope 899
2.2 General Requirements 899
2.3 Unplastisized Polyvinyl Chloride (UPVC) pipes & Fittings material 900
2.4 HDPE pipes & fittings 900
2.5 Pipes hangers, supports, clamps etc. 902
2.6 Installation of soil, waste & vent pipes 903
2.7 Traps 904
2.8 Cleanout Plugs 905

Project Name : -
Site Address :-
2.9 Pipe sleeves 906
2.10 Pipe protection 906
2.11 Cutting and making good 906
2.12 Handling 907
2.13 Laying 907
2.14 Jointing 907
2.15 Testing 908
SECTION 3 910
EXTERNAL SEWERAGE SYSTEM 910
3.1 Scope 911
3.1 Trenching for pipes and drains 912
3.3 Piping material 916
3.4 UPVC/PVC Pipes and Fittings 919
3.5 Construction of manhole 921
3.6 Measurements 922
3.7 Drop Connection 923
3.8 Making Connections 925
3.9 Grease Trap 925
3.10 Testing 929
SECTION 4 930
WATER SUPPLY SYSTEM 930
4.1 General 930
4.2 Water system 931
4.2.2 PPR pipes and fittings for water connections 931

Project Name : -
Site Address :-
4.2.3 GI pipes and fittings for water connections 938
4.2.4 CPVC pipes 940
4.3 Color code for water supply pipes 941
4.4 Testing 942
4.5 Disinfection of the pipe network 942
4.6 Mode of measurement 942
4.8 Mode of measurements 951
4.9 Water hammer arrestors 951
4.10 Pumps 952
4.11 General requirements: 955
4.12 Pump Test: 957
4.13 Tank fitments 971
SECTION 5:- 973
SANITARY INSTALLATION AND FIXTURES 973
5.1 General 973
5.2 European type water closet 974
5.3 Wash basins 975
5.4 Sinks 976
5.5 Urinal 976
5.6 Toilet accessories 977
5.7 Water coolers 979
5.8 Horizontal geyser 979
APPENDIX -A. RECOMMENDED MAKE LIST FOR WATER980
SUPPLY & SANITARYINSTALLATION 980

Project Name : -
Site Address :-
APPINDIX-B BILL OF QUANTITIES 983
SECTION-08 COMMISSIONING & GUARANTEE 983
8.1. Scope of work 983
8.2. Pre-commissioning 984
8.5. Rejection of installation / plant 986
6. WARRANTY AND HANDOVER 986
7. HANDING OVER OF DOCUMENTS 987
8.8. Pipe colour code: 989
8.9. Check list for commissioning 991
APPENDIX-C 995
LIST OF BUREAU OF INDIAN STANDARDS AND OTHER INTERNATIONAL CODES

995
APPENDIX-D WATER TREATMENT SYSTEM & ACCESSORIES 1007
1. General 1007
2. Reverse osmosis plant 1019

Project Name : -
Site Address :-
SECTION 1:-GENERAL PROVISIONS
1.1 Scope
The General character and the scope of work to be carried out under this section is
illustrated in the drawings and specifications attached herewith. The contractor shall
carry out and complete the said work under this contract in every respect in
conformity with the rules and regulations of the local authority. The Contractor shall
furnish all labour, materials, appliances, tools and equipment necessary for the work
for plumbing services installation including testing and commissioning as specified
herein, and as per the relevant Bureau of Indian Standards (BIS), British Standards
codes, and as shown on the drawings. This also includes any material, appliances and
equipment not specifically mentioned herein or noted on the drawings as being
furnished or installed which are necessary and customary to make a complete
installation properly connected and in working order.
Carryout all incidental works connected with plumbing services installation such as
excavation of trenches and back filling, cutting and chasing in concrete and brick and
making good, cutting / drilling holes through walls, floors, and grouting for fixing of
fixtures / equipment and so forth.
Furnish and install complete workable plumbing services installation as shown on the
drawings and described in this specification and as per the latest Bureau of Indian
Standards (BIS), British Standards (BS) specifications including all that which is
reasonably inferred to all the buildings, internally and externally.
Complete installation of the sewerage and sewerage appurtenances internally as well

as around the building.
Complete installation of all sanitary and plumbing fixtures in all buildings.
Co-operation with other trades in putting the installation in place. Any work done
without regard or consultation with other trades, shall be removed by the contractor
without additional cost to the Owner, to permit proper installation of all other work,
as desired by the Main Contractor.
Project Name : -
Site Address :-
Repair all damage done to the premises as a result of this installation to the
satisfactory levels and remove all debris left by those engaged for this installation to
the satisfaction of main contractor.
Cleaning of all plumbing and sanitary fixtures, testing and proving the satisfactory
performance of all fixtures at the time the buildings are handed over to the main
contractor.
It is the responsibility of the sub-contractor to take care of all the fixtures fitted until
the time of handing over to the main contractor
Painting/identification of all concealed and exposed pipes as specified.
Assume full responsibility for getting the entire installation duly approved by the
authorities concerned and for all expenses in connection with the same. Assume
responsibility for obtaining and delivering to the main contractor’s certificate of final
inspection and approval by the concerned authorities.
1.2 Licensed Plumber
All work to be executed by a registered plumbing supervisor possessing a valid

registered plumbing contractor’s license employing Engineers, Technicians, Foremen,
Plumbers, Masons, Helpers, etc., as required.
1.3 Regulations and Standards
The installation shall conform in all respects to the following standards in

general:
IS 651 – 1992 : Specification for Salt Glazed stoneware pipes and

fittings
(Fifth revision)
IS 7558 – 1974 : Code of practice for domestic hot water installation

Project Name : -
Site Address :-
IS 5329 – 1983 : Code of practice for sanitary pipe work above ground
for buildings.
IS 12251 – 1987 : Code of practice for drainage of building basements
IS 2064 – 1973 : Code of practice for selection, installation and

maintenance of sanitary appliances
IS 1200 (Part 1) : Method of measurement of building earthwork
IS 1200 (Part 16) : Method of measurement of laying of water and sewer

lines including appurtenant
IS 1200 (Part 19) : Method of measurement of Water supply, plumbing

and drains.
IS 783 – 1959 : Code of practice for laying of concrete pipes
IS 13592 – 1992 : Specification for un plasticized PVC pipes for soil and
waste discharge system inside building including
ventilation and rainwater.
IS 2527 – 1984 : Code of practice for fixing rainwater gutters and down
pipes for roof drainage.

maintenance of sluice valves.
IS 6784 – 1984 : Method of performance testing of water meters

(Domestic type).
IS 12235 (Parts 1 : Methods of test for un plasticized PVC pipes for

to 11) portable water supplies.
IS 458 – 1988 : Specification for pre-cast concrete pipes (with or

without reinforcement)
IS 2692 – 1989 : Specification of ferrules for water services

Project Name : -
Site Address :-
IS 12701 – 1989 : Specification for rotational moulded polyethylene

water storage tanks.
IS 771 – (Part 3to : Specific requirements for urinals

6)
IS 2548 (Part 1&2) : Specification for plastic seats and covers for water
closets.
IS 3004 – 1979 : Specification for plug cocks for water supply purposes.
IS 1711 – 1984 : Specification for self-closing taps for water supply
IS 1703 – 1977 : Specification for ball valves (Horizontal plunger type)

including floats for water supply purposes.
IS 4038 – 1979 : Specification for foot valves for water works purposes.
IS 1172 – 1983 : Code of basic requirements for water supply, drainage

& sanitation (revised).
IS 1239 – 1990 : Specifications for mild steel tube, tubular and other
steel pipe fittings.
(Part I)
IS 1239 – 1992 : Specifications for mild steel tube, tubular and other
steel pipe fittings.
(Part II)
IS 1726 – 1991 : Code for cast iron manhole frame and cover (third
revision).
IS 1742 – 1983 : Code of practice for building drainage. (Second

revision)

maintenance of sanitary appliances.
IS 2065 – 1983 : Code of practice for water supply to buildings.

Project Name : -
Site Address :-
IS 3114 – 1985 : Code of practice for Laying of CI pipes
IS 4111 – 1986 : Code of practice for Ancillary structures in sewerage

system
IS 4127 – 1983 : Code of Practice for laying glazed stone ware pipe.
BS 4515 : Specification for un plasticized PVC pipe fittings.
IS 4985 – 1988 : Specification for un plasticized PVC pipes for portable

water supplies (second revision)
IS 732 & IS 2274 – : Indian Standard code of practice for electrical wiring &
1963 installation.
IS 780 – 1984 : Specification for sluice valves for water works

purposes.
National building Code for Water Supply, drainage and Sanitation. Part IX Plumbing
services section 1 and 2.
The installation shall also be in conformity with the bylaws and requirements of the
local authority in so far as these become applicable to the installation. Wherever this
specification calls for, a higher standard of materials and / or workmanship than
those required by any of the above regulations and standards, then this specification
shall take precedence over the said regulations and standards.
Wherever drawings and specifications require something that may conflict with the
regulations, the regulations shall govern. This shall be referred to the Superintendent
for arbitration.
1.4 Fees, Permits and Notices
The sub-contractor shall comply with all bye-laws and regulations of local and other
statutory authorities having jurisdiction over the works and shall be responsible for
the payment of all fees and other charges, giving and receiving of all necessary notices
with the consent of the main contractor. Sub-Contractor shall keep the
Project Name : -
Site Address :-
Superintendent/main contractor timely informed about regulations and

requirements of statutory authorities and shall obtain the final certificates of
inspection and approval from the authorities.
1.5 Introduction to the Project
The following services are envisaged for the Project :
Water Treatment System for meeting the domestic water quality requirement
with chemical parameters in acceptable limits as per World Health Organisation
(WHO) SP:35(S & T) 1987 which is considered safe for human consumption, WTP
system design shall be verified for suitability prior to installation in accordance to
latest water analysis report.
Domestic water supply through Hydropnumatic System or Gravity system for

making water available at the residual pressure 1.5 to 2.0 kg / sq.cm. The pressure at
the inlet of fixture shall be limited to 4.0 Kg/cm2.
Sewage and Sullage collection system based on IS:1742 and and ASPE
standards applicable standards for domestic drainage.
Sewage / Effluent Treatment Plant comprising of preliminary, primary,

biological and tertiary treatment for recycling of the effluent. The treated effluent
shall be used for flushing water required and for make-up to the cooling tower of air
conditioning and of DG sets, wet scrubber and for gardening / irrigation purpose.
Separate and independent garden hydrant or for horticulture operation, using

treated effluent recycled for external / non-guest areas, and use of domestic water for
internal courtyard and water bodies recirculation system for Swimming Pool and
water bodies.
Hot water system comprising of HSD / Dual Fuel Fired Hot Water Generators
of adequate capacity to cater for hot water requirement for domestic purpose.
Project Name : -
Site Address :-
Provision of Solar hot water system as per compliance to ECBC – 2007 and / or
MoEF, EC whichever is stringent.
Fire Fighting system for the project comprising of Hydrant, Hose Reels,
Sprinklers and portable fire extinguishers.
1.6 Water storage & distribution system
Water Requirement The water requirement for the project is proposed to be

based on the provisions of IS:1172 and prevalent practice. The estimated requirement
of water per day for the Complex based on the number of users and other services
shall be _________ KL / day.
Source of Water
It is expected that part of the daily domestic water requirement for the project
shall be through municipal mains supply. Since it is unlikely that municipality
would be able to meet the entire daily requirement, supply will have to be
supplemented by having provision of adequate number of tube wells. Provision
of tanker water fill feasibility shall also be made.
Water Storage
The static storage for Fire Protection is at present sized for ____ KL. The total
water storage in raw & domestic water tanks is of __________ KL / day capacity.
Water Quality
Project Name : -
Site Address :-
Domestic Water Requirement: The total domestic water shall be passed

through basic water treatment plant and further specialized treatment shall be done
based on the water analysis report and requirement. The basic water treatment plant
shall comprise of MG Sand filter, Activated Carbon Filter, Softener and U.V Steriliser.
Disinfected Water: It is proposed to provide localized UV units for water

consumption points for direct consumption in Kitchen / Pantry.
Soft Water: Provision of polishing softener shall be made for feed water
requirement of hot water generators. This feed water chemical parameters shall be as
detailed in IS-20392.
Recycled Water from STP: Water recovered from tertiary sewage treatment
plant shall be used as flushing water supply through separate storage tank and
pumping system and shall also be used as make-up water in Air Conditioning
and DG cooling towers, for wet scrubbers and for external landscape irrigation.
Water Distribution
The water distribution for hot and cold water supply for the project shall be
designed on principle of zoning to ensure availability of adequate residual head
at user outlet. Provision of pressure reducing station and non-return valve shall
be made for effective and efficient water distribution in the Complex. Design is
such that the hot and cold water pressure and flow shall be fairly equal to avoid
reversal of flow from one service to another. Variable speed hydropematic
system shall be provided fully equipped with pre-charged, non-toxic food grade
bladder. Separate direct connection from header shall be taken for water
requirement of Kitchen etc., and for hot water mixing tank connection. Zoning
of cold and hot water supply for floors at lower and higher levels shall be
provided.
Project Name : -
Site Address :-
Appurtenant
Following components shall be included in the water supply system for

efficient functioning:
Isolation valves at strategic points.
Non Return valves for backflow prevention.
Automatic air vent at each of the high point.
Drain valve at each of the low point.
Strainer.
Cross connection.
Pressure Reducing valve where abnormally high pressure is to be reduced.
Water Hammer Arrestors (as required).
Air Vessel to confront Surge pressure.
Flow meter.
Pressure Gauge.
Anchor block / thrust block.
Sewage and sullage water
The soil and waste shall be carried down in separate independently vented
pipes. Two pipe drainage systems shall be adopted as per NBC (Part-IX). Provision of
ASP vertical vent shall also be made for hygiene, safety consideration and to avoid
foul smell entering through trapped gully in WC and Urinal trap. Provision of grease
trap shall be made for waste water from Kitchen.
Project Name : -
Site Address :-
Design Limitations
The system is designed considering the following:
High thrust developed at soil & Waste pipe connections.
Termination of vent cowl at terrace level.
Provision of adequate slope for horizontal header pipes for achieving self- cleansing
velocity in the pipes.
Provision of cleanout plug and Rodding eye.
Minimum diameter of Soil pipe as 100 mm and Waste pipe as 80mm.
Workmanship
The workmanship shall be best of its kind and shall conform to the
specifications, as below or Indian Standard Specifications in every respect or latest
trade practices and shall be subject to approval of the Owner’s Site Representative. All
materials and/or Workmanship which in the opinion of the Owner’s Site
Representative / Architect / Consultant is defective or unsuitable shall be removed
immediately from the site and shall be substituted with proper materials and/or
workmanship forthwith.
Materials
All materials shall be best of their kind and shall conform to the latest Indian
Standards.
Project Name : -
Site Address :-
All materials shall be of approved quality as per samples and origins approved
by the Owner’s Site Representative / Architect / Consultants.
As and when required by the Owner’s Site Representative / Consultant, the

contractor shall arrange to test the materials and/or portions of works at his own
cost to prove their soundness and efficiency. If after tests any materials, work or
portions or work are found defective or unsound by the Owner’s Site Representative
/ Consultant, the contractor shall remove the defective material from the site, pull
down and re-execute the works at his own cost to the satisfaction of the Owner’s Site
Representative / Consultant. To prove that the materials used are as specified the
contractor shall furnish the Owner’s Site Representative with original vouchers on
demand.
1.7 As Built Drawings
On completion of works, the Sub- Contractor shall submit one complete set of original
tracings and two prints of “As built” drawings to the main contractor. Also shall
submit all drawings / information in AutoCAD 2007 or later version. These drawings
shall have the following information:
Exact run and sizes of all piping on all floors, in the ceiling and vertical stacks.
Ground and invert levels of all drainage pipes together with location of all manholes
and connections up to outfall.
Run of all water supply lines with diameters, location of control valves, access panels.
Location of all mechanical equipment with layout and piping connections.
The Sub-Contractor shall provide four sets of catalogues, performance data and list of
spare parts together with the name and address of the manufacturer for all electrical
and mechanical equipment provided by him.
All “Warranty Cards” given by the manufacturers shall be handed over to the main
contractor and shall be addressed to as specified by the main contractor.
1.8 Manufacturers’ Instructions

Project Name : -
Site Address :-
Where manufacturers have furnished specific instructions relating to the materials

used in this job and methods of construction that are not specifically mentioned in
these documents, such instructions shall be followed in all cases. The Sub-contractor
shall also furnish detailed instruction and operation manuals in triplicate including
detailed completion drawings and Plans on a tracing sheet to approved scale. Further
it is the responsibility of the sub-contractor to train the concerned personnel in the
operation and maintenance of the system in the presence of the main contractor.
1.9 Materials
Materials shall be of approved make and quality specified. They shall conform to the
respective Bureau of Indian Standards, British Standards Specifications and
supported by Manufacturing Certificate / test certificate.
Samples of all materials shall be as per the list of approved brand manufacture, which
shall be approved by the main contractor before placing the order.
In any case of non-availability of materials in metric sizes, the nearest size of the units
shall be provided with prior approval of the main contractor at no extra cost.
1.10 Guarantee
The sub-contractor shall guarantee both the material and workmanship of first class
quality corresponding to standard engineering practice. Any defective materials /
workmanship shall be rejected, the contractor has to rectify / replace at his own cost.
Guarantee certificate of the materials supplied shall be handed over to the owner.
Project Name : -
Site Address :-
SECTION 2:-SOIL,WASTE & VENT WATER PIPES
2.1 Scope
Work under this section consists of furnishing all labour, materials, equipment and
appliances necessary and required to completely install soil, waste and vent pipes as
required by the drawings, specified herein after and given in the bill of quantities.
Without restricting to the generality of the foregoing, the soil waste and vent piping
system shall include the following: -
a) All Shafts and basements piping shall be UPVC/PVC pipes and fittings.
b) Vertical and Horizontal Soil & Waste centrifugal UPVC/PVC pipes and fittings,
joints, clamps.
c) Connection of all pipes to sewer lines as shown on the drawings.
d) Testing of all pipelines.
Materials shall be of the approved make and quality specified. They shall
conform to the respective Bureau of Indian Standards Specifications and supported
by Manufacturing Certificate.
Project Name : -
Site Address :-
Pipes and fittings shall be fixed shall be conforming to the standards of the
Bureau of Indian Standards (BIS), British Standards (BS), shall bear ISI mark, shall be
of uniform colour, truly vertical, horizontal or on slopes as required in a tidy manner
conforming to all quality requirements.
Pipes, drains/floor traps shall be fixed/ installed, constructed and routed in a

manner as to provide easy accessibility for repair and maintenance and shall not
cause obstruction in shafts, passages etc.,. However, any such details in the drawing
shall be brought to the notice of the main contractor for alternate details/locations.
Pipes shall be fixed securely to walls and ceilings by suitable clamps, supports
at intervals specified as per standards. Access door for fittings and cleanouts shall be
so located that they are easily accessible for repair and maintenance.
2.3 Unplastisized Polyvinyl Chloride (UPVC) pipes & Fittings material
UPVC (SWR) class pipes of dia. 75mm, 110mm, 160mm, of Type B for soil,
waste and ventilation system and conforming to IS 13592, shall be used and above
160mm pipes shall be as per IS:4985 10 kg/cm2 (unless otherwise specified) . The
pipes shall be supplied in nominal lengths of 2, 3, and 4 or 6 meters, tolerance on
specified lengths shall be +10mm and – 0mm. physical test requirements shall be as
per IS13592. Where these pipes are passing over inhabited areas, these shall be
suitably insulated for acoustic insulation by approved method.
2.4 HDPE pipes & fittings

Project Name : -
Site Address :-
Materials
All pipes and fittings to be HDPE manufactured to DIN 19535, DIN 19537, DIN 8074,
DIN 8075 fittings to carry a BBA certificate No. 92/2796.
All materials should be manufactured under a BS 5750 / ISO 9000 approved scheme.
All component parts of the system shall be covered by a manufacturer’s warranty.
b. Installation
All pipes and fittings to be fusion welded by either electro sleeve coupling or butt
weld.
Fixed points must be provided at a maximum of 5 metre intervals and / or changes in

direction.
Intermediate sliding supports must be provided in accordance with the manufacturer

recommendations/ application technique manual
All operatives to be trained in welding and jointing techniques by the manufacturer.
c. Inspection & testing

Project Name : -
Site Address :-
The work shall be inspected and tested during installation at agreed stages. All work
which will be concealed shall be tested before it is finally enclosed.
Work to be inspected regularly by the manufacturer who is to verify compliance with

manufacturer's installation guidelines
2.5 Pipes hangers, supports, clamps etc.
All vertical pipes shall be fixed by galvanized clamps and galvanized angle
brackets truly vertical. Branch pipes shall be connected to the stack at the same angle
as that of the fittings. No collars shall be used on vertical stacks. Each stack shall be
terminated at top with a cowl (terminal guard).
Horizontal pipes running along ceiling shall be fixed on galvanized structural

adjustable clamps of special design shown on the drawings or as directed. Horizontal
pipes shall be laid to uniform slope and the clamps adjusted to the proper levels so
that the pipes fully reset on them.
Contractor shall provide all sleeves, openings, hangers, inserts during the
construction. He shall provide all necessary information to the building contractor for
making such provisions in the structure as necessary. All damages shall be made good
to restore the surfaces.
All pipes clamps, supports and hangers shall be galvanized. Factory made
prefabricated clamps shall be preferred. Contractor may fabricate the clamps of
special nature and galvanize them after fabrication but before installation. All nuts,
bolts, washers and other fasteners shall be factory galvanized.
Clamps shall be of approved design and fabricated from MS flats (which shall
be galvanized after fabrication) of thickness and sizes as per drawings or contractor’s
Project Name : -
Site Address :-
shop drawings. Clamps shall be fixed in accordance to manufacturer’s details/shop

drawings to be submitted by the contractors.
When required to be fixed on RCC columns, walls or beam they shall be fixed
with approved type of galvanized expansion anchor fasteners (Dash fasteners) of
approved design and size according to load.
Structural clamps e.g., trapeze or cluster hangers shall be fabricated by electro-

welding from MS structural members e.g. rods, angles, channels flats as per
contractors shop drawings shall be galvanized after fabrication. All nuts, bolts and
washers shall be galvanized.
Galvanized slotted angle/channel of approved sizes supports on walls shall be

provided wherever shown on shop drawings. Angles/channels shall be fixed to brick
walls with bolts embedded in cement concrete blocks and to RCC walls with anchor
fasteners mentioned above. The spacing of support bolts on support members fixed
horizontally shall not exceed 1 m.
2.6 Installation of soil, waste & vent pipes
Soil, waste & vent pipes in shafts under the floors / suspended below slab shall
consist of PVC pipes as described earlier. Waste pipes from bottle trap to floor/urinal
traps for wash basin, urinal and sink shall be PVC/UPVC pipes and fittings.
All Horizontal pipes running below the slab and along the ceiling, shall be fixed
on structural adjustable clamps, sturdy hangers of the design as called for in the
drawings. The pipes shall be laid in uniform slope and proper levels. All vertical pipes
shall be truly vertical fixed by means of stout clamps in two sections, bolted together,
built into the walls, wedged and neatly jointed. The branch pipes shall be connected
to the stack at the same angle as that of fittings. All connections between soil, waste
and ventilating pipes and branch pipes shall be made by using pipe fittings with
Project Name : -
Site Address :-
inspection doors for cleaning. Pipes shall be fixed in a manner as to provide easy
accessibility for repair and maintenance and shall not cause obstruction in shafts.
Where the horizontal run off the pipe is long or where the pipes cross over building
expansion joints etc. suitable allowance shall be provided for any movements in the
pipes by means of expansion joint etc. such that any such movement does not damage
the installation in any way.
2.7 Traps
Floor Traps
Floor traps where specified shall be siphon type full before P or S type having a
minimum 50 mm deep seal. The trap and waste pipes when buried below ground
shall be set and encased in cement concrete blocks firmly supported on firm ground
or when installed on a sunken RCC structural slab. The blocks shall be in 1:2:4 mix (1
cement : 2 coarse sand : 4 stone aggregate 20 mm nominal size).
Contractor shall provide all necessary shuttering and centering for the blocks. Size of
the block shall be 30 x 30 cms of the required depth.
Floor Trap Inlet /Hopper
Bath room traps and connection shall ensure free and silent flow of discharging
water. Where specified, contractor shall provide a special type of floor inlet fitting
fabricated from GI pipe, with one, two or three inlet sockets welded on side to connect
the waste pipe. All joint between waste hopper and CI inlet socket shall be drip
Project Name : -
Site Address :-
seal/Lead Caulked. Inlet shall be connected to a “P” trap. Floor trap inlet and the traps
shall be set in cement concrete blocks where burried in floors without extra charge.
Floor trap for the shower cubicle shall suit site and as per the approval of Owner’s site
representative. All fabricated hopper shall be hot dip galvanized.
Floor Trap Grating
Floor and urinal traps shall be provided with 100 – 150 mm square or round stainless
steel/PVC gratings, with frame and rim of approved design and shape or as specified
in the schedule of quantities approved by the Owner’s site representative.
2.8 Cleanout Plugs
Floor Clean Out Plug
Clean out plug for soil, waste water pipes laid under floors shall be provided
near pipe junctions bends, tees, “Y” and on straight runs at such intervals as required
as per site conditions. Cleanout plugs shall terminate flush with the floor level. They
shall be threaded and provided with key holes for opening. Cleanout plugs shall be
cast brass suitable for the pipe dia. With screwed to a GI socket. The socket shall be
drip seal joined/ Lead Caulked to the drain pipes.
Cleanout on Drainage Pipes
Cleanout plugs shall be provided on head of each drain and in between at

locations indicated on plans or directed by Owner’s site representative. Cleanout
plugs shall be of size matching the full bore of the pipe but no exceeding 150 mm dia
CO plugs on drains of greater diameters shall be 150 mm dia. Fixed with a suitable
reducing adapter.
Project Name : -
Site Address :-
Floor cleanout plugs shall be cast brass.
Cleanouts provided at ceiling level pipe shall be fixed to a CI flanged tail piece.
The cleanout doors shall be specially fabricated from light weight galvanized sheets
and angles with hinged type doors with fly nuts, gasket etc. as per drawing.
2.9 Pipe sleeves
Pipe sleeves, next larger diameter than pipes shall be provided wherever pipes
pass through walls & slabs and annular space filled with fiberglass & finished with
retainer rings. All pipes shall be accurately cut to the required sizes in accordance
with relevant BIS codes and burrs removed before laying. Open ends of the pipe shall
be closed as the pipe is installed to avoid entrance of foreign matter.
Cast iron soil and waste pipes under floor in sunken slabs and in wall chases
(when cut specially for the pipe) shall be encased in cement concrete 1:2:4 mix (1
cement : 2 coarse sand : 4 stone aggregate of 12 mm size) 10 cm bed and around.
When pipes are running well above the structural slabs, the encased pipes shall be
supported with suitable cement concrete pillars of required height and size at
intervals directed by the Project Manager.
2.11 Cutting and making good
Pipes shall be fixed and tested as building proceeds. The contractor shall
provide all necessary holes, cutouts and chases in structural members as building
work proceeds. Wherever holes are cut or left originally they shall be made good with
Project Name : -
Site Address :-
cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 stone aggregate 20 mm nominal

size) or cement mortar 1:2 (1 cement : 2 coarse sand). Cured and the surface restored
to original condition.
2.12 Handling
Because of their light weight, there may be a tendency for the PVC pipes to be thrown
much more. Reasonable care should be taken in handling and storage to prevent
damage to the pipes. Contractor should hold the fullest responsibility in this case. On
no account the pipes should be dragged on the ground. Pipes should be given
adequate supports at all times.
2.13 Laying
The PVC pipes shall be laid under the floors below slab or on walls either
buried or exposed as the case may be, as shown in the drawings. The minimum
thickness of fittings shall be of 3.2 mm. the fittings shall be of injection mould type
with solvent cement joint or rubber ring joint. The pipes and fittings shall be capable
of withstanding sun’s rays. PVC pipes laid below slab or suspended in ceiling shall be
supported by angle brackets / supports as detailed in the drawings..
2.14 Jointing
The jointing of pipes to fittings shall be done as per the manufacturer’s

instructions / recommendations.
The PVC pipes and fittings shall be joined with Solvent Cement and jointing
shall be carried out as follows:
Project Name : -
Site Address :-
Cut the spigot end of the pipe square.
All burrs from the internal and external surfaces should be removed.
The spigot should be marked with a pencil line and a distance equivalent to the socket
depth. Clean the surface within the marked area.
Apply uniform coat of solvent cement on the external surface to the pipe and a lighter
coat on the internal surface of the fitting.
Insert the pipe end into the socket of the fitting and push it in up to the mark.
Remove the excess solvent cement and hold the joint firmly in position for 30seconds
to dry. Gluing should be avoided in a rainy or foggy weather.
The other method of jointing shall be by rubber rings. The material of rubber ring
should conform to IS 5382-1969.The rings are housed in groove formed in a plastic or
metallic housing. The rubber is compressed and makes a seal between the pipe and
housing. Lubricating paste should be applied before compressing the rubber. Where
natural rubber rings are used, mineral oil or petrol or grease should be used.
2.15 Testing
UPVC pipes and fittings assembled shall be tested in accordance with IS 13592. The
openings of the pipes shall be sealed for the section to be tested. The water column of
1m shall be maintained for a maximum of 60 minutes. The Plumbing and Sanitary
Nominated contractor with the attendance of the Management Plumbing and Sanitary
Nominated contractor / Professional Team shall examine carefully all the joints for
leakage. All UPVC pressure pipes will be tested to 1.5 times the rated pressure. The
Project Name : -
Site Address :-
openings of the pipes shall be sealed for the section to be tested. The water pressure
of 0.5Mpa (50.98 m of h2o or 5.98 kg/cm2) shall be maintained for a maximum of one
hour. The Engineer-in-Charge shall examine carefully all the joints for leakage.
Mode of measurement pvc pipes
PVC Pipes shall be measured along the centre line of the pipeline including the
specials in running meter (Rm.) between:
a) Chambers: Shall be recorded from the inside of one chamber to inside of

another chamber.
b) Gully trap and Chamber: Shall be recorded between socket pipe near gully trap
and inside of chamber.
The quoted rate shall include the following:
i) The cost of pipes, fittings/accessories, specials and other jointing

materials.
ii) Laying, jointing and curing.
iii) Testing and making good the defects, if any.
2.16 UPVC pressure pipes and fittings
The UPVC pressure pipes and fittings shall be used for conveying wastewater from
washbasins, kitchen sinks etc., to floor drains.
The pipes shall be class III, 6 Kg/cm2. UPVC pipes and fittings shall be jointed with
solvent cement. The pipes shall conform to IS 4985. Fittings shall be of injection
moulded UPVC conforming to IS 7634 (Part1).
Project Name : -
Site Address :-
Laying and Fixing
The pipe laying and jointing shall be done in accordance with IS 7634 ( Part 3). Pipes
shall be cut to size and chamfered well. Burrs if any shall be removed. Pipes and
fittings shall be jointed using solvent cement or rubber ring joints. The pipes and
fittings shall be jointed accurately without any stress to achieve leak proof joints.
Testing
The methods which is commonly in use is filling the pipe with water, taking care to
evacuate any entrapped air and slowly raising the system to the test pressure at 1m
water column.
SECTION 3EXTERNAL SEWERAGE SYSTEM

Project Name : -
Site Address :-
3.1 Scope
The scope of this section comprises the supply, installation, testing and
commissioning of external drainage & sewage disposal services.
General Scheme
The contractor shall install a drainage system to effectively collect, drain and
dispose all soil and waste water from various parts of the buildings, appurtenances
and equipment. The piping system shall finally terminate and discharge into the
STP/ETP. The piping work mainly consists of laying of UPVC/PVC/Stone ware
Pipes/HDPE pipes as called for on the drawings. All piping shall be installed at depth
greater than 80 cm below finished ground level. The disposal system shall include
construction of gully traps, manholes, intercepting chambers as indicated. The piping
system shall be vented suitably at the starting point of all branch drains, main drains,
the highest/lowest point of drain and at intervals as shown. All ventilating
arrangements shall be obstructive and concealed. The work shall be executed strictly
in accordance with IS: 1742. The sewage system shall be subject to smoke test for its
soundness as directed by the Project Manager. Wherever the sewerage pipes run
above water supply lines, same shall be completely encased in cement concrete 1:2:4
all round with the prior approval of the Project Manager.
Without restricting to the generality of the foregoing, the drainage system shall
inter-alia include:
Sewer lines including earth work for excavation, disposal, back filling and compaction,
pipe lines, manholes, drop connections and connections to the municipal or existing
sewer.
Project Name : -
Site Address :-
All materials shall be new and of quality conforming to specifications and subject to
the approval of the Owner’s site representative. Wherever particular makes are
mentioned, the choice of selection shall remain with the Architect / Consultant /
Owner’s site representative.
Drainage lines and open drains shall be laid to the required gradients and profiles.
All drainage work shall be done in accordance with the local municipal bye-laws.
Contractor shall obtain necessary approval and permission for the drainage system
from the municipal or any other competent authority.
Location of all manholes, etc shall be got confirmed by the Project Manager before the
actual execution of work at site. As far as possible, no drains or sewers shall be laid in
the middle of road unless otherwise specifically shown on the drawings or directed by
the Project Manager in writing.
All materials shall be rust proofed; materials in direct or indirect contact shall be
compatible to prevent electrolytic or chemical (bimetallic) corrosion.
3.1 Trenching for pipes and drains
General
All the material shall be new of best quality conforming to specifications and
subject to the approval of the Architects. Drainage lines shall be laid to the required
gradients and profiles. All drainage work shall be done in accordance with the local
municipal by-laws.
Project Name : -
Site Address :-
Contractor shall obtain necessary approval and permission for the drainage
system from the municipal or any other competent authority. Location of all
manholes, catch basins etc. shall be finalized and shown in approved shop drawings
before the actual execution of work at site. All work shall be executed as directed by
the Project Manager.
Alignment & Grade
The sewer water pipes shall be carefully laid to levels and gradients shown in
the plans and sections but subject to modifications as shall be ordered by the
Architects from time to time to meet the requirements of the works. Great care shall
be taken to prevent sand etc. from entering the pipes. The pipes between two
manholes shall be laid truly in straight lines without vertical or horizontal
undulations. The body of the pipes shall rest on an even bed in the trench for its
length and places shall be excavated to receive collar for the purpose of jointing. No
deviations from the lines, depths of cuttings or gradients as called for on the drawings
shall be permitted without the written approval of the Architect. All pipes shall be laid
at least 60cms below the finished ground level or as called for on the drawings.
Setting out Trenches
The contractor shall set out all trenches, manholes, chambers and such other
works to true grades and alignments as called for. He shall provide the necessary
instruments for setting out and verification for the same. All trenches shall be laid to
true grade and in straight lines and as shown on the drawings. The trenches shall be
laid to proper levels by the assistance of boning rods and sight rails which shall be
fixed at intervals not exceeding 10 meters or as directed by the Project Manager.
Timbering of Sewer and Trenches

Project Name : -
Site Address :-
The Contractor shall at all times support efficiently and effectively the sides of
all the trenches and other excavations by suitable timbering, piling and sheeting and
they shall be close timbered in loose or sandy starta and below the surface of the sub
soil water level.
All timbering, sheeting and piling with their wallings and supports shall be of
adequate dimensions and strength and fully braced and strutted so that no risk of
collapse or subsidence of the walls of the trench shall take place.
The Contractor shall be held responsible and shall be accountable for the
sufficiency of all timbering, bracings, sheeting and piling used and also for, all damage
to persons and property resulting from improper quality strength placing,
maintaining or removing of the same.
Shoring of Buildings
The Contractor shall shore up all buildings, walls and other structures, the
stability of which is liable to be endangered by the execution of the work and shall be
fully responsible for all damages to persons or property resulting from any accident.
Obstruction Road
The contractor shall not occupy or obstruct by his operation more than one
half of the width of any road or street and sufficient space shall then be left for public
and private transit. He shall remove the materials excavated and bring them back
again when the trench is required to be refilled. The contractor shall obtain the
consent of the Project Manager in writing before closing any road to vehicular traffic
and the foot walks must be clear at all times.
Protection of Pipes etc.

Project Name : -
Site Address :-
All pipes, water mains, cables etc. met in the course of excavation shall be
carefully protected and supported. Care shall be taken not to disturb the cables, the
removal of which shall be arranged by the contractor with the written consent from
the Project Manager.
Contractor to restore settlement and Damages
The contractor shall at his own costs and expenses, make good promptly
during the whole period for the works in hand if any settlement occurs in the surfaces
of roads, beams, footpaths, gardens, open spaces etc. in the public or private areas
caused by his trenches or by his other excavations and he shall be liable for any
accident caused thereby. He shall also, at his own expense and charges, repair (and
make good) any damage done to building and other property. If in the opinion of the
Project Manager he fails to make good such works with all practicable dispatch, the
Project Manager shall be at his liberty to get the work done by other means and the
expenses thereof shall be paid by the contractor or deducted from any money that
may be or become due to him or recovered from him by any other manner according
to the laws of land.
The contractor shall at his own costs and charges provide places for disposal of
all surplus materials not required to be used on the works. As each trench is refilled,
surplus soil shall be immediately removed, the surface shall be properly restored and
roadways and sides shall be left clear.
Removal of Water from Sewer, Trench etc.
The contractor shall at all times during the progress of work keep the
excavations free from water which shall be disposed by him in a manner as will
neither cause injury to the public health nor to the public or private property nor to
the work completed or in progress nor to the surface of any road or streets, nor cause
any interference with the use of the same by the public.
Project Name : -
Site Address :-
If any excavation is carried out at any point or points to a greater width of the
specified cross section of the sewer with its cover, the full width of the trench shall be
filled with concrete by the contractor at his own expense and charges to the
requirements of the Project Manager.
Removal of Filth
All night soil, filth or any other offensive mater met with during the execution of the
works, shall not be deposited on the surface of any street or where it is likely to be a
nuisance or passed into any sewer or drain but shall be immediately, after it is taken
out of any trench, sewer or cess pool, put into the carts and removed to a suitable
place to be provided by the Contractor.
3.3 Piping material
RCC pipes (for encasing the pipes at road crossing)
All pipes shall be centrifugally spun RCC pipes NP2. Pipes shall be true and
straight with uniform bore throughout. Cracked, warped pipes shall not be used on
the work. All pipes shall be tested by the manufacturer and the Contractor shall
produce, prior to use on site, a certificate to that effect from the manufacturer.
The pipes shall be with or without reinforcement as required and of the class
as specified. These shall conform to IS:458-1971.
All pipes shall be true to shape, straight, perfectly sound and free from cracks
and flaws. The external and internal surface of the pipes shall be smooth and hard.
Project Name : -
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The pipes shall be free from defects resulting from imperfect grading of the aggregate
mixing or moulding.
Laying
RCC spun pipes shall be laid on cement concrete bed of cradles as specified and
shown on the detailed drawings. The cradles may be precast and sufficiently cured to
prevent cracks and breakage in handling. The invert of the cradles shall be left 12 mm
below the invert level of the pipe and properly placed on the soil to prevent any
disturbance. The pipe shall then be placed on `the bed concrete or cradles and set for
the line and gradient by means of sight rails and boning rods, etc. Cradles or concrete
bed may be omitted, if directed by the Project Manager.
Jointing
Semi flexible type collar joint.
Hemp rope soaked in neat cement wash shall be passed round the joint and
inserted in it by means of caulking tool. More skein of yarn shall be added and
rammed home. Cement mortar with one part of cement and two part of sand and with
minimum water content but on no account soft or sloppy, shall be carefully inserted,
punched and caulked into the collar and more cement mortar added until the space of
the collar has been filled completely with tightly caulked mortar. Provision of rubber
sealing ring in the collar joint shall also be made. The joint shall then be finished off
neatly outside the socket at an angle of 45 deg.
Curing:
The joint shall be cured for at least seven days. Refilling at joints will be
permitted only on satisfactory completion of curing period.
Project Name : -
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Cement Concrete for Pipe Supports:
Unless otherwise directed by the Project Manager cement concrete for bed, all round
or in haunches shall be as follows:
upto 1.5 m upto 3 m

beyond 3 m depth
depth depth
Stoneware pipes buried in

All round In Haunches In Haunches
open ground (no sub soil
(1:3:6) (1:3:6) (1:3:6)
water)

RCC or SW in sub soil water
(1:3:6) (1:3:6) (1:3:6)

PVC / HDPE pipe
(1:2:4) (1:3:6) (1:3:6)

CI Pipes (in all conditions)
(1:4:8) (1:4:8) (1:4:8)
All round All round

All pipes under building All round (1:2:4)
(1:2:4) (1:2:4)
ii. Pipes may be supported on brick masonry or precast RCC or in situ cradles.
Cradles shall be as shown on the drawings.
Project Name : -
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iii. Pipes in loose soil or above ground shall be supported on brick or stone
masonry pillars as shown on the drawings.
Measurement:
a. Excavation
Measurement for excavation of pipes trenches shall be made per linear meter.
b. Trenches shall be measurement between outside walls of manholes at top and

the depth shall be the average depth between the two ends to the nearest cm. The
rate quoted shall be for a depth upto 1.5 metre or as given in the Bill of Quantities.
Payment for trenches more than 1.5 m in depth shall be made for extra depth as given
in the Bill of Quantities and above the rate for depth upto 1.5 m.
c. RCC pipes shall be measured for length of the pipe line per linear meter.
i. Length between manholes shall be recorded from inside of one manhole or

inside of other manhole.
ii. Length between gully trap and manhole shall be recorded between socket of
pipe near gully trap and inside of manhole.
3.4 UPVC/PVC Pipes and Fittings
The pipes shall be round and shall be supplied in straight lengths with
socketed ends. The internal and external surfaces of pipes shall be smooth, clean, free
Project Name : -
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from grooving’s and other defects. The ends shall be cleanly cut and square with the
axis of the pipe. The pipes shall be designed by external diameter.
Fittings
Fittings shall be of the same make as that of pipes, injection moulded and shall
conform to Indian Standard.
Laying in Trenches
UPVC/PVC pipes shall be laid on cement concrete bed of width 300mm over
the outside diameter of pipe, and 100 mm thickness. Fine sand shall be carefully filled
around the lower half of the pipes so as to buttress them to the sides of the trench.
The filling shall then be continued to 150mm over the top of the pipe using fine
sand, watered and rammed on both sides of the pipes. The process of filling and
ramming with fine handpicked material shall proceed evenly in layers not exceeding
150mm thickness, each layer being watered and consolidated so as to maintain an
equal pressure on both sides of the pipe line.
S.W. Gully Trap
Gully trap shall be stoneware conforming to IS:651. These shall be sound and free
from visible defects such as fire cracks, or hair cracks. The glaze of the traps shall be
free from cracks. They shall give a sharp clear note when struck with light hammer.
There shall be no broken blisters. Each gully trap shall have one CI grating of square
size corresponding to the dimensions of inlet of gully trap. It will also have a water
tight CI cover with frame inside dimensions 300 x 300mm the cover weighing not less
than 4.5 kg and the frame not less than 2.7kg. The grating cover and frame shall be of
good casting and shall have truly square machined seating faces.
Project Name : -
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Fixing of S.W. Gully Trap
The excavation for gully traps shall be done true to dimensions and levels as indicated
on plans or as directed by the Project Manager /Consultant / Architect. The gully
traps shall be fixed on cement concrete foundation 65cm square and not less than
10cm thick. The mix for the concrete will be 1:4:8. The jointing of gully outlet to the
branch drain shall be done similar to the jointing of S.W. Pipes described earlier. After
fixing and testing gully and branch drain, a brick work of specified class in cement
mortar 1:5 shall be built with a half brick masonry work round the gully trap from the
top of the bed concrete upto ground level. The space between the chamber and trap
shall be filled in with cement concrete 1:3:6. The upper portion of the chamber i.e.
above the top level of the trap shall be plastered inside the cement mortar 1:3 finish
with a floating coat of neat cement. The corners and bottom of the chamber shall be
rounded off so as to slope towards the grating.
CI cover with frame 300 x 300 mm (inside) shall then be fixed on the top of the
brick masonry with cement concrete 1:2:4 and rendered smooth. The finished top
cover shall be so as to prevent the surface water from entering the gully trap.
Measurements
Gully traps shall be measured by the number and rate which shall include all
excavation, foundation, concrete, brick masonry, cement plaster inside and outside, C
I grating and sealed cover and frame.
3.5 Construction of manhole
Where manholes are to be constructed, the excavation, filling back and ramming,
disposal of surplus earth, preparation of bottom and sides etc. shall be carried out as
Project Name : -
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described earlier under trench excavation. Manhole shall be sized and depths as
called for in the drawings and Bill of Quantities.
The manhole shall be built on a base concrete 1:3:6 of 150mm thickness for
manholes upto 1500mm depth and 250mm thickness for manholes from 1500 to
2500mm depth and 300mm thickness manholes of depth greater than 2500mm.
Reinforcement as shown shall be provided in the base slabs.
The walls shall be of brick work of thickness as shown in drawings built in

cement mortar 1:5. The joints of brick work shall be raked and plastered internally in
cement mortar 1:3 (at least 12 mm thick) and finish with a coat of neat cement,
external plaster shall be rough plaster in 1:3, PCC benching & semicircular channels of
the same diameter as the pipes shall be provided and finished with neat cement
coating.
Above the horizontal diameter, the sides of channel shall be extended

vertically to the same level as the crown of the outgoing pipe and the top edge shall be
suitably rounded off. The branch channels shall also be similarly constructed with
respect to the benching but at their junction with the main channel an appropriate fall
suitably rounded off in the direction of flow in the main channel shall be given. All
manholes / sumps shall be provided with poly propylene coated steel reinforced foot
rest. The polypropylene shall confirm to ASTM D-4101 specification, injection
moulded around 12 mm dia IS-1786 grade FE-415 steel reinforcing bar. These rungs
shall be set at 30cms interval in two vertical runs at 380mm apart horizontally. The
top rung shall be 450mm below the manhole cover. Unless otherwise mentioned,
manholes shall be constructed to the requirements of Indian Standard IS:4111 (Part
I). All manholes shall be constructed so as to be water tight under test. All angles shall
be rounded to a 75mm radius with cement plaster 20mm thick. The benching at the
side shall be carried out in such a manner so as to provide no lodgment for any
splashing in case of accidental flooding. Manhole cover with frame shall be of cast iron
of an approved make. The covers and frame shall generally be double seal as specified
in the Bill of Quantities.
3.6 Measurements
Project Name : -
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Manhole shall be measured in numbers as indicated in the Bill of Quantity. The depth
of manhole shall be measured from invert of channel to the top of manhole cover.
Manhole with depth greater than specified under the main item shall be paid for
under Èxtra Depth’ and shall include all items as given for manholes depth will be
measured to the nearest cm. Depth of the manholes shall be measured from top of the
manhole cover to bottom of channel. The following are inclusive in the cost of
manhole viz;
Bed concrete
Brick work.
Plastering (inside & outside)
R C C top slab, benching and channeling including drop connections.
Supply and fix foot rests.
Keeping holes and embedding pipes for all the connections.
Excavation, refilling, necessary de-watering and disposing off surplus soil to a places
as directed by Project Manager.
Curing
Cost of angle frame and embedding the frame in concrete bed.
Testing.
De-watering of chambers.
3.7 Drop Connection
Drop connection shall be provided between branch sewer and main sewer in
the main sewer itself in steep ground when the difference in invert level of two
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exceeds 60 cms of the required sizes. Drop connections from gully traps to main
sewer in rectangular shall be made inside the manholes and shall have CI special
types door bend on to top and heel rest bend at bottom connected by a CI pipe. The
pipe shall be supported by holder bat clamps at 180 cms intervals with atleast one
clamp for each drop connection. All joints shall be lead caulked joints 25mm deep.
Drop connections from branch sewer to main sewer shall be made outside the
manhole wall with CI / CI class LA pipe, connection, vertical pipe and bend at the
bottoms. The top of the tee shall be finished upto the surface level and provided with
a CI hinges type frame and cover 30cms x 30cms. The connection and tee upto the
surface chamber of the tee.
Drop connection made from vertical stacks directly into manholes shall not be
considered as drop connections.
Road Gully chambers
The chamber shall be of brick masonry with Bricks of class designation 75 in cement
mortar 1:5 (1 cement : 5 coarse sand) and shall have a PCC/SFRC/D.I gully grating
with frame fixed in 150mm thick cement concrete 1: 2 :4 (1 cement : 2 coarse sand : 4
hard stone ballast 20mm nominal size) on top. The size of the chamber shall be taken
as the clear internal dimension as specified in the schedule of quantities. The brick
walls on the top of the bed concrete 1:4:8 (1 cement : 4 coarse sand :8 hard stone
ballast 40 mm and down gauge) of the chamber shall be plastered with 12mm thick
cement plaster 1:3 (1 cement : 3 coarse sand) internally and externally and finished
with a floating coat of neat cement . The excavation shall be done true to dimension
and level shown in the drawing.
Masonry Drains
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Brick masonry drains shall be of a minimum width of 30cms for depth upto 45cm and
a maximum width of drains shall be 45cms for depths beyond 45cms. However, in
special cases where the depth is very high, the width of drain shall be in proportion of
1:5 with the depth. Brick masonry drains shall be constructed in brick masonry in
cement mortar 1:5 in cement concrete foundations as specified in the schedule of
quantities. Whereever specified, masonry drains shall be plastered with cement
mortar inside. The outer surface shall be flush pointed without additional charge.
All brick masonry covered drains shall be provided with Cast Iron perforated cover
with frame or cast in situ or precast RCC slabs as specified in drawings. All drains
shall be plastered with cement mortar 1:4, 12mm thick with a coat of neat cement. All
finished work shall afford specified gradient to ensure free and efficient discharge.
Payment for masonry drains shall be made under individual items of masonry,
cement concrete and plaster by volume of area as given in the drawings and schedule
of quantities.
3.8 Making Connections
Contractor shall connect the new sewer line to the existing manhole by cutting
the walls benching and restoring them to the original condition. A new channel shall
be cut in the benching of the existing manhole for the new connection. Contractor
shall remove all sewage and water if encountered in making the connection without
additional cost.
3.9 Grease Trap

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Size of Grease Trap
The size given in Bill of Quantities and drawings shall be internal size of
chamber. The work shall be done strictly as per standard drawing and following
specifications.
Bed Concrete
Shall be in 1:4:8 cement concrete 150 mm thick.
Brick work
Brick work shall be with best quality bricks in I:5 CEMENT MORTAR.
Baffle walls shall be of R.C.C and of size as mentioned in Bill of Quantities. Brick
partition constructed of best quality table moulded bricks in cement mortar 1:5 shall
be provided for the entire height of chamber.
Plaster
The walls of chamber shall be plastered from inside with 12 mm thick cement
plaster 1:3 and finished smooth with a floating coat of neat cement & rough plaster on
outside in cement mortar 1:3.
Chamber Covers
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Covers shall be of size and duty as mentioned in Bill of Quantities. Covers shall
be of cast iron as per the details given in the drawing and shall be fixed on frame
embedded in concrete.
C. I steps shall be provided at two corners of the chamber.
All Cast Iron and MS items shall be painted with two coats of bitumastic paint.
Technical Specification
Polymer Concrete Channel for External Drainage System:
The Channel shall be of specification EN 1433 for External Application. It shall be Pre
casted of V Shape cross section, the material of construction is Polymer Concrete and
it has integrated edge rail and safety groove. It should provide water tight laying, the
grating will have a locking system so that it can fit on safety groove. The Gratings are
as per load class A15, B125, C250, D400 and E600 of materials C.I. or S.S. or G.I.
depending on the application. The Channels shall have tongue & groove facility for the
Interlocking for uniformity of a line.
S.S gullies and channels for wet area:
Gully and Channel are made up of S.S. 304 or 316 for Corrosion resistance. It shall be
with Removable F.A.T. (Foul Air Trap), the Water drainage capacity shall be upto 1.2
l/s. The product should have Horizontal or Vertical Spigot Outlet with Water Seal of
30mm-50mm. The Products shall be with Pickle passivated to prevent Corrosion at
joints.
Project Name : -
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Recessed access covers:
The Recess Access Covers shall be of specification EN 124. The material of

Construction is Aluminium, Galvanise Steel or S.S. depending on the Applications
(Indoor or Outdoor). Load Bearing Capacity of A 15, B 125, C 250 AND D400
depending on the Application. The Covers shall be Gasket Seal and Locking Screw
Fixed Type. The Covers shall be Triple Seal (Air Tight, Water Tight and Dustproof).
The Recess Cover shall have provision for infill (50mm-110mm) to match the surface
finish.
PP (Polypropylene) channels
The Product shall be of specification EN1433. The material is made of PP

(Polypropylene). It shall be Prefabricated & of 1Mtr Length. Gratings shall be of load
class A 15, B 125 & C 250 of Materials P.P, G.I. or S.S. depending on the applications,
Gratings are Friction Fit for eliminating Grating Movements. Slot Gratings shall also be
available with opening of 12.5mm Slit depending on the application. The Channels can
be Inter locked for uniformity of a line.
PP (Polypropylene) Gullies
The Product shall be of specification EN 1253. The material is made of PP

(Polypropylene), highest grade in Plastic. The Gully shall have removable F.A.T (Foul
Air Trap) and shall have a Height Adjustable riser depending on the Floor Height. It
shall have Water Seal of 30mm-50mm. It shall carry Flow Rate of 1.8 l/s. The Product
shall be available with Horizontal and Vertical Outlet (Sizes 50mm,75mm,110mm)
Grass grids
Project Name : -
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The Product is made of PE (Polyethylene) & shall protect the grass roots. It shall also
take the impact of moving load. The load carrying capacity of the product shall be
more that 250 tonnes / m2. The grid can be used in walkway, car park, drive way
area.
Cast iron Manhole cover and Frame
The Cast Iron Manhole Cover and Frame shall conform to IS:1726 and the
grade and types have been specified in the Bill of Quantities. The cover and frames
shall be cleanly cast and they shall be free from air and sand holes and from cold
shuts. They shall be neatly dressed and carefully trimmed. All castings shall be free
from voids whether due to shrinkage, gas inclusion or other causes. Covers shall have
a raised checkered design on the top surface to provide an adequate non-slip grip.
The sizes of covers specified shall be taken as the clear internal dimensions of
the frame.
The covers and frames shall be coated with a black bituminous composition.
The coating shall be smooth and tenacious. It shall not flow when exposed to a
temperature of 63° C and shall not brittle as to chip off at a temperature of 0° C.
3.10 Testing
All rights of the sewer and drain shall be carefully tested for water tightness by
means of water pressure maintained for not less than 30 minutes. Testing shall be
carried out from manhole to manhole. All pipes shall be subject to a test pressure of
1.5 meter head of water. The test pressure will however, not exceed 6 meters head at
any point. The pipes shall be plugged preferably with standard design plugs or with
rubber plugs on both sides, the upper end shall, however, be connected to a pipe for
filling with water and getting the required head poured at one time.
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Sewer lines shall be tested for straightness by :
i. Inserting a smooth ball 12 mm less than the internal diameter of the pipe. In
the absence of obstructions such as yarn or mortar projecting at the joints the ball
shall roll down the invert of the pipe and emerge at the lower end.
ii. means of a mirror at one end a lamp at the other end. If the pipe is straight the
full circle of light will be seen otherwise obstructions or deviations will be apparent.
iii. The contractor shall give a smoke test to the drain and sewer at his own
expense and charges, if directed by the Owner’s site representative.
iv. A test register shall be maintained which shall be signed and dated by
contractor and Owner’s site representative.
SECTION 4
WATER SUPPLY SYSTEM
4.1 General
4.1.1 Scope
Provide and install a complete water supply system as per drawings and as described
below and on the drawings.
4.1.2 Manuals
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Three sets of all manuals for the systems shall be submitted to the main contractor.
This shall include instruction and maintenance manuals.
4.1.3 As-built Drawing
As built drawings as specified in the contract shall be submitted to the main

contractor on completion of work.
Drawing shall clearly show pipe routes, component details including with different
colours w.r.t. the application.
4.1.4 Training
It is the responsibility of the Contractor to train the concerned personnel in the

presence of the main contractor for operation and maintenance of the system.
4.2 Water system
Overview
Required number of deep bore wells in addition to the city municipal water
connection supply water to an underground water tank.
The underground water tank comprises raw water storage, fire service water storage
and domestic treated water storage. Two manhole access holes are provided for each
compartment in the tank system to provide for access into the tank for maintenance
purposes. Air vents are fitted to each compartment.
4.2.2 PPR pipes and fittings for water connections
This specification covers requirements, test methods, and methods of marking for
Poly propylene random (PPR) plastic hot-and cold-water distribution system
components made in one standard dimension ratio These components comprise pipe
and tubing, socket-type fittings, plastic-to-metal transition fittings. Requirements and
methods of test are included for materials, workmanship, dimensions and tolerances,
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hydrostatic sustained pressure strength, and thermo-cycling resistance. The

components covered by this specification are intended for use in hot and cold, potable
water distribution systems. The PPR pipe should be suitable for supply hot and cold
water under the specified pressure and temperature for long durations of time as
specified it shall also be ideal for using in the air conditioning and heating system in
the building if specified. The operating class of the PPR pipes should be of PN-16 or
PN-20 at the specified pressure and temperature for both cold and hot water
distribution.
Standards:
The ppr pipes should be manufactured in accordance to DIN 8077 and DIN 8078
standards.
The pipes should be conforming to BIS standards-IS 15801:2008.
DIN 1598 Test Method for Time-to-Failure of Plastic Pipe Under Constant Internal
Pressure
DIN 1399 Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe,
Tubing and Fittings.
Terminology
i.Definitions:The abbreviation for Poly Propylene Random pipes is PPR pipes.

Corrosion resistant pressure pipe, IPS sizes 1/8" through 24", for use at temperatures
up to and including 140°F. Pressure rating (120 psi to 1230 psi) varies with schedule,
pipe size, and temperature. Generally resistant to most acids, bases, salts, aliphatic
solutions, oxidants, and halogens. Chemical resistance data is available and should be
referenced for proper material selection. Pipe exhibits excellent physical properties
and flammability characteristics. Typical allications include: chemical processing,
plating, high purity applications, potable water systems, water and wastewater
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treatment, drainage, irrigation, agricultural, and other applications involving

corrosive fluid transfer.
Materials
Basic Materials Description— Poly propylene random plastics used to make pipe,
tubing, and fittings meeting the requirements of this specification are categorized by
two criteria; namely, basic short-term properties, and long-term hydrostatic strength
Installation:
PPR pipe should be heat fused together to form a joint that is as strong as or stronger
than the pipe itself and should be leak free. This should eliminate the potential leak
points every 10-20 feet as found usually with PVC and Ductile Iron bell and spigot
connections.
The heat joints to be done by a skilled plumber so that the fused joints/fittings are
made to the required quality.
Requirements for Pipe, Tubing and Fittings
Dimensions and Tolerances:
The selection of PPR pipes have to be done as per the below table.
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Plastic-to-Metal Transition Fittings:
The PPR pipes fittings should be conforming to DIN 16962 standards suitable for both
PPR pipes and metal/brass elements. The pipe should be suitable for the fittings PPR
to PPR by heat welding/fusing or the fittings should be with metal insert sunk in the
PPR body allowing connection to equipment/fitting installed previously or any other
threaded metal elements.
Hydrostatic Sustained Pressure:

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General — Pipe, tubing, and fittings (tested as assemblies) shall meet the minimum
hydrostatic sustained pressure requirements of both test conditions as per standards;
when tested in accordance with TEST METHODS FOR PIPE, TUBLING AND FITTINGS.
Pipe and Tubing Quality shall be termed as the primary sustained pressure test for
pipe and tubing and shall be used for quality control. It shall also be termed as the
secondary sustained pressure test for pipe and tubing and shall be used for periodic
performance qualification. Failure to pass either test is cause for rejection.
Fitting Quality— shall be termed the primary sustained pressure test for fittings and
shall be used for quality control. It shall also be termed as the secondary sustained
pressure test for fittings and shall be used for periodic performance qualification.
Failure to pass either test is cause for rejection.
Thermo cycling — Plastic-to Plastic and Plastic to -metal transition fittings (other
than metal socket-type transitions for use with heat weld assembled according to the
manufacturer's instructions, shall not separate or leak when thermo cycled 1000
times between the temperatures of 60F and 180F [16C and 82C] in accordance with
TEST METHODS FOR PIPE, TUBLING AND FITTINGS.
Assembly
The welds are made by first heating the outside surface of the pipe and the inside
surface of the fitting simultaneously on the welding machine dies. The pipe is then
inserted in the fitting to create a socket joint.
The heating and socket joint process should be done as per the processing table
below.
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The punching process should be done by using a special scraping tool by hand or with
the aid of a drill to ensure the PPR coating is removed and once the heating time is
passed as specified the repair bar must be inserted into the hole when this operation
is complete wait for the specified cooling time and then cut off the excess part of the
repair.
Installation
The Installation shall be done in accordance to the latest IS Codes and as per the
specifications. The installation/laying of the pipes shall be done as per the drawings.
Handling/storage:
The pipes or pipe bundles must be protected against excessive external stresses such
as shaking, knocks, hammer blows. It is even more important that the storage should
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be done in ambient temperature since at low temperatures the pipe is more rigid and
has less elasticity.
Testing:
The pipes after preliminary installation on site should be tested by a skilled plumber
in the presence of the main contractor. Also the pipes and fittings installed should be
visually checked and ensure no damages or leakages are there in the installation. The
pressure test to conducted at ambient temperature taking care to vent the air present
in the pipe at a testing pressure specified as per standards for a period of 24 hours.
Note: While conducting the pressure test ensures that the CP fittings are not fixed to
avoid damages to the CP fittings since; CP fittings have testing pressures which are
specified by the manufacturer. Any such damages shall be at the risk and cost of the
sub-contractor the main contractor shall not bear any extra cost for replacement.
Test methods for pipe, tubling and fittings
Sampling - A Sufficient quantity of Pipe, tubing or fittings, as agreed upon between the
purchaser and the seller, shall be selected from each lot or shipment and tested In the
case of no prior agreement, random samples selected by the testing laboratory* shall
be deemed adequate.
Test Specimens-Not less than 50% of the test specimens required for any pressure
test shall have at least a pan of the marking in their central sections. The central
section is that portion of pipe, which is at least one pipe diameter away from an end
closure.
Flattening- Flatten three specimens of the pipe. 2 in. [50-mm] long, between parallel
plates in a suitable press until the distance between the plates is 40 % of the outside
diameter of the pipe or the walls of the pipe touch, whichever occurs first. The rate of
loading shall be uniform and such that the compression is completed within 5 min.
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upon removal of the load, examine the specimens for evidence of splitting, cracking,
or breaking.
4.2.3 GI pipes and fittings for water connections
GI pipes and fittings shall be used for cold-water services above and below ground
applications. All internal (shafts) and exposed piping shall be of medium quality
(Class B) galvanized iron, screwed socketed and shall conform to IS 1239 (Part-I) &
below ground shall be heave quality ( Class C) galvanized iron. All fittings shall be
malleable iron galvanized fittings of approved best Indian make. The details of pipes
and sockets regarding nominal bore, thickness and weight in kg/m are as per IS-1239
(Part-I).
The following manufacturing tolerance s shall be permitted on tubes and

sockets.
Thickness
i) Light tubes butt welded + Not limited - 8 percent
ii) Medium and Heavy tube + Not limited - 10 percent butt welded
iii) Medium tubes seamless + Not limited - 12.5 percent
Weight
i) Single tube (light series) + 10 percent - 8 percent
ii) Single tube (medium and heavy series) + /- 10 percent
iii) For quantities per load of 10 tonnes, + /- 5 percent Min(light

series)
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iv) For quantities per load of 10 tonnes, + /- 7.5 percent Min

(medium and heavy series)
Laying and fixing
Where pipes have to be cut or re-threaded, ends shall be carefully filed so that no
obstruction to the bore is offered. For internal work all pipes and fittings shall be
fixed truly vertical and horizontal, either by means of standard pattern holder bat
clamps keeping the pipes 1/2” (12mm) clear of the wall everywhere or concealed as
directed. For external work, G.I. pipes and fittings shall be laid in trenches. The width
of the trench shall be the minimum width required for working. The pipes laid
underground shall be not less than 60cm. from the finished ground level and a
minimum horizontal distance of 60CM shall be maintained between other services
lines.
Wrapping of concealed GI pipes
Cleaning
Pipe surfaces shall be thoroughly cleaned and dried before tape is applied and shall
be free of dirt, grease and rust scale or other foreign matter. The pipe shall be cleaned
mechanically.
Oil and grease, if present on the pipe surface should be removed by using a suitable
solvent and clean rags. The use of dirty, oily rags should not be permitted.
Field Application of tape

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The tape shall be wrapped in accordance with the manufacturers recommendations

in a manner that shall meet the adhesion requirement. During application, care shall
be taken to ensure that there are no air pockets or bubbles beneath the tape.
The tape should be wrapped with an overlap of 50% for TEES. The first wrapping
shall be done individually. The tape may be cut if required to suit the profile. There
shall be two layers of tape wrappings. The first layer is to be wrapped on the pipe
directly after cleaning the pipe surface. The second layer is to be applied over the first
layer. The second layer should also be wrapped with 50% overlap.
4.2.4 CPVC pipes
CPVC pipes and fittings shall be used for cold & hot water service applications. All
concealed and inside shaft pipes and fittings upto 50mm diameter will be CPVC SDR
11 grade(operating pressure-7 Bar @ 82 Deg C) and above 50mm dia will be CPVC
SDR 13.5 ( Schedule – 40/80) confirming to ASTM D-2846. CPVC pipes and fittings
shall be used for cold & hot water service applications. All concealed and inside shaft
pipes.
Laying and fixing (CPVC pipes)
Where pipes have to be cut, a wheel type plastic pipe cutter or a hack-saw blade shall
be used. Burrs and fillings inside and outside the pipe shall be removed and a slight
bevel on the end of the tubing shall be made for easy entry of the tubing into the
fitting socket.
Only solvent cement confirming to ASTM-493 shall be used for joining pipes and
fittings as per manufacturer’s instruction.
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All exposed CPVC pipes and fittings shall be rigidly supported on MS pipe supports,
hangers, ‘U’ clamps, and bolts etc., as shown on the detailed drawings and as per the
Engineers’ instructions. All the pipe supports shall be hot dip galvanised as per the
Indian standard specifications. All the pipe supports shall be painted with two coats
of enamel paint over a coat of zinc chromate primer. The colour of the paint shall be
approved by the Engineer. For internal work all pipes and fittings shall be fixed truly
vertical and horizontal, either by means of standard pattern holder bat clamps
keeping the pipes 1/2” (12mm) clear of the wall everywhere or concealed as directed.
4.3 Color code for water supply pipes
Color code for water supply pipes shall be as per standard requirement. Details as
mentioned below.
COLOR CODE FOR GENERAL SERVICES
SL DESCRIPTION GROUND FIRST COLOR SECOND

NO COLOR BAND COLOR BAND
A WATER
1.0 Cooling Sea green French blue ------
2.0 Boiler feed Sea green ------ ------
3.0 Condensate Sea green Light brown Signal red
4.0 Drinking Sea green French blue ------
5.0 Treated Sea green Light orange Canary

yellow
6.0 Cold water from storage tank. Sea green French blue
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4.4 Testing
Before any pipes are painted or covered, they shall be tested to a hydrostatic pressure
of 7kg/sqcm. or twice the working pressure of the pumping main whichever is lighter.
Pressure shall be maintained for at least eight hours without an appreciable drop in
pressure. In addition to the sectional testing of water supply pipes, the contractor
shall test the whole installation to the entire satisfaction of the Engineer in charge. He
shall rectify any leakages, failure of fittings or valves or CP fittings.
4.5 Disinfection of the pipe network
The entire water distribution network is to be disinfected by using residual chlorine

of 0.2 ppm for a period of 2 (two) hours. The entire chlorinated pipe network is to be
flushed out with fresh water before the water supply system is put into operation for
domestic usage.
4.6 Mode of measurement
G.I. pipes above ground shall be measured along the centre line of the pipes and
fittings. The quoted rate for respective item shall be per Rmt and shall include the
following:
Cost of respective pipes and specials.
Laying, fixing and jointing with standard pipe clamps available for different sizes
inside the wall chase and fixed on MS angle iron brackets and GI U clamps for pipes in
ducts as shown on the drawing.
Cutting holes and chases in walls, floors, etc. and making good the same.
All supporting arrangements, brackets, etc.

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Testing and making good the defects, if any. G.I. pipes below ground shall be
measured as stated elsewhere in the specifications.
4.7 Valves, strainers and pressure gauges
General
This section deals with different type of valves like butterfly valves, gate valves, ball
valves, check valves, balancing valves and Strainers and pressure gauges. The
contractor shall refer to the approved make of materials specified in the document &
relevant drawings.
Valves shall be provided on branch pipe connections to mains and at connection to

equipment where indicated. All valves are to be located for easy access. All valves
shall be supported wherever necessary with MS brackets. Valves shall comply with IS
780 (Class I) for C.I sluice valves and IS 778 for G.M valves and tested.
Pressure gauges shall have outer diameter not less than 115mm with 10mm BSP full
thread, brass body syphon and gauge cock of size 10mm. Dial gauges shall have
adequate response for the pressures encountered within the specified (Range
0-15Kg/sq.cm).
Ball valve
The primary function of a gate valve is for starting and stopping of flow. It has a disc
actuated by a stem screw and hand wheel, moves up and down at right angles to the
path of flow of fluid and seats against two faces to shut of flow. As the disc of the gate
valve presents a flat surface to the direction of flow, this valve is only for starting and
shutting the flow in the pipe.
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These valves are of GM make. Supplying, fixing and testing correspond to IS 778-
1984, Specifications for Copper Alloy Gate, Globe and Check Valves for Water Works.
All globe and check valves shall have working parts suitable for hot and cold water, as
required. Valves shall be tagged with permanent label under hand wheel indicating
type or duty.
All valves should have manufacturer’s test certificate indicating the date of shop test
and other quality control tests with the material used for the same. Gate valves shall
be of the size as specified in the BOQ.
Also the following standard corresponds to their manufacture.
Design - API600/BS1414
Face to Face/
End to End - ANSI B 16.10
Flange
Dimension - ANSI B 16.5
Butt Weld Ends - ANSI B 16.25
Pressure/
Temperature
Ratings - ANSI B 16.34
Testing - API 598
Ball valve
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The ball valve shall be of high pressure type and shall be of sizes as specified in the
BOQ. The normal size of a ball valve shall be that, corresponding to the size of the pipe
to which it is fixed. Ball valves shall have body of carbon steel. The ball and the shaft
shall be of stainless steel. The seat shall be of PTFE (polytetrafloraethylene). The
valve shall be complete with socket weld ends and the float of copper sheet. The
minimum thickness of copper sheet used for making the float shall be 0.45mm for a
float exceeding 115mm dia. The body of the high pressure ball valve when assembled
in working condition with the float immersed to not more than half of its diameter
shall remain closed against a test pressure of 3.5kg/sqcm.
The ball valve shall generally conform to IS specification No.1703: 1977. The weight
of ball cock and the size of the ball cock shall be as per IS specification.
Foot valves
Foot valves are provided with cast iron body with brass disc and strainer of approved
quality as specified in BOQ. The foot valve shall be of spring loaded or flapper type
depending on the requirement. The valves should be tested physically for free
operation before being mounted or assembled to the pipeline.
Butterfly valves
Butterfly valves shall be slim seal, short wafer type with standard finish. The valves
shall be suitable for mounting between flanges drilled to ANSI 125. The valve body
shall be cast iron. The disc shall consist of disc pivot and driving stem shall be in one
piece centrally located. The disc shall move in bearings on both ends with ‘O’ ring to
prevent leakage. The seat shall be moulded with black nitrile rubber or nylon and
shall line the whole body. The spindle shall be AISI 41 steel. The valve shall be
suitable for a working pressure of 16.5 kg/sq.cm and shall be complete with flow
control lever and notches, factory machined companion flanges and bolts and nuts.
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These valves conform to BS 5155 with electro steel nickel coated SG Iron (N) and seat
material EPDM3.
Also the following standard corresponds to their manufacture
Design - API609 / BS5155
Face to Face/
Flange
Pressure/
Temperature
Body - Heavy duty CI to IS210 Gr
FG220 & BS 1452
Seating - moulded in situ resilient
lining of black nitrile rubber.
Disk - Nylon coated SG iron of IS
1865 / SF400 / 127BS2729
Gr. 420 / 12
Shaft - shafts are to be made of SS AISI 431 Only, flanged valves to be

used with Flanges drilled to BS10 table F, valves Shall be capable of being locked in
open Position. Hand wheel shall be with Worm and worm wheel operated for
Smooth opening and closing. Key rod with MS Coated extended spindle to be provided
wherever the valves are not approachable from the ground surface.
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Check valves
Check valves are designed to prevent reversal of flow. These are also called Non-
return valves or reflux valves to avoid reversal of flow. Check valves shall be Dual
Plate check valves with CI body, Aluminium bronze plate SS 316 hinge pins and
springs and Buna-N seals to ANSI series 125. They can also conform to IS 778-1984,
Specifications for Copper Alloy Gate, Globe and Check Valves for Water Works.
Also the following standard corresponds to their manufacture
Design - BS1873 / IS 5312 Part I
Face to Face/
Flange
Pressure/
Temperature
Strainers
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“Y” strainers up to 50mm shall be of gunmetal and above 50mm shall be of cast iron
body. Strainers shall incorporate a removable bronze screen with 3.175 mm (1/8”)
perforations and a permanent magnet. Strainers shall be provided with flanges at
both inlet and outlet. They shall be designed to enable blowing out of accumulated
dirt and facilitate dirt and facilitate removal and replacement of the screen without
disconnection of the main pipe.
All strainers shall be provided with equal size isolating “Slim Seal” butterfly valves of
approved brands as shown in drawings so that the strainer may be cleaned without
draining the system
Flanges and unions
Sufficient number of flanges and unions shall be provided as required to facilitate

maintenance work after the piping is installed. Mild steel flanges shall be used for
pipes. The flanges shall be connected to the pipeline by screwing or welding
depending on the requirement. The flanges shall conform to the relevant ASTM
standard for the particular material used for its manufacture. The flanges shall also
conform to IS 5211.
Brass bib cock and stop cock
A bibcock is a draw off tap with a horizontal inlet and free outlet and stop cock (stop
tap) is a valve with a suitable means of connections for insertion in a pipeline for
controlling or stopping the flow. They shall be of specified size and shall be screw
down type. The closing device should work by means of a disc carrying a renewable
non-metallic washer, which shuts against water pressure on a seating at right angles
to the axis of the threaded spindle, which operates if. The handle shall be either crutch
or butterfly type securely seated pattern. The cocks (taps) shall open in anticlockwise
direction.
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The bibcock and stopcock shall be polished bright (Chrome plated). The minimum
finished weights of bib tap (cock) and stop tap (cock) as given in the IS specification
are reproduced in the table:
Minimum finished weight
Size Bib tap Stop tap
Mm kg. Kg.
8 0.25 0.25
10 0.30 0.35
15 0.40 0.40
20 0.75 0.75
Level sensors
Level sensor shall consist of control unit, preamplifier and one full insulated probe-
mounted vertically or two part insulated probe mounted from tanks side wall
adjustable switching system for pump control application, the same to be housed in
stove enamel painted cast Aluminium weather proof suitable for black panel / wall
mounting etc.,
The enclosure of probes shall be manufactured with SS316 material. The least count
of the central unit with amplifier should be +/- 0.10mm for response value of 30
seconds.
Level indicators
A level control system with electronic level probes is mounted on the face of the
reservoir. The top two level sensors provide the ON-OFF signal for the treated water
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transfer pumps. A third level sensor enunciates a low level alarm condition to the
paging system and a fourth sensor enunciates an alarm to the paging system and
stops the domestic water pumps from operating.
Relief vents
Drainage systems, especially those in tall buildings, are frequently found to develop
extremely high and objectionable pneumatic effects in several specific portions of
such piping. Special air pressure relief vents are recommended to control, within
tolerable limits.
The air pressure relief vent, at least one-half the diameter of the building drain,
should be provided at the top of vertical offset so as to supply such additional air to
the drain as may be required by the sudden increase in liquid velocity in the vertical
offset Where a building trap or other sharp change in flow direction is provided in the
building drain downstream from the vertical offset, an air pressure relief vent should
be provided at the base of, and within 3 ft (0.900m) of, the vertical offset. Lower relief
vent should be branch –connected to the upper relief vent at a sufficient height.
The recommended provision for soil and waste stacks more than ten stories in height
is to provide a yoke relief vent at each tenth story of the drainage stack, counting
downward from the top story. The lower end of the yoke relief vent should connect to
the drainage stack by means of a Y located below the horizontal branch drain serving
fixtures in that story, and the upper end should connect to the vent stack by means of
a T or inverted Y located atleast 3 ft (0.900m) above the floor level as shown in the
drawing.
Installation of valves
Valves should be installed in true tolerance of +/-5mm with respect to the centerline
of the pipe. Where threaded joints are encountered the threads should be initially
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sealed with PVC tape to avoid leakage due to improper tightening and leakage from
threading.
Proper care has to be taken in welded installation so that the centerline of valve
should not deviate from the pipe causing uneven load on the pipe and further stress
during its operation. The welding should be done only after proper inspection of the
joint by the Engineer-in-charge in the tacked position of the joint.
Before putting the line in operative mode the valves should be checked for free and
easy operation of the hand wheel. Any burrs or foreign materials should be removed
by flushing before final operation so that no choking in the valves should occur which
might damage the valve seating.
4.8 Mode of measurements
Valves shall be measured in number only and the cost shall include:
a) Cost of valves and jointing materials.
b) Fixing and jointing with necessary bolts, nuts, rubber inserting, etc.
Testing and making good the defects if any.
4.9 Water hammer arrestors
The effective fluid hammer which result in breaking of pipeline caused due to series
of hydraulic shock should be arrested by means of a water hammer arrestor. The
arrestor shall be capable of withstanding pressures upto 500 P.S.I. and temperatures
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in the range of –400F to 2120F (-540 C to +1000C). It shall be maintenance free with a
companion flange to suit in the pipeline. The following materials are used for its
manufacture
Barrel Type ‘K’ hard drawn copper.
Cap Standard wrought copper fittings attached to
Barrel with 95-5 solder.
Piston & Thread
Adaptor Machined of free turning brass.
Seals “O” rings shall be of Parker spec. EP-5778-80
Seal
Lubricant Dow-corning silicone compound #111, FF & DA
Listed for use in potable water system or
Nickel-plated for seawater application.
4.10 Pumps
Different types of pumps:
The pump set offered shall be generally horizontal centrifugal pump, single stage or
multistage or monobloc pump to satisfy the duty conditions stipulated in the bill of
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quantities. The pump set shall conform to IS 8034-1972, IS 5120-1968 for handling
water.
The pumps shall be selected having their maximum efficiency at average operating
conditions. The maximum speed at which a pump shall run is determined by the net
positive head available at the pump, the quantity of liquid being pumped and the total
head.
Material of construction for centrifugal pumpsets:
Material of construction for different parts of pump set shall be as per IS 5120.
Following are indicated for guidance for pumps handling clear, cold fresh water
Bronze fitted pump
Casing Cast iron – grade 20 of IS 210-1970
Impeller, casing ring,
Impeller ring, shaft
Sleeve Bronze – grade V of IS 318-1962
Shaft -Steel
All cast iron -Grade 20 of IS 210-1970
All bronze -Grade V of IS 318-1962

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Standard fitted
Casing - Cast iron – grade 20 of IS 210-1970
Impeller, casing ring,
Impeller ring, shaft
Sleeve - Bronze – grade V of IS 318-1962
The material of construction for different classes of construction shall be generally as

follows:
All cast iron pump All bronze Bronze fitted STD. Fitted
Casing Cast iron gr.20 Bronze Cast iron

Castiron Impellers Cast iron gr.20 Bronze
Bronze Bronze
Impeller
Wearing
Rings & bush Cast iron gr.20 Bronze Bronze

Bronze
Shaft Steel Steel Steel Steel
Shaft sleeve Mild steel Bronze Bronze

Bronze
Sleeve nuts Mild steel Bronze Bronze

Bronze
Gland Cast iron / GM CI / GM CI / GM CI / GM

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4.11 General requirements:
Since the motor and the pump are directly coupled or close coupled, the manufacturer
shall indicate the minimum size of the borehole in which the submersible pump can
be erected and suspended freely.
For smooth and efficient working of the submersible pumpset, the manufacturer shall
recommend the minimum submergence.
Gaskets, seals and packing’s:
The gaskets, seals and packing’s used in special purpose pumps shall be suitably
chosen so as to withstand the effect of liquid being pumped.
Liquid pumped Material for seals.
Clear cold fresh water Mechanical seal or cotton yard (lubricated) seal.
Sewage Mechanical seal or white metal foil seal crinkled, lubricated

asbestos yarn.
Accessories:
Essential for pump set used for pumping water.
Oil lubricator with oil level indicator if the pump is lubricated.

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Grease cup for grease lubricated bearings.
Flanged ball valve / Gate valve on suction side if there is positive suction.
Flanged ball valve / Gate valve on delivery side.
Flanged horizontal / vertical check valve on delivery side.
Pressure relief valve.
Pressure gauge (for delivery pipe) and vacuum gauge (for suction pipe) with
copper tubing and winch cock.
Priming funnel with separate or integral air cock.
Float switches or automatic level operated control switch.
Base plate.
Foundation bolts and nuts.
Essential design features:
The pumps shall have suitable features properly designed to ensure satisfactory
performance. In particular design features, such as the following shall be
incorporated.
For water pump sets:
In case of more than one duty point, the performance range is to be indicated and the
prime mover should be of sufficient power to take the entire load in this range. Head
(restrictions) shall be indicated in the nameplates to avoid overloading of the prime
mover.
For working in parallel pumps should be with stable head capacity characteristics.
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Arrangement for cooling of bearings where required.
Balancing water leakage connection should be provided in case of multistage pumps

with balancing discs.
Thrust bearing of adequate size.
4.12 Pump Test:
Pump tests are made to determine the following:
The discharge against the specified head when running at the rated speed under
specified suction lift or head.
The power absorbed by the pump at the pump shaft (BP) under the above specified
conditions and efficiency of the pump under the above specified conditions.
The pump has to be tested at manufacturers works and a test certificate furnished
before supply and tested at site after installation as per procedure as per clause 13 of
5120 – 1968.
Pump Installation:
Installation:
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Certain precautions must be observed in planning a pump installation and during the
erection period. Some of this point will now be considered.
Piping: Both the suction and discharge lines should be independently supported so as
no strains will be thrown on the casing such strains may cause distortions and
rubbing.
The suction line should be as short and straight as possible. Any elbows should have
large radii. For pumps operation with suction lifts no valves other than a foot –valve
should be placed in it. Generally, the diameter is made one or two sizes larger than
the pump flange size. All these precautions insure the maximum available suction
head on the pump. When an oversize line is used an eccentric reducer which is
horizontal at top is placed between it and the pump flange size.
It is very important to have the suction line airtight and to avoid high spots at which
dissolved gases or air might separate out and destroy the vacuum. After piping is
installed and the pump is running all joints should be inspected with a flame, as air
leakage will draw the flame to the opening. The same method can be used to
determine leakage through the packing box, the eccentric reducer is used at the
suction flange to avoid high spot at which the air might collect. The inlet end of the
suction line i.e., submergence should be 1 to 2 m below the minimum water level of
the pump (not less then 1 m) to prevent air from being drawn into the pipe with the
water.
It is desirable to have as long a length of straight piping between the elbow and
suction flange as possible to even out the flow of the water as it enters the pump. The
pump should be placed to secure the greatest possible suction head and yet to be
available for inspection and repair work.
A check valve and gate valve are usually placed in the discharge line. The gate valve is
used to regulate the flow and the check valve prevents backflow into the pump which
might cause it to operate like a turbine and perhaps be damaged on account of over
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speed. The check valve is placed between the gate valve and the pump so that it may
be inspected or rewired without emptying the discharge line.
Foundation: The foundation should be heavy to reduce vibrations and should be

rigid to avoid any twisting or misalignment. A space of 2 to 4 cm is allowed between
the base plate and top of the foundation which is filled with grouting to secure a
uniform load distribution.
When the grouting had dried the base plate should be drawn down evenly to avoid
springing it. After this has been done the shaft is finally aligned both radically and
axially with the driver by means of shims or wedges so that it turns freely. If the shaft
is not properly aligned there will be vibration and excessive wear on the bearings,
packing and wearing rings.
Pump Operation:
Trail/Testing operation: The operation of centrifugal pump is quite simple and safe.
There are relatively few valves and the pump will not be damaged even if the
discharge valve is closed for short periods of time. This has to be done in the presence
of the main contractor.
Starting: The pump must be primed before it will deliver any fluid. Failure to prime
the pump may cause the wearing, rings, rub and seize or the shaft may be scored at
the packing boxes. During starting it is wise to have the vent cock in the casing open
slightly to remove any dissolved air in the water.
It is best to have the discharge valve set so that the least load is thrown on the driver
when the pump is started. The valve should be opened gradually to avoid throwing a
large sudden load on the driver and to prevent a sudden surge in the discharge line.
The discharge valve should be fully open when starting mixed flow or propeller
pumps because the Brake Horse Power will then be a minimum.
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Running: When the unit is running it requires very little attention beyond
occasionally checking to see that
The journal and thrust bearings are running cool and have a sufficient supply of oil.
The packing is adjusted to permit a slight leakage to cool and lubricate it, and the
water is flowing to the water seal of the suction gland to prevent air from leaking in.
Shutting Down: When shutting down, the discharge valve should be in the same
position as when starting up by closing the discharge valve gradually so that less
power is dropped from the line and any sudden pressure surges in the pipe system
are avoided.
Inspection and Maintenance: The subcontractor shall submit all the Manufacturer
supply instruction books/manuals, which give directions for the operations for the
operation and maintenance of each pump. The following information is general.
The wearing ring clearance should be checked as they will increase with time and
thus cause a decrease in efficiency. The frequency of the inspection will depend upon
the liquid handled. If the liquid contains gritty materials or is corrosive, inspection
may be made monthly, but if clear water is pumped it may be sufficient to check them
annually. A general rule is to replace the rings when the clearance has increased 100
percent above the original.
The packing should be replaced after it becomes hard and tends to score the shaft.
When the packing is being replaced the finish of the shaft sleeves should be examined
for smoothness. It is essential that the lantern ring be placed directly under the water
inlet when putting in the new packing to insure a circulation of the water and a
satisfactory seal. The packing should be gradually compressed with the pump
running. It should not be compressed too much as local heating of the shaft and
consequent misalignment will result. A slight leakage will insure proper lubrication
and cooling.
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If the base is not too rigid the shaft alignment should be checked occasionally when
the pump is at a temperature corresponding to running conditions. This must be
done with the packing removed. At the same time the clearance of the journal
bearings should be checked for wear.
The oil should be changed as required band at that time inspected for the presence of
water. If water appears in the oil the pump casing should be examined to find the
leak.
Guarantee of Performance:
The pumps shall be guaranteed by the manufacturer / supplier against defects in

material and workmanship under normal use and service for a period of at least one
year from the date of dispatch.
Guarantee of performance: the supplier shall indicate the working range of the pump
and the efficiency of the pump shall be guaranteed at a specified point of rating only
and shall not be guaranteed to cover the performance of the pump under conditions
varying there from nor for a sustained performance for any period of time. If the
purchaser so desires, the manufacturer shall guarantee the non-overload of the prime
mover for variations in the head in the working range. In the case of pumps where
acceptance tests cannot be conducted on the liquid for which the pump is designed,
the manufacture shall indicate the liquid performance of the pump based on the
results of the tests conducted by him on the pump with water as indicated under 13
and interpolated as explained under 14 (IS 5120). However, in these cases, the
manufacture shall guarantee for the performance of the pump with water for the
specified range.
Tolerance: A tolerance of ±2.5 percent shall be permissible on discharge. However,

for small discharge up to 9000 litres per minute, a tolerance of ±2.5 percent or +24
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liters per minute which ever is higher is allowed. While the negative tolerance 2.5
percent is maintained.
The pump efficiency shall be not less than the specified valve by more than 2.5
percent. This tolerance may be raised to 5 percent in case the prime mover does not
get overloaded.
General requirements:
The specified range shall lied on the stable portion of the head characteristic curve.
This is applicable in case of parallel operations of pumps only.
Suction and delivery ends: The size of the suction end of a double suction pump
should preferably be one size larger then that of the delivery. This is to offset the
increased loss in the suction. Typical practices of piping used are:
85 / 65m, 100 / 75m, 125 / 100m, 150 / 125m, 200 / 150m and 250 / 200m etc.,
For a high-pressure pump, a reflux valve shall be connected on the delivery side and a
pressure relief valve installed in pumping main outside pump house. Need for surge
control devices verified.
Fluid passages: All the liquid passages in the casing and the impeller which are
inaccessible to machining shall be finished to smooth surface as for as possible.
Drainage plugs: Tapped drain holes with plugs shall be provided for draining the fluid
that may drip from the sealing arrangement. The sealing arrangement shall be
sufficiently deep to provide for sufficient quantity of packing to prevent leakage of air.
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Lantern ring: In case, where a lantern ring is used in a stuffing box, it shall be
sandwiched between rows of pickings and shall be easily removable.
Casing: Casing shall be of robust construction and tested to withstand 15 times the
shut-off pressure or twice the rated pressure whichever is higher.
Impeller: The impeller shall be properly balanced along with any other un-machined
rotating parts on proper balancing equipment so as not to cause any vibrations.
Shaft: The shaft shall be finished to close tolerance at the impeller coupling, pulley
and bearing diameters. The impeller, pulley and shaft sleeves shall be firmly secured
to the shaft by keys or nuts of both.
Shaft couplings: Shaft couplings, where provided, shall be properly aligned and firmly
secured to the shaft by keys or nuts on both.
The size of the shaft shall be calculated on the basis of the maximum combined shear
stress. This shall not exceed 30 % of the elastic limit in tension or 18% of the ultimate
tensile strength.
The next higher standard size of shaft in accordance with the relevant standard shall
be chosen.
The design of the shaft shall also be taken into consideration the critical speed of the
shaft, which shall differ from the actual working speed by at least ten percent on
either side.
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Bearings: The bearings should be designed for a minimum life of 20,000 hours or
40,000 hours as required. The bearing housings be designed in such a manner that no
liquid being pumped should enter the housing.
The bearing may be ball, roller or sleeve bearings. In the latter case, some sort of
thrust bearings are necessary. If sleeve bearings are used, they are to be machined for
close running fit. The bearings shall be so designed as to take up the necessary radial
load as well as the net hydraulic axial thrust. Bearings shall be lubricated properly.
Where there is a possibility of fluid entering the bearing the pump shall be provided
with suitable preventive arrangements for example. Deflectors.
Stuffing Boxes: The stuffing boxes shall be extra deep and provided with a cooling
water jacket if so required. In addition, provision for tapping off the leakage liquid
shall also be make. The packing materials employed shall be suitable for
withstanding special conditions such as temperature, corrosion due to the fluid being
handled etc. wherever possible, suitable mechanical seals may be used.
Base plates: The base plates which accommodates the pump and the prime mover,
when provided shall be rigid so that alignment is not affected under normal working
conditions.
Prime mover: The prime mover shall be of a such capacity a provide, under working
site conditions a power which is more then maximum power required by the pump at
any point in the specified range should be a specific margin be required by the
customer in the power of the prime mover, he should go advise the manufacturer for
obtaining the proper recommendations.
Name plate: Every pump shall have a name plate indicating:

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Name and address of the pump manufacturer.
Type, size and serial number of the pump and
Speed, total head, capacity and corresponding pump input for the duty point.
For corrosive liquids the material of the name plate shall suitable to withstand the
corrosive atmosphere.
Different types of pumps:
The pump set offered shall be generally horizontal / vertical centrifugal pump, single
stage or multistage or monobloc pump to satisfy the duty conditions stipulated. The
pump set shall conform to IS 8034-1972, IS 5120-1968 for handling water, IS 8034-
1976 for submersible pump sets and IS 5600-1970 for pumping storm water and
sewage.
The pumps shall be selected having their maximum efficiency at average operating
conditions. The maximum speed at which a pump shall run is determined by the net
positive head available at the pump, the quantity of liquid being pumped and the total
head. All the motors shall have minimum Power Factor of 0.82
The number of pumps, type of pumps and duty conditions for different applications
are tabulated in the end of the section.
Material of construction for centrifugal pump sets:
Material of construction for different parts of pump set shall be as per IS 5120.
Following are indicated for guidance for pumps handling clear, cold fresh water
Project Name : -
Site Address :-
Bronze fitted pump Casing Cast iron – grade 20 of IS 210-1970
Impeller, casing ring, impeller ring,

Bronze – grade V of IS 318-1962
shaft sleeve
Shaft Steel
All cast iron Grade 20 of IS 210-1970
All bronze Grade V of IS 318-1962
Standard fitted Casing Cast iron – grade 20 of IS 210-1970
Impeller, casing ring, impeller ring,

Bronze – grade V of IS 318-1962
shaft sleeve
Material of construction for submersible pumpsets: generally confirm to

IS:8034-1976
Bearing sleeve Grade 3,4 or 5 of IS:318-1962
Casting wear ring Grade 3,4 or 5 of IS:318-1962 or gr. FG 200 of IS:210-1978
Discharge casing Grade FG 200 of IS:210-1978.
Impeller Grade 2 of IS:318-1962 or grade FG 200 of IS:210-1978.
Pump bowl Grade FG 200 of IS:210-1978.
12 percent chromium steel (grade 04 or 13, 12 or 13 and

20 or 13) conforming to IS:1570 (Part-V)-1972 or grade
Pump shaft
C40 or C45 of IS:1570-1961 ‘Schedules for wrought steels
for general engineering purposes.
Suction casing Grade FG 200 of IS:210-1978.

Project Name : -
Site Address :-
General requirements:
Since the motor and the pump are directly coupled or close coupled, the manufacturer
shall indicate the minimum size of the sump in which the submersible pump can be
erected and suspended freely.
For smooth and efficient working of the submersible pumpset, the manufacturer shall
recommend the minimum submergence.
Submersible motor:
The submersible motor shall be squirrel case induction motor.
The windings shall be wet or dry type.
The motors shall be suitable for operation on voltages and the frequency conforming
to IS:585-latest edition voltage and frequency for AC transmission and distribution
systems (revised).
The earthing of the motor shall comply with IS:3043-latest edition ‘code of practice
for earthing’.
The thrust bearing shall be of adequate size to withstand the weight of all rotating
parts as well as the imposed hydraulic thrust. These shall be lubricated suitably.
The motor shall be protected by means of cable glands, rubber seals, etc., from ingress
of borewell water, sand and other foreign matter.
Project Name : -
Site Address :-
The rotor shaft shall be provided with shaft protecting sleeves having a surface finish
conform to IS:3073-latest edition. However, for short length of shaft made of stainless
steel, protecting sleeves may not be provided.
The motor shall be made of corrosion resisting materials or suitably treated materials
to resist corrosion under normal conditions.
The motor shall have a name plate giving the following information:
Induction motor
Name of manufacturer
Manufacturer’s number and frame reference
Type of duty
Frequency in Hz
Number of phases
Rated output in KW
Rated voltage and winding connections
Current, approximate, in amperes at rated output and
Speed in revolution per minute at rated output.
There shall also be an indication to identify a motor with its pump.
The cable used for submersible motors shall conform to IS:694 (Part-I)-1964 –
Specification for UPVC insulated cables with copper conductors.
Material of construction for other parts of pumps shall be as per IS:5120 for pumps
handling clean cold fresh water.
Material of construction for handling sewage shall be as per IS:5600-1970.

Project Name : -
Site Address :-
All cast iron fitted – grade 20 of IS:210-1962.
All stainless steel - Schedule I of IS:1570-1961.
Booster set should include non return valves, isolating valves, pressure transmitter
on discharge side, non-return valve, pressure gauge.
Booster set should ensure constant pressure on discharge side through continuously
variable adjustment of speed of one of the pumps, while the remaining pumps in
operation are running on mains operating at full speed to bring about pump
performance to meet consumption levels. Also provision should be made for alternate
change over between pumps in operation once every 24 hours & frequency converter
operation of pumps by rotation - all should be built in, cyclically, in the controls to
ensure equal wear and tear of all pumps in the booster set. Means should be provided
for friction loss compensation for increased consumption rate.
Booster set should incorporate following “Power saving features” as standard.
Selection of 3 basis set points for pressure relative to time.
Pipe compensation i.e. Change of set point depending on water consumption.
Compulsory change of staring of sequence, i.e. Equal operating time for pump, both
for frequency control and ON/OFF regulation.
Inputs and outputs for external communication.

Project Name : -
Site Address :-
A small sized pressure tank, (accumulator) to provide for reducing impact of water
hammer and minimize short cycling of the pumps. The accumultors are piped to
allow for in service maintenance.
The functions of the Controller should incorporate the following features.,
Ÿ Closed loop control .
Ÿ On / Off operation at low flow.
Ÿ Automatic cascade control of pumps
Ÿ Selection of switching sequences , automatic pump change and pump

priority.
Ÿ Manual Operation.
Ÿ Analog set point influence
Ÿ Friction loss compensation
Ÿ Set point adjustment
The remote control functions should have the following features.,
Ÿ System On / Off
Ÿ Set point control
Ÿ Switching of individual pumps
The monitoring functions should have the following features.,
Ÿ Min / Max Levels
Ÿ Pre pressure
Project Name : -
Site Address :-
Ÿ Motor protection
Ÿ Water shortage monitoring
Enclosure Class : Control Box IP 54.
Motors IP 55.
Tank fitments
Puddle flanges for reservoir (inserts)
Inlets, outlets, interconnection sleeves and drain outlets for the reservoir shall be
made through mild steel bath galvanised puddle flanges obtained from reputed
manufacturers and to be inserted at suitable levels as indicated on the drawings. The
Contractor shall be responsible for placing the inserts at required level well in
advance and before making the final shuttering layout for casting the walls.
Manhole covers
The manhole covers shall be of heavy-duty type (cast iron) with double seal, locking
arrangement and lifting hooks. (Weight 110kgs.) Manufactured as per IS-1726. The
shape of the cover to be as per the drawings.
Aluminium step ladder
For effective maintenance of the reservoir portable Aluminium step ladder to suit the
depth of the tank shall be provided with necessary hooks.
Link seals
Project Name : -
Site Address :-
Link seal is a seal which is used as a substitute for puddle flanges in underground
sumps and overhead tanks and in places where positive hydrostatic sealing is
mandatory. The link seals shall be suitable to withstand a pressure of 20 psig (40 feet
of head). It should be capable of withstanding temperatures from as low as –600 F to
as high as 4000F, it should provide three minimum three hours of protection against
flames, smoke, gases and water even when exposed to temperatures up to 19000F.
The seal should be of HDPE thermoplastic / heavy wall welded or seamless pipe to
withstand angular and off- center pipe misalignment and has to seal effectively.
The following table indicates the materials for accessories of different models of link
seals.
MODEL TYPE SEAL PRESSURE BOLTS & TEMPERAT

ELEMENT PLATES NUTS URE
RANGE
(0F)
C Standard EPDM COMPOSITE STEEL -40 to +250

Black zinc-
dichromat
e
S Stainless EPDM COMPOSITE 316 -40 to +250

Black STAINLES
S STEEL
O Oil-resistant NITRILE COMPOSITE STEEL -40 to +210

Green zinc-
dichromat
e
OS Oil-resistant NITRILE COMPOSITE 316 -40 to +210

STAINLES
Project Name : -
Site Address :-
Green S STEEL
T High/low SILICONE STEEL zinc- STEEL -67 to +400

temperature Grey dichromate zinc-
dichromat
e
FD/FS Fireseals SILICONE STEEL zinc- STEEL -67 to +400

Grey dichromate zinc-
dichromat
e
M Non- EPDM STEEL STEEL -40 to +250

insulating Black zinc-
dichromat
e
SECTION 5:-
SANITARY INSTALLATION AND FIXTURES
5.1 General
All fixtures shall be fixed in a neat workman like manner true to line and as
recommended by the manufacturer or shown in the drawings. Care shall be taken to
Project Name : -
Site Address :-
fix all fixtures, brackets and accessories by proper wooden cleats, rawl plugs, bolts
and nuts.
Care shall be taken in fixing all approved chromium plated (CP) fixtures and
accessories so as not to leave any tool marks or damages on the finish. All such
fixtures shall be tightened with fixed spanners. Use of `Stillson' type pipe wrenches
with toothed jaws shall not be allowed.
All fixtures shall be thoroughly tested after connecting the drainage and water supply
system. All fixtures shall be thoroughly finished and any leakage in piping valves and
waste fittings corrected to the complete satisfaction of the Consultant / Engineer.
Upon completion of the work, all labels, stickers, plaster, etc. shall be removed from
the fixtures and all fixtures shall be cleaned with soap and water so as to present a
neat and clean toilet.
5.2 European type water closet
The closet shall be white or colored as per BOQ and made of vitreous China and shall
be of the best quality manufactured by an approved firm, and fixed by approved
means. It shall have 100 mm dia `P` or `S` trap depending on the location of water
closets and soil stacks with effective seal. Each closet shall be provided with the
following accessories:
a) Double flapped heavy urea formaldehyde seat cover of approved make quality
and color with rubber buffers and C.P. brass screws fixed to the pan.
b) 15mm C.P health faucet with angle valve.

Project Name : -
Site Address :-
c) Cast-iron chair or cantilever bracket for wall hung type with C.P bolt & nut.
Mode of measurement
These items shall be measured in numbers and the rate quoted shall be per number
only. The quoted rate shall include.
a) The cost of W.C pan.
b) Plastic seat cover.
c) Jointing and fixing material.
d) C.I chair / cantilever bracket.
e) Fixing the WC as per the drawing
f) Testing as specified, if any.
5.3 Wash basins
They shall be white or colored as per BOQ and of vitreous China with best quality
manufactured by an approved firm and size as specified. Oval / circular washbasins
shall be supported on a RC counter with necessary steel reinforcement and
rectangular washbasins with or without pedestals shall be supported by a pair of CI
brackets of approved design. The washbasin shall be circular or oval shape below or
above counter or rectangular with or without pedestal type as specified in Schedule of
Quantities.
Mode of measurement
Project Name : -
Site Address :-
All the items above shall be measured in numbers only and the quoted rate shall be
per number, which shall include:
a) The cost of respective materials.
b) Necessary fixtures.
c) Fixing in position and
d) Testing where necessary / specified.
5.4 Sinks
They shall be Stainless steel of best quality and shall be supported on necessary
brackets. Each sink shall be provided with 40 mm CP waste coupling, CP bottle trap,
spout as per BOQ.
Mode of measurement
Sinks shall be measured in numbers including all items stated above and shall include
the cost of all fixing materials and fixing in position.
5.5 Urinal
Urinal shall white or colored as per Schedule of Quantities. The urinal shall be large
flat back type fixed with hanger and brackets. Others shall supply the partition. Each
urinal shall be provided with the following units.
- 40 mm dia. C.P waste coupling with dome grating.
- 40 mm dia. C.P bottle trap.

Project Name : -
Site Address :-
- C.P urinal spreader & C.P flush pipe.
Auto flush system with sensor, solenoid valve, gate valve, and conduit and wiring
complete. (If this system is specified in BOQ)
IWC, Shower, Emergency Shower
Mode of measurement
Urinal shall be measured in numbers including all items stated above and shall
include the cost of all fixing materials and fixing in position. In case of Auto Flush
systems including wiring, fixing of solenoids, conduiting and other electrical related
works etc., shall be measured in numbers.
5.6 Toilet accessories
Mirror
Mirrors shall be of the best quality and of approved make, 6.0 mm thick with copper
backing fixed to 8mm thick commercial plywood fixed to the back of the mirror and
encased with teakwood frame. The mirror shall be fixed to wall with stainless steel
mirror head screws.
Towel rail
Towel rail shall be of C.P. with reinforced bends and circular flanges. The size of the
rail shall be as specified. The bracket shall be fixed by means of stainless steel screws
to wooden / plastic cleats firmly embedded in the wall.
Project Name : -
Site Address :-
Toilet paper holder
Toilet paper holder shall be of chromium plated as specified in the B.O.Q.
Towel ring, soap tray, etc.
These shall be of CP specified in the Schedule of quantities. These shall be fixed by

means of stainless steel screws to wooden / plastic cleats firmly embedded in the
wall.
Electric hand drier
The electric hand drier shall be twin blower type interpreted with timer range 0 to 3
minutes. The drier shall be fully automatic. The power requirement shall be 230V,
1PH, and 50Hz 1700 watts. The drier shall be wall-mounted type.
Soap dispenser
The Soap dispenser shall be wall mounted type tough ABS plastic with soap pouch
and pump system as per list of recommended makes. The capacity of dispenser shall
be 500 ml.
Mode of measurement
Project Name : -
Site Address :-
All the items above shall be measured in numbers only and the quoted rate shall be
per number, which shall include:
The cost of respective materials.
Necessary fixtures.
Fixing in position, wiring, conduiting and
Testing where necessary / specified.
5.7 Water coolers
Water coolers specified shall be exterior stainless steel construction; they should
have PUF insulation to reduce the effective electrical power consumption. The water
cooler should be capable of supplying water to the drinking standards as enumerated
in Indian Standard 10500 – 1980. The cooler to be installed in plumbing with the floor
level and should consists of rubber mounted adjustable jack bolts to suit parallelism
of the floor. The compressor is too rugged and dependable and hermetically sealed for
any leakage. Surge drums in the refrigerant circuit should be well enough to prevent
leakage in the compressor unit. The cooling and loading capacities should be
sufficient as per the bill of quantities. The nominal cooling capacities through a drop
of temperature should conform to IS 11475.
Mode of measurement
Electric water coolers shall be measured in numbers and should include all the items
as mentioned above.
5.8 Horizontal geyser
Horizontal geyser shall be floor mounted type and include following item
Project Name : -
Site Address :-
Titatinum enamel coated tank
magensium anode release positive ions that gives additional protection to the enamel
tank
Thick polyurethane foam (PUF)insultation:Reduces standing heat loss and power

consumption
Digital control panelHi-tech control panel to set temperature and time.
Power consumption of 3kw power.
APPENDIX -A. Recommended make list for water supply & sanitaryinstallation
No. Name of Meterial / Name of Reference Remarks

Equipment Supplier/Manufacturer
A PLUMBING
Sanitary ware Hindware / Parryware
CP Fixtures Jaquar / ESS ESS
Urinal Sensor AOS/ROBO
Hand Drier Danum / Nova Tech

Project Name : -
Site Address :-
Soap Dispenser Kimberley Clarke
Mirror Saint Gobian
Water Heater AO smith / Venus / Racold
u PVC Pipe and Fittings Prince / Supreme / Kissan
PPRC Pipe and Fittings Prince / Supreme
HDPE Pipe and Fittings Prince / Supreme / Rishi
RCC Hume Pipe Indian Hume Pipe / Pragati
CI Manhole Frame /
Neco / Southern
Cover
GI Pipes / MS Pipes TATA / Jindal
Butterfly valves Audco / Intervalve / Zoloto
Gate valves / Ball valves Zoloto / Leader / Sant
Check Valves Advance / H Sarkar / Audco
Strainers Kirlosker / Audco / Zoloto
Pressure Gauge H Guru / Bells control
Air release valves Leader / Hawa
Paint Asian / Berger
Wrapping & coating Pipe coat / Tapex
Hydronumetic Pumps Grundfos / KSB / DP
Borewell Pumps Texmo / Kirloskar / Grundfos
Sewage Pumps Grundfos / WILO / DP
Aqua Inteltech / Filpro /

Level Indicator
Digitech
Water Meter BHEL / Anand Asahi /

Project Name : -
Site Address :-
Capstan
Flow Meter Eureka / Toshiniwala
Pipe Supports Hitech Pipe Supports

Project Name : -
Site Address :-
APPINDIX-B BILL OF QUANTITIES
COMMISSIONING & GUARANTEE
SECTION-08COMMISSIONING & GUARANTEE
8.1. Scope of work

Project Name : -
Site Address :-
Work under this section shall be executed without any additional cost. The rates
quoted in this tender shall be inclusive of the works given in this section.
Contractor shall provide all tools, equipment, metering and testing devices required
for the purpose.
On award of work, Contractor shall submit a detailed proposal giving methods of

testing and gauging the performance of the equipment to be supplied and installed
under this contract.
All tests shall be made in the presence of the Architect or his representative or any
inspecting authority. At least five working days notice in writing shall be given to the
inspecting parties before performing any test.
Water flow rates of all equipment and in pipe lines through valves shall be adjusted to
design conditions. Complete results of adjustments shall be recorded and submitted.
Contractor shall ensure proper balancing of the hydraulic system and for the pipes /
valves installed in his scope of work by regulating the flow rates in the pipe line by
valve operation. The contractor shall also provide permanent Tee connection (with
plug) in water supply lines for ease of installing pressure gauge, temperature gauge &
rota meters. Contractor shall also supply all required pressure gauge, temperature
gauge & rotameter for system commissioning and balancing. The balancing shall be to
the satisfaction of Consultant / Project Manager.
Three copies of all test results shall be submitted to the Engineer in A4 size sheet
paper within two weeks after completion of the tests.
8.2. Pre-commissioning
Project Name : -
Site Address :-
On completion of the installation of all pumps, piping, valves, pipe connections,

insulation etc. the Contractor shall proceed as follows:
a. Prior to start-up and hydraulic testing, the Contractor shall clean the entire
installation including all fitments and pipe work and the like after installation and
keep them in a new condition. All pumping systems shall be flushed and drained at
least once through to get rid of contaminating materials. All pipes shall be rodded to
ensure clearance of debris, cleaning and flushing shall be carried out in sections as the
installation becomes completed.
b. All strainers shall be inspected and cleaned out or replaced.
c. When the entire systems are reasonably clean, a pre-treatment chemical shall
be introduced and circulated for at least 8 hours. Warning signs shall be provided at
all outlets during pre-treatment. The pre-treatment chemical shall:
· Remove oil, grease and foreign residue from the pipe work and fittings;
· Pre-condition the metal surfaces to resist reaction with water or air.
· Establish an initial protective film;
· After pre-treatment, the system shall be drained and refilled with fresh water
and left until the system is put into operation.
· Details and procedures of the pre-treatment shall be submitted to the

Architect for approval.
Project Name : -
Site Address :-
d. Check all clamps, supports and hangers provided for the pipes.
e. Check all the equipment, piping and valves coming under hot water system
and operate each and every valve on the system to see if the valves are functioning
properly. Thereafter conduct & hydro test of the system as for (b) above.
f. Fill up pipes with water and apply hydrostatic pressure to the system as given
in the relevant section of the specification. If any leakage is found, rectify the same
and retest the pipes.
8.5. Rejection of installation / plant
Any item of plant or system or component which fails to comply with the
requirements of this Specification in any respect whatsoever at any stage of
manufacture, test, erection or on completion at site may be rejected by the Architect
either in whole or in part as he considers necessary/appropriate. Adjustment and/or
modification work as required by the Architect so as to comply with the Authority's
requirements and the intent of the Specification shall be carried out by the Contractor
at his own expense and to the satisfaction of the Authority/Architect.
After works have been accepted, the Contractor may be required to carry out assist in
carrying out additional performance tests as reasonably required by the
Architect/Employer.
6. WARRANTY AND HANDOVER

Project Name : -
Site Address :-
S.No Services/Equipments Ground First Second Band

Colour Colour Colour
Band Band
The Contractor shall warrant that all plant, materials and equipment supplied and all
workmanship performed by him to be free from defects of whatsoever nature before
handover to the Owner.
7. HANDING OVER OF DOCUMENTS
All testing and commissioning shall be done by the Contractor to the entire
satisfaction of the Owner’s site representative and all testing and commissioning
documents shall be handed over to the Owner’s site representative.
The Contractor shall also hand over all maintenance and operation manuals, all
certificates and all other documentation as per the terms of the contract to the
Owner’s site representative.
Project Name : -
Site Address :-
Width Spacing
(mm) (mm)
A. WATER
1. Fire water Fire Red Crimson - 25 1500

Red
2. Municipal Raw water Sea - - - -

Green
3. Treated Domestic water Sea Light - 25 1500

Green Orange
4. Drinking water Sea French Signal 25 1500

Green blue Red
5. Cold water downtakes Canary 25 1500

Sea French
from Overhead storage Yellow
Green blue
tanks
6. Domestic Hot water Sea Light - 25 1500

from localised heaters Green Grey
7. Centralised heating Sea Canary - 25 1500

below 600C Green Yellow
8. Soft water Sea Light Signal 25 1500

Green Brown Red
9. Recycled treated water Sea Light - 25 1500

for Flushing Green Brown
10. Boiler feed water Sea Gulf Red - 25 1500

Green
11. Condensate Sea Light - 25 1500

Green Brown
Project Name : -
Site Address :-
12. Landscape sprinkle and Sea Signal 25 1500

White
hydrant water Green Red
B. DRAINAGE
1. Soil Black - - - -
2. Waste Black White - 25 1500
3. Vent Black White - 25 1500
4. Rain water Black - - 25 1500
C. Natural Gas Light White & - 25 1500

Brown Blue
D. Equipments and others
1. Pumps and Motors Canary - - - -

Yellow
2. Pipe supports Black or - - - -

as
directed
3. Electric panels Steel - - - -

Grey
8.8. Pipe colour code:
Notes: All colours and code refer to Synthetic Enamel colours. The painting shall be
with synthetic enamel paint unless otherwise specified.
Project Name : -
Site Address :-
Identification
The system of colour coding shall consist of a ground colour and colour bands
superimposed on it.
8.1 Ground Colours
The ground colour shall identifies the basic nature of the fluid carried (see
Fig.1) and also distinguishes one fluid from another. The various ground colours are
indicated in Table above.
8.1.1 Ground colour shall be applied throughout the entire length for un-insulated
pipes, for insulated pipes, on the metal cladding or on the pipes of material such as
non-ferrous metals, austenitic stainless steel, plastic, etc., ground colour coating of
minimum 2m length or of adequate length, not to be mistaken as colour band, shall be
applied.
8.2 Colour Bands
Colour bands shall be superimposed on the ground colour.
Wherever the ground colour is not applied throughout the entire length, it
shall be applied near valves, junctions, joints, service appliances, bulkheads, walls, etc.
(see Fig. 3)
They shall be superimposed on ground colour at the following location:
At battery limit points;
Intersection points and change of direction points in piping ways;
Other points such as midway of each piping way, near valves, junction joints of
service appliances, walls, on either side of pipe culverts;
Project Name : -
Site Address :-
For long stretch yard piping at 50m interval; and
At start and terminating points.
The relative proportional widths of the first colour band to the subsequent bands
shall be 4:1
Minimum width of colour band shall confirm to the following Table;
Nominal Pipe Size Width L (mm)
80 NB and below 25
Over 100 NB upto 150 NB 50
Over 200 NB upto 300 NB 75
Over 350 NB 100
For insulated pipes nominal pipe size means the outside diameter of
insulation.
Valves shall be painted with the same colour as the main pipelines except
when the pipeline has been provided with the safety colour, the valves shall be
painted red, for fire fighting; yellow, with black diagonal stripes, for warning of
danger; and french blue in conjunction with the green basic colour, to denote pipes
carrying fresh water, either potable or non-potable.
8.9. Check list for commissioning
Checklist for commissioning.

Project Name : -
Site Address :-
Water Supply, Drainage Equipment
1) Operate each and every valve on the system to see if the valves are functioning
properly.
2) Check all clamps, support and hangers provided for the pipes.
3) Check rotation of each motor and correct the same if required.
4) All the pumps shall run continuously for one hour. Record the pressure and
motor current and voltage readings.
5) Check all annunciations by simulating the alarm conditions if any at site.
Remove grease trap manhole covers. Check for cleanliness, check for partitions, and
put back the cover.
7) Remove manhole covers on sewer lines, inspect for cleanliness. After they are
found to be clean, pour water into the first manhole and see that all the lines are clear.
Make sure that all the covers are put back after the inspection.
8) Check gully traps by opening of covers and check that water seal in the traps
are maintained. Check for general cleanliness.
9) Check installation of proper vents and cowls at the roof level for all soil and
waste pipes.
Project Name : -
Site Address :-
10) Performance test to be carried out and recorded in the following table for the
pumps.
Sr. Pump Tag No. Mode Desig Actua P Full Remar

No. l No. n l Flow kg/c load ks
Flow LPS m2 Amps
LPS
1) Domestic Water
Hydro-pneumatic
Pump No. 1
2) Domestic Water
Hydro-pneumatic
Pump No. 2
3) Domestic Water
Hydro-pneumatic
Pump No. 3
4) Filter feed Pump no. 1
5) Filter feed Pump no. 2
6) Softener transfer
Pump no. 1
5) Softener transfer
Pump no. 2
(Similar Readings shall be taken for all other pumps)
Simulate low level in the domestic water tanks to trip domestic Filter Feed Pumps.
Simulate high level in treated water tanks to trip softener feed pumps. Simulate low
level in treated water tanks to trip treated water hydro-pneumatic pumps.
Project Name : -
Site Address :-
Submersible Sump Pumps
1) Fill the sump with water, while observing the level.
2) Keep the pump starter switch on ‘OFF’ position to check for start of pump.
3) By keeping the starter switch on ‘Auto’ position, both the pumps should start.
As the water level starts receeding, one pump should switch off by itself. The second
pump should switch off on further reduction in water level.
4) Fill the sump with a little water and check both the pumps in ‘Manual’ position
momentarily.
5) Leave the switches in ‘Auto’ position for both the pumps.
MGF , ACF and softener
Thoroughly back wash the filters, before putting them on line.
Operate the filter feed pump and record the pressure at the inlet and outlet ports of
the filters. This will give us the pressure drop across clean filters for record purposes.
Softening Plant
The plant shall be run for 3 regenerations + 3 service cycles to establish

output, quality of treated water.
Project Name : -
Site Address :-
APPENDIX-C
LIST OF BUREAU OF INDIAN STANDARDS AND OTHERINTERNATIONAL CODES
All equipment, supply, erection, testing and commissioning shall comply with the
requirements of Indian Standards and code of practices given below as amended upto
………………….date. All equipment and material being supplied by the contractor shall
meet the requirements of IS and other specified.
Tarrif advisory committee’s regulation (fire insurance), electrical inspectorate and

Indian Electricity rules and other Codes / Publications as given below:
SL.NO 1 Pipes and Fittings
Specification for precast concrete pipes (with and without

1 IS : 458
reinforcement)
2 IS : 651 Salat glazed stone ware pipes and fittins.
IS : 1239 (Part Mild steel, tubes, tubulars and other wrought steel fittings
3
1) : Part 1 Mild Steel tubes.
Mild Steel tubes, tubulars and other wrought steel fittings

IS : 1239 (Part
4 : Part 2 Mild Steel tubulars and other wrought steel pipe
2)
fittings.
Centrifugally cast (spun) iron pressure pipes for water,

5 IS : 1536
gas and sewage.
Vertically cast iron pressure pipes for water, gas and

6 IS : 1537
sewage.
Cast Iron fittings for pressure pipes for water, gas and
7 IS : 1538
sewage.
Project Name : -
Site Address :-
Sand Cast iron spigot and socket soil, waste and

8 IS : 1729
ventilating pipes, fittings and accessories.
9 IS : 1879 Malleable cast iron pipe fittings.
10 IS : 1978 Line pipe
11 IS : 1979 High test line pipe.
12 IS : 2501 Copper tubes for general engineering purposes
IS : 2643 (Part Dimensions for pipe threads for fasterning purposes : Part
13
1) 1 Basic profile and dimensions.
IS : 2643 (Part Dimensions for pipe threads for fastening purposes : Part
14
2) 2 Tolerances.
IS : 2643 (Part Dimensions for pipe threads for fastening purposes : Part
15
3) 3 Limits of sizes.
16 IS : 3468 Pipe nuts.
Seamless or electrically welded steel pipes for water, gas

17 IS : 3589
and sewage (168.3 mm to 2032 mm outside diameter).
Centrifugally cast (sun) iron spigot and socket soil, waste

18 IS : 3989
and ventilating pipes, fittings and accessories.
Specifications for washers for use with fittings for water

19 IS : 4346
services.
20 IS : 4711 Methods for sampling steel pipes, tubes and fittings.
21 IS : 6392 Steel pipe flanges
Cast iron and malleable cast iron flanges for general

22 IS : 6418
engineering purposes.
Specification for horizontally cast iron double flanged

23 IS : 7181
pipe for water, gas and sewage.
24 IS:782 Specification for caulking lead (3rd rev.)

Project Name : -
Site Address :-
25 IS:6163 Cast Iron Low Pressure Pipes
26 IS:13592 PVC Pipes
HDPE Pipes for Potable water supply, Sewage and Ind.

27 IS:4989
Effluent
28 I.S:985 UPVC Pipes for Potable water supply
Code of Practise for coating and wrapping of U.G M.S

29 IS:110221
Pipelines
Code of Practise for laying C.I Pipes (2nd rev.)

30 IS:3114
(Amendment 2)
2 Valves
Specification for copper alloy gage, globe and check valves

1 IS : 778
for water works purposes.
Specification for sluice valves for water works purposes

2 IS : 780
(50 mm to 300 mm size).
Specification copper alloy float valves (horizontal plunger

3 IS : 1703
type) for water supply fittings.
Specification for sluice valves for water works purposes

4 IS : 2906
(350 mm to 1200 mm size)
5 IS : 3950 Specification for surface boxes for sluice valves.
IS : 5312 (Part Specification for swing check type reflux (non return)
6
1) valves : part 2 Multi door pattern.
IS : 5312 (Part Specification for swing check type reflux (non return)
7
2) valves : part 2 Multi door pattern.
IS : 12992 (Part
8 Safety relief valves, spring loaded : Design
1)
9 IS : 13095 Butterfly valves for general purposes.

Project Name : -
Site Address :-
3 Sanitary Fittings
IS : 771 (Part 1
1 Specification for glazed fire clay sanitary appliances.
to 3)
Specification for flushing cistern for water closets and

2 IS : 774
urinals (other than plastic cistern)
Specification for cast iron brackets and supports for wash

3 IS : 775
basins and sinks
Specification for cast copper alloy screw down bib taps

4 IS : 781
and stop valves for water services.
5 IS : 1700 Specification for drinking fountains.
IS : 2548 (Part Specification for plastic seats and covers for water closets
6
2) : Part 1 Thermoset seats and covers.
IS : 2556 (Part Specification for vitreous sanitary appliances (Vitreous

7
1) china) :
Part 1 General requirement.
Specification for vitreous sanitary appliances (vitreous

IS : 2556 (Part
1 china) : Part 2 Specific requirements of wash-down water
2)
closets.
IS : 2556 (Part Specification for vitreous sanitary appliances (vitreous

2
3) china) : Part 3 Specific requirements of squatting pans.

3
4) china) : part 4 specific requirements of wash basins.

IS : 2556 (Part 6
4 china) : part 6 Specific requirements of urinals, section 2
Sec 2)
half stall urinals.
IS : 2556 (Part 6 Specification for vitreous sanitary appliances (vitreous

5
Sec 4) china) : Part 6 specific requirements of urinals, section 4
Project Name : -
Site Address :-
partition slabs.

IS : 2556 (Part 6
6 china) : Part 6 Specific requirements of urinals, section 5
Sec 5)
waste fittings.

IS : 2556 (Part 6
7 china) : Part 6 Specific requirements of urinals, section 6
Sec 6)
water spreaders for half stall urinals.

IS : 2556 (Part
8 china) : Part 7 Specific requirements of half round
7)
channels.

IS : 2556 (Part
9 china) : Part 8 Specific requirements of siphoning wash
8)
down water closets.

10
11) china):Part 11 Specific requirements for shower rose.

11
12) china) : Part 12 Specific requirements of floor traps.

IS : 2556 (Part
12 china) : Part 15 Specific requirements of universal water
15)
closets.
13 IS : 2692 Specification for ferrule for water services
Glossary of terms relating to vitreous enamelware and

14 IS : 2717
ceramic metal systems
Specifications for waste plug and its accessories for sinks

15 IS : 2963
and wash basins.
Specification for waste plug and its accessories for sinks

16 IS : 3311
and wash basins.
17 IS : 5961 Specification for cast iron gratings for drainage purposes.

Project Name : -
Site Address :-
Specification for gel-coated glass fibre reinforced

18 IS : 6249
polyester resin bath tubs.
Specification for gel-coated glass fibre reinforced

19 IS : 6411
polyester resin bath tubes.
Specification for copper alloy fancy single taps,

20 IS : 8931 combination tap assembly and stop valves for water
services.
Specification for flush valves and fitting for water closets

21 IS : 9758
and urinals.
IS : 3025 (Parts Method of sampling and test (physical and chemical) for
1
1 to 44) water and waste water.
Tolerance limits for sewage effluents discharged into

2 IS : 4764
inland surface waters.
3 IS : 10500 Drinking Water
5 Pumps & Vessels
Specification for horizontal centrifugal pumps for clear

1 IS : 1520
cold fresh water.
Steel plates for pressure vessels for intermediate and high

2 IS : 2002
temperature service includng boilers.
3 IS : 2825 Code for unfired pressure vessels.
IS : 4648 (Part Code of practice for lining of vessels and equipment for
4
1) chemical processes Part 1 : Rubber lining.
5 IS : 5600 Specification for sewage and drainage pumps
Specification for submersible pump sets for clear, cold,

6 IS : 8034
fresh water.
Project Name : -
Site Address :-
Specification for horizontal centrifugal self priming

7 IS : 8418
pumps.
6 General
1 National Building Code of India 2005 Part IV and Part IX
2 Uniform Plumbing Code of India 2008
3 SP : 6 (1) Structural Steel Sections
4 IS : 325 Three Phase Induction Motors
Code of practice for plain and reinforced concrete (3rd

5 IS: 456
rev.) (Amendment 2)
Dimensions for pipe threads where pressure tight joints

6 IS : 554
are required on the threads.
PVC insulated cables for working voltages upto &

7 IS : 694
including 1100 V.
8 IS : 779 Specification for water meters (domestic type).
9 IS : 782 Specification for caulking load.
10 IS : 800 Code of practice for general construction in steel
Electroplated coatings of nickel plus chromium and

11 IS : 1068
copper plus nickel plus chromium.
Code of Basic requirements for water supply drainage and

12 IS : 1172
sanitation
IS : 1367 (Part Technical supply conditions for threaded steel fasteners :

13
1) Part 1 introduction and general information.
IS : 1367 (Part Technical supply conditions for threaded steel fasteners :

14
2) Part 2 product grades and tolerances.
IS : 1554 (Part PVC insulated (heavy duty) electric cables : Part 1 for
15
1) working voltages upto and including 1100 V.
Project Name : -
Site Address :-
IS : 1554 (Part PVC insulated (heavy duty) electric cables : Part 2 for
16
2) working voltages from 3.3 KV upto and including 11 KV.
17 IS : 1726 Specification for cast iron manhole covers and frames.
18 IS : 1742 Code of practice for building drainage.
Selection, installation and maintenance of sanitary

19 IS : 2064
appliance code of practice.
20 IS : 2065 Code of practice for water supply in buildings.
21 IS : 2104 Specification for water meter for boxes (domestic type)
22 IS : 2373 Specification for eater meter (bulk type)
23 IS : 2379 Colour code for identification of pipe lines.
Code of practice for fixing rainwater gutters and down

24 IS : 2527
pipes for roof drainage.
Recommended practice for hot dip galvanizing on iron

25 IS : 2629
and Steel.
26 IS : 3114 Code of practice for laying of cast iron pipes
IS : 4111 (Part Code of practice for ancillary structures in sewerage

27
1) system : Part 1 manholes.
28 IS : 4127 Code of practice for laying glazed stoneware pipes.
Recommended practice for radiographic inspection of

29 IS : 4853
fusion welded butt joints in steel pipes.
Code of practice for sanitary pipe work above ground for

30 IS : 5329
buildings.
31 IS : 5455 Cast iron steps for manholes.
Recommended practice for design and fabrication of

32 IS : 6159
material, prior to galvanizing.
33 IS : 7558 Code of practice for domestic hot water installations.

Project Name : -
Site Address :-
34 IS : 8321 Glossary of terms applicable to plumbing work.
IS : 8419 (Part Requirements for water filtration equipment : Part 1

35
1) Filteration medium sand and gravel.
IS : 8419 (Part Requirements for water filtration equipment : Part 2

36
2) under drainage system.
Code of practice for provision and maintenance of water

37 IS : 9668
supplies and fire fighting.
38 IS : 9842 Preformed fibrous pipe insulation.
Coal tar based coating materials and suitable primers for

39 IS : 9912
protecting iron and steel pipe lines.
Code of practice for coating and wrapping of underground

40 IS : 10221
mild steel pipelines.
41 IS : 10446 Glossary of terms relating to water supply and sanitation.
42 IS : 11149 Rubber Gaskets
Code of practice for preparation of butt-welding ends for

43 IS : 11790
pipes, valves, flanges and fittings..
IS : 12183 (Part Code of practice for plumbing in multistoried buildings :

44
1) Part 1 water supply.
45 IS : 12251 Code of practice for drainage of building basements.
46 IS : 5572 Code of practice for sanitary pipe work.
Specification for design, installation, testing and

47 BS : 6700 maintenance of services supplying water for domestic use
within buildings and their cartilages.
48 BS : 8301 Code of practice for building drainage.
Sanitary tap were, waste fittings for basins, bidets and

49 BSEN : 274
baths. General technical specifications.
Project Name : -
Site Address :-
7 Fire Fighting & Fire Protection
Compliance with Local Fire Officer’s Provisional NOC
1 NBC Part – IV National Building Code of India; Part IV Fire & Life Safety
2 TAC Tariff Advisory Committee fire protection manual Part-I.
Rules of Tariff Advisory Committee for automatic

3 TAC
sprinkler system.
4 NFPA : 13 Installation of Sprinkler System
5 NFPA : 14 Installation of Standpipe & Hose System
6 NFPA : 20 Installation of Stationary pump for Fire Protection
7 IS : 636 Non-percolating flexible fire fighting delivery hose.
8 IS : 884 Specification for first aid hose reel for fire fighting.
Specification for couplings, double male and double

9 IS : 901
female, instantaneous pattern for fire fighting.
10 IS : 902 Suction hose couplings for fire fighting purposes.
Specification for fire hose delivery couplings, branch pipe,

11 IS : 903
nozzles and nozzle spanner.
Specification for 2-way and 3-way suction collecting

12 IS : 904
heads for fire fighting purposes.
Specification for suction strainers, cylindrical type for fire

13 IS : 907
fighting purposes.
14 IS : 908 Specification for fire hydrant, stand post type.
Specification for underground fire hydrant, sluice valve

15 IS : 909
type.
16 IS : 910 Specification for portable chemical foam fire extinusiher.
17 IS : 933 Specification for portable chemical foam fire extinguisher.

Project Name : -
Site Address :-
Code of practice for fire safety of building (general) : Fire

18 IS : 1648
fighting equipment and its maintenance.
Specification for portable fire extinguishers dry powder

19 IS : 2171
(catridge type)
Selection, installation and maintenance of first aid fire

20 IS : 2190
extinguishers – Code of practice.
Specification for branch pipe, universal, for fire fighting

21 IS : 2871
purposes.
Specification for fire extinguishers, carbon dioxide type

22 IS : 2878
(portable and trolley mounted).
Code of practice for installation and maintenance of

23 IS : 3844
internal fire hydrants and hose reel on premises.
24 IS : 5290 Specification for landing valves.
Specification for coupling, branch pipe, nozzle, used in

25 IS 5714
hose reel tubing for fire fighting.
Specification for controlled percolation type hose for fire

26 IS : 8423
fighting.
Specification for higher capacity dry powder fire

27 IS : 10658
extinguisher (trolley mounted).
Code of practice for fire safety of libraries and archives

28 IS : 11460
buildings.
External hydrant systems – Provision and maintenance –

29 IS : 1309
Code of practice.
IS : 5514 (Parts
30 Reciprocating internal combustion engines : Performance.
1 to 7)
IS : 15105 : Design & Installation of Fixed Automatic Sprinkler Fire

31
2002 Extinguishing System – Code of Practice.
32 IS : 1554 ( PVC insulated ( Heavy Duty) electric cables for working

Project Name : -
Site Address :-
Part - I ) voltages upto and including 1100 volts.
Electrical installation fire safety of buildings (general)

33 IS : 1646
Code of practice.
34 IS : 1885 Glossary of items for electrical cables and conductors
35 IS : 2071 Methods of high voltage testing
Protection of building and allied structures against

36 IS : 2309
lightning
37 IS : 2551- Danger notice plate.
38 IS : 3043 Code of practice for earthing.
Cross linked polyethylene insulated PVC sheathed cables.

39 IS : 7098 -
For working voltages up to and including 1100Volts.
40 (Part - I)
Cross linked polyethylene insulated PVC sheathed cables.

41 IS : 7098 - For working voltages from 3.3 KV upto and including 33
KV
42 (Part - II)
43 IS : 8130 Conductors for insulated electric cables and flexible cords
IS : 8623 (Part Factory built assemblies of switchgear and control gear

44
–I) for voltages upto and including 1000 V AC and 1200 V D C.
45 IS : 8828 Miniature Circuit Breakers
Rigid Steel Conduits for electrical wiring (Second

46 IS : 9537
Revisions)
47 IS : 10810 Methods of test for cables.
48 IS : 12640 Earth Leakage Circuit Breakers
IS : 13947
49 Air Circuit Breakers
(Part-II)
Project Name : -
Site Address :-
50 IS : 13947 Moulded Case Circuit Breakers
51 IS : 15652 Rubber mats for electrical purposes.
APPENDIX-D WATER TREATMENT SYSTEM & ACCESSORIES
1. General
1.1 Scope
This section of the contract involves the design, supply, installation, testing and
commissioning of the complete Water Treatment plant for domestic water and
swimming pool water.
All installation work shall comply with the latest rules and regulations.
The work embraced by this specifications covers the design, submission to

authorities, supply, delivery on site, installation, testing, commissioning and
maintenance of the Water treatment system installation of the building.
The scope of work shall include the following (list is indicative and not exhaustive) :
- Complete Raw Water Treatment System. The Contractor shall be responsible

for carrying out water analysis for the raw water from borewell / tanker supply and
design all system components/equipment so as to achieve the potable water quality
as per specified Standards SP:35 (S&T 1987) & IS 10500.
Project Name : -
Site Address :-
- The Raw Water Treatment System as a minimum shall consist of feed pumps,
filters with back wash provisions with all accessories complete with all controls,
softner, U/V Treatment System, PH automatic control and monitoring system,
electrical panels, cabling, etc.
- All the pipework between the raw water tanks, treated water tanks and all the
interconnecting pipework amongst the Water Treatment pumps and other
equipment.
- Complete Swimming Pool System including all equipment such as the filtration
pumps, sand filters, chemical dosing system, UV Units, complete pipework, nozzles,
swimming pool accessories like suction sweepers etc.
- Electrical equipment and installation work including the necessary wiring etc.
in Control panel.
- Painting and labelling of pipework and equipment;
- Provision of all hold down bolts, spigots struts and the like required to be built
in during construction;
- Provision of dry contacts to BMS indicating the status of the pumps and
pressure vessel in form of hardware interfacing panels inside each control panels of
all pumps.
- Provision of all level switches, flow switches and other sensing devices for
status indication.
- All interfacing work with other trades.

Project Name : -
Site Address :-
- Testing and commissioning and balancing of the complete Water Treatment

system;
- Provision of twelve (12) months maintenance and breakdown services;
- Provisions of operating instructions and maintenance manuals;
- Provision of spare parts;
- Training of the employer's staff for proper operation of the entire systems;
- Liaison with Local Authorities to obtain all necessary certificates and

approvals, including the completion of all submission drawings, forms and payment
of any fees and charges. All the costs for all the tests required by Local Authorities
shall be included. To attend to any Authorities inspection regardless of whether this
inspection is carried out after the defect liability period;
- Provisions of the necessary installation which include pumping works,

pipework within the pumping unit up to suction and discharge manifolds, conduit
and control wiring, etc. to form a workable system required;
- All other works and systems as specified in the Contract document and or
shown on the drawings.
- All cutting, patching, framing up, furring in, chasing and making good
associated with the building construction for the passage of pipes, conduits and the
like including providing GI pipes sleeves of required size corresponding to pipe dia,
wherever pipes crossing fire rated walls and floors and sealing with glass wool in
Project Name : -
Site Address :-
between and fire sealent compound on either end. Details on shop drawings shall
also be provided.
1.2 General
Equipment offered for supply and installation shall include the following:
All minor items and incidental work, equipment accessories and materials may
not be specifically mentioned but are required for the proper completion of the
installations in accordance with the true intent and meaning of this Specification.
All necessary safety devices for the protection of personnel against injury and
the protection of plant and equipment against damage including relief valves, belt
guards, fan inlet and/or discharge guards, safety railing, effective earthing of
electrical components, electrical interlocks, warning lights and alarms.
Readily accessible, dust-proof lubricating facilities on all moving parts and

equipment including provision for cleaning all lubricating lines and bearings and
charging same with the correct lubricants after installation but prior to testing and
commissioning.
Clearly visible and robust manufacturer's name-plates permanently fitted each

and every item of equipment and showing the manufacturer's name, type and/or
model number, serial number, and all essential operating data such as speed, capacity,
voltage, current draw, etc.
The Contractor also shall allow provision for the inspection of all plant and
equipment by the manufacturer or his licensed representative, at least twice during
the course of the installation.
Project Name : -
Site Address :-
1.3. Filtration
1.3.1 Scope
The scope of this section comprises the supply, installation and

commissioning of FRP composite vessel filter.
1.3.2 FRP composite vessel filter
The filter shall be constructed of FRP material with inner shell of integrated
polyethylene, polypropylene and other material as per manufacturer's standard.
The inter distribution system and the underbed draw off system shall be of
Hub & Lateral type of polypropylene material. The filter shall be provide with
manhole cover, hand hole, flanged outlet for piping / valve connection and adequate
tripod with skid self supporting structure for making the installation completed. The
filter shall also be provided with vacuums breaking connection / accessories to avoid
any collapse of internal lining. All filters shall be provided with lifting lugs. The filter
bed depth shall be 1500 mm.
1.3.3 Face piping
Each filter shall be provided with interconnecting face piping comprising of

inlet, outlet, and backwash complete with valves.
1.3.4 Accessories
Project Name : -
Site Address :-
Each filter shall be provided with following accessories :-
a. Air release valve with connecting piping.
b. 100 mm dia dial bourden type gunmetal pressure gauges with brass isolation
ball valve and connection piping on inlet and outlet.
c. Sampling valves (ball valves) on raw water inlet and filtered water outlet.
d. Individual drain connection with brass fullway ball valve for each filter.
1.3.5 Filter media
The filter media shall comprise of gravel / silica of various grade in varying
thickness. The cut-section of the filter along with filter media detail shall be subject to
approval by the Consultant.
1.3.6 Test kits (optional)
Provide one test kit with initial requirement of reagent:
a) PH meter ( electronic)
b) Turbidity meter
Project Name : -
Site Address :-
Detail of equipment with technical literature shall be supplied with the tender.
1.3.7 Piping
The pipes and fittings in the domestic Water Treatment plant room shall be GI
class `C' (heavy class) conforming to IS: 1239 ( Part-I) for pipes and IS:1879 (Part 1 to
10) for malleable cast iron fittings.
1.4 Pumps
Pumps shall be vertical, centrifugal, multistage directly coupled to motor.

Provision of pump with pump head & base of cast iron and other parts in SS 304 shall
be made for pumps required in Hydropneumatic System, swimming pool and water
fountain re-circulation system. Impeller shall be hydraulically balanced and
keyed to shaft. Pump shall be mounted on a concrete foundation, projecting at least
15 CM above finished floor level. The pumps base shall be set on a vibration
elimination pad. The pump shall be lubricated in strict accordance with the
manufacturer’s instructions and shall be factory aligned prior to shipment. All motors
and bases shall be painted with approved finish shop coat of paint. The pump shall be
selected for the lowest operating noise level and shall be complete with flexible
connections, valves, and pressure gauges. The pumps shall include cost of foundation
channel complete.
1.5. Alum / soda ash dosers
All dosers shall be of the electronic metering plunger type confirming to the
requirements specified in the Bill of Quantities. They shall be complete with low level
switch, low level alarm, tank and interconnecting piping.
1.6. Uv unit
Project Name : -
Site Address :-
UV unit shall be complete with reactor, cabinet housing, cabinet cooling, treatment
chamber, electrical panel, temperature safety control, lampout alert, UV radiometer
along with UV monitoring system and UV monitoring readout panel. The UV Dosage
should be > 30,000 uW – Sec / sq.cm. The lamps should be selected based upon the
flow requirement of respective unit.
1.7. Surflow nozzles
Nozzles shall be constructed of unalterable UV resistant ABS plastic & shall be

designed for low noise and smooth flow at desired rate. The nozzle shall be suitable
for three adjustable set positions and shall be connected through ferrule / saddle
connection to CILA pipe equidistant positioned on the swimming pool floor.
1.8 Suction sweeper
Suction sweeper shall consists of centrifugal pump directly coupled through flexible
coupling to 400/440 volts, 3 phase 50 cycles motor and both units mounted on a
trolley complete with suitable starter, 30 meters (appx.) of cable terminating with a
three pin plug with 600 mm wide suction sweeper head with wheels, spring loaded
brush and towing rope, 20 meters length of internally armoured hose with necessary
coupling and floats. Contractor to submit the technical detail and catalogue of the
suction sweeper model along with the bid for the review & approval of the Owner
/Consultant.
1.9. Water quality
The domestic water treatment basis of design is as per raw water analysis..
Contractor shall get the raw water analysis done at his own expense (in accordance to
IS:10500 prior to submission of the water treatment scheme.
Project Name : -
Site Address :-
The contractor shall ensure domestic water of potable water standard after
the treatment system. The acceptable standard of potable water shall be in
accordance to SP:35 S & T : 1987 as per acceptable limits.
The technical tolerances for water for swimming pool shall be as follows:
S.No. Characteristic Tolerance
i. PH value 7.5 to 8.5
ii. Total alkalinity (as CaCOs), mg/1, Max 50 to 500
iii. Aluminium (as A1), mg/1, Max 0.1
iv. Total residual chlorine, mg/1
a. At inlet, Max 0.5
b. At outlet, Min 0.2
v. Oxygen absorbed in 4 hours at 27 deg.C mg/1, 1.0

Max
vi. Chloride (as CI), mg/1, Max 500
vii. Iron, mg/1, Maxx 0.1
viii. Heavy metals (as pb), mg / 1, Max 0.1
ix. Colour, Hazen units, Max 10
x. Turbidity, NTU, Max 10
xi. Odour Odourless
xii. Taste Palatable
1.10. Floatless type level switch in water tanks

Project Name : -
Site Address :-
The Contractor shall supply and install floatless type switch probes in the water tanks
as indicated below and shown on the drawings.
Raw Water Tanks below/above ground
· High level alarm (over-flow);
· Low level alarm;
· Low level cut-out for raw water pumps;
· Earthing probe.
Treated Water Tank below /above Level
· High level alarm (over-flow);
Low level alarm;
Low water level cut-out for the hydropneumatic pumps;
· Earthing probe.
Each probe shall be of the correct length for the particular application and tank
location. Electrodes shall be of polished stainless steel 20 mm OD. Electrode holders
shall be weatherproof in all respect.
The earthing probes shall be connected and wired to the building earth systems of the
building.
Project Name : -
Site Address :-
The level switch set shall operate with a stepped down voltage at 24V maximum.
Stepped down transformers shall be provided for each set of control probes and shall
be installed inside centralised control cubicles inside pump room.
1.11 Control of duty / standby pumps
Operation of the duty and standby pumps shall be carried out by the following
method:
a Automatically by means of pressure sensor (i.e. pressure switches);
b Manually by means of a local start/stop push buttons on pump local motor

control panel and emergency stop switch.
The pressure switch shall be installed next to the manual release valve. When the
level drops to the pre-determined level, a signal will be sent to the pump local motor
control panel to start the pump.
Automatic controls shall be operated by electronic, floatless type level switches.
1.12 Pump indicator
The following audible and visible indication shall be provided at the pump local
control panels as applicable:
a Red "overflow level" indicator with buzzer for the associated water tanks;
b Amber "extra high water level" indicator for the associated water tank;
Project Name : -
Site Address :-
c Amber "high water level" indicator;
d Amber "low water level" indicator;
e Red "pump trip" indicator for each pump;
f Green "pump on" indicator for each pump;
g "Pump electrical supply healthy" indicator for each pump;
h Amber "remote/local" status indicator.
1.13. UV Unit
UV unit shall be complete with reactor, cabinet housing, cabinet cooling, treatment
chamber, electrical panel, temperature safety control, lampout alert, UV radiometer
along with UV monitoring system and UV monitoring readout panel. The UV Dosage
should be > 30,000 uW – Sec / sq.cm. The lamps should be selected based upon the
flow requirement of respective unit.
1.14 Chemical & bacteriological / microbiological test parameter of raw water
The above mentioned parameters shall be tested in accordance to :
IS : 10500 – 1991, Amendment No : 2-2003
The Chemical and Physical Parameter (30 Parameter) shall be as follows :
Colour, Odour, Turbidity

Project Name : -
Site Address :-
Total Hardness, pH, Total Iron, Chloride, Dissolved Solids, Calcium,

Magnesium, Copper, Hexavalent Chromium, Manganese, Sulphate, Nitrate, Fluoride,
mercury, Cadmium, Selenium, Arsenic, Cyanide, Lead, Zinc, Aluminium, Boron,
Phenolic Compounds, Detergents, Mineral Oil, Alkalinity, Silica.
Note : It is desired to also obtain probable composition of Total Solids if the

TDS parameter exceeds 1000 ppm.
The bacteriological / Microbiological Test Parameter shall be as follows :-
MPN Coliform Organism, Cloiform Bacteria, E. Coli (Typical Faecal Organism).
The above tests shall be carried out by the contractor prior to submitting the
technical submittal of the water treatment plant equipment. Contractor shall also
submit the test report of raw water & treated water after the commissioning of the
plant. The cost of the tests (one pre equipment & two post equipment installation /
commissioning) is deemed to be included in the quote.
2. Reverse osmosis plant
2.1 Scope
The scope of this section on comprises the supply, installation, testing and
commissioning of RO plant suitable for Raw Water Intake & with Treated Water
Outlet chemical parameter in acceptable limits of SP:35 and Indian Standards.
2.1.2 Bore well Water Supply:

Project Name : -
Site Address :-
Bore wells are existing in the surrounding area of the site. The optimum yield
of water from these bore wells is about …….. cub m. per hour. The bore well water has
became progressively saline in nature. The total hardness of bore well water is …….
ppm while total dissolved solids are in the range of …….. to ……… ppm. The quality of
bore well water is likely to further deteriorate in near future. Chemical analysis
report for bore well water is enclosed as Appendix-1.
The contractor shall ensure that water chemical test are carried out by him
before design of the plant. The quality of the water shall be checked by the contractor
before submitting of this quote. The owner / consultant do not confirm the chemical
parameter as listed in Appendix-I and the test is indicative only. It is contractor
responsibility to design the install the RO plant as per existing water quality at site
and deliver treated water from the RO plant. Sufficient contingency in the design shall
be kept on account of variation in quality of raw water.
2.1.2 Water Consumption & Store
It has been estimated that the total requirement of water for the complex is
……… Cub M/ day.
The storage tanks ( underground of R C C ) are located below ground. The

water from raw water storage tank ( holding borewell and tanker water) is taken to
the water treatment plant and after treatment is delivered to domestic water tank
and is subsequently distributed through hydropneumatic system to entire complex.
2.2 Design parameter
The reverse osmosis plant shall be designed for a maximum of 18 hour

operation cycle per day.
Project Name : -
Site Address :-
The water treatment system has been designed on the basis of raw water
analysis report from the existing borewell. The raw water analysis of the borewell is
enclosed in Appendix I. The basis of design however shall be for TDS at ………… ppm.
Borewell water shall be stored in the raw water storage tank. This raw water
shall be supplied to the filtration plant, dosing system and subsequently to the R O
system. RO stream shall be installed for permeate capacity of treated water output as
per detail given in BOQ Treated water output shall be stored in underground
domestic water storage tanks.
2.3 Analysis
2.3.1 Water Treatment System – Reverse Osmosis:
It is evident from the enclosed borewell water analysis report that raw water
shall require Reverse Osmosis treatment for bringing the treated water to an
acceptable standard for various applications. Output water parameters desired after
treatment from the plant are listed in Appendix-2
2.3.2 R O System Operation
Raw water pumped by raw water pumps shall be first subject to chlorination
so as to eliminate marine growth, fouling and remove iron present in feed water,
subsequently filtration through dual media filter is done, so as to achieve outlet water
quality with turbidity less than 5 NTU.
Project Name : -
Site Address :-
Dechlorination is further done ( to prevent free chlorine from reaching the

membrane), online ORP meter with auto dump valve to be installed after
dechlorination.
Output water shall be dosed with Antiscalent solution in order to avoid any
scale formation on the R O membrane. The water after dosing shall be passed through
a micron filtration unit suitable to deliver desired flow of micro filtered water. This
shall avoid choking of the membranes.
This pretreated water shall be fed to R O feed water high pressure pumps ( one
working and one standby). The high pressure pumps shall be multistage vertical
pumps.
2.4. Output water quantity
Water Requirement : ………. KL/Day ( Approx)
RO Permeate Flow Rate : ……….. cu-m / Hr
2.5. Power requirement
The total estimated power requirement for the proposed system shall be
guaranteed by the vendor. All power calculation shall be based on the present feed
water quality.
Project Name : -
Site Address :-
Engine oil Storage Tank
Engine oil Storage Tank ................................................................................................................................. 1023

1.0 40 KL Engine oil Storage Tank ........................................................................................ 1025
1.1 Scope ......................................................................................................................................... 1025
1.2 Fitting for the Tank ............................................................................................................. 1025
1.3 Unloading Hose ..................................................................................................................... 1025
1.4 Unloading Pump ................................................................................................................... 1026
1.5 Transfer Pump ...................................................................................................................... 1026
1.6 Day tank (990 L each) ........................................................................................................ 1026
1.7 Inside Yard Piping................................................................................................................ 1026
1.8 Outside Yard Piping ............................................................................................................ 1026
1.9 Electrical control panel ...................................................................................................... 1027
1.10 Earthing ................................................................................................................................... 1027
1.11 Fire Protection ...................................................................................................................... 1027
1.12 Civil Inside Yard.................................................................................................................... 1027
1.13 Approval & Licensing ......................................................................................................... 1028
1.14 Vendors Qualifications ....................................................................................................... 1028
1.15 Codes and Standards .......................................................................................................... 1028
1.16 Delivery and Handling ....................................................................................................... 1028
1.17 Submission ............................................................................................................................. 1029
1.18 As built Drawings / Handing over documents ......................................................... 1029
1.19 Warranty and Service. ........................................................................................................ 1030
1.20 Drawings enclosed with this document. ..................................................................... 1030
1.21 Examination ........................................................................................................................... 1030
1.22 Preparation ............................................................................................................................ 1030
1.23 Storing ...................................................................................................................................... 1031
1.24 Installation.............................................................................................................................. 1031
1.25 Commissioning ..................................................................................................................... 1031
Project Name : -
Site Address :-
1.26 Training ................................................................................................................................... 1031

1.27 Clean Site ................................................................................................................................. 1031
1.28 Completion ............................................................................................................................. 1032
1.29 Data Sheet ............................................................................................................................... 1032
4.14.
Project Name : -
Site Address :-
Engine oil Storage tank

1.0 40 KL Engine oil Storage Tank
40 KL Engine oil storage tank shall be made as per API 650 with design pressure
atmospheric+ static head and design temperature -5 deg C to +55 deg C. manufacturer
test certificate shall be required for Hydro test pressure, Pneumatic test, radiography
for welded joints. Painting shall be done with zinc phosphate primer and two coats of
synthetic epoxy enamel after sand blasting to SA 2 1/2.
1.1 Scope
The scope shall be complete design along with drawings, supply, installation and
liasoning including all related civil works, piping, fire protection inside yard, Electrical
works inside yard, control panel, integration of basic automation and licensing. The
system shall meet petroleum act codes 1957.
1.2 Fitting for the Tank
Tank shall be installed with float and counter weight level indicator for measurement.
Level transmitter shall be installed with Gliodomat type transmitter coupled with the
level gauge. inlet shall be 3" NB with NRV and outlet fitted with brass / gun metal foot
valve.
1" NB drain shall be provided with ball valve
24NB Manhole on top of the tank provided with ladder till bottom and another
manhole at 500 height from bottom of the tank
1.3 Unloading Hose

Project Name : -
Site Address :-
Unloading shall be 3" NB x 5 Metre Neoprene unloading hose with inline pot strainer
(100/80 mesh filtering net) & DP gauge and 3" NB oval wheel type flow
transmitterfor flow of10000LPH, approved by weights and measure department.
1.4 Unloading Pump
Rotary gear type unloading Pump shall be with 30m discharge head for 15 CUM / Hr
flow. And 15 HP flame proof motor meeting to IS 2148 Gr IIA/B
1.5 Transfer Pump
Vendor shall provide Rotary gear type transfer Pump with 50m discharge head for 6
CUM / Hr flow and 3 HP flame proof motor meeting to IS 2148 Gr IIA/B
1.6 Day tank (990 L each)
Tank shall be installed with level transmitter, high level switch with alarm, inlet
on/off automation with bye pass arrangement. Lube dispensing gun with totaliser
accuracy of +/- 10 ml
1.7 Inside Yard Piping
Inside Yard Piping shall be done with all necessary valves, strainers, Pressure gauge
and fittings. Painting with red oxide primer and synthetic enamel two coats.
1.8 Outside Yard Piping

Project Name : -
Site Address :-
Outside Yard Piping shall be done with all necessary fittings and pipe supports.
Painting with red oxide primer and synthetic enamel two coats. Required outside
yard cabling shall be done.
1.9 Electrical control panel
Panel shall be with switch gears, PLC, Process indicators, connectors, ammeter and
voltmeter. All level and flow digital indication output for BMS at 4-20mA. Auto /
manual selector switch for day tank selection. All cabling underground shall be HDPE
/ GI conduit. Incomer specification: 50 Amp, 415 V, 50 Hz.
1.10 Earthing
Electrical Equipments shall be with 25mm x 3 mm GI flat earthing connected to 2m x

1 1/2" dia GI pipe installed in a pit of salt and charcoal. Connections shall be made
with GI Nuts.
1.11 Fire Protection
Fire buckets and fire extinguisher with mounting stand, type extinguisher. And safety
sign boards of No smoking, safety procedure, operating procedure, emergency
procedure and licence display board, FLP Lights
1.12 Civil Inside Yard
All relevant, required civil works shall be in scope of vendor including necessary
structural works. The vendor has to quote including civil works as one package inside
the Petrol Storage yard.
Project Name : -
Site Address :-
1.13 Approval & Licensing
Plan approval and factory test certificate for Tank design. CCoE plan approval. CCoE
Storage license
Vendor shall provide Rule 126, 133 Certification for installations.
Vendor has to get the Local statutory approval necessary for CCoE Approval.
Client /Server architecture and Web server Functionality shall be available as option.
1.14 Vendors Qualifications
The Supplier / Vendors propose must be approved by the Shimizu corporation India
Pvt. Ltd and shall have regularly engaged in Supply and installation of relevant
storage facility for a period of not less than 10 years.
1.15 Codes and Standards
All equipment supplied shall meet all applicable IS, API, ANSI, and ASA standards.
The design, material, construction, manufacture, inspection, testing and performance
of the storage facilities shall comply with all currently applicable standards,
regulations and safety codes in the locality where the facility shall be installed. The
facility shall also confirm to the latest applicable standards and codes of practice. In
the case of conflict between the applicable standards and this specification, this
specification shall govern.
1.16 Delivery and Handling
The storage tanks/ facilities shall be delivered to site properly packaged and mounted
on pallets or skids to facilitate handling of heavy items. Factory- fabricated type
containers or wrappings shall be utilized for components, which shall protect
equipment from damage. Engine-driven equipment shall be handled carefully to
Project Name : -
Site Address :-
prevent physical damage to equipment and components. Any damaged equipment

shall be removed from site and replaced with new equipment.
1.17 Submission
The successful vendor shall provide the following details for approval.
a) Layout plan for approval

b) P&I Diagram for approval
c) Schedule including liasoning, civil works till ready for operation
d) Drawing showing sectional elevation of equipments.
e) Weights of equipments.
f) Outline drawing showing entry and distribution of piping and cable to
storagefacilities.
g) Schematics for supply line and controls
h) Schedule of supply, installation , execution and commissioning
1.18 As built Drawings/ Handing over documents
3 Sets of hard copies and all drawings in a CD.
General Arrangement drawings
Sectional Elevation
Component detailed drawings
Pipe / distribution routing etc.,
Details for servicing.
Maintenance instructions.
Manuals
Spare parts with part numbers.

Project Name : -
Site Address :-
All routine and site test reports.
After sales service support details with escalation matrix
Guarantee / Warranty certificate of major equipments
1.19 Warranty and Service.
The supplier shall warrant the facility to be free from defects in material and
workmanship for 18 months from the date of start up and for 24 months from the
date of supply of equipments and materials, whichever is earlier.
Vendor shall have established network of service centers capable of servicing the
specified equipments. The personnel shall be factory trained and shall be available for
servicing of equipments with short notice.
1.20 Drawings enclosed with this document.
Site layout shall be provided to Vendor showing location of HSD storage, HSD Storage,
Petrol Storage and Engine oil storage to prepare respective layouts in detail and P&I
Diagrams.
5001.6.
1.21 Examination
The vendor shall inspect the site and compare conditions to those provided in
specification and drawings and notify Shimizu of any discrepancies.
1.22 Preparation
Project Name : -
Site Address :-
Vendor shall Co-ordinate the work with other trades, especially electrical& utility as
per schedule submitted and approved by Shimizu.
1.23 Storing
Allmaterials are received on site shall be inspected and stored in a safe place
identified by Shimizu.
1.24 Installation
The Employer shall witness the start of the installation to ensure compliance with the
required standard.
The Vendor shall give minimum seven working days notice toShimizu before
commencing installation.
1.25 Commissioning
Shimizu shall witness the commissioning.
A minimum of seven working days notice shall be given to the Shimizu prior to the
start of commissioning.
1.26 Training
Shimizu’s technical team shall be trained in all aspects of operation, maintenance and
administration of the system as many times of times desired by Shimizu.
1.27 Clean Site
The Vendor shall leave the site in a tidy condition, free from rubbish to the
satisfaction of Shimizu.
Project Name : -
Site Address :-
1.28 Completion
Vendors work shall be completed in accordance with Contract documents and written
variation orders issued by Shimizu.
1.29 Data Sheet
Items Designation
No. of Tanks
Fluid Being handled
Licensed Capacity
Normal Capacity
Working Pressure
Design pressure
Test Pressure. Kg/Cm2 (g)
Working Temp.
Type and Shape
Calibration of Tanks
Location
Corrosion Allowance
Size of Tanks
Diameter
Length
Nozzle Size (NB)

Project Name : -
Site Address :-
Inlet
Outlet
Vent
Manhole Shell
Flame Arrestor
Drain
Level Gauge (Dip Stick)
Material of Construction
Shell & Ends
Nozzle & Accessories
Flanges
Shell Thickness
End Plate Thickness
Unloading Pumps
Service Conditions
Service
Type
Make
Project Name : -
Site Address :-
No. off
Location
Duty
Operating Conditions
Capacity Ltr/ Min.
Operating Temp.
Discharge Pressure
(Kg/Cm2 (g)
Max Pressure
Liquid Chamber
Inlet / Discharge Manifold
Outer Piston
Bearing
Center Section
Air Valve
Diaphragm
Ball valve
Accuracy
Instruments
Project Name : -
Site Address :-
Pressure Gauges
Type
Range
Dial Size
Make
Level Gauge
Type
Display
Pipes
Class 150, S.O.R.F
Flow Meter
Flow Rate
Accessories
Qty.
Leak Detection System
proposed any Leak Detection System
TECHNICALSPECIFICATION
Project Name : -
Site Address :-
4.16. HSD STORAGE TANK
HSD STORAGE TANK....................................................................................................................................... 1036

1.0 GENERAL ................................................................................................................................. 1037
1.1 SCOPE ....................................................................................................................................... 1037
1.2 80 KL Storage Tank ............................................................................................................. 1037
1.4 Unloading ................................................................................................................................ 1038
1.5 Transfer Pump ...................................................................................................................... 1038
1.6 Inline Flow Meter cum Transmitter ............................................................................. 1038
1.7 Day tank (990 L each) ........................................................................................................ 1038
1.9 Earthing ................................................................................................................................... 1039
1.10 Electrical Panel and cabling ............................................................................................. 1039
1.11 Fire Protection ...................................................................................................................... 1039
1.12 Optional ................................................................................................................................... 1039
1.13 Civil inside the Yard ............................................................................................................ 1039
1.18 Submission ............................................................................................................................. 1041
1.22 Examination ........................................................................................................................... 1042
1.23 Preparation ............................................................................................................................ 1043
1.24 Storing ...................................................................................................................................... 1043
1.25 Installation.............................................................................................................................. 1043
1.26 Commissioning ..................................................................................................................... 1043
1.27 Training ................................................................................................................................... 1043
1.28 Clean Site ................................................................................................................................. 1044
1.29 Completion ............................................................................................................................. 1044
1.30 Data Sheet ............................................................................................................................... 1045
Project Name : -
Site Address :-
1.30 GENERAL
For Shimizu Corporation India Pvt Ltd., proposed80KLx3 Nos. underground diesel
tank and Fuel Unloading, Pumping system, considering Design, drawing for complete
storage and supply systems as per IS 10987:1992. Fuel analysis of HSD taken from IS
1460: 2005.
1.31 SCOPE
1.32 80 KL Storage Tank
80 KL HSD storage tank shall be made as per IS 10987 with design pressure
atmospheric+ static head and design temperature -5 deg C to +55 deg C. manufacturer
test certificate shall be required for Hydro test pressure, Pneumatic test, radiography
for welded joints. Anchoring shall be with foundation bolts. Gasket shall be CAF 54/
Neoprene. Painting shall be done with zinc phosphate primer and two coats of
synthetic coal tar epoxy after sand blasting to SA 2 1/2.
Tank shall be installed with brass Dip stick gauge for level measurement with
calibration certificate.
Level transmitter shall be installed with measuring range of 5 meter with PVDF
sensor, EPDM seal and application safety. Inlet shall be 3” NB with NRV and outlet
fitted with submersible pump.
Project Name : -
Site Address :-
40NB Inverse U Vents with flame arrester at 2 meter high.
1.34 Unloading
Vendor shall provide 3" NB x 3 Meter unloading hose, integrated unloading system
with inline strainer and 3"" NB gas separator cum eliminator approved by weights
and measure department.
1.35 Transfer Pump
Transfer pump shall be submersible pump, 40 LPM flow at 36m head with Dry run
protection and internal bye pass valve at 36 M head, required 2 Nos. per tank
5001.7.
1.36 Inline Flow Meter cum Transmitter
Flow meter shall be oval wheel flow meter model with basket type strainer and air
eliminator, digital flow rate indicator for flow range of 35-350 LPM
Day tank of 990 L each shall be installed with level transmitter, high level switch with
alarm, inlet on/off automation with bye pass arrangement.
Relevant Fuel Piping inside yard shall be done with radiography of weld joints,
painted with red oxide primer and synthetic enamel two coats.
Project Name : -
Site Address :-
1.39 Earthing
Electrical equipments shall be earthed with 25mm x 3 mm GI flat earthing connected

to 2m x 1 1/2"" dia. GI pipe installed in a pit of salt and charcoal. Connections shall be
made with GI Nuts"
1.40 Electrical Panel and cabling
/ GI conduit. Incomer specification: 50 Amp, 415 V, 50 Hz."
Fire protection shall be with Fire buckets and fire extinguisher with mounting stand,
ABC type extinguisher. Vendor shall provide safety sign boards of No smoking, safety
procedure, operating procedure, emergency procedure and license display board, FLP
Lights
1.42 Optional
Vendor shall quote for following items.
Outside Yard Piping and cabling on Unit basis
Leak deduction system with 6 Nos. detectors for HSD system
1.43 Civil inside the Yard

Project Name : -
Site Address :-
the HSD Storage yard.
Vendor shall provide Plan approval from government agencies, Tank design and
factory test certificate, CCoE plan approval and CCoE Storage license.
Vendor shall provide Rule 126, 133 certification HSD tank installations
Vendor has to get the Local NOC statutory approval necessary for CCoE Approval.

Project Name : -
Site Address :-
1.48 Submission
i) Layout plan for approval

j) P&I Diagram for approval
k) Schedule including liasoning, civil works till ready for operation
l) Drawing showing sectional elevation of equipments.
m) Weights of equipments.
n) Outline drawing showing entry and distribution of piping and cable to
storagefacilities.
o) Schematics for supply line and controls
p) Schedule of supply, installation , execution and commissioning
Sectional Elevation
Manuals
Project Name : -
Site Address :-
Diagrams.
5001.8.
5001.9.
1.52 Examination
Project Name : -
Site Address :-
1.53 Preparation
1.54 Storing
1.55 Installation
required standard.
1.56 Commissioning
1.57 Training
Project Name : -
Site Address :-
1.58 Clean Site
1.59 Completion
Project Name : -
Site Address :-
1.60 Data Sheet
Items Designation
No. of Tanks
Fluid Being handled
Licensed Capacity
Normal Capacity
Working Pressure
Design pressure
Working Temp.
Type and Shape
with Plain ends
IS 10987
Location
Corrosion Allowance
Size of Tanks
Diameter
Length
Nozzle Size (NB)
Inlet
Project Name : -
Site Address :-
Outlet
Vent
Manhole Shell
Flame Arrestor
Drain
Shell & Ends
Flanges
Shell Thickness
End Plate Thickness
Unloading Pumps
Service Conditions
Service
Type
Make
No. off
Location
Duty
Project Name : -
Site Address :-
Capacity Ltr/ Min.
Operating Temp.
Discharge Pressure
(Kg/Cm2 (g)
Max Pressure
Liquid Chamber
Inlet / DischargeManifold
Outer Piston
Bearing
Center Section
Air Valve
Diaphragm
Ball valve
Accuracy
Instruments
Project Name : -
Site Address :-
Pressure Gauges
Type
Range
Dial Size
Make
Level Gauge
Type
Display
Pipes
Class C
Fittings
Part II, Heavy Duty
Flanges
Flow Meter
Flow Rate
Accessories
Qty.

Project Name : -
Site Address :-
Petrol Storage System
Petrol Storage System ..................................................................................................................................... 1049

1.0 General ..................................................................................................................................... 1050
1.1 Scope ......................................................................................................................................... 1050
1.3 Unloading ................................................................................................................................ 1050
1.4 Transfer Pump ...................................................................................................................... 1051
1.5 Day tank (60 L each) ........................................................................................................... 1051
1.7 Electrical Panel and cabling ............................................................................................. 1051
1.8 Earthing ................................................................................................................................... 1051
1.9 Fire protection & Safety .................................................................................................... 1052
1.10 Optional ................................................................................................................................... 1052
1.11 Civil inside Yard .................................................................................................................... 1052
1.16 Submission ............................................................................................................................. 1054
1.20 Examination ........................................................................................................................... 1055
1.21 Preparation ............................................................................................................................ 1055
1.22 Storing ...................................................................................................................................... 1056
1.23 Installation.............................................................................................................................. 1056
1.24 Commissioning ..................................................................................................................... 1056
1.25 Training ................................................................................................................................... 1056
1.26 Clean Site ................................................................................................................................. 1056
1.27 Completion ............................................................................................................................. 1057
1.28 Data Sheet ............................................................................................................................... 1057
Project Name : -
Site Address :-
1.61 General
20 KL Petrol storage tank shall be made as per IS 10987 with design pressure
atmospheric+ static head and design temperature -5 deg C to +55 deg C.
manufacturer test certificate shall be required for Hydro test pressure, Pneumatic
test, radiography for welded joints. Painting shall be done with zinc phosphate
primer and two coats of synthetic coal tar epoxy after sand blasting to SA 2 1/2.
1.62 Scope
Tank shall be installed with brass Dip stick gauge for level measurement with
calibration certificate.
Level transmitter shall be installed with measuring range of 5 metre with PVDF
sensor, EPDM seal and application safety Inlet of 3" NB with NRV and outlet fitted
with submersible pump.
40NB Inverse U Vents with flame arrester at 2 metre high.
1.64 Unloading
Vendor shall provide 3" NB x 3 Metre unloading hose, integrated unloading system
with inline strainer and 3" NB gas separator cum eliminator approved by weights
and measure department.
Project Name : -
Site Address :-
4.17.
1.65 Transfer Pump
Vendor shall supply and install Submersible pump with Dry run protection for 20
LPM flow at 36m head and internal bye pass valve at 36 M head Inline Flow Meter
cum Transmitter with Bye pass flow meter shall be oval wheel flow meter model
with basket type strainer and air eliminator, digital flow rate indicator for flow range
of 15-250 LPM
4.18.
Tank shall be installed with level transmitter, high level switch with alarm, inlet
on/off automation with bye pass arrangement.
4.19.
Inside Yard Piping shall be done with radiography of weld joints, painting with red
oxide primer and synthetic enamel two coats.
4.20.
1.68 Electrical Panel and cabling
/ GI conduit. Incomer specification: 50 Amp, 415 V, 50 Hz.
4.21.
1.69 Earthing
Project Name : -
Site Address :-
Electrical Equipments shall be earthed with 25mm x 3 mm GI flat earthing connected

to 2m x 1 1/2" dia GI pipe installed in a pit of salt and charcoal. Connections shall be
made with GI Nuts
4.22.
1.70 Fire protection & Safety
Vendor shall provide Fire buckets and fire extinguisher with mounting stand, ABC
type extinguisher. And safety sign boards of No smoking, safety procedure, operating
procedure, emergency procedure and licence display board, FLP Lights.
Leak detection system with 3 Nos. detectors for petrol system
1.71 Optional
Vendor shall quote for following items.
Outside Yard Piping and cabling on Unit basis
Leak deduction system with 3 Nos. detectors for Petrol storage system
1.72 Civil inside Yard
the Petrol Storage yard.
Project Name : -
Site Address :-
Plan approval, Tank design and factory test certificate. CCoE plan approval. CCoE
Storage license
Vendor shall provide Rule 126, 133 certification HSD tank installations
Vendor has to get the Local NOC statutory approval necessary for CCoE Approval.
Client /Server architecture and Web server Functionality shall be available as option.
Project Name : -
Site Address :-

1.77 Submission
q) Layout plan for approval

r) P&I Diagram for approval
s) Schedule including liasoning, civil works till ready for operation
t) Drawing showing sectional elevation of equipments.
u) Weights of equipments.
v) Outline drawing showing entry and distribution of piping and cable to
storagefacilities.
w) Schematics for supply line and controls
x) Schedule of supply, installation , execution and commissioning
Sectional Elevation
Manuals

Project Name : -
Site Address :-
Diagrams.
5001.10.
1.81 Examination
1.82 Preparation
Project Name : -
Site Address :-
1.83 Storing
1.84 Installation
required standard.
1.85 Commissioning
1.86 Training
1.87 Clean Site
Project Name : -
Site Address :-
1.88 Completion
1.89 Data Sheet
Items Designation
No. of Tanks
Fluid Being handled
Licensed Capacity
Normal Capacity
Working Pressure
Design pressure
Working Temp.
Type and Shape
with Plain ends
IS 10987
Location
Corrosion Allowance
Size of Tanks
Project Name : -
Site Address :-
Diameter
Length
Nozzle Size (NB)
Inlet
Outlet
Vent
Manhole Shell
Flame Arrestor
Drain
Shell & Ends
Flanges
Shell Thickness
End Plate Thickness
Unloading Pumps
Project Name : -
Site Address :-
Service Conditions
Service
Type
Make
No. off
Location
Duty
Capacity Ltr/ Min.
Operating Temp.
Discharge Pressure
(Kg/Cm2 (g)
Max Pressure
Liquid Chamber
Inlet / DischargeManifold
Outer Piston
Bearing
Center Section
Project Name : -
Site Address :-
Air Valve
Diaphragm
Ball valve
Accuracy
3. Instruments
Pressure Gauges
Type
Range
Dial Size
Make
b. Level Gauge
Type
Magneto/Restrictive Gauge in the yard
Control Room, as an option
Pipes
Class C
Project Name : -
Site Address :-
Fittings
Part II, Heavy Duty
Flanges
to ANSI B-16.5,
Class 150, S.O.R.F
Flow Meter
Accessories
Qty.
- Model V 810X-3-3 with battery back-up and
Alarm Unit/Indicator Unit
- Model KD2A Detectors

Project Name : -
Site Address :-
Propane Storage Facility
1.90 General
For Shimizu Corporation India Pvt Ltd., proposedMounded Propane storage of

50MTx3 Nos., volumetrically 120KLx3 Nos., considering the Consumption pattern of
Propane as under,200 Kg/hr Maximum In line with
Four number of Vaporisers with 200 Kg/hr,20 CUM Buffer tank, sledge separator.
Tanks shall be designed as per IS 2825 Specifications and Cathodic Protection of the
tanks with Latest Anode flex Material with 50 Years Design Life.
1.91 Scope
Complete design, supply, installation and liasoning including all related civil works,
piping, fire protection inside yard, control panel, integrating with basic automation
and licensing.
1.92 Tank Construction
PROPANE Storage Tank of 3 numbers 50 MT (120 Cubic meter) comprising Dsign

code IS 2825 and SMPV (U) Rules 1981 approval received from Third party
inspection agency approved by CCoE shall be with
Design pressure 21 Kg/cm2
Design Temperature -42 Deg C to +55 Deg C
Hydro test pressure 28 Kg/cm2 g
Corrosion allowance 1.5 mm
Radiography 100% Third party Inspection Third party inspection agency

approved by CCoE
Project Name : -
Site Address :-
Joint efficiency 1
Heat treatment As per rule
Construction Cylindrical horizontal shell with two nos. Torispherical /

Hemispherical dished ends,
With One Manhole and One Dome with all Process Connections
Shell/ Dished ends SA 516 Gr 70 or SA 537 Class 1
Supports Bearing Pads
Nozzle neck SA 516 Gr 70 or SA 537 Class 1
Manhole cover SA 516 Gr 70 or SA 537 Class 1
Nuts SA 320 Gr.L7 / SA 194 Gr 7
Studs SA 320 Gr L7
Flanges SA 350 LF 2
Pipes SA 333 Gr.6
Couplings SA 350 LF 2
Gasket SS Spiral wound
1.93 Structural Work for the Tank
Ladder and Platform with necessary fencing shall be done at mounded top.
1.94 Painting
Project Name : -
Site Address :-
Tank surface shall be sand/ grit blasted finish up to 60 microns. And Painting shall be
done with epoxy based zinc phosphate primer 50 micron and tow pack polyurethane
400 microns of sigma marine.
1.95 Tank Nozzles and Associated Safety Fittings.
Vendor shall provide Safety Relief Valve of 1” NB, 300# fitted with Screwed Type
SRVs, Shut off and Spool Pieces of 2m Height of 65NB.
Liquid Inlet shall be 2” NB, 300# fitted with SS304 S/W type EFCV and One Shut off
Valve.
Vapor In from Fill Point shall be 11/2” NB, 300# fitted with SS304 S/W type EFCV
Shut off Valve
Vapor Out to consumption shall be 11/2” NB, 300# fitted with SS304 S/W type and
Shut off Valve
Liquid Outlet 2”NB, 300# shall be fitted with Virgo Make Remote Operated Valve
SS304 S/W type Drain of 1” NB, 300# shall be provided with Two Shut off Valve
Fixed Liquid Level Gauge, top Mounted Rochester Level Gauge shall be provided.
Pressure Gauge with 0-42Kg/cm2, 4” Dial, Pressure Gauge with Brass EFCV shall be
provided.
6 “ long Thermo well with Temperature Gauge of 0-100 Deg C, 4” Dial shall be
provided.
Project Name : -
Site Address :-
High Level Alarm, Pressure Transmitter, Level Transmitter. Temperature

transmitters with remote level indication shall be provided.
1.96 Unloading Pump
5001.11.
Unloading pump shall be positive displacement, vane type, Ductile Iron Body with dry
run protection, double mechanical seal with satellite graphite ring, SS 304 rotor, and 5
HP flameproof motor to IS 2148 with DOL starter. Pop action valve, isolating valve,
strainer with sight flow indicator and NRV shall be provided for each pumps.
1.97 Unloading Compressor
Unloading compressor shall be vertical, non lubricating with inlet knock out drums.
Piston displacement shall be at 300 rpm : 160 Lit/Min and 825 rpm : 440 Lit / Min.
Max pressure shall be 24.14 bars
Motor shall be 7.5 HP, flameproof to IS 2148
Pressure gauge / indicator shall be provided at suction and discharge.
Strainer shall be provided at suction for filtration.
Isolation valves shall be provided for interchanging suction and discharge ports.
Safety interlock shall be done for
Inlet low pressure,
Outlet high pressure (HPS)
Outlet high temperature (HTS)
High tank level (HTL)
Overload protection (O/L)
High level at the suction drum (LS)

Project Name : -
Site Address :-
1.98 Unloading Hose with Crash Post and Bulk Head
Unloading hose set shall be one number 2” NBx4.5 Meter hose and 1” NBx4.25 Meter
with quick release action coupling UL approved design and most safest hoses
available.
Bulk head shall be made out of ‘C’ channels to anchor the unloading pipes and grouted
firmly
Crash post shall be made out of 4” NB ERW B class pipe.
1.99 Product Piping
Product piping shall be with ASA 106 Gr B, Seamless Sch. 80, test pressure 30 kg/cm2
and max. Work pressure 8.5kg/cm2. Piping includes necessary Ball valves, Y strainer,
NRV, Gaskets, studs and nuts.
Pipe flanges shall be raised face forged 300# and fittings shall be forged steel.
Painting shall be done with two coats of red oxide primer and two coats of synthetic
enamel paint as per code.
4 Kg DCP type 4 Nos, Fire extinguishers ISI make shall be provided
8 Nos of sand buckets shall be provided with a mounting stand.
Hydrant system shall be provided with 63mm fire hydrant valve, 15 Mtr long fire
canvas hose reel and fire hose box.
Project Name : -
Site Address :-
1.101 Propane Vaporizer
5001.12.
Electric Vaporizer with 24 KW heater for capacity of 200 kg / Hr 4 Nos – 3 working
and one standby option shall be provided, shell design as per IS 2825, coil ASA 106 Gr
B Sch 40 coil, 50 mm glass wool insulated with 24 SWG aluminum cladding. Pressure
control, temperature control shall be with two set points with digital display. Flow
control with FLP solenoid valve. Flame proof fittings used shall be with CMRI and
CCoE approved make. Control panel location shall be inside yard near to vaporizer
with FLP enclosure approved by CMRI and CCoE.
1.102 Electrical Control Panel
Control panel shall me fabricated out of 14/16 SWG, MS sheet, according to the
requirement, floor mounted, non draw out type feeder, powder coated with cement
grey shade color. Panel box Designed to accommodate all power and motor
distribution and distribution.
Incoming Amps: 300 Amp, 415V, 3 Ph 50 Hz. Total load: 150 KW
Display parameters: Control panel shall be provided with display of Tank Pressure,
Level of tank to cut off, remote operated valve on off position, pump dry run
protection alarm, all alarms as described in Compressor, overload alarm as described,
vaporizer on/off, vaporizer outlet temperatures and pressure at the delivery line
outside the yard.
UPS: 1 KVA UPS shall be provided with 30 Min. power backup. Emergency shutdown
switch of all remote operated valves and alarming signals shall be done in Gate entry,
Unloading point, and control panel.
Cabling: Necessary cabling shall be done from equipment to PLC and MCC panel.
Above ground cabling shall be done with Cable trays.
Project Name : -
Site Address :-
1.103 Liquid Trap / Sledge Separator
Liquid trap shall be with 300 Liter capacity constructed in cylindrical shell with
torispherical head provided with SS 304 demister pad at the top. Design pressure
shall be 21 KG/cm2, level gauge, safety relief valve, drain fitted.
1.104 Pressure Regulating Train
Pressure regulator of spring loaded, diaphragm type shall be 200Kg/hr capacity with
bucket type filter. Inlet pressure shall be 0-21 kg/cm2 and outlet shall be adjustable
between 0.5 kg/cm2 to 4.0 kg/cm2. Pressure gauge at both inlet and outlet, safety
relief valve at outlet shall be provided.
1.105 Piping outside Yard
Piping outside yard shall be done with IS1239 Heavy piping. Above ground piping
shall be done with one coat of mastic primer and two coats of synthetic enamel.
Underground piping shall be with wrapping coating of pipe up to 2, thickness.
1.106 Mass flow Meter
Coriolis type Mass flow meter shall be provided with field display accuracy to 0.75%
to 1% provided with ball valves.
1.107 Earthing
Project Name : -
Site Address :-
Earthing shall be done for all electrical equipments with 25mm x 3mm GI Flat
connected to 2m x 1 ½ “ Dia. Pipe installed in a pit of salt and charcoal. Jumpers
between flanges shall be 25mm x 3 mm copper strips at all flanged joints on piping.
1.108 Leak Detection System
Leak detection shall be installed with 10 channels, 3 for tank bottom, 1 at pump room,
2 at vaporizer room, 1 at PRV station and 3 at mounded tank top to suit propane
storage.
Leak detection system shall work in operating voltage 240 V AC or 6V DC and to

operate at temperature Up to 95oC. Control panel shall be with 10 Nos. indicators,
modular design for card replacement, and digital indicator for leak detection showing
the % leakage and fault indicator and two reset buttons.
1.109 Cathodic Protection System
Cathodic Protection system for 20 years shall be provided
Sacrificial type shall be with High potential magnesium anodes of 7.6 kg each with one
common test station.
1.110 Remote operated Valves
Single acting, normally closed type Remote operated valves shall be provided at liquid
outlet of each tank (3) as per ANSI b 16.5 of 300#, SS 316 internals, and PTFE on-off
ball valve. Actuators shall be spring retainer construction, self lubricating with life
span of 1 million cycles, min air pressure required 3kg/cm2 – 6kg/cm2. Local
indication of on/off provided. Solenoid valve for pneumatic connections shall be FLP
type. Limit switches shall be provided for on/off position and displayed at control
panel
Project Name : -
Site Address :-
1.111 Civil inside Yard
the Propane storage yard.
Plan approval, Tank fabrication plan and design approval. Third party inspection and
completion certificate for tank fabrication
Rule 33 approvals for installation
Vendor has to get the Local approval received from District magistrate.
5001.13.
Project Name : -
Site Address :-
1.116 Submission
y) Layout plan for approval

z) P&I Diagram for approval
aa) Schedule including liasoning, civil works till ready for operation
bb)Drawing showing sectional elevation of equipments.
cc) Weights of equipments.
dd)Outline drawing showing entry and distribution of piping and cable to
storagefacilities.
ee) Schematics for supply line and controls
ff) Schedule of supply, installation , execution and commissioning
Sectional Elevation

Project Name : -
Site Address :-
Manuals
Diagrams.
5001.14.
Project Name : -
Site Address :-
1.120 Examination
1.121 Preparation
1.122 Storing
1.123 Installation
required standard.
1.124 Commissioning
Project Name : -
Site Address :-
1.125 Training
1.126 Clean Site
1.127 Completion
1.128 Data Sheet
Items Designation
Design Pressure
Design Temperature
Hydraulic Test Pressure
Corrosion Allowance
Radiography
Heat Treatment
Flanges
Project Name : -
Site Address :-
Couplings
Studs
Nuts
Size of Manway
Safety Fittings -
Safety Fittings like SRVs/EFCVs etc.
Pressure Gauges/Temp. Gauge
High Level Switch
Rochester Gauge (without Transmitter)
Optional Items
Transmitter for Rochester Gauge
Radar Gauge
Compressor Bulk Plant
Model No.
Make
Type of Compressor
type specially designed for LPG Service
Bore
Stroke
Piston Displacement
Max. Working Pressure
Motor Type and Rating
Push Button
Project Name : -
Site Address :-
Max. Compression Ratio
Continuous Duty
Intermittent Duty
Optional Items
Flame Proof Control Panel with
the following safety interlocks
Low Suction Pressure Switch
High Delivery Pressure Switch
Low Oil Pressure
High Delivery Pressure
High Delivery temperature
Propane Booster Pumps
Type
Capacity
Max. Diff. Pressure
Type of Seal
Motor Type & rating
Gases
Drive
Qty.
Make
Model
Note
Project Name : -
Site Address :-
Vaporizer (Electrical)
Make
Capacity
Power
Controls
RTD’s for Temp. Control
Temp. Controller
Electrical
Qty.
Yard Piping
Type
Specifications
Jointing
Shut Off Valves
First Stage Pressure Regulators
Type
Range for Inlet
Capacity
Additional Feature
Outlet Pressure
Model/make
Quantity
Crash Post
Bulk Head
MCC
Project Name : -
Site Address :-
Incoming Feeder
Outgoing Feeder
Cathodic Protection System
Design Parameters
Bare Steel at the end of Design Life
Current Density
Consumption of Zinc Ribbon Anode
Efficiency
Life of the System

All Specs Latest - 16th June 2017

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SHIMIZU CORPORATION INDIA PVT LTD Cilent

SCI / QHSE / QA QC / / 2014// R0

3.6 Technical Specification.

SCI / QHSE / QA QC / / 2014// R0

BASIC ELECTRICAL REQUIREMENTS

HIGH VOLTAGE,LOW VOLTAGE CABLES

UNINTERRUPTIBLE POWER SUPPLY SYSTEM

WIRING FOR LIGHTING & SMALL POWER

MCBs, RCDs, RCBOs, ISOLATORS & MCB DISTRIBUTION BOARD

COMMISSIONING CHECK LIST

APPROVED PREFFERED MAKE OF MATERIAL

SCI / QHSE / QA QC / / 2014// R0

I Basic Electrical Requirements

 Supply, storage, installation, testing and commissioning of all equipment,

 Organize for day to day adequate labor, tools, machinery andtesting

 Day to day supervision of the installation work by at least 1 full time

 Co ordination for construction of HT/LT panel, transformer foundations,

Testing and commissioning of the installation in accordance with the relevant/recent

 House keeping during the Execution of the contract.

SCI / QHSE / QA QC / / 2014// R0

 Shall submit samples of all discrete components, like conduits, switches,

 Shop drawing/method statements shall be prepared before starting the work

 All equipment included in scope of supply shall be tested at

 Liaisoning with Local Electrical authority/CEIG and other statutory

1.2 Licensed Electrical Contractor

SCI / QHSE / QA QC / / 2014// R0

1.3.1 H.T SWITCH GEARS

IS : 2099 : Bushings for alternating voltage above 1000V.

IS : 2516 : AC Circuit Breakers

IS : 2705 : Current Transformers

IS : 3156 : Voltage Transformers

IS : 3427 : Metal enclosed switch gear & Control gear for

IS : 6875 : Control switches for Voltages up to and including

IEC : 60056 : HV Alternating current circuit breakers.

IS : 2147 : Degree of protection for enclosure

IS : 3842 : Specification for HRC fuse link up to 650V.

1.3.2 DISTRIBUTION TRANSFORMERS

IS : 2026 Part-I to IV, : Power Transformers IEC : 76 BS-171

IS : 3939 : Fittings and Accessories

IS : 6600 : Guide for Loading of oil immersed Transformer

IS : 8468 : On Load Tap Changers

IS : 10028 Part-II : Installation & Maintenance of Transformers

IS : 335 : Insulating oil.

IS : 2099 : Bushing for alternating voltage above 1000V.

SCI / QHSE / QA QC / / 2014// R0

IS : 4257 : Porcelain bushings for Transformer

IS : 2705 : Current Transformers

IS : 8478 : Application guide for tap changers.

IS : 13947(Part-II) : Air circuit breakers & MCCB’s

IS : 13947 : Air break contactor

IS : 4237 : General Requirements for Switchgear

IS : 2147 : Degree of protection provided by enclosure for

IS : 8623 : Factory built assembly of switchgear & control gear.

IS : 1248 : Electrical Indicating instruments

IS : 2705 : Current Transformer

IS : 3156 : Potential Transformer

IS : 375 : Marking and arrangement of Bus bars.

IS : 8828-1996 : MCB (Miniature circuit breakers)IEC : 898-1995

IS : 12640-2000 : RCBOs/RCCBs IEC:61008-1996,IEC-61009-1

IS : 13947, Part-III : Load Break Isolators IEC 947-3

IS : 13779I : kWH Meter IEC –1036

IS : 6875 : Indicating lamps

IEC:60255, IEC:61000 : Protection Relays IS3231, IS8686

IS : 2959 : AC Contactors up to 1000V.