technical specs_tender document - part b

8/12/2019 Technical Specs_Tender Document - PART B

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NTPC Limited(A GOVERNMENT OF INDIA ENTERPRISE)

Section -VI

TECHNICAL SPECIFICATIONS

for

DEVELOPMENT OF 10 MW (PHASE-1)

SOLAR PHOTO VOLTAIC PLANT

AT NTPC- RAMAGUNDAM,

ANDHRA PRADESH

Bid Document No: CS-5705-004-9


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Development of 10 MW (Phase-1)

Solar Photo Voltaic Plant at

NTPC Ramagundam

Bid Doc. No.

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TABLE OF CONTENTS

Description

Part-A SCOPE OF SUPPLY AND WORK

1.0 Introduction

2.0 Inputs provided by NTPC

3.0 Scope of Work

4.0 SPV and its Auxiliaries5.0 Electrical Works

6.0 Civil Works

7.0 General Requirements

8.0 Specifications for Operation & MaintenanceContract

9.0 Performance Guarantee (PG) Test

10.0 Quality Assurance chapters

Part-B LIST OF EXHIBITS1.0 Topographical Survey of the proposed area

2.0 Summary of Geotechnical studies of the proposed area

Part-C GENERAL TECHNICAL REQUIREMENTS

Part-D ERECTION CONDITIONS OF CONTRACT

Part-E TECHNICAL DATASHEET


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1. INTRODUCTION

NTPC Limited, a public sector company was incorporated in the year 1975 toaccelerate power development in the country as a wholly owned company of

the Government of India. At present, Government of India holds 84.5% of thetotal equity shares of the company and the balance 15.5% is held by FIIs,Domestic Banks, Public and others. Within a span of 36 years, NTPC hasemerged as a truly integrated power company, with power generating facilitiesin all the major regions of the country.

NTPC has set a target to have an installed power generating capacity of1,28,000 MW by the year 2032. The capacity will have a diversified fuel mixcomprising 56% coal, 16% Gas, 11% Nuclear and 17% Renewable EnergySources(RES) including hydro. By 2032, non fossil fuel based generationcapacity shall make up nearly 28% of NTPCs portfolio.

As on date the installed capacity of NTPC is 35,354 MW through its 15 coalbased (27,535 MW), 7 gas based (3,955 MW) and 6 Joint Venture Projects(3,864 MW).

In view of Global Warming and fast depleting fossil fuels, Renewable Energybased projects are being considered as one of fuel mix portfolio. In thiscontext, NTPC has formulated its business portfolio including a capacityaddition of 1000 MW through Renewable Energy Sources by 2017. In addition301 MW is proposed to be added through Solar Energy by 2014.

PROJECT INFORMATION

The proposed Solar Photo Voltaic plant shall be located at NTPCRamagundam (Ramagundam Super Thermal Power Station). NTPCRamgundam is situated in the Karimnagar district of Andhra Pradesh. It is wellconnected by rail and road route. It is appx. 60 kms from Karimnagar and isabout 5 kms from Ramagundam.

Spread over 9558 acres, the station has total coal based installed capacity of2600 MW. It is having latitude and longitude of 18o45 and 79o28respectively.

LAND

Appx. 50 acres of land is available for the plant and other facilities. Land is inthe possession of NTPC Ramagundam. Bidder has to ensure optimum use ofthe land. Prior to submission of bid, bidder is expected to visit the site for firsthand experiences of the project site.


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2.0 INPUTS PROVIDED BY NTPC

1. Land details and topographical Survey of the proposed site.2. Daily Global average (twenty years) Solar radiation on horizontal surface

as per Meteonorm for each month ( kWhr/m2/day ) for 12 months.3. Summary of Geotechnical studies of the proposed site.


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3.0 SCOPE OF WORK

Design, engineering, supply, packing and forwarding, transportation,unloading, storage, installation and commissioning of 10 MWp (DC) grid

connected (export of power to grid) Solar PV based power project on turnkeybasis at NTPC Ramagundam.

Bidder shall provide comprehensive operation & maintenance of the plant fora period of one year from the date of successful completion of trial run.

3.1 PLANT EQUIPMENT AND ASSOCIATED WORKS

3.1.1 Civil Works

1. Site grading, levelling of the identified area including soil testing andcutting of vegetation.

2. Requisite foundation and structures wherever required3. Requisite cable routings(s) through cable trenches (underground)

wherever required.4. Main and service roads, with suitable drainage arrangements wherever

necessary.5. Construction of Control room and other facilities as per clause 6.2.6. Fencing of complete plant including module yard, control room and 33 kV

switchyard.

3.1.2 Solar PV Plant

The system shall consist of (but not limited to) following equipment:

(a) Suitable Nos. of SPV Module 150 Wp

(b) Power conditioning unit

(c) SCADA

(d) Control equipments

(e) Mounting structures

(f) Cables and hardware

(g) Junction boxes and distribution boxes

(h) Earthing kit

(i) Lightening arrestors

(j) Tool Kits for maintenance

(k) Pyranometer

(l) Mandatory spares


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3.1.3 Grid interfacing, including all equipment required for the same such astransformers, breakers, isolators, lightening arrestor, panels, protectionequipment, cables, earthing of transformer and Panel yard etc. as per statutory

requirements and comply to CERC Grid code.

3.1.4 Metering of outgoing energy at the 33 kV outgoing feeder.

3.1.5 Design & construction of Centralized Monitoring & Control System(CMCS) to house control panels, protection panels, inverters, SCADAsystem for remote monitoring & control the plant etc.

3.1.6 Fire protection and fire fighting equipment.

3.1.7 Arrangement of water supply during construction and O&M period shallbe done by the contractor. Bidder shall also lay suitable lines etc. tomake permanent arrangement for module washing and their drainage.

3.1.8 Supply & providing suitable illumination for the proposed SPV plant,evacuation system including control room and other facilities.

3.2 ENGINEERING DATA & DRAWINGS

3.2.1 Engineering drawing, data etc including calculations shall be preparedby the bidder and got approved from the owner before

commencement of the project.

3.2.2 Successful bidder shall furnish operation and maintenance manual insix (06) sets prior to commencement of warranty period in hard aswell as soft form.

3.3 TRAINING OF EMPLOYERS PERSONNEL

The bidder shall provide training to at least four personnel of NTPC for aminimum period of 10 days at his works and at site for erection, testing,commissioning and O&M. Expenses towards travel, stay, lodging, and

boarding and other expenses for the personnel shall be borne by NTPC.

3.4 TERMINAL POINTS & EXCLUSIONS

The terminal point under the scope of this assignment shall be line isolator of33 kV outgoing feeder. Further transmission line and related equipment shallbe under the scope of NTPC.

3.5 The scope of the contractor shall be deemed to include all such itemswhich although are not specifically mentioned in the bid documents and/or incontractors proposal but are needed to make the system complete in all


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respects for its safe, reliable, efficient and trouble free operation and the sameshall be furnished and erected unless otherwise specifically excluded as perSection Terminal Points & Exclusions.


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4.0 SPV and Its Accessories

4.1 SPV Module

Only Silicon Crystalline SPV cells shall be used in the Solar Photovoltaicmodule. Peak power rating of the module shall not be less than 150 Wp. Themodule efficiency shall be more than 13% at standard test condition and thecell should have minimum fill factor of 0.7. It shall be made of hightransmittivity glass & front surface shall give high encapsulation gain. Biddershall guarantee minimum 14.936 Million Unit (annually) at 33 kV outgoingfeeder. Bidder shall also furnish the month wise generation in the datasheetcorresponding to the radiation data provided by NTPC.

All materials used shall have a proven history of reliability and stableoperation in external applications. It shall perform satisfactorily in relativehumidity up to 100% with temperatures between -10 C and +50 C and shallwithstand gust up to 150 km/h on the surface of the panel. Each and everySPV module shall be checked for conformity with relevant standard and nonegative tolerance shall be accepted.

4.1.1 General requirements for PV module:

a. Module shall be manufactured in India. Module shall be made up of monoor poly crystalline silicon cells.

b. The interconnected cells shall be laminated in vacuum to withstandadverse environmental conditions

c. The module frame is made of corrosion resistant materials, preferablyhaving aluminium anodized finish

d. The minimum clearance between the lower edge of the modules and thedeveloped ground level shall be 400 mm. All the panels shall haveprovision to adjust it at three angular position i.e. latitude angle, latitudeangle-150, latitude angle +150.

e. Surge arresting device to be provided at junction box and module shall beprovided with bypass diode.

f. The bidder shall carefully design & accommodate requisite numbers of themodules in the available area (refer topographical survey) to achieve therated power in his bid. NTPC shall allow only minor changes only duringerection of modules.

g. The SPV module must be IEC 61215 and IEC 61730 Part I and Part IIcertified from any of the accredited certifying agencies.


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h. Each Solar PV modules used in solar power plants/ systems must bewarranted for their output peak watt capacity, which should not be lessthan 90% at the end of 10 years and 80% at the end of 25 years from thecompletion of the trial run.

i. The bidder shall provide the sample solar PV module electricalcharacteristics including current-voltage (I-V) performance curves andtemperature coefficients of power, voltage and current.

j. Each PV module deployed must use a RF identification tag. The followinginformation must be mentioned in the RFID used on each modules(Thiscan be inside or outside the laminate, but must be able to withstand harshenvironmental conditions)

i. Name of the manufacturer of the PV module

ii. Name of the manufacturer of Solar Cells

iii. Month & year of the manufacture(separate for solar cells andmodules)

iv. Country of origin(separately for solar cells and module)

v. I-V curve for the module

vi. Wattage, Im, Vm and FF for the module

vii. Unique Serial No and Model No of the module

viii. Date and year of obtaining IEC PV module qualification certificate

ix. Name of the test lab issuing IEC certificate

x. Other relevant information on traceability of solar cells and moduleas per ISO 9001.

4.1.2 MODULE MOUNTING STRUCTURE

1. Modules shall be mounted on a non-corrosive support structures

2. All the Panels shall have provision to adjust it at three angularposition i.e. Latitude angle(00), latitude angle(-150), latitudeangle (+15

0). The locking arrangement for adjusting the angle of

module shall be accessible from the ground.

3. The base columns shall be made with reinforced cementconcrete as per design based on site related data.


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4. The frames and leg assemblies of the array structures shall bemade of MS hot dip galvanized. Minimum thickness ofgalvanization should be at least 120 microns.

5. All fasteners shall be of Stainless steel - SS 304. Nut & bolts,supporting structures including module Mounting Structures shallhave to be adequately protected against all climatic condition.

4.2 INSTRUMENTS FOR METEOROLOGICAL MEASUREMENTS.

Bidder shall provide following measuring instruments with all necessarysoftware & hardware required to make it compatible with SCADA.

4.2.1 Pyranometer:

Bidder shall provide pyranometer for measuring incident global solarradiation. The specification is as follow:

1. Spectral Response- 0.31 to 2.8 micron.2. Sensitivity-9 micro-volt/w/m

2

3. Time response(95%): Max 15 s4. Non linearity: 0.5%5. Temperature Response: 2%6. Temperature Response= Max 2%7. Tilt error: 0.5%.

8. Zero offset thermal radiation: 7 w/m29. Zero offset temperature change 2 w/m

2

10. Operating temperature range: - 40 deg to +80 deg.11. Uncertainty(95% confidence Level): Hourly- Max-3%

Daily- Max-2%12. Non stability: Max 0.8%13. Resolution: Min + / - 1 W/m214. Input Power for Instrument & Peripherals: 230 VAC (If required)15. Output Signal: Analogue form which is compatible with the data

Each instrument shall be supplied with necessary cables. Calibrationcertificate with calibration traceability to World Radiation Reference(WRR) or WorldRadiation Centre (WRC) shall be furnished along withthe equipment. The signal cable length shall not exceed 20m. Biddershall provide Instrument manual in hard and soft form.

4.2.2 Thermometer:

Bidder shall also provide at least one RTD type / semiconductor typeambient temperature measuring instrument at suitable place in PVarray. Instrument shall have a range of -5oC to 60oC.


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g. The PCU should be suitably designed for parallel operation. Each solidstate electronic device shall have to be protected to ensure long life ofthe inverter as well as smooth functioning of the inverter.

h. The PCU shall have anti islanding protection.

i. The PCU must have the feature to work in tandem with other similarPCUs and be able to be successively switched ON and OFFautomatically based on solar radiation variations during the day.

j. The system shall tend to balance unequal phase voltage (with 3-phasesystems) with reference to the red phase (line-1).

k. The PCU front panel shall be provided with a display (LCD orequivalent) of all important parameter such as DC input voltage, DC

input current, AC input voltage, AC input current, AC output power,frequency etc.

If the bidder is not able to provide PCU with display, the same has tobe made available at SCADA.

l. Nuts & bolts and the PCU enclosure shall have to be adequatelyprotected taking into consideration the atmosphere and weatherprevailing in the area.

m. Dimension and weight of the PCU shall be indicated by the bidder inthe offer.

The PCU shall include appropriate self protective and self diagnosticfeature to protect itself and the PV array from damage in the event ofPCU component failure or from parameters beyond the PCUs safeoperating range due to internal or external causes. The self-protectivefeatures shall not allow signals from the PCU front panel to cause thePCU to be operated in a manner which may be unsafe or damaging.Faults due to malfunctioning within the PCU, including commutationfailure, shall be cleared by the PCU protective devices.

It should have Local LCD (Liquid crystal display) and keypad forsystem control, monitoring instantaneous system data, event logs, datalogs and changing set points. Control and read-out should be providedon an indicating panel integral to the Inverter. Display should be simpleand self explanatory display to show all the relevant parameter relatingto PCU operational data and fault condition in form of front Panelmeters / LEDs or two line LCD Display.


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Output frequency 50 Hz +/- 0.5% Hz ( Inverter to followgrid frequency upto +/- 3 Hz of thenominal output frequency during normaloperation)

Maximum Inputvoltage

1000 V DC

THD Less than 4 %

Ambient temperature 0 to 50 deg C

Humidity 95 % non- condensing

Enclosure IP 20 ( Indoor type )

IP 54 (Outdoor type)

The Inverter shall have following features:

a. No load loss


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m. Ground fault detector which is essential for large PV generatorsin view of appreciable discharge current with respect to ground.

n. Over voltage protection against atmospheric lightning discharge to

the PV array is required.

The power conditioner must be entirely self-managing and stable in operation.A self diagnostic system check should occur on start up. Functions shouldinclude a test of key parameters on start up.

4.4 SOIL TEST

To ascertain soil parameters of the proposed site for construction of controlroom substation & array yard, the contractor shall carry out Sub Soilinvestigation through certified soil consultantThe scope of sub soil investigation covers: execution of complete soilexploration including boring, drilling, collection of undisturbed soil samplewherever possible, otherwise disturbed soil samples, conducting laboratorytest of samples to find out the various parameters mainly related to loadbearing capacity, ground water level, settlement and sub soil condition andsubmission of detail reports with recommendation regarding suitable type offoundation for each bore hole along with recommendation for soilimprovement wherever necessary.The soil test also includes analysis of water sample. There will be minimum

three numbers of boring each with required depth.

4.5 EARTHING

Each array structure of the PV yard shall be grounded properly as per IS 3043- 1987. All metal casing / shielding of the plant shall be thoroughly groundedin accordance with Indian electricity act / IE Rules.

4.6 Control, Automation and Data Acquisition System.

The plant shall be automatically operated and shall be controlled by

microprocessor-based control system SCADA. There shall be data loggingand display system for continuous monitoring of data.

An integrated SCADA shall be supplied which should be capable ofcommunicating with all inverters and provide information of the entire SolarPV Grid connect power plant.

SCADA shall provide instantaneous along with 15 minute daily, monthly andannual average of following parameters:

1. Power at 33 kV terminal


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2. Ambient temperature

3. Wind Speed

4. AC and DC side Power of each inverter

5. Solar irradiation/isolation

6. Voltage of the HT Side

7. Any other parameter considered necessary by supplier based oncurrent prudent practice

SCADA shall provide 15 minute daily, monthly and annual average offollowing parameters:

1. Exported Energy

2. Energy of each inverter

The SCADA shall have the feature to be integrated with the local system as

well as remotely via the web using either a standard modem or a GSM/WIFI

modem. The bidder shall provide compatible software and hardware so data

can be transmitted via standard modem.

SCADA shall be provided with a reliable power supply alongwith a backupsupply for at least one hour to cater to outage of grid.


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5.0 ELECTRICAL WORK

The power evacuation system shall comprise of atleast two (02) transformerbay feeding 33 kV bus. In addition, the substation shall also have one (01)

feeder bay to evacuate power.Bidder to submit the Single line diagram and layout diagram of the electricalsystem to NTPC for approval.

5.1 AC SWITCH BOARD

An AC Distribution Boards (ACDBs) in the control room shall be provided inbetween PCU and 33kV transformer if paralleling of PCU is done by isolatingtransformer or galvanic isolation. It shall have MCB/MCCB or Circuit breakerof Suitable rating for connection and disconnection of PCU from Grid. The

connection between ACDB and Transformer shall be either Busbar or Cable.It shall have provision to measure bus voltage, current and power feeding thetransformer.

5.1.1 CONSTRUCTIONAL DETAILS OF SWITCHBOARDS

5.1.1.1 All Switchboards i.e., 415 V Switchgears, Motor Control Centres(MCCs), ACDBs, 220 V DC Distribution Boards (DCDBs) andSolenoid Valve Distribution Boards, shall be of metal enclosed,indoor, floor-mounted, free-standing type.

5.1.1.2 All switchboard frames and load bearing members shall befabricated using suitable mild steel structural sections or pressedand shaped cold-rolled sheet steel of thickness not less than 2.0mm. Frames shall be enclosed in cold-rolled sheet steel ofthickness not less than 1.6 mm. Doors and covers shall also be ofcold rolled sheet steel of thickness not less than 1.6 mm.Stiffeners shall be provided wherever necessary. The gland platethickness shall be 3.0 mm (minimum) for hot / cold-rolled sheetsteel and 4.0 mm (minimum) for non-magnetic material.

5.1.1.3 All panel edges and cover / door edges shall be reinforced

against distortion by rolling, bending or by the addition of weldedreinforcement members. The top covers of the panels should bedesigned such that they do not permanently bulge/ bend by theweight of maintenance personnel working on it.

5.1.1.4 The complete structures shall be rigid, self-supporting, and freefrom flaws, twists and bends. All cutouts shall be true in shapeand devoid of sharp edges.

5.1.1.5 All switchboards shall be of dust-proof and vermin-proofconstruction and shall be provided with a degree of protection of


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IP: 52 as per IS: 13947. However, the busbar chambers having adegree of protection of IP: 42 are also acceptable wherecontinuous busbar rating is 1600A and above. Provision shall bemade in all compartments for providing IP: 52 degree of

protection, when circuit - breaker or module trolley has beenremoved. All cutouts shall be provided with synthetic rubbergaskets.

5.1.1.6 Provision of louvers on switchboards would not be preferred.However, louvers backed with metal screen are acceptable on thebusbar chambers where continuous busbar rating is 1600 A andabove.

5.1.1.7 All switchboards shall be of uniform height not exceeding 2450

mm.

5.1.1.8 Switchboards shall be easily extendable on both sides by theaddition of vertical sections after removing the end covers.

5.1.1.9 Switchboards shall be supplied with base frames made ofstructural steel sections, alongwith all necessary mountinghardware required for welding down the base frame to thefoundation / steel insert plates. The base frame height shall besuch that floor finishing (50 mm thick) to be done by Owner aftererection of the switchboards does not obstruct the movement of

doors, covers, withdrawable modules etc.

5.1.1.10 All switchboards shall be divided into distinct vertical sections(panels), each comprising of the following compartments:

5.1.1.11 BUSBAR COMPARTMENT

A completely enclosed bus bar compartment shall be provided forthe horizontal and vertical busbars. Bolted covers shall beprovided for access to horizontal and vertical busbars and alljoints for repair and maintenance, which shall be feasible without

disturbing any feeder compartment. Auxiliary and power busbarsshall be in separate compartments.

5.1.1.12 SWITCHGEAR / FEEDER COMPARTMENT

All equipment associated with an incomer or outgoing feeder shallbe housed in a separate compartment of the vertical section. Thecompartment shall be sheet steel enclosed on all sides with thewithdrawable units in position or removed. Insulating sheet at rearof the compartment is also acceptable. The front of the


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compartment shall be provided with the hinged single leaf doorwith captive screws for positive closure.

5.1.1.13 CABLE COMPARTMENT OR CABLE ALLEY

A full-height vertical cable alley of minimum 250mm width shall beprovided for power and control cables. Cable alley shall have noexposed live parts and shall have no communication with busbarcompartment. Cable terminations located in cable alley shall bedesigned to meet the Form IVb Type 7 (as per IEC 61439 part 2Annex AA) for safety purpose. The termination for each moduleshall have its own integral glanding facility. Wherever cable alleysare not provided for distribution boards, segregated cable boxesfor individual feeders shall be provided at the rear for direct

termination of cables. For circuit breaker external cableconnections, a separately enclosed cable compartment shall alsobe acceptable. The contractor shall furnish suitable plugs to coverthe cable openings in the partition between feeder compartmentand cable alley. Cable alley door shall be hinged.

5.1.1.14 CONTROL COMPARTMENT

A separate compartment shall be provided for relays and othercontrol devices associated with a circuit breaker.

5.1.1.15 Sheet steel barriers shall be provided between two adjacentvertical panels running to the full height of the switchboard, exceptfor the horizontal busbar compartment. Synthetic rubber gasketshall be provided between the panel sections to avoid ingress ofdust into panels. Each shipping section shall have full metalsheets at both ends for transport and storage.

5.1.1.16 After isolation of power and control circuit connections it shall bepossible to safety carryout maintenance in a compartment withthe busbar and adjacent circuit live. Necessary shroudingarrangement shall be provided for this purpose. Wherever two

breaker compartments are provided in the same vertical sectioninsulating barriers and shrouds shall be provided in the rear cablecompartment to avoid accidental touch with the live parts of onecircuit when working on the other circuit.

5.1.1.17 All 415V switchgear (circuit-breaker) panels shall be of single-front type. MCCs and DBs shall be of single-front / double-frontconstruction as specified in "Bill of Materials". All single-frontswitch boards shall be provided with single-leaf, hinged or boltedcovers at the rear. The bolts shall be of captive type. The coversshall be provided with "DANGER" labels. All panel doors shall


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5.1.1.24 Each switchboard shall be provided with undrilled, removable typegland plate, which shall cover the entire cable alley. Bidder shallensure that sufficient cable glanding space is available for all thecables coming in a particular section through gland plate. For all

single core cables, gland plate shall be of non-magneticmaterial. The gland plate shall preferably be provided in twodistinct parts for the easy of terminating addition cables in future.The gland plate shall be provided with gasket to ensure enclosureprotection. Recommended drilling chart of gland plates for allpower and control cables in the vertical panels shall be indicatedby the Contractor in the respective G.A. drawings of the boards.

5.1.1.25 The Bidder shall consider layout of panels in a switchboardconsisting of various feeder modules in a straight line, unless

specified otherwise. The actual composition and disposition ofvarious modules in a switchboard shall be finalised duringdetailed engineering. The Bidder shall include in his quoted pricethe cost of any adopter panel / dummy panel required to meetvarious configuration / arrangement of busbars adopted by theBidder.

5.1.1.26 CLEARANCES

The minimum clearance in air between phases and betweenphases and earth for the entire run of horizontal and vertical

busbars and bus-link connections at circuit-breaker shall be 25mm. For all other components, the clearance between "two liveparts", "a live part and an earthed part", shall be atleast ten (10)mm throughout. Wherever it is not possible to maintain theseclearances, insulation shall be provided by sleeving or barriers.However, for horizontal and vertical busbars the clearancesspecified above should be maintained even when the busbars aresleeved or insulated. All connections from the busbars upto switch/ fuses shall be fully shrouded / insulated and securely bolted tominimise the risk of phase to phase and phase to earth shortcircuits.

5.2 CABLES AND ACCESSORIES

CABLES

LT Power & control cables having shall be of minimum 1100 volts grade XLPE/ PVC insulated conforming to IS 1554 for utilization voltages less than equalto 415 V. Instrumentation / signal cable shall be of 225 V grade. For otherapplications cables shall be rated as per requirement and in line with relevantnational / international applicable standard. MV / HV cables shall bemanufactured using dry curing method. The cables shall be suitably colour


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coded for the required service. The cables shall be routine & acceptancetested as per relevant national / international standards and technicalspecification.

CABLE ENDS

The cable ends shall be terminated with adequate size metallic doublecompression cable glands. Cable glands shall be of robust constructioncapable of clamping cable and cable armour (for armoured cables) firmlywithout injury to insulation. The glands shall be earthed at two locations.Suitable lock type crimping lugs shall be used for cable end terminations.Where cables are raising from ground, suitable PVC pipe guarding shall beprovided for cable raising with sealing of the guarding PVC pipe including asuitable clamp.

5.3 EARTHING

Earthing system shall be in accordance with IS:3043 and Indian ElectricityRules, Codes of practice and regulations existing in the location where thesystem is being installed

5.4 PROTECTION CLASS OF CABINET / PANELS, ENCLOSURES etc.

All switch board shall be provided with adequately rated copper busbar,incoming control, outgoing control etc. as a separate compartment inside the

panel to meet the requirements of the Chief Electrical Inspector General(CEIG). All live terminals and busbars shall be shrouded. The out goingterminals shall be suitable to receive suitable runs and size of cables requiredfor the Inverter/Transformer rating.The degree of protection for following equipment shall be

1. Indoor Inverter : IP 202. Outdoor Inverter : IP 543. Indoor Junction box : IP 204. Outdoor Junction Box : IP 65

Unless specified the degree of protection shall be

1. In door air-conditioned areas :IP 202. In-door Non A.C. areas

a. Ventilated enclosure :IP42b. Non-Ventilated :IP54

3. Out-door :IP55

The Switchboard shall be designed and manufactured in accordance with therelevant International and Indian standards suitable for the site conditions,and the specific code number and validity should be mentioned. Separatecontrol and power panels shall be provided with separate power circuit forisolated operation of control circuit.


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MW demand since the last demand reset; accumulated total(instantaneous) MWh and MVARh with a plus/minus sign, date andtime; and instantaneous current and voltage on each phases.

ix) All the registers shall be stored in a non-volatile memory. Meterregisters for each metering interval, as well as accumulated totals, shallbe downloadable. All the net active/reactive energy values displayed orstored shall be with a plus /minus sign for export/import.

x) At least the following data shall be stored before being over-written forthe following parameters.

Sl.No. Parameters Details Min No of days

1. Net MWH 15 min block 40 days in meter

2. Aver Freq 15 min block 40days in meter

3. Net MVARH for V >103%

15min block 40days in meter

4. Net MVARH for V

103%

At everymidnight

10 days in Meter / 40days in PC

7. Cumulative NetMVARH for V 100)

3.0 - 10.0 m Rock (Sandstone)

The rock is sedimentary in nature. It is typical Gondwana formation

found in the vicinity of Ramagundam. It is partially weathered and

slightly porous.

The above data is confirmed through the Trial Pits.

B) No water table is seen in the bore holes, but during Trial Pit

excavation period , there were heavy rains, and Water accumulated

in the TPs.

SUMMARY OF GEOTECH INVESTIGATION


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C) The range of properties for rock is as follows:

Specific gravity .. 2.1 - 2.4

Porosity .. 10.0 - 18%

Dry density .. 21 - 23 kN / cu m

UCC .. 65 - 100 kg/ sq cm (in-situ condition)

Slake Durability.. 50 - 60

Point Load Index.. 2 - 3 MN/ sq m

Deformation modulus .. 1 - 1.5 x 105kg / sq cm.

D) Plate Load tests have not yielded any significant settlements in

PLT-1 to PLT-6 and PLT-8. Hence SBC is recommended based on

core samples. In PLT-7, SBC is recommended as 10 t/ sq m.

Modulus of Elasticity : The settlements in rock are insignificant.

Modulus of Elasticity = 1 x10 5kg / sq cm

Modulus of Subgrade Reaction= 20 kg/ sq cm/ cm

E) Based on the above properties, it is recommended that open

isolated, combined or raft foundations be used for all foundations.

F) The recommended safe bearing capacity in rock formation is

600 kN / sq m. The actual depth and size of foundations will be

based on the loading from the super structure units.


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G) The recommended safe bearing capacity in cohesive soil is 10t/sq m.

H) For foundations resting in top soil at depth of 1.0 m, safe bearing

capacity is recommended as 200 kN/ sq m.

I) No expansive soil is found at the site. No special precautions are

required for the construction of roads.

J) The sub soil is not susceptible to liquefaction effects.

K) In view of sand stone formation at shallow depth (less than 2 m), no

special precautions are needed in the excavation of slopes and deep

excavations.

Important Note: The recommendations are based on Geo technical investigations at particular boreholes. However, the stratistical conditions may or may not be the same in the total site. Hence thecompany is not responsible for the rare uncertainities in the stratistical conditions.

For Geo Technical Services

(Dr. D. Babu Rao)M.E., Ph.D. (USA), MIGS

Consulting Geo Technical EngineerIMS ReddyChief Consultant


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CLAUSE NO. GENERAL TECHNICAL REQUIREMENTS

Development o f 10 MW (Phase-1)

Solar Photo Voltaic Plant atNTPC Ramagundam

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NTPC LIMITED(A GOVERNMENT OF INDIA ENTERPRISE)

SECTION-VI

PART-C


(GENERAL TECHNICAL REQUIREMENTS)


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1.00.00 INTRODUCTION

This part covers technical requirements which will form an integral part ofthe Contract. The following provisions shall supplement all the detailedtechnical requirements brought out in the Technical Specifications andthe Technical Data Sheets.

2.00.00 BRAND NAME

Whenever a material or article is specified or described by the name of aparticular brand, manufacturer or vendor, the specific item mentionedshall be understood to be indicative of the function and quality desired,

and not restrictive; other manufacturer's products may be consideredprovided sufficient information is furnished to enable the Employer todetermine that the products proposed are equivalent to those named.

3.00.00 BASE OFFER & ALTERNATE PROPOSALS

The Bidder's proposal shall be based upon the use of equipment andmaterial complying fully with the requirements specified herein. It isrecognized that the Contractor may have standardized on the use ofcertain components, materials, processes or procedures different thanthose specified herein. Alternate proposals offering similar equipmentbased on the manufacturer's standard practice may also be considered,

provided the base offer is in line with technical specifications and suchproposals meet the specified design standards and performancerequirement and are acceptable to the Employer. Sufficient amount ofinformation for justifying such proposals shall be furnished to Employeralongwith the bid to enable the Employer to determine the acceptability ofthese proposals.

4.00.00 COMPLETENESS OF FACILITIES

4.01.00 Bidders may note that this is a contract inclusive of the scope as indicatedelsewhere in the specification. Each of the plant shall be engineered anddesigned in accordance with the specification requirement. All engineering

and associated services are required to ensure that a completelyengineered plant is provided.

4.02.00 All equipment furnished by the Contractor shall be complete in everyrespect, with all mountings, fittings, fixtures and standard accessoriesnormally provided with such equipment and/or those needed for erection,completion and safe operation & maintenance of the equipment and for thesafety of the operating personnel, as required by applicable codes, thoughthey may not have been specifically detailed in the respective specifications,unless included in the list of exclusions.


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All similar standard components/ parts of similar standard equipmentprovided, shall be interchangeable with one another.

5.00.00 CODES & STANDARDS

5.01.00 In addition to the codes and standards specifically mentioned in the relevanttechnical specifications for the equipment / plant / system, all equipmentparts, systems and works covered under this specification shall comply withall currently applicable statutory regulations and safety codes of theRepublic of India as well as of the locality where they will be installed,including the following:

(a.) Bureau of Indian Standards (BIS)

(b.) Indian electricity act

(c.) Indian electricity rules

(d.) Indian Explosives Act

(e.) Indian Factories Act and State Factories Act

(f.) Indian Boiler Regulations (IBR)

(g.) Regulations of the Central Pollution Control Board, India

(h.) Regulations of the Ministry of Environment & Forest (MoEF), Government

of India

(i.) Pollution Control Regulations of Department of Environment, Governmentof India

(j.) State Pollution Control Board.

(k.) Rules for Electrical installation by Tariff Advisory Committee (TAC).

(l.) Any other statutory codes / standards / regulations, as may be applicable.

5.02.00 Unless covered otherwise by Indian codes & standards and in case nothing to

the contrary is specifically mentioned elsewhere in the specifications, the latesteditions (as applicable as on date of bid opening), of the codes and standardsgiven below shall also apply:

(a.) Japanese Industrial Standards (JIS)

(b.) American National Standards Institute (ANSI)

(c.) American Society of Testing and Materials (ASTM)


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(d.) American Society of Mechanical Engineers (ASME)

(e.) American Petroleum Institute (API)

(f.) Standards of the Hydraulic Institute, U.S.A.

(g.) International Organisation for Standardization (ISO)

(h.) Tubular Exchanger Manufacturer's Association (TEMA)

(i.) American Welding Society (AWS)

(j.) National Electrical Manufacturers Association (NEMA)

(k.) National Fire Protection Association (NFPA)

(l.) International Electro-Technical Commission (IEC)

(m.) Expansion Joint Manufacturers Association (EJMA)

(n.) Heat Exchange Institute (HEI)

5.03.00 Other International/ National standards such as DIN, VDI, BS, GOST etc.shall also be accepted for only material codes and manufacturing standards,subject to the Employer's approval, for which the Bidder shall furnish,alongwith the offer, adequate information to justify that these standards areequivalent or superior to the standards mentioned above. In all such cases

the Bidder shall furnish specifically the variations and deviations from thestandards mentioned else where in the specification together with thecomplete word to word translation of the standard that is normally notpublished in English.

5.04.00 As regards highly standardized equipment such as Steam Turbine andGenerator, National /International standards such as JIS, DIN, VDI, ISO,SEL, SEW, VDE, IEC & VGB shall also be considered as far as applicablefor Design, Manufacturing and Testing of the respective equipment. Inaddition, these standards shall be referred for the design of machinefoundations, wherever specifically mentioned in the specifications. However,for those of the above equipment not covered by these National /

International standards, established and proven standards of manufacturersshall also be considered.

5.05.00 In the event of any conflict between the codes and standards referred to inthe above clauses and the requirement of this specification, the requirementof Technical Specification shall govern.

5.06.00 Two (2) English language copies of all-national and international codesand/or standards which are not available with NTPC and same is used inthe design of the plant, equipment, civil and structural works shall be


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provided by the Contractor to the Employer within two calendar months fromthe date of the Notification of Award.

5.07.00 In case of any change in codes, standards & regulations between the dateof bid opening and the date when vendors proceed with fabrication, theEmployer shall have the option to incorporate the changed requirements orto retain the original standard. It shall be the responsibility of the Contractorto bring to the notice of the Employer such changes and advise Employer ofthe resulting effect.

6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE

6.01.00 The functional guarantees of the equipment under the scope of the Contractis given elsewhere in the technical specification. These guarantees shallsupplement the general functional guarantee provisions covered under

General Conditions of Contract.6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during

the performance guarantee tests shall be assessed and recovered from theContractor as specified elsewhere in this specification.

7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITYCONSIDERATIONS

7.01.00 Design of Facilities

All the design procedures, systems and components proposed shall havealready been adequately developed and shall have demonstrated good

reliability under similar conditions elsewhere.

The Contractor shall be responsible for the selection and design ofappropriate equipment to provide the best co-ordinated performance ofthe entire system. The basic requirements are detailed out in variousclauses of the Technical Specifications. The design of variouscomponents, assemblies and subassemblies shall be done so that itfacilitates easy field assembly and dismantling. All the rotatingcomponents shall be so selected that the natural frequency of thecomplete unit is not critical or close to the operating range of the unit.

7.02.00 Maintenance and Availability Considerations

Equipment/facilities offered shall be designed for high availability, lowmaintenance and ease of maintenance. The Bidder shall specifically statethe design features incorporated to achieve high degree of reliability/availability and ease of maintenance. The Bidder shall also furnish detailsof availability records in the reference plants stated in his experience list.

Bidder shall state in his offer the various maintenance intervals, spareparts and man-hour requirement during such operation. The intervals foreach type of maintenance namely the minor and major overhauls shall be


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b) Sequence of erection.

c) Erection instructions.

d) Critical checks and permissible deviation/tolerances.

e) List of tool, tackles, heavy equipment like cranes, dozers, etc.

f) Bill of Materials

g) Procedure for erection.

h) General safety procedures to followed during erection/installation.

i) Procedure for initial checking after erection.

j) Procedure for testing and acceptance norms.

k) Procedure / Check list for pre-commissioning activities.

l) Procedure / Check list for commissioning of the system.

m) Safety precautions to be followed in electrical supply distribution

during erection

(b.) Operation & Maintenance Manuals

i) The operating and maintenance instructions together with

drawings (other than shop drawings) of the equipment, as

completed, shall be in sufficient detail to enable the Employer to

operate, maintain, dismantle, reassemble and adjust all parts of

the equipment. They shall give a step by step procedure for all

operations likely to be carried out during the life of the plant /

equipment including, operation, maintenance, dismantling andrepair including periodical activities such as chemical cleaning of

the generator. Each manual shall also include a complete set of

drawings together with performance/rating curves of the

equipment and test certificates wherever applicable. The contract

shall not be considered to be completed for purposes for taking

over until these manuals have been supplied to the Employer.

ii) If after the commissioning and initial operation of the plant, the

manuals require any modification / additions / changes, the same

shall be incorporated and the updated final instruction manuals

shall be submitted to the Employer for records.

iii) A separate section of the manual shall be for each size/ type of

equipment and shall contain a detailed description of

construction and operation, together with all relevant pamphlets

and drawings.

iv) The manuals shall include the following :


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a) List of spare parts along with their drawing and

catalogues and procedure for ordering spares.

b) Lubrication Schedule including charts showing

lubrication checking, testing and replacement

procedure to be carried daily, weekly, monthly & at

longer intervals to ensure trouble free operation.

c) Where applicable, fault location charts shall be

included to facilitate finding the cause of mal-

operation or break down.

v) Detailed specifications for all the consumables including lubricant

oils, greases, chemicals etc. system/equipment/assembly/sub-

assembly - wise required for the complete plant.

vi) On completion of erection, a complete list of bearings /

equipment giving their location, and identification marks etc. shall

also be furnished to the Employer indicating lubrication method

for each type/category of bearing.

8.02.02 Project Completion Report

The Contractor shall submit a Project Completion Report at the time ofhanding over the plant. After final acceptance of individual equipment/system by the Employer, the Contractor will update all original drawingsand documents for the equipment/ system to "as built" conditions andsubmit.

8.03.00 ENGINEERING INFORMATION SUBMISSION SCHEDULE

Prior to the award of Contract, a Detailed Engineering InformationSubmission Schedule shall be tied up with the Employer. For this, thebidder shall furnish a detailed list of engineering information alongwith theproposed submission schedule. This list would be a comprehensive oneincluding all engineering data / drawings / information for all bought outitems and manufactured items. The information shall be categorised intothe following parts.

(a.) Information that shall be submitted for the approval of the Employerbefore proceeding further, and

(b.) Information that would be submitted for Employers information only.

The Engineering Information Schedule shall be updated month-wise.

The schedule should allow adequate time for proper review andincorporation of changes/ modifications, if any, to meet the contract


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without affecting the equipment delivery schedule and overall projectschedule. The early submission of drawings and data is as important asthe manufacture and delivery of equipment and hardware and this shallbe duly considered while determining the overall performance andprogress.

8.04.00 ENGINEERING PROGRESS AND EXCEPTION REPORT

8.04.01 Report giving the status of each engineering information including

(a.) A list of drawings/engineering information which remainsunapproved for more than four (4) weeks after the date of firstsubmission

(b.) Drawings which were not submitted as per agreed schedule.

8.04.02 The draft format for this report shall be furnished to the Employerwithin four (4) weeks of the award of the contract, which shall thenbe discussed and finalised with the Employer.

8.05.00 TECHNICAL CO-ORDINATION MEETING

The Contractor shall organize and attend at least one monthly progressMeetings with the Employer/Employer's representatives during the periodof Contract at mutually agreed venues for review of progress & resolvingtechnical clarifications, if any. The Contractor shall attend such meetingsat his own cost and fully co-operate with such persons and agenciesinvolved during the discussions.

The Contractor shall ensure availability of the concerned experts /consultants/ personnel who are empowered to take necessary decisionsduring these meetings. The Contractor shall be equipped with necessarytools and facilities so that, if required, the drawings/documents can beresubmitted after incorporating necessary changes and approved duringthe meeting itself.

The Contractor shall furnish monthly progress report to the Employerdetailing out the progress achieved on all erection activities as comparedto the schedules. This shall be supplemented by printed colourphotographs and video in VCD/DVD indicating various stages of erection

and the progress of the work done at Site. The report shall also indicatethe reasons for the variance between the scheduled and actual progressand the action proposed for corrective measures, wherever necessary.

8.06.00 DESIGN IMPROVEMENTS

The Employer or the Contractor may propose changes in the specificationof the equipment or quality thereof and if the parties agree upon any suchchanges the specification shall be modified accordingly.


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If any such agreed upon change is such that it affects the price andschedule of completion, the parties shall agree in writing as to the extentof any changing the price and/or schedule of completion before theContractor proceeds with the change. Following such agreement, theprovision thereof, shall be deemed to have been amended accordingly.

8.07.00 EQUIPMENT BASES

A cast iron or welded steel base plate shall be provided for all rotatingequipment which is to be installed on a concrete base, unless otherwisespecifically agreed to by the Employer. Each base plate which supportthe unit and its drive assembly, shall be of a neat design with pads foranchoring the units, shall have a raised lip all around, and shall havethreaded drain connections.

8.08.00 PROTECTIVE GUARDS

Suitable guards shall be provided for protection of personnel on allexposed rotating and/or moving machine parts. All such guards shall bedesigned for easy installation and removal for maintenance purpose.

8.09.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS

The Bidders scope includes all the first fill and one years topping,requirements of consumables such as oils, lubricants including grease,servo fluids, gases and essential chemicals etc. Consumption of all these

consumables during the initial operation and final filling after the initialoperation shall also be included in the scope of the Bidder.

8.09.01 As far as possible lubricants marketed by reputed companies shall beused. The variety of lubricants shall be kept to a minimum possible.

Detailed specifications for the lubricating oil, grease, gases, servo fluids,control fluids, chemicals etc. required for the complete plant coveredherein shall be furnished. On completion of erection, a complete list ofbearings/ equipment giving their location and identification marks shall befurnished to the Employer alongwith lubrication requirements.

8.09.02 Lubrication

Equipment shall be lubricated by systems designed for continuousoperation. Lubricant level indicators shall be furnished and marked toindicate proper levels under both standstill and operating conditions.

8.10.00 Material of Construction

All materials used for the construction of the equipment shall be new andshall be in accordance with the requirements of this specification.


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Materials utilised for various components shall be those which haveestablished themselves for use in such applications.

8.11.00 RATING PLATES, NAME PLATES & LABELS

8.11.01 Each main and auxiliary item of plant including instruments shall havepermanently attached to it in a conspicuous position, a rating plate of non-corrosive material upon which shall be engraved manufacturers name,equipment, type or serial number together with details of the ratings,service conditions under which the item of plant in question has beendesigned to operate, and such diagram plates as may be required by theEmployer.

8.11.02 Such nameplates or labels shall be of white non-hygroscopic materialwith engraved black lettering or alternately, in the case of indoor circuit

breakers, starters, etc. of transparent plastic material with suitablycoloured lettering engraved on the back. The name plates shall besuitably fixed on both front and rear sides.

8.11.03 Hanger/ support numbers shall be marked on all pipe supports, anchors,hangers, snubbers and restraint assemblies. Each constant and variablespring support shall also have stamped upon it the designed hot and coldload which it is intended to support. Suitable scale shall also be providedto indicate load on support/hanger.

8.11.04 Nameplates shall be as per best practices of the industry

8.11.05 All such plates, instruction plates, etc. shall be bilingual with Hindi

inscription first, followed by English. Alternatively, two separate plates onewith Hindi and the other with English inscriptions may be provided.

8.11.06 All segregated phases of conductors or bus ducts, indoor or outdoor, shallbe provided with coloured phase plates to clearly identify the phase ofthe system

8.12.00 TOOLS AND TACKLES

The Contractor shall supply with the equipment one complete set of allspecial tools and tackles and other instruments required for the erection,assembly, disassembly and proper maintenance of the plant and

equipment and systems (including software). These special tools will alsoinclude special material handling equipment, jigs and fixtures formaintenance and calibration / readjustment, checking and measurementaids etc. A list of such tools and tackles shall be submitted by the Bidderalongwith the offer.

The price of each tool / tackle shall be deemed to have been included inthe total bid price. These tools and tackles shall be separately packedand sent to site. The Contractor shall also ensure that these tools andtackles are not used by him during erection, commissioning and initial


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operation. For this period the Contractor should bring his own tools andtackles. All the tools and tackles shall be of reputed make acceptable tothe Employer.

8.13.00 Welding

If the manufacturer has special requirements relating to the weldingprocedures for welds at the terminals of the equipment to be per formedby others the requirements shall be submitted to the Employer in advanceof commencement of erection work.

8.14.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES

All equipment/ piping/ pipe services are to be painted by the Contractor inaccordance with Employers standard colour coding scheme, which will

be furnished to the Contractor during detailed engineering stage.

8.15.00 PROTECTION AND PRESERVATIVE SHOP COATING

8.16.00 PROTECTION

All coated surfaces shall be protected against abrasion, impact,discoloration and any other damages. All exposed threaded portionsshall be suitably protected with either metallic or a nonmetallic protectiondevice. All ends of all valves and pipings and conduit equipmentconnections shall be properly sealed with suitable devices to protect themfrom damage. The parts which are likely to get rusted, due to exposure to

weather, should also be properly treated and protected in a suitablemanner. All primers/paints/coatings shall take into account the hot humid,corrosive & alkaline, subsoil or overground environment as the case maybe.

8.17.00 Preservative Shop Coating

All exposed metallic surfaces subject to corrosion shall be protected byshop application of suitable coatings. All surfaces which will not be easilyaccessible after the shop assembly, shall be treated beforehand andprotected for the life of the equipment. All surfaces shall be thoroughlycleaned of all mill scales, oxides and other coatings and prepared in the

shop. The surfaces that are to be finish-painted after installation orrequire corrosion protection until installation, shall be shop painted with atleast two coats of primer.

Transformers and other electrical equipment if included shall be shopfinished with one or more coats of primer and two coats of high graderesistance enamel. The finished colors shall be as per manufacturersstandards, to be selected and specified by the Employer at a later date.


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Shop primer for all steel surfaces which will be exposed to operatingtemperature below 95 degrees Celsius shall be selected by theContractor after obtaining specific approval of the Employer regarding thequality of primer proposed to be applied. Special high temperature primershall be used on surfaces exposed to temperature higher than 95degrees Celsius and such primer shall also be subject to the approval ofthe Employer.

All other steel surfaces which are not to be painted shall be coated withsuitable rust preventive compound subject to the approval of theEmployer.

All piping shall be cleaned after shop assembly by shot blasting or othermeans approved by the Employer. Lube oil piping or carbon steel shallbe pickled.

Painting for Civil structures shall be done as per relevant part of technicalspecification

9.00.00 QUALITY ASSURANCE PROGRAMME

9.01.00 The Contractor shall adopt suitable quality assurance programme toensure that the equipment and services under the scope of contractwhether manufactured or performed within the Contractors works or athis sub-contractors premises or at the Employers site or at any otherplace of work are in accordance with the specifications. Suchprogrammes shall be outlined by the Contractor and shall be finally

accepted by the Employer/authorised representative after discussionsbefore the award of the contract. The QA programme shall be generallyin line with IS/ISO-9001.A quality assurance programme of the contractorshall generally cover the following:

9.02.00(a.) His organisation structure for the management and implementation

of the proposed quality assurance programme

(b.) Quality System Manual

(c.) Design Control System

(d.) Documentation and Data Control System

(e.) Qualification data for bidders key personnel.

(f.) The procedure for purchase of materials, parts, components andselection of sub-contractors services including vendor analysis,source inspection, incoming raw-material inspection, verification ofmaterials purchased etc.

(g.) System for shop manufacturing and site erection controls includingprocess, fabrication and assembly.


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(h.) Control of non-conforming items and system for corrective actionsand resolution of deviations.

(i.) Inspection and test procedure both for manufacture and fieldactivities.

(j.) Control of calibration and testing of measuring testing equipment.

(k.) System for Quality Audits.

(l.) System for identification and appraisal of inspection status.

(m.) System for authorising release of manufactured product to theEmployer.

(n.) System for handling, storage and delivery.

(o.) System for maintenance of records, and

(p.) Quality plans for manufacturing and field activities detailing out thespecific quality control procedure adopted for controlling the qualitycharacteristics relevant to each item of equipment/component.

9.03.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE

9.03.01 All materials, components and equipment covered under this specificationshall be procured, manufactured, erected, commissioned and tested at allthe stages, as per a comprehensive Quality Assurance Programme. Anindicative programme of inspection/tests to be carried out by thecontractor for some of the major items is given in the respective technicalspecification. This is, however, not intended to form a comprehensive

programme as it is the contractors responsibility to draw up andimplement such programme duly approved by the Employer. Thedetailed Quality Plans for manufacturing and field activities shall be drawnup by the Bidder and will be submitted to Employer for approval.Schedule of finalisation of such quality plans will be finalised beforeaward on enclosed format No. QS-01-QAI-P-01/F3. Monthly progressreports on MQP/FQP submission/approval shall be furnished on enclosedformat No. QS-01-QAI-P-02/F1

9.03.02 Manufacturing Quality Plan will detail out for all the components andequipment, various tests/inspection, to be carried out as per therequirements of this specification and standards mentioned therein and

quality practices and procedures followed by Contractors/ Sub-contractors/ sub-supplier's Quality Control Organisation, the relevantreference documents and standards, acceptance norms, inspectiondocuments raised etc., during all stages of materials procurement,manufacture, assembly and final testing/performance testing. The QualityPlan shall be submitted on electronic media e.g. floppy or E-mail inaddition to hard copy, for review and approval. After approval the sameshall be submitted in compiled form on CD-ROM.


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9.03.03 Field Quality Plans will detail out for all the equipment, the qualitypractices and procedures etc. to be followed by the Contractors "SiteQuality Control Organisation", during various stages of site activitiesstarting from receipt of materials/equipment at site.

9.03.04 The Bidder shall also furnish copies of the reference documents/plantstandards/acceptance norms/tests and inspection procedure etc., asreferred in Quality Plans along with Quality Plans. These Quality Plansand reference documents/standards etc. will be subject to Employersapproval without which manufacturer shall not proceed. These approveddocuments shall form a part of the contract. In these approved QualityPlans, Employer shall identify customer hold points (CHP), i.e.test/checks which shall be carried out in presence of the EmployersProject Manager or his authorised representative and beyond which thework will not proceed without consent of Employer in writing. All

deviations to this specification, approved quality plans and applicablestandards must be documented and referred to Employer along withtechnical justification for approval and dispositioning.

9.03.05 No material shall be dispatched from the manufacturers works before thesame is accepted, subsequent to predispatch final inspection includingverification of records of all previous tests/inspections by EmployersProject Manager/Authorised representative and duly authorised fordispatch by issuance of Material Despatch Clearance Certificate (MDCC).

9.03.06 All material used for equipment manufacture including casting and forgingetc. shall be of tested quality as per relevant codes/standards. Details of

results of the tests conducted to determine the mechanical properties;chemical analysis and details of heat treatment procedure recommendedand actually followed shall be recorded on certificates and timetemperature chart. Tests shall be carried out as per applicable materialstandards and/or agreed details.

9.03.07 The contractor shall submit to the Employer Field Welding Schedule forfield welding activities in the enclosed format No.: QS-01-CQA-W-11/F1.The field welding schedule shall be submitted to the Employer along withall supporting documents, like welding procedures, heat treatmentprocedures, NDT procedures etc. at least ninety days before schedulestart of erection work at site.

9.03.08 All welding and brazing shall be carried out as per procedure drawn andqualified in accordance with requirements of ASME Section IX/BS-4870or other International equivalent standard acceptable to the Employer.

All welding/brazing procedures shall be submitted to the Employer or itsauthorised representative for approval prior to carrying out thewelding/brazing.


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9.03.09 All brazers, welders and welding operators employed on any part of thecontract either in Contractors/sub-contractors works or at site orelsewhere shall be qualified as per ASME Section-IX or BS-4871 or otherequivalent International Standards acceptable to the Employer.

9.03.10 Welding procedure qualification & Welder qualification test results shallbe furnished to the Employer for approval. However, where required bythe Employer, tests shall be conducted in presence ofEmployer/authorised representative.

9.03.11 For all pressure parts and high pressure piping welding, the latestapplicable requirements of the IBR (Indian Boiler Regulations) shall alsobe essentially complied with. Similarly, any other statutory requirementsfor the equipment/systems shall also be complied with. On all back-gauged welds MPI/LPI shall be carried before seal welding.

9.03.12 Unless otherwise proven and specifically agreed with the Employer,welding of dissimilar materials and high alloy materials shall be carriedout at shop only.

9.03.13 No welding shall be carried out on cast iron components for repair.

9.03.14 All the heat treatment results shall be recorded on time temperaturecharts and verified with recommended regimes.

9.03.15 All non-destructive examination shall be performed in accordance withwritten procedures as per International Standards, The NDT operator

shall be qualified as per SNT-TC-IA (of the American Society of non-destructive examination). NDT shall be recorded in a report, whichincludes details of methods and equipment used, result/evaluation, jobdata and identification of personnel employed and details of co-relation ofthe test report with the job.

All plates of thickness above 40mm & all bar stock/Forging above 40mmdia shall be ultrasonically tested. For pressure parts, plate of thicknessequal to or above 25mm shall be ultrasonically tested.

9.03.16 The Contractor shall list out all major items/ equipment/ components to bemanufactured in house as well as procured from sub-contractors (BOI).

All the sub-contractor proposed by the Contractor for procurement ofmajor bought out items including castings, forging, semi-finished andfinished components/equipment etc., list of which shall be drawn up bythe Contractor and finalised with the Employer, shall be subject toEmployer's approval on enclosed format No. QS-01-QAI-P-01/F3. Thecontractors proposal shall include vendors facilities established at therespective works, the process capability, process stabilization, QCsystems followed, experience list, etc. along with his own technicalevaluation for identified sub-contractors enclosed and shall be submittedto the Employer for approval within the period agreed at the time of pre-


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awards discussion and identified in "DR" category prior to anyprocurement. Monthly progress reports on sub-contractor detailsubmission / approval shall be furnished on enclosed on format no. QS-01-QAI-P-02/F2. Such vendor approval shall not relieve the contractorfrom any obligation, duty or responsibility under the contract.

9.03.17 For components/equipment procured by the contractors for the purposeof the contract, after obtaining the written approval of the Employer, thecontractors purchase specifications and inquiries shall call for qualityplans to be submitted by the suppliers. The quality plans called for fromthe sub-contractor shall set out, during the various stages of manufactureand installation, the quality practices and procedures followed by thevendors quality control organisation, the relevant referencedocuments/standards used, acceptance level, inspection ofdocumentation raised, etc. Such quality plans of the successful vendors

shall be finalised with the Employer and such approved Quality Plansshall form a part of the purchase order/contract between the Contractorand sub-contractor. With in three weeks of the release of the purchaseorders /contracts for such bought out items /components, a copy of thesame without price details but together with the detailed purchasespecifications, quality plans and delivery conditions shall be furnished tothe Employer on the monthly basis by the Contractor along with a reportof the Purchase Order placed so far for the contract. **

9.03.18 Employer reserves the right to carry out quality audit and qualitysurveillance of the systems and procedures of the Contractors or theirsub-contractors quality management and control activities. The

contractor shall provide all necessary assistance to enable the Employercarry out such audit and surveillance.

9.03.19 The contractor shall carry out an inspection and testing programmeduring manufacture in his work and that of his sub-contractors and at siteto ensure the mechanical accuracy of components, compliance withdrawings, conformance to functional and performance requirements,identity and acceptability of all materials parts and equipment. Contractorshall carry out all tests/inspection required to establish that theitems/equipment conform to requirements of the specification and therelevant codes/standards specified in the specification, in addition tocarrying out tests as per the approved quality plan.

9.03.20 Quality audit/surveillance/approval of the results of the tests andinspection will not, however, prejudice the right of the Employer to rejectthe equipment if it does not comply with the specification when erected ordoes not give complete satisfaction in service and the above shall in noway limit the liabilities and responsibilities of the Contractor in ensuringcomplete conformance of the materials/equipment supplied to relevantspecification, standard, data sheets, drawings, etc.


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9.03.21 For all spares and replacement items, the quality requirements as agreedfor the main equipment supply shall be applicable.

9.03.22 Repair/rectification procedures to be adopted to make the job acceptableshall be subject to the approval of the Employer/ authorisedrepresentative.

9.03.23 Burn in and Elevated Temperature Test Requirement for Electronics SolidState Equipment

(a.) All solid state electronic systems/equipment shall be tested as acomplete system/equipment with all devices connected for aminimum of 168 hours (7 Days) continuously under energizedconditions prior to shipment from manufacturing works, as per thefollowing cycle.

(1.) Elevated Temperature Test Cycle

During the elevated temperature test which shall be for 48 hours of thetotal 168 hours of testing, the ambient temperature shall be maintained at50 deg. C. The equipment shall be interconnected with devices which willcause it to repeatedly perform all operations it is expected to perform inactual service with load on various components being equal to thosewhich will be experienced in actual service.

During the elevated temperature test the cubicle doors shall be closed (orshall be in the position same as they are supposed to be in the field) and

inside temperature in the zone of highest heat dissipatingcomponents/modules shall be monitored. The temperature rise inside thecubicle should not exceed 10 deg. C above the ambient temp. at 50 deg.C.

(b.) Burn in Test Cycle

The 48 hours elevated temperature test shall be followed by 120 hours ofburn in test as above except that the temperature shall be reduced to theambient temperature prevalent at that time.

During the above tests, the process I/O and other load on the system

shall be simulated by simulated inputs and in the case of control systems,the process which is to be controlled shall also be simulated. Testing ofindividual components or modules shall not be acceptable.

In case the Contractor/ sub-contractor is having any alternate establishedprocedure of eliminating infant mortile components, the detail proceduresfollowed by the Contractor/ sub- contractor along with the statisticalfigures to validate the alternate procedure to be forwarded.


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The Contractor/Sub-contractor shall carry out routine test on 100% itemat contractor/sub-contractors works. The quantum of check/test forroutine & acceptance test by employer shall be generally as percriteria/sampling plan defined in referred standards. Wherever standardshave not been mentioned quantum of check/test for routine / acceptancetest shall be as agreed uring detailed engineering stage.

9.03.24 QUALITY ASSURANCE AND INSPECTION FOR CIVIL WORKS

INTRODUCTION

This part of the specification covers the sampling, testing and qualityassurance requirement (including construction tolerances and acceptance

criteria) for all civil and structural works covered in this specification.

This part of the technical specification shall be read in conjunction withother parts of the technical specifications, general technical requirements& erection conditions of the contract which covers common QArequirements. Wherever IS code or standards have been referred theyshall be the latest revisions.

The rate for respective items of work or price shall include the cost for allworks, activities, equipment, instrument, personnel, material etc.whatsoever associated to comply with sampling, testing and qualityassurance requirement including construction tolerances and acceptancecriteria and as specified in subsequent clauses of this part of the technicalspecifications. The QA and QC activities in all respects as specified in thetechnical specifications/ drawings / data sheets / quality plans / contractdocuments shall be carried out at no extra cost to the owner.

The contractor shall prepare detailed construction and erectionmethodology scheme which shall be compatible to the requirements ofthe desired progress of work execution, quality measures, prior approvalsif any and the same shall be got approved by the Engineer. If required,work methodology may be revised/ reviewed at every stage of executionof work at site, to suit the site conditions by the contractor at no extra costto the owner.

QA AND QC MANPOWER

The contractor shall nominate one overall QA coordinator for the contractdetailing the name, designation, contact details and address at the time ofpost bid discussions. All correspondence related to Quality Assuranceshall be addressed by the contractors QA coordinator to NTPC. NTPCshall address all correspondence related to Quality issues to thecontractors QA coordinator. The contractors QA coordinator shall beresponsible for co-ordination of Quality activities between various


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divisions of the contractor and their sub-vendors on one hand & withNTPC on the other hand.

The contractor shall appoint a dedicated, experienced and competentQA&QC in-charge at site, preferably directly reporting to the ProjectManager, supported as necessary by experienced personnel, to ensurethe effective implementation of the approved QAP. The contractor shallfinalize and submit a deployment schedule of QA&QC personnel alongwith their details to NTPC for approval/ acceptance and further shallensure their availability well before the start of the concern activity.

SAMPLING AND TESTING OF CONSTRUCTION MATERIALS

The method of sampling for testing of construction materials and work /job samples shall be as per the relevant IS / standards / codes and in line

with the requirements of the technical specifications / quality plans. Allsamples shall be jointly drawn, signed and sealed wherever required, bythe contractor and the engineer or his authorized representative.

The contractor shall carry out testing in accordance with the relevant IS /standards / codes and in line with the requirements of the technicalspecifications / quality plans. Where no specific testing procedure ismentioned, the tests shall be carried out as per the best prevalentengineering practices and to the directions of the Engineer. All testingshall be done in the presence of the engineer or his authorizedrepresentative in a NABL accredited / Govt. Laboratory acceptable toNTPC. This includes all IITs, NCB, CSMRS, reputed government /autonomous laboratories / o

technical specs_tender document - part b

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