GTS, PTS & Technical Data Sheet of Pakaldul H.E.project

CHENAB VALLEY POWER PROJECTS [P] LIMITED
(A Joint Venture of NHPC Ltd., JKSPDC Ltd. & PTC India Ltd.)
PAKALDUL H.E. PROJECT

(JAMMU AND KASIMIR)
1000 MW (4 x 250 MW)
Volume – 4
Section IIIA, IIB, IIIC & IIID- General Technical Specifications
(GTS),Particular Technical Specifications (PTS),Technical Dta Sheets
(TDS) & Model Quality Assurance Plan (MQAP)
For
HM Works: Design,Procurement,Manufacture,Inspection,Shop Assembly, Testing,
Painting, Transportation, Site Storage & Site Erection, Testing &
Commissioning including provision for all labour, Plant & material for
the above ,handing over to Owner ,supply of necessary Spares for 5
years trouble free operation
JUNE 2017
2nd Floor, JKPCC Building

Rail Head Complex, Panama Chowk
JAMMU-180006 (J&K)
Pakal Dul H E Project
Index - General Technical Specification

Contents Page
1.0 General Description
1.1 Introduction 1
1.1.1 Location and Communication 1
1.1.2 Project Layout 1
1.2 The Document 2
1.3 Scope of Work 2
1.3.1 Tunnel Spillway Radial Gates, Hydraulic Hoists, Bulkhead Gates 2
& Gantry Crane & Steel liners for Tunnel Spillway
1.3.2 Surface Spillway Radial Gates, Flap Gate, Hydraulic Hoists, 4
Stop logs Gate & Gantry Crane
1.3.3 Intake Gates and Hoist, Intake Bulkhead Gates & Hoists 6
1.3.4 Intake Trash Rack 7
1.3.5 Valves for environmental flow pipe 7
1.3.6 Adit Inspection gates 8
1.3.7 Pressure shaft liners 8
1.3.8 Tail Race Gates and Hoists 8
1.3.9 Automatic Reservoir monitoring & control systems 9
1.3.10 Diesel Generating set and Hydraulic oil filtering unit 9
1.3.11 Spares 9
1.3.12 Tools and tackles
1.3.13 Operation & Maintenance Manuals
2.0 Standards
2.1 Standards for General Applications 10
2.2 Standards for Design and Testing 11
2.3 Material Standard 13
2.3.1 Substitute Material 16
2.3.2 Sub-Contractors/Vendors
2.4 Permissible Stresses 17
2.4.1 Permissible Stresses for Spillway Gates, Adit gates & Intake 17
Gates
2.4.2 Permissible Stresses for Embedded parts 18
2.4.3 Permissible Stresses for Surface spillway stoplog, Tunnel 18
spillway, Bulkhead gate, Intake bulkhead gate, Tail race tunnel
gate
2.4.4 Permissible Stresses for Rope drum Hoist Equipment 19
.
2.4.5 Permissible Stresses for Hoist Bridge, Hoist Support, 19
Trestles & Hand Railing (Clearly above Water)
2.4.6 Permissible Stresses for Trash racks 19
2.4.7 Permissible Stresses for Hydraulic cylinder and their
Components
i
2.4.8 Permissible Stresses and design of Power pack for 20

Hydraulic cylinder
2.4.9 Stresses under occasional forces/ exceptional loads 20
2.4.10 Permissible Stresses for Steel Pressure shaft/ Penstocks lining
& Tunnel spillway Liner specials
2.4.11 Permissible stresses for Gantry cranes
2.4.12 Minimum thickness of plates 20
3.0 Technical Documents

3.1 General 20
3.2 Design and Drawings 21
3.3 Submissions 23
3.4 List of Schedules 31
3.4.1 Motor Lists 31
3.4.2 Motor Starter Lists 32
3.4.3 Cable List/ Inter Connection List 33
3.4.4 List of Measurements 33
3.4.5 Alarm List 33
3.4.6 List of Final Control Elements 34
3.4.7 Workshop Test Schedules 34
3.4.8 Site Test Schedules 34
3.4.9 List of Tools and Appliances 34
3.4.10 Spare Part Lists 35
3.4.11 List of Works Identification Numbers 35
3.5 Installation and Commissioning Procedures 35
3.5.1 Installation Procedures 35
3.5.2 Commissioning Procedures 35
3.6 Operation and Maintenance Manuals 35
3.7 Progress Reports 36
3.7.1 Progress Report during Design and Manufacturing 36
3.7.2 Progress Report during Installation at Site 37
4. Spare Parts and Tools

4.1 Spare Parts 37
4.1.1 Mandatory Spare Parts 38
4.1.2 Recommended Spare Parts 38
4.2 Tools and Tackles 38
4.2.1 Mandatory tools and tackles 38
4.2.2 Recommended tools and tackles 38
5.0 Design and manufacture

5.1 Design and Construction Requirements 38
5.2 Design Criteria 40
5.3 Tolerance and Clearance 41
5.3.1 General Clearances 42
5.3.2 Fabrication Tolerances 42
5.3.3 Installation Tolerances 43
5.4 Standardization of Works 43
5.5 Material and Workmanship 44
5.6 Works Identification System 45
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5.7 Identification Plates 45

5.7.1 General 45
5.7.2 Manufacturer’s Names Plates 45
5.7.3 Instruction Plates 45
5.7.4 Warning Plates 45
5.8 Fabrication 46
5.8.1 Gates and Stoplogs 46
5.8.2 Embedded Parts 47
5.8.3 Fabrication of steel works 47
5.8.4 Fabrication of Pressure shaft Steel Liner/ Tunnel Spillway liner 48
5.8.4.1 Preparation of Pipe Course 48
5.8.4.2 Cutting the Plates 48
5.8.4.3 Preparation of Plate Edges and Openings 48
5.8.4.4 Stiffener Rings 49
5.8.4.5 Bends and Reducers 50
5.8.4.6 Unit and Match Marking 50
5.9 Surface Finish 50
5.9.1 Finished Surfaces 50
5.9.2 Unfinished Surfaces 50
5.9.3 Protection of Finished Surfaces 50
5.10 Fasteners 51
5.11 Welding 51
5.11.1 Welding requirements for Pressure shaft steel liners 53
5.11.1.1 Preheating and Thermal Stress Relieving 53
5.11.1.2 Post Weld Heat Treatment 54
5.11.1.3 Butt Straps 54
5.11.1.4 Alignment and Tolerances 55
5.11.1.5 Non destructive Examination 56
5.11.1.5.1 Radiographic Examination 56
5.11.1.5.2 Ultrasonic Examination 56
5.11.1.5.3 Other Examination 56
5.12 Corrosion Protection 57
5.12.1 Surface Treatment and Protection 57
5.12.2 Painting Systems 58
5.12.2.1 Gates, Bulkheads, Embedded parts, Trash racks and Lifting beam 58
5.12.2.2 Hoist & Cranes 59
5.12.2.3 Power Pack and Hydraulic Hoist 59
5.12.2.4 Bonnet Cover 60
5.12.2.5 Machined Surfaces 60
5.12.2.6 Colour Scheme 60
5.12.3 Corrosion protection for Pressure Shaft Steel Liners 61
5.12.3.1 Exterior surface of steel liners 61
5.12.3.2 Interior surface of Steel liners 61
5.12.4 Repair Of Primer and Finish Coats 62
5.12.5 Quality Control 62
5.12.6 Galvanising 62
5.13 Metal Work 63
5.13.1 Embedded Metal Work 63
5.13.2 Miscellaneous Metal Work 63
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6.0 Installation
6.1 Installation of Gates and Bulkheads 64
6.2 Installation of Frame, Guide and Tracks 64
6.3 Placing Concrete in Blockout 65
6.4 Hoist &Crane 65
6.5 Installation of Pressure shaft steel liners/ Tunnel Spillway steel
liners
6.5.1 General 65
6.5.2 Erection/ Laying Procedure 66
6.6 Seals 67
6.7 Drives and Gears 68
6.8 Lubrication, Lubricants and Oils 68
6.9 Oil piping 69
6.9.1 Pipe Supports and Hangers 69
6.10 Mechanical Instruments 69
6.11 Hydraulic servomotor Systems 70
7.0 Electrical Works

7.1 General 70
7.2 Main Distribution System 71
7.2.1 Board 71
7.2.1.1 General 71
7.2.1.2 Name Plate 71
7.2.1.3 Bus Bar 71
7.2.2 Air Circuit Breaker 72
7.2.2.1 General 72
7.2.2.2 Contacts 72
7.2.2.3 Protection 72
7.2.3 Moulded Case circuit Breaker 72
7.2.3.1 General 72
7.2.3.2 Contacts 73
7.2.4 Current Transformers 73
7.2.5 Interlocks 73
7.3 Local control panel 73
7.4 Standards 74
7.5 Color code 74
7.6 Electric motors 74
7.6.1 General 74
7.6.2 Rating 75
7.6.3 Starting 75
7.6.4 Windings and Insulation class 76
7.6.5 Ventilation and type of enclosure 76
7.6.6 Bearings 76
7.6.7 Shafts and couplings 77
7.6.8 Terminal boxes and earthing 77
7.6.9 Noise level and vibrations 77
7.6.10 Tests 78
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7.7 Auxiliary Works 78

7.7.1 Auxiliary Switches 78
7.7.2 Anti Condensation Heaters 79
7.7.3 Protection Devices 79
7.8 Terminal Points 80
7.9 Cables 81
7.9.1 General 81
7.9.2 Colour Code 81
7.9.3 Illumination system 82
7.10 Earthing System 82
7.11 Labels and Plates 82
7.11.1 General 82
7.11.2 Equipment Labels and Instruction Plates 82
7.11.3 Warning labels 83
7.11.4 Labels for Conduits Etc. 83
7.11.5 Labels for Cables 83
7.11.6 Rating Plates 83
7.12 Key System for Electric Boards 83
8.0 Transport and Storage

8.1 General 83
8.2 Packing 84
8.3 Marking 84
8.4 Storage 85
9.0 Inspections and Tests

9.1 General 85
9.2 Workshop Inspections and Tests 87
9.2.1 Material Tests 88
9.2.2 Checking of Dimensions 89
9.2.3 Workshop Assembly 89
9.2.4 Hydrostatic Pressure Tests 90
9.2.5 Functional Tests 91
9.2.6 Operational Tests 91
9.2.7 Insulation tests 91
9.2.8 Electrical Tests 92
9.2.9 Inspection and Tests for Pressure shaft steel liners 92
9.2.9.1 Inspection during Fabrication, Laying and Erection 92
9.2.9.2 Testing at Contractor'
s premises 93
9.2.9.3 Testing at site 93
9.3 Site Inspection and Tests 93
9.3.1 Commissioning and Trial Run 94
9.3.2 Acceptance 97
10.0 Measurement
10.1 General 98
10.2 Steel liner 98
10.2.1 Weight of straight ferrule 98
10.2.2 Weight of Bend section 99
v
10.2.3 Stiffener Rings, Thrust and Anti-Percolation Rings 99

10.3 Gate 99
10.3.1 1st Stage embedded parts 99
10.3.2 2nd stage embedded parts 99
10.3.3 Gate leaf structure 99
10.4 Miscellaneous 99
Annexure-A
vi
General Technical Specification
1 General Description
1.1 Introduction
The project is proposed on river Marusudar, a major tributary of river Chenab,
in Kishtwar district, Jammu and Kashmir. The dam is envisaged near
Drangdhuran village and power house is proposed near Trimuli village. The
proposed dam site is located at about 23 km upstream of the confluence of
Marusudar river with Chenab river near Bhandarkut village. Drangdhuran
village is connected by a 13.5 km long road to the nearest town Patimahal.
1.1.1 Location and Communication

The project headquarter is located at Kishtwar, about 240 km from Jammu,
the winter capital town of J&K. The dam site is about 46 km from Kishtwar.
The nearest rail head (broad gauge) is Udhampur. The nearest domestic
airport is at Jammu and the international airport is at New Delhi.
1.1.2 Project Layout
The proposed site for the construction of Dam is located near village
Drangdhuran, in Tehsil Kishtwar and lies at Latitude 33° 27' 30'' N and
Longitude 75° 48' 50'' E. The river bed level at the Dam site is at about EL
1540m. Corresponding to an FRL at EL 1700M, the Gross storage of the
reservoir is 125.4 M.cum and area under submergence is 228 Ha.
Underground P/house is proposed on the right bank of the river Chenab
near Trimuli and is located approx. 1.5 km U/s of Dam of the Dulhasti H.E.
Project. Water from Drangdhuran reservoir is to be diverted through 2
No.,approx. 10 km long, 7.2m dia horse shoe/ circular shaped Head Race
Tunnels (HRT) to the Power House. The water from Power House would
be discharged through 4No, 125 m long, 5.5 m dia, horse shoe shaped
Tail Race Tunnels (TRT) into the reservoir of Dulhasti H.E. Project on river
Chenab. The regulated flows of water from Drangdhuran project would
enhance the generation of Dulhasti H.E. Project in lean periods.
The main features of the project are as under:

1 A 167m high (above river bed level), 305m long (at top) Concrete
Face Rockfill
2 Dam across river Marusudar near village Drangdhuran
3 1 no., 11 m dia. and 813 m long horse shoe shaped diversion
tunnel.
4 Reservoir with gross storage of 125.4 M.cum at FRL & 17.01
M.cum at MDDL and having submergence area of 228 Ha.
5 1 no., intake structure with 2 nos gates of opening size 5.6 m(W) x
7.7m(H).
6 2 nos, 7.2 m dia, 10 Km long horse shoe/circular shaped head race
tunnels with a bed slope of 0.67%.
7 2 nos, 16 m dia., 200 m high open to surface with restricted Orifice
surge shafts.
8 2 No. 6.00 m Ø and 380 m long pressure shaft steel liners taking
off from 2 No. 16m dia surge shafts, further bifurcating into 4 No.
3.9 m Ø in upper horizontal portion before connecting to Butterfly
valve at valve house. The 3.9m dia lower horizontal shaft further
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reduces to 2.9m dia., connects to Butterfly valve in MIV cavern

before feeding to 4 No. generating units 49m d/s of MIV.
9 1 Nos. Valve houses located D/s of surge shaft of size 101.5m (L)
X 8m(W) x 18.8m(H).
10 An underground power house of cavern size 166 m (L) x 20.20 m
(W) x 51.00 m(H) to accommodate 4 units of 250 MW each.
11 4 Nos., 5.5 m dia, horse shoe shaped, 125M long (each) concrete
lined tail race tunnels.
.
1.2 The Document
The Contractor shall strictly observe this General Technical

Specification in conjunction with the Particular Technical
Specifications. He shall carry out all works in a skilled and good
workmanship manner in compliance to modern methods of engineering. All
design calculations, materials, works, manufacturing and testing shall
conform to the latest applicable standards.
In addition, the Contractor shall conform to all applicable regulations

regarding the execution of construction and installation work, and shall follow
all instructions issued by the Competent Authorities and the Engineer-in-
charge.
The Particular Technical Specifications shall take precedence over the

General Technical Specifications in case of any contradiction. Clause number
cross-references refer to the volume in which they occur unless stated
otherwise.
1.3 Scope of work
It is not the intention of these specifications to specify the complete details of

equipment, however the contractor shall supply the equipment/ finished
material, which will meet in all respect, the requirements of the owner in regard
to performance, durability and satisfactory operations. All the equipments/
finished materials supplied or works done shall conform to the relevant Indian
Standards. Wherever the Indian Standards are not existent or silent, relevant
ASTM, DIN, Japanese Industrial Standards (JIS) or BS standard shall be
followed.
The broad scope of the work shall include the following: -
Design, procurement, manufacture, inspection, shop assembly, testing,

painting, transportation, site storage & site erection, testing and commissioning
including provision for all labour, plant & material for the above, handing over to
owner, supply of necessary spares for 5 years trouble free operation. Supply
and installation of all incidentals not specified but necessary for the proper
completion and satisfactory functioning of works and guarantee of the
permanent equipment, alongwith all auxiliary equipment in the designated
location of the project as specified in the following sections of technical
specifications, shall also be in the scope of work:-
1.3.1 Tunnel Spillway Radial Gates, Hydraulic Hoists, Bulkhead Gates ,

Gantry Crane & Steel liners for Tunnel Spillway
(i) Gate & Hydraulic Hoists
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Two numbers of radial gate for clear opening size of 6.20m wide x 7.00m high
complete in all respect with skin plate, stiffeners, bracings, arms, girders,
trunnion assemblies, trunnion brackets, anchorage system for trunnions, seal
assemblies, guide roller assemblies, dogging device, lifting attachment and
other miscellaneous fittings i.e. walkways, hand railings, ladders etc. as
specified complete in all respect.
Two sets of first stage and 2nd stage embedded parts complete with
embedments for first stage, lintel beam, sill beam, seal seats, wall plates,
embedments for trunnion brackets to fix in the concrete beam, embedments for
hoist supporting structure, dogging devices , groove embedded frame at deck
level suitable for removable/ fixed steel groove cover with removable steel
groove cover.
Two sets of double acting hydraulic cylinders of sufficient capacity but not less
than 900T (2 X 450T per gate for pulling and 2 x 100 T per gate for pushing),
with spherical self lubricating plain bearings on either trunnion ends, hoist
supporting structure including anchorage system, and other associated
components required necessary for the erection and commissioning etc.
Two independent units of hydraulic power pack for the two numbers of gates
each comprising two motors( One standby), two pumps (One standby), control
panel, piping, hydraulic oil for first filling, pressure gauges, flow control valves,
direction control valves etc. with controls, manual controls, limit switches and
other fittings. Each power pack shall be standby for the adjacent unit for which
inter linking shall be made.
Two sets of double acting hydraulic cylinders and requisite power pack of
sufficient capacity but not less than 500T (1 x 500T per gate) alongwith power
packs for partial movement of eccentric trunnion pin, with spherical self
lubricating plain bearings on trunnion ends, hoist supporting structure including
anchorage system, and other associated components required necessary for
the erection and commissioning etc.
One No. portable oil filter unit for filtration, dehydration and degasification of
hydraulic oil.
Provision shall be made for supply of one number gasoline engine operated
portable power pack capable of operating one radial gate at 25% of the rated
operating speed.
Two sets of 1200mm dia air vent pipes for each tunnel spillway for aeration
requirements downstream of the tunnel spillway radial gates sill area. (This air
vent pipe shall be provided as per model studies recommendation.)
One electrically operated gantry crane of adequate capacity (but not less than
40T) with appropriate gears, pinion, reducers, motors, brakes, limit switches,
rope drums, wire ropes, lifting attachments, sheaves, crane rails and
embedments, end stoppers, fixtures, cable reeling/ trailing cable for all supply
arrangement, operator’s cabin, ladders, hand railings, walkways etc. for
installation and maintenance purposes of hydraulic hoists and tunnel spillway
gates.
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(ii) Tunnel Spillway Bulkhead and Gantry Crane
One wheeled type Bulkhead gate, for clear opening size of 6.20m wide x 7.0m
high comprising of skin plate, vertical stiffeners, horizontal girders, end vertical
girders, seal assemblies, filling in valves in top unit, lifting attachment, side
guide shoe assemblies, bumpers etc.
Two sets of first stage embedded part inserts, corner angles, groove
embedded frame at deck level suitable for removable/ fixed steel groove cover
etc.
Two sets of second stage embedded parts complete with wheel tracks, sill
beam, Lintel beam, side seal seats and bases, groove and lintel liner, side
guides, dogging devices, groove covers and receiving frames, anchors with
double nuts and washers removable steel groove cover etc.
230T), shall be provided with appropriate gears, pinion, reducers, motors,
brakes, limit switches, rope drums, wire ropes, lifting attachments, sheaves,
crane rails and embedments, end stoppers, fixtures, cable reeling/ trailing cable
for all supply arrangement, operator’s cabin, ladders, hand railings, walkways
etc. The bulkhead gate shall be directly attached to Gantry crane.
(iii) Steel Liner for Tunnel Spillway

Two set of steel liner of 10.0 m circular dia. from tunnel spillway intake to tunnel
spillway gate groove. Three No. steel transitions are provided in each tunnel
spillway, One No at bell mouth areas, One No. u/s of tunnel spillway bulkhead
gates and One No. at the end of gate groove from rectangular section to 10.5
m dia circular section in accordance with the specification and drawing.
(iv) Model study of complete tunnel spillway gate arrangement to
determine the hydrodynamic forces on each tunnel spillway
bulkhead gate/ radial gate and aeration requirement of Tunnel
Spillway Radial Gate and Bulkhead Gate.
1.3.2 Surface Spillway Radial Gates, Flap Gates, Hydraulic Hoists, stoplog
Gates & Gantry Crane.
i) Gate & Hydraulic Hoists
Two No. crest type radial gate for clear opening size of 12.0m wide x 16.00m
high complete in all respect with skin plate, stiffeners, bracings, arms, girders,
trunnion assemblies, trunnion brackets, shields, flow breakers, post tensioned
anchorage system for supporting trunnion beams, seal assemblies, guide roller
assemblies, dogging device, lifting attachment and other miscellaneous fittings
i.e. walkways, hand railings, ladders etc. as specified complete in all respect.
Two sets of first stage and 2nd stage embedded parts complete with
embedments for first stage, lintel beam, sill beam, seal seats, wall plates,
embedments for steel trunnion beam/yoke girder for fixing the gate trunnion,
fabricated radial pier guide members, trunnion bearing foundation plates, post
tensioned trunnion anchor rods, sleeves, nut, frames/supports, embedments for
hoist supporting structure, dogging devices groove embedded frame at deck
level suitable for removable/ fixed steel groove cover with removable steel
groove cover etc.
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Two pairs of hydraulic cylinders of sufficient capacity but not less than 200T
(100T each), with spherical self lubricating plain bearings on either trunnion
ends, hoist supporting structure including anchorage system, and other
associated components required necessary for the erection and commissioning
etc.
portable power pack capable of operating one radial gate at 25% of the rated
operating speed.
Two sets of 8.00m x 2.00m size flap gate in the skin plate body of above radial
gates complete with skin plate, stiffeners, girders, seal assemblies, guides,
lifting attachment complete in all respect.
Two pairs of double acting hydraulic cylinders of sufficient capacity but not less
than 100T each with spherical self lubricating plain bearings/bushings on either
ends, gate position indicators and other associated components required
necessary for the erection and commissioning etc.
Two independent units of hydraulic power pack & Control system for the flap
gates to be operated individually including motor, pump, control panel, piping,
pressure gauges, flow control valves, direction control valves etc. with controls,
manual controls, limit switches, lightings and other fittings. Each power pack
shall be standby for the adjacent unit for which inter linking shall be made.
One number oil purifier of capacity 15-17 lts/hr complete with all accessories,
equipments, instruments etc. for radial gate shall be provided to purify the
hydraulic oil used in servomotor. The hydraulic oil purifier shall be
electrostatic liquid cleaner type and able to purify the suspended particle
more than 5 µm. Unit shall be supplied along with paper and other
consumable required for 5 years of successful operation of machine.
One number of Low vacuum dehydration and degasification unit for Radial
Gates shall be provided to remove moisture and dissolved gases from the
used hydraulic oil in servomotor. The capacity of the vapouriser shall not be
less than 50 lts and capacity of vacuum pump shall not be less then 50
lts/min.
(ii) Surface Spillway Stoplogs and Gantry Crane
One set of stoplogs/bulkhead consisting of 3 units for clear opening size of

12.0m wide x 16.00m high comprising of skin plate, vertical stiffeners,
horizontal girders, end vertical girders, bearing member seal assemblies, filling-
in-valves in top unit, lifting attachment, side guide roller assemblies, bumpers,
pilot guide pins with matching receiving pipes, probe mechanism/ arrangement
to ensure proper seating of stoplog units on sill/ on the lower unit etc.
Two sets of first stage embedded parts insert, corner angles groove embedded
frame at deck level suitable for removable/ fixed steel groove cover etc.
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Two sets of second stage embedded parts complete with slide tracks, sill
beam, lintel beam, side seal seats and bases, groove liner, removable steel
groove cover, side guides, dogging devices, anchors with nuts and washers
etc.
Two sets of storage structure including its embedded parts comprising, side
guides, dogging arrangement and removable steel groove covers suitable to
cover for stop log units.
One lifting beam with automatically engaging and disengaging hooks, lifting
lugs and sheaves, side frames with guide rollers, pilot tubes, probe mechanism/
arrangement to ensure proper seating of lifting beam with stop log units.
One electrically operated gantry crane 100T capacity, having Long travel and
Cross travel arrangement provided with appropriate gears, pinion, reducers,
motors, brakes, limit switches, rope drums, wire ropes, lifting attachments,
sheaves, crane rails and embedments, end stoppers, fixtures, cable reeling/
trailing cable for all supply arrangement, operator’s cabin, ladders, hand
railings, walkways, lighting etc.
1.3.3 Intake Gates and Hoists, Intake Bulkhead Gates & Hoists
i) Intake Gates and Hoists

Two numbers of fixed wheel bonneted type intake gates for opening size
5.60m wide x 7.70m high including skin plate, vertical stiffeners, horizontal
girders, bottom lip, end vertical girders, wheel assemblies, guide rollers
assemblies, top, side and bottom seals, lifting attachments, bonnet cover and
all other accessories and appurtenance.
Three sets of first stage embedded parts and corner angles, bonnet body etc.
and groove embedded frame at deck level suitable for removable/ fixed steel
groove cover etc.
Three sets of second stage embedded parts complete with wheel tracks, sill
beam, lintel beam, side seal seats and bases, groove liners, removable steel
groove cover, side guides, suitable dogging arrangements to hold the gates in
open position, bonnet body, cylinder supports etc. 2nd stage anchorages with
nuts and washers etc.
Two sets of double acting hydraulic hoist of sufficient capacity but not less than
(350T pulling/305T pushing each), with spherical self lubricating plain
bearings and other associated components required necessary for the erection
and commissioning etc.
portable power pack capable of operating one Intake gate at 25% of the rated
operating speed.
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30T) having long travel and cross travel arrangements with appropriate gears,
pinion, reducers, motors, brakes, limit switches, rope drums, wire ropes, lifting
attachments, sheaves, crane rails to cover all 3 (three) Intakes, end stoppers,
fixtures, including embedments, cable reeling/ trailing cable for all supply
arrangement, operator’s cabin, ladders, hand railings, walkways etc. for
installation and maintenance purposes of hydraulic hoists and Intake gates.
ii) Intake Bulkhead Gates and Gantry Cranes

One No. wheeled type intake bulkhead gate for opening size 5.60m wide x
7.70m high is envisaged for inspection and maintenance of 2 No. intake gates
and embedded parts. The gate shall comprise skin plate, vertical stiffeners,
horizontal girders, end vertical girders, bottom lip wheel assemblies, side guide
roller assemblies, seal assemblies, lifting attachments and all other accessories
and appurtenance etc.
Three sets of first stage embedded parts and corner angles, groove embedded
frame at deck level suitable for removable/ fixed steel groove cover.
Three sets of second stage embedded parts complete with wheel track
assemblies, sill beam, lintel beam, side seal seats and bases, groove liners,
side guides, suitable dogging arrangements to hold the gates in open position,
2nd stage anchorages with double nuts and washers removable steel groove
cover etc.
One nos. electrically operated gantry crane of adequate capacity but not less
than 165MT for operation of gate under balance head condition having long
travel arrangement provided with appropriate gears, pinion, reducers, motors,
brakes, limit switches, wire ropes, rope drums, lifting attachments, sheaves,
crane rails and embedment, end stoppers, fixtures, cable reeling/ trailing cable
for all supply arrangement, operator’s cabin, ladders, hand railings, walkways
etc.
(iii) Model study of complete intake gate and trash rack arrangement to
determine the hydrodynamic forces on each Intake bulkhead gate/ Intake
gate and aeration requirement of Intake Gate and Bulkhead Gate.
1.3.4 Intake Trash Rack
One set of first stage inserts and embedded parts suitable for trash rack
covering complete opening of intake structures 88.50m (wide) x 19.50m
(Vertical Height), (consisting of an intermediate pier at the center line of intake
and 0.5 m bearing for trash rack at each end) in all respect in accordance with
these specifications.
One set of vertical trash racks and fabricated in 88 numbers of panels each of
size 3.05m wide x 6.5m high comprising of trash bars, framing members,
vertical support members, panels for all three Intakes complete in all respect in
accordance with these specifications.
1.3.5 Valves for environmental flow pipe
One set of 500mm dia. and three sets of 400mm dia. electrically operated
Knife edge gate valves to regulate flow through environment release pipes
including supports, dismantling joints etc. (The pipes are not in HM Contractor’s
scope).
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GTS
1.3.6 Adit Inspection gates
Four number hinged type adit gate suitable for opening size of 3.0m wide x
3.0m high comprising of skin plate, stiffeners, girders, sealing and bearing
members, connecting hinge members and suitable piping and valves (
minimum 250 mm Ø) for dewatering purpose and pressure gauge for
measuring HRT water pressure. These gates are proposed for adit plugs at
adit-1 , adit-1A, adit-2 and adit-2A.
Four sets of fabricated embedded parts for gate opening of 3.0m x 3.0m
consisting of track cum sealing frames, embedments required for fixing hinges
and locking bolts etc. complete in all respects including first stage anchors.
1.3.7 Pressure Shaft Liners

Steel lining for two numbers pressure shafts each consisting of a transition
section (6.0m x7.2m rectangular section to circular to 6.0m circular), upper
horizontal portion having an internal diameter of 6.0m, each bifurcating to 2sets
of 3.9m. dia each, connection to butterfly valve on both ends in the valve
house, vertical portion, lower horizontal portion having an internal diameter of
3.9m (reduced to 2.9m before MIV) including steel transition and plan bends,
connection to butterfly valve on both ends in the MIV cavern, Manhole, thrust
collar in accordance with the specification and drawing.
1.3.8 Tail Race Gates and Hoists
Four No. fixed wheel type Tail race gates for opening size 5.5 m wide x 5.5
m high including skin plate, vertical stiffeners, horizontal girders, bottom lip,
end vertical girders, wheel assemblies, guide rollers assemblies, top, side and
bottom seals, lifting attachments, dogging arrangement etc suitable for 2nd
stage embedded parts.
Four sets of first stage embedded parts and corner angles, etc. and groove
embedded frame at deck level suitable for removable/ fixed steel groove
cover.
Four sets of second stage embedded parts complete with wheel tracks, sill
beam, lintel beam, side seal seats and bases, groove liners, removable steel
groove cover, side guides, suitable dogging arrangements, etc. 2nd stage
anchorages with nuts and washers etc.
Four sets of electrically operated fixed rope drum hoists of capacity not less
than 85 MT, including wire ropes, drums, shafts, couplings, gearing
arrangement, brakes, motors, gate position indicator, limit switches, control
panels, cables and wiring with fixing plates and covers, manual operating
arrangements etc.
Four sets of hoist supporting structure, trestles, hoist housing, foundation

anchors, stairway, walk ways, (chequered plates, grating and removable hatch
covers) hand railings etc. complete in all respect in accordance with the
specification.
8
GTS
1.3.9 Automatic Reservoir Monitoring and Control Systems
The main items of remote control equipments & instruments to be supplied

and installed under this section shall comprise of: -
i) Computerised remote control system complete in all respect located at

Dam top for Control and operation of spillway radial gates and reservoir
level control in local/remote/auto modes.
ii) Gate position indication and monitoring of tunnel spillway gates, surface
spillway gates and gate position indication of Intake gates and tail race
gates.
iii) Monitoring and indication of discharge measurement for discharge

through tunnel spillway& surface spillway radial gates.
iv) Two sets of Differential pressure measurement and indication equipment

across trash rack.
v) Two sets of water level measuring and indication Equipment along with
necessary alarms at dam area.
vi) Two sets of water level measuring system to indicate balance head
condition of intake gates.
vii) Four sets of water level measuring system to indicate balance head
condition of Tail race gates.
All the necessary transducers and instrumentation, terminals, contacts,

cabling etc. for the above at various locations shall be provided and
incorporated in the control system.
Remote indication arrangements shall also be provided in the Power House.

For indication of equipments in power house, necessary hardwired interfaces
required for the Control system in a separate cubicle shall be provide. The
communication protocol shall be based on IEC 60870-5 series and interfaces
shall be capable of supporting the same.
One Uninterruptible power supply at each station to provide back up

(minimum sixty minutes) to the system in case of failure of main power supply
to equipment shall also be provided.
1.3.10 Diesel Generating set and Hydraulic Oil Filtering Unit.
Supply of four No. 250 KVA, 415V, 50 Hz AC output, three-phase

synchronous type Diesel engine generating sets complete with all accessories,
equipment, instrument, wiring and acoustic enclosures for making the
equipment complete and for warranting a trouble free safe operation including
its design, manufacturing, testing and commissioning. The diesel generating
set shall provide back-up supply to gate operating equipments and also to the
computerized control system in case of power failure.
9
GTS
1.3.11 Spares
Mandatory spare parts for gates, hoists and cranes, remote control system, DG
set etc. as per list. Additional spares recommended by bidder for 5 years
trouble free operation.
1.3.12 Tools and Tackles
Tools and equipment including special tools required for repair and
maintenance as per list enclosed.
1.3.13 Operation and Maintenance Manual
Ten (10) sets of operation and maintenance manual containing drawings, all
catalogue and brochures for plants and machinery, handling procedures for
assemblies & sub assemblies of all equipment covered under this specification.
2.0 Standards
Latest Indian Standards for design, testing, workmanship, material and Works
have been selected mostly in these specifications as a basis of reference.
Except where modified by this specification, works and materials shall be in

accordance with INDIAN STANDARD. If relevant Indian Standards are not
available in any case or cases, then relevant International Standards shall be
proposed by the Contractor for approval by the Engineer.
When IEC or ISO Recommendations or other Standards are referred to, the
edition shall be current at the time of issue of Tender Documents, together
with any amendments issued to that date.
If requested by the Engineer-in-charge, the Contractor shall supply at his own

expense three copies in English of latest edition and one in the original
language of any national standards, which are applicable to the Contract.
2.1 Standards for General Application
Standard publications issued by the following organizations of standardisation

are considered being approved standards for the works with a priority to use
Indian standards.
• BIS : Bureau of Indian Standards.
• ASTM : American society for testing & material.
• ASME : American society of mechanical Engineers.
• ASCE : American society of civil Engineers.
• CECT : European committee for Boiler making &

kindered steel structures.
• DIN : Deutsches Institut fur Normung.
• BS : British standard.
• IEC : International electromechanical Commission.
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GTS
• JIS : Japanese Industrial Standard.
• EN : European Standard
2.2 Standards for Design & Testing
Following is the list of Indian Standard Specifications. The latest Edition of

these standards shall be followed wherever the detailed requirements have not
been outlined in these specifications: -
S. No Description Standard
1. Recommendation of structural design of
fixed wheel gates. IS: 4622
2. Recommendation of structural design

of Radial gates. IS: 4623
3. Recommendations for structural design

criteria for low head slide gates. IS: 5620
4. Recommendation for structural design

of medium & high head slide gates. IS: 9349
5. Code of practice for design of rope drum

and chain hoists for hydraulic gates. IS: 6938
6. Code of practice for electric over head IS: 3177

Traveling cranes and gantry cranes other
than steel work cranes
7. Code of practice for design manufacture

erection & testing of cranes & hoists. IS: 807
8. Code of practice for use of structural

steel in general building construction. IS: 800
9. Design criteria of hydraulic hoists for

Gates.
a. Hoist capacity, Design of hoist components
Like hydraulic cylinder, cylinder head, stem,
Piston etc. IS: 10210
b. Hydraulic operating system (Power Pack) and
Its components like oil tank, pump and motor,
Valves, piping etc. DIN: 19704(part II)
10. Recommendation for inspection, testing

& maintenance of fixed wheel & slide gates. IS: 7718
11. Recommendation for Inspection, testing

& maintenance of Radial gates & their hoist. IS: 10096(Part I)
12. Recommendation for Inspection, testing &

maintenance of Radial gates & their hoists. IS: 10096(Part II)
11
GTS
13. Recommendation for Inspection, testing &

maintenance of Radial gates & their hoists. IS: 10096 (Part III)
14. Approval test for welding procedures IS: 7307 (Part I)
15. Approval testing of welders working

to approved welding procedures(Part I). IS: 7310 (Part l)
16. Approval tests for welders when welding

procedures approval is not required. IS: 7318
17. Code of practice for liquid penetrant flow

detector. IS: 3658
18. Code of practice for Ultrasonic tube echo

testing by contact and immersion methods. IS: 3664
19. Code of practice for magnetic flow detector. IS: 3703
20. Code for unfired pressure vessels IS: 2825
21. Code of practice for radiographic testing. IS: 2595
22. Code of practice for structural safety

of buildings loading Std. IS: 875
23. Code of practice for plain & reinforced concrete. IS: 456
24. Sluice valves & Gate valve. IS: 780
25. Criteria for Earthquake resistant design

of structures IS: 1893
26. Recommendations for design of Trash racks

for Intakes. IS: 11388
27. Structural design of penstock- criteria buried/ IS: 11639(Part-2)

Embedded penstocks in rock
28. Structural design of penstock- criteria specials/ IS: 11639 (Part-3)

for penstocks.
29. Code of Practice for Pre-stressed Concrete IS: 1343
30. Uncoated stress relieved low relaxation seven IS 14268

Ply strands for prestressed concrete
Reference should be made only to the relevant Indian Standard Specification.

However, where such code is silent on certain specific provision, reference may
be made to other appropriate & relevant ASTM, ASME, DIN, JIS, BS or ASCE
etc.
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GTS
Standards other than those stipulated in the Bid documents shall be acceptable
after scrutiny provided they ensure equal or higher quality than those specified
in the specifications. The contractor shall submit for approval the detailed
standards, which he proposes to use.
It shall be confirmed by the contractor that in case the standards proposed by

him are not found acceptable by owner during engineering, conformance of the
offered equipment to the respective standards as specified in the bid
documents shall be ensured by him at no extra cost to the owner.
If these specifications conflict in any way with any of the above standards or
codes, these specifications and drawings shall take precedence.
2.3 Material Standard
All material used for the fabrication of the equipment shall conform to relevant
Indian standard or equivalent International standard as DIN, ASTM, or BS
unless otherwise specified.
A. Materials for Gates, Bulkhead gates, Stoplogs, Embedded Parts,

Lifting Beam, Trash racks, Piping etc.
Sl. Component Part Recommended Code reference

No. Material / Make
i.(a) Structural parts of gate leaf Structural steel IS 2062 IS

including skin plate, stiffeners,
horizontal girders, diaphragms,
track base, seal base, seal seat
base, liners, seal clamp, lifting
lugs, structural parts of lifting
beam, guide, Structural parts of
trash racks, anchor bolts,
anchors etc.
(b) Stainless steel/ 2062+IS 1570

Radial gate skin plate Stainless steel (AISI (Part-V)
304) cladded over X04Cr.19Ni9
structural steel
ii. a Wheels Cast steel / forged IS 1030 Gr. 27-

steel 54 IS 2004 Cl. IV
Self aligning spherical roller SKF(Germany/India)

b. bearings/ antifriction bearings ,FAG(Germany/Indi
a), INA(Germany),
NTN (Japan),
Tenmat (Germany)
c. Wheel pins Corrosion resistant IS 1570 (Part V)

steel Gr.20 Cr.13
d. Retainers Structural steel IS 2062
13
GTS
e. Sleeves for pin Corrosion resistant IS 1570 (Part -

steel V) Gr.04Cr19Ni9
f. Trunnion pin Corrosion resistant IS 1570 (Part V)
steel Gr.20 Cr.13
g. Trunnion hub/ bracket Cast Steel/ IS:1030, IS:2062
Structural Steel
h. Trunnion bushing Self lubricating ASTM B-22

C86300
iii. a Guide roller Cast steel IS 1030 Gr.27-54

or Gr. 26-52
b. Guide roller pin Stainless steel IS: 1570 (Part-V)

Gr.04Cr19Ni9
c. Bushing (other than radial gate i) Self lubricating Standard make
trunnion bushing) bush IS: 305,Gr-AB-2
ii) Al.Bronze IS: 318,Gr-1
(for lifting beam
links)
iv. Seals Rubber IS: 11855
v. Track Corrosion resistant IS: 1570 (Part-V)

steel Gr.20 Cr.13 or
Gr.30Cr.13
vi. Seal seat Stainless steel IS 1570 Gr. 04

Cr. 19 Ni 9
vii. Seal fasteners Stainless steel IS 1570 Gr. 04

Cr. 19 Ni 9
viii. Ballast if any Cast Iron/ Structural IS: 210/ IS: 2062
steel
ix. Lifting hooks (for lifting beam) Forged steel IS: 2004 Cl. IV
x Lifting Pins Corrosion resistant IS: 1570 (Part-V)

steel Gr.20 Cr.13
xi Material for filling-in-valve
a Spring Spring steel
b Seal Bronze/rubber
seating on stainless
c Stem Corrosion resistant IS 1570 (Part-V)
steel
xii Piping Mild Steel IS: 2062
xiii Tendons for prestressed HTS Strand IS:14628

anchors
14
GTS
B. Material for components of Hoist Bridge, Hoist Support, Trestles,

Walkways, Railing, Gantry Girder, Dogging Devices etc.
i) Base plate, anchors, columns, Structural steel IS: 2062

stiffeners, bracings, lugs, Rolled sections
gantry-girders etc. IS: 808
ii) Walkway Chequered Plate IS: 3502
iii) Bridge bearings Neoprene or Standard

Plate bronze
IS 305/IS 318
iv) Handrails & Posts IS 1239 MS

Black Medium
duty
C. Materials for hydraulic hoist
Sl. Materials component Material Specifications

No.
1. Hoist Cylinder Type MW 450N DIN designation:

20MNV6, Mat.
No. 1.5217
2. Upper & Lower Cylinder head Type St 52-3 / Standard DIN
S355J2G3 17100
3. Stem Rod Corrosion Resistant 42Cr Mo4 DIN-

steel/ low alloy 1.7225/EN10083
carbon steel /
stainless steel with
Ceramic coating or
Stainless steel with X17Cr Ni16.2,
multi-layered hard DIN17440, Mat.
chrome plating of No. 1.4057 or
not less than 50µm. any other eqvt.
material.
4. Clevis, Head, Piston, Trunnion, Type St 52-3 / DIN 17100
bottom, Piston part, sealing S355J2G3
flange etc.
5. Piping X 6 Cr Ni Mo Ti17 DIN 17440, Mat.

12.2 No. 1.4571
6. Piston Guides Bronze IS 318
D. Materials for Rope Hoists and Cranes

i) Wire rope Steel IS: 2266
Improved plow
ii) Drums Cast steel/ M.S. IS: 1030/IS: 2062
iii) a) Gears Cast steel/ IS: 1030
Structural steel IS: 2062
b) Pinions Carbon steel IS: 1570C40
Forged Steel IS: 2004 Cl. IV
15
GTS
iv) Sheaves and pulleys Cast steel IS: 1030

v) Shafts Forged steel IS: 2004Cl.IV
Carbon steel IS: 1570 C 40
vi) Speed reducer, Motors, wire rope
Electromagnetic,
Thruster brakes,
Plummer blocks with bearings,
Limit Switches, Control equipment,
Electrical bought out items etc.
vii) Wheels Forged Steel/ IS: 2004 Cl. IV

Cast Steel IS: 1030
viii) Pins Forged steel/ IS 2004/
Carbon steel IS 1570-C40
ix) Bushing Bronze/Al-Bronze IS: 305/IS:318
x) Steel for shrunk fit Forged steel/ IS: 2004
gear rims Carbon steel/ IS:1570-C40
xi) Threaded fasteners IS: 1363
IS: 1367
E. Hydraulic Oil ISO Grade
F. Materials for Pressure shaft liners/ Tunnel Spillway steel liners

S. Component Part Recommended Materials Code reference
No.
i. Pressure shaft liners, Boilers quality/pressure ASTM A517 Gr. F

Ferrules, bends, thrust vessels quality steel
collars, stiffener rings
ii. Bond Breaking Material Mixture of high quality DIN: 16729

polyethylene copolymer with
amorphous bitumen having
following properties:
Density : 0.97 g/cm3
Modulus of rigidity: 130 MPa
Shrinkage reduction: 30%
iii. Tunnel spillway steel Boilers quality/pressure ASTM A537 Cl. 1

liners vessels quality steel
G .Materials for Knife edge gate valve - As per standard Manufacturer’s

recommendation
2.3.1 Substitute Material
16
GTS
In case the material specification of any component(s) proposed by the

contractor is not in accordance with the technical specification, data in respect
of those materials shall be submitted for assessing the suitability of the same.
However the bidder shall confirm that in case the materials proposed by him
are not found acceptable, he shall abide by the materials specified in the
specifications without any extra financial implications to the owner.
2.3.2 Sub-Contractors/ Vendors
The bidder shall include details of proposed sub contractors including vendors
for items of supply or services, it proposes to sublet or procure bought out
items. The capabilities of sub contractors and vendors shall be evaluated for
acceptability based on previous references/ experience / credentials etc. to be
furnished by the bidder along with tender. A list of approved vendors along with
qualification criteria is given in annexure A.
If required the bidder may substitute an acceptable sub contractor or vendor

without any change to the bid price.
2.4 Permissible stresses
2.4.1 Permissible Stresses for Spillway Gates, Adit gates and Intake Gates
a) Structural steel
i) Direct compression and compression
in bending 0.45 Y.P.
ii) Direct tension & tension in bending 0.45 Y.P.
iii) Shear stress 0.35 Y.P.
iv) Combined stress 0.60 Y.P.
v) Bearing stress 0.65 Y.P
b) Bearing stresses
i) Bearing stress in bronze 0.035 U.T.S.
ii) Bearing stress in self lubricated bush
for radial gate trunnion 0.1 YP
c) Wheel
i) Contact stress (line contact) 1.4 U.T.S.
ii) Point contacts 2.1 U.T.S.
iii) Wheel bearings (F.O.S) Static Capacity shall be

1.5 times the designed
wheel load
d) Wheel pin
i) Bearing 0.65 Y.P.
17
GTS
ii) Shear 0.132 U.T.S. or 0.35

Y.P. (whichever is
less)
iii) Bending 0.2 U.T.S. or 0.45 Y.P.

(whichever is less)
e) Corrosion allowance of 1.5 mm for the skin plate of gate except for Tunnel
Spillway radial gate is to be considered.
2.4.2 Permissible Stresses for Embedded Parts
a) Structural steel
i) Direct compression and compression
in bending 0.4 Y.P.
iii) Shear stress 0.3 Y.P.
v) Bearing stress 0.45 Y.P
b) Bearing stresses
i) Bearing stress in concrete 0.25x(28days) characteristics

strength of concrete
ii) Bearing stress in Bronze 0.03 UTS
2.4.3 Permissible Stresses for surface spillway stop log, tunnel spillway
bulkhead gate, Intake bulkhead gate, Tailrace tunnel gates.
Structural steel
i) Direct compression and compression 0.55 Y.P.
in bending
iii) Shear Stress 0.40 Y.P.
v) Bearing stress 0.75 Y.P.
b) Bearing stresses
i) Bearing stress in bronze 0.035 U.T.S.
c) Wheel
i) Contact stress (line contact) 1.4 U.T.S.
ii) Point contacts 2.1 U.T.S.
18
GTS
iii) Wheel bearings (F.O.S) Static Capacity shall be

1.5 times the designed
wheel load
d) Wheel pin
i) Bearing 0.65 Y.P.
ii) Shear 0.132 U.T.S. or 0.35 Y.P.

(whichever is less)
iii) Bending 0.2 U.T.S. or 0.45 Y.P.

(whichever is less)
2.4.4 Permissible Stresses for Rope Drum Hoist Equipment
a) Drum
Permissible compressive stresses for various materials are:

Cast steel IS 1030 0.2 UTS
Structural steel IS 2062 0.17 UTS
b) Gears
Allowable stress 0.2 U.T.S.
c) Shafts
i) Maximum allowable bending stress 0.5Y.P.or 0.2UTS

(Whichever is less)
ii) Maximum allowable torsional shear stress (τ) 0.3 Y.P.
iii) Combined stress 0.24 U.T.S
iv) Allowable stress for shafts with keys will be 75% of above value.
v) Equivalent bending or twisting stress shall not exceed 1.2 times

maximum allowable bending stress/shear stress at (i) and (ii) above.
2.4.5 Permissible Stresses for Hoist Bridge, Hoist Support, Trestles & Hand
Railing (Clearly above Water)
As per IS 800, if not specified otherwise except hydraulic hoist support structure
where the permissible stresses shall be taken as per clause 2.4.1 of GTS
(Permissible Stresses for Gates).
2.4.6 Permissible stresses for Trash racks
The permissible stresses for trash racks shall be as specified in IS: 11388.
19
GTS
2.4.7 Permissible Stresses for Hydraulic Cylinder and their components

The calculation of cylinder working pressure and various frictional losses shall
be as per DIN 19704-1. However, maximum theoretical working pressure at
cylinder rod end shall be restricted to 20MPa. Relief valve at cylinder side
may be adjusted at 10% (maximum) higher than the cylinder working
pressure. The permissible stresses of various components of hydraulic
Cylinder shall be as per table 1 of latest edition of IS: 10210.
2.4.8 Permissible Stresses and design of Power Pack for Hydraulic Cylinder
The selection of various components of power pack shall be suited to the

pressure calculated as per DIN: 19704. The hydraulic power unit shall be
designed for a maximum design pressure at pump restricted to 22.5Mpa at
pump. However, relief valve at pump side may be adjusted at 10%
(maximum) higher than the design pressure. The allowable stresses of
hydraulic pipes shall be as per Appendix A of latest edition of IS: 6631.
2.4.9 Stresses under occasional forces / exceptional loads
The stresses in the various parts of the gate under the action of occasional
force like earthquake effect, storm wind, MWL condition, Max. Surge level,
Break Down Torque condition etc. shall not exceed 133 per cent of the
permissible stresses mentioned above (125% in case of fasteners)
subject to the maximum of 80% of the yield stress.
2.4.10 Permissible stress for steel pressure shaft/penstocks lining and Tunnel
Spillway Liner specials:
Permissible stress for steel pressure shaft/penstocks lining and

specials shall be as per following standards:
Design criteria for internal and external pressure shall be as indicated

in clause 10.5.1 for Particular Technical Specifications.
IS: 11639 (part2) : Structural design of Penstock-Criteria buried/

embedded penstocks in rock
IS: 11639(part3) : Structural design of Penstock-Criteria

specials for penstocks
IS: 2825 : Code for unfired pressure vessels
ASCE : Steel Penstock manual
CECT : European committee for Boiler making &

kindered steel structures.
2.4.12 Permissible stresses for Gantry cranes
The permissible stresses for gantry cranes shall be as specified in IS: 3177 &
IS: 807.
2.4.13 Minimum Thickness of plates
Minimum thickness of plates to be adopted = 10mm.
3.0 Technical Documents

3.1 General
This Chapter specifies the general scope and gives a definition of the
documents which, together with those listed in the Particular Specifications,
20
GTS
shall be delivered by the Contractor to the Engineer within the periods, and in
a number and quality as specified in the General and Special Conditions.
The Engineer reserves the right to request the Contractor additional
documents as may be required for proper understanding and definition of
constructional, operational, co-ordination or other matters.
The contractor shall inform the owner about the software to be used for
analysis and design. The diskettes / CD of such software shall be
provided to the owner at no cost to the owner.
The Contractor shall co-operate with other Contractors in the exchange of
drawings, dimensions, data and all other information required to ensure
proper co-ordination of the work. All documents to be supplied shall be
submitted in accordance with the agreed programme so that any comment
and change requested by the Engineer can be taken into account before
starting of the manufacturing in the workshop and/or erection or installation at
the Site.
If the Contractor fails to submit such documents, then the later execution of
changes requested by the Engineer and the resulting additional cost and/or
delays shall be the Contractor's liability. The Contractor shall not be released
of his responsibility and guarantee after drawings and computations have
been approved by the Engineer.
The preparation of drawings, computations or other technical documents shall
not be subcontracted by the Contractor without the written authorisation of the
Engineer. In such a case of subcontracting the Contractor shall be fully
responsible for such drawings, computations and other technical documents
as if they were done by himself.
If required for proper understanding of the documents, additional
descriptions/explanations shall be given on these documents or on separate
sheets. All symbols, marks, abbreviations, etc., appearing on any document
shall clearly be explained by a legend on the same document or on an
attached sheet.
Each device appearing on any document (drawing, diagram, list, etc.) shall
clearly be designated. The abbreviation mark used for an individual device
shall be identical throughout the complete documentation so as to avoid
confusion. All documents shall have a uniform title-block as outlined in the
specification. Beginning with the very first submittal to the Engineer, the
Contractor's drawings shall bear a serial number corresponding to a drawing
classification plan of the owner.
Revised technical documents replacing previously submitted documents shall

be marked accordingly. Also, the revised part in the Document itself shall be
marked clearly. The documents required to be supplied shall be clearly
marked as regard to their status namely "FOR APPROVAL" (A), or "FOR
INFORMATION " (I), respectively.
Any comment given by the Engineer on "I" type drawing shall have the same
effect as if it were given on "A" type drawing.
3.2 Design & drawings
The Contractor shall submit details of estimated machinery imposed

loads on concrete structures, location of anchors, groove details and
21
GTS
checks in structures constructed by others shall be provided within 90

days of award of Contract for interfacing with civil works.
Manufacturer shall submit design computations and drawings to the

Engineer-in-charge for approval/information (as per requirement listed under
para (3.3)), which shall include in sufficient detail to show:
• Design calculation for all components and parts in accordance with
design criteria & specification to prove their adequacy supported by
catalogues / technical literature of all bought out components with
selection criteria & characteristics.
• Kinematic details in the form of line diagram/sketches/data of gate and
hoist establishing and describing the working stroke, total stroke, reserve
stroke on piston end side and head end side of the cylinder, the cylinder
location and position in gate fully closed and in gate fully open position
etc.
• General Layout (overall view of related structure showing all the
equipments) drawing.
• General arrangement drawing indicating all the dimensions, sections and
detail of components.
• Blockout drawings dimensioning locations of anchors and 1st stage
concrete outlines.
• Assembly/installation assembly drawings showing the details of welding
sizes adopted in design calculation, dimensions of the parts of the
equipment to be supplied under the contract.
• Material lists covering specifications, sizes, quantities, weight of each
component from which the various parts will be made
• For all larger pieces of works which, due to their dimensions and/ or
weight and transport limitations, will require special means for their
transportation, the contractor shall submit necessary loading drawings
indicating dimensions weights, etc. of the respective pieces of works and
the necessary trailer for its transportation to the site.
• Weld details welding rod broad specifications.
• Machining and assembly tolerances and fits.
Diagrams
• The circuit diagrams shall show the power circuits in all phases with the
main apparatus as well as the pilot circuits (measuring and control
circuits). It shall show in full the functioning of part or all installations,
works or circuits with all required technical information. This shall show
all technical blocks control cubicle, cable details, cable tracks etc.
• Electrical wiring diagrams of hoist, hydraulic circuit, piping / cable lay out
drawings, performance curves, specifications and catalogue numbers of
all motor control centres, control panels, motors and accessories.
• Automatic or manual lubrication system, controls, control panels, motors

and accessories.
• All handling attachment for site assembly.
22
GTS
• Control & Indicators.
All drawings shall be carefully checked by Manufacturer for accuracy,

completeness and clarity before submission to Engineer in-charge.
Manufacturer shall be responsible for correctness and adequacy of the design
in relationship to the specifications.
Approval by Engineer in-charge for the contractor's design and drawings

shall not relieve the contractor for any part of the contractor's obligation
to meet all the requirements of the specifications or of the responsibility
for the correctness of the contractor's drawings and designs.
The Engineer in-charge shall have the right to ask the contractor to make any
change in the designs and drawings, which may be necessary in the opinion of
the Engineer in-charge to make the equipment conform to the provisions and
intent of those specifications without additional cost to the purchaser.
The requirements of any such alterations requested by Engineer-in-charge

shall not be construed to mean that the drawings have been checked in detail.
It shall not be accepted as justification for an extension of time and shall not
relieve Manufacturer from responsibility for the adequacy of the designs and
correctness of the drawing.
The Contractor shall carry out and be responsible for the design of works.
Design shall be prepared by qualified designers who are engineers or other
professionals and have experience and capability necessary for the design.
The contractor undertakes that the designers shall be available to attend
discussions with the Engineers at all reasonable times until the date of
relevant Defect notification period.
The Contractor shall prepare all Contractors’ Documents, and shall also
prepare any other documents necessary to instruct the Contractor’s
Personnel. The Employer’s Personnel shall have the right to inspect the
preparation of all these documents, wherever they are being prepared.
Any approval or consent, or any review shall not relieve the Contractor from
any obligation or responsibility therein contract.
3.3 Submissions
The documents/design computations/drawings required to be submitted to the

owner for approval or information are broadly listed hereunder: -
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GTS
Design
Tunnel Spillway Radial Gate and Hydraulic Hoist
Radial Gates
For approval For information
Design criteria, design calculations of radial Guide Roller Assembly, C.G.

gates including Trunnion assembly, Design & Calculation, model study reports,
arrangement for trunnion movement, Lifting Walkway/ hand railings/gratings
attachments, Connection details between etc.
various members (welded/bolted), Hydraulic
Cylinder Supporting Mechanism, Load Model study report.
bearing anchors/bolts, Joints/welds,
Anchorage system, Dogging arrangement &
Hoist capacity calculation, trunnion
movement device
Hydraulic Hoists
Design Criteria, Design of Cylinder, Stem, Cylinder heads end connections

Rod end clevis, Head end clevis/attachment, (fasteners), piston, threads and
Fully extended/fully collapsed length of connections among various mating
cylinder assembly, Kinematic details in form components, Details & specification
of line diagram/sketches/data of gate & hoist of sealing and bearing
establishing & describing working stroke, total components, position indicators,
stroke, reserve stroke on both ends. Details of all other components.
Power Pack
Selection of Pump, motor tank capacity, Selection of piping, filters, valves,

Selection of portable power pack powered by gauges, controls, pressure
Gasoline engine. switches & other components of
hydraulic & electric circuits.
Surface Spillway Radial Gate and Hydraulic Hoist
Design criteria, design calculations of radial Guide Roller Assembly, C.G.

gates including Trunnion assembly, Flap Calculation, Walkway/ hand
gate, Lifting attachments, Connection details railings/gratings etc.
between various members (welded/bolted),
Hydraulic Cylinder Supporting Mechanism,
Load bearing anchors/bolts, Joints/welds,
Anchorage system, Dogging arrangement &
Hoist capacity calculations.
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GTS
Hydraulic Hoists
Design Criteria, Design of Cylinder (Radial & Cylinder heads end connections
Flap gate), Stem, Rod end clevis, Head end (fasteners), piston, threads and
clevis/attachment, Fully extended/fully connections among various mating
collapsed length of cylinder assembly, components, Details & specification
Kinematic details in form of line of sealing and bearing
diagram/sketches/data of gate & hoist components, position indicators,
establishing & describing working stroke, total Details of all other components.
stroke, reserve stroke on both ends.
Power Pack/Potable Power Pack
Selection of Pump, motor tank capacity, Selection of piping, filters, valves,

Selection of portable power pack powered by gauges, controls, pressure
Gasoline engine. switches & other components of
hydraulic & electric circuits.
Intake Gates, Intake bulkhead gates, Tunnel Spillway bulkhead gate,

Surface Spillway stoplogs, Tail Race Gates
Design Criteria, Design of Gate with lifting Guide wheels, Bumper

attachments, Wheel Assembly / bearing block arrangement, model study
(on slide gates), Wheel Track/Bearing Track (For reports, other components.
slide gates), Connection details (weld/bolt),
Dogging device, Filling-in-valve, Hoist capacity
calculations.
Pressure Shaft Liner/ Tunnel spillway steelliners
Detail design of all Pressure Shaft A complete list of all technical data,
Liner/ Structural analysis/ FEM analysis/
software used etc.
Penstock, their specials (like Bends,
manholes, transitions, bifurcations
thrust collar etc) and liner thickness
including stiffeners, if any, and
respective welding details.
All details of equipment and materials required for design /fabrication and/or
assembly and drawings to be cross-referenced to all other documents
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Detailed design of all Tunnel Liner/ A complete list of all technical data,
their specials (like transitions etc) and liner Structural analysis/ FEM analysis/
thickness including stiffeners, if any, and software used etc.
All details of equipment and materials required for design /fabrication and/or
assembly and drawings to be cross-referenced to all other documents
Knife edge Valves
Selection of Knife edge gate valves. A complete list of all technical data.
Adit Gates
Design Criteria, Design of Gate with hinge Sub assembly, Other

supports, bushing details, bearing block, components.
Track/Bearing Track, Connection details
(weld/bolt).
Rope Drum Hoists/Gantry Crane/EOT Crane
Design Criteria, Design/ End carriage, Rails and attachments, Pulleys/ sheaves
Selection of Rope drum, & attachments, buffer/bumper, overload/slack rope
Reduction gearing, mechanism, limit switches, power supply arrangement,
Shafts, Wire rope and storm/parking clamps/anchors, Turn buckles, cabin,
attachments, Motors, Walkway, ladders, handrails, grating/ chequered
Brakes, Wheels, hoist plate/hatch covers, hydraulic actuators, hydraulic
Supporting structure/ control system other components, rope clamps,
Gantry frame structure. couplings, Plummer blocks.
Trash rack
For approval For review/Information
Bar, Horizontal Embedded frame, Guides, other details
members
Connections (weld/bolt)
Lifting beam
Design of Lifting beam. Probe mechanism, End guide

frames/arrangement
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Instrumentation and Remote Control System
System configuration, Specification of Specifications & characteristics of

components with installation instruction, components with manufacturer’s
Design criteria & logic, schematic diagram, catalogue/ literature, Instrument
Detailed write-up or description of working technical data sheet/catalogue,
methodology. detailed drawings of all
components, Application software
etc.
DG Set
Name of manufacturer Test certificates, Operating

characteristics, detailed
specifications, data/ parameters
supported with manufacturer’s
catalogue/ literature.
Oil Filter Unit
Name of manufacturer, Operating Data/ parameters supported with

characteristics, detailed specifications manufacturer’s catalogue /
literature.
Drawings
Radial Gates/ Flap Gates
1) General arrangement drawing of radial All types of sub-assembly drawings,

gates including details of trunnion assembly detailed drawings of all components
& hoisting equipment /Anchorage/ Flap including anchorage system, dogging
2) Block out & Ist & 2nd stage embedded arrangement etc.
parts details (Assembly drawings)
3) Detail of gate (Assembly drawings)
4) Details of Trunnion movement
arrangement.
5) Retractable/ Inflatable sealing
arrangement.
6) Post-tensioned anchorage etc.
Intake Gates, Intake bulkhead gates, Tunnel Spillway Bulkhead, surface

Spillway stoplogs, Tail Race gates
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GTS
1) General arrangement drawings of gates All types of sub-assembly drawings

including details of hoisting equipment including wheel assembly, filling-in-
2) Block out & 1st & 2nd stage embedded valve, dogging arrangement etc. &
parts details detailed drawings of all components.
3) Detail of gate
Lifting beam
General assembly drawing of lifting beam Probe mechanism, all types of sub-
assembly drawings, detailed
drawings of all components etc.
Trash rack
1. General arrangement drawing All types of sub-assembly drawings,

Detailed drawings of all components
2. 2nd stage embedded parts details and and general installation drawings.
general installation drawings.
Hydraulic hoist/Portable Power pack
General arrangement drawing, Cylinder Cable schedule, Hydraulic control

assembly, hydraulic and electrical circuit panel, Electrical control panel,
drawings, functional description Position indicator, hydraulic piping
arrangement, All other detailed
drawings
Rope Drum Hoists/Gantry Crane/EOT Crane
1) General arrangement with gate & hoist LT Drive Assembly, CT drive

(lifting & sitting position) with technical assembly, Drum Assembly, End gear
particulars assembly, central drive unit
assembly, Plummer blocks, Wheels,
2) General arrangement drawings of Rail/attachments, Shafts, Gears,
Hoist/LT/CT along with wheel bogie Couplings, Structural detailed
details drawings, All components drawings,
Structural sub-assembly drawings
3) G.A. drawings of structure along with etc.
connection details
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GTS
DG SET
Foundation drawings. Sub-Assembly drawings, Detailed

drawings.
Adit Gates
1. General arrangement drawing All types of sub-assembly drawings,

Detailed drawings of all components
2. Embedded parts details and general such as hinge members, piping and
installation drawings. valve arrangement for dewatering
purpose etc. complete and general
installation drawings.
Instrumentation System

Installation details, Panel details, Schematic Data/ parameters supported
piping layouts, Cable layouts, Instrument with manufacturer’s catalogue
catalogues. / literature
Knife edge gate valve
Name of manufacturer, selection of model, Data/ parameters supported with

Operating characteristics, detailed manufacturer’s catalogue /
specifications. literature, selection of piping,
transition piece, dismantling joints,
supports.
Pressure Shaft Liners / Tunnel spillway steel liners

General Arrangement Drawings showing A complete list of all drawings and
outline drawings to scale, showing relation technical data.
of the equipment components, materials,
and accessories. All detailed fabrication drawings.
Detail Drawings of all pressure shaft liner /
penstock, their specials and liner thickness
including stiffener dimensions, if any, and
All details of equipment and materials required for fabrication and/or

assembly and drawings to be cross-referenced to all other drawings
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GTS
Submission of Drawings/data for Pressure Shaft Liners /Tunnel Spillway

steel liner
The Contractor shall provide certain types of drawings and other technical
data to the Engineer for approval, such as the following to the extent
applicable:
(1) Drawing List: A complete list of all drawings and technical data.
(2) General Arrangement Drawings: Outline drawings to scale, showing

relation of the equipment components, materials, and accessories.
(3) Design calculations: Design calculations for penstock pipes,

specials, bifurcation, thrust collars, joints, manholes etc. for whole
of steel lined portion of penstocks.
(3) Detail Drawings: All penstock and liner thicknesses shall be clearly
defined, including stiffener dimensions, if any, and respective welding
details shall be shown. All details of equipment and materials required
for fabrication and/or assembly shall be clearly defined. These drawings
are to be cross-referenced to all other drawings.
(4) A QA/QC plan as per ASME Section VIII, Division 2, or equal, shall be
submitted. This plan shall also cover subcontract monitoring. The
QA/QC plan shall ensure weld trace-ability to the welder (such that code
stamping of welder identification on the weld will not be required, e.g.
through the use of a weld map) both for field and shop weld.
The plan shall address frequency and scope of fabrication, shop audits
and job site erection audits. Also the plan shall define the procedure to
be used to ensure that test coupon welding is representative of the
actual procedure being executed.
(5) Welding procedure specifications with procedure qualification records

shall be submitted. All other documents required by ASME Section IX
shall be available.
(6) Material certification shall be submitted to the Engineer with all test
results for approval. This also includes welding consumables and
miscellaneous materials.
(7) All deviations from the Specifications and/or Drawings shall be clearly
noted and submitted to the Engineer for approval.
(8) Liner Certificates
The Contractor shall provide a certificate with the following information for
each steel liner (penstock pipe) section:
- Identifying number of the plates used for the liner section.

- Heat number of the plates.
- Numbers of the appropriate acceptance certificates for the plates.
- Records and numbers of certificates relating to tests performed on
plates and on the completed liner section.
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- Theoretical weight of the complete liner section.

- Documentation for welder trace-ability, to welds.
- Measured dimensions including plate thickness, liners section length,
circumference, two perpendicular diameters, one of which is measured
through the longitudinal weld, ovality and out of roundness.
- Radiographs.
- Results of ultrasonic tests.
- Results of surface examination, (MT or PT).
- Thermal treatment.
- Results of water pressure tests.
- Special remarks.
- Number and dates of the relevant reports.
Each certificate shall show in sketch form the sequence of the welds, the
position of the radiographs and repair locations. A sample certificate (with
hypothetical entries) shall be submitted to the Engineer for review prior
to liner shipments.
3.4 Lists of Schedules
The following schedules are required to be furnished by the contractor after

the approval and commissioning of the equipment. These information are to
be appended with the operation and maintenance manuals.
3.4.1 Motor Lists
The motor lists shall be prepared and shall contain at least the following
information/data:
• Works identification number
• Description
• Manufacturer, type, rated data of driven machine
• Manufacturer and type of electric motor
• Rated capacity
• Service factor (ratio between motor output and power requirement of the
driven machine)
• Rated speed
• Rated voltage
• Rated current
• Ratio of starting current to rated current
• Ratio of pull-out torque to rated torque
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• Power factor at rated capacity
• Efficiency at rated capacity
• Power consumption at machine design loading
• Design/enclosure/cooling (acc. to IEC)
• Duty (continuous/intermittent/start-up)
• Starting method/permissible starting frequency
• Denomination of feeder
• Motor protection
• Applicable Standard Circuit Diagram (Category)
• Maximum number and overall diameter of power cable(s)
• Manufacturer and type of bearing(s)
• Manufacturer, type and quantity of lubricant, service interval
• Manufacturer, type, number, size, spring pressure and service interval

of brushes if applicable).
3.4.2 Motor Starter Lists
The motor starter lists shall include all starters, thyristors and contactors used
for motors and contain the following technical information as a minimum:
• Electrical design data as nominal and actual current rating, voltage

rating, coil rating, making and breaking capacity, mode of operation
• Power cable size
• Control cable size
• Current transformer ratio, class and capacity
• Type of protection relaying and catalogue number
• Setting of protection relays and maximum continuous rating of the

protected circuit
• Type and current rating of the back-up fuses/MCBs for the main and
control circuits
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GTS
• Type of thyristor, voltage, current and power rating
• Type of heat sink for thyristor
• Type of protection used for thyristor circuits
3.4.3 Cable Lists / Interconnection Lists
The Cable Lists shall include for each individual cable the following as a
minimum:
• Cable number, in accordance with Identification System.
• Cable type
• Rated voltage
• Number and size of conductors
• Overall diameter
• Cable termination at each end
• Connection point at each end with cubicle/Works identification and

terminal numbers
• Cable routing
Using interconnecting cubicles list shall be prepared to show:
• Cable termination for incoming and outgoing cables
• Interconnecting wiring
3.4.4 List of Measurements
• This list shall indicate all measurements, local as well as remote, and
shall contain at least:
• Item/code number, function code
• Description and denomination of measuring loop
• Data of tapping point
• Data of local devices (as detectors, instrument transformers,

transmitters)
• Data of remote devices.
3.4.5 Alarm Lists
These lists shall indicate all alarms and shall contain at least:
• Item/code number and function code
• Description and denomination of alarm
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GTS
• Data of alarm detector (contact) referring to applicable circuit diagram
• Data of alarm annunciator (location and clear text labelling)
3.4.6 List of Final Control Elements
This list shall indicate all control actuators and control valves and shall
contain at least:
• Item/code number
• Data of pipe and valve connections
• Data of valve layout
• Maximal required and rated power
3.4.7 Workshop Test Schedules
Individual Workshop Test Schedules shall be prepared for Works/installations

(such as gates, hoists, cranes, hydraulic hoists, switchgears, control gear,
cables) and shall contain at least:
• Manufacturer
• Place of manufacture
• Place of test
• Date of test
• Objective of test (all individual tests)
• Standards applied
• Certification
• Inspection (by Engineer / Independent Test Authority / Contractor/

Subcontractor)
• Release for shipment
• Remarks
On the above schedule or on separate sheets the Test Procedure shall be

specified giving for each test item (kind of test) a description, test method /
Standards, used instruments, sample/routine test, test judgement.
3.4.8 Site Test Schedules
Scope as in 3.4.7 above - as applicable.
3.4.9 List of Tools and Appliances
Lists of Tools and Appliances shall detail for all tools and appliances included
in the scope of supply:
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- Item and code number
- Description
- Quantity
- Weight
- Gross storage requirements (separate for open-air, indoor, air

conditioned) for individual component sets.
3.4.10 Spare Part Lists
Spare part lists shall detail for all parts included in the scope of supply:
• Item and code number
• Description
• Quantity
• Weight
• Gross storage requirements (separate for open-air, indoor, air

conditioned) for individual component sets.
3.4.11 List of Works Identification Numbers
This list shall contain the used Works identification numbers in alphanumeric
order and for each of them a description (the defined Works denomination, for
example as written on the Works label) and the location (short definition of
outdoor area and level elevation or building/room with elevation and room
number).
3.5 Installation and Commissioning Procedures
3.5.1 Installation Procedures
The installations procedures shall describe in sequential steps the erection of

major equipment and shall contain sufficient details such as equipment
preparation on erection bay, handling of large and heavy pieces, leveling,
anchoring, site welding, site painting, erection checks, site pressure tests, site
flushing and cleaning of hydraulic systems, alignment and run out checks to
allow the engineer to plan and supervise the Works at site. The contractor
may submit his proposals for such installation but shall have to obtain the
approval of the owner before acting. Detailed instruction to the installation of
the gates shall be given by the purchaser or his authorized representatives at
site and shall be binding on the contractor.
3.5.2 Commissioning Procedures
The commissioning procedures shall sequentially and in sufficient detail

describe activities and tests for all systems covered by the Contract
Document.
3.6 Operation and Maintenance Manuals
The operation and maintenance manual shall be prepared and provided by the
contractor and shall contain following information in sufficient detail to enable
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GTS
the employer to maintain dismantle, reassemble, adjust and operate the works
with all its works and installation.
The manuals shall include a separate and complete section describing the
following:
• Description of works &equipment.
• Operating principle & characteristics.
• Operating instruction. (For normal & emergency operation.)
• Testing & adjustments.
• Maintenance instructions.
• As built drawings.
• Catalogue of bought-out items
• Spare parts.
The manuals shall describe and illustrate the procedure for assembling,
adjusting, operating and dismantling of each component and control system.
The maintenance of each component shall be described, including the
recommended frequency of inspection and lubrication.
Three (3) copies of the manuals shall be submitted in English in draft for
approval of Engineer- in-charge within 3 months after the final approval of the
equipment. Ten (10) suitably bound copies shall be provided to
Engineer-in-charge along with soft copies on good quality compact disc (two
sets) suitable for editing and printing of the text & drawings not later than 30
days after receipt of approval.
If revision of the manuals becomes necessary, as a result of information gained

during installation and initial operation, Manufacturer shall make the necessary
revisions and furnish ten (10) copies of the revised section sheets with the
revision symbols along with the floppy of the same.
The manuals shall include a complete list of all drawings prepared by

Manufacturer, a list of spare parts and a list of parts for each component or item
of equipment. The parts list shall include manufacturer's name and serial
numbers. The manual shall include data, literature and catalogues of bought
out items.
Manufacturer shall ensure that his installation supervisor has a copy of all
approved drawings and the manuals in his site office.
3.7 Progress Reports
3.7.1 Progress Reports during Design and Manufacturing
The Contractor shall monthly submit four (4) copies of the progress reports in
a format acceptable to the Engineer, detailing the progress of the work during
the preceding period. The report shall contain (but not be limited to) the
following information:
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GTS
• A general description of the Works performed during the reporting

period on each main activity.
• Overall percentages of the works completed, with reference to the CPM

programme.
• The percentages of each main work activity completed during the

reported month with reference versus the scheduled programme.
• A list of activities scheduled to be started within the next period of three

(3) months, with expected starting and completion dates. Any notable
problems, differences, comments with reference to the schedule may be
supported with appropriate documents.
3.7.2 Progress Reports during Installation at Site
During erection the Contractor shall, before the tenth (10th) day of each
calendar month, submit four (4) copies of the monthly progress reports in a
format acceptable to the Engineer, detailing the progress of the work during
the preceding month. The report shall contain but are not be limited to the
following information:
• A general description of the Works performed during the reporting

period on each main activity.
• The total overall percentages of erection works completed, with

reference to the CPM program.
• The percentages of each main work activity completed during the

reported month with reference versus the scheduled program.
• A list of all activities of scheduled and actual progress during the

reporting period including actual starting dates versus scheduled
starting dates and actual completion dates versus scheduled completion
dates for each activity.
• A list of activities scheduled to be started within the next period of two

(2) months, with expected starting and completion dates. If the
expected starting and/or completion dates are different from those
shown on the CPM program, an explanation shall be given.
• Contractor shall also briefly report the manpower strength and

expatriate personnel employed, equipment etc. deployed during the
reporting period.
• A statement concerning potential problems and recommendations on

how they could be resolved.
4 Spare Parts and Tools
4.1 Spare Parts
All spare parts to be supplied shall be interchangeable with the corresponding

parts of all the Works supplied under these Specifications and shall be of the
same material and workmanship. They shall be replaceable without cutting or
destruction of adjacent components. Before issue of the Taking-Over
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GTS
Certificate the spare parts shall be checked and tested at the Site by the
Contractor in presence of the Engineer.
Acceptance of any spare parts will not take place before the Contractor has
submitted the complete final detailed list of all spare parts and tools.
All spare parts shall be protected against corrosion and shall be marked with
identification labels in the Ruling Language. The identification shall be in
accordance with the agreed Works Identification System.
All spare parts, tools and materials shall be delivered in marked boxes of
sufficient sturdy construction to withstand long term storage.
4.1.1 Mandatory Spare Parts
The required Mandatory spare parts are listed separately in the Particular
Technical Specifications. The price for each listed special spare part shall be
quoted individually in the Price List; the total price shall be included in the
Total Tender Price.
4.1.2 Recommended Spare Parts
If any additional spare parts are recommended by the tenderer, these shall be
stated in quantity and description in the Technical Data Sheets for each item.
The prices for that may be indicated in separate price schedule. This may not
be treated as the part of tender price schedule.
Orders for recommended spare parts shall be optional to the Employer

for a period up to three years after the date of contract award.
4.2 Tools and Tackles
The scope of work shall include all special tools, as well as all special devices
including lifting devices, ropes, etc. necessary for total assembly and
disassembly of all parts of the supplied Works.
4.2.1 Mandatory Tools and Tackles
Tools and tackles required for maintenance of the specified equipment shall
be quoted individually in the price list. The total price shall be included in the
total tender price.
4.2.2 Recommended Tools and Tackles
If any additional tools and tackles are recommended by the tenderer, these
shall be stated in the quantity and description in the Technical data Sheets for
each item.
Orders for recommended tools and tackles shall be optional to Employer, for
a period of three years after the date of Contract award.
5 Design and manufacture
5.1 Design and Construction Requirements
The following directions, information and technical requirements for layout,

design and erection shall be observed as far as they are applicable to the
Works to be offered. The technical requirements of the General Technical
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GTS
Specifications are valid for all parts of the Works except where they are varied
by additional and/or special requirements, specified in the Particular
Technical Specifications.
Conceptual design of the submerged radial gate shall be got executed

by the reputed designer/ consultant who are having experience of
designing radial gates having A X H ≥ 2600 & head ≥ 60m.
Whenever a Tenderer deviates from these Specifications, he shall furnish the

data called for in the Technical Data Schedules and give a summary of and
the reasons for all deviations in the "List of Technical Deviations from
Specifications". Failure to accomplish this may cause the elimination of his
Tender, especially when a major deviation is involved. Any changes of the
design of any part of the Works, which may become necessary after signing
the Contract have to be submitted in writing to the Engineer for approval,
being sufficiently substantiated and justified.
Change in cost can only be accepted in case of change in basic design

by the Engineer after award of Contract.
The Works shall be designed, manufactured, arranged and installed to

provide functional design and neat appearance. All parts of the Works shall
be arranged to facilitate surveillance, maintenance and operation. All control
sequences shall be simple and rational.
The parts of the Works shall be designed and arranged so that they can be
easily inspected, cleaned, erected and dismantled without involving large
scale dismantling of other parts of the Works. They shall be designed, and
manufactured in accordance with the latest recognised rules of workmanship
and modern engineering practice.
The regulations, standards and guidelines listed in these Specifications shall

be observed in the design, calculation and manufacture of the Works.
All parts of the Works shall be suitable in every respect for continuous
operation at maximum output under the climatic conditions and operating
conditions prevailing at the Site.
Special attention shall be given to Works, parts of which are delivered by

different manufacturers. Problems arising in this conjunction shall be solved
by the Contractor and be defined in writing.
For individual items of the Works, materials and design are to be selected
which are best suited for the operating conditions to which the parts in
question will be subjected. Only such design and types of Works shall be
offered which has confirmed its reliability in long-term continuous operation.
Innovations cannot be accepted for the main Tender but can be offered as an
alternative proposal.
All live, moving and rotating parts shall be adequately secured in order to
avoid danger to the operating staff. All electrical components shall be earthed
as per the latest practice.
Manufacturers shall take appropriate measure to prevent the ingress of dust

into any Works (such as bearings, relays, control and measuring equipment
etc.), which may be endangered thereby.
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GTS
Suitable lifting eyes and backing-out bolts shall be provided where required or
where they will be useful for erection and dismantling.
Pockets and depressions likely to hold water shall be avoided, and if not
avoidable they shall be properly drained. Parts of the Works principally
intended for standby purposes shall be protected from corrosion by careful
choice of material and if necessary, by additional means these should not
reduce their continuous standby readiness.
All design details and layout matters shall be discussed in periodic meetings
with the Engineer. The first design meeting between the Contractor and the
Engineer shall take place within 28 days after the Date of Commencement.
Further design meetings shall take place as agreed between the participants
until the design work is completed.
Lettering of the drawing shall be at least 3 mm high in block capitals. The

sizes of Manufacturers drawings shall conform to International Organisation
for Standardization (ISO) sizes. All drawings shall bear the mutually agreed
title block, and drawing number as per the coding and pattern available with
the employer. All drawings shall be drawn in accordance with Indian
Standards, to scale, and shall be legible. Wording on drawings shall be in
English. Symbols shall be in accordance with Indian Standards.
Manufacturer shall submit to the Engineer-in-Charge 4 prints each of all
documents / drawings for approval/ information. If revisions are required
after a drawing has been submitted, manufacturer shall resubmit 4 additional
prints for approval after incorporating the comments. Fabrication shall not
commence until Engineer-in-charge has approved drawings and thereafter no
change shall be made on any drawing without the approval of the
Engineer-in-charge.
After designs and drawings are completed and approved, the manufacturer
shall supply 4 prints of all the design and 8 prints of drawings. However,
prior to completion of contract manufacturer shall supply 6 prints of all
approved “As Built Drawings” plus soft copy on good quality compact
disc (two sets) suitable for editing and printing along with 2(two) good
quality polyester film transparencies suitable for micro filming.
Drawings shall be submitted to Engineer-in-charges for approval 45 days

prior to the date on which they will be required to ensure that the work is
carried out in compliance with approved schedule of work.
5.2 Design Criteria
The Works shall be designed for the worst possible combination of the
following loading conditions:
• All static and dynamic hydraulic loads,
• All loads due to dead weight and frictional forces,
• Seismic or wind loads, and
• Other loads
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GTS
The full reservoir level, maximum water level, sill elevation and design criteria
are described in particular specification required for the design.
The basic wind load of 600 N/m.sq. shall be applied on the vertical
projected area of exposed equipment, multiplied by the form factors for
the different type of structures in accordance with IS:875.
The wind load for the stability check of gantry crane, etc. shall be 600
N/m sq. while operating and 1500 N/m sq. when out of service.
Other Loads
Load on the foot path, balcony floor, platform/ groove cover: 5000N/m2.
Vertical load on steel roof structures : 2500N/m2.
Vertical load on each part of ladder : 1800N/m2 or a

concentrated load of
1500N.
COMBINATION OF LOADS
1. Normal Load Case- considers the most unfavorable values and

combinations of the hydrostatic loads at normal water levels (including the
influence of waves), hydrodynamic effects, friction forces, dead weight,
buoyancy, transit loads, normal operating wind and driving forces.
2. Occasional load case- considers the loads which occur less frequently,
such as:
a. Hydrostatic and hydrodynamic forces at unusual water levels (MWL).
b. Wind loads
c. Temperature effects
3. Exceptional Load case- considers loads occurring during transportation,

erection, maintenance services or other exceptional cases, as well as the
following:
a. Jamming of the gate or damage to bearings.
b. Seismic effects
The simultaneous occurrence of these loads and their combinations

with each other and with those of the preceding item should only be
considered when possible and probable.
5.3 Tolerance and Clearance
The following design clearance shall be submitted to the Engineer In-charge for
approval: -
• Clearance between end of main Roller housing (side of gate) and gate
guide.
• Clearance between moving gate components with respect to face of

concrete/steel lined grooves.
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GTS
5.3.1 General clearances
• Side guide to guide track :6 mm in any

direction.
• Pre-compression of side and top seals : 3 & 5 mm
• Pre-compression of bottom wedge type seal : 5 mm

• Minimum clearance between gate/bulkhead
Bottom face to dogging or deck (whichever is higher) : 500 mm
• Minimum clearance from extreme top

Part of gate /bulkhead to crane/hoist : 300 mm
• Minimum recess from concrete face to

Extreme part of gate / bulkhead : 100 mm.
5.3.2 Fabrication Tolerances
All components shall be fabricated in accordance with IS: 4622, IS: 4623, IS:
5620 & IS: 9349 except as noted below: -
• All dimensions under 400 mm shall be ±0.8 mm unless otherwise

specified and are non cumulative. All other dimensions shall be ±1.5 mm.
• The machined sealing surface of the sill and lintel beams and side guides
shall be straight within 0.5 mm and level within 1.0mm over the whole
length with a straight edge.
• The roller path below the lintel shall be straight within 0.4 mm in any 3 m
length and within 0.8 mm over the whole length and shall not deviate from
a vertical line in any direction by more than 1.0 mm. Roller path faces for
the same gate shall be in the same plane within 1.0 mm
• The roller path above the lintel shall not deviate from a vertical line in
any direction by more than 2 mm and shall be straight within 2 mm over
the full length.
• The side roller paths shall be straight within 1.0mm in any 3 m length
and within 2mm over the full length. The side roller path shall not
deviate from a vertical line in any direction by more than 2mm
• The distance between the side roller paths and the main roller paths
shall not vary by more than 3mm.
• Radial run out of assembled roller shall not exceed 0.025mm of total
indicator reading measured at the roller tread.
• The bearing surface of roller treads on an assembled gate section shall

be straight within 0.1mm over the full height of the section. The roller
axis shall be parallel to the machined top and side seal bases of the
gate within 15 minutes.
• Wheel treads, seal bases (top and side), bearing faces and seal faces
(side and top) on an assembled gate should be in a true plane.
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GTS
• For pressure shaft liners all components shall be fabricated in accordance

with tolerances specified under Cl.no.5.11.1.4
5.3.3 Installation Tolerances
Installation tolerances shall not exceed 1.5 times the corresponding

fabrication tolerance or the tolerances specified in the relevant IS codes
whichever is the more stringent. Design and fabrication of the gates, hoist
and embedded parts shall be suitable for the achievement of such tolerances
during installation.
5.4 Standardisation of Works
Every effort shall be made to standardise parts and minimise costs

throughout the Works in order to facilitate replacement, interchangeability,
keeping stocks, maintenance etc.
The Engineer-in-Charge, therefore, reserves the right to request the different

Contractors to use uniform types or makes of Works and materials. The
Contractor shall not be entitled to claim extra payment due to this request.
This request shall especially be applicable to small mechanical and electrical
Works such as:
• Seals
• Fasteners
• Oils and lubricants
• Valves
• Thermometers
• Pressure gauges
• Flow meters
• Water level gauges
• Terminals and terminal racks
• Indicating instruments and meters
• Auxiliary relays
• Contactors, fuses
• Motor protection switches
• Control devices
• Lights, bulbs, plugs, sockets
The types or makes to be used shall be decided later by the Engineer-in-

Charge.
All instrument scales shall be written in the Ruling Language of the Contract.
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GTS
5.5 Material and Workmanship
For general requirements concerning the quality of materials and Works refer
to the General Conditions of contract.
All materials shall comply with the latest IS standards, or other Standards
specified unless otherwise specified. All drawings and /or material lists shall
show IS Standard. The materials and workmanship throughout shall be the
best of their respective kind and free from defects. The design of all equipment
shall be such that installation, replacements and general maintenance may be
undertaken with the minimum of time and expense. All fitted joints shall be
machined and castings shall be spot faced for nuts. All components shall be
built in accordance with approved drawings only. No patching plugging or other
such means of overcoming defects, discrepancies or errors shall be done
without written permission of Engineer-in-charge.
No welding, burning, filling or plugging of defective castings or any other

components shall be permitted without the Engineer's agreement in writing.
Where stainless steel cladding consists of plates welded to mild steel

sections, the welds shall be adequate to ensure that the stainless steel is
securely fixed for all conditions of load and wear. Generally, all stainless steel
parts shall be welded with stainless electrodes. The thickness of the stainless
steel cladding shall not be less than 3 mm. However, for gate leaf of
submerged radial gate, stainless steel cladding shall be done by mill rolling.
Similar parts shall be made to gauge where possible, to ensure that such parts
are interchangeable one with the other.
The Contractor shall be responsible for the accurate manufacture and

fabrication of equipment in accordance with the best modern practice in the
manufacture and fabrication of materials of the types covered by these
specifications not withstanding the minor errors or omission there from.
Dimensions shown on the drawings shall be adhered to closely and the work
shall in all cases be of high grade and carefully performed to the satisfaction of
the Engineer-in-Charge. The contractor shall warrant all materials and
workmanship furnished by him to be free from injurious defects. He shall
replace free of cost any defective materials or workmanship discovered during
erection or in guarantee period and shall pay the actual cost of the correction
on the field of any errors for which he is responsible.
The Contractor shall supervise the leveling and adjustment of all parts of the
equipment on the foundations and after each item is set up and the
Engineer's approval obtained, grouting or concreting will be carried out by the
civil works contractor's and verified by the Contractor. The Contractor shall be
responsible for ensuring that such work is carried out to his satisfaction and
that levels and adjustments made by him are not disturbed by the grouting
operation. The Contractor shall be responsible for ensuring that the positions,
levels and dimensions of the Works are correct according to the drawings
notwithstanding that he may have been assisted by the Engineer in setting
out the said position, levels and dimensions.
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GTS
5.6 Works Identification System
An approved, uniform Works identification system shall be applied for all

mechanical, electrical and Instrumentation and Control (I&C) Works to be
agreed upon during detailed design.
5.7 Identification Plates
5.7.1 General
Each important part to be delivered under this Contract shall be equipped with
permanent identification plates in readily visible locations. Whether a part
shall be considered as important in this respect shall be decided by the
Engineer.
The identification plates shall be protected during erection and especially

during painting. Damaged or illegible identification plates shall be replaced by
new ones. The identification plates of non-corroding, non-disintegrating
material (except manufacturer's nameplates of small standardized
components) shall be inscribed in the Contractual language.
The inscription shall be printed, stenciled, or handwritten, but in any case

water-proof, oil-proof and wear-resistant. Works (machines, transformers etc.)
nameplates shall be either of the enameled type or be of stainless steel
covered after stamping with a transparent paint. Wording, size and material
of all labels and plates shall be subject to the Engineer's approval.
5.7.2 Manufacturer's Nameplates
All equipment shall be provided by a securely fastened name plate showing the
maker's name, model, serial numbers, year of manufacture, main
characteristics data of the respective equipment and further relevant
information specified in the applicable standards or necessary for the proper
identification of the equipment involved.
5.7.3 Instruction Plates
All plates showing designations or instructions for operation, safety,

lubrication, etc., shall have a uniform design. Instruction plates, sequence
diagrams or instruction to operating staff shall be displayed on the inside of
the front door of the control panel/switch board. All works inside cubicles,
panels, boxes etc. shall be properly labelled with their item numbers. This
number shall be the same as indicated in the wiring diagrams works lists,
operation and maintenance manual.
All instruction plates displayed on the sub-assemblies like servomotors,

power pack hoist etc. shall show operational parameters, safety, lubrication
etc. which shall have a uniform format.
5.7.4 Warning Plates
Warning labels for safety of equipment as well as operating staff shall be

provided and shall be of synthetic resin with letters engraved in the contract
language.
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GTS
5.8 Fabrication
5.8.1 Gates and Stop logs
The gates shall be of welded steel construction with dimensions as shown in

drawings. All parts of the gate shall be fabricated in strict accordance with the
Standards as per specification. Special care shall be taken in fabrication of
parts affecting the strength, rigidity or water tightness of the gates. Caulking of
rolled edge plates will not be permitted. All pockets or depressions shall be
provided with drain holes to prevent collection of water.
The structural members of gates shall be securely connected by welding or by

fit bolts. Highly important joints and connections which will be heavily stressed
under load shall be made without flaw. These joints shall include the
connection between horizontal girders and end girder box, splicing joints in
gates and stoplogs. For welding of such connection, only the approved
qualified welders shall be assigned. The splicing arrangement shall be
designed to allow flexibility in the gate assembly to facilitate installation. The
lengths of the members shall be so selected to keep splice joints to a
minimum subject to transportation limitations. All splices shall be designed
with watertight sealing arrangement. The welding procedure for the gate body
shall be planned to control and minimize distortion. All welded connections
shall be ensured flawless welding.
Care shall be taken that the side seals of gate bear evenly and with uniform
pressure throughout their length on the side seal seats embedded in the faces
of the piers and that the bottom seals bear evenly on the bottom seal seat (sill)
embedded in crest. The roller axle supports and lifting connection shall be
accurately line bored so that the axis of all such holes be perpendicular to the
vertical centre line of the gate and shall lie in a common plane which shall be
parallel to the finished surface for the seal bases. The wheel pins shall be
finished to required surface finish. The sealing faces for the vertical seals,
bearing bars and lintel seal shall be finished to required surface finish. The bolt
holes for guide rollers shall be accurately bored only after the gate has been
completely field assembled and position of guide rollers located in stop logs /
gates.
The structural members of radial gates shall be securely connected by welding

or by fit bolts. Highly important joints and connections which will be heavily
stressed under load shall be made without flaw. These joints shall include the
connection between thrust block, rest beam and trunnion pedestal (Bracket),
trunnion bearing hub and end arms, and arms and the horizontal girders and
vertical stiffeners, splicing joints or welding of such connections, only the
approved qualified welders shall be assigned.
Trunnion bearing hub prior to matching of casting shall be stress relieved if

welded.
5.8.2 Embedded Parts

All structures, parts of the gate frames anchorages shall be straight and free
from twist. The bottom sill beam, seal seats etc., shall be fabricated as steel
plates, structural sections and shall be provided with suitable anchorage for
rigid connection to the crest and the piers.
Both faces of the track base flanges carrying the track shall be truly
perpendicular to the web. The flange face shall be finished to provide a truly
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GTS
plane surface for the track. The faces of the seal seats shall be finished so as
to lie in one plane within permitted tolerances. The crowns of the track shall lie
in a true vertical plane. The splice length for embedded parts such as seal
seats, track paths, guides etc. shall generally not be less than 6.0m.
All structures, parts of the gate frames shall be straight and free from twist.
Trunnion pedestal shall be stress relieved. The rest beam supporting the
trunnion bearings shall be securely fastened to anchor bolts embedded in the
piers. All the connections in the trunnion pedestal are heavily stressed under
load and special precaution should therefore be taken to ensure that such joints
are without flaw. The bottom sill beam, wall plates, liners etc. shall be fabricated
of steel plates/ structural sections and shall be provided with suitable
anchorages for rigid connection to the spillway crest, breast wall and the piers.
5.8.3 Fabrication of steel works
Roundings, Chamfers and Edges: The edges of surfaces to be painted

shall be rounded (minimum radius 2 mm) or chamfered accordingly. This
requirement must be stated in all shop drawings for the relevant parts.
Structural steel: Work shall conform to the requirement hereinafter specified,

unless otherwise called for in these specifications or on the drawings. Finished
members shall be free from twists, bends and open joints. Compression joints
shall have surfaces truly faced so as to have full contact bearing when aligned
and welded or bolted.
Straightening of materials: Before being laid off or worked, rolled material

shall be straightened and shall be cleaned of all rust and dirt. If straightening is
necessary, it shall be done by methods that will not be cause for rejection of the
material.
Shearing and cutting: Shearing and cutting by torch shall be performed

carefully and in all work which will be exposed to view after completing shall be
finished neatly. Sheared or cut edges of plates more than 16mm thick, which
carry computed stresses shall be planed to a depth of 6mm. Re-entrant cuts
shall be filleted before cutting.
Holes: Holes in structural steel members carrying calculated stresses shall be

sub-punched to 3mm less than the nominal diameter and reamed to full size or
drilled after assembly. All other members may be punched to full size. Main
members shall be assembled in the shop prior to reaming or drilling holes for
field connection.
Accuracy of punched holes: Holes shall be punched so accurately that after

assembling the component parts of a member, a cylindrical pin 3mm smaller in
diameter than the nominal diameter of the punched hole may be entered
perpendicular to the face of the member, without drifting in not less than 75 per
cent of any group of continuous holes in the same plane. All holes shall punch
a pin 5 mm smaller in diameter than the nominal diameter of the holes.
Reaming: Reamed holes shall be cylindrical, perpendicular to the member,

and not less than 1.5 mm nor more than 2.5 mm than the nominal diameter of
the bolts. Built up members shall be assembled and firmly bolted together
before any reaming is done. Reamed parts shall not be interchanged. Burrs
and savings from reaming shall be removed and, if necessary, reamed pieces
shall be taken apart before being joined and the shavings removed.
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GTS
Drilling: Drilled holes shall be cylindrical perpendicular to the member and

1.5mm larger than the nominal diameter of the rivet/bolt.
Accuracy of reamed and drilled holes: Holes shall be drilled and reamed so
accurately after assembly that not less than 85 per cent of any group of
continuous holes in the same plane shall show no off-set greater than 0.8mm
between adjacent thickness of metal.
Removal of burrs: Burrs resulting from reaming or drilling shall be removed

with a tool making a 1.5mm level.
5.8.4 Fabrication of Pressure shaft Steel Liner/ Tunnel Spillway liners
The fabrication of the steel liners for pressure shaft shall be in accordance with
the specification, drawing and the corresponding approved design and
fabrication drawings and latest version of Indian Standard for unfired pressure
vessels (IS: 2825) or the equivalent standards specified under this Chapter. In
case of any difference between the above the specification shall govern.
5.8.4.1 Preparation of Pipe Course

Each course of pipe shall be made with the minimum number of plates
depending upon the availability of plate sizes or as directed by the Engineer -
in-charge.
The longitudinal welds in case of three plates located approximately 120

degree from the horizontal centerline of the pressure shaft shall be staggered.
When two plates of almost equal lengths are made available, the longitudinal
joints shall be located at quarter points and staggered between sections.
When two plates of equal lengths are not made available or when the course is
made of a single plate, the longitudinal joints/joint shall be placed approximately
at 90 degree from the vertical centerline of the pipe and shall be staggered in
adjoining course. The longitudinal welds shall be located so that they will not
intersect the nozzles, manholes, or other outlets. The normal lengths of each
course shall be limited to plate width available. When three plates are used,
the displacement angle of the joint from the vertical centerline may be
approximately 45 degree.
5.8.4.2 Cutting the Plates
Plates to be welded shall be cut to size and shaped by machining and/or flame
cutting. Where the plate thickness does not exceed 25mm, cold shearing may
be used provided that the sheared edge is cut back by machining or chipping
for a distance one quarter of the plate thickness but in no case less than 3mm.
5.8.4.3 Preparation of Plate Edges and Openings
Welding preparations and openings of the required shapes may be formed by

the following methods: -
a) Machining/chipping or grindings: chipped surfaces, which are not covered

with weld material, shall be ground smooth after chipping.
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GTS
b) Plate cutting may include plasma arc, oxy-acetylene gas with or without flux
injection or equivalent fusion cutting process. Any material damaged in the
process of cutting plates to size or forming welding grooves shall be
removed by machining, grinding or chipping back to sound metal. Surfaces
which have been flamecut shall be cut back by machine grinding so as to
remove all burnt metal, notches, slag and scale but slight discoloration of
machine flame cut edges on mild steel shall not be regarded as detrimental.
After the edges of the plates have been prepared for welding they shall be
given a thorough visual examination for flaws, cracks, laminations, slag
inclusion or other defects. When plates are flame cut, the edges should be
examined after this operation. Edges which have been flame cut by hand
shall be cut back by machining or chipping for a distance of one quarter of
plate thickness but in no case less than 3mm.
Rust, scale, painting, oil slag etc. from the flame cutting or other
contamination of the fusion pieces shall be removed before welding is
commenced. The surfaces to be welded shall be free from foreign material
such as grease, oil or marking paint for a distance of at least 25mm from the
welding edges. Irregularities in fusion faces, which are likely to affect the
quality of welding, shall be removed before welding is commenced. All plate
edges after cutting and before carrying out further work upon them shall be
examined for lamination and also to make certain that marks have not been
caused by shearing. Plates for shell sections shall be formed to required
shape by a process that does not impair the quality of the material. However,
correction of curvature by blows will not be permitted. Cold-formed plates
material shall not be subjected to a deformation of more than five percent,
unless suitable heat treatment is carried out after such forming. Heat
treatment shall, however, be carried out even when the deformation is less
than 5 per cent if there is pronounced risk of brittleness through aging. The
deformation expressed as a percentage is obtained from the formula:
Deformation = t x 100
D
Where t = thickness of plate
D= internal diameter to which the plate is being bent or formed.
Cold forming shall not be undertaken when the temperature of the metal is
less than 0°C. If the forming or bending operation takes place in hot
condition, no subsequent heat treatment is required, if the final shaping
process terminates within the correct temperature limits for the particular
material.
Plates of unequal thickness
Where two plates at a welded joint differ in thickness the thicker plates shall be
trimmed to a smooth taper as per para 6.3.5 IS 2825 -1969.
5.8.4.4 Stiffener Rings
Stiffener rings shall be fabricated in not more than ten circumferential sections
butt welded together and properly fitted and welded to the pipes, so that the
plane of rings will be normal to the axis of the pipe.
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GTS
5.8.4.5 Bends and Reducers
Bends and reducers shall be made of short segment of pipe with mitered ends.
Deflection angle between each successive segments shall not be more than
100. The segments shall be made with equal deflection angles except for the
end ones, which shall be of smaller deflection angles than the other segments.
The number of segment along with stiffener rings shall be adequate to take
care of the loads.
5.8.4.6 Unit and Match Marking
Each part of the pressure shaft liner section, curvature of the shell or surface to
which they are attached or its auxiliary parts shall be legibly marked to show
the unit of which it is a part and match marked to show its relative position in
the finished structure to facilitate assembly in the field. To ensure proper
matching of sections at the joints, expanding struts spiders may be used. Each
section shall be marked struts to show top of vertical diameter and the direction
of the flow. Unit marks and match marks shall be made with heavy stamps and
with paints. The contractor shall prepare marking drawings of each Pressure
shaft liner indicating clearly the location of each section and appurtenant parts
in the completed structure and shall furnish to the Corporation such drawings.
If Pressure shaft liner ferrules are transported for a long distance necessary
precaution shall be taken to provide bracing /spider to prevent deformation.
5.9 Surface Finish
5.9.1 Finished Surfaces
Where the finish is not indicated or specified, the type of finish shall be that
type which is most suitable for the surface to which it applies and shall be
consistent with the class of fit required.
Surface finish shall be indicated on the shop drawings by symbols.

Compliance with the specified surface shall be determined by the sense of
feel and by visual inspection of the work compared to applicable "Standard
Roughness Specimens", or with roughness filler gauge instruments. Both
"Standard Roughness Specimens" and filler gauge instrument shall be
provided by the Contractor at the request of the Engineer.
5.9.2 Unfinished Surfaces
As far as practicable, all work shall be laid out to secure proper matching of
adjoining unfinished surfaces. Where there is a large discrepancy between
adjoining unfinished surfaces, they shall be chipped and ground smooth, or
machined to secure proper alignment.
Unfinished surfaces shall be true to the lines and dimensions shown on the
drawings and shall be chipped or ground free of all projections and rough
spots. Depressions or holes not affecting the strength or usefulness of the
parts shall be filled in a manner approved by the Engineer.
5.9.3 Protection of Finished Surfaces
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GTS
Finished surfaces shall be thoroughly cleaned of foreign matter. Finished

surfaces of large parts and other surfaces shall be protected with wooden
pads or other suitable means. Unassembled pins or bolts shall be oiled or
greased and wrapped with moisture-resistant paper or protected by other
approved means.
5.10 Fasteners
Bolts, Studs, Nuts and Screws : They shall have standard threads and be of
high quality steel. All standard size bolts, studs, nuts and screws (including
their washers) shall be heavily protected against corrosion or made of stainless
steel if so specified in the technical Specifications. Nuts and bolts heads shall
be hexagonal in shape & truly faced. Nuts & bolts and screws, which might
become loose during operation shall be locked in fastened position by means
approved by the Engineer-in-charge.
All bolts shall have unified threads. Bolts in tension shall have a net section at
root of thread, 15 percent in excess of the net section required in tension.
Field Jointing: All fasteners for field joint shall be supplied 5 per cent in excess
of actual requirements. This should be indicated in the drawings/bill of material.
5.11 Welding
Members to be joined by welding shall be cut accurately to size, and where

required, shall be rolled or pressed to proper curvature in accordance with the
approved drawings. The dimensions and shape of edges to be joined shall be
such as to allow thorough fusion and complete penetration and plates shall be
planed if necessary, to accomplish this result. Members to be welded together
shall be in sufficient intimate contact at the time of welding so that members will
not be forced more closely together with the cooling of the weld, thus setting up
additional strains and distortions in the weld and parent metal.
The cut surface shall be free from all visible defects such as lamination, surface
defects caused due to shearing or cutting or flame cutting operations. The
surfaces of plates to be welded shall be free from dust, grease and scale for a
distance of 12mm from the welding edge at the time of welding. Flame cutting
may be used in the preparation of the various members provided the operation
is performed carefully and the edge so cut are cleaned thoroughly after being
cut so as to expose clean metal. Any contour irregularities at points of critical
stress shall be removed by grinding.
All welding shall be carried out using a suitable welding

sequence/procedures approved by the Engineer and in such a way that
harmful effects of welding are avoided.
When the welding process has been approved by the Engineer, the contractor
shall produce a record drawing to show the approved process. The drawing
shall include details such as the form of edges to be welded, electrodes and
other welding materials, welding sequence etc. Changes in the welding process
after the welding method has been approved shall require the consent of the
Engineer.
Additional copies of all records of all welding procedures, including preheating

and stress relieving, chemical analysis and physical properties, shall be made
available to the Engineer-in-Charge upon request.
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GTS
Unless otherwise allowed by the Engineer all welded parts to be welded shall
be manufactured of steel produced by open-hearth or electric furnace with
carbon content not more than 0.20 % and a Phosphorous content not more
than 0.05%.
A welding process approved by the Engineer generally in accordance with the

standards specified in the Technical Specification shall be followed. Approval of
the welding procedure shall not relieve the Contractor of his responsibility for
correct welding and correct selection of electrodes and minimising of defects in
the finished structure.
All welding shall be done by the electric arc method or by a process, which will
exclude the atmosphere from the molten metal, except where otherwise
specifically permitted. The welding electrodes shall be heavily coated type
designed for all position welding. In assembling and during welding, the
component parts of built up members shall be held in place by sufficient
number of clamps or other adequate means to keep all parts in proper position.
The Contractor shall follow the steel manufacturers instructions/

recommendations concerning electrodes and other materials and post &
preheat treatment. Notwithstanding the above, the suitability of electrodes to be
used for welding for both shop and field welding shall be demonstrated by trials
to the satisfaction of the Engineer-in-Charge.
The strength of welding of all equipment subject to high and/ or alternating

stresses, vibrations etc. shall be at least equal to the strength of the parts being
welded. Between plates and other sections where such stresses are to be
transmitted only butt welds shall be permitted. At welded butt joints, where the
weld material is required to be deposited on both sides of the joints, the weld
shall be chipped thoroughly to obtain a clean surface prior to the application on
the first head of the welding on the opposite side of the joint. Where fillet welds
are used, the lapped sections shall fit closely and shall be held together during
the welding operation. Surfaces to be welded shall be cleaned of loose scale,
slag, rust, paint and other foreign matter, except that a thin coat of linseed oil
need not be removed before welding. When weld metal is deposited in two or
more layers, each layer shall be brushed with a wire brush or otherwise
cleaned before subsequent layer is deposited. In welding precautions shall be
taken to minimise stresses due to expansion or contraction by peening the
welds while hot, or by other satisfactory methods. After welding is completed
and the place is cold, correction of distortion by blows will not be permitted.
Upon completion, the welds shall be brushed with wire brushes and shall show
uniform section, smoothness of weld metal, feather edges without excessive
overlaps and freedom from porosity and clinkers. Visual inspection at edges
and ends of fillets and butt joints welds shall indicate good fusion and
penetration into base metals.
The specification regarding welding including the technique of welding

employed, the appearance and quality of welds made, and the methods used
in testing of the welds, and in correcting defective work shall conform to
relevant Indian Standard or other standards specified.
All shop and field welding performed on the work shall be subject to inspection
by Engineer-in-charge when welding plates, of which one or both exceed
25mm in thickness. Continuous areas of plates around the welding operation
shall be preheated to not less than 700 c and kept at a substantially uniform
temperature throughout the process. The temperature shall be measured by
52
GTS
Temple sticks or other approved means. Low hydrogen electrodes shall be

used wherever necessary, particularly if the temperatures are below 100 c.
Peening of multiple pass welds to control distortion or to minimise residual
stresses may be carried out with light blows from a power hammer using an
elongated round nosed tool. Peening shall be done after the weld has cooled
to a temperature warm to the hand. Care shall be exercised to prevent scaling,
flaking or rupturing of weld and base metal from over peening. Neither the first
nor the last pass of a multiple pass weld shall be peened.
All welds on stress-carrying members shall be done in Manufacturer's shop

unless otherwise agreed by Engineer-in-charge. In general, only non-load-
carrying seal welds will be permitted in the field. All field welding shall have
prior agreement of Engineer-in-charge. Tack welds shall be permitted only as
a temporary welds required for assembly purposes.
The welding sequence shall be planned to control and minimise distortion and,
where necessary, shall include stress relief to minimise residual stresses.
Minimum stress-relieving requirements are specified in the appropriate sections
of these specifications.
Welded components subject to vibration and stress reversals shall be

fabricated with full-penetration welds.
For welding of principal stress carrying parts the standards of welding

procedures, qualification of welders and welding accessories shall conform to
relevant Indian Standards or equivalent to the requirements of the ASME Boiler
and pressure vessel codes section VIII and IX, or DIN EN 287. All welders
assigned to the work shall have passed a performance qualification test. If
more than one year has elapsed since the welder passed his last test, then he
shall be tested and qualified again.
Stress Relieving
The post weld thermal stress relieving shall be part of approved welding
procedure and shall be carried out in accordance with the relevant provision
ASME boiler and pressure vessel code section VIII division–2 or IS: 2825. The
method statement procedure for conducting thermal stress relieving shall
depend upon the particular structure, grade and composition of steel and
thickness involved. The contractor shall obtain prior approval regarding the
above from Engineer.
Stress relieving of the parts where required shall be accomplished by heating

the member in closed stress relieving furnace to a temperature of 5400 C to
5500C for one hour for each 25mm of metal thickness and allowing the member
to cool slowly in the furnace. Below 3150C the member may be removed from
the furnace and allowed to cool in still air.
All plates to be welded above the thickness of 28mm shall be stress

relieved except if specified otherwise. All forgings shall be normalised and
all castings shall be annealed.
5.11.1 Welding requirements for Pressure shaft steel liners

5.11.1.1 Preheating and Thermal Stress Relieving
When preheating is the part of approved welding procedure, weld joints shall
be preheated in accordance with the kind of steel materials and plate thickness
as per the recommendation of the steel manufacturer. Maximum interpass
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GTS
temperature of preheating shall be 2000C and preheating area shall be over a

distance of more than four times of plate thickness for each side from the
welding joints.
If welding work is made under the condition of ambient temperature less than
5˚C, steel materials on weld joints shall also be preheated even though
application of preheating is not required due to the kind and thickness of the
steel materials under normal welding condition.
The relations between the carbon equivalent and the preheating temperature in
cases of manual welding shall be as follows:
Carbon equivalent Plate thickness Preheating

(Ceq) % (mm) temperature for low
hydrogen welding
rods (˚C)
0 - 0.28 0 - 100 -
0.28 - 0.38 0 - 25 -
0.28 - 0.38 25 - 100 40 - 60
0.38 - 0.48 0 - 25 40 - 60
0.38 - 0.48 25 - 100 80 - 100
more than 0.48 0 - 100 100 - 150
Note: Ceq (%)= C+1/6 Mn + 1/24 Si + 1/40 Ni + 1/5 Cr + 1/4 Mo + 1/14 V and
Cu, P, etc., could be added as necessary.
Post weld thermal stress relieving shall be a part of approved welding

procedure and shall be carried out in accordance with the relevant provisions of
ASME boiler and pressure vessel code section –VIII division –2 or IS: 2825.
The method statement procedure for conducting thermal stress relieving shall
depend upon the particular structure, grade and composition of steel and
thickness involved. The contractor shall obtain prior approval regarding the
above from Engineer –in-charge.
5.11.1.2 Post Weld Heat Treatment
Weld procedure must conform to section IX of the ASME code or IS 2825,

including conditions for post weld heat treatment. All penstock sections and
parts must be given a post weld heat treatment at temperatures not less than
those specified in the ASME code, section VIII, division 1 (Table UCS-56, UCS-
56.1, UHA-32, and UHT-56) when the nominal thickness of any welded joint in
the penstock section or parts exceeds the limit in those tables or as per Table
6.3 of IS 2825.
5.11.1.3 Butt Straps

All in-situ welding of the liners must be carried out from the inside with
provision of butt strap from outside. As the butt straps provided from outside
are integrated to the circumferential joint then additional welding methodology
incorporating following precautions shall be incorporated in the WPS:
a) After carrying out the complete first pass welding, the same shall be
grinded so as to achieve a U shaped groove in the backing strip, to enable
appropriate welding by 3.15mm electrode
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GTS
b) After completion of root run & subsequent passes, the weld shall be
subjected to D.P. test for checking of surface defects needing rectification.
c) After completion of full welding again D.P. shall be done for checking of
surface soundness.
d) Full circumferential field weld shall then be checked by U.T. to 100%

extent.
Contractor can offer an alternative procedure/methodology of the erection and

field welding without sacrificing the soundness of weld and requirement of NDT
in accordance with sound Engineering practice for approval of Engineer- in-
charge.
5.11.1.4 Alignment and Tolerances
The shell sections of the completed Pressure shaft liner/pressure shaft liners
shall be circular within the limits defined hereunder. Measurement shall be
made to the surface of the parent metal and not to a weld, fitting or other raised
part. There shall be no flats or peaks at welded seams and the local departure
from circularity shall be gradual.
Alignment: - Before any welding is commenced, it shall be ascertained that the

chamfered edges are in alignment and that the defects in alignment at the
surfaces of the plates are less than:
a) For plates of thickness 5mm or less than t/6 for a longitudinal seam and
t/4 for circumferential seam subject to a maximum of 1mm.
b) For plates over 5mm in thickness before any welding is commenced it

shall be ascertained that the prepared edges are in alignment to meet the
requirements of the welding process and that the defects in alignment at
the surface of the plates are not more than:
1. 10 percent of the nominal plate thickness with a maximum of 3mm. for

longitudinal joint. However, for plates upto and including 10mm thick a
misalignment of 1mm is permitted.
2. 10 percent of the maximum nominal plate thickness plus 1mm with a

maximum of 4mm for circumferential joints.
Circumference: -The circumference shall conform to para 6.6.3 of IS 2825-

1969.
Out of roundness of vessel: - The difference between the maximum and

minimum diameters at any cross section of the shell welded longitudinally shall
not exceed 1% of the nominal internal diameter subject to a maximum of
D1+1250
200
Where D1 is internal diameter in mm.
The individual cylindrical shell shall be reasonably square and straight. The
axis of the pipe sections shall be normal to the axis of the pipe within a
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GTS
tolerance of 2mm on the radius. The edges of the plates of each course shall
be properly prepared for field welding. Unless otherwise specified the out of
straightness of the shell shall not exceed 0.3 per cent both of the total
cylindrical length any 5m. length (This tolerance may be omitted where the
individual shell length does not exceed 2m).
Attachments and fittings: - All lugs, brackets, saddle type nozzle,

reinforcement around openings and other attachments shall conform
reasonably to the curvature of the shell or surface to which they are attached.
5.11.1.5 Non destructive Examination
5.11.1.5.1 Radiographic Examination
All longitudinal joints of liner including bends shall be subjected to 100%

radiographic examination. Other circumferential joints shall be spot
radiographed to 10%. In addition to this 100mm of circumferential joints on
either side of longitudinal joints shall also be tested radiographically. All
circumferential welds of bends shall also be subjected to 100% radiographic
examination. All the longitudinal and circumferential joints of specials like Y
piece shall be subjected to 100% radiographic examination. Field butt joints of
wye pieces shall be radiographically tested and got accepted prior to jointing of
stiffeners or sickle plates at appropriate locations. The procedure for the
radiographic examination, the acceptable standards of welds, the repair of
defective welds and the re-examination of repaired welds shall conform to the
relevant section of IS: 2825, IS: 2595, IS: 1182 and IS: 4853. All repairs shall
be fully radiographed.
5.11.1.5.2 Ultrasonic Examination
All field welds, wherever not spot radiographed or such joints which are
inaccessible to radiographic examination shall be subjected to ultrasonic
examination. The circumferential joints of pressure shaft liner not subjected to
radiographic examination shall be tested ultrasonically to 100%. The procedure
for the ultrasonic examination, the acceptance standards for welds etc. shall
conform to the relevant articles of ASME Boiler and pressure vessel code-
Section V.
5.11.1.5.3 Other Examination
Discontinuities such as cracks, seams, laps, cold shuts, laminations and

porosity can be detected using other methods viz-
Liquid Penetrant Examination
Magnetic Particle Examination
All weld metal build up shall be examined over the full surface of the deposit by
either liquid penetrant examination or by magnetic particle examination. All
permanent hold down logs or devices welded to the steel Pressure shaft liner
shall be examined by either of the above two methods. Removal of temporary
logs and devices tack welded to the pressure shaft liner shell and subsequent
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GTS
dressing shall be followed by either of the above two examinations viz. LPE or
MPE of the connection area.
The procedure and acceptance standards for the above methods shall conform
to the relevant articles of ASME boiler and pressure vessel code -Section V.
The notch toughness of welds and heat-affected zones shall be determined

using charpy-V notch impact tests. Impact tests shall be in accordance with the
requirement of article T-2 ASME code3, Sec. B, Div.2 and made on procedure
qualification test plates and vessel test plates of the material to be fabricated.
The cost of weld tests such as radiographic, ultrasonic, magnetic particle/ liquid
penetrant examination shall be borne by the contractor and shall be included in
the unit rate of various items. Prior to making the radiographs of the welds the
contractor shall place suitable identification markings adjacent to the welds.
Such markings shall be so designed and located that the images will appear in
the radiographs. The markers shall be painted, stamped or fastened to the
shells as directed by the Engineer-in-charge and shall not be removed until all
the welds have been accepted. All X-ray films of the joints shall be the property
of the Employer and shall be forwarded properly identified to the Engineer-in-
charge for record. Radiography by X-ray may be replaced by Gamma ray
methods using Cobalt-60, Iridium-192 and Caesium-187. Records of all non
destructive tests including radiography, ultrasonic test, liquid-penetrant test,
magnetic particle inspection shall be maintained in a suitable format to be
evolved in consultation with the Engineer-in-charge showing the unique
identification of the weld, its location, size, extent of flow, if any and
interpretation of the results of the non-destructive test along with the results of
repairs, if any.
5.12 Corrosion Protection
5.12.1 Surface Treatment and Protection
The manufacturer shall provide as part of his work/supply the surface

treatment, priming, corrosion protection and painting of the equipment
furnished. Such work shall include the coating and painting work at the
workshop and at the site unto and including the finish painting. Unless
otherwise specified the coating and painting shall be carried out in accordance
with the latest Indian Standards or International standards.
All primer and painting material shall satisfactorily fulfill the requirements
imposed by the site conditions, as well as the stresses to which the respective
equipment is subjected during operation of the works. Shades of the finished
coatings shall be as approved by the Engineer-in-charge.
Each coat of primer and paint shall be compatible with the previous and
subsequent coats. All pigmented primers and paints which will be used for
primer and painting at the site shall be delivered in original and sealed
containers packed by the manufacturer bearing brand name, colour
designation, storage and handling instructions.
The manufacturer shall supply full details regarding the extent to which
sand-blasting, primer and paintings will be carried out in his workshops (or his
sub-contractors, as the case may be) at the site and after erection. A properly
equipped paint shop shall be set up at the site using a specialist organisation,
experienced and skilled in the preparation and application of protective
coatings at the conditions prevailing at the site.
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GTS
Materials shall be thoroughly mixed at the time of application. It is essential that

before any primer and coat of paint is applied, the surface is properly prepared.
Such preparation shall include sand-blasting, cleaning, soothing, drying and
similar operation that may be required to ensure that the primer and/or paint is
applied on suitable surfaces. Clean cloths and clean fluids shall be used to
avoid having film or grease residue on the surfaces being cleaned.
Each coat shall be free from runs, drops, pinholes, waves, laps, sags and
unnecessary brush marks and shall be allowed to dry or to harden before the
succeeding coat is applied.
Machinery paint may be thinned, if necessary to permit satisfactory application,

but the amount of thinner shall be kept to a minimum.
For removing rust and mill scale from structural steel, plate sheets, piping and
other steel surfaces, as well as from other parts blast cleaning shall be carried
out to clean bare metal. The average surface roughness after sand blasting
shall not exceed 40 microns. Sand blasting shall be performed with corundum
or sand of type approved by engineer-in-charge. Parts which cannot be blast-
cleaned shall be cleaned free from rust and scale by power tool cleaning to the
highest possible degree.
Coal tar painted surface which is directly exposed to Ultra violet rays should be
painted with aliphatic polyurethane having DFT of 75 microns in addition to total
DFT mentioned as below.
Stainless steel and bronze surfaces shall only be cleaned but not painted. All
surfaces of the embedded parts, which are to come in contact with concrete,
shall be cleaned as mentioned above and given two coats of cement latex to
prevent rusting during shipment and while awaiting installation. All finished
surfaces of the gates and stoplogs that will be exposed to atmosphere during
shipment or while awaiting installation shall be given a coat of gasoline
soluble rust preventive compound. For preservation of hydraulic cylinders
during shipment and while awaiting installation these shall be filled minimum
10% with hydraulic oil suited to temperature range for the particular Project,
and 2% VSI or equivalent corrosion inhibitor shall be added prior to dispatch
to site .The grade of oil shall be got approved from owner.
All ferrous surfaces including non-mating finished surfaces exposed to

atmosphere or water shall be given a coat of rust inhibitive phosphate wash by
brush immediately following the cleaning operation. Proper reaction of the
phosphate wash is indicated by a light grey film after drying. A dark sticky
residue results if the reaction is not complete. This should be wiped off with
dampened rags and area retreated. If the surface is very hot, it may be
necessary to dilute the phosphate wash solution with water to obtain proper
reaction. Within one hour after the rust inhibitive wash has dried thoroughly,
one coat of priming paint shall be applied by brushing, without thinning.
5.12.2 Painting Systems
5.12.2.1 Gates, Bulkheads, Embedded parts, Trash Racks and Lifting beam
Perfect cleaning of all surfaces which are not to be covered with concrete shall
be carried out by sand blasting to the requirements of SA 2½ of Swedish
Standard SS 05.5900.
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GTS
Over the prepared surfaces one coat of inorganic zinc rich primer / 2 coat of
Zinc rich primer by spray (preferably airless spray) should be applied giving a
dry film thickness of 70 ± 5 microns.
The interval between surface preparation and painting shall be as short as

practicable and in no case longer than 4 hours. Over the primer, two coats of
solvent-less coaltar epoxy paint shall be provided at an interval of about 24
hours. Each coat shall give a dry film thickness of 150 microns. The total dry
film thickness of all the coats shall not be less than 350 microns.
Lifting Beams
The following painting system shall be adopted for lifting beams. Over the
prepared surfaces by sand blasting, two coats of priming with zinc rich/Zinc
Phospahte primer conforming to IS 102, each coat giving a dry film thickness of
40 microns shall be applied. The finished paint shall consist of two coats of
alkyd based micaceous iron oxide paint. Each coat of paint shall give a dry film
thickness of 75 microns. The interval between coats shall be 24 hours. The
total DFT of all the coats shall not be less than 210 microns.
5.12.2.2 Hoists and Cranes
a) Structural components: Cleaning of all the surfaces shall be done by sand

blasting to SA 2½. In such areas where it is not possible the parts shall be
cleaned by brushing and scraping.
Hoists and supporting structure:- The parts after surface preparation shall
be given two coat of inorganic zinc silicate / Zinc phosphate primer paint
conforming to IS: 102 in the shop before dispatch. One further coat of primer
shall be applied after erection. The primer coats shall give a minimum dry film
thickness of 40 microns per coat. The finish paint shall consist of two coats of
alkyd based micaceous iron oxide/ synthetic enamel of thickness 50 micron per
coat or one coat of alkyd based micaceous iron oxide paint of thickness 65
microns followed by two coats of synthetic enamel paint of thickness 25 micron
per coat. The interval between coats of micaceous iron oxide paint or synthetic
enamel paint shall be 24 hours. The total dry film thickness should not be less
than 175 microns.
b) Machinery: All surfaces of machinery (except machined surfaces) including

motor, gearing, housing, shafting bearing pedestals shall be given one coat of
Zinc Phosphate, of thickness 50 micron. The finish paint should consist of three
coat of aluminium paint/ synthetic enamel of thickness 25 micron per coat.
crons. Total DFT of paint should not be less than 125 microns. Unfinished
interior surfaces of oil reservoir and gearboxes and unfinished surfaces of
gears which will run in oil need not be painted.
5.12.2.3 Power Pack & Hydraulic Hoist and Bonnet Cover

Cleaning of all the surfaces shall be done by sand blasting to SA 2½ as per
SSPC.
Power Pack
The outside surface of oil tank shall be given one coat of epoxy zinc rich primer
by spray giving a dry film thickness of 50 microns. Over the primer,
intermediate coat of epoxy polyamine to give a dry film thickness of 60 micron
followed by top coat of glossy polyurethane enamel to give a dry film thickness
of 60 microns. The total DFT of all the coats shall not be less than 170 microns.
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GTS
The inside surface of oil tank shall be given one coat of epoxy zinc rich primer
of dry film thickness of 50 microns.
Hydraulic Hoist Cylinder

The surfaces shall be given one coat of polyamide epoxy primer giving a dry
film thickness of 50 microns. Over the primer, one intermediate coat of
micaceous iron oxide pigmented polyamide epoxy coat giving a dry film
thickness of 75 microns and top coat of semiglossy aliphatic acrylic
polyurethane finish to give a dry film thickness of 75 microns to have end color
as mentioned in the technical specification. The total DFT of all the coats shall
not be less than 200 microns.
Unmachined and Unfinished surfaces(Piston and Cylinder head)

All surface should shall be given one primer coat of chlorinated rubber based
zinc phosphate of thickness 50 microns.The finished paint consists of three
coats of vinyl resin/ chlorinated rubber of thickness 30 microns per coat. The
5.12.2.4 Bonnet Cover
A) Exposed to water:-The surface shall be given one coat of inorganic
zinc silicate of thickness 70 microns. The finished coat should consist of
two coat of solventless coal tar epoxy of thickness 150 microns. The
B) Unexposed to water:- The surface shall be given two coat of zinc

phosphate of thickness 40 microns per coat. The finished coat shall
consist of one coat of alkyd based micaceous iron oxide of thickness 65
micron followed by two coats of synthetic enamel paint of thickness 25
micron per coat. The total DFT of all the coats shall not be less than
175 microns.
5.12.2.5 Machined Surfaces

Machined surfaces shall be protected with adhesive tapes/or other suitable
means during the cleaning and painting operations. All machined surfaces of
ferrous metal including screw threads, which will be exposed during shipment
or while awaiting installation, shall be cleaned with solvent and coated with a
gasoline soluble rust preventive compound.
5.12.2.6 Colour Scheme
S.No. Item Colour/Scheme
1. E. Parts, and other components immersed Black

in water.
2. Super structure including columns, trestles, Grey

Hoist platform, lifting beam, staircase etc.
3. Hoist Machinery Grey
4. Gantry Crane/ EOT Crane Orange
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GTS
5. Handrails Black & white

alternate
6. Hydraulic cylinder & Oil tanks Grey
5.12.3 Corrosion protection for Pressure Shaft Steel Liners

5.12.3.1 Exterior surface of steel liners
Before encasing/laying the Pressure shaft liner pressure shaft liner in concrete
the outside surface of the lower and upper half of the Pressure shaft liner in
area d/s of thrust collar shall be given suitable wrapping of bond breaking
material like lucobit-1218 of thickness 10mm over the painted surface (refer
painting schedule in the table). Remaining part of steel liner embedded in
concrete shall be given two coats of cement latex after clearing. The concrete
encasement shall be poured in the portions shown in the drawings only after
such inspections and approval. However, the embedments of timber supports
in concrete will not be permitted at all. All internal bracings and foreign matter
shall be removed from the inside of the pressure shaft liner after the liner have
been erected and embedded in concrete.
Purpose Surface Prime Coat Intermediate Finishing Coat Total

Preparation Coat Depth
U/s of Cleaned 2 coats of
thrust cement latex
Collar
D/s of Cleaned 2 x zinc rich 2 x coal tar Bond breaking 15.25mm.
thrust primer Dry film epoxy Dry film material such
Collar thickness: thickness: as Lucobit-
Nowhere less Nowhere less 1218
than 0.050 than 0.200 wrapping.
mm. mm. Nowhere less
than 15mm.
5.12.3.2 Interior surface of Steel liners
All interior surfaces of the Pressure shaft steel liners shall be protected against
corrosion. The contractor shall furnish prepare and apply all materials for
cleaning, primer coating and painting of the liners. Cleaning, primer coating and
painting shall be performed prior to, during or after installation of the penstocks
subject to the approval of the Engineer-in-charge, provided that the completed
coatings shall in all respects conform to the detailed requirements of these
specifications at the time of final acceptance by the Employer.
Primer and coal tar epoxy: Before the application of Zinc rich primer the surface
shall be cleaned by surface blasting to Sa-2.1/2 quality of Swedish standard or
to any approved equivalent. Over the prepared surfaces, two coats of Zinc rich
primer with epoxy resin, containing 90% zinc on the dry film shall be applied;
each coat providing a dry film thickness of at least 25 microns. This shall be
followed by application of two coats of coal tar epoxy paint; each coat providing
a dry film thickness of 100 microns. The total dry film thickness of all the four
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GTS
coats shall not be less than 250 microns. Workmen skilled in the trade shall
perform the application of zinc primer and epoxy paint and related operations
under experienced supervision.
Purpose Surface Prime Intermediate Finishing Total Depth

Preparation Coat Coat Coat
Internal Dry blast clean 2 x zinc rich 1 x coal tar 1 x coal tar 0.350 mm.
surfaces of according to primer epoxy epoxy
Penstock, ISO 8501-1 or Dry film Dry film Dry film
Bends and Sand blasting thickness: thickness: thickness:
Bifurcations. (SA 2 ½ of Nowhere Nowhere less Nowhere less
Swedish less than than than
standard) 0.050 mm. 0.150 mm. 0.150 mm.
5.12.4 Repair of Primer and Finish Coats
For touching up, the same paint shall be used as for the original painting work.
Repaired finish coats shall be of identical appearance with the original and no
difference in the colour shall occur. Severely damaged coatings may be
removed and repainted as per requirement of Engineer.
5.12.5 Quality Control
The minimum dry film thickness prescribed in these Specifications shall be

observed. Of each 100 m2, one area of 10m2 will be measured for dry film
thickness. No measured thickness shall be less than the specified thickness.
Where the minimum thickness is not achieved, the coat shall be re-applied to
reach the specified minimum dry film thickness as per the specification.
The dry film thickness shall be measured by approved gauges, and the cost
of two new electronic gauges shall be included in the Tender for the use of
Engineer.
For checks on porosity, the Contractor shall furnish a D.C. variable high-
tension test instrument with built-in pore counter. The test voltage shall not
exceed 2000 V. The tests shall not be performed within 0.5 m distance from
uncovered, corrosion resistance surfaces.
Upon completion of each coat, the painter shall make a detailed inspection of
the painting finish and shall remove from all adjoining works all splattering of
paint material. He shall make good all damage that can be caused by such
cleaning operations.
A detailed inspection of all painting work shall be made, and all abraded,
stained, or otherwise disfigured portions shall be touched up satisfactorily or
refinished as required to produce a first-class job throughout and to leave the
entire work clean and acceptable condition.
5.12.6 Galvanising
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GTS
Parts to be galvanised shall be properly prepared and galavanised by hot dip

galvanising process which shall have a purity of minimum 98.5% in according
to DIN 50976 or ASTM Specification A 123. All cutting, drilling and welding
shall be done prior to galvanising. The minimum average thickness of the zinc
coat shall mainly be according to ISO 1461.
5.13 Metal Work
5.13.1 Embedded Metal Work
Unless otherwise specified, any foundations, wall and roof openings and
coverings, concrete floor filling, sleeves in foundations and walls and trenches
with floor plates for cables & hydraulic pipe, will be provided by the Civil
Contractor.
The Contractor shall supply all anchors, fasteners, embedded metalwork,

piping, and sleeves associated with and required for the equipment to be
installed under this Contract, except if otherwise mentioned in the
Specifications.
As far as practicable, the supports shall be of consistent design throughout

and preferably of an approved proprietary type.
Attachments to concrete shall wherever practicable be by means of

embedded inserts of an approved proprietary type.
The Contractor will be responsible for the determination and details of all
loads and forces exerted by his equipment and transferred to the foundation.
The Contractor shall show the location and full details of all embedded
components on his drawings and shall be responsible for the completeness
and accuracy of his drawings and the information supplied to others.
Anchorages to be embedded in primary concrete will be installed by the civil
contractor as per Contractor's drawings. The Contractor shall be responsible
for the adequacy and accuracy of the location of all embedded components
supplied by him or by others.
All adjustments to foundation levels, embedment, bedding and grouting of

Works on foundations and cementing into walls and floors will be carried out
by the civil Contractor, but all levelling and adjusting of Works on foundations
shall be carried out by the Contractor.
The grouting will be carried out by the civil contractor under the supervision of
the Contractor and the mix and grouting pressure shall be approved by the
Contractor. The Contractor shall satisfy himself that the grouting has been
carried out to his entire satisfaction.
Any steel work which is to be built into the concrete foundations shall not be
painted or coated unless otherwise approved or specified.
5.13.2 Miscellaneous Metal Work
Except where otherwise indicated elsewhere in the Particular Technical

Specifications, the Contractor shall supply the following:
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GTS
All platforms, ladders, guards and handrails necessary for easy and safe
access to Works supplied under the Contract. Handrails shall be of tubular
steel construction.
The use of ladders shall be kept to a practicable minimum. Where ladders

are approved for use they shall be of steel, have an inclination of 70o to the
horizontal and a minimum width of 450 mm.
Safety guards at each point where normal access provision would permit
personnel to come within reach of any moving equipment to be provided
under the Contract.
All covers for pipe and cable trenches, required for completing the floors
around and over Works supplied under the Contract will be supplied and
installed by the civil contractor. Unless otherwise approved, floor plates shall
be of an angular pattern.
Covers and curbing for dismantling hatches in main floors will be provided by
the civil contractor.
6.0 Installation
6.1 Installation of Gates and Bulkheads

The gate complete with the seal arrangement and guides shall be properly
assembled and installed as per the drawings approved by the owner. All these
assemblies and installations have to be done in good workmanship manner, to
the specifications and tolerances etc. indicated in the drawings. After
installation, it shall be checked that all the parts are smooth with no wavy
surface. Each gate leaf transported in sub-assemblies and seal sub-assemblies
shall be assembled and erected in strict compliance with the details shown on
the final approved shop drawing and with manufacturer's instructions, special
precautions have to be taken to ensure that the joints are made water tight
wherever required. The side, top and bottom of gates shall be in true
alignments so that Rubber seals when installed shall have tight and even
bearing on the sealing surface of embedded frame.
6.2 Installation of Frame, Guide and Tracks
Assembly and Erection: Each set of frame, guides, tracks and seal seat
arrangements shall be assembled in the respective blockouts, brought to line,
grade and plumb within the erection tolerance and secured in place by
anchorage as shown on the drawings or otherwise, according to best modern
practice and as necessary for successful functioning of these units. The
erection tolerances for frames and guides will be as indicated on the drawings.
Extreme care should be taken to ensure that their surfaces be in a true plane
within the tolerances (as stated above) throughout their length, otherwise
serious damage to the gate may result during operation. Assembly shall be by
bolting and welding and connections to embedded anchorages shall be
adjusted and firmly tightened to hold the frames and guides securely in position
while concrete is being placed in the blockouts.
1st stage inserts shall be embedded in primary concrete by the civil contractor if
not mentioned otherwise.
Erection supports shall be suitably braced so that activities like chipping/
denting of 1st stage concreting, opening out of bent dowels & 2nd stage
concreting operation does not in any way affect the alignment.
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GTS
After the erection/installation of the second stage embedded parts, there is

time gap during which the embedded parts remain un-concreted and have a
tendency to get displaced/ misaligned due to some of the work activities going
on in the vicinity of the embedded parts. It is therefore the responsibility of the
manufacturer to ensure that the alignment of the embedded parts remain
intact and does not get dislodged/displaced due to any activity in the
neighborhood. To ensure this, the manufacturer may suitably brace the
embedded parts by provision of additional steel members, if necessary. The
cost of all labour, materials and use of tools and equipment for ensuring the
same shall be included in the item rates of second stage embedded parts in
the price schedule.
6.3 Placing Concrete in Block-out
Placement of concrete in block outs will be done by the Owner and contractor
shall give a detailed programme of fixing and aligning the embedded parts to
the Owner for this purpose. Before placing the concrete in any one lift and
between placements of successive lifts, alignment tolerances shall be checked
and remedial action be taken if any displacement is noticed. The block out (2nd
stage) concrete will conform to the grade M-30 (minimum) unless
otherwise specified on drawings.
6.4 Hoist & Cranes
Hoist bridge and hoist/crane sub-assemblies shall be assembled and erected in

strict compliance with the details shown in the final approved shop drawing and
with manufacturer's instructions. Special precautions shall be taken to ensure
perfect alignment between mating components and for placements of the hoist
drums so as to match with the centre to centre of lifting lugs of the gates.
For hoist and gantry crane/EOT Crane, the contractor shall prepare a complete
erection procedure which shall describe the sequence of operations to be
carried out, the methods to be used, the measurements to be taken and the
tolerances to be met, in the erection and alignment of the equipment.
6.5 Installation of Pressure shaft steel liners / Tunnel Spillway Steel Liners
6.5.1 General
Before erection is started the Contractor shall supply eight complete sets of
erection schedules, procedures and erection drawings to the Engineer-in-
Charge for approval. The Contractor will be required to lay/erect the Pressure
shaft liner pressure shaft liners in place and do the welding of field joints. All
civil works e.g. excavation, concrete and back-fill as also the anchor and
foundation for supports etc. will be done by the contractors as per the items in
civil works.
The contractor shall complete all preliminary works at site well before the arrival
of pressure shaft liner such as keeping in readiness of electrical winches,
mobile cranes, jig poles, all tools and tackles, welding sets etc. as part of this
contract, and any other work that may be necessary to start erection
immediately after the fabrication. The Contractor shall arrange for such
number of erection equipment, supervision, labour and other arrangements so
as to carry out the work efficiently.
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GTS
The contractor shall be solely responsible for correctness of laying steel liners.
The checking and approval by the Engineer in charge will not absolve the
contractor from the responsibility of erecting the steel liners in true alignment.
Establishing and maintaining temporary benchmarks and connecting to the
permanent benchmarks by double leveling shall be the responsibility of the
Contractor. No extra payment shall be made to them.
6.5.2 Erection/ Laying Procedure
The steel liners shall be assembled in the field in accordance with

erection/laying drawings. The liners sections shall be installed in place
accurately, to line and grade and embedded in concrete by stiffener rings and
supporting brackets. When assembled and ready for welding, the distance
between the ends of adjoining sections which are to be connected together with
the field girth welds shall not be greater 3mm as per joint details and shall be of
6mm in case of joint with backing strips. Care shall be exercised to avoid
excessive length, growth or shrinkage in pipe lengths.
The Contractor shall furnish and install such permanent structures, erection
supports permanent or temporary including holding down straps and internal
bracings as may be required to support the liners securely in place and prevent
distortion during erection, welding and placing of concrete. Cost of all such
structures including erection supports (permanent or temporary) shall be
included in the unit rate of various items. The girth seams shall then be welded
as soon as practicable. After field welding by the electric arc method of girth
seams the joints are to be tested ultrasonically/spot radiography as given under
non-destructive examination, and if any joint is found defective the same shall
be repaired to the satisfaction of Engineer-in-charge. To ensure the matching of
sections at the joints expanding struts or spiders may be used. Tack welds
where used to hold the sections in line, shall be removed so that they may not
become part of the joints. The schedule of installation of pressure shaft liner on
the supports and the field welding and embedments in concrete have to be
carefully synchronized with the works of civil contractor who shall be doing the
concreting of pressure shaft. When the pressure shaft liner has been installed,
with all structural supports, rods, wedges, etc. as may be required to hold the
pipes securely in place while being embedded in concrete, all such work shall
be inspected and approved by the Engineer in charge. It shall be ensured by
the Contractor that the provision of supports (permanent or temporary) and
chairs are sufficient to prevent any misalignment of the pressure shaft due to
buoyancy of wet concrete during concreting.
When erection, welding and inspection of the steel lining have been completed
in accordance with these specifications, the steel lining shall be encased in
concrete. The Contractor shall supply and install sufficient interior bracing's in
addition to that required for welding to maintain the roundness within the
specified tolerances until the encasement is completed. The Contractor shall
supply and install sufficient exterior bracings and anchor bands and bars to
resist the loading due to the placing of concrete.
----
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GTS
6.6 Seals
Rubber seals shall be of the moulded type only. The materials used for rubber
seals shall be compound of natural rubber, a copolymer of butadiene and
styrene, or a blend of both, and shall contain reinforcing carbon black, zinc
oxide, accelerators, anti-oxidants, vulcanising agents and plasticizers. The
contractor shall provide all seal with adequate temperature and age resistant
properties which will provide, in the moulded form, suitable sealing properties.
The seals shall meet the properties as per IS: 11855
All corners shall be remoulded and have a suitable radius on the inside edge.
All joints, both shop and field, shall be located at reasonable distance from the
corners and shall meet the following requirements:
a) All shop joints shall be vulcanised. Joint geometry shall be such as to avoid
feather edges on the sealing surfaces.
b) Field joints shall be kept to a minimum and shall be accurately machine

cut and carefully butted during assembly to an interference fit. The field
joints shall be held with double fasteners on each side of the joint.
c) Vulcanised joints shall not break on tear when bent 180 degrees around a
mandrel of a diameter equal to the maximum cross section thickness of the
seal
d) The longitudinal strength in tension of vulcanised joints shall be not less

than 71.4 kg/cm2 as verified by tests on a tensile specimen prepared from
one joint in accordance with ASTM D15 Part C. The joint tested shall be
located at the midpoint of the test specimen and its strength determined in
accordance with ASTM D 412.
e) The joints in the rubber seal shall be vulcanised but joints and at right angle
to the rubber seal. Oblique joints at the corner shall not be permitted in the
rubber seal. Vertically placed strips of rubber seals shall be formed in one
piece and no joints of any sort shall be permitted in them.
f) Sufficient quantity of seal jointing compound shall be supplied along with

rubber seals for site requirements.
Joints shall be water tight and seal materials shall have following physical
properties as determined by tests made in accordance with the relevant
Standards.
Property Limits
Tensile strength 14.5 Mpa minimum
Ultimate elongation 450% minimum
Durometer hardness (Shore, Type A) 60 - 70
Specific gravity 1.1 to 1.3
Water absorption (700C for 48 hours) 5% by weight (max.)
Compression set 30% maximum

Tensile strength after accelerated ageing in 80% (min.) of tensile
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GTS
Oxygen (48 hours at 700C) strength before ageing
The Contactor may propose seals with higher specifications/properties

considering functional requirements
6.7 Drives and Gears
All moving parts of machinery including shafts, couplings, collars, projecting

key heads, gear wheels, rope/belt-drives shall be completely guarded to
provide full protection. All setscrews on revolving shafts shall be countersunk
or suitably protected. The guards shall be of approved design and shall be
fitted, where necessary, with inspection doors/openings. All guards shall be
arranged so that they can be removed without disturbing the parts of the
gears and Works, which they protect.
Gears shall be designed so that all stresses are within allowable limits when
the maximum loads are being handled. All gears shall be designed and
calculated in accordance with IS Standards or equivalent international
standards, or widely approved methods and to the individual experience of
the manufacturer. On request of the Engineer, the manufacturer shall submit
the calculation of the gears.
Where worm gears are used as a direct drive, they shall have the same load
and time rating as the motors driving them. The gears shall work in oil and the
temperature rise of the oil bath shall not exceed 500C under normal working
conditions at Site. The materials of the mating faces of worm wheel and worm
shall be of a bronze/steel alloy.
Where practicable gear wheels shall be forced fit on the shaft and in addition,
shall be keyed adequately to prevent any relative motion between the wheel
and shaft. Where gears and couplings are secured in position by means of
keys, they shall be easily accessible for tightening or removal. All keyways
shall be machine cut. Couplings and collars shall be the shrouded or
protected-type, free from projections of any kind.
All bearings shall be mounted in dustproof housings. Base of bearing

supports shall be machined, and shall rest on machined-surfaces.
6.8 Lubrication, Lubricants and Oils
Efficient means of lubrication, suitable for use under Site conditions, shall be
provided for all moving parts.
Self-lubricating types of bearings shall be given preference, unless otherwise

specified or practicable.
The contamination of the air, water and soil by lubricants and fuel shall by all
means be avoided by applying an appropriate design and layout of the Works
in conformity with the latest recognized standards for modern engineering
practice.
The number of different lubricants, transformer oils, oils for pressure systems,
etc. used in the items of Works throughout the Works shall be limited to a
minimum in order to facilitate keeping stocks and maintenance.
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GTS
The Owner reserves the right to request the different Contractors to use
certain types of lubricants, oils etc. The Contractor shall not be entitled to
claim extra payment for this request. All different types of oils, lubricants, etc.,
shall be stated in the Tender and are subject to the written approval of the
Engineer.
Unless otherwise stated in the Particular Technical Specifications, the first oil
or grease filling for bearings, pressure oil systems, transformers, etc.,
including the necessary quantity for flushing and for the first oil change, shall
be included in the Tender Price.
6.9 Oil Piping
Pipes shall be made of stainless steel. They shall be welded except at

terminal points and as necessary for erection and future dismantling. The
Contractor shall select the location of the weldments as to ensure sufficient
access for adequate touch-up treatment for corrosion protection. Pipe
connections larger than 50 mm in diameter shall be provided with steel-
flanged connections.
All piping shall be hydrostatically tested at a pressure 150 % than the

maximum working pressure for 30 minutes. The entire pipe arrangement shall
be subjected to the pressure test after complete assembly at the site.
Oil pipes shall not be embedded in concrete. Oil pipes crossing civil
structures shall be routed through sleeves embedded in the concrete.
All oil piping shall be acid-treated to guarantee clean surfaces, completely

free from welding residues.
The piping can either be treated in an acid-bath or being completely filled with
acid. The duration of the treatment shall be approx. 6 hours. After that the
piping shall be neutralised, flushed and corrosion protected for final
installation.
6.9.1 Pipe Supports and Hangers

All pipe work and accessories shall be mounted and supported in a safe and
neat manner. All brackets, stays, frames, hangers and supports for carrying
and staying the pipes, including their fasteners shall be included in the supply
and completed by the Contractor at the Site. Pipes and fittings shall be
supported at or near flanges wherever possible.
Supports and hangers shall be designed and arranged so that any pipe can
be withdrawn without disturbing the others. Minimum spacing of piping
supports shall be as per BS: 4575 Part-I.
All heavy valves and other mountings shall be supported independently of the
pipes to which they connect, to the satisfaction of the Engineer.
The Contractor shall supply drawings showing the location of each major
anchor and support and the weight to be carried by that support.
6.10 Mechanical Instruments
All mechanical parts of instruments shall be suitably protected against shocks
and vibrations, heat, humidity and splash water etc.
Pressures gauges shall be provided with a damping liquid, e.g., glycerine, to
compensate vibrations. Pressure gauges without damping means are not
permitted, unless approved by the Engineer.
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GTS
6.11 Hydraulic Servomotor Systems

Hydraulic tanks shall be designed, fabricated and tested in accordance with
approved standards. The appropriate inspection certificates shall be
furnished.
Oil sump tanks shall be provided with:
- Suitable access openings
- Fine mesh strainer combined with a magnetic filter through which all oil
returning from the servomotors shall pass. The strainer shall be readily
removable for cleaning.
- Dehumidifying air filter
- Flush-mounted oil-level indicator
- Filling connection with a suitable strainer
- Drain connection with hand operated shut-off valve.
Sump tanks shall be installed so that the bottom of the tank and the drain
connection are at least 40 cm above the floor. The bottom of the tank shall
be inclined in the direction of the drainage. The pumps shall be removable
without the necessity of emptying the tank.
Servomotors shall be provided with suitable connections for pressure gauges
on the pressure and suction sides of the piston.
Servomotor piston rods made-up of stainless steel with multi-layered chrome
plating needs to satisfy the surface hardness not less than 320 BHN and
surface finish ≤ 0.3 µm.
Servomotor piston rods made-up of low alloy carbon steel/stainless steel
provided with ceramic coating shall have following requirements ensured by
manufacturer:
Surface hardness > 650 HV to 750 HV
Adhesion according ASTM C633 > 25 N/mm2 to 50N/mm2
Impact to ASTM D 2794 > 50 J to 100 J
Surface roughness of ceramic coating > Ra 0.15 µm to 0.30 µm
Bending Stress > 300 N/mm2
The surface preparation for steel substrate > 9 µm to 13 µm
7 Electrical Works
7.1 General
The electrical items of Works of any electrical or mechanical installation to be
provided under this Contract according to the Particular Technical
Specifications shall - if not stated otherwise therein-fulfill the requirements of
this Section.
All components shall be of an approved and reliable design. The highest
extent of uniformity and interchangeability shall be reached. The design shall
facilitate maintenance and repair of the components.
The Works shall be pre-assembled to the highest possible extent in the
Contractor's or Sub-Contractor's workshop, complete with all devices and
wired up to common terminal blocks.
Unless otherwise agreed, ratings of main electrical Works (infeeds, bus-ties)
as selected or proposed by the Contractor, whether originally specified or not,
shall generally include a safety margin of 10% under consideration of the
worst case to be met in service. Prior to approval of such basic characteris-
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GTS
tics, the Contractor shall submit all relevant information such as consumer
lists, short circuit calculations, de-rating factors etc.
Short-circuit calculations shall be evaluated giving full evidence that every
electrical component can withstand the maximum stresses under fault
conditions, for fault levels and duration's obtained under the worst conditions,
e.g., upon failure of the corresponding main protection device and time
delayed fault clearing by the back-up protection device.
All Works shall be suitable for the prevailing climatic conditions.
Outdoor installations shall be protected against solar radiation by means of
adequate covers, where required.
The Contractor shall ensure that all the supplied Works is insensitive to any
signals emitted by wireless communication equipment.
7.2 Main Distribution System
7.2.1 Board
7.2.1.1 General
The 415 V board switchgear shall be metal enclosed indoor cubicles free floor
standing type.
The cubicle assemblies shall be designed in accordance with the

recommendations of IEC Publication 60439-1 with protection class IP 55
according to IEC Publication 60529. The assemblies must be built to suit the
equipment shown on the single line diagram. Hinged doors and removable
covers shall be provided wherever necessary to allow access to all
equipment. The frame of the cubicles shall be sufficiently sturdy and the metal
sheeting of sufficient thickness to ensure safe transport, mounting and
operation without deformation or bulging. Natural ventilation as required shall
be provided. Provision for future expansion of cubicles shall be made in end
cubicles.
Continuous lifting angle or lifting hooks shall be provided to facilitate the

installation of the cubicles.
7.2.1.2 Name Plates
Each feeder shall be clearly identified with suitably located nameplate(s).

Nameplates shall be furnished for all instruments, control switches, etc. Each
section of an assembly shall have an identifying nameplate placed near the
top edge.
7.2.1.3 Bus Bars
The bus bars of Main distribution system shall have adequate continuous
current carrying capacity. Bus bar conductors shall be made of copper. All
connections shall be in accordance with the best modern practice.
Phase arrangements shall be R-Y-B from top to bottom, from back to front
and from left to right when facing the front of the equipment. All bus bars shall
be clearly marked by engraved letters.
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GTS
Adequate provisions must be made for the expansion and contraction of the
bus bars and other bus bar connections with variation in temperature. Bus
bars shall be so arranged that they can be extended in length without
difficulty.
7.2.2 Air Circuit Breakers
7.2.2.1 General
The air circuit breakers shall be designed in accordance with the

recommendations of IEC Publications 60947.1 and 60947.2. All circuit
breakers shall be of the draw out type, housed in individual metal-enclosed
compartments. Each air circuit breaker shall be mounted on a carriage
assembly with wheels running on tracks secured to the inside of the
compartment.
The air circuit breakers shall be three pole electrically operated with motor
driven stored-energy operating mechanism. The motor for operating the
spring loading device shall be for 220 V D.C. supply. The closing and tripping
coils shall be for 220 V DC.
The operating handle shall be located so that the air circuit breakers can be
operated without opening the compartment door.
A mechanical interlock shall prevent moving of the air circuit breaker from the
connected position, while the breaker is closed, and prevent the access door
being opened unless the circuit breaker is in test or withdrawn position.
7.2.2.2 Contacts
The main circuit breaker contacts shall be of the self-cleaning type, made
from an arc resisting material and provided with auxiliary arcing contacts as a
protection against burning during the operation of the breaker. All contacts
shall be self-aligning, and shall be readily replaceable.
Main and secondary disconnecting contacts shall be silver plated with

springs, which will ensure high-pressure contacts.
Auxiliary contacts for position indication, control, interlocks, etc., showing

whether the breaker is in open, closed or tripped position and whether the
operating spring is locked, shall be provided and wired to terminals.
7.2.2.3 Protection
The air circuit breakers shall be equipped with adjustable magnetic short
circuit over current and instantaneous trip mechanism/ relay, with auxiliary
magnetic short circuit contacts for indication of tripped condition. The
protection equipment shall be interchangeable.
7.2.3 Moulded Case Circuit Breakers
7.2.3.1 General
The MCCBs shall be designed in accordance with the IEC Publications

60947.1 and 60947.2. All MCCBs shall be manually operated and shunt trip
type.
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GTS
All MCCB shall be of the draw out type, housed in individual metal-enclosed
compartments. Arrangement shall be provided for easy removal and handling
of the units. ON, OFF TRIP position of MCCBs should be indicated.
A mechanical interlock shall prevent moving of the MCCB from the connected
position, while the breaker is closed, and prevent the access door being
opened unless the breaker is in withdrawn position.
7.2.3.2 Contacts
The MCCB contacts shall be of the self-cleaning type, made from an

approved arc resisting material. All contacts shall be self-aligning, and shall
be readily replaceable.
Main and secondary disconnecting contacts shall be silver plated, with spring,
which will ensure high-pressure contact.
7.2.4 Current Transformers
The Contractor shall provide single-phase current transformers manufactured

in accordance with IEC Publication 60044-1
Required no. of single core current transformers for each main air circuit
breaker coming from unit auxiliary transformers and Station service
transformers for protection and measuring:
Accuracy class
Over current and E/F: 5P20
7.2.5 Interlocks
The breakers connecting the Board shall be interlocked mutually in order to

prevent paralleling of the supply during normal operation. Interlocking scheme
to prevent parallel operation of main supply and DG set supply shall also be
provided.
7.3 Local Control Panel
The local control panel shall be an Indoor/ outdoor type (degree of protection
of enclosure type IP-55) made of steel sheet of thickness not less than
2.5mm, containing all necessary equipment for the control, protection/safety
and supervisory elements as required and shall be completely painted and
wired. The panel frame structure shall be self-supporting, free standing on
floor or suitable for wall/vertical post mounting.
Cubicles and panels shall be vermin proof. Removable gland plates shall be
supplied and located to provide adequate working clearance for the
termination of cables. Under no circumstances shall the floor/ roof plate be
used as a gland plate. The cables and wiring shall enter from bottom or top as
approved by Engineer.
The cubicles and panels shall be adequately ventilated, if required, by vents
or louvers and shall be so placed as not to detract from the appearance. All
ventilating openings shall be provided with corrosion resistant metal screens
or a suitable filter to prevent entrance of insects or vermin. Space heating
elements with thermostatic control shall be included in each panel.
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GTS
Cubical/panel will be of sufficient size so as to neatly and methodically

accommodate all the electrical power and control equipment. Indicating
lamps, push buttons, all the necessary relays, starters, fuses, limit switches,
selector switches, terminal blocks, circuit breakers, contactors, current
transformers, protection gears, Inter locks, alarms, measuring instruments
including all wiring and all other accessories necessary for safety, control and
operation of the hoist.
The controls, indicating lamps, push button, selector switches etc. will be
installed flush mounted on the out side door of the control panel so as to give
clear view of all the indicating lights, measuring instruments, position indicator
so that the gate and hoist can be operated with the cabinet door closed. The
remaining equipment will be installed inside the cabinet being accessible
when the door is opened.
The panel door shall have close fitting, gasketted, hinged, swing off
construction capable of being opened through 180 degree. The doors shall be
provided with integral lock and master key. A mechanical interlock shall be
provided so as to ensure de-energisation of the panel as soon as the door is
opened. Suitable provision may, however, be made to bypass the above
interlock under extraordinary requirements when manual energisation of
panel is necessary under open condition. Panel shall be provided with door
switch operated illumination.
All terminals will be of block type. Wiring inside the control panel is made at
least with 650 Volt insulation grade, 1.0 mm2, 1.5 mm2 and 2.5 mm2 Control
cable and required size of power cable. All cables shall be brought at terminal
blocks mounted inside the control panels to facilitate connection with the
external cables. All the metallic parts of the switchboards and all the earth
wires of the circuits shall be connected with the Earthing bus of not less than
25 sq. mm copper conductors. All control cables and components will be
marked in a systematic manner on drawings on the accordingly tagged cables
and components in the control panel. All necessary auxiliary devices for
connection to limit switch shall also be provided. The control equipment shall
generally meet the requirements of Clause 6.6 of IS: 6938 -1989.
7.4 Standards
The design, manufacture and testing of all Works and installations shall
strictly comply with the latest edition of the relevant IEC publications.
7.5 Colour Code
The manufacturer's painting systems shall be used to the maximum possible

extent, but shall by all means be subject to the approval of the Engineer. Final
coats of paint shall be matching adjacent installations, where required.
7.6 Electric Motors
7.6.1 General
All motors shall be of approved manufacture and shall comply with the
requirements of this Chapter. Motors of the same type and size shall be fully
interchangeable and shall comply with Indian standard and to IEC standard
motor dimensions.
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GTS
The general construction shall be stiff and rigid, no light metal alloy casings
will be accepted. All precautions shall be taken to avoid any type of corrosion.
All motors shall be fitted with approved types of lifting hooks or eye bolts as
suitable.
AC motors shall have squirrel cage type rotors.
7.6.2 Rating
The rating of motor other than Hydraulic Hoist motors shall be adequate to
meet the requirement of its associated equipment. The service factor, being
the ratio of the installed motor output to the required power at the shaft of the
driven machine at its expected maximum power demand, shall be applied as
follows:
Power Demand of Driven Machine Service Factor
Up to 5 kW 1.2
More than 5 kW 1.1
AC motors shall be capable of operating continuously under rated output

conditions at any frequency between 95% and 105% of the rated frequency
and/or with any voltage variation between 90% and 110% of the nominal
voltage. A transient over voltage of 130% of the nominal voltage shall as well
be sustained.
Further, the motors shall be capable of maintaining stable operation when

running at 70% nominal voltage for a period of 10 seconds. The pull-out
torque for motors shall not be less than 225% of the rated torque.
7.6.3 Starting
A.C. motors shall be designed for thyristorised controlled/ direct on-line

starting. They shall be capable of being switched on without damage to an
infinite bus bar at 110% of the nominal voltage with an inherent residual
voltage of 100% even in phase opposition. For starting the motors from the
individual main and auxiliary bus bars, a momentary voltage drop of 20%
referred to nominal voltage should be taken into consideration. With 85% of
the nominal voltage applied to the motor terminals, each motor shall be
capable of accelerating its associated load to full speed with a minimum
accelerating torque of 5% of full load torque.
The maximum starting currents (without any tolerance) shall not exceed value
5 times of rated current for motors.
Generally, all motors shall be able to withstand three cold starts per hour,
equally spaced. In addition, each motor shall be capable of enduring two
successive starts with the motor initially at operating temperature under the
same conditions or once every twenty minutes without detrimental heating.
Motors for frequent automatic starting shall have an adequate rating. In the
motor list the Contractor shall state the frequency of starts permitted in
compliance with the motor design.
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GTS
7.6.4 Windings and Insulation Class
The insulation of all motors shall be of class F but maintain in operation the
temperature limits of class B materials. It shall be suitable for operation in
damp locations, for occasional contact with corrosive gases and vapours and
for considerable fluctuations in temperature.
The stator winding shall be suitably braced to withstand the forces due to
thyristorised controlled/ direct-on-line starting and transfer conditions as
mentioned before. The winding envelopment and tails shall be non-
hygroscopic. The stator winding shall withstand the maximum fault current for
the period determined by the associated protective devices.
The rotor winding (if applicable) shall be designed to give trouble-free

continuous service including repeated thyristorised/direct-on-line starting. The
rotor shall be subjected to a 120% overspeed test for 2 minutes without
showing any winding dislocation.
7.6.5 Ventilation and Type of Enclosure
All motors shall be of the totally enclosed fan-cooled type, protection class IP
54 according to IEC Recommendation 144. Cable terminal boxes shall be of
class IP 55.
They shall have a closed internal cooling air circuit recooled by an external
cooling air circuit drawn from the opposite side of the driving end.
Where motors are installed outdoors, a weather-proof design shall be chosen.

Above shall be equipped with automatically controlled heating elements for
protection against internal condensation of moisture during standstill periods.
Motors installed outdoors and directly subjected to solar radiation shall be

rated such as not to exceed a maximum metal temperature of 850C. Where
necessary, such motors shall be provided with sun shields.
Vertical motors shall be provided with a top cover to prevent the ingress of dirt
etc.
7.6.6 Bearings
As far as possible, the motors shall have sealed ball or roller bearings
lubricated for life. All other motors with ratings of about 1 kW and above shall
be equipped with lubricators permitting greasing while the motor is running
and preventing over-lubrication. Additionally, the bearings shall be fitted with
grease nipples permitting the use of a universal grease gun. Vertical motors
shall have appropriate thrust bearings.
All bearings shall be easily controllable during operation or standstill without

dismantling the bearings. The bearings shall further be protected and sealed
against dust penetration and oil leakage.
In case of independent bearings, motor and bearing pedestals shall be fitted

on a common base plate.
Suitable packing/special bearing inserts shall be provided to prevent damage

during transport of motors equipped with ball or roller bearings.
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GTS
7.6.7 Shafts and Couplings
The motors shall be provided with a free shaft extension of cylindrical shape
with key and keyway according to IEC Recommendation 72-1 and with the
motor side-coupling which shall be pressed on the motor shaft and be
balanced together with it. A coupling guard shall also be provided.
7.6.8 Terminal Boxes and Earthing
The terminal leads, terminals, terminal boxes and associated equipment shall
be suitable for terminating the respective type of cables as specified in these
General Technical Specifications and in the Particular Technical
Specifications.
The terminal boxes shall be of ample size to enable connections to be made

in a satisfactory manner. Supports shall be provided at terminal boxes as
required for proper guidance and fixing of the incoming cable.
The terminal boxes with the cables installed shall be suitable for connection to
supply systems with the short-circuit current and the fault clearance time
determined by the motor protective devices.
A permanently attached connection diagram shall be mounted inside the

terminal box cover. If motors are provided for only one direction of rotation,
this shall be clearly indicated.
Terminal boxes shall be totally enclosed and designed to prevent the ingress
of moisture and dust. All joints shall be flanged with gaskets of neoprene or
similar material. For motors above 1 kW, the terminal box shall be sealed
from the internal air circuit of the motor.
Depending on the size, the terminal box of L.V. motors shall be fitted either
with an approved cable sealing-end or with a gland plate drilled as required
and provided with suitable fittings for cable fixing and sealing. Such openings
shall be temporarily plugged or sealed during transportation.
Terminal boxes of M.V. motors shall be fitted with an approved cable sealing
end and a pressure relief diaphragm suitably located. For plastic insulated
and sheathed cables filling with compound is not required.
The three neutral ends of the windings of M.V. motors shall be brought out to
a separate terminal box.
For earthing purposes, each motor shall have adequately sized bolts with
washers at the lower part of the frame. In addition, each terminal box shall
contain one earthing screw.
7.6.9 Noise-Level and Vibrations
Under all operating conditions, the noise level of motors shall not exceed
85 dB (A).
In order to prevent undue and harmful vibrations, all motors shall be statically
and dynamically balanced. Vibration displacements or velocity shall be
measured in accordance with DIN 45 665 for IEC motor sizes 80 to 315. The
results for all motors shall be within the "R" (reduced) limits.
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GTS
7.6.10 Tests
Each motor shall be factory tested and shall undergo a test at site. The
following tests shall be performed under full responsibility of the Contractor.
Workshop Tests:
• Measurement of winding resistance
• No-load and short-circuit measurements
• Measurement of starting current and torque
• Efficiency measurement (type test)
• Heat test run
• Dielectric test
• Measurement of insulating resistance
• Over speed test
Site Tests:
• Measurement of insulation resistance
• Measurement of motor vibrations
• Measurement of starting time
7.7 Auxiliary Works
7.7.1 Auxiliary Switches
Where appropriate, each item of Works shall be equipped with all necessary
auxiliary switches, contactors and devices for indication, protection, metering,
control, interlocking, supervision and other services. All auxiliary switches
shall be wired up to terminal blocks on the fixed portion of the Works.
All auxiliary switches and mechanisms shall be mounted in approved

accessible positions clear from the operating mechanism and are to be
protected in an approved manner. The contacts of all auxiliary switches shall
be strong and shall have a positive wiping action when closing.
Control Switches
Control switches for electrically operated circuit breakers shall be of the pistol
grip or discrepancy type. They shall operate clockwise when closing the
circuit breakers and anti-clockwise when opening them. The control switches
shall be so designed as to prevent them from being operated inadvertently,
and where switches of the discrepancy type are used they shall require two
independent movements to effect operation. Control switches shall be so
designed that when released by the operator, they return automatically to the
neutral position after having been turned to the "closed" position and shall at
the same time interrupt the control voltage supply to the operating mechanism
of the circuit breaker.
Switches for other apparatus shall be operated by shrouded push buttons or

have handles of the spade type, the pistol grip type shall be used for circuit
breaker operation only.
Control, reversing, selector and test switches shall be so mounted,

constructed and wired as to facilitate the maintenance of contacts without the
necessity for disconnecting wiring.
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GTS
7.7.2 Anti-Condensation Heaters
Each individual enclosure accommodating electrical Works which is liable to

suffer from internal condensation due to atmospheric or load variations shall
be fitted with heating devices suitable for electrical operation at the specified
standard A.C. voltage, being of sufficient capacity to raise the internal
temperature by about 10°C above the ambient temperature. Heaters in
motors and similar devices shall be switched on automatically upon opening
of the motor starter, and vice-versa. Heaters in switchgear/MCC cubicles,
control cubicles, panels, desks, etc., shall be controlled automatically by
adjustable hydrostats (setting range about 50 - 100% relative humidity). The
electrical apparatus so protected shall be of such design that the maximum
permitted temperature is not exceeded if the heaters are energized while the
apparatus is in operation.
Heaters shall be equipped with a suitable terminal box. All Works, whether
fitted with a heating device or not, shall be provided with suitable drainage
and be free from pockets in which moisture can collect.
7.7.3 Protection Devices
The main parts of the Works shall be protected and interlocked so as to

prevent malfunctions and other fault occurrences, and to maintain safety
during all operation phases.
Electric protection relays shall be the standard product of an experienced and

reliable protection relay manufacturer. They shall be of the static or
mechanical/magnetic, tropicalized type and be mounted in suitable dust proof
and shock-absorbing casings. They shall not be affected by external magnetic
fields or any other influence (radio, computer, signals, impulses, etc.)
consistent with the place or method of mounting. Electro-magnetic relays
shall have a transparent cover with appropriate seals.
The protection relays shall be equipped with all necessary auxiliaries such as
tripping unit, time relay, external resetting device (hand reset flag with seal-in
operation). The relays shall provide easy access for testing and setting
purposes.
Pre-warning alarms shall be initiated as early as possible before the

protection system trips, in order to enable the operators to take precautions.
Tripping of a protection system as well as the sources of the protective action
shall be indicated and recorded as an alarm.
Unless otherwise required for special purposes, protection relays shall remain
in the tripped position until the operator resets the relay manually. The
protection and auxiliary relays shall be grouped and mounted on plug-in
modules or stationary-mounted on swing frame with separate plugs and
sockets to feature easy replacement and testing. The construction shall be
sturdy and such that all parts are easily accessible for adjustment. Relays
installed in switchboards shall be arranged in compartments separated from
the switchgear.
Besides the mechanical-operated flag type indicator, all relays shall have
sufficient contacts and/or auxiliary relay contacts to perform all the tripping,
inter-tripping, interlocking, indication and alarm functions required. Spare
contacts (1 N.O., 1 N.C.) shall be provided for later use. The contacts shall
be silver-plated or of the seal-in type with the main contacts adjustable. The
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relay contact rating shall be for the specified standard voltage and for 200%
of the nominal passing current. The relay coil shall be able to operate
properly at voltage variations of -25% to +15%.
Relays shall be capable of withstanding at least one million operations without

any defect.
Testing of the individual relays shall be carried out either by stationary-

mounted or portable testing devices.
7.7.8 Terminal Points
Contractor shall be provided the following electric power supply points as

applicable
i) 415/230V AC supply in the vicinity of Dam area for Spillway

Equipments, Water level sensor, lighting & automatic remote control
system
ii) 415/230 V A.C supply in the vicinity of Intake for Intake Equipments.
iii) 415/230 V A.C supply in the vicinity of Tailrace gate hoist.
The electric service power provided by the Employer or the other Contractors
shall be as follows:
- 415/230 V, 50 Hz, three-phase system with earthed neutral for feeding
three-phase and single-phase consumers (connected between neutral).
- 230 V, 50 Hz, permanent supply, single phase earthed.
- 48 V, D.C. system, isolated from earth, for the supply of electronic
equipment, telecontrol, telecommunications. etc. wherever necessary
shall be provided by the Contractor.
Supply Tolerances
System 415/230 V 230 V 48 V, D.C.
Limits of the supply
Voltage
a) Steady +5/-10% ± 2% +10/-15%
b) Transient +30% ± 10%
Limits of the frequency ± 2% ± 1%
The Contractor shall supply and install all terminals, control boxes, cables,
conduits, fittings including main distribution system comprising of Air Circuit
Breaker (ACB), Moulded case circuit breaker (MCCB), Current Transformer
(CT), Potential Transformer (PT), bus bars in sufficient capacity along with at
least two nos. of spare MCCBs for operating units supplied by others from
terminal points for the distribution of electric power supply to the electrical
equipment and its controls including lighting to be supplied under this
contract. The power supply cables shall be designed so that the voltage drop
between the terminal points and the respective equipment shall be limited to
within 2.5 % of the rated voltage. In MDS, the provision shall also be made for
automatic changeover from mains to DG so that no time lag may be there.
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7.9 Cables
7.9.1 General
The Contractor shall provide the relevant design and engineering of the
relevant cable systems and, in close co-operation with the Civil Contractor,
prepare the cable installation drawings with cable routing, connection
diagrams, and cable lists, details etc.
The power cables and control cables shall be of copper as per Indian
Standards or IEC publications and the power cables shall be of minimum size
16 mm2 and control cables shall be of minimum size 1.5 mm2.
All cables and accessories shall be suitable for installation under site
conditions (e.g. aggressive soil conditions, etc.).
The Contractor shall select the most suitable cable routes and raceways
ensuring a minimum of interference with other installations.
7.9.2 Colour Code
Live parts of electrical connections shall be colour coded as follows.

Conductor Coding Symbol Colour
Designation Alphanumeric
A.C. network phase 1 L1 red
phase 2 L2 yellow
phase3 L3 blue
neutral N black
D:C: network positive L+ +white

Negative L- -black
neutral M blue
Protective earthed neutral PE/N

green/yellow
Earth E grey
Colour Coding for Mimic Diagrams
Mimic diagrams to be arranged on switchgear cubicles, control panels/desks

etc. shall be colour coded as bellow:
380 V white
110 V D.C. violet
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7.9.3 Illumination System
The contractor shall supply and install the lighting fixtures including high
pressure mercury/sodium vapour lamps etc to provide proper illumination
over and under all the hoist equipment/gantry cranes /EOT cranes etc. to
enable the operator and O&M crew to work on the equipment.
7.10 Earthing System
All electrical system shall be properly earthed as per the latest ruling practice
for the safety of the equipment, operating staff as well as the system. All
protection devices for the control equipments including grounding system/ pit
wherever required shall be provided by the Contractor.
7.11 Labels and Plates
7.11.1 General
Labels and data plates shall be provided in accordance with applicable

standards and as detailed hereunder.
The proposed material of the labels, size, exact label lettering and proposals
for the arrangement of the labels shall be submitted to the Engineer for
approval.
Where applicable, designations in the selected local language shall appear

above or to the right of the designation in the Contract language. The
translations and writings in the local language shall be submitted for approval.
7.11.2 Equipment Labels and Instruction Plates
Labels written in the Contract language shall be provided for all instruments,
relays, control switches, push buttons, indication lights, breakers, etc. In case
of instruments, instrument switches and control switches, where the function
is indicated on the device, no label is required. The label shall be fixed close
to the devices in such a way that easy identification is possible. Fixing on the
dial glass of instruments will not be accepted. The wording shall conform to
the wording used in engineering documents.
Each separate construction unit (cubicle, panel, desk, box etc.) shall be
identified by its Works identification number. Cubicles and similar units shall
also bear this identification number on the rear side if rear access is possible.
The overall designation of each unit shall be given in the Contract language
and - if required - also in a selected local language. These labels shall be
made of anodised aluminium with black engraved inscriptions, arranged at
the top section of the units. Manufacturer's trade labels shall - if desired -
appear in the bottom section of the units.
All Works inside cubicles, panels, boxes, etc., shall be properly labelled with
their item number. This number shall be the same as indicated in the
pertaining documents (wiring diagrams, Works list etc.).
Instruction plates, sequence diagrams or instructions for maintenance shall

be fitted inside of the front door of the electrical switchboards. These shall be
in the contract language and if required in the selected local language.
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7.11.3 Warning Labels
Warning labels shall be made of synthetic resin with letters engraved in the
Contract language and in particular cases, where required, in the selected
local language.
For indoor circuit-breakers, starters etc. transparent plastic material with

suitably contrasting colours and engraved lettering would be acceptable.
7.11.4 Labels for Conduits etc.
The material shall be non-corrosive and the description be done with 4 mm

high letters/figures.
7.11.5 Labels for Cables
Each cable when completely installed shall have permanently attached to

each end and at intermediate positions as may be considered necessary by
the Engineer. Non-corrosive labels detailing identification number of the
cable, voltage, and conductor size shall be provided.
The cable identification numbers shall comply with those of the cable list.
All cables in cable pits and at the entry to buildings shall be labelled utilising
the aforementioned type of label.
7.11.6 Rating Plates
Works (hoists, machines, transformers etc.) rating plates and other technical
data/informative plates shall either be of the enamelled type or be of stainless
steel suitably protected after engraving with a transparent paint resistant to
aggressive atmosphere and solar radiation.
7.12 Key System for Electric Boards
The locks or padlocks shall be coordinated for the different applications and
shall be supplied with three keys. A key cabinet at the end of each board
(distribution board, MCC, control cubicles etc.) shall be provided for storing
the keys of that board. For all locks supplied there shall be six master keys to
open any lock or padlock supplied. Each key shall have one identification
label fixed above the key hanging hook inside the cabinet.
The cabinet door keys shall be similar and shall be six (6) in number.
8 Transport and Storage
8.1 General
Shipping, transportation, loading and storage shall be performed by or under

the responsible direction of the Contractor. An appropriate period for
transportation shall be considered.
The general co-ordination of storage and erection work as well as the civil
engineering work on site will be done by the Engineer.
The delivery dates, transportation and erection periods indicated in the

Contract Documents shall be strictly adhered to.
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From the time of manufacturing until commissioning all parts of the plant shall
be protected against damage of any kind. Parts, which are damaged during
transport, shall be replaced at the Contractor's expense.
The Contractor shall provide the Engineer with complete packing lists of each
performed shipment.
8.2 Packing
After the workshop assembly and shop inspection and tests including witness
inspection by the Engineer or his authorised representative wherever
specified and prior to dismantling for shipment to the Site, all items shall be
carefully marked to facilitate site erection. Wherever applicable, these
markings shall be punched or painted so they are clearly visible.
Dismantling shall be done into convenient sections, so that the weights and
sizes are suitable for transport to Site and for handling on the Site under the
special conditions of the Project.
All individual pieces shall be marked with the correct designation shown on
the Contractor's detailed drawings and other documents (packing lists, spare
part lists, in Operating and Maintenance Instructions etc.).
Marking shall be done preferably by punching the marks into the metal before
painting, galvanising etc., and shall be clearly legible after painting,
galvanising etc. In labelling, the Contractor shall endeavour to use as few
designations as possible, and each part of identical size and detail shall have
the same designation, regardless of its final position in the plant.
All parts of the Works shall be packed at the place of manufacture. The
packing shall be suitable for shipment by sea and for all special
requirements/limitations of the transportation to Site. Where necessary,
double packing shall be used in order to prevent damage and corrosion
during transportation, unloading, reloading or during intermediate
storage.
All parts including electrical parts shall be suitably protected against

corrosion, water, sand, heat, atmospheric conditions, shocks, impact,
vibrations etc. by packing them into high pressure polyethylene foil.
The Engineer reserves the right to inspect and approve the packing before
the items are dispatched but the Contractor shall be entirely responsible for
ensuring that the packing is suitable for transit and such inspection will not
exonerate the Contractor from any loss or damage due to faulty packing.
All packing costs shall be included in the contract price.
8.3 Marking
The Contractor shall mark all containers with the implementing document
number pertinent to the shipment. Each shipping container shall also be
clearly marked on at least two sides as follows:
- Consignee :
- Contract No. :
- Port of destination :
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- Item number (if applicable) :

Package number, in sequence
and quantity per package
- Description of Works :
- Net and gross weight, volume :
8.4 Storage
The Contractor shall inform himself fully as to all relevant transport facilities
and requirements, loading gauges and other limitations and shall ensure that
the equipment as prepared for transport shall conform to such limitations. The
Contractor shall also be responsible for obtaining any permit from the railway
or highway authorities that may be required for the transport of loads
exceeding the normal gauges.
The contractor shall be responsible for all Custom clearance of the

consignments from the Indian port if by sea and or from airport if shipped as
air cargo, local storage and further transportation to site.
The Contractor shall provide means for all unloading and reloading for all
consignments of the plant, during transport to Site. Unloading on the Site will
be provided for by the Contractor. Consignments shall be unloaded
immediately on arrival at Site. The Contractor is required to take the
necessary steps in order to provide the carriage, special supporting structures
for heavy loads etc.
The contractor shall develop necessary storage facility for proper and safe
storage of all the materials. The warehouses shall be waterproof, well
ventilated and of designated floor etc.
If large parts are stored in the open air, they shall be provided with weather
resistant and fire-resistant covers. Electrical parts which are not packed in
heavy duty polyethylene foil and those so packed but whose packing has
been damaged shall be kept in suitable places from the moment of storage to
the moment of installation.
All insulation materials which will be taken from the warehouse for installation
and which are stored temporarily in the station shall be protected from
weather or humidity.
9 Inspections and Tests
9.1 General
In addition to the provisions established in the Conditions of Contract

regarding general procedure of inspections and tests, terms and definitions,
and time schedules for inspections and tests the following stipulations shall
apply.
Approval of assemblies, tests, inspections, related procedures etc. and

acceptance of pertinent test and inspection certificates, or waiving of
inspections or tests, shall in no way relieve the Contractor of his contractual
obligations for finishing the Works in accordance with the provisions of the
Specifications.
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Three (3) sets of all test records, test certificates, performance curves, tables
etc. of all inspections and tests, whether or not attended by the Engineer shall
be supplied soonest after performance of each inspection or test. After
completion of all testing two (2) sets of the above-mentioned documents
shall be supplied properly bound in books.
All test certificates shall be endorsed with sufficient information for

identification of the equipment and material to which the certificates refer.
In addition, the following references shall be entered in the top right-hand

corner:
Contractors name
Project title
Plant's (stage's) name
Contractor's drawing No.
Date
Inspection and testing of equipment shall include all inspections, tests, checks
etc., whether mechanical, hydraulic or electrical, as required to ensure that
the equipment supplied meets the requirements of the Specifications.
They shall comprise, but not be limited to the following:
• Chemical analysis of materials
• Destructive and non-destructive tests of materials
• Checks and examination of welds
• Checks of fits and assemblies
• Dimensional checks
• Balancing tests
• Inspection of paints and coatings (thickness and porosity)
• Hydrostatic pressure and tightness tests
• Electrical tests
• Running tests (incl. Measurement of sound level)
• Functional tests
• Performance tests
• Load and overload tests
• Type tests
• Acceptance test
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The technique, equipment and instrumentation to be used for these tests,

checks, inspections, examinations, etc. shall be in accordance with the
pertinent and internationally accepted Standards, rules or Codes, in particular
these mentioned in the specifications.
If in the Employer's Representative opinion instruments apparatus, devices

etc, used by the Contractor (or his Subcontractor) need calibration or
recalibration, then such instruments, apparatus, devices etc. shall be
calibrated at the contractor's cost by an independent authority or institute
subject to approval by the Employer's Representative.
All inspections and tests shall be in accordance to the approved "Quality

Assurance Plan" as per the formats enclosed as Annexure to this part of
the volume of Technical Specification.
The contractor shall be responsible to carry out and keep record of all
inspection/tests during manufacture through his quality assurance group. This
shall be supplemented by third party inspection by reputed Firms well versed
in carrying out inspection activity in accordance with the approved Quality
Assurance Plans namely Lloyds / Bureau Veritas for all components under
fabrication at manufacturer’s/sub contractor’s works. In addition Owner’s
inspection representatives shall get associated for specific inspections as
specified in the approved quality assurance plan.
The cost of third party inspection shall be deemed to be included in the

respective costs of the items of supply in schedule of prices. (No
separate cost to be quoted.)
In case these parties do not operate in the region of the manufacturer, he

may propose suitable alternative Inspection agencies of international repute
furnishing their detailed particulars, previous references etc. The owner
reserves the right to reject any or all of such proposed agencies.
Manufacturer shall arrange the third party inspection through one of the
above named agencies or the alternative approved agency, without any
financial implication for the owner.
9.2 Workshop Inspections and Tests
As far as practicable, quality of materials, workmanship and performance of

all items of the Works to be furnished under this Contract shall be inspected
at the places of manufacture.
When placing orders for major material and equipment with sub suppliers, the
Contractor shall send unpriced copies of such orders in triplicate to the
Engineer.
Where the Contractor desires to use stock material, not manufactured

specifically for the Works, satisfactory evidence that such material conforms
to the requirements of the Contract shall be submitted. Tests on these
materials can be waived.
Arrangements shall be made for expediting the shop inspection by having all
shop assemblies or pieces covering a single shipment ready at one time. Any
painting work as well as transport to the site of the Works shall not be started
before the approval of the Engineer has been obtained.
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Free and unrestricted access to the Contractor's factory and shops (including
those of his Subcontractors) shall be granted to the Engineer, and upon
reasonable notice by the Engineer or others nominated by him if deemed
necessary by the same for additional witnessing of assembly work or
inspections and tests.
Should an agreed inspection not be carried out as proposed because of lack

of preparation, obvious negligence or material and/or equipment being
presented in a state, which does not correspond to the proposed procedure or
is clearly not acceptable such an inspection shall be repeated. The cost
incurred for all regular as well as repeated inspections shall be fully borne by
the Contractor. The travel expenses for each additional or repeated
inspection shall be borne by the contractor.
Inspection at manufacturer's works/ vendor's works (for bought out items)
All the requirements of section 9.2.1 to 9.3.1 of the specifications shall be

covered including the following
• Inspection of materials with material verification test certificate
• Inspection of bought out items/ components with manufacturer's test

certificate.
• NDT for welding (Radiography, Ultrasonic, MPT, DPT)
• Inspection of shop assembly of embedded parts
• Inspection of shop assembly of gates
• Inspection of shop assembly of hoist/ operating equipment including

operational tests (Gate manufacturer works or vendor's works).
• Inspection of shop assembly of hoist supporting structure.
The above inspections shall also include dimensional accuracy checks,

tolerance check for critical dimensions.
9.2.1 Material Tests
Unless otherwise specified, the quality of materials shall be verified generally

by:
• Chemical analysis
• Mechanical tests (yield point, tensile strength, elongation's, notch impact
Strength etc.)
• Welding tests (welding procedure, welding material, welding tensile

strength, welding bend test, welding reversed bend test, etc.)
• Non-destructive x-rays, ultrasonic, magnaflux, liquid penetration tests

visual inspection, magnetic particles etc.)
• Electrical tests (voltage losses, tan-delta, insulation, magnetic

properties)
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Certified mill test reports of plates will be acceptable when these comply with
the requirement for "Reports of Inspections and Tests" as stated in the
Special Conditions. Test specimen and samples for analysis shall be plainly
marked to indicate the materials they represent.
Castings and forgings shall be tested in the rough state in order to detect
flaws in time thus avoiding delays. Magnetic particle inspection of important
castings shall cover the whole surface of the casting. After partial machining
further tests can be conducted. Important castings and forgings like Gate
wheels, hoist drum, gears, crane wheels etc. shall be ultrasonically tested. The
acceptable limit for ultrasonic testing of castings shall be level I of SA-603 of
ASME Section-5 and that of forgings shall be as per SA 388 of ASME
Section-5.Load tests on crane hooks, steel wire ropes, chains, etc. shall be
considered as material tests.
9.2.2 Checking of Dimensions
The dimensions, especially clearances and fits (ISO 286), which are essential
for operation and efficiency shall be carefully checked in an approved
manner, as for example:
- Run out and roundness tolerances of shafts, pistons, etc., to be

measured on single parts as well as (wherever possible) on the
assembled components,
- Fits and clearances of gates, bearings, servomotor pistons, valves,

guiding, distributing and actual actuating elements, etc.,
- Accuracy, surface roughness and shape of sliding and guiding surfaces

of seals, bearings, water passages in hydraulic machinery, valves, etc.,
- Dimensions of couplings or connections for assembly with other

deliveries from the Contractor, Sub-contractors or other contractors.
9.2.3 Workshop Assembly
In addition to the quality and production control tests, the following shop
assembly work and tests shall be made to check measurements, fitting and
functioning.
Works to be furnished shall be shop assembled to a status sufficient to prove
that the design and workmanship have been executed in accordance with the
Specifications, that the delivery is complete, and that no work remains to be
done at Site, which reasonably can or should be done in the shop.
The metal work shall be shop-assembled to ensure that all parts are properly
fitted and that the dimensional and tolerance requirements shown on the
drawings have been obtained. All holes for field connections of parts
furnished under these specifications shall be drilled or reamed as noted on
the drawings, with the embedments so assembled. Members to be shop-
bolted shall have all parts well pinned up and drawn together with bolts before
bolting is commenced.
To commence the shop assembly of radial gates the 2 gate arms shall be
supported in their relative position at the same elevation properly spaced
centre to centre and so that the machined pin holes have a common
horizontal axis. With the arms in the position the gate leaf shall be erected
between them. The vertical lift gates shall be assembled in a vertical or
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horizontal position and holes for field connections carefully drilled or reamed.
Connections, which have to be dissembled for shipment, shall be made by
the use of erection pins, one size less in diameter than the designed size of
temporary machine bolts.
Stoplog/bulkhead/gate & lifting beam shall be assembled in shop for checking

all dimensions specifically critical dimensions as per final approved shop
drawings and manufacturers instructions. The lifting beam shall be checked
for its verticality for the both the positions of counter weight and shall be
checked for satisfactory operation of grappling and ungrappling of its hook
with stoplog/bulkhead/gate units.
The Hoist / crane shall be completely assembled in the shop to ensure that all
parts are properly fitted. Surfaces of metal, which will be in contact, shall be
cleaned before the parts are assembled. The parts shall be adjusted to line
and fit and shall be well pinned and bolted so that the surfaces are in close
contact before reaming, drilling, bolting or welding is commenced. The field
connections shall be fitted and checked in the shop to assure proper fit during
field erection.
After shop assembly the Hoist / crane shall be tested at manufacturer's

workshop for functional tests.
Where applicable each item of the works shall be assembled completely prior
to painting.
Field joints shall be temporarily connected.
All parts shall be properly match marked, identified and doweled where
practicable, to facilitate correct and quick field assembly and alignment.
Where necessary, suitable dowels shall be provided for insertion after field
assembly and drilling. The holes for any fitted bolt shall be accurately reamed.
During workshop assembly all instruments, control devices and piping shall
be fitted.
If the assembly shows defects in the design or manufacture or unforeseen

difficulties in assembling and dismantling, these shall be eliminated. If
required, design alterations or corrective measures can be executed provided
that reliability of operation or interchangeability are not reduced and provided
that the agreement of the Engineer has been obtained.
If the corrections cannot be carried out in accordance with the terms

mentioned above, the components concerned will be rejected. The decision
on possible subsequent corrections is reserved exclusively to the Engineer.
Faulty parts or Works shall by no means be delivered.
The assembled parts shall subsequently be subject to tests as per applicable

standards or required by the Engineer.
9.2.4 Hydrostatic Pressure Tests
Before final machining, each of the hydraulic hoist cylinder shall be subjected to
a hydrostatic pressure of one and a half time pump capacity or 30 N/mm2,
whichever is more. The test pressure shall be held on each cylinder for a
sufficient length of time to permit inspection of all joints. Any leakage in joints
may be repaired by rewelding at the discretion of and, in a manner acceptable
to the purchaser. The purchaser, at his discretion may require additional stress
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relieving and radiographic examination of the hoist cylinder that have been
repaired by rewelding. All test heads and other equipment required for testing
shall be furnished by the Contractor free of cost and will remain his property
after the completion of the tests.
9.2.5 Functional Tests
Functional tests shall be defined as tests of the function of assemblies, sub-

assemblies or parts of the Works under no load conditions. Functional tests
shall be performed on all Works prior to the execution of operational tests.
9.2.6 Operational Tests
As far as practicable operational test shall be carried out on all Works,

simulating operating conditions.
Parts to be delivered by sub suppliers shall be tested either at the premises of

the sub supplier or of the Contractor, as agreed by the Engineer.
Before testing the Contractor shall submit a notice containing full information
on the tests with detailed tables or graphs on the latest edition of the
characteristic values of the Works to be tested and on the test facilities and
equipment.
Operational tests of lifting equipment and other machinery shall include tests
under following condition
(i) No load
(ii) 5% of rated load
(iii) 125 % of rated load
unless otherwise specified. The deflection test shall be carried out with the
safe working load at rest.
9.2.7 Insulation tests
The following tests shall be carried out at shop as well as at site after erection.
i) After erection but before the hoist/crane is connected to the supply, the
insulation of the electrical equipment shall be tested by a suitable
instrument and any defects revealed shall be rectified. The voltage
required for the insulation resistance test shall be d. c. voltage not less
than twice the rated voltage.
ii) Any reading less than 0.5 mega ohm obtained with an insulation
resistance tester of the un-regulated type shall be disregarded and the
wiring under test shall be sub-divided until a reading higher than 0.5
mega ohm is obtained. Failure to obtain a higher reading shows an
unsatisfactory state of insulation. If an installation has been sub-divided
for test purposes, each sub-division shall meet the requirement.
iii) The insulation resistance of each wiring circuit exclusive of connected

apparatus shall be not less than 2 mega ohm, If necessary, it shall be
permissible to disconnect individual items of equipment while making this
test.
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9.2.8 Electrical Tests
Electrical Works shall be tested in accordance with applicable Standards and

agreed test programs and procedures. Testing of the electrical Works shall be
performed in accordance with applicable Standards, they shall include but not
be limited to tests or heating, loading, overloading, losses. However before
the complete installation is put to commercial service, tests shall be carried out
to ascertain the following:
i) The satisfactory operation of each controller, switch, contactor, relay and

other control devices and in particular the correct operation of all limit
switches under the most unfavourable conditions.
ii) The correctness of all circuits and interlocks and sequence of operation.
iii) Satisfactory operation of all protective devices.
iv) The satisfactory operation of each motion of the crane.
v) The compliance of the crane with the specified performance requirement.
vi) Tolerances on specified speeds on full load shall be within 10%
The measurement shall not be taken on the first application of the load.
9.2.9 Inspection and Tests for Pressure shaft steel liners

9.2.9.1 Inspection during Fabrication, Laying and Erection
The Engineer-in-charge or his duly authorized representative shall have at all
reasonable times access to the Contractor's premises or works and shall
have the power at all reasonable time to inspect and examine the materials
and workmanship of the pressure shaft liner during its manufacture or laying
and erection at Contractor's premises or works site. If part of the plant is
being manufactured or erected in other premises or works, the Contractor
shall obtain for the Engineer-in-charge and for his duly authorized
representative permission to inspect during fabrication and erection of the
pressure shaft liner as if the plant of material were manufactured on the
Contractor’s own premises or works. The Engineer-in-charge shall, on giving
seven days notice in writing to the contractor setting out the grounds of
objections which he may have in respect of the work be at liberty to reject all
or any materials plants or workmanship which is the subject of any of the said
grounds of objection which in his opinion are not in accordance with the
contract or are in his opinion defective for any reasons whatsoever provided
that if such notice is not sent to the Contractor with in reasonable time after
the grounds upon which notice is based have come to the knowledge of the
Engineer-in-charge. He shall not be entitled to reject the said materials, plants
or workmanship on such grounds, unless specifically provided otherwise, all
tests shall be made at the Contractor’s works before transport. The
Contractor shall give the Engineer-in-charge notice of any material being
ready for testing, and the Engineer- in-charge or his duly authorised
representative shall, on giving twenty four hours previous notice in writing to
the Contractor, attend at the Contractor's premises or works within twenty one
days of the date on which the material is notified as being ready failing which,
the Contractor may proceed with the tests, which shall be deemed to have
been made in the Engineer-in-Charge’s presence and he shall forthwith
forward to the Engineer-in-charge duly certified copies of the test certificates
in duplicate.
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9.2.9.2 Testing at Contractor's premises
In all cases, where the Contractor provides for test whether at his premises of
work or of any sub Contractor the Contractor except where otherwise
specified shall provide free of charges, such labour, material electricity, fuel,
water, stores, apparatus and instruments as may reasonably be demanded to
carry out efficiently such tests of the plant in accordance with the contract and
shall give facilities to the Engineer-in-Charge or his authorized representative
to accomplish such testing. If special tests other than those specified in the
contract are required, the Corporation shall pay them for as "Variations".
When the tests have been satisfactorily completed at the Contractor's/Sub
Contractor’s premises or works the Engineer-in-charge shall issue a
certificate to that effect and no plant shall be transported before such
certificate has been issued. The satisfactory completion of these tests or the
issue of the certificate shall not bind the Engineer-in-charge to accept the
plant so passed for dispatch, should it on further tests be found not to comply
with the specifications.
9.2.9.3 Testing at site
Wherever possible all tests shall be carried out before dispatch. Should
however, it is necessary for the final tests as to performance and guarantees
to be held over until the plant is erected at site they shall be carried out in the
presence of Contractor's representative within one month of the completion of
erection. In all such cases except where otherwise specified, the Contractor
shall provide free of charge all the facilities, equipment and material as may
be required from time to time and as may reasonably be demanded for
efficiently carrying out such tests of the pressure shaft liner, material, or
workmanship in accordance with the contract. Should the results of test not
come within the margin specified, then test shall, if required, be repeated
within one month from the date of the steel lining being ready for re-test and
Contractor shall repay to the Engineer-in-charge all reasonable expense to
which he may be put by such tests.
9.3 Site Inspection and Tests
During erection, commissioning and trial operation the Contractor shall

organise at suitable intervals all inspections and tests in the presence of the
Engineer in order to prove the orderly execution of the works in accordance
with the Contract.
Unless otherwise specified, all costs for testing at site and of the works and
charges associated with it shall be borne by the Contractor. This includes the
measuring devices (properly calibrated) and any pertinent accessories, which
shall be made available by the Contractor for the entire duration of the tests.
The Contractor shall delegate his experts to supervise the tests at site.
The tests, checks, examinations at site shall comprise but not be limited to:
• Checks and examinations of welds
• Hydrostatic pressure test
• Tightness tests
• Dielectric tests
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• Functional checks (on all operating mechanism, on protective devices,

automatic and manual controls, monitoring, supervisory equipment etc.)
• Running tests
• Overload tests (on cranes and hoists)
• Reliability tests
• Performance tests and determination of characteristic data
All such tests and checks shall be performed in the presence of the
Employer's Representative. If not satisfied with the performance of the tests
and checks the Owner’s Representative shall have the liberty to ask for
additional tests or repetition of same.
The testing at Site shall be complete in every respect to prove the successful
performance and operation of all the works and Works supplied and erected
under the Contract.
For the procedure of inspections and test at site, notice to the Engineer,
reports, commissioning, trial runs and trial operation, and acceptance tests
refer to General Conditions.
9.3.1 Commissioning and Trial Run
After the contractor has notified the Owner’s Representative and received his
agreement that the equipment is ready for the commissioning tests, the
Contractor shall start with the Tests as stipulated in the Conditions of
Contracts.
The tests shall comprise the following stages: -

a) Pre-commissioning Tests
b) Commissioning Tests
c) Trial Operation
a) Pre-Commissioning Tests shall include the appropriate inspections and

(dry or cold) functional tests to demonstrate that each item of Plant can
safely undertake the next stage (b).
Stage inspection at site
• Requirement of IS 7718-1991 shall be covered. Inspection of

embedded parts duly assembled/ erected in location, fully aligned and
adjusted including installation of sill beam, side guide members, lintel
members, sill seats/ tracks/ bearing pads and hoist supporting structure.
This inspection involves measurement of critical dimensions, verticality,
co-plainerness of sealing/ bearing surfaces and dimensional accuracy
within permissible erection tolerances.
• Prior to concreting, it shall be ensured that the embedded parts which

have been erected/ aligned and inspected are supported by additional
bracing etc. so that they do not get disturbed during concreting.
• After concreting, critical dimensions of embedded parts shall again be

inspected for clearance of any excess concreting require chipping etc.
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• Inspection of gate at site after its complete assembly and checking of

dimensional accuracy, critical dimensions, co-plainerness of skin plate
and bearing / sealing faces.
• Inspection of structural components of hoist support, their dimensional

accuracy, correct location and rigidity.
• Inspection of lifting beam for proper matching with all units of stoplogs.
• Inspection of hoist/ Crane for exact location of hook/ pulley block over
the lifting point of the gate and for proper matching and connections.
Final Checking and Testing at Site
General
After completion of various phases of works final checking of the entire work
shall be done, by the contractor to ensure that all the equipments erection
and wiring etc. have been done strictly according to the specification drawings
and as approved by the Engineer-in-charge. All the works shall be thoroughly
inspected keeping in view the following main points:
• Check for completion of all works in accordance with specifications and

drawings.
• Checking of alignment of all mating components.
• Checks for correctness of connections, continuity check, insulation

resistance test
• Checks, adjustment and characteristic test of all controls/ protective

equipment in accordance with manufacturers instructions.
• Setting and calibration of components e.g. relays, control valves,

pressure relief valves etc.
• Checking of equipment for proper mechanical adjustment and proper

operation.
• All routine and pre-commissioning tests and any other special tests
required to be conducted at site on each and every equipment as per
relevant standards and manufacturers instructions and
recommendations.
• All other tests as specified under relevant standards and codes of

practice but not mentioned here
• Functional tests/ checks for various components.
• Tests & commissioning of control panels.
Proper record shall be maintained for all visual inspections, settings and
checks carried out.
For Hydraulic Hoist
The functional tests on hydraulic hoist shall be carried out by the hydraulic
hoist manufacturer's representative.
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• Checking of fluid tank and piping for completion as per drawings as well
as for cleanliness before filling the hydraulic fluid.
• Checking of connections of individual components to hydraulic

installations according to circuit diagram.
• Aligning the pump and motor.
• Filling of hydraulic fluid.
• Commissioning of pump and motor.
• Setting of pressure relief valves/ safety valves, pressure switches,

temperature controllers and pressure unloading valves to the prescribed
value and locking.
• Commissioning of control gear and actuators.
For Lifting Beam
• Functional tests with all units.
Gantry Crane / EOT Crane
• Ensuring completion of all component parts in accordance with the

drawings.
• Ensuring proper lubrication of all components.
• Functional test of various assemblies including hoist, LT drive, CT drive,

Slewing mechanism, raking mechanism, unloading mechanism etc.
Dry Testing Of Gate & Hoist
The dry testing of the gate and hoist shall be carried out generally in
accordance with Cl. 8.1, 8.2, 8.3 and 8.4 of IS 7718- 1991. The gate & hoist
shall be functionally operated, fully closed, fully opened and it shall be
ensured that there is no obstruction during the operation, the movements are
smooth without any jerks and no undue effort is required for operation.
Contact between gate seals and seal seats shall be checked and pre-
compression ensured by viewing the contact surface against a light source.
The operation of the hoist shall be smooth without any undue noise/
excessive friction and without excessive vibrations in the gate, hoist and
supporting structure. The operation of hydraulic hoist shall be without any
increase in oil pressure beyond design limits and motor current shall be within
design value.
IMPORTANT: Any 'Dry' testing movements should have Rubber seals & seal
faces lubricated with WATER (Do not use grease/ oil). For Metal-to-Metal
sealing/ bearing surfaces grease be used.
b) Commissioning Test, which shall include the specified operational tests

to demonstrate that the works or section can be operated safely and as
specified, under all available operating conditions; and shall include:
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• Satisfactory operation of all equipment, after erection.

• Satisfactory vibration and noise level during entire cycle of operation
• The testing of gate and hoist for aspects as per Cl. 8.1 to 8.7 of IS:
7718-1991 shall be performed with water pressure against the gate
(preferably up to design head)
Completion certificate shall be issued by the engineer in charge after

successful commissioning of the facility as per above.
c) Trial operation: After issue of completion certificate, trial operation shall

commence which will demonstrate that the works or section perform safely &
as specified with reliability during repeated operation and in accordance with
the Contract.
During the trial operation period the Contractor may request any minor
adjustments, which do not in any way, interfere with or prevent the use of the
equipment by the Owner’s or result in reducing the output or decreasing the
efficiency.
If any failure or interruption occurs in any portion of the equipment covered by

the Contract due to, or arising from, faulty design, materials, workmanship
(but not otherwise sufficient to prevent full use of the equipment the trial
operation period is to recommence after the Contractor has remedied the
cause of defect.
A certificate of suitability for Operation shall be signed by an authorised

representative of the Employer’s Engineer and the Contractor.
This Certificate shall state:
• the conditions of commissioning
• the names of the participants
• the date of commencement of trial run
• the list of minor defects, if any
During the trial run the Contractor shall make familiar the Owner’s personnel
with the properties, the operation and maintenance of the Works and its
auxiliaries to such extent that thereafter the duties can be assigned to the
Owner’s trained personnel.
The operational acceptance certificate shall be issued thereafter.
9.3.2 Acceptance
The taking-over testing of any part or section of the Permanent Works which
can operate as an independent unit, shall be performed in accordance with
the standards and regulations laid down in the "Particular Technical
Specifications" and following the test procedure agreed upon between
Engineer and Contractor.
Immediately upon termination of any such testing of a part or section of the

permanent Works a "Protocol of Acceptance" shall be issued by the Engineer.
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This document shall be signed by an authorised representative of the

Owner’s, the Engineer and the Contractor and shall form an integral part of
the later "Taking-Over Certificate".
The acceptance of the equipment will be based upon:
• Mutual acceptance of results of test between the contractor and the
purchaser.
• Acceptance of Inspection and test records/ Test certificate carried out at

“Works” and at “Site”.
• This "Protocol of Acceptance" shall state.
 The date of testing.
 Statement of all minor defects and/or irregularities, which have to be

corrected by the contractor.
 Confirmation that the guaranteed data have been proven.
 Confirmation that all contractual documents have been submitted.
 Confirmation that the Owner’s personnel has been familiarised with

the Works and that they will be able to operate and maintain the
Works.
If any test for the verification of the guaranteed data could not be performed
for operational reasons beyond the Contractor's responsibility, this part of the
acceptance shall be stated in the "Protocol of Acceptance" and be postponed
for a mutually agreed period.
10.0 Measurement
10.1 General
For the purpose of measurements of gates/ pressure shaft liner etc., linear
dimension such as length, breadth, diameter and thickness shall be in
millimetres. The dimension shall be taken for only finished item. For example,
in case of machined item, dimension shall be measured after final machining.
Weight shall be calculated in Kilograms. Rounding off will be only in weight up
to third decimal places in tonnes.
Payment for each item shall be made at unit rate per tonne (1000 kg) of steel
as finally laid and accepted. For gates/ pressure shaft liner, measurement of
linear dimensions including the welds/ the holes less than 300mm (maximum
dimension of hole) shall be considered as continuous dimension. The steel
density shall be considered to be as 7850 kg/m3 for calculation of weights.
The weight calculation shall be made on the basis of theoretical volume thus
arrived. For the variation in thickness relevant code may be referred for the
tolerances.
10.2 Steel Liner
10.2.1 Weight of Straight Ferrule
For the purpose of calculating the weight of the straight portion finished
lengths as laid in position shall be measured and then weight calculated on
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the basis of measurement of each section. In straight reaches where holes

have been provided deduction shall be made for the weight of the plate cut for
the opening more than 300mm. Weight of back strip provided for facilitating
welding shall not be considered and will have to be accounted in the
theoretical weight of liners.
10.2.2 Weight of Bend Section
For the bend, the length along central axis of the curve shall be measured
and weight calculated there from.
10.2.3 Stiffener Rings, Thrust and Anti-Percolation Rings
For the purpose of calculating the weight of the stiffener rings etc. the
thickness, inner and outer diameter of the ring etc. shall be measured. The
outer dia of the pressure shaft liner at a particular section shall be the inner
dia of the ring and the outer dia shall be equal to the inner dia plus the height
of the stiffener.
10.3 Gate\Hoist
10.3.1 1st Stage Embedded Parts
The weight of the steel shall be calculated on the basis of sectional

measurements.
10.3.2 2nd Stage Embedded Parts

measurements. Regarding the stainless steel, corrosion resistant steel plate
the density shall be taken as 8000 kg/m3. The finished thickness shall be
taken for the measurement.
10.3.3 Gate Leaf Structure

measurements. The finished thickness shall be taken for the measurement.
Weights of all the other small components such as wheels, bearings, splice
joint components etc. shall also be calculated on the basis of theoretical
section only. All other components such as rubber seal etc. shall be deemed
to be included on the above total weight.
10.4 Miscellaneous
Where ever the gate items\penstock are embedded, structural steel supports
required to hold them in position and which are finally embedded in concrete
shall be deemed to be included in the unit prices of various items mentioned.
No separate payment shall be made for such supports or any other type of
temporary or permanent supports. The unit price accepted for the various
items shall be considered to include cost of all materials, transport, plant and
equipment, labour, tools and tackles, fabrication, erection, non-destructive
tests (both at shop and field), surface preparation, painting, protective
coating, wrapping, machining, supervision, Supply, installation, testing and
commissioning of equipments, etc. complete as required for all the operations
specified herein above in addition to those specifically so provided or
otherwise so specifically directed for particular item of work.
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ANNEXURE - A
LIST OF APPROVED SUB-CONTRACTORS/ VENDORS
Si. Item of Facilities Name of Sub Country of

No. contractors /Vendors Origin of
/Make Goods
1 Self Lubricating (i) Lubrite USA

Bush/Bearing for
Trunnion (radial gate) (ii) Devaglide Germany
(iii) INA Germany
(iv)Fiberglide UK
2 Hydraulic Cylinder (i) Rexroth Hydrodyne Netherlands

(ii) Hunger Germany
(iii) Montan Germany
3 Hydraulic Power Packs (i) Rexroth India

(ii) Vickers India
(iii) Montan India
4 Module & Software for (i) Siemens Germany

Remote Control system
(ii) ABB India
(iv) Allen Bradley USA
(v) Rockwell USA/India
(vi) Schneider electric France/India
5 Hardware Monitor (i) H P

(ii) IBM
(iii) Compaq
(iv) Samsung
6 Spherical/Roller/ (i) SKF Germany/India

Cylinder Clevis Bearing
(ii) FAG Germany/India
(iii) NTN India
(iv) INA India
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(v) Tenmat Germany
7 Gasoline Engine for (i) Kohler Germany

portable power pack
(ii) Honda Japan
(iii) Yamaha Japan
8 D G Set (i) Caterpillar India

(ii) Kirloskar India
(iii)Cummins India
(iv) Greaves Crompton India
QUALIFICATION CRITERIA FOR SUB-ONTRACTORS/VENDORS

PROPOSED BY THE BIDDER.
In case bidder proposes Sub Contractor/Vendor other than given in Annexure A, he

may do so subject to fulfillment of Specific Qualification Criteria as below after
acceptance from the owner.
Sl. Item of Name of Specific Qualification Criteria

No. Facilities Subcontractors /
Vendors and
Nationality
1 Self 1) Must have supplied specified grade
Lubricating (as per technical specification) or
Bush/ equivalent international standard bush/
Bearing for bearing for internal diameter greater
Trunnion than 450mm for similar application.
(radial gate)
2) Should have experience in
manufacture of similar products for
preceding ten years (minimum).
3) List of projects where the vendor’s

product has been used in similar
application. Certificate indicating
satisfactory performance since last five
years from at least two clients.
4) Documentary proof regarding bush/

bearing being manufactured and tested
as per relevant ISO/ ASTM/DIN/BS/
any other equivalent international
standard.
5). Bush/bearings being supplied

should fall under the vendors regular
manufacturing range and should be
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supported with manufacturer product

catalogue etc.
2 Hydraulic 1) Must have Supplied the Hyd.

Cylinder Cylinders with stroke more
than 10 m and Capacity
greater than 150 MT for
similar application.

manufacture of specified grade
products for preceding five years
(minimum).

satisfactory performance since last two
years from at least two clients.
4) Documentary proof regarding

hydraulic cylinder being manufactured
and tested as per relevant ISO/
ASTM/DIN/BS/any other equivalent
international standard.
3 Hydraulic 1) Must have supplied Power Pack

Power Packs capable to operate the hydraulic
cylinder of capacity > 150 MT for dam
gates.

manufacture of similar products for
preceding five years (minimum).

satisfactory performance needs to be
submitted from at least two clients.

hydraulic power pack being
manufactured and tested as per
relevant ISO/ASTM/DIN/BS/any other
equivalent international standard.
5) Certificate regarding use of all sub-

components adhering to
ASTM/DIN/BS/ any other equivalent
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4 Module & 1) Should have experience in

software for manufacture of similar products for
Remote preceding ten years (minimum).
Control
system 2) List of projects where the vendor’s
submitted from at least five clients.

manufacturing and testing as per
relevant ISO/ ASTM/ DIN/BS/ any
other equivalent international standard.
5 Hardware 1) Should have experience in

Monitor 21” manufacture of similar products for
preceding ten years (minimum).


manufacturing and testing as per
relevant ISO/ ASTM/ DIN/BS/ any
6 Spherical / 1) Should have experience in

Roller/ manufacture of similar products for
Cylinder preceding ten years (minimum).
Clevis
Bearing 2) List of projects where the vendor’s

Bearing being manufactured and tested
as per relevant ISO/ ASTM/ DIN/BS/
any other equivalent international
standard.
4) Bearings being supplied should fall

under the vendors regular
manufacturing range and should be
supported with product catalogue etc.
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7 Gasoline 1) Should have experience in

Engine for manufacture of similar products for
portable preceding five years (minimum).
Power Pack
submitted from at least two clients.

gasoline engine and power pack being
manufactured and tested as per
relevant ISO/ ASTM/DIN/BS/any

components adhering to ISO/ ASTM/
DIN/BS/ any other equivalent
8 DG Set 1) Must have supplied DG Set of

capacity > 200 KVA.

manufacture of similar products in
preceding five years (minimum).

4) Documentary proof regarding DG

Set being manufactured and tested as
per relevant BIS/ ISO/ ASTM/ DIN/
BS/ any other equivalent international
standard.

components adhering to BIS/ ISO/
ASTM/ DIN/BS/ any other equivalent
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vii). Valve knife-edge plate and valve seat shall be of stainless steel with
precision buffed for tight shut off. Valve body shall be of carbon steel
conforming to IS: 2062 Grade-B. Body lining shall also be stainless steel.
A silt guard ring of stainless steel shall be provided.
viii). Test Pressure: The valves shall be tested for a test pressure of 1.5
times the maximum operating pressure.
Operating Criteria for Valves
The operation of two knife-edge gate valves shall be as under:

i). Emergency/maintenance valve shall normally remain in open position
and shall be closed only during inspection/maintenance of service valve.
ii). The service valve shall always remain in closed position and shall be
operated to release water downstream of the river during lean season
depending upon site conditions/ operating instructions.
iii). Both the valves shall be capable of operating for partial openings against
design head.
iv). The valves shall be operated by means of electro-mechanical actuators
of suitable capacity.
v). During power failure, the valve shall be capable of manual operation.
The control for valve operation shall be located in valve chamber. Suitable
limit switches shall be inbuilt in the device to stop the movement of operation
to both extreme travels of the valves. Overload relays shall also be provided
in the electrical circuit to check the overloading of the device.
10 Pressure Shaft Liner
10.1 Details of Pressure Shaft Liner
The steel pressure shaft liners shall be designed, fabricated and installed as
per general layout drawing no. NHPK-3KT3-45-GA-004-00. However, the
final layout and details shall be decided at the time of detail design. The
various items involved in the scope of work mentioned herein shall generally
consist of the following but not necessarily be restricted to:
1. Two nos. Steel transition from 6.0mx7.2m rectangular sections to 6.0m

circular of 10.0m length starting from the just D/s of Surge Shaft as per
Pressure shaft liner General Arrangement Drawing and specification
2. 2 No. horizontal Pressure shaft steel liners having an internal diameter

of 6.0m including plan bends leading to steel bifurcation as per
technical specifications and drawings.
3. Pressure shaft steel liners (4 sets) having an internal diameter of 3.9m

in the upper horizontal portion including plan bends from downstream of
bifurcation up to valve house. Connections to butterfly valves housed in
valve room (upstream and downstream sides) including 200mm extra
length for each sides for matching with components supplied by E&M
contractor & shown in the layout drawing.
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4. Upper steel lined vertical Bend (4 set) of mean radius 15.0m and
internal diameter 3.9 meter.
5. Manhole (4 sets) of internal diameter 800mm at upper vertical bends

with manhole cover, gasket, bolts and nuts etc. including aeration valve.
6. Pressure shaft steel liner (4 set) in vertical shaft having an internal

diameter of 3.9m as per drawings and specifications.
7. Lower steel lined vertical Bend (4 sets) of mean radius 15.0m and
internal diameter 3.9m.
11 Pressure shaft steel liners (4 sets) in the lower horizontal portion

starting from downstream of lower vertical bend up to MIV having an
internal diameter of 3.9 m upto reducer cone and 2.9 m downstream
side. Connection to butterfly valves on both sides including 200mm
extra length on each side for matching it with parts supplied by E&M
contractor & shown in the layout drawing
12. 4 sets of Thrust collars at suitable locations on the u/s of MIV, details to
be finalised during detailed design. No grout holes shall be provided in
the reach downstream of the thrust collar.
13. Valve house and Butterfly valves including welding with pressure shaft
liners shall be in scope of other contractor.
14. Provision of piezometric connection and drain holes etc. in each

pressure shaft, details to be finalised at detailed design stage.
15. Grouting holes to be provided in liners for grouting purpose as per

drawings and specification. No. and spacing to be finalised at the time
of detailed design. These holes shall be plugged using threaded steel
plugs and welding as per drawing.
16. Surface preparation, painting, application of bond breaking coating etc.

shall be provided as per specifications and design requirement.
Work by others: -
1. Welding of steel liners with butterfly valves in the valve house.

2. Welding of steel liners with MIV in the power house.
3. Providing and fixing of piezometers, drain hole accessories.
4. Concreting around steel liners and grouting.
10.2 General Requirements
It is envisaged that plates conforming to ASTM A517 Grade F or approved

equivalent will be used and shall be 100% ultrasonically pre-tested and
certified at the manufacturer’s shop. As such the pressure shaft ferrules and
bends need not be subjected to hydrostatic testing. However the welded
joints shall be subjected to appropriate NDT as specified. It is intended that
all shop fastenings and field fastenings shall be of welded type unless
65
otherwise specified. Automatic welding would be preferred for the
fabrication at site. Suitable equipment for doing such type of work is a pre-
requisite for a tender being considered. The fabricator must, have in his
shop, satisfactory facility for plate bending edge preparation and end milling
of members as advised by Engineer-in-charge. Fabrication of steel work
shall be at fabricators shop to be set up by the contractor in the project
areas. Shop fabrication of heavy parts and other specials, requiring
precision finishing such as bends shall be done in regular workshop. The
contractor shall arrange at his own cost the transport of such materials from
site as well as fabricated materials from his shop to the project site. Any loss
or damage in transit on account of this shall be to the contractor’s account.
10.3 Layout
The contractor shall complete all preliminary works at site well before the
arrival of pressure shaft liner such as keeping in readiness of electrical
winches, mobile cranes, jig poles, all tools and tackles, welding sets etc. as
part of this contract, and any other work that may be necessary to start
erection immediately after the fabrication. The Contractor shall arrange for
such number of erection equipment, supervision, labour and other
arrangements so as to carry out the work efficiently.
The contractor shall be solely responsible for correctness of laying

penstocks. The checking and approval by the Engineer in charge will not
absolve the contractor from the responsibility of erecting the penstocks in
true alignment. Establishing and maintaining temporary benchmarks and
connecting to the permanent benchmarks by double leveling shall be the
responsibility of the Contractor. No extra payment shall be made to them.
10.4 Specification & Standard
The item wise specifications are intended for the general description of
quality, workmanship etc. desired for the items covered in the general
technical specification and scope of work. Specifications are not however,
intended to cover all the minute details and the work shall be executed in
accordance with the spirit of the tender specifications. In the absence of
specifications for any particular item of work it shall be executed as per
relevant IS code (latest revision) IS: 2825 i.e. Indian Standard Code for
Unfired Pressure vessels. In case neither of the above mentioned
specification and code are available for any particular item of work, the work
shall be executed as per section VIII ASME Unfired Pressure Vessel code
and ASTM Standards or as directed by the Engineer-in-charge. These
specifications shall be read in conjunction with the description of the items in
the schedule of items.
10.5 Design Criteria & General Description
Objectives
66
The Steel lining of Pressure shaft shall be designed with the following
objectives:
a) Internal water pressure corresponding to maximum surge in the

upstream surge shaft i.e EL. 1741.50m or static head along with
maximum normal water hammer pressures at turbine inlet whichever is
higher.
b) External water pressure either corresponding to normal reservoir level
i.e. EL 1700.0m or the ground level vertically above the penstock i.e.
invert level whichever is less.
c) The linings shall be able to restrict the leakage to power house.
Thickness shall be calculated on the basis of tentative water hammer head.

These may be slightly altered after finalisation of water hammer head and
distributor setting by the supplier of the equipment.
The alignment of penstock as shown in drawings have been based on the

available topographical and geological data. It is likely that these may alter
due to additional data and information obtained due to subsequent
investigations. The changes as necessary will be communicated in
reasonable time in writing to the contractor by the Engineer-in-charge.
These changes in lengths in the penstock courses and bend angles and/or
numbers shall be carried out by the Contractor. No claim on this account will
be entertained except when already manufactured pieces are altered.
10.5.1 Loads to be considered
a) Normal Condition
• Internal water pressure corresponding to maximum surge in the upstream
surge shaft i.e.EL.1741.50m or static head along with maximum normal
water hammer pressure at turbine inlet whichever is higher.
• External water pressure either corresponding to normal reservoir level

i.e.EL.1700.0m or the ground level vertically above the penstock i.e invert
level whichever is less.
• Load induced due to temperature variation of water from 6°C to 14°C
(Tentative & shall be confirmed during detail design).
• Poisons effect associated with radial expansion of liner under internal water
pressure.
b) Intermittent condition
• Intermittent condition includes those during filling and draining of penstock.
• Internal water pressure corresponding to maximum surge in the upstream
surge shaft i.e EL 1741.5m with pressure rise during normal water hammer
at turbine inlet. The internal pressure shall be assumed to be linearly varying
between surge shaft and turbine inlet for the above water head.
• External water pressure either corresponding to normal reservoir level i.e
EL.1700.0m or the ground level vertically above the penstock i.e. invert level
which ever is less.
• Load included due to temperature variation of water from 6°C to 14°C
(Tentative & shall be confirmed during detail design).
67
• Poisons effect associated with radial expansion of liner under internal water
pressure.
c) Emergency condition
• This condition includes partial gate closure in critical time of penstock
(2L/seconds) at maximum rate, and the cushioning stroke being inoperative
in one unit.
d) Exceptional condition
• The dynamic pressure rise due to needle slam on loss of oil pressure or
mechanical failure. As the needles are hydraulically balanced at mid-point
turbine flow cut off shall be taken as instantaneous.
Basis for Design:
• The Liner thickness shall be dimensioned for maximum internal pressure

without considering rock participation and external water pressure as per IS
code/ ASCE/ CECT.
• The liner thickness shall be calculated for maximum external water pressure
from Amstutz relations or the method suggested by Jacobson whichever is
conservative. Clearance or gap to be assumed between pipe and concrete
shall be computed for concrete shrinkage and steel shrinkage (fabrication
temperature to ambient water temperature) and shall be adopted
accordingly for external pressure design.
f) Minimum corrosion allowance shall be taken as 1.5mm for all the

pressure shaft liner. However, for vertical pressure shaft an additional
allowance of 0.5 mm shall be considered.
g) Miter Bend
Deflection angle between each successive segment shall not be more
than10°.Bends shall be designed with consideration given to the
concentration of hoop tension stresses along the inside of the bend.
Following formula shall be used to check the stresses.
t=P D (D/3 tanØ/2 + S/2)/S f
where t= required elbow wall thickness, cm

P=design pressure, kg/cm2
f=allowable tensile stresses at design pressure, kg/cm2,
D=outside diameter of elbow, cm
S=segment length along inside of elbow
Ø = segment deflection angle, degree
j) Handling Consideration
• Minimum handling thickness shall be provided for the rigidity of the structure
during fabrication and handling during erection:
t o = (R+0.25)/200
where t o = minimum handling thickness in m, and
R =radius of penstock in m.
68
10.6 Submittals
The Contractor shall submit design & drawings and other technical data to the
Engineer for approval, as detailed in General Technical Specifications.
10.7 Materials
(1) All materials incorporated in the Work shall be of first-class quality, free
from defects and imperfections and, where shown, of the classifications
and grades designated. Materials not specifically designated herein shall
be suitable for the purpose intended and shall, as far as practicable,
comply with the latest specifications of the American Society for Testing
Materials (ASTM) and the ASME Boiler and Pressure Vessel Code
Section VIII, Division 2 or equivalent European Standard.
(2) Plate material for liners and pressure shafts shall be ASTM A517Gr. F or
approved equal.
(3) Material certification and testing shall be as per ASTM A20 manual and
ASME Boiler and Pressure Vessel Code Section VIII, Division 2 and with
supplementary requirements as in the following paragraphs of ASTM
A20:
- S5 Charpy-V-Notch toughness tests as per table no. A1.15

of A20 of ASTM manual in transverse direction of each
plate.
- S14 On total 3 plates of y. p. > 280 Mpa steel material one

bend test for each heat as follows:
One on plate with most frequently used wall thickness
- One on plate with maximum wall thickness
- One on plate with an intermediate wall thickness.
- S8 Ultrasonic examination as per ASTM A435.
Complete mill test reports are to be submitted with above certification

showing results of all mandatory and supplementary requirements.
(4) Steel Tubes Certification: The Contractor shall provide a certificate for
each steel pipe section as stipulated in this clause.
(5) Steel material of the same quality (ASTM A517Gr. F) or equal shall be
purchased from one manufacturer only.
(5) All material used, fabricated and welded to the liners and penstocks,
which are not particularly specified above, shall be compatible in respect
to chemical, mechanical and welding properties as defined by ASME
Code.
69
(6) Welding consumables shall be as per AWS Filler Metal specifications as
recommended by the steel manufacturer. Only "Low hydrogen welding
consumables" shall be used for welding. Consumables shall be baked
when necessary as recommended by the consumable manufacturer to
moisture levels required by the steel manufacturer. FCAW electrodes
and SAW flux electrode combinations shall be certified by the
manufacturer to meet the diffusible hydrogen limits given below.
Diffusible hydrogen shall be determined in accordance with AWS A 4.3-
86.
Specified weld Max. Hydrogen,

Metal strength ml/100 g
760 MPa (110,000 psi) 5
(7) Temporary and embedded supports for securing liners and penstocks
during concreting shall be of good quality and suitable for the intended
purpose. In addition, the same precautions shall be exercised when any
attachment is welded to the steel liners.
10.8 Loads to be considered
Loads arising during installation and concreting of the liners, due to self
weight of shell weight of shell between support and due to buoyancy forces
resulting when concrete is placed around the liners.
11.0 Adit inspection gates
11.1 Inspection Gates

Four no. Hinged type gate for opening size 3.0m wide x 3.0m high has
been proposed to be provided in the concrete plugs at construction Adits no.
1, Adit No. 1A, Adit -2, and Adit-2A in both HRTs to give access to the head
race tunnels in the event of any inspection, repair and maintenance in future.
The gate will be operated manually. It shall be provided with skin plate on
the tunnel side and seals on the Adit side. The gate shall be hinged to the
gate frame embedded in concrete. The gate shall be provided with
machined bearing blocks to transfer the water load to the civil structure
through embedded parts. For sealing purpose suitable shaped seals shall
be provided on the gate frame all round which shall bear against stainless
steel embedded parts fixed in the concrete. The gate shall be held in
position by fastening the bolts provided on the gate to the embedded frame
from Adit end. Provision shall be made for a 250 mm Ø pipe along with two
number gate valves in the bottom portion of the gate for dewatering purpose
in the Adit gates. In the same piping a suitable sized pressure gauge shall
be provided for measuring water pressure inside the HRT.
The gate, embedded parts and associated components shall be designed for
Reservoir water level of EL.1700.00m at normal allowable stresses as given
in General Technical Specifications. The gate and all related components
shall be checked for head corresponding to maximum surge level of
70
SURGE SHAFT -2 CONCRETE M20
650 THK
STEEL LINER
196131 Ø
560 00
97 29
9585 11142 1195
1 15
18
7
SURGE SHAFT -1
161840 THRUST COLLAR
(INDICATIVE) C
SECTION
A
11142 11951 D
2703
STEEL LINER 15 SECTION
18
3695
5
7
VALVE HOUSE, (101.5MX8MX18.8M)
4
THRUST COLLAR
6000
CONCRETE M20
1134
650 THK
2126
5
PRESSURE SHAFT ERECTION GALLERY
(LOWER),7M DIA D SHAPE
5
D PRESSURE SHAFT ERECTION GALLERY (UPPER),
7M DIA D SHAPE
6000
3500
Ø
THRUST COLLAR
0
3900 (105MX10MX19M)
MAIN INLET VALVE
1875
B
CR ETE
CON
0
ILL
CKF
) BA
ICAL
4081
TYP
HK.(
3900
T
650
5
B
SECTION
(STIFFENERS NOT SHOWN)
2900
A
SECTION
LINE
6000 Ø
(STIFFENERS NOT SHOWN)
LINE
C
3900 Ø
LINE
5525
2B
LINE
2A
0
1B
USE
1A
DRG. NO. NHPK - 3KT3 - 45 - GA - 004 - 00
W E R HO 51M)
PO 0.2MX NOMENCLATURE OF THE
X2
( 166M PRESSURE SHAFT LINES IS INDICATIVE ONLY.
CHENAB VALLEY POWER PROJECTS (P) LTD.

(A Joint Venture of NHPC, JKSPDC & PTC(I) Ltd.)
GENERAL LAYOUT ikdy nqy ¼æaX|qju½ tYk fo|qr ifj;kstuk

(PLAN VIEW) PAKAL DUL (DRANGDHURAN) H.E. PROJECT
GENERAL ARRANGEMENT DRAWING

Ø OF
3900
SICKLE PLATE PRESSURE SHAFT
PLAN STEEL LINER SHEET 1 OF 3
TYPICAL BIFURCATION 30.03.1600 ISSUED FOR TENDER
DRAWN
mnzsf[kr
SUBMITTED
izLrqr
RECOMMENDED
vuq'kaflr
APPROVED
vuqeksnu
DATE DRG. NO.
DATE NO. REVISION OR ISSUES BY. CH.APP. fnukad MAR -2016
mnzs[k la[;k NHPK-3KT3-45-GA-004-00
IMS/DED/F-02 REV. NO: 02 EFF. DATE : 29.11.2010
STEEL LINER
500 THK. BACKFILL CONCRTE

VALVE HOUSE
[8.0M.(W)X20.3M.(H)]
SURGE SHAFT 1
STEEL TRANSITION PRESSURE SHAFT

3900 Ø
MANIFOLD
ERECTION GALLERY
3900
PRESSURE SHAFT (UPPER)
6000 Ø
DN. SURGE
EL 1548.00 EL 1542.00
EL 1544.70
EL 1538.60
00
1 50 MANHOLE
56097 9585 161840 11142 21265 R
7200
35000
B
TURNING POINT
TURNING POINT
TURNING POINT
SECTION (STIFFENERS NOT SHOWN)
NOTES :-
1. ALL DIMENSIONS ARE IN MILLIMETERS AND ELEVATIONS IN
METERS.
B 2. MATERIAL OF STEEL LINER SHALL CONFORM TO
ASTM A 517 GR F. OR EQUIVALENT.
PRESSURE SHAFT LINER 3. EXTRA LENGTH OF 3.9M Ø OF 200MM(APPROX.) (4 Nos.) FOR
(LINE 1 A) JOINING HORIZONTAL PORTION OF PRESSURE SHAFT U/S &
3900 D/S OF EACH BUTTERFLY VALVE IN THE VALVE HOUSE.
PRESSURE SHAFT 4. DETAILS OF ANCHOR RINGS/THRUST RINGS AT SUITABLE
(STEEL LINED) LOCATIONS ON THE U/S OF MIV SHALL BE FINALIZED BY
CONTRACTOR DURING DETAIL DESIGN .
5. GROUTING HOLE TO BE PROVIDED IN LINER . HOLES SHALL
BE PLUGGED WITH THREADED STEEL PLUGS AND WELDING.
NO GROUT HOLES SHALL BE PROVIDED IN THE
DOWNSTREAM OF THE THRUST COLLAR.
6.EXTRA LENGTH OF 3.9M Ø OF 300MM (APPROX.) FOR
VALVE HOUSE JOINING EACH HORIZONTAL PORTION OF THE PENSTOCK TO
[8.0M.(W)X20.3M.(H)] REDUCER CONE OF MIV SUPPLIED BY OTHERS IN THE
POWER HOUSE.
SURGE SHAFT 1 7.WELDING ELECTRODE SHALL BE USED OF REPUTED MAKE
LIKE ESAB,D&H ,ADVANI.
STEEL TRANSITION 8.PAINITNG SHALL BE DONE AS PER SPECIFICATION.
MANIFOLD
9. NO SITE PAINTING IS ENVISAGED IN STEEL LINERS ( FROM
VALVE HOUSE TO THRUST COLLAR).
PRESSURE SHAFT 10.DOWNSTREAM OF THRUST COLLAR SHALL BE WRAPPED
DN. SURGE WITH BOND BREAKING MATERIAL.
6000 Ø
EL 1548.00 11.MINIMUM CORROSION ALLOWANCE SHALL BE TAKEN AS

40815 55250
1.5MM THICK. HOWEVER, FOR VERTICAL PRESSURE SHAFT AN
EL 1538.60 ADDITIONAL ALLOWANCE OF 0.5MM THICKNESS SHALL BE
CONSIDERED.
00
56097 9585 161840 11142 119511518711345
7200
50
2900
R1
TURNING POINT
TURNING POINT
TURNING POINT
DRG. NO. NHPK - 3KT3 - 45 - GA - 004 - 00
1400
EL 1247.50
MIV CAVERN
THRUST COLLAR CHENAB VALLEY POWER PROJECTS (P) LTD.
PRESSURE SHAFT LINER (A Joint Venture of NHPC, JKSPDC & PTC(I) Ltd.)
PRESSURE SHAFT
(LINE 1 B) ERECTION GALLERY
ikdy nqy ¼æaX|qju½ tYk fo|qr ifj;kstuk
(LOWER) PAKAL DUL (DRANGDHURAN) H.E. PROJECT

OF
PRESSURE SHAFT
STEEL LINER SHEET 2 OF 3
DRAWN SUBMITTED RECOMMENDED APPROVED
30.03.1600 ISSUED FOR TENDER mnzsf[kr izLrqr vuq'kaflr vuqeksnu
DATE DRG. NO.
STEEL LINER
500 THK.
BACKFILL CONCRTE
PRESSURE SHAFT
ERECTION GALLERY
3900 Ø
3900
VALVE HOUSE
[8.0M.(W)X20.3M.(H)] 15000 (UPPER)
SURGE SHAFT 2
EL 1542.00
STEEL TRANSITION
MANIFOLD
00
1 50 MANHOLE
PRESSURE SHAFT R
35000
6000 Ø
DN. SURGE
EL 1548.00
A
EL 1538.60 SECTION
196131 11142 36954

7200
(STIFFENERS NOT
A
SHOWN)
TURNING POINT
3900 F
PRESSURE SHAFT
(STEEL LINED)
PRESSURE SHAFT LINER
(LINE 2 A)
7200
7200
6000 Ø
FLOW
VALVE HOUSE
[8.0M.(W)X20.3M.(H)]
SURGE SHAFT 2
10000 7200
STEEL TRANSITION
MANIFOLD
SECTION F
6000 Ø
DN. SURGE PRESSURE SHAFT

EL 1548.00 40815 55250
STEEL
EL 1538.60
TRANSITION DETAIL
00
11142 15187
50
196131
7200
2900
R1
27035
TURNING POINT
11951
DRG. NO. NHPK - 3KT3 - 45 - GA - 004 - 00
1400
EL 1247.50
MIV CAVERN
THRUST COLLAR CHENAB VALLEY POWER PROJECTS (P) LTD.
PRESSURE SHAFT LINER (A Joint Venture of NHPC, JKSPDC & PTC(I) Ltd.)
(LINE 2 B) PRESSURE SHAFT

ERECTION GALLERY
ikdy nqy ¼æaX|qju½ tYk fo|qr ifj;kstuk
(LOWER) PAKAL DUL (DRANGDHURAN) H.E. PROJECT

OF
PRESSURE SHAFT
STEEL LINER SHEET 3 OF 3
DRAWN SUBMITTED RECOMMENDED APPROVED
30.03.1600 ISSUED FOR TENDER mnzsf[kr izLrqr vuq'kaflr vuqeksnu
DATE DRG. NO.

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CHENAB VALLEY POWER PROJECTS [P] LIMITED

PAKALDUL H.E. PROJECT

2nd Floor, JKPCC Building

Index - General Technical Specification

2.4.8 Permissible Stresses and design of Power pack for 20

3.0 Technical Documents

4. Spare Parts and Tools

5.0 Design and manufacture

5.7 Identification Plates 45

7.0 Electrical Works

7.7 Auxiliary Works 78

8.0 Transport and Storage

9.0 Inspections and Tests

10.2.3 Stiffener Rings, Thrust and Anti-Percolation Rings 99

General Technical Specification

1.1.1 Location and Communication

The main features of the project are as under:

reduces to 2.9m dia., connects to Butterfly valve in MIV cavern

The Contractor shall strictly observe this General Technical

In addition, the Contractor shall conform to all applicable regulations

The Particular Technical Specifications shall take precedence over the

1.3 Scope of work

It is not the intention of these specifications to specify the complete details of

The broad scope of the work shall include the following: -

Design, procurement, manufacture, inspection, shop assembly, testing,

1.3.1 Tunnel Spillway Radial Gates, Hydraulic Hoists, Bulkhead Gates ,

(i) Gate & Hydraulic Hoists

(ii) Tunnel Spillway Bulkhead and Gantry Crane

(iii) Steel Liner for Tunnel Spillway

(ii) Surface Spillway Stoplogs and Gantry Crane

One set of stoplogs/bulkhead consisting of 3 units for clear opening size of

i) Intake Gates and Hoists

ii) Intake Bulkhead Gates and Gantry Cranes

1.3.4 Intake Trash Rack

1.3.5 Valves for environmental flow pipe

1.3.6 Adit Inspection gates

1.3.7 Pressure Shaft Liners

1.3.8 Tail Race Gates and Hoists

Four sets of hoist supporting structure, trestles, hoist housing, foundation

1.3.9 Automatic Reservoir Monitoring and Control Systems

The main items of remote control equipments & instruments to be supplied

i) Computerised remote control system complete in all respect located at

iii) Monitoring and indication of discharge measurement for discharge

iv) Two sets of Differential pressure measurement and indication equipment

All the necessary transducers and instrumentation, terminals, contacts,

Remote indication arrangements shall also be provided in the Power House.

One Uninterruptible power supply at each station to provide back up

1.3.10 Diesel Generating set and Hydraulic Oil Filtering Unit.

Supply of four No. 250 KVA, 415V, 50 Hz AC output, three-phase

1.3.12 Tools and Tackles

1.3.13 Operation and Maintenance Manual

Except where modified by this specification, works and materials shall be in

If requested by the Engineer-in-charge, the Contractor shall supply at his own

2.1 Standards for General Application

Standard publications issued by the following organizations of standardisation

• BIS : Bureau of Indian Standards.

• ASTM : American society for testing & material.

• ASME : American society of mechanical Engineers.