Volume - 2 - Part I - General Technical Specification

MAKAR JITUMAYA HYDROPOWER PRIVATE LIMITED
UPPER SURI KHOLA HYDROPOWER PROJECT
Lot 04: HYDROMECHANICAL WORKS

(Design, Manufacture, Supply, Erection, Testing and Commissioning of
Hydromechanical Equipment)
Contract Identification No: USKHP-HM-04-077/78
VOLUME 2: SPECIFICATIONS
PART I: GENERAL TECHNICAL SPECIFICATIONS
Makar Jitumaya Hydropower Pvt. Ltd. Lot 04: Hydromechanical Works
Upper Suri Khola Hydropower Project Volume 2 Part I: General Technical Specifications
TABLE OF CONTENTS
LIST OF ABBREVIATIONS............................................................................................................V
1 GENERAL PROVISIONS............................................................................................................1
1.1 PROJECT DESCRIPTION......................................................................................................1
1.2 ROAD ACCESS TO THE SITE...............................................................................................1
1.3 THE SITE..............................................................................................................................2
1.3.1 Extents of the Site..........................................................................................................2
1.3.2 Land Availability and Temporary Land Acquisition.....................................................2
1.4 SCOPE OF WORKS...............................................................................................................2
1.5 WORKS TO BE EXECUTED BY THE EMPLOYER OR OTHER CONTRACTORS.....................3
1.6 DESIGN CALCULATION, DRAWING, MANUALS, DESIGN CODE........................................3
1.7 PROCEDURE FOR COMPLAINTS AND CLAIMS FOR DAMAGE............................................4
1.8 MOBILIZATION TO THE SITE..............................................................................................4
1.9 DEMOBILIZATION FROM THE SITE....................................................................................5
1.10 MEASUREMENT OF PAYMENT OF GENERAL FIXED ITEMS..............................................5
1.11 MANAGEMENT MEETINGS..................................................................................................5
1.12 SITE DIARY..........................................................................................................................5
1.13 PROGRESS REPORTS...........................................................................................................6
1.14 DISTURBANCES ON WORKING ENVIRONMENT..................................................................6
1.15 TIDINESS OF SITE................................................................................................................6
1.15.1 Vibration........................................................................................................................6
1.15.2 Noise Level....................................................................................................................7
1.15.3 Seismic Coefficient........................................................................................................7
1.15.4 Levels and reference points............................................................................................7
1.15.5 Survey and setting out....................................................................................................7
1.16 PACKING, STORAGE AND IDENTIFICATION.......................................................................7
1.17 AVOIDANCE OF INTERFERENCE.........................................................................................8
1.18 COMMUNICATION SYSTEM.................................................................................................8
1.19 PHOTOGRAPHS AND VIDEO................................................................................................8
1.20 EMERGENCY ARRANGEMENTS...........................................................................................8
1.21 STANDBY EQUIPMENT, TOOLS AND INSTRUMENTS..........................................................9
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1.22 CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS.............................9

1.23 CONTRACTOR’S CAMP AND FACILITIES............................................................................9
1.24 RECREATION FACILITIES.................................................................................................10
1.25 ACCESS ROAD AND TEMPORARY SITE ROADS...............................................................10
1.26 WATER SUPPLY AND WASTE DISPOSAL..........................................................................10
1.27 CONSTRUCTION POWER...................................................................................................10
1.27.1 General.........................................................................................................................10
1.27.2 Alternative Source of Power........................................................................................10
1.27.3 Protection.....................................................................................................................11
1.27.4 Cables and Joints..........................................................................................................11
1.28 SAFETY PRECAUTIONS......................................................................................................11
2 INTERFACE MANAGEMENT AND PROJECT CONTROL..............................................13
2.1 GENERAL...............................................................................................................................13
2.1.1 Overall Project Programme..........................................................................................13
2.1.2 Contract Interfaces.......................................................................................................13
2.2 INTERFACE DETAILS.........................................................................................................13
2.2.1 Electro-mechanical Works ↔ Hydro-mechanical Works...........................................13
2.2.2 Hydro-mechanical Works ↔ Civil Works...................................................................14
3 GENERAL TECHNICAL SPECIFICATION..........................................................................19
3.1 INTRODUCTION..................................................................................................................19
3.2 DESIGN AND DRAWINGS...................................................................................................19
3.3 DOCUMENTS TO BE SUBMITTED DURING ENGINEERING DESIGN AND
MANUFACTURING..............................................................................................................20
3.3.1 Preliminary Design Data..............................................................................................20
3.4 MATERIALS........................................................................................................................20
3.5 QUALITY ASSURANCE PLAN AND QUALITY CONTROL PROCEDURE.............................22
3.5.1 General.........................................................................................................................22
3.5.2 Quality Assurance Policy.............................................................................................23
3.5.3 Quality Assurance Plan................................................................................................23
3.5.4 Quality Assurance Documents.....................................................................................23
3.5.5 Quality Control Procedure...........................................................................................24
3.5.6 Quality Control Testing...............................................................................................26
3.5.7 Quality Assurance Manager.........................................................................................26
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3.5.8 Quality Inspectors at Site.............................................................................................26

3.5.9 Quality Control Records Manual.................................................................................26
3.5.10 Monitoring...................................................................................................................27
3.5.11 Performance Test.........................................................................................................27
3.6 MANUALS...........................................................................................................................27
3.6.1 Erection Manuals.........................................................................................................27
3.6.2 Operation and Maintenance Manuals..........................................................................27
3.7 MAINTENANCE TOOLS, WORKSHOP EQUIPMENT AND SPECIAL TOOLS.......................29
3.8 WELDING CONSUMABLES.................................................................................................30
3.8.1 Types of Electrodes, Wires and Fluxes........................................................................30
3.8.2 Heating and Baking Requirements..............................................................................31
3.9 QUALIFICATION OF WELDERS AND WELDING OPERATORS..........................................31
3.9.1 General.........................................................................................................................31
3.10 PRODUCTION WELDING....................................................................................................33
3.10.1 General.........................................................................................................................33
3.10.2 Welding Sequence........................................................................................................33
3.10.3 Weld Preparations........................................................................................................33
3.10.4 Weld Execution............................................................................................................34
3.10.5 Preheating and Interpass Temperature.........................................................................37
3.11 SPARE PARTS.....................................................................................................................37
3.12 CONSUMABLE GOODS.......................................................................................................38
3.13 SURFACE TREATMENT AND PAINTING.............................................................................38
3.13.1 General.........................................................................................................................38
3.13.2 Steel Structures, Protection Systems............................................................................39
3.13.3 Protection of Main Structures......................................................................................40
3.13.4 Protection of Auxiliary Equipment..............................................................................41
3.13.5 Hot Dip Galvanizing....................................................................................................42
3.13.6 Colours, Painting and Marking....................................................................................42
3.13.7 Inspection and Approval of Surface Treatment...........................................................44
3.14 CONSTRUCTION ELEMENTS..............................................................................................45
3.14.1 Bolts, Studs, Nuts, Screws, Washers...........................................................................45
3.14.2 Stairs, ladders and platforms........................................................................................46
3.15 CRANES AND LIFTING EQUIPMENT..................................................................................46
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3.15.1 Design and Calculation................................................................................................46

3.15.2 General Design Particulars...........................................................................................47
3.15.3 Electric Cable and Wiring............................................................................................47
3.15.4 Motor Stator and ammeters..........................................................................................48
3.15.5 Conduits.......................................................................................................................48
3.15.6 Enclosure......................................................................................................................48
3.15.7 Convenience Outlets....................................................................................................48
3.15.8 Limit Switches.............................................................................................................48
3.15.9 Indicating Lights..........................................................................................................48
3.15.10 Instruments and Meters..........................................................................................48
3.15.11 Lighting Fixtures....................................................................................................49
3.15.12 Electrical Relays.....................................................................................................49
3.16 GROUNDING.......................................................................................................................49
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LIST OF ABBREVIATIONS
ASTM American Society of Testing and Materials

FAT Factory Acceptance Test
GoN Government of Nepal
ISO International Organization for Standardization
km Kilometre
m Metre
MW Megawatt
masl Meter above sea level
MCCB Moulded Case Circuit Breaker
O&M Operation and Manuals
QAP Quality Assurance Plan
VDC Village Development Committee
WHO World Health Organization
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1 GENERAL PROVISIONS
1.1 PROJECT DESCRIPTION

Upper Suri Hydropower Project is located at Gaurishanker Rural Municipality-5 of Dolakha
District, Janakpur Zone of Central Development Region. The proposed headworks site lies at
Hulak and Kapti, Gaurishanker Gaunpalika-6 and powerhouse site is proposed just upstream of
the confluence of KolungKhola with Hulak Khola and upstream from Suri Khola HPP
headworks. The project facilities such as weir, intake, settling basin, water conveyance system
and powerhouse are located on left and right bank of Hulak Khola, PenteKhola and Kolung
Khola. Geographically, the project structures are located between latitudes 27°43'00" and
27°45'00" North and longitudes 86°15'00" and 86°17'30" East in Dolakha District.The plant
capacity of the project is 7 MW. The gross head of the project is 448 m and net head of the
project 434.21 m. The estimated annual energy generation is 44.31 GWh.
1.2 ROAD ACCESS TO THE SITE

Charikot is 133 km away from Kathmandu in the North-East direction. Nearest market is
Charikot, (i.e. headquarter of Dolakha district) which is about 42 km away from the power
house site. The project is connected by earthen road from Bhorle at Tamakoshi access road.
There is RCC Bridge under construction over Tamakoshi River near Bhorlebazzar. The earthen
road starts after crossing Tamakoshi River Bridge near Bhorle. This road connects proposed
alignment and powerhouse.
S.N. Distance from To Distance(Km) Description

Route
1 Kathmandu Khadichaur 78 Arniko Highway

(Maitighar)
2 Khadichour Charikot 55 Lamosangu-Jiri

Highway
3 Charikot Singati 39.5 Graveled Road
4 Singati PH Suri 11 Earthen Road
5 PH Suri Surgetank 9 To be construct
6 Surgetank Intake 3 To be construct
Total Road Length From Kathmandu to PH 195.5 kM
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1.3 THE SITE
1.3.1 Extents of the Site
The Site comprises the access ways, the site establishment areas, the areas for the
Permanent Works and Temporary Works as shown on the Drawings and any other area
designated by the Employer as defined in the Contract. The Contractor will, during the
execution of the Works, have free and temporary use of working areas and access thereto within
the Site.
1.3.2 Land Availability and Temporary Land Acquisition
The Employer will acquire all the lands necessary for the permanent and temporary construction
works. The Contractor shall, during the execution of the works, have free use of working areas
and access there to in the Employer's area of land, except where shown otherwise on the
Drawings. Depending on the availability of land, the Contractor will be permitted to construct
site office, store, workshop etc. within the area provided by the Employer. The Contractor shall
follow the following procedure while acquiring the land and other private properties required for
temporary works:
i. The Contractor shall make an assessment report on his needs in terms of temporary land
acquisition, possible impacts, households to be affected, and compensation
arrangements before taking possession of or entering in to the assets and submit it to the
Employer;
ii. The Employer and the Employer together shall verify on the ground, review and approve
the Contractor’s request;
iii. After getting the approval from the Employer, the Contractor shall enter into an
agreement with the owner of the land and provide a copy of the agreement to the
Employer before entering into the land or occupying such property. All rentals, lease
amount, compensation to loss of any crops, vegetation, trees etc. shall be paid by the
Contractor at his own cost. The Contractor shall not take the possession of any private
land before the approval of the Employer and the Employer.
iv. The Contractor shall make efficient plan for the provided land by the Employer. Subject
to the availability of limited open area at the site, the Contractor shall use land
economically and temporary housing area may be required to be designed and adjusted
accordingly Standard Professional Practice
The Contractor shall respect globally accepted principles, norms, rules, standards and
practices for effective and successful execution of the construction work. Priority
regarding the adoption of the standards for the cases that are not specified in this
specification shall be as stated by Nepalese standard code or other International standard
codes whichever is available.
1.4 SCOPE OF WORKS

The scope of works in this Contract covers designing, manufacturing, testing during
manufacturing, supply, transportation, transit insurance, delivery of components of the Plant,
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storage at site, erection, testing, commissioning, trial run and handing over of the
Hydromechanical Works required for operation of Upper Suri Hydropower Project.
The Contractor shall strictly observe the requirements of the General Technical Specification in
conjunction with the Particular Technical Specification of individual items/ components. The
Contractor shall carry out all work in a skilled and workmanlike manner in complete accordance
with modern methods of engineering. All design, calculations, materials, manufacture and
testing shall be in conformity with the latest applicable standards.
The Contractor shall comply with all applicable regulations regarding the execution of
construction and installation work and shall follow all instructions issued by the Employer.
Any items or components even though not specifically covered in the Employer’s requirement,
but required for successful operation of the Plant, shall be deemed to be covered in the scope of
Work without any extra cost.
The Contractor shall prepare operation and maintenance manual including as built drawings of
the components installed and provide training to the Employer’s operation and maintenance
staff. The training shall include on the job training for 30 days after taking over to establish a
group of well-trained operation and maintenance staff capable of running the Plant
independently and efficiently.
Temporary Works and services provided and operated by the Contractor shall conform to the
applicable Nepali laws, regulations, standards, codes and sanitary requirements stipulated for
such purpose. In addition, they shall comply fully with all Nepali laws and regulations relating
with environmental protection, mitigating measures for reducing environmental impacts and
remedial works on completion of the Works.
The Contractor shall prepare final completion report of the Plant with technical details.
1.5 WORKS TO BE EXECUTED BY THE EMPLOYER OR OTHER CONTRACTORS

The Employer will arrange all the work necessary for the completion of the Project, other than
that covered by the Contract, to be executed by the other Contractors as follows:
The works covered by the other contractors will include, but shall not be limited to, as follows:
i. Installation of First Stage Embedded parts under the supervision of Hydromechanical
Contractor.
ii. 2nd Stage concrete after the installation of 2nd stage embedded parts.
iii. Foundation works for all equipment to be supplied, installed and commissioned under
this contract.
1.6 DESIGN CALCULATION, DRAWING, MANUALS, DESIGN CODE

Before manufacturing of the equipment and site construction works are to be commenced, the
detailed calculations, dimension drawings & diagrams showing all details of the equipment and
materials to be used as well as all arrangement related to the other Contractor's works and the
adhered design code during the detail design (in the English language) shall be submitted to the
Employer for review and/or approval. In any case, these drawings shall be submitted with
sufficient time allowance to permit modifications to be made, if such are deemed to be necessary
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and /or are instructed by the Employer without delaying the completion of the works. The
drawings which are requested to be modified as necessary by the Employer shall be resubmitted
for re-approval.
The Contractor shall prepare and submit all conceptual drawing, basic force calculation which
affects the civil design on the submission of tender.
The Contractor shall design and prepare detail drawings & calculations and submit within three
month after award of the contract for review and/or approval by the Employer if otherwise not
agreed between the parties. After receiving the design, calculation and drawing, the Employer
will review and respond to the contractor within one month of receipt of the documents. The
contractor will be started execution of works after getting the approval from Employer.
Approval of calculations and drawings in case of purchased materials and equipment shall in no
way relieve the Bidder of his full and sole responsibility as to the quality and completeness of
the equipment and structures supplied and compliance with the contractual requirements.
After all items of the work have been manufactured and erected bound prints and negative of
drawings as built in each station shall be submitted to the employer and the Employer within one
(1) month after the date of taking over.
1.7 PROCEDURE FOR COMPLAINTS AND CLAIMS FOR DAMAGE

Details of all claims or warnings of intended claims that the Contractor may receive in respect of
matters against which he is required by the Contract to indemnify the Employer shall be notified
without delay to the Employer, who shall likewise pass to the Contractor any such claims or
warnings which may be submitted directly to the Employer.
1.8 MOBILIZATION TO THE SITE

The Contractor shall do the necessary preparatory work and operations, including but not limited
to, those required for the movement of personnel, Contractor’s Equipment, Materials, Plant,
supplies, and incidentals to the Project site; establishment of all Contractor's camps and offices
or other facilities necessary for starting the Contractor's operations at the site. Mobilization
activities shall be as per the “Mobilization Schedule” and “Work Method Statement” submitted
by the Contractor during the Tender preparation stage or with any modification as required by
the Employer.
Mobilization shall also include assembly and delivery to the site of the Contractor's equipment,
materials, and supplies necessary for the prosecution of work but which are not intended to be
incorporated in the Works; the clearing of and preparation of the Contractor's work area; the
complete assembly, in working order, of the Contractor's equipment necessary to perform the
required work; personnel services preparatory to commencing actual work; and all other
preparatory work required to permit commencement of the actual work on construction items for
which payment is provided under the Contract.
1.9 DEMOBILIZATION FROM THE SITE

The Contractor shall do the necessary work and operations, including but not limited to, those
required for the removal of personnel, Contractor’s Equipment, Materials, Plant, supplies from
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the Project site; disassembly and removal of all temporary structures such as Contractor's camps
and offices as instructed by the Employer; general clean-up and disposing all garbage, night
soils, and waste as instructed by the Employer; and housekeeping needed to restore a neat and
orderly project site, leave the project site in the same or better condition than at the start of the
project.
1.10 MEASUREMENT OF PAYMENT OF GENERAL FIXED ITEMS

Payment for mobilisation, establishment and demobilization of Contractor's general site facilities
including temporary accommodation for his personnel, offices, medical services, canteens,
plants, workshops, store, warehouses, assembly, storage and material yards etc., including
operation, maintenance and restoration of sites shall be made in two instalments: (i) 75% for
mobilization and establishment and (ii) the remaining 25% for demobilization, removal and
restoration of sites. Payment for the mobilisation and establishment of the Contractor's general
site facilities including temporary accommodation for his personnel, offices, medical services,
canteens, plants, workshops, store, warehouses, assembly, storage and material yards etc. and
their operation, maintenance shall be made only after the Employer has agreed that all these
facilities have been substantially established and are in a clean, finished and fully functional
condition. Payment for the demobilization and removal from site of the Contractor's general site
facilities including temporary accommodation for his personnel, offices, medical services,
canteens, plants, workshops, store, warehouses, assembly, storage and material yards etc., shall
be made only after all buildings, facilities and plants have been removed and the respective site
establishment areas have been cleared and left free of obstruction, rubbish and nuisance of any
kind, on completion of the works.
1.11 MANAGEMENT MEETINGS

Site meetings will normally be held weekly but will be called whenever the progress of the
works so requires, or when required by the Employer. The Contractor's Representative who
shall be in the power and authority to commit in all matters concerning the Contract shall
represent the Contractor at all meetings.
Other management meetings will be held in Kathmandu as required.
1.12 SITE DIARY

The Contractor shall keep a site diary wherein full details of all works carried out each day shall
be recorded. The diary shall be available for inspection by the Employer any time during normal
office hours. At least the following details shall be included:
 location of the various works undertaken
 type, quality and quantity of work achieved
 equipment and plant that arrive on site
 number of employees and plant working
 tests carried out and results
 weather conditions
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 accidents
 visitors to the site
 photograph of major activities and events
 interaction with local people
1.13 PROGRESS REPORTS

The Contractor shall submit weekly progress reports to the Employer, on the first day of the
following week concerned, containing at a minimum the following information:
 location of the various works undertaken
 actual progress versus planned progress
 any work delays with causes
 anticipated problems
 tests carried out including results
 prepared materials
 supplied materials
 two week look-ahead schedule
 accidents, injuries and near misses
Once every 4 weeks the Contractor shall submit a revised master schedule.
1.14 DISTURBANCES ON WORKING ENVIRONMENT

The Contractor shall not be involved in or shall not support or provoke any activities such as
Strikes and Banda which creates disturbances on the working environment during the
construction of the Project.
1.15 TIDINESS OF SITE

The Contractor shall be responsible for the proper upkeep and maintenance of the site and the
works. The Contractor shall collect and accumulates the rubbish and other waste material and
coordinates with other Contractor for its disposal.
Materials and equipment shall be positioned, stored and stacked in an orderly manner.
1.15.1 Vibration
All rotating parts shall be designed to operate without undue vibration. Special precaution is to
be taken to run the equipment smoothly.
The balancing shall be done to a maximum extent at the works. Trim balancing shall not be
carried out at site to bring down vibration level to acceptable limits.
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1.15.2 Noise Level
The noise level shall not exceed 90 dB (A) when measured at a distance of 1.0 m (one metre).
Any vibration caused by the machine should not be in resonance with any part of the equipment
delivered. The frequency band shall be indicated by the manufacturer and high vent noise shall
be avoided.
1.15.3 Seismic Coefficient
The seismic coefficient of the project area is about 0.25g for both vertical and horizontal
movement.
1.15.4 Levels and reference points
The datum point for co-ordinates and levels shall be the permanent benchmarks as indicated on
the Drawings.
1.15.5 Survey and setting out
The Contractor shall be responsible to fix the position of the saddle plates (embedded steel part
in penstock’s saddle) before the civil construction contractor commences the concrete work in
the same. The Contractor shall be responsible for correct alignment of the penstock including its
line, level and angle at straight portion as well as bends.
1.16 PACKING, STORAGE AND IDENTIFICATION

All Plant shall be effectively protected against damage (including all deterioration) during
transport from the place of manufacture to the Site in a location and during storage. Large parts
shall be supported to distribute their mass uniformly and thus avoid any permanent deformation.
An approved drying agent shall be included with all items which may be affected by moisture or
excessive humidity and with all items which are enclosed in plastic or other impervious material.
The packaging shall be made to suit the transportability to the project site under prevailing
access conditions.
Immediately upon receipt at Site, all packages shall be checked by the Supplier/ Bidder against
the shipping list for loss and inspected for damage during transit. The Supplier/ Bidder shall
report all damage and the proposed remedial work therefore to the Employer for approval in
accordance with the Contract.
The Employer will provide storage area with suitable condition for keeping, loading and
unloading facilities as required for the Plant. The Contractor shall provide necessary covering of
storage, drainage facilities and protection from any damages.
All packing material, except that required for storage of spare parts, shall remain the property of
the Supplier/ Bidder and shall be removed from the Site. Only parts for immediate use shall be
delivered from the works storage area, and their packing material shall be removed quickly from
the installation site and disposed to the satisfaction of the Employer.
The Contractor shall be responsible for acquiring the land and arrange at his own expense for
covered storage or other protection of all materials and equipment against corrosion and
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mechanical damage. Any corrosion or damage that may occur to any item shall be made good
before that item is installed.
The Contractor shall provide all dunnage and weather protection for storage of the plant to meet
the requirements of the Employers.
All cases containing machinery shall be placed under covered storage. Weather-proof items and
structural steel members may be stored in the open, but in all instances shall be protected to the
Employer's approval. The Contractor shall be responsible for the adequacy of all protection.
The adequacy of storage and protection shall be such as to permit periodic inspection by the to
check the effectiveness of the protection.
1.17 AVOIDANCE OF INTERFERENCE

Before commencing any Works, where possibility of damage to private and public property is
likely, The Contractor shall ascertain the location of all existing public utilities and other
structures which may be encountered during the execution of the Works. As soon as any such
utilities or structure is encountered during the performance of the Contract, the Contractor shall
make a record of the location and description of such service or structure and shall send the
same forthwith to the Employer.
The Contractor shall establish prior contact to inform all possible owners within the work area to
avoid conflict and misunderstandings. Construction work shall be done in such a way in
protecting/rehabilitating all such facilities with prior consent of likely affected owners. The
Contractor shall temporarily support or divert and subsequently reinstate all such utilities and
structures as necessary and to the satisfaction of the Employer and the owner. No reimbursement
shall be made to the Contractor for such works who shall be deemed to have included the full
cost hereof in the tendered rates.
1.18 COMMUNICATION SYSTEM

The Contractor shall provide and maintain adequate internal communications system around the
Site. All offices, workshops, stores, and other major installations and site facilities shall be
served by a telephone network.
1.19 PHOTOGRAPHS AND VIDEO

The Contractor shall supply soft copy and 2 copies of colour prints of photographs, 2 copies of
DVD, of initial stage, works in progress, major construction events and completed portion of the
Works, as may be directed by the Employer. The cost for this item shall be in-built with other
related items and no separate payment shall be made for this item.
1.20 EMERGENCY ARRANGEMENTS

The Contractor shall maintain arrangements whereby he can quickly call out labour outside
normal working hours to carry out any work needed for an emergency associated with the
Works. The Employer shall be provided at all times with a list of addresses and telephone
numbers of the Contractor's staff who are currently responsible for organising emergency work.
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No separate payment shall be made for the emergency preparedness.
1.21 STANDBY EQUIPMENT, TOOLS AND INSTRUMENTS

The Contractor shall plan for standby equipment, tools and instruments to ensure continuity and
proper completion of his operations, including, welding of penstock and completion of crucial
activities in accordance with programme of Works.
1.22 CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS

In addition to the Contractor, there will be following other Contractors working at the site
1. Civil Construction Works
2. Electromechanical Works
3. Transmission Line and Interconnection Works
The Contractor shall fully cooperate to the other Contractors during the execution of the works.
The Contractor shall make his program schedule matching with the interface linkage with the
activities to be carried out by the Other Contractors as presented in the Time Schedule included
in Part 4: Tender Drawings and Construction Work Schedule of the Tender Document.
The Contractor shall allow free passage to Other Contractors through and over the Site in the
furtherance of their obligations under their Contracts. The Contractor shall make available the
Other Contractors: safe and reasonable access, clean and clutter free work areas, temporary
services required, and any other cooperation and assistances as may be reasonably required for
the completion of the Project Works,
The Contractor shall co-ordinate his general day to day activities with the Other Contractors to
avoid hindrance and obstruction to the Other Contractors as far as appropriate and reasonable.
This shall include but not limited to joint use of facilities such as scaffolding and other general
Site services. Such general co-operation and interface coordination shall be foreseen and
provided for in the Contractor’s programming and is deemed to be included in the Contract
Price.
1.23 CONTRACTOR’S CAMP AND FACILITIES

The Employer will acquire all the lands necessary for the permanent and temporary construction
works.
The Contractor shall be responsible of constructing all necessary temporary facilities such as his
offices, stores, warehouse, motor pool, laboratory, workshops, repair shop, fuel and lubricant
service facilities and equipment, staff quarters and labour camp. The area for workshops,
warehouses and yards will be properly prepared, levelled, drained, and the road works
including manoeuvring and parking surfaces will be prepared to an appropriate design to allow
for heavy vehicle traffic by civil Contractor in coordination with the Contractor and to the
approval of the Employer.
The Contractor shall submit for approval of the Employer within thirty (30) days from the date
of Employer's Notice to precede his detailed plan and/or construction drawings of such
temporary facilities that he proposes to construct or rent, including his proposals for power and
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water supply, roads, parking places, drainage and sewage facilities. All buildings and facilities
shall conform to the Employer's standards. His proposals shall be amended if required and
construction of such temporary facilities and all buildings shall not be started until his proposals
have been finally approved by the Employer.
No separate payment shall be made for the cost of Contractor’s camp and other facilities stated
under this item. It shall be deemed to be covered by the lump sum amount of mobilization
quoted in price schedule.
1.24 RECREATION FACILITIES

The Contractor shall provide appropriate recreational facilities for his employees, sub-
contractor’s employees and direct labourers as necessary.
1.25 ACCESS ROAD AND TEMPORARY SITE ROADS

The Employer will facilitate the access road for the transportation of mechanical components to
the headwork, powerhouse site and penstock & headrace site.
1.26 WATER SUPPLY AND WASTE DISPOSAL

The Contractor will be fully responsible to supply water and to provide waste disposal services
to the work sites, as required for his own needs as well as to the facilities for the Employer, the
Employer and the Contractor. Drinking water supplied will be of WHO standard.
1.27 CONSTRUCTION POWER
1.27.1 General
The Civil Contractor shall make all necessary arrangements with the Nepal Electricity Authority (NEA)
for the provision of the temporary and permanent transmission lines for construction power at the
Headworks and Powerhouse areas. However, the HM Contractor shall be responsible for
delivery and erection of energy meter, cables, poles & accessories from distribution cabinet to
their control cabinets for their own use and pay the electricity cost as per actual. The Cost of the
electricity shall be deemed to be covered by related items. No separate payment shall be made to
the Contractor for the cost of construction power.
1.27.2 Alternative Source of Power
The Contractor can have his own generator. In case the Contractor opt for his own generator, the
fuel for construction power shall be managed by the Contractor and shall plan for occasional
fuel shortage and road blockade in Nepal. The contractor shall use a separate area as a fuel
storage yard with safety precautions approved by the Employer. No additional claims for such
events like shortage and road blockade will be entertained except for Force Majeure events and
for otherwise agreed in the Contract or by the Employer.
In case the Contractor has his own diesel generator sets for the electricity generation, the
locations for installing generators shall be approved by the Employer. The Contractor shall be
responsible to provide all poles, cables and other accessories he will need for supply of power to
May 2021 Page | 10

the construction sites, offices, work shop and camps. No separate payment shall be made for the
cost of construction power. It shall be deemed to be covered by related items.
The Employer will have the right, at all times, to inspect the Contractor's electrical installations.
Those which are unsatisfactory shall be modified immediately by the Contractor to the
Employer's satisfaction, at no additional cost to the Employer.
1.27.3 Protection
All circuits and apparatus shall be well protected using appropriate protective switches gears,
Moulded Case Circuit Breakers (MCCB) or Miniature Circuit Breakers (MCB) of adequate
rating shall be installed for each circuit.
1.27.4 Cables and Joints
Each circuit shall be equipped with copper core cable of adequate dimension as directed by the
Employer and have standard sheathed PVC insulation able to resist moisture and shall be
watertight.
Where multicore cables are used, cables of different colours shall be used for different phases
and the neutral cable (red, yellow and blue for the phase wires and black for the neutral wire).
The earthing cable shall be of green colour.
All joints shall be minimised as far as possible and they shall be well constructed. They shall be
capable of withstanding ambient conditions to provide uninterrupted power supply and be free
from danger.
1.28 SAFETY PRECAUTIONS

The Contractor shall provide his and his subcontractor's personnel as well as the Employer’s or
his representatives and visitors with appropriate personal safety equipment. The use of such
equipment shall be compulsory. The safety-toe footwear with steel caps shall be worn by all
employees engaged in work having an inherent danger to the feet. Light footwear such as
sandals, canvas or tennis shoes shall not be permitted for construction work. During the works
and in the areas where the employees are exposed to harmful noise levels, ear protectors shall be
made available and required to wear. Employees engaged in work having an inherent danger of
eye or face injury shall be furnished and required to wear protection glasses, goggles or masks.
Where irritant or toxic substances may come in contact with the skin or clothing, employees
shall be wearing the protective clothing or shall be required to apply a protective ointment by a
competent physician. Employees working on steep slopes or otherwise subject to possible falls
from levels not protected by fixed guardrails or safety nets, shall be secured by safety belts and
lifelines.
All working sites shall be adequately illuminated during night shift work as well as during
repairing and maintenance work at night. All electrical and hydraulic equipment and appliances
shall be earthed electrically.
May 2021 Page | 11

2 INTERFACE MANAGEMENT AND PROJECT CONTROL
2.1 GENERAL
2.1.1 Overall Project Programme
The critical time path governing the total construction time for the project passes through
construction of Headrace Pipe, and the erection, testing and commissioning of the
Hydromechanical equipment. The total time allowed in the Contract from the Commencement
Date for Lot 2 Hydromechanical Works to the completion of the Works (issue of the Taking-
Over Certificate for the whole of the Works) is presented in Schedule.
2.1.2 Contract Interfaces
The requirements with respect to coordination and clarification of interfaces between the
different Contracts specified in this Section apply in connection with:
 construction and erection
 planning, designing and delivery of Plant
 completion
 testing
 commissioning
 taking over.
2.2 INTERFACE DETAILS
2.2.1 Electro-mechanical Works ↔ Hydro-mechanical Works
Location EM Contractor HM Contractor

Penstocks/ Responsible for delivery and adjustment at Responsible for delivering, transporting,
inlet pipes site of the inlet pipes and designing the and installing the manifold bifurcations
weld groove for welding the connection into the penstock pipe. Responsible for
between the penstock and the inlet valves delivering, installing and embedding
in the power station. (performed by the Civil Contractor
Responsible for delivery of the inlet according to the instructions of the HM
cone/pipe with 200 mm over-length and Contractor) for the branch pipes from
adjustment of the length to fit the each bifurcation to the powerhouse wall
previously embedded branch pipes. and adjusting and securing the pipes to
their final position according to the
Responsible for performing and testing the
requirements of the EM Contractor.
weld seam between the branch pipe linings
and the turbine inlet pipes. The downstream end of the pipes shall
Responsible for cleaning the weld seams be chamfered according to the weld
between the penstock and the turbine inlet groove designed by the EM Contractor.
pipes and cones down to the upstream side The HM Contractor shall connect the
May 2021 Page | 12

Location EM Contractor HM Contractor

of the turbine inlet valve after all penstock by means of welding to the
concreting work and all transportation short pipes of the turbine inlet valve
through the steel linings is completed. provided by EM Contractor.
Finally responsible for the painting of the
weld seam and the inlet pipes.
Trash racks The EM Contractor is responsible for Responsible for designing and building
supplying the HM contractor with the trash racks with the free opening as
information on the maximum opening per the information from EM contractor.
between bars in the fine trash racks.
2.2.2 Hydro-mechanical Works ↔ Civil Works
Location HM Contractor Civil Contractor

General Responsible for the supply of drawings Responsible for excavation and all
showing all hydromechanical equipment related concrete works.
to be delivered and erected, with Responsible for installing under the
dimensions of all the equipment and supervision of HM Contractor all rock
indicating the necessary space required for bolts and anchor steel to be embedded in
installation, operation and maintenance of the primary concrete, for the works
the equipment. related to the interface with HM
Responsible for specifying the necessary equipment.
space required for transportation of his
deliveries to the different erection sites
during erection and later during overhaul
and maintenance of the equipment.
Responsible for drawings showing
detailed locations of rock bolts, embedded
plates and foundation bolts required in
primary concrete as anchoring and
foundations for hydromechanical
equipment. These drawings shall also
show all forces to be transferred to the
rock and/or primary concrete. For
hydromechanical structures to be anchored
and fixed to bolts, all welding shall be
carried out by the HM Contractor.
Responsible for calculation, delivery and
installing all foundation bolts, steel beams
for connection to the bolts and
construction parts to be embedded.
Responsible for necessary anchoring to
bolts and stiffening of his equipment in
connection with embedding the
May 2021 Page | 13


hydromechanical equipment and for
determining maximum allowable rise
speed of concrete in pours in embedment
forms.
Responsible for specifying required
locations and capacities of suspension
bolts/lugs for lifting and pulling for
moving and erection of his equipment.
The HM Contractor shall advise and show
on drawings the locations of all necessary
lifting points for installation and
maintenance.
Responsible for assessing permissible rate
of rise of concrete during pours for
embedment of hydromechanical
equipment and permissible pressures to be
used for injection of the boundary between
steel parts and concrete.
Responsible for all surface protection
treatment after erection.
Temporary Responsible for design, supply and Responsible for supply of electric
supply of installation of cables from the central power, including central distribution
power and distribution cabinets to the different cabinets at the Headworks and
lighting
erection sites for electric power supply Powerhouse areas and lighting during
during erection. The HM Contractor is erection.
responsible for provision of working
lighting for his own erection works.
Gates, Responsible for delivering the equipment Responsible for all local transport,
trashracks, at the dedicated storage yards near the handling and site erection of parts to be
stoplogs etc. erection sites. embedded in the first stage concrete.
Responsible for undertaking and carrying Responsible before the erection starts
out the local transport and site erection of for delivery and embedment of
all parts of the supply, except parts to be reinforcing bars as well as lifting lugs in
embedded in the first stage concrete. the first stage concrete according to
Responsible for supplying all necessary specifications supplied by the HM
equipment for this transportation, loading Contractor. Dowel plates and special
and unloading. items required for erection by the HM
Responsible for site erection of all parts of Contractor shall be delivered by the HM
the supply, except parts to be embedded in Contractor, but shall be installed by the
the first stage concrete. The erection shall Civil Contractor during the first stage
include welding, tests, compliance with concreting.
tolerance requirements, stiffening and
anchorage before concreting, managing
May 2021 Page | 14


the time schedule for erection, etc.
Responsible for embedding guides and
Responsible for delivering dowel plates
frames etc. in the second stage concrete,
and special items required for erection.
and performing grouting as deemed
Responsible for the adjustment and necessary and taking all measures
alignment of frames and guides etc., and required to avoid deformation of steel
performing the necessary bolted and linings or other embedded parts.
welded connections and anchorage.
Responsible for finalising the erection.
Hydraulic Responsible for delivering the equipment Responsible for undertaking and
systems at the storage yard close to the erection carrying out the local transport and site
site. erection of parts to be embedded in the
Responsible for all local transport, first stage concrete.
handling and site erection of all parts of Responsible for making the equipment
the supply, except parts to be embedded in rooms in the operating buildings ready
the first stage concrete. Responsible for and painted once (before erection), and
supplying all necessary equipment for this all pipe trenches ready, before the
transportation, loading and unloading. installation of the hydraulic systems.
Responsible for finalising the erection.
Headrace and Responsible for the delivery of the Responsible for the excavation of the
Penstock Pipe penstock sections to the dedicated storage foundations and all related concrete
yard(s) near the tunnel entrances. works for saddle support, including also
Responsible for finishing and making embedment of the steel linings and the
ready all pipe sections including bends bifurcations.
and bifurcations for erection before Responsible for embedding all the
transport into the tunnels. anchoring bars for the penstock sections
according to the specifications supplied
Responsible for all local transport, by the HM Contractor.
handling and site erection of all parts of
Responsible before erection starts for
the steel linings including bends and
establishing a grout fan at the penstock
bifurcations from the storage yard and
inlet.
through the access tunnel and construction
adits into the locations for erection. Responsible for concreting of saddles
Responsible for supplying all necessary and anchor blocks in Penstock pipe
means for this transport, loading and Responsible for embedding the
unloading. anchoring bars and lifting lugs for the
Responsible for the branch pipe sections, penstock sections according to the
bifurcations and main steel lining sections specifications supplied by the HM
from the powerhouse to the bottom of the Contractor.
penstock shaft to be skidded singly Responsible for delivery and erection of
upwards in the tunnels from the the anchors for the skid-rails, and
downstream end, and welded to the erection of the skid-rails according to
previous section starting from the instructions provided by the HM
May 2021 Page | 15


upstream end. Contractor.
Responsible for the pipe sections to be Responsible for installing and operating
erected in the penstock shaft by lowering the winches / hoists in the penstock
from the top of the shaft and welding to installations.
the previous section, starting from the Responsible for embedding the steel
vertical bend at the bottom of the shaft. lining from the top of the penstock, the
Responsible for supplying and operating manifold pipe and branch pipes to the
winches, hoists and all other necessary upstream wall of the powerhouse. The
equipment for all transportation of pipes to embedment of the pipes shall generally
final location. be made section by section following
Responsible for assessing and providing erection.
the required number and capacities of
anchoring bolts, as necessary.
The Civil Contractor shall be
Responsible for all erection to be done by
responsible for backfilling and covering
the HM Contractor, including welding,
the Penstock if required.
tests, in compliance with tolerance
requirements, stiffening and anchorage
before concreting, management of the
time schedule for erection, etc. Only
circumferential butt-joints, anchors and
bracings shall be welded during erection.
Responsible for removing all internal
stiffeners, and grinding weld spots smooth
and flush with the lining surface when the
concrete is set and before the steel
temperature starts to increase on curing.
Responsible for determining and
supplying a drawing showing the extent of
possible voids between the steel linings
and the concrete during curing of the
concrete, at maximum lining temperature
and recording the maximum steel lining
temperature.
Responsible for drilling grouting holes,

threaded and supplied with protection
sleeves, if additional grouting is needed as
determined by the Employer based on the
drawings of possible voids between the
lining and the concrete. Responsible for
removing the protection sleeves and
closing the holes as specified.
Responsible for blast cleaning the weld
May 2021 Page | 16


seams and the entire steel linings after all
concreting work and all transportation
through the steel linings and bifurcation
has ended. Finally responsible for the
painting of the linings and bifurcations.
Water level Responsible for delivery of water level Responsible for erection of water level
measuring measuring pipes. measuring pipes in the first stage
pipes concrete according to the instructions
provided by the HM Contractor.
Water level Responsible for delivery and erection of Responsible for delivery and erection of
staff gauges water level staff gauge. base plates for the water level staff
gauge scales according to instructions
provided by the HM Contractor.
Cables, and The HM Contractor shall prepare The Civil Contractor shall install
cable pipes, drawings showing the locations and culverts, pipes, ducts, routing ways and
ducts, and dimensions for hydraulic pipes and hoses. conduits in accordance with drawings
routing ways
and conduits The HM Contractor shall prepare and information supplied by the HM
for cables and drawings showing the locations and Contractor.
pipes dimensions for culverts, pipes, ducts, The Civil Contractor shall excavate and
routing ways and conduits for internal backfill all outdoor pipe and cable
cabling for which the HM Contractor is trenches in accordance with the
responsible for installation. instructions of the HM Contractor.
The HM Contractor shall provide all pipe Where instructed by the Employer, Civil
and cable protection material such as Contractor shall make the fire protection
spacer blocks, plastic shields and warning sealing in the block-outs and install
tape, as well as clamps and fixing details. protection materials under the
supervision of the HM Contractor.
May 2021 Page | 17

3 GENERAL TECHNICAL SPECIFICATION
3.1 INTRODUCTION
The purpose of this Section is to provide the Contractor with the general technical requirements
applicable to the Plant and these General Technical Specifications are therefore to be read
together with the Particular technical specification of the items/ components of the Plant.
If the Tenderer finds discrepancies in, or omissions from, these Specifications or from the other
documents, or should he be in doubt as to their meaning, he shall immediately contact the
Employer for interpretation, clarification or correction thereof before submitting his Tender.
Such action shall, however, in no case be considered as cause for altering the Tender opening
date.
The Works shall comply with the functional guarantee and guaranteed technical parameters
stated in the relevant Schedules. The Contractor shall be responsible for any discrepancies,
errors and omissions in the technical parameters and functional guarantees.
3.2 DESIGN AND DRAWINGS

All Plant and supplies shall be designed according to the modern and accepted engineering
practice and as per the prevalent international standard. The life of the Plant shall be as per the
prevalent international practice. All calculations shall be based on internationally accepted
methods and standards. All plant shall be designed with appropriate factor of safety duly
considering unforeseen loads, shock loads, most severe operational flooding, seismic activity
and stresses, during transportation, erection etc. All parts and assemblies of the Plant shall be
suitable in every respect for continuous operation at maximum output under the climatic
conditions and operating conditions prevailing at the Site.
The Plant shall possess a functional design and pleasant appearance. All parts of the plant shall
be arranged in a simple manner to facilitate easy surveillance by the operators, simple
maintenance and operation, and all control manoeuvres shall be straight forward. The
design shall allow easy operation, maintenance and replacement of worn parts as well as a long
service life under the prevailing conditions.
Before manufacturing of the Plant, the detailed design calculations, dimension drawings &
diagrams showing all details of the Plant and Materials to be used as well as all arrangement
related to the Other Contractor's works and the adhered design standard and code during the
detail design (in the English language) shall be submitted to the Employer for No Objection. In
any case, these drawings shall be submitted with sufficient time allowance to permit
modifications to be made so that it does not affect the Time Schedule. The design and drawings
which are requested to be modified as necessary by the Employer shall be resubmitted for No-
Objection.
The Contractor shall furnish for record of Employer complete information, including
computations, regarding the maximum unit stresses used in the design.
The design shall be as per the prevalent international standard and the Contractor shall provide
the design standard and design codes.
May 2021 Page | 18

The Tenderer shall prepare and submit all conceptual drawing, basic force calculation which
affects the civil design on the submission of tender.
3.3 DOCUMENTS TO BE SUBMITTED DURING ENGINEERING DESIGN AND

MANUFACTURING
3.3.1 Preliminary Design Data
The Contractor shall submit 3 (three) sets of basic drawings and other basic design calculation
within 90 days after Commencement Date. Such design information shall provide descriptions
of all apparatus and Plant that will have influence on other contractor's work, and shall include
the following information as far as applicable:
 Overall layout
 Preliminary Indoor and outdoor layouts (Plot Plans)
 Equipment arrangement and outline drawings
 Weights and foundation forces
 Power supply requirements
 Motor schedules
 Instrument schedules
 Control, indication and operation principles
 Manufacture and inspection schedule
 Other relevant drawings and documents in the form of basic information of the Works.
Based on information requests from the Employer, the Contractor shall provide supplementary
design information as required.
3.4 MATERIALS
All items of the Plant shall be designed and manufactured in the most sound manner, using
Materials most suited to the particular service and giving due consideration to the most recent
technical advances. All materials and components shall be new and unused. The Materials shall
be such as to enhance service life, operational reliability, freedom from wear and tear and ease
of maintenance, inspection and adjustment. Back-up facilities shall be provided in order to
ensure reliable and safe operation in event of faults. The design shall also take into account the
aesthetic aspects of the Plant to blend with the general architecture of works. (This relates more
particularly to the equipment in the general control room, the lighting fixtures, the colour shades,
the routing of ducts and pipes.) Reference of Material are as per below.
Reference Material for Gates and Parts:
S.No. Material Specifications
1 StructuralSteel IS2062/ASTMA36/A572
GeneralPurposeCorrosionResi IS1570Part V/ASTMA276orA240,
2
stantSteel Type304or304L
May 2021 Page | 19

IS1570PartV/ASTMA276,Type410
CorrosionResistantSteelforMachine
CompatibleNutsfor410Bolts:ASTMB21,All
3 ryUseandforBoltsandBars
oy464,HalfHard(Naval
HardenedCorrosionResistantStee Brass)
4 lMachineryUseforHighStrengthB ASTMA564,Type630orEqual
ars
CorrosionResistantSteelforHighStren Bolts:ASTMA193,Class2,B8Nuts:
5
gthBoltsandNuts ASTMA194,Grade8S
6 ForgedSteel IS2004/ASTMA668
IS1367,IS1363/ASTMA307,A325,
7 SteelBoltsandNuts
A490
IS2644,Grade3(CS840)/ASTMA
8 CastSteel 27,Grade65-35andASTMA486Class
70
IS318/ASTMB21,Alloy464HalfHard(
9 Brass/Bronze
NavalBrass)
Self-
LubricatingBearingsandWashers( “Lubrite“,includingCastBronzeAlloy(ASTMB22,Alloy
10
CoefficientofFrictionwithStainless 863)withTypeGself-lubricating
Steellessthan0.15)
11 WireRope IS2266
12 WireRopeFittings IS2485,IS3937
13 RubberSeals IS11855,IS15466
IS9975,Vulcanizedcompoundofnitrilebutadienerubber,D
14 ElastomericSealingRings(Oring
urometerAhardness55+/-
s)
5.176Kg/cm2minimumtensilestrength.
Reference Material for Penstock:

S.No Description Standards
PressureVessel/BoilerQualityPlatesforSteelLinerand
1 IS:2062E 250, 350,450
stiffeners
M.S.Bolt-studs,nutsandwasherS.SboltsandNuts
2 IS1364
3 BackingStrip IS:2062E250
4 Gasketorjointingmaterial BS1737
IS:2825,IS:814
5 WeldingElectrodes ASME–
BoilerandPressurevesselCodeSection
6 ForDesignandDetails XIIIDiv.I
IS:11639Part–
Forsteellinersincludingbifurcations,bendsandreducer
a 2forundergroundworksandIS:11639Pa
rt–1forexposedpartsofLiner.
b Manhole IS:2825/ASMESecVIIIDiv.1
ASCEmanual79/IS:11639Part –2
c Thrustring
/ASMESec.VIII
d Welding IS:2825/ASMESecVIIIDiv.1
7 SurfacePreparationandPainting Mechanical CleaningandAWWA-C-203-78
IS2825-1969/ASMESectionVIII
8 InspectionandTesting
Division1andSectionV
May 2021 Page | 20

3.5 QUALITY ASSURANCE PLAN AND QUALITY CONTROL PROCEDURE
3.5.1 General
The Contractor shall prepare his detailed Quality Assurance Plan (QAP) and Quality Control
procedures to ensure that the Works to be performed by the Contractor and his other
Manufacturers and Supplier shall meet the Employer’s Requirement during all phases of the
Works including but not limited to design, manufacturing, and installation. The quality control
procedure shall be provided for each item of work to be carried out by the Contractor under this
Contract. The Contractor shall submit the documents for the Employer's review not later than 28
days after the Commencement Date. The Employer will either approve the documents or
instructs amendments to be made, and the Contractor shall implement all such amendments
within 14 days and re-submit the documents to the Employer for approval. The Contractor shall
abide by the approved Quality Assurance Plan (QAP) and Quality Control procedures.
The Contractor’s quality system shall comply with the latest standards and with all the
requirements of the Contract as well as with the requirements for quality assurance and testing
as set out in this Sub-Clause. It shall be the responsibility of the Contractor to demonstrate to the
Employer that compliance with the specified requirements is achieved.
The Contractor shall implement the Quality Control in compliance with the approved QAP and
Quality Control Procedure.
The Employer’s approval of the QAP and Procedure shall not relieve the Contractor from his
responsibility of the quality of the Works as per the Conditions of Contract and these
Specifications nor shall the Employer’s approval of the QAP and procedure exempt the
Contractor of any procedure to inform the Employer in writing or request for the Employer’s
approval or re-approval as specified in the Conditions of Contract and/or in these Specifications.
The Contractor shall monitor and update the QAP and Procedure on the basis of the decisions
taken at the periodic review meetings or as directed by the Employer.
The Contractor shall provide Table of Contents and brief description of his Quality Assurance
Plan in his Tender
The Contractor shall submit:
 Quality Assurance Policy
 Quality Assurance Plan
 Quality Control Procedures
3.5.2 Quality Assurance Policy
The Quality Assurance Policy shall be a general comprehensive document outlining the
Contractor’s basic organizational policies. The Contractor shall also submit Quality Assurance
Policy of his Manufacturers of major components of works, if the Contractor himself does not
manufacturer those components.
May 2021 Page | 21

3.5.3 Quality Assurance Plan
The Contractor shall submit detail Contractor’s Quality Assurance Plan applicable throughout
the Contract period to ensure that the Plant under the scope of this contract whether
manufactured or fabricated within the Contractor’s premises or at other manufacturer or
supplier’s premises or at the Employer’s site or at any other place are in accordance with the
Employer’s requirement. It is the underlying philosophy of these Specifications that the quality
built into the works shall be maintained throughout the design, manufacturing, installation and
commissioning stages. The quality and workmanship shall be consistent with the design life of
the Works.
The Quality Assurance Plan shall include but not limited to:
Organisational structure for the management and implementation of the proposed quality
assurance plan
 Quality control during Design stage including control of drawings and documentation
 Quality Control during manufacturing including purchase of materials, parts,
components and selection of supplier’s service including vendor analysis, source
inspection, incoming raw-material inspection, testing, and verification of materials
purchased; system for process control, inspection and testing during manufacturing; and
system for inspection and testing of final product
 System for packaging, handling, transportation up to the site, delivery, inspection and
storage at site of the materials and components
 Process control and activities checklists during installation at site
 Cleaning and protection procedures
 Inspection and testing Procedures at site
 Control of non-conforming items and system for corrective actions
 Control and calibration of measuring and testing Equipment
 System for maintenance of quality records
 System for quality audit
3.5.4 Quality Assurance Documents
The Contractor shall be required to submit the following applicable Quality Assurance
Documents to the Employer for approval prior to packaging and shipping of the Plant:
I. Record drawings (as manufactured)
II. Contractor’s data report
III. All Non-Destructive Examination procedures, stress relieving and weld repair procedure
actually used during manufacturing/ fabrication.
IV. Non-Destructive Examination result, reports including radiography and ultrasonic
interpretation reports
May 2021 Page | 22

V. Sketches and drawings used for indicating the method of traceability of the radiographs/
ultrasonic reports to the location on the equipment.
VI. Welder identification list, listing welders and welding operator’s qualification procedure
and welding identification symbols.
VII. Certified material mill test reports on components as specified by the specification.
VIII. The inspection plan with verification, inspection plan check points, verification sketches,
if used, and methods used to verify that the inspection and testing points in the inspection
plan were performed satisfactorily.
IX. Stress relief charts and heat treatment charts.
X. Certificate of compliance
XI. Non-conformance reports
XII. Routine and special test reports
XIII. Final inspection report including factory test results for testing required as per applicable
codes and standards referred in the specification.
XIV. Factory Acceptance Test reports duly signed by Quality Assurance personnel of the
Employer and the Contractor. During the course of inspection, the following will also be
recorded :
a. Any important rectifications carried out or to be carried out to make the Plant acceptable.
b. The rectification work remains part of the accepted product quality.
3.5.5 Quality Control Procedure
The Contractor shall have written quality control procedures to assure that the required
component or sub-component testing is properly performed. The Contractor’s quality control
procedure shall be submitted in sufficient detail to delineate those items to be inspected and the
manner in which they are to be inspected, and shall adequately describe all quality control
activities contemplated, including provision for adequate documentation of Contractor’s
performance of such quality control and inspection. The procedure shall address pertinent test
pre-requisites, such as test instrumentation selection and calibration, acceptance criteria,
documentation of test results, and evaluation of test results by qualified personnel. The
Contractor shall also conduct a continuous program of deign quality control , manufacturing
quality control and installation quality control during the Contract period.
Detailed shop inspection/testing schedule shall be submitted by Contractor to Employer for
approval Quality control procedure shall take into account various provisions of specifications.
Non-destructive examination shall be carried out for the principal parts of materials and the weld
seams of fabricated components in accordance with the requirements of applicable IS
specifications or A.S.T.M. standards.
Material mill certificates and material identification record for important components shall be
submitted after completion of fabrication.
May 2021 Page | 23

The method of rectification of manufacturing errors, material defects and performance

shortcomings shall be to the approval of the Employer.
All necessary tests as per specifications and applicable codes and standards shall be conducted
during various stages of manufacture.
The test and inspection certificates shall be submitted to the Employer prior to dispatch of
equipment components/assembly concerned.
To ensure implementation of quality assurance plan, all inspection and tests on various material,
components, assembly and equipment shall be sub-divided into following categories:
I. Tests by the Contractor’s inspector for components manufactured by the Contractor
II. Tests by other manufacturer’s inspector and approval by the Contractor’s inspector.
III. Tests certificates of other suppliers and approval by the Contractor’s inspector
IV. All inspection/tests are subject to Employer’s review.
Quality assurance plan shall be offered for all components of the Plant covered under the
contract.
As far as practical, provisions and guidelines of IS0: 9001 and ISO 14001 will be applicable and
implemented for quality control and assurance.
The Contractor shall prepare detail quality control procedures proposed to be adopted for
controlling the quality characteristics relevant to each item of Plant such as penstock, radial
gates, trash racks etc and shall be submitted to the Employer for approval along with the QAP or
as instructed by the Employer. The Quality Control procedure shall include the applicable tests
including but not limited to radiographic test, Ultrasonic test, magnetic particle test, Dye
penetration test, etc. The Quality Control procedure shall include but not limited to following:
a. Material test of raw material.
b. Non-destructive examination
c. Component inspection and tests
d. Assembly inspection and tests
e. Pressure test
f. Operational tests
g. Performance and efficiency tests as applicable
h. Estimate of the number of tests to be carried out, list and number of appropriate
equipment to conduct them, list of tests to be conducted outside the site laboratory, if
any, identification of the outside laboratory where proposed to carry out the test.
i. List of staff assigned their position and responsibilities in the quality control procedures,
their qualification and experience.
j. The list of sources of materials and/or of manufactured articles, their main
characteristics, their identification mode as provided by the supplier when required; the
programme of supply and procurement of material and/or manufactured.
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k. The list of tests and quality control procedures to be implemented by the manufacturers,
suppliers, if any, pointing out the “critical” acceptance testing procedures.
3.5.6 Quality Control Testing
The Contractor shall prepare, and update daily, control charts or graphs of the results of quality
control tests. A separate control chart or graph shall be kept for each type of procedure or test. A
copy of the updated charts shall be provided to the Employer whenever requested by the
Employer.
All records shall be maintained in a secure storage area. Access to inspect and examine these
records shall be provided by the Contractor at the request of the Employer at all times.
3.5.7 Quality Assurance Manager
The Contractor shall designate a Quality Assurance Manager with authority to develop and
enforce the Contractor's Quality Assurance Program and all quality control activities during
design, manufacturing, installation as well as coordination with other manufacturers and
Suppliers and also with the Employer.
3.5.8 Quality Inspectors at Site
The Contractor shall designate experienced Quality inspector separately for penstock and gates
at sites for quality control activities related with penstock such as fabrication of penstock and
laying of penstock and activities related with installation of gates and other components.
3.5.9 Quality Control Records Manual
The Contractor shall submit the Quality Control Records Manual to the Employer within28 days
after the issuance of Taking-Over Certificate in three copies. The manual shall include copies of
all formal certificates, reports and results of tests and inspections related to the Works covered
by these Specifications and other documents as instructed by the Employer.
3.5.10 Monitoring
During the course of the Contract, the Employer reserves the right to monitor the
implementation of the Contractors Quality Assurance arrangements including those of the
manufacturers and suppliers by the Employer or by a third party.
3.5.11 Performance Test
The Contractor shall perform the performance tests as required to verify that the permanent
components of the works designed and built by the Contractor meet the required performance
criteria as mentioned in following sub-clause of Particular Technical Specification. All the tests
shall be carried out in the presence of Employer or getting his approval as specified in the
Contract documents.
 Inspections and Testing
 Shop Assembly and Test
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 Installation and Test during Installation
3.6 MANUALS
3.6.1 Erection Manuals
The Contractor shall supply erection manuals which include appropriate procedures for the
installation of the main items of the Plant. These documents shall include all drawings,
specifications and sketches necessary for proper erection and disassembly, in particular:
1. The use of erection platforms with overall dimensions sketch,
2. Lifting and handling equipment required,
3. Detailed operation sequences,
4. Erection drawings,
3.6.2 Operation and Maintenance Manuals
The Contractor shall provide Draft Operation and Maintenance Manual, for Employer’s review,
before the start of the formal training program to the Employer’s personnel. The Contractor shall
provide one soft copy and five sets of Operation and Maintenance Manuals (O & M manuals), it
shall be submitted to the Employer within 60 days after Taking Over. The scope of the manuals
shall be suitable for fully informing the Employer’s staff on all aspects of the operation and
maintenance of the Plant. The content of the O & M manuals shall be directly applicable to the
Plant. Standard instructions covering a number of sizes and/or models of proprietary equipment
will be accepted provided they cover the items supplied and these items are clearly identified
throughout the O & M manual.
The Operation and Maintenance Manuals to be provided by the Contractor shall contain the
following information in sufficient detail to enable the Employer to maintain, dismantle, repair,
reassemble, adjust and operate the Works with all his Plant:
(a) Table of Contents
(b) List of Illustrations
The list shall contain in alphanumeric order all drawings, sketches or any kind of
illustration required for a proper understanding of the equipment.
(c) Introduction
The Introduction shall comprise:
i. General description of the equipment,
ii. Brief description of the use of the equipment,
iii. Definition of technical terms used throughout the manual,
iv. A complete list of all items in accordance with the Plant Identification System.
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(d) Detailed Description

The Detailed Description shall give complete and precise information on the equipment,
all components and ancillaries, their assembling and dismantling. An accurate list stating
clearances, tolerances, temperatures, fits, etc. shall be included.
(e) Operating Principles and Characteristics
The technical operating principles and specific characteristics of the equipment
shall be summarised briefly.
(f) Operating Instructions
The instructions shall be precise and easy to understand, and shall contain the sequence
of individual manipulations required for operation. It shall include details of the
indicators installed and their application during operation. The information shall be
presented in such a manner that the contents of this section can be used for instructing
personnel in the operation of the equipment. Tables, lists and graphic presentations
should be used whenever possible for making the description readily understandable.
(g) Testing and Adjustment
The entire testing and adjustment procedure for testing and adjusting the Plant, modules
or sub-modules during operation, as routine maintenance work or after repair work or
after overhauls shall be described.
(h) Maintenance Instructions
This section shall be divided as follows:
i. Preventive Maintenance: Indicating the inspections required at regular
intervals, the inspection procedure, the routine cleaning and lubricating
operations, condition monitoring (if applicable), the regular safety checks and
similar steps.
In addition a maintenance schedule shall be prepared, listing the required activities
in daily, weekly, monthly, quarterly, yearly, or other cycles. This document shall
provide brief and fully comprehensive information including all references to the
applicable detailed maintenance instructions.
ii. Repair and Adjustment: Describing the inspections, fitting and dismantling of parts,
error search, repair and adjustment procedures.
An appropriate trouble-shooting list shall be provided including fault-tree diagnosis
diagrams, logic and analysis.
Detailed Repair manual shall be supplied enabling the Employer to carry out proper
maintenance and repair work. It shall include disassembly and assembly
procedure. The drawings shall indicate sufficient details dimensions, tolerances,
clearances and material specifications to enable the repair or replacement of such
parts as is common practice to perform. It shall provide lists of required test
instruments and maintenance tools, diagrams showing test instruments connections
and instruments setting, and detailed step-by-step procedures for identifying fault
May 2021 Page | 27

where at each step are specified the instrument set-up, the correct measurement at
this stage and the route(s) to follow when incorrect measurements.
The detailed technical descriptions, diagrams and charts which are required as
reference documentation for the detailed fault identification, repair and tests and
adjustment procedures, shall also be included.
iii. Spare parts catalogues giving all necessary data for ordering of spare parts directly
from the manufacturers, suppliers with name and complete address
iv. List of Tools and Appliances
Precautions and warnings relating to the safety of personnel and of the Plant shall
be clearly stated at the beginning of the manual. Sketches or photographs shall be
included in the text whenever necessary for clarity. The Contractor shall submit for
approval draft copies of each manual. Final version shall take into account the
amendments required by the Employer, final setting values determined during the
commissioning of the Plant, etc.
3.7 MAINTENANCE TOOLS, WORKSHOP EQUIPMENT AND SPECIAL TOOLS

The Contractor shall supply all the Maintenance Tools, Workshop Equipment, if specified in
different components of the Plant in this document. The Contractor shall supply one set of all
necessary tools required for maintenance and repair including dis-assembly and assembly of the
components of the Plant and all the tools that will be specified in the Operation and Maintenance
manual. The cost of the tools shall be in built in the Price Schedule for the components and shall
not be separately paid.
The customary tools shall be of the forged and polished chrome-vanadium type and shall be long
lasting. The maintenance tools and equipment shall be supplied in a lockable cabinet fitted
internally so that the tools may be safely stored in an orderly manner. Suitable wall mounted
hardwood or steel storage racks as well as tool carts and/or tool boxes shall also be supplied for
easy accessibility of frequently used tools. The supplied tools shall be identifiable as per the
maintenance manual.
Furthermore, the Contractor shall submit with his Tender, a recommended list of special tools
which may be necessary during long term operation. The schedule will not be considered as part
of the Contract. However, the Employer, at his discretion, may order any of the special tools
from this schedule during the Contract period.
The Employer, at his discretion, shall be entitled to take over the entire erection tools, appliances
and instruments at mutually agreed conditions from the Contractor.
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3.8 WELDING CONSUMABLES
3.8.1 Types of Electrodes, Wires and Fluxes
1.1
 General
The electrodes, wires and fluxes used in fabrication shall be selected to produce welds with
mechanical properties equivalent to those required for the base metal or as specified by the
Employer.
When steels of different strengths are joined, the tensile properties of the weld metal shall be
matched to the lower strength steel.
 Covered Electrodes
All covered electrodes for welding of structural steel shall be low hydrogen electrodes. The
hydrogen content shall not exceed 10 ml per gram of deposited weld metal.
Electrodes shall be selected from a list of approved types of electrodes, such a list to be
submitted to the Employerfor approval prior to selection being made.
Electrodes shall only be used under conditions, in positions, and using the welding parameters
recommended by the manufacturer
 Wire and Flux for Submerged Arc Welding
Wire and flux shall be carefully selected and the flux shall be of the fully basic type. The storage
and use of wire and flux shall be as recommended by the manufacturer. The flux supplier shall
define the range of chemical composition of wire to be used for his particular flux. No low-alloy
wires shall be accepted. The proposed wire and flux shall be submitted for approval to the
Employer.
 Wire for Gas Metal Arc Welding
The gas metal-arc process may only be used on mild steel in enclosed shop fabrication
conditions, and provided that the filler wire selected is such that the welds produced have the
same mechanical properties as the base metal.
 Conditions and Storage
Electrodes shall be supplied in hermetically sealed metal boxes and stored in a dry storage room
where the minimum temperature is 20 C. All manual type electrodes shall be properly
identifiable (see AWS A 5.1 and 5.5) up to the time of usage, each electrode being
distinguishable by colour code marking. If baking, handling or other causes destroy colours, the
electrodes shall not be used. Batch numbers shall be recorded.
Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of other
types, such as rutile or organic type electrodes.
Wire spools for automatic and semi-automatic processes shall be stored in cabinets with supplier
wrapping not removed and remain clearly identifiable up to the time of usage. Unidentifiable
wire shall not be used.
Flux shall be supplied and stored in accordance to this Specification.
Each batch of flux and wire shall be labelled with the information from the supply container.
The labels with batch number shall be recorded for reference.
All unidentifiable, damaged, wet, rusty or otherwise contaminated consumables shall be
scrapped.
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A consumable handling, storage and issuing procedure shall be submitted to the Employer for
approval prior to the start of any fabrication.
3.8.2 Heating and Baking Requirements
All low hydrogen electrodes shall be baked at 270ºC to 330°C one hour prior to use. On
completion of baking, the electrodes shall be transferred to a holding oven at 150ºC. When later
removed from the holding, the electrodes shall be transferred to heated quivers or containers at
75ºC and used within 8 hours.
Electrodes not used within 8 hours or for some reason exposed to adverse atmospheric
conditions shall be re-baked for one hour then transferred to the holding oven for later use.
Electrodes shall be re-baked only once.
Flux for submerged arc welding shall be issued as required for immediate use. They shall be
held in heated silo at 70 ºC.
3.9 QUALIFICATION OF WELDERS AND WELDING OPERATORS
3.9.1 General
1.2
 Qualification Required
Welders and welding operators shall be qualified in accordance with the requirements of DIN
EN 287, ASME or AWS D1.1 and this Specification. Only qualified welders shall be employed
during the fabrication including tack welding, structural welding and repair welding of any
structural steel part. They shall only perform welding for positions and processes for which they
are qualified. Backing materials shall not be used during testing. The Contractor shall ensure
that welders of any subcontractor or of any otherwise nominated contractor are qualified in
accordance with this Specification. The purpose of a welder qualification test is to verify that the
welder can apply a qualified welding procedure making welds of satisfactory quality.
 Witness and Approval of Test before Welding
All welders and welding operator’s tests shall be witnessed and approved by the Employerbefore
the welder or welding operator is permitted to work on the structure. The decision by the
Employerregarding qualification of any welder or welding operator shall be final. Evidence of
previous qualification tests may be accepted solely at the discretion of the Employer.
 Provision of Equipment and Costs of Test
The Contractor shall provide equipment for the welder qualification tests and shall bear all costs
for the non-destructive testing, the cutting and machining of test specimens and mechanical
testing of specimens.
 Welder Identification System
An identification system shall be worked out for welders and welding operators. The system,
which shall include a numbering and identification card index, shall be established and agreed
with the Employer. Whilst on the Works, the welder/welding operator shall always be
identifiable by a badge bearing his name. In the event that a welder leaves the Works, his mark
shall not be assigned to another welder employed on the Works.
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 Marking of Welds
Each qualified welder and welding operator shall be supplied with an identification marker. The
welder shall clearly mark the plate or pipe adjacent to his weld using soft die stamps with the
identification mark assigned to him in his qualification certificate. Tack welding of components
need not be marked.
 Base Material
As far as it practicable, welders and welding operators shall be qualified on the same material to
be used for fabrication. Similar types of materials may be substituted at the discretion of the
Employerprovided that it can clearly be demonstrated that the weldability is equivalent to the
material intended for use in the fabrication.
 Retest
If the test joint does not meet the requirements, the welder or welding operator may at the
discretion of the Employer, carry out a new joint of the same type as the one rejected. Failing of
both these tests shall result in the welder or welding operator not being employed further for the
Contract.
 Welder Qualification Record
A record of the welder’s qualification tests, including a reference to the corresponding WPS
number, the essential variables according to Clause 3.9above and the test results shall be issued
for each welder or welding operator for each test they pass.
 Period of Effectiveness
(a) Welders and welding operators who will perform welds in the process/position
combinations for which they were previously qualified need not re-qualify for those
combinations if both of the following requirements are met:
 The Contractor can show that the welder’s performance has been monitored and proven
satisfactory since the qualification test.
 A recognised Certifying Authority has endorsed the welder certificate at a date less than six
months before construction starts.
(b) During construction, the Contractor shall provide evidence indicated in a) above to the
Employer so that the welder certificates can be re-endorsed within six months of the
previous endorsement date. Any certificate not endorsed every six months shall be
considered invalid.
(c) A qualified welder or welding operator may, at the discretion of the Employer, be required
to re-qualify if inspection reveals that an unacceptable number of repairs are necessary.
3.10 PRODUCTION WELDING
3.10.1 General
Preparation and welding of structural members shall be in accordance with the appropriate
qualified welding procedure specifications. Manual electrodes, wires and flux shall be of the
same type and manufacture as those used in the procedure qualification tests.
Welding equipment shall confirm to the appropriate sections of AWS, ASME, DIN or BS 638.
Any equipment found not to comply with these requirements should be replaced. Welding
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current and voltage shall be the same as the test values, or within the range specified in the
welding procedure.
No welding shall be done until as much of the structure as will be stiffened thereby has been
properly aligned.
3.10.2 Welding Sequence
The Contractor shall develop welding sequences to control warping, creeping and the build-up
of excessive internal stresses in the structure. The sequences shall be submitted to the
Employerfor approval before the assembly of any components. The Contractor shall furnish the
necessary supervision to ensure that the planned sequences are followed.
Sequences shall include:
(a) Welding procedure specification to be applied.
(b) Sequence of plates to be welded.
(c) Any differences from the specified welding procedures, such as areas of pre-heating,
reinforcements, etc.
(d) Post weld heat treatment, heating and cooling rates.
(e) Number and location of welders at each stage of assembly.
(f) Tack welds and spacers used in the assembly of components.
3.10.3 Weld Preparations
1.3
 Alignment
(a) At Splices (butt welding)
The offset at butt joints shall not exceed T/10 (where T is the thickness of the thinner material)
or 4 mm, whichever is less. The offset in longitudinal seams shall not exceed T/10, or 3 mm,
whichever is less. All offsets greater than 2 mm shall be given a 1:4 transition.
(b) At Welded Intersections
The utmost attention shall be paid to good alignment of the structural parts on opposite sides of
the through member.
 Surface Cleaning Before Welding
Surface to be welded shall be free from loose scales, slag, rust, grease, paint and any other
foreign material.
 Edge Preparation
Preparation of weld edges by gas cutting shall, wherever practicable, be done with a
mechanically guided torch. Edges shall be left free of slag and the cut surface shall be ground to
a smooth uniform surface by removing approximately 0.5 mm of metal. After grinding, the weld
edges shall be visually examined to ensure freedom from defects.
 Cleaning During and After Welding
Upon completion of each welding pass, the weld shall be cleaned of spatter, slag and flux
deposits. After welding is complete, adjacent surfaces shall be thoroughly cleaned of all spatter
and deposits.
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3.10.4 Weld Execution
1.3.4
 Welding Position and Progression
(a) SMAW, GMAW Welding
Electrodes shall only be used in the position recommended by the manufacturer. Weld
progression in vertical joints shall utilise the uphill method. For the 1G, 2G, 1F and 2F positions,
the maximum size of electrode allowed is 6.4 mm. For any other position, the maximum size of
electrode shall be 5.0 mm. The capping passes shall always be done with 4.0 mm maximum
electrode.
(b) SAW Welding
This shall be done in the flat position and in the case that it is done on pipe, the pipe shall be
mechanically rotated.
 Size of Welds
To obtain optimum toughness, a small bead multipass technique shall be used. The weave width
for SMAW, i.e. maximum oscillation of the electrodes, shall not exceed two and a half times the
electrode diameter and the welding speed shall be 375 mm per minute minimum.
The width of SAW beads shall not exceed six times the electrode diameter and the welding
speed shall be 375 mm per minute minimum.
Fillet welds shall be completed in three or more runs except for welds, which may be done in
one run. Two run fillet welds are not permitted.
The Employer shall have the right to limit the thickness of each weld bead or pass when this
exceeds those given in the weld procedure qualification test.
 Intermittent Welding
Stitch welding i.e. partial seal welds shall not be allowed.
 Seal Welds
Where stress bearing welds are required by contract drawings to extend only partially around a
member, including plates joining another member, a seal weld of 4 mm minimum fillet shall be
applied continuously to the remainder, but note should be taken that a hardness of HV 325
maximum shall not be exceeded.
 Tack Welds
Bridge tacking is the preferred method to avoid the tack becoming part of the final weld. If
another method is selected, tack welding shall be performed with the same qualified welding
procedure as will be used for structural welds. These tack welds shall be ground (feathered) and
checked before actual welding commences. Tack welds are to be a minimum of approximately
50 mm long and spaced so that shrinkage forces cannot cause cracking.
 Butt Welds
Design of the groove and performance of welding shall be in accordance with the approved
WPS. However, in general, the groove shall be bevelled to give an included angle of not less
than 30 degrees and shall be of the V type or X type (single bevel or double bevel). The root
opening shall not be less than 2 mm and not greater than 5 mm and the root face, if any, shall not
be greater than 3 mm.
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Where access to both sides is possible, double bevel groove welds shall be used to minimise
welding stresses and shrinkage effects.
When different thickness is to be butt welded, a 1:4 taper shall be provided on the thicker
member stating at the toe of the weld cap.
At any joint, no butt weld shall be located such that an incoming member will result in a weld
overlapping the butt weld.
 Plate Joints
Design of the groove and performance of welding shall be in accordance with the approved
WPS. The bevel shall be preferably be feather edged and the root opening shall be 3 - 5 mm or
according to an approved procedure.
Welding of minor members shall be full penetration type weld and where fabrication method
permits; welding from both sides shall be carried out.
 Weld Compatibility
All weld joints shall develop the mechanical properties specified for the steel being welded.
Where different grades of steel are joined, the weld metal shall be matched to the lower strength
steel. The procedure shall be such as to safeguard the mechanical properties of the higher
strength member.
 Weld Finish
Welds shall be left as welded and not be doctored with a torch or by any mechanical means to
change their appearance. Any grinding or other mechanical dressing is only being permitted,
after authorisation through the Employer.
 Weld Interruption
Welding of each weld shall be a continuous operation, with the exception of manually welded
root runs for submerged arc welding. In the case that welding must be discontinued, this shall
not take place before at least half of the final weld thickness is achieved. The maximum time
that a production weld will remain part welded is two days. The maximum number of heat
cycles that will be used in a production weld shall be two. Slow cooling of the weld area shall be
ensured. Before continuation of welding, the weld shall be inspected for cracks visually and by
MPI.
 Weather Protection
Shelters shall be provided at all times to give protection to the weld area from winds, rain and
moisture. No welding shall be carried out when the weld surface is wet or the work area is
exposed to high winds.
Precautions required:
(a) The weld surfaces shall be thoroughly dried by preheating (not above 300º C). Temperature
control shall be carried out.
(b) Special precautions made to provide conditions maintaining a satisfactory surrounding
temperature and freedom from the effects of winds shall be subjected to the approval of the
Employer.
(c) If any fabrication is to be carried out in the vicinity of equipment already installed in
connection with the Work, then, before such fabrication work commences, the Contractor
shall provide adequate protection to prevent any damage from weld spatter, flame cutting
droplets and the like. Such protection shall be subject to the approval of the Employer.
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 Peeling
The peeling of welds is not permitted.
 Arc Strikes
Arc shall be struck only on fusion faces and contact of electrodes or the non-insulated parts of
the electrode holder with the assembly shall be avoided.
Places where any stray arcs have accidentally occurred shall be subject to repair or rejection at
the discretion of the Employer.
Where permission to repair arc strikes mechanically has been given, the procedure shall include,
but not necessarily be limited to, the mechanical removal of the defective material, blending of
the excavation, checking by MPI and confirmation that the thickness of the repaired material is
within permitted tolerances.
 Welding of Structural Steels
To enable full throat thickness to be provided at the ends of butt-welded points “run-on” and
“run-off” plate extension pieces shall used. “Run-on” plates and “run-off” plates shall comply
with the following requirements:
(a) One pair of ‘run-on’ plates and one pair of ‘run-off’ plates prepared to the same thickness
and profile as the parent metal shall be attached, preferably by clamps, to the start and
finish of all butt welds:
(b) Butt welds shall extend at the full weld profile for a minimum distance of 25 mm into both
the ‘run-on’ and the ‘run-off’ plates:
(c) When removing the ‘run-on’ and ‘run-off’ plates by cutting, the cut shall not be nearer than
3 mm to the sides of the parent metal and the remaining metal shall be removed by grinding
or another method agreed by the Employer.
 Welding of Steel Casting
Fusion welding of steel castings shall comply with requirements of DIN-Standards and BS 4570.
The proposed welding procedures shall be submitted in writing, in accordance with the
requirements of either BS 4570: Part 1, BS 4570: Part 2 or approved DIN-Standards, for
approval of the Employer before commencing welding of steel castings.
 Pins and Pin Holes
Pins shall be parallel throughout and shall have smooth surface free from flaws. They shall be of
sufficient length to ensure that all types connected thereby will bear fully on them. Where ends
are threaded they shall be turned to a smaller diameter and shall be provided, where necessary,
with a pilot nut to protect the thread.
The pinholes shall be bored smooth, straight and true to gauge and at right angles to the axis of
the member. Boring shall be done only after the member is finally bolted or welded unless
otherwise agreed with the Employer.
For pins up to and including 250 mm diameter. The diameter of the pin shall be within a
tolerance of –0.25 mm and –0.40 mm and the diameter of the pin hole shall be within a tolerance
of 0 mm to + 0.15 mm.
For pins exceeding 250 mm diameter, the clearance between the pin and the pinhole shall be not
less than 0.40 mm and not more than 0.75 mm.
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3.10.5 Preheating and Interpass Temperature
1.3.5
 General
Preheating shall be carried out by electrical resistance induction equipment or with gas burners
specifically made and shaped for this type of operation. Torches for flame cutting or gouging
shall not be used.
The preheating temperature shall be established to a distance of at least 75 mm on either side of
the weld line and throughout the wall thickness prior to welding and be maintained over the full
length of the weld joint until the weld is completed unless specifically agreed otherwise by the
Employer.
The weld area shall be protected from draughts and lagging shall be provided on adjacent areas,
if necessary, to maintain the required temperature of preheating during welding.
The temperature measurements for preheating may be by thermocouples or temperature
sensitive crayons, or a combination of both as may be appropriate for the type of joint being
heated and the method of heating.
Before welding commences at all joints where preheating is required, the joint must be subjected
to temperature checks through the Employer.
During welding particularly where preheat has been used and for high heat input processes, care
shall be exercised to control the interpass temperature and in no event should it exceed 300ºC or
that indicated in the WPS. The interpass temperature shall be monitored by means of thermo
sticks or another approved method.
 Temperature Requirements
a) Preheat temperature shall be as indicated in the approved WPS.
b) Preheat temperature for lifting lugs or pad eyes shall be 150ºC minimum.
c) For tack welding where the tack becomes part of the main weld. The preheat temperature
shall be 150ºC higher than specified on the WPS with a maximum of 300ºC.
3.11 SPARE PARTS

All spare parts for the plant shall be listed in the appropriate Spare Parts Schedules. The cost of
spare parts shall for each supply item be carried to the Spare Parts Summary Sheet.
The Employer shall have the option of ordering or omitting any of the spares listed in the
schedules.
The requirements regarding testing, surface treatment and painting, delivery point, terms of
payment, guarantees, etc., in accordance with the Contract Documents and applicable to the
supplies shall also apply to the spares.
All spares furnished shall be interchangeable with the corresponding original parts. They shall
also be of the same material and workmanship, and shall have all the features and provisions of
the corresponding original parts.
All spares are to be suitably treated and packed for long-term storage under conditions
prevailing at the site. Each spare shall be clearly marked or labelled on the outside of its packing
with description and purpose, and, when more than one spare is packed in a single case, box or
container, an inventory list is to be shown on the outside of same, and a detailed list enclosed
inside. All cases, containers, boxes and other packages shall be suitably marked and numbered
for the purpose of identification.
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The Contractor shall manufacture the spare parts and deliver them to site at the same time as the
rest of the Plant. Spares shall be handed over to the Employer not later than at the date 28 days
prior to the start of the Tests on Completion; they shall not be packed in the same packages at
Plant to be installed by the Contractor.
3.12 CONSUMABLE GOODS

All consumable goods needed for completing the installation as well as for maintaining and
operating the Work for at least five (5) years after Taking Over shall be furnished and shall be
included in the Contract Price and shall be handed over to the Employer not later than at the date
28 days prior to the start of the Tests on Completion. Such consumables shall be separately
packed and shall include oil, grease, paint, electrodes (if required), solvents, filters, bulbs, tubes,
fuses and any other goods as required for normal maintenance and operation.
A specified list of consumables shall be submitted to the Employer for approval.
3.13 SURFACE TREATMENT AND PAINTING
3.13.1 General
The specifications for the surface treatment given below are based on the conditions and
environmental data available at the time the Tender Documents are issued. The Employer
reserves the right to prescribe improvements on such treatment, should the available information
and operational conditions prior to manufacture make it necessary.
The Contractor shall provide a complete and reliable surface treatment of the equipment
furnished. All paints, painting materials and accessories required for the shop as well as field
painting shall be supplied by the Contractor and shall be included in the price bid. The paints
proposed by the Contractor must be approved by the Engineer before application of the same.
The detailed analysis in respect of paint properties, paint composition and performance
requirements of the proposed paints shall also be submitted by the Contractor for examination
and approval of the Engineer before the application of the paint. All paints shall be applied by
skilled workers in a workman like manner in accordance with the provisions contained in IS
14177 or equivalent.
The Contractor shall, however, in all respects fulfil the requirements imposed by the site
conditions, such as the quality of water, climatic conditions and other environmental conditions
which may in any way affect the quality and suitability of the surface protection. The quality
shall in all respects ensure long-life protection of the equipment, and due consideration shall be
given to the fact that the Plant, to a large extent, will be difficult to maintain once they are taken
into use.
The Contractor shall submit for the Employer's approval full details of the preparation, type of
materials, methods and sequences he proposes to use to comply with the requirements for the
protection of the structures, machinery and equipment during transport, site storage, building
and concreting and subsequent erection, and the extent to which cleaning, priming and painting
will be carried out in his workshop (or his subcontractor's, as the case may be), at the site and
after erection.
Before the application of paint, the surface preparation shall be carried out by the mechanical
cleaning. The rust, oil, grease and dirt shall be removed from the surface by the help wirebrush,
cup brush, mineral spirit, xylol or white gasoline etc. prior to apply the paint.
May 2021 Page | 37

The Contractor shall ensure that the materials, methods and sequences he proposes to use
comply with relevant safety rules and health standards, and does not contaminate the
environment.
The Contractor shall submit full details of materials including volatile matter content, nature of
solvent, number of components, type of coat, specific coverage, time interval between coats and
number of coats, compatibility of each coat with the previous coat, toxic properties, physical
properties, shelf life, pot life, resistance against chemical attack, resistance against ozone and
UV-radiation, compatibility with drinking water standards, etc.
Temporary protection of steel materials, prior to, and during production, or during
transportation, is not included in this specification.
Components of stainless steel shall in general not be painted or galvanised.
3.13.2 Steel Structures, Protection Systems
Steel structures shall in general be treated with one of the following surface protection systems:
System No. 1
Outdoor surfaces, surfaces in contact with water or humid air:
(i) Perfect cleaning of all surfaces by Mechanical Cleaning.
(ii) Application of a rust converter primer (epoxy-based) to a dry-film thickness of
maximum 50 microns. The primer shall contain not less than 95% by weight of
metallic zinc in the dry film.
(iii) Application of successive finishing coats with paint on two-component epoxy basis,
resistant to water and atmospheric agents. Alternative paint systems, see below.
The final total dry film thickness of System No. 1 shall be 350 microns. No individual coat shall
be applied with a thickness (dry) of more than 150 microns unless approved by the Employer.
Alternatively the first coat of two-component epoxy paint may be applied directly on the steel
surface without the zinc-rich primer if recommended by the paint manufacturer and approved by
the Employer.
Other paint systems shall be approved by the Employer. Where intended, their use shall be
specified in the Tender Documents. Such systems may be used for the following purposes:
 Equipment carrying potable water and water for fish hatcheries: The paint system may be on
solvent free epoxy- or polyurethane basis, with an official health certificate from a recognised
institution.
 Equipment where another colour than black is required: The paint may be epoxy based. For
outdoor equipment, only subject to occasional rain/snow, but not to condensing water, paint
on chlorinated rubber basis may be used.
 Equipment subject to direct sunshine or UV radiation: The topcoat shall be UV-resistant. On
some paint types a separate top coat on polyurethane basis may be applied. This can also be
used if special colours are required.
System No. 2
Ladders, stairs railings as well as outdoor surfaces of auxiliary equipment:
(i) Cleaning by as described under System No. 1.
(ii) Galvanized by the hot-dip process in a full zinc bath. The thickness of the galvanising
coating shall, unless otherwise specified, be according to ISO 1461.
May 2021 Page | 38

(iii) Zinc-coated surfaces shall not be painted, unless specified in the Particular
Specifications.
If painting is specified, System No. 1 or 3 shall be applied. The hot dipped zinc surface shall be
roughened by applying a light sand-sweeping or a special etch primer. "White rust" corrosion
shall be removed prior to painting.
No welding, flame cutting, bending or any other work that will harm the zinc coating shall be
applied on zinc coated components.
System No. 3
Surfaces of indoor equipment not exposed to condensed water or humid air:
(i) Cleaning by as for System No. 1.
(ii) Application of a suitable zinc- or ferro-oxide primer according to manufacturer's
specification.
(iii) Application of successive finishing coats of paint on chlorinated rubber or epoxy base.
Minimum dry-film thickness shall be 150 microns.
Paint with alkyd or other base may be applied only on auxiliary equipment after approval of the
Employer.
System No. 4
Exterior surfaces of buried pipes, penstocks etc.:
(i) Cleaning by as for System No. 1.
(ii) Application of a suitable zinc-primer as for System no. 1, or according to the
Manufacturers Specification.
(iii) Either coating by polyethylene according to DIN 30670 or DIN 30674, normal
requirements unless otherwise specified.
Or coating by glass fibre reinforced bitumen according to ISO 5256, Class I unless
otherwise specified. One reinforcement layer, minimum total thickness 3 mm shall be
used.
3.13.3 Protection of Main Structures
The permanent surface treatment systems shall be applied as follows:

 Trashracks:................................................................................. System No. 1
 Trashrackcleaner:.................................................................... System No. 1 and 3
 Gates, stoplogs and beams:....................................................... System No. 1
 Gate hoists:................................................................................. System No. 1 and 3
 Outdoor steel structures:............................................................. System No. 1
 Steel linings, penstocks:............................................................. System No. 1
All concrete-embedded parts shall, except for a 200 mm wide bordering zone, shall be cleaned
according to System No. 1 for protection during transportation and erection. Alternative
protection systems are subject to the Employers approval. Prior to embedding all loose rust,
scale, dust, oil or grease shall be thoroughly removed.
Machined surfaces to be left bright and clean in service shall be protected during manufacture,
transport and erection by a readily removable anticorrosive compound.
May 2021 Page | 39

Surfaces to be finally painted at Site, shall be given a suitable temporary protection, usually by
cleaning and shop priming.
3.13.4 Protection of Auxiliary Equipment
The permanent surface treatment systems shall be applied as follows unless otherwise specified:
 System No. 3 for indoor service components in dry air with no condensing water. Otherwise
System No. 1.
 Bolts, nuts and washers to be used on components painted with System No.3 shall be painted
according to the same system, or electrolytic galvanized. Stainless steel bolts, nuts and
washers shall be used whenever specified, and generally for sizes less than M10. Larger bolts,
nuts and washers may be hot dip galvanized.
 All structural steel and all exterior and interior surfaces of electric equipment (of steel) for use
outdoor or in humid air and all screws, nuts and washers on such parts shall be galvanized
according to System No. 2. Bolted joints shall be used, and all parts shall be galvanised before
assembly.
 Electrolytic galvanizing or sherardizing may be used alternatively for nuts, bolts and washers
of sizes less than M10 or for thinner steel sheets as appropriate to the particular element.
 All railings, stairs, platforms and ladders, complete with brackets and hangers, shall be
galvanized according to System 2. Bolted joints shall be used and parts shall be galvanised
before assembly. Electrolytic galvanizing may be used as an alternative for nuts, bolts and
washers of sizes less than M10.
 Surfaces in contact with oil shall be blast cleaned to degree Sa 2.5 and painted with two coats
of oil-resistant paint to a dry-film thickness of minimum 80 microns. Where there is danger of
collecting condense-water or in humid air (inside oil accumulators, sump tanks or similar) an
oil resistant two-component epoxy paint shall be used according to System No. 1.
Oil-Carrying Pipes:
 Generally stainless steel pipes shall be used. Any alternatives are subject to approval by the
Employer.
Water-Carrying Pipes, Pumps, Valves etc.:
 All cooling-water pipes and drain-pipes shall in general be made from stainless steel.
 Pipes for sanitary water and drinking water may, when approved by the Employer, be in- and
outside hot-dipped galvanised.
 Pumps, valves, filter housings etc. shall be painted with System No. 1, or outside powder
coated by epoxy and inside powder coated or rubber lined.
Chains, steel ropes, lifting tackles etc. shall be hot-dip galvanised, except when for indoor use
only.
Concrete embedded parts and parts to be finally treated at Site, as well as parts to be left clean in
service, shall be treated in the same way as described under main structures and equipment.
3.13.5 Hot Dip Galvanizing
Material
For galvanizing, only original blast-furnace raw zinc shall be applied, which shall have a purity
of 98,5 %, according to ISO 1459.
The minimum average thickness of the zinc coat shall mainly be according to ISO 1461:
May 2021 Page | 40

 For screws, nuts and washers 375 g/m2, approximately 55 microns.

 For all other parts, except for steel with thickness less than 5 mm or for hydraulic steel
structures or parts intermittently or permanently submerged in water, 500 g/m2,
approximately 70 microns.
 For steel components of thickness between 5 mm and 1 mm, varying linear from 500 g/mm2
to 350 g/m2, approximately from 70 to 50 microns.
 For hydraulic steel structures or parts intermittently submerged in water, 700 g/m2 or
approximately 100 microns.
Cleaning
All material to be galvanized shall be cleaned carefully of rust, mill scale, dirt, oil, grease, and
other foreign substances. Particular care shall be taken to clean slag from welded areas.
Galvanizing of Hardware:
Bolts, nuts, washers, locknuts and similar hardware shall be galvanised in accordance with the
relevant standards. Excess spelter shall be removed by centrifugal spinning.
Straightening after Galvanizing
All plates and shapes which have been warped by the galvanising process shall be straightened
by being re-rolled or pressed. The material shall not be hammered or otherwise straightened in a
manner that will injure the protective coating. Materials that have been harmfully bent or warped
in the process of fabrication or galvanising shall be rejected.
Repair of Galvanizing
Material on which galvanizing has been damaged shall be re-dipped unless the damage is local
and can be repaired by gun-spraying, soldering or by applying a galvanizing repair compound;
in the latter case, the compound shall be applied in accordance with the manufacturer's
instructions.
3.13.6 Colours, Painting and Marking
The Contractor shall after award of the Contract submit to the Employer for approval an overall
colour scheme.
The colour code for mechanical and electro-mechanical equipment, such as piping for water, oil,
air, combustibles, poisonous or aggressive liquids or gases, servomotors, valves, gates, cranes,
parts of turbines, pumps, generators, etc., shall be determined in accordance with the agreed
colour scheme. The colouring of pipelines shall preferably follow internationally understood
standards, e.g. DIN 2403.
Each coat of primer and painting shall be compatible with the previous and subsequent coats.
The coats of primer and each subsequent coats of paint shall each be of different shades of
colour where practicable to facilitate the identification of each coat.
Paints shall be applied by means of high pressure airless spraying. Areas difficult to reach may
be brush coated or coated by means of glove. Other application methods shall be approved by
the Employer.
Coating of any surface shall only take place under acceptable temperature and humidity
conditions. The steel temperature shall always be minimum 3 OC higher than the dew-point
temperature of the ambient air. Painting work shall not be carried out on surfaces which
temperature is below +5 OC or above +30 OC, unless approved by the Employer. The
temperature of ambient air shall during painting work be kept within limits as recommended by
the paint manufacturer and approved by the Employer.
May 2021 Page | 41

Care shall be taken to maintain full paint thickness at all corners and edges and special attention
shall be paid to the application of protective coatings over welds.
Each coat shall be free from runs, drops, pinholes, waves, laps, sags and unnecessary brush
marks, and shall be allowed to dry or to cure before the succeeding coat is applied, unless
otherwise specified by the paint manufacturer.
Shop coats shall be checked for good quality before proceeding with the painting or coating
operations at the site. The Contractor shall clean and repair all shop coats which are defective or
damaged.
The Contractor shall consider that some damage to paint work during shipment, storage and
erection is unavoidable and the application of all protective treatment should be programmed
accordingly. Care must be taken to remove salt crystals liable to become deposited during sea
transport and/or storage at a seaport, by thorough washing with clean fresh water. It is essential
that before any coat of paint is applied, the surface shall be prepared as described above so that it
is clean and free from all deleterious matter and completely dry.
The Contractor shall provide all means and tools for carrying out all site and shop painting in
compliance with the requirements of the paint manufacturer, i.e. heaters, ventilators,
dehumidifiers, dust removers, etc., all as required. All related costs shall be included in the
Contract Price.
To deal with protective treatment at Site, a properly equipped paint shop shall, if necessary, be
set up at the Site using experienced and skilled personnel for the preparation and application of
surface protection work.
All paints and primers shall be delivered at site in sealed containers packed by the manufacturer.
The manufacturer's instructions for preparation and application of all painting and protective
coats shall be strictly observed.
The Contractor shall provide appropriate quantities of each priming and finishing paint and be
responsible for all general and touch-up wok at Site, the cost of which shall be included in the
Contract Price.
Application of paint shall never be undertaken under such conditions that dust, sand, etc. can
settle on the wet paint film.
3.13.7 Inspection and Approval of Surface Treatment
Primer or paint shall not be applied without the Employer's approval of the surface preparation
and shop/site conditions.
The Contractor shall:
 Keep constant supervision of the work and assure himself that the specified conditions are met
in all respects,
 Prior to applying paint, make certain that the surface pre-treatment is in accordance with the
specification,
 Stop the work immediately if the specified conditions are not met. The work shall commence
only after all specified conditions such as quality of cleanliness, temperature, humidity and
ventilation are met,
 Remove any coats applied under non-specified conditions,
 Prepare a record at the commencement and end of every shift, or at least twice every day
where the following shall be recorded and signed:
 working place
May 2021 Page | 42

 type of work (priming, paint, sand-blast)

 air temperature
 relative humidity
 dew point temperature
 steel temperature
 area of painted/sandblasted surface (in the period)
 consumption of sand/paint in that period
 paint type and production number
 remarks to any irregularities
The records shall be filed by the Contractor, but at site copies shall be handed to the Employer
every day for approval and filing together with inspection and test reports.
The Employer has a right to inspect the structure after the pre-treatment is finished (cleaning)
before the commencement of paint application. The Contractor shall give notice well in advance.
If the dry film thickness per coat exceeds the specified value, the Employer may demand a
complete removal and new application.
If total dry film thickness of the fully-cured paint is less than specified, the Employer may
demand additional coats until specified thickness is obtained.
If the adhesion of fully-cured paint is less than 7 N/mm2 for System No. 1 or 2.0 N/mm2 for
other paint systems, the Employer may demand complete removal of the paint and new
treatment. Unless otherwise agreed, the adhesion should be measured with an "Adhesion
Tester", ISO 4624.
After an adhesion test has been made, the supplier shall assure that the areas damaged during
testing are touched up immediately to the specified coating thickness.
The specified dry film thickness is to be understood as the mean value of 10 measurements per
0.04 m2 (0.2 m x 0.2 m). No single measurement shall have a thickness less than 80% of that
specified. No single measurement shall show thickness higher than 250% of the specified value.
The mean dry film thickness of the completed paint film shall not be less than 100% and not
more than 200 % of the guaranteed total dry film thickness provided that the numbers of coats
are as specified.
The dry-film thickness shall be measured by approved magnetic or electronic gauges. The
gauges shall be calibrated against a plastic or metal foil of representative thickness placed on a
surface of the same roughness as the surface to be painted. If the gauge is tested against a
smooth surface, the average surface roughness of the components to be tested shall be added by
calibrating the gauge accordingly.
The measurements shall be performed on completely cured paint, but not less than 24 hours after
final application.
Upon completion of each coat, the painter shall make a detailed inspection of the painting finish
and shall remove from adjoining work all spattering of paint material. He shall make good all
damage that may be caused by such cleaning operations.
Upon completion of the paint work, a detailed inspection 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 in a clean and acceptable
condition.
Unless waived by the Employer the surface treatment shall be inspected at the end of the Defects
Liability Period. The Contractor or his representative shall be present.
May 2021 Page | 43

3.14 CONSTRUCTION ELEMENTS
3.14.1 Bolts, Studs, Nuts, Screws, Washers
All bolts, studs, nuts etc., shall have standard metric threading and conform to the relevant
standards as regards shape and tolerance. They shall be marked by the manufacturer's symbol
and class of strength.
In general, screws etc with Strength Class above 8.8 shall not be used in wet or humid
environment unless approved by the Employer.
All bolts, studs, nuts, washers, screws, etc., used in steel structures, above size M 10, shall, if not
in stainless steel or other corrosion resistant material, be hot dip galvanised, except for bolts
above Strength Class 8.8, for which corrosion resistant materials or electrolytic zinc-coating will
be preferred.
Bolts, etc., smaller than size M 10 shall be electrolytic zinc coated if not provided in stainless
steel or other corrosion resistant material.
Bolts, nuts, studs and screws which require frequent tightening and unbolting during inspection
or maintenance procedures shall be of stainless steel.
For equipment within closed cabinets, in oil sumps and similar locations the Employer may
approve other types of corrosion protection.
All bolts, nuts and screws shall be secured in an approved manner against their becoming loose
during operation.
The Contractor shall supply the net quantities plus 10% spare of all permanent bolts, screws and
other similar items and materials required for installation of the works at the site. Spare parts
shall be wrapped, marked and handed over to the Employer.
3.14.2 Stairs, ladders and platforms
Stairs and ladders shall have an preferable inclination of approximately 35º or 75º. Stairs and
platforms shall be complete with handrails of minimum 90 cm vertical height and skid boards of
8 cm height.
Adequate clearance of at least 2 m shall be given to overhead structures to provide for
unobstructed passage.
Vertical ladders shall be installed alternating to left-hand/right-hand side of horizontal platforms
placed approximately every 6 m of vertical height. Vertical ladders of more than 3 m height
shall be caged. Unless otherwise specified or stipulated in the applicable standards the load
assumptions for ordinary platforms shall be:
 For platforms used by personnel and for support of light equipment
3000 N/m2
with single weights of less than 500 N:.............................................
 For all other platforms:...................................................................... 5000 N/m2
Platforms and stairs shall be provided with slip resistant gratings or checker plates.
The steel material for stairs etc. shall at least conform to EN-10025-2, S235JR
At the Employers approval, stairs, ladders and platforms etc. may be manufactured in
Aluminium.
May 2021 Page | 44

3.15 CRANES AND LIFTING EQUIPMENT
3.15.1 Design and Calculation
Generally for the design, stress calculation, manufacture and installation, the following
standards and codes, shall be applied:
Fédération Européenne de la Manutention (FEM)
Section I: Rules for the Design of Hoisting Appliances.
Heavy Lifting Equipment, steel structures and mechanisms.
Section IX: Rules for the Design of Serial Lifting Equipment (Mechanisms)
Alternatively, or in addition, alternative standards can be applied.
Safety devices for the operating personnel shall be provided wherever it is deemed necessary.
Unless otherwise specified in the Particular Specifications, the lifting equipment shall be
classified to FEM as follows:
 For lifting capacity up to and including 100 kN (10T) group classification: A4
(structural)/M4 (1A m) (mechanisms), representing an average daily working time of 2 hours
and an equal share of small, medium and heavy loads (normal) duty.
 For lifting capacity larger than 100 kN (10T) group classification: A4 (structural)/M4 (1 Am)
(mechanisms), representing an average daily working time of 2 hours and a small share of
heavy load lifts (light duty).
The Contractor shall clearly state the group classifications of cranes and auxiliary hoists.
All lifting equipment up to and including 100 kN (10T) shall be subject to a test operation with
an overload:
 1.20 x nominal load for dynamic testing
Static testing according to the FEM-rules is not performed unless required by local laws.
The Contractor is responsible for furnishing the test loads up till 100 kN and dynamometers.
For lifting equipment with a capacity exceeding100 kN (10T) the test programme shall be
approved especially by the Employer. Equipment with a well-defined maximum load, as an
example equipment used for erection or dismantling of well-defined parts, can have a
provisional testing with 100 kN followed by final testing during the first maximum load.
3.15.2 General Design Particulars
The mean pressure exerted by the crane rails and their fixing elements upon the concrete shall
not exceed 10 N/mm2
The crane girders and runway tracks shall be calculated for a deflection not exceeding 1:750 of
the span at maximum nominal load.
Steel structures of lifting equipment shall be of welded construction, which can be assembled at
site. All field connections and joints shall be bolted.
Hoist, bridge and trolley drives shall be equipped with adjustable brakes which are spring set
and electrically released. The braking action shall be smooth.
The drives shall be equipped with electrical motors especially designed for smooth starting and
stopping.
Flexible couplings shall be installed where necessary to relieve the bearings and shafts from any
stresses due to misalignment and to facilitate the removal of motors, wheels and gears.
May 2021 Page | 45

All wheels shall have double flanges and be made from cast steel.
All bearings shall be of the self-lubricating type designed to permit easy shaft disassembly and
easy replacement.
Oil bath lubrication shall be provided for all high speed gears and pinions. Low speed gears may
be grease lubricated. Suitable oil and grease catching drip pans shall be installed and be readily
accessible for draining and cleaning.
Nameplates stating the nominal load capacity in metric tons shall be attached to both sides of the
lifting equipment structure and to both sides of the rope block. The printing shall be clearly
legible from the floor.
For lubrication, inspection and maintenance, permanent ladders, platforms and stairs shall be
provided.
3.15.3 Electric Cable and Wiring
The contractor shall be responsible for wiring, laying and furnishing of control and power cables
and/or wires which are necessary for required operation.
All wiring in the control cabinets shall be with PVC insulated stranded conductor, formed neatly
into groups and properly supported. There shall be no splices in the wires or cables and all
connection shall be made only at terminal blocks or studs.
All external wiring between the control cubicles, motors, limit switches, etc., shall be with
multicore copper, PVC insulated, PVC sheathed, 600 volt grade jacket type cable.
3.15.4 Motor Stator and ammeters
All starters shall be suitable for direct-on-line starting of motors, provided with 3 phase
induction type over current relays for overload phenomenon with manual resetting, open-phase
relays and undervoltage release feature. Overcurrent relays shall be field adjustable to be rated
full load currents of motors. Backup protection shall provide with high rupturing capacity
enclosed fuses or moulded case circuit breakers. The control voltage shall be 230 volt. AC.
All motors shall be provided with disconnect switches or quickbreak no-fuse circuit brekers with
operating handles locakable in “off position”. They shall be rated to interrupt the full load
current of motor or other equipment in the circuit.
3.15.5 Conduits
Rigid steel conduit shall be galvanized. It shall be of a minimum thickness of 2.3 millimeters
and have a minimum inside diameter of 16 millimeters.
3.15.6 Enclosure
Motors enclosures shall be weatherproof and totally enclosed. Enclosures for all other
equipment shall in general be dustproof, weatherproof and vermin proof where required.
Enclosures, trim and doors shall be coated with two coats of a suitable primer and finished with
enamel paint, the color of which will be decided by the Employer.
May 2021 Page | 46

3.15.7 Convenience Outlets
Convenience outlets shall be of 2-pin with scraping earth or 3-pin type rated for amps at 230
volts, suitable for English pattern plug used inside the power plant. Outlets shall be in
weatherproof enclosure or suitably protected from weather.
3.15.8 Limit Switches
The limit switches shall have weatherproof enclosures and shall be mounted suitable for easy
adjustment and for rigidly locking in position after being adjusted. They shall be of heavy-duty
rating and shall have stainless steel rotating parts and permanently lubricated bearing. They shall
allow the arms to be fully deflected by operator without damage to the switch
3.15.9 Indicating Lights
All indicating lights shall be of filaments with colored plastic lenses type for long life and
service under conditions of shock, vibration and rough handling.
3.15.10 Instruments and Meters
All instrumental and meters shall have approximately 110 millimeters dial, shall be of heavy-
duty, industrial type suitable for extreme shock and severe vibration applications.
3.15.11 Lighting Fixtures
The lighting fixtures shall be complete with lamps. Fluorescent lighting fixtures shall be
equipped with complete fittings for A-C, 230-volts, 50 Hz source and a ballast or ballasts of
high power factor.
Incandescent lighting fixture shall have lamp holders in accordance with the local standards.
The lighting fixtures for outdoor use shall be weatherproof type.
Special care shall be exercised on selection of fixtures so that illumination of the lamps is not
obstructed by accumulation of insects and dust.
3.15.12 Electrical Relays
Electrical relays for controls and auxiliary relays for protection circuits shall be of the plug-in
type and the plug-in connection shall be made and broken by pressure contacts. Alternatively,
the Employer may approve the use of plug-in trays containing groups of relays.
Relays shall be provided with non-flammable dust and moisture proof cases.
Relay contacts shall be adequately rated for the service conditions. Relay coils shall be
continuously rated whether the control scheme require them to be continuously energized or not.
At least one spare normally opened contact and one spare normally closed contact shall be
provided on each relay in addition to the contact required by the control scheme.
3.16 GROUNDING
All Electric equipment in the plant shall be substantially grounded to the grounding system
comprising main grids and stubs to be installed by the other contractor. Grounding wiring and
connections from the equipment to the ground stubs shall be provided by the contractor.
Adequate size of the copper grounding conductor, based on the maximum ground fault current
May 2021 Page | 47

and the protection in the circuit, shall be used, but the minimum size shall be 10 mm 2, and where
possible, shall run inside the conduits with power conductors.
May 2021 Page | 48

Volume - 2 - Part I - General Technical Specification

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MAKAR JITUMAYA HYDROPOWER PRIVATE LIMITED

UPPER SURI KHOLA HYDROPOWER PROJECT

Lot 04: HYDROMECHANICAL WORKS

Contract Identification No: USKHP-HM-04-077/78

May 2021 Page | i

1.22 CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS.............................9

May 2021 Page | ii

3.5.8 Quality Inspectors at Site.............................................................................................26

May 2021 Page | iii

3.15.1 Design and Calculation................................................................................................46

May 2021 Page | iv

ASTM American Society of Testing and Materials

May 2021 Page | v

1.1 PROJECT DESCRIPTION

1.2 ROAD ACCESS TO THE SITE

S.N. Distance from To Distance(Km) Description

1 Kathmandu Khadichaur 78 Arniko Highway

2 Khadichour Charikot 55 Lamosangu-Jiri

3 Charikot Singati 39.5 Graveled Road

4 Singati PH Suri 11 Earthen Road

5 PH Suri Surgetank 9 To be construct

6 Surgetank Intake 3 To be construct

Total Road Length From Kathmandu to PH 195.5 kM

May 2021 Page | 1

1.3 THE SITE

1.3.1 Extents of the Site

1.3.2 Land Availability and Temporary Land Acquisition

1.4 SCOPE OF WORKS

May 2021 Page | 2

1.5 WORKS TO BE EXECUTED BY THE EMPLOYER OR OTHER CONTRACTORS

1.6 DESIGN CALCULATION, DRAWING, MANUALS, DESIGN CODE

May 2021 Page | 3

1.7 PROCEDURE FOR COMPLAINTS AND CLAIMS FOR DAMAGE

1.8 MOBILIZATION TO THE SITE

1.9 DEMOBILIZATION FROM THE SITE

May 2021 Page | 4

1.10 MEASUREMENT OF PAYMENT OF GENERAL FIXED ITEMS

1.11 MANAGEMENT MEETINGS

1.12 SITE DIARY

May 2021 Page | 5

1.13 PROGRESS REPORTS

1.14 DISTURBANCES ON WORKING ENVIRONMENT

1.15 TIDINESS OF SITE

May 2021 Page | 6

1.15.2 Noise Level

1.15.3 Seismic Coefficient

1.15.4 Levels and reference points

1.15.5 Survey and setting out

1.16 PACKING, STORAGE AND IDENTIFICATION

May 2021 Page | 7

1.17 AVOIDANCE OF INTERFERENCE

1.18 COMMUNICATION SYSTEM

1.19 PHOTOGRAPHS AND VIDEO

1.20 EMERGENCY ARRANGEMENTS

May 2021 Page | 8

No separate payment shall be made for the emergency preparedness.

1.21 STANDBY EQUIPMENT, TOOLS AND INSTRUMENTS

1.22 CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS

1.23 CONTRACTOR’S CAMP AND FACILITIES