Mech Spec PDF

Specifications
for
Mechanical Works
INDIAN OIL CORPORATION LIMITED
Page 1 of 46
SECTION - 1 SPECIFICATIONS FOR MECHANICAL WORKS
TANK AND PUMP INSTALLATION
CONTENTS
SR.NO. DESCRIPTION PAGE NO.
1. TANK INSTALLATION FOR UNDERGROUND TANKS 2
2. EXCAVATION 2
3. SOIL CLASSIFICATION 2
4. BAILING OUT WATER 2
5. SHORING 2
6. TANK FOUNDATIONS 2
7. DOPING OF TANKS 3
8. LOWERING OF TANKS 3
9. BACK FILLING 3
10. INSTALLATION OF SUPPLIED 10 KL TANK 4
13. INSTALLATION OF SUPPLIED 50/70 KL TANK 18
14. INSTALLATION OF CORPORATION SUPPLIED DISPENSING PUMP 23
15. INSTALLATION OF UNDERGROUND TANK IN EXISTING PIT/

FOUNDATION 23
16. LOADING / UNLOADING CHARGERS FOR 15/20/50/70 KL TANKS 23
17. INSTALLATION OF 5 KL TANK 23
CAPEX / SPECS / MECH / 07- 08 / REV 1

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1.1 TANK INSTALLATION FOR UNDERGROUND TANKS

1.1.1 This relates to the general scope for installation of all types of M.S. horizontal tanks in
Earth/ Masonry pit with strip or mat raft as per standard drawings/procedure.
1.2 Excavation
1.2.1 The excavation shall be carried out as per the relevant detailed specifications (for
excavation) mentioned in Section – 2 of Civil works.
1.2.2 All levels prior to excavation shall be taken. The setting out shall be done before the
excavation. Excavation shall be carried out to precise locations and levels. Any extra
or over excavation shall not be paid for and shall be rectified as described in detailed
specifications for excavation.
1.2.3 Proper gradient wherever required shall be given while excavating itself. Consolidation
to the final surface be done with hand rammers/rollers including watering, etc.
1.3 Soil Classification

1.3.1 The type of soil shall be identified and commencement of excavation shall be got
approved from the IOC/Engineer.
1.3.2 While excavating, each strata depth to be recorded and shown in the cross-section of
the tank pit.
1.3.3 Separate record shall be maintained if soft or hard rock strata encountered while
excavating.
1.4 Bailing out Water

1.4.1 Wherever the sub-soil water or any other water exists, the water accumulated in the
tank pit shall be removed continuously with the help of a suction pump.
1.4.2 The water shall not be allowed to accumulate in the tank pit, and regularly pumped out
to avoid any damage to the pit or tank foundations.
1.5 Shoring
1.5.1 Shoring of wooden sleepers or steel plates with sufficient supports shall be provided
for restricting falling of earth from the side embankment wherever required as per IS
3764. All timber shoring shall be as per detailed specifications mentioned for this item
in Civil Works.
1.5.2 The shoring shall only be removed after the entire work is completed.
1.6 Tank Foundations

1.6.1 The sand for filling purposes, shall be clean, hard, sharp and free from organic/
vegetable matters /dirt /lumps /stones etc. and filled/ consolidated In 200 mm layers
as per laid down procedure, therein.
1.6.2 The cement concrete for the sub-grade shall be of specified ratio, and shall be laid /
consolidated as per standard specifications mentioned in Civil Works.

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1.6.3 The cement concrete for the tank foundation in the prescribed ratio shall be laid as per
relevant standard specifications mentioned in Section –3 of Civil Works. The holding
down anchor bolts and general reinforcement shall be provided wherever required as
per the standard drawings before laying concrete.
1.6.4 The formwork for the purpose of casting tank foundation shall be wooden or steel of
specified thickness and size, as per relevant standard .2
1.7 Doping of Tanks

1.7.1 CONTRACTOR shall be responsible for doping after final hydro-testing of the tank
inside the pit as per the specifications. Contractor shall bail out all water after hydro-
testing.
1.7.2 The surface preparation shall be on the outside surface of the tank. The turn buckle,
anchor bolts, buried portion of the manholes, nozzles, saddles, etc shall be thoroughly
cleaned to bare metal. All mill scales, dirt shall be thoroughly cleaned and
anticorrosive coating as specified in the items shall be applied.
1.8 Lowering of Tanks

1.8.1 The M.S. Horizontal tank is lowered in the earth/masonry pit in one of the following
procedure
a) Mechanical Method
The tank is lifted mechanically with the help of a suitable capacity crane and the tank
is lowered very carefully/smoothly and made to rest over the tank foundations. Care
shall be taken that no damage is done to tank, the foundation and tank pit.
b) Chain Pulley Method
The M.S. Horizontal tank is rolled over the wooden-sleepers very carefully and
brought to the edge of tank pit parallel to the foundation. The tank shall thereafter be
lowered in the pit over a temporary earth ramp with the help of chain Pulley
arrangement. Care shall be taken while rolling as well as lowering that no damage is
done either to tank or foundations.
1.8.2 Subsequent to lowering in the pit/masonry enclosure, each tank is required to tested
hydrostatically as per the standard procedure and then doped with anticorrosive paint
as per the standard specifications.
1.8.3 Finally, the tank is aligned and positioned so as to maintain correct level, and both the
manholes are in one horizontal plane. Then the fixing of hold down bolts supplied,
shall be completed.
1.9 Back Filling

1.9.1 Backfilling operations are most important to the life of Installation. Back filling below,
around and above tanks should be of clean, non-corrosive material, such as, clean
sand. Watering and consolidation should be as per detailed specifications mentioned
in Civil Works.

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1.10 INSTALLATION OF SUPPLIED 10 KL TANK AS PER SPECIFIED DRAWINGS

AND AS PER WORK DESCRIPTION:
1.10.1 In earth pit with RCC strip raft as per Drg.:
(1) Installation of New/Old tank with or without manhole.
(2) Detaching all inside/outside fittings from tank.
(3) Keeping the tank with fittings in safe custody till handing over the installation to
Engineer, Consumer or Dealer.
(4) Shifting/rolling of the tank (with fittings) to the place of installation within the site
limit.
(5) Clearing the site of installation from any bushes, vegetation or any other
materials lying at site.
(6) Earthwork excavation is to be done as per drawing, in all types of soils such as
ordinary / hard soil, kankar, murrum gravel, pebbles, Bajri, stone boulders big
or small, soft rock, mud, asphalted / WBM driveways & with CC / RCC.
(7) Dressing / levelling & consolidation of the tank pit area.
(8) Bailing out sub-soil water or any other water, if met with, from tank pit area.
(9) Shoring shall be done with necessary wooden planks, ballies or steel Plates as
approved by the Engineer-in-charge.
(10) Spreading clean dry coarse sand under the tank over the entire area of the tank
upto a consolidated depth as indicated in the standard drawings.
(11) Handling, lowering, aligning and positioning the tank in the pit. The tank is
required to be lowered in the pit with mechanical aids, such as crane/chain
pully only. No extra payment shall be made on this account.
(12) Testing the tank hydrostatically to a pressure of 0.75 Kg/Cm2, including supply
of potable water, emptying and cleaning the tank as per clause No.34.
(13) The transporter will thoroughly examine the tank for any dents etc. at the time
of taking over the equipment at the fabrication yard. If any, dents, puncher,
damage etc, has taken place on the equipment during the transportation, the
same has to be rectified by the transporter at free of cost.
(14) Cleaning the tank from inside with gunny bags, jute, etc. In case of old tank the
contractor will have to remove the dead stock, sludge, and store at a place as

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directed by the Engineer-in-charge, prior to testing of the tank. The contractor

will make the tank gas free as per the approved procedure under the
supervision of the Engineer-in-charge, prior to taking up the cleaning/repairs to
the tank.
(15) Scrapping and doping of tank as per clause No.33. In case of old tank, the
Contractor will have to scrap the old primer & anticorrosive paint to the
satisfaction of the Engineer-in-charge by the methods as approved by him/her,
before applying the fresh paint, without any extra cost to the Corporation. Cost
includes supplying the anticorrosive paint.
(16) Fixing, Corporation supplied, inside and outside dip pipes, gun metal cap,
locking arrangement, including fixing/tightening of bushes & flanges.
(17) Fixing, Corporation supplied, inside fill pipes, suction pipe including
fixing/tightening of bushes and flanges and also fixing corporation supplied
outside fill pipe at the decanting point.
(18) Fixing of manhole cover plate in position including replacement of 3mm thick
CAF, permanite oil gasket conforming to IS 2712 Gr O/1, nuts, bolts, washers
(approved make), which might have been damaged / missing. Item also
includes facing of manhole flange and cover plate to be done before fixing.
(19) Filling with the clean dry sand inside the tank pit is to be done and unwanted /
debris are to be transported beyond municipal limits or unobjectionable place
for disposal, as directed by Engineer-in-charge.
(20) Providing and laying R.C.C. blocks (1:1.5:3) (1 cement : 1.5 coarse sand : 3
crushed graded stone metal of 12 to 20mm nominal size) complete as per
drawing referred above, including shuttering centering, curing, supply of MS /
TOR / TMT reinforcement, cutting, bending positioning and binding with 16
gauge MS binding wire (This includes the cost of reinforcement and binding
wire). Item also includes embedding, Corporation supplied, Anchor bars in
R.C.C. block (2 Nos. bars in each block) as per drawing.
(21) Assembling, fixing & tightening of Corporation supplied, holding down bolts,
turn buckles after RCC blocks are fully set.
(22) Providing Brick Masonry 230 mm thick with locally available good quality
approved bricks in cement motor 1:5 (1 : cement : 5 coarse sand ) for kerbing
around tank with leveling course in P.C.C. 1:4:8 and plastering 12 mm thick
with cement motor 1:4 (1 : cement : 4 coarse sand ) as per drawing referred
above including curing, etc. complete with all lead and lifts.
(23) In case of any hard rock (required chiseling / blasting), measurement shall be
taken and payment shall be made under appropriate item of civil works, after
deducting the value for earthwork excavation.

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(24) Number of suction points shall be indicated as per the requirement at site.
1.10.2 In Earth Pit with RCC matt raft as per Drg. :
(1) Item No. 1.10.1 (1) to (9), (11) to (19) & (22) to (24).
(2) Providing and laying base cement concrete as per drawing referred above in
the entire area of the pit including ramming, consolidation, curing etc.
(3) Providing and laying R.C.C. (1:1.5:3) (1 cement : 1.5 coarse sand : 3 crushed
graded stone metal of 12 to 20mm nominal size) Mat Raft, complete as per
drawing referred above including shuttering centering, curing, supply of MS /
TOR / TMT reinforcement bars with 16 gauge of M.S. binding wire (This
includes the cost of M.S./TOR/TMT reinforcement, M.S. bars for chairs and
binding wire). Item also includes embedding Corporation’s supplied Anchor
bars in R.C.C. mat raft. (2 Nos. bars in each Anchor bolts).
(4) Providing and laying cement concrete 1:2:4 (1 cement : 2 coarse sand : 4
crushed graded stone metal of 12 to 20mm nominal size) pedestals (4 Nos.)
complete as per drawing referred above including shuttering, centering & curing
etc.
(5) Handling assembling fixing and tightening of corporation supplied holding down
bolts, turn buckles after the RCC matt raft is fully set.
1.10.3 In Brick Masonry pit with RCC strip raft & blocks under driveway including RCC
top slab as per Drg. :
(1) Item No. 1.10.1 (1) to (21), (23) & (24).
(2) Providing and laying base cement concrete (as per drawing referred above)
along the periphery of the tank pit including shuttering, ramming and curing etc.
(3) Providing brick masonry 330mm thick of locally available good quality approved
bricks as per drawing referred above, in cement mortar (1:5) (1 cement : 5
coarse sand) including curing, providing scaffolding, raking of joints, complete
as per drawing.
(4) Providing and laying 150mm thick plain cement concrete (1:2:4) (1 cement : 2
coarse sand : 4 crushed graded stone metal) coping continuous all-round over
the width of the masonry wall including centering, shuttering as per drawing.
(5) Plastering brick masonry internal wall surfaces in masonry pit with 12mm thick
cement mortar (1:3) (1 cement : 3 coarse sand) including curing, raking of joints
irrespective of all lead and lifts.

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(6) Providing and laying R.C.C. 1:1.5:3 (1 cement : 1.5 coarse sand : 3 crushed
graded stone metal of 12 to 20mm nominal size) top slab 325mm thick
complete as per drawing referred above including shuttering, centering, curing,
supply of M.S./TOR/TMT reinforcement bars including its cutting, bending
positioning and binding with 16 gauge of M.S. binding wire (This includes the
cost of reinforcement bars and binding wire).
(7) Back filling is to be done on outsides of the masonry wall with excavated or
imported earth, free from all foreign matter, boulders etc. in 200mm thick layers
well watered and consolidated up to top most level of tank pit.
(8) The Exact number of chambers & covers for manholes required as per site
conditions are to be constructed / provided. Additional manhole covers apart
from shown in the drawings shall be paid separately under item rate.
1.10.4 In Brick Masonry pit with RCC matt raft & blocks under driveway including RCC
top slab as per Drg.:
(1) Item No. 1.10.1 (1) to (9), (11) to (19), (23) & (24) of the above.
(2) Item No. 1.10.2 (2) to (5) of the above.
1.10.5 Handling, installing of 10 KL tank above ground on existing brick masonry

chairs.
(2) Providing 50mm thick layer of coarse sand mixed with hot bitumen on the
380mm wide beds of existing 4 Nos. chairs.
(3) Handling, hoisting, positioning, aligning, leveling the tank on the chairs.
(4) Testing the tank hydrostatically to a pressure to 0.75 Kg/Cm2 including supply
of potable water, emptying, cleaning the tank as per clause No.34.
(5) The contractor will thoroughly examine the tank for any dents etc. at the time of
taking over the equipment at the fabrication yard. If any, dents, puncher
damage etc, has taken place on the equipment, the same has to be rectified by
the transporter at free of cost.

Page 8 of 46

the tank.
(7) Scrapping and painting of the tank outer surface with 2 coats, to a DFT of 30-
35 micron per coat, of red oxide Zinc Phosphate primer and two coats of
synthetic Aluminium finish paint to a DFT of 15-20 microns per coat as per IOC
specification. In case of old tank, the Contractor will have to scrap the old
primer & paint before applying the fresh primer & paint without any extra cost to
Corporation. Also, painting 2 Nos. Indian Oil monograms (of required size) and
writing name of product, capacity of tank as per direction of site Engineer.
locking arrangement, including fixing, tightening of bushes & flanges.
(9) Fixing, Corporation supplied, inside suction pipe including fixing / tightening of
bushes/flanges.
(10) Fixing, Corporation supplied, inside fill pipes including fixing/tightening of

bushes, flanges and also fixing, corporation supplied outside fill pipe at the
decanting point.
(11) Fixing of manhole cover plate in position including replacing of 3mm thick CAF,
permanite oil gasket conforming to IS 2712 Gr O/1, nuts, bolts (approved
make), washers, which might have been damaged/missing. Item also includes
facing of manhole flange and cover plate before fixing.
1.11 INSTALLATION OF SUPPLIED 15 KL TANK AS PER SPECIFIED DRAWINGS AND

AS PER WORK DESCRIPTION:
1.11.1 In earth pit with RCC strip raft as per Drg. No.:
limit.
materials laying at site.
(6) Earthwork excavation is to be done as per drawing. In all types of soils such as
ordinary/hard soil, kankar, murrum gravel, pebbles, Bajri, stone boulders big or
small, soft rock, mud, asphalted / WBM driveways & with CC / RCC.

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(8) Bailing out water or any other water, if met with, from tank pit area.
(9) Shoring shall be done with necessary wooden planks, ballies or steel Plates.
(10) Spreading clean dry sand under the tank over the entire area of the tank upto a
consolidated depth as per drawing.
required to be lowered in the pit with mechanical aids, such as crane / chain
pully, No extra payment shall be made.
of water, emptying and cleaning the tank as per clause No.34.
of taking over the equipment at the fabrication yard. If any, dents, puncher
the tank.
permanite oil gasket conforming to IS 2712 Gr O/1, nuts, bolts, washers
(approved make), which might have been torn out/missing. Item also includes
facing of manhole flange and cover plate, to be done before fixing.

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(19) Filling with the clean dry coarse sand inside the tank pit is to be done and
disposals of unwanted/debris are to be transported beyond municipal limits or
un-objected place as directed by Engineer-in-charge.
(20) Providing and laying R.C.C. blocks 1:1.5:3 (1 cement : 1.5 coarse sand : 3
drawing referred above, including shuttering centering, curing, supply for MS /
gauge of MS binding wire (This includes the cost of reinforcement, and binding
(21) Assembling fixing & tightening of Corporation supplied, holding down bolts,
(22) Providing Brick Masonry 230 mm wide of locally available good quality bricks in
cement motor 1:5 (1 : cement : 5 coarse sand ) for kerbing around tank with
leveling course in P.C.C. 1:4:8 and plastering 12 mm thick with cement motor
1:4 (1 : cement : 4 coarse sand ) as per drawing referred above including
curing irrespective of all lead and lifts.
(23) In case of any hard rock (required chiseling/blasting) strata measurement shall
be taken and payment shall be made under appropriate item after deducting
the value for earthwork excavation.
1.11.2 In Earth Pit with RCC matt raft as per Drg. :

(1) Item No. 1.10.1 (1) to (9), (11) to (19) & (22) to (24).
TOR reinforcement with 16 gauge of M.S. binding wire (This includes the cost
of M.S./TOR reinforcement, M.S. bars for chairs and binding wire). Item also
includes embedding Corporation’s supplied, Anchor bars in R.C.C. mat raft. (2
Nos. bars in each Anchor bolts).
etc.

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(1) Item No. 1.10.1 (1) to (21), (23) & (24).
(3) Providing brick masonry 330mm thick of locally available good quality bricks as
per drawing referred above, in cement mortar (1:5) (1 cement : 5 coarse sand)
including curing, providing scaffolding, raking of joints, complete as per
drawing.
coarse sand : 4 crushed graded stone metal) coping continuous alround over
supply of M.S./TOR reinforcement including its cutting, bending positioning and
binding with 16 gauge of M.S. binding wire (This includes the cost of M.S.
Reinforcement and binding wire).
well watered and consolidated upto top most level of tank pit.
from shown in the drawings shall be paid separately, under item rate.

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1.11.5 Handling, installing of 15 KL tank above ground on existing brick masonry

chairs as per Drg. No. ENG 311 – 1/2 & 2/2.
of water, emptying, cleaning the tank as per clause No.34.
the tank.
Aluminium finish paint to a DFT of 15-20 microns per coat as per IOC
Corporation. The item also includes painting 2 Nos. Indian Oil monograms (of
required size) and writing name of product, capacity of tank as per direction of
site Engineer.

Page 13 of 46
bushes/flanges.

decanting point.
make), washers, which might have been torn out/missing. Item also includes
1.12 Installation of supplied 20 KL tank as per specified drawings and as per work
description:
1.12.1 In earth pit with RCC strip raft as per Drg.:
limit.
(5) Clearing the site of installation from any bushes, trees, vegetation or any other
(6) Earth work in excavation as per drawing. In all types of soils such as
ordinary/hard soil, kankar, murrum gravels, pebbles, Bajri, stone boulders big
or small, soft rock, mud, asphalted / WBM driveways & with CC / RCC.
(8) Bailing out of water or any other water, if met with, from tank pit area.

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(10) Spreading clean dry coarse sand under the tank over the entire area of the tank
upto a consolidated depth as per drawing.
(12) Testing the tank hydrostatically to a pressure of 0.75 Kg/Cm2 including supply
the tank.
(17) Fixing, Corporation supplied inside fill pipes, suction pipe including
(approved make), which might have been damaged / missing. Item also
includes facing of manhole flange and cover plate to be done before fixing.
(19) Back filling with the excavated or imported earth free from all foreign matters,
boulders etc. in 200mm thick layers, each layer well watered and consolidated
upto top most level of tank pit.

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drawing referred above, including shuttering, centering, curing, supply of
MS/TOR/TMT reinforcement bars, cutting, bending positioning and binding with
16 gauge of M.S. binding wire. (This includes the cost of reinforcement bars
and binding wire). Item also includes embedding, Corporation supplied Anchor
bars in R.C.C. block (2 Nos. bars in each block) as per drawing.
(21) Assembling, fixing & tightening of Corporation supplied, holding down bolts,
(22) Providing Brick Masonry 230 mm wide of locally available good quality
above including curing irrespective of all lead and lifts.
(23) In case of any hard rock (required chiseling/blasting), measurement shall be

taken and payment shall be made under appropriate item after deducting the
value for earthwork excavation.
1.12.2 In Earth Pit with RCC matt raft as per Drg.:
(1) Item No. 1.11.1(1) to (9),(11) to (19) (22) to (24) of the above.
the entire area of the pit, including ramming, consolidation, curing etc.
graded stone metal of 12 to 20mm nominal size) Mat Raft complete as per
drawing referred above including shuttering centering, curing, supply of M.S. /
TOR / TMT reinforcement bars including cutting, bending, positioning and
binding with 16 gauge of M.S. binding wire (This includes the cost of M.S. /
TOR / TMT reinforcement bars, M.S. bars for chairs and binding wire). Item
also includes embedding, Corporation’s supplied Anchor bars in R.C.C. mat raft
(2 Nos. bars in each Anchor bolts) as per drawing.
complete as per drawing referred above including shuttering, centering, curing
etc.

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(5) Handling, assembling, fixing and tightening of corporation supplied, holding

down bolts, turn buckles after the RCC mat raft is fully set.
(1) Item No. 1.11.1 (1) to (21), (23), (24) of the above.
along the periphery of the tank pit, including shuttering, ramming and curing
etc.
including curing, providing scaffolding, raking of joints complete as per drawing.
(4) Providing and laying 150mm thick cement concrete (1:2:4) (1 cement : 2 coarse
sand : 4 crushed graded stone metal) coping, continuous all round over the
width of the masonry wall including centering, shuttering, curing as per drawing.
(6) Providing and laying R.C.C. (1:1.5:3) (1 cement : 1.5 coarse sand : 3 crushed
supply of M.S. binding wire (This includes the cost of M.S./TOR/TMT
reinforcement bars, M.S. bars for chairs and binding wire).
(7) Back filling is to be done on outsides of the masonry wall excavated or

from shown (2 Nos) in the drawings shall be paid separately. Under item rate.
1.12.4 In Brick Masonry pit with RCC mat raft & blocks under driveway
including RCC top slab as per Drg.:
(1) Item No. 1.11.1 (1) to (9), (11) to (19) & (23), (24) of the above.

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1.12.5 Handling, installing of 20 KL tank above ground on existing brick / stone

masonry chairs.
the tank.
site Engineer.
bushes/flanges.

decanting point.

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1.13 Installation of supplied 50/70 KL tank as per specified drawings and as per work
description:
1.13.1 In earth pit with RCC strip raft as per Drg. No.:
limit.
materials lying at site.
(6) Earth work in excavation is to be done as per drawing. In all types of soils such
as ordinary / hard soil, kankar, murrum gravels, pebbles, Bajri, stone Boulders
big or small, soft rock, mud, asphalted / WBM driveways & with CC / RCC.
(7) Dressing / leveling & consolidation of the tank pit area.
(8) Bailing out of water or any other water, if met with, from tank pit area.
(9) Shoring shall be done with necessary wooden planks, ballies or steel plates.
(10) Spreading clean coarse dry sand under the tank over the entire area of the tank
upto a consolidated depth as per drawing.
(12) Testing the tank hydrostatically to a pressure of 0.75 Kg/Cm2 including supply

Page 19 of 46
the tank.
(18) Fixing of manhole cover plate in position including replacing of 3mm thick
permanite packing gasket, nuts, bolts, washers (approved make), which might
have been damaged/missing. Item also includes facing of manhole flange and
cover plate to be done before fixing.
(19) Filling with clean dry coarse sand inside the tank pit is to be done and
unwanted/debris are to be transported beyond municipal limits or un-objected
place for disposal as directed by Site Engineer.
TOR / TMT reinforcement, cutting, bending poisoning and binding with 16
gauge of MS binding wire (This includes the cost of M.S. reinforcement, and
binding wire). Item also includes embedding Corporation supplied Anchor bars
in R.C.C. block (2 Nos. bars in each block) as per drawing.

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(21) Assembling fixing & tightening of Corporation supplied holding down bolts turn
buckles after RCC blocks are fully set.
(22) Providing Brick Masonry 230 mm wide of locally available good quality
above including curing irrespective of all lead and lifts.
(23) In case of any hard rock (required chiseling/blasting), measurement shall be

taken and payment shall be made under appropriate item after deducting the
value for earthwork excavation.
1.13.2 In earth pit with RCC Matt raft as per Drg.:
(1) Item No. 1.12.1 (1) to (9), (11) to (19) & (22) to (24) of the above.
the entire are of the pit including ramming, consolidation, curing etc.
(3) Providing and laying R.C.C. 1:2:4 (1 cement : 2 coarse sand : 4 crushed
graded stone metal of 12 to 20mm nominal size) Mat. Raft complete as per
drawing referred above including shuttering, centering, curing, supply of MS /
TOR / TMT reinforcement bars with 16 gauge of M.S. binding wire (This
includes the cost of M.S./TOR/TMT reinforcement, M.S. bars for chairs and
binding wire). Item also includes embedding, Corporation’s supplied, Anchor
bars in R.C.C. mat raft. (2 Nos. bars in each Anchor bolts).
complete as per drawing referred above including shuttering, centering, curing
etc.
(5) Handling, assembling, fixing and tightening of corporation supplied, holding

down bolts, turn buckles after the RCC mat raft is fully set.
1.13.3 In Brick masonry pit with RCC strip raft & blocks under driveway including RCC
top slab as per drg.:
(1) Item No. 1.12.1 (1) to (21) & (23), (24) of the above.

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along the periphery of the tank pit, including shuttering, ramming and curing
etc.
(3) Providing brick masonry 330mm thick of locally available good quality bricks
(50 class bricks) as per drawing referred above, in cement mortar (1:5) (1
cement : 5 coarse sand) including curing, providing scaffolding, raking of joints
complete as per drawing.
(4) Providing and laying 150mm thick cement concrete (1:2:4) (1 cement : 2 coarse
sand : 4 crushed graded stone metal) coping, continuous alround over the
width of the masonry wall including centering, shuttering, curing as per drawing.
(6) Providing and laying R.C.C. (1:1½:3) (1 cement : 1½ coarse sand : 3 crushed
complete as per drawing referred above including shuttering centering, curing,
supply of M.S / TOR / TMT reinforcement including cutting, bending, positioning
and binding with 16 gauge of M.S. binding wire (This includes the cost of M.S.
(7) Back filling is to be done on outsides of the masonry wall excavated or

imported earth free from all foreign matter, boulders etc. in 200mm thick layers
from shown (2 Nos) in the drawings shall be paid separately. Under item rate.
1.13.4 In Brick masonry pit with RCC Matt raft & blocks under driveway including RCC
top slab as per Drg. No.:
(1) Item No. 1.12.1 (1) to (9), (11) to (19) & (23), (24) of the above.

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1.13.5 Handling, installing of 50/70 KL tank above ground on existing brick / stone
masonry chairs as per drg. No. Eng/326-1/2 & 2/2:
380mm wide beds of exiting 4 Nos. chairs.
(3) Handling, hoisting, positioning, aligning and levelling the tank on the chairs.
the tank.
synthetic Aluminium finish paint to a DFT of 15-20 microns per coat as per IOC
site Engineer.
bushes/flanges.

bushes, flanges and also fixing, supplied, outside fill pipe at the decanting
point.

Page 23 of 46
make), washers etc, which might have been damaged/missing. Item also
includes facing of manhole flange and cover plate before fixing.
1.14 INSTALLATION OF CORPORATION SUPPLIED DISPENSING PUMP:
1.14.1 Un-packing of the dispensing pump from the wooden crate. Wooden crate shall be
the property of the contractor.
1.14.2 Handling and shifting to the pump island and handing over loose items like nozzles,
hose pipe, handles etc. to Engineer, dealer/consumer.
1.14.3 Providing and laying CC 1:2:4 (1 cement : 2 coarse sand : 4 crushed stone metal of
12 to 20mm nominal size) for foundation bolts, including boxing as per Manufacturers
requirement or as directed by Engineer.
1.14.4 Aligning and positioning of dispensing pump over CC foundations, supplying and
tightening the nuts with washers.
1.14.5 Sand filling in the hollow portion under the dispensing unit.
1.15 INSTALLATION OF UNDER GROUND TANK IN EXISTING PIT / FOUNDATION
1.15.1 Installation of tank in the existing pit/foundation with all-necessary fittings and
providing all necessary pipeline connection etc.
1.15.2 Back filling the tank pit with sand, etc., complete shall be paid separately.
1.16 LOADING / UNLOADING CHARGERS FOR 15/20/50/70 KL TANKS:

1.16.1 Handling, loading/unloading of 15/20/50/70 KL tanks with all fittings.
1.16.2 Contractor shall be responsible for any damages / losses during loading/unloading of
materials.
1.17 INSTALLATION OF SUPPLIED 5 KL TANK AS PER SPECIFIED DRAWINGS AND

AS PER WORK DESCRIPTION:
1.17.1 In earth pit with RCC strip raft as per standard Drg. No.:

Page 24 of 46
limit.
(6) Earthwork excavation is to be done as per drawing. In all types of soils such as
ordinary/hard soil, kankar, murrum gravel, pebbles, Bajri, stone boulders big or
small, soft rock, mud, asphalted / WBM driveways & with CC / RCC.
(8) Bailing out water or any other water, if met with, from tank pit area.
(10) Spreading clean dry sand under the tank over the entire area of the tank upto a
consolidated depth as per drawing.
required to be lowered in the pit with mechanical aids, such as crane / chain
of water, emptying and cleaning the tank as per clause No.34.
the tank.

Page 25 of 46
(approved make), which might have been torn out/missing. Item also includes
facing of manhole flange and cover plate, to be done before fixing.
(19) Filling with the clean dry coarse sand inside the tank pit is to be done and
disposals of unwanted/debris are to be transported beyond municipal limits or
un-objected place as directed by Engineer-in-charge.
gauge of MS binding wire (This includes the cost of reinforcement, and binding
(21) Assembling fixing & tightening of Corporation supplied, holding down bolts,
(22) Providing Brick Masonry 230 mm wide of locally available good quality bricks in
cement motor 1:5 (1 : cement : 5 coarse sand ) for kerbing around tank with
leveling course in P.C.C. 1:4:8 and plastering 12 mm thick with cement motor
1:4 (1 : cement : 4 coarse sand ) as per drawing referred above including
curing irrespective of all lead and lifts.
(23) In case of any hard rock (required chiseling/blasting) strata measurement shall
be taken and payment shall be made under appropriate item after deducting
the value for earthwork excavation.
1.17.2 In Earth Pit with RCC matt raft as per standard Drg. :
(1) Item No. 1.10.1 (1) to (9), (11) to (19) & (22) to (24).

Page 26 of 46
TOR reinforcement with 16 gauge of M.S. binding wire (This includes the cost
of M.S./TOR reinforcement, M.S. bars for chairs and binding wire). Item also
includes embedding Corporation’s supplied, Anchor bars in R.C.C. mat raft. (2
Nos. bars in each Anchor bolts).
etc.
top slab as per standard Drg.:
(9) Item No. 1.17.1 (1) to (21), (23) & (24).
including curing, providing scaffolding, raking of joints, complete as per
drawing.
coarse sand : 4 crushed graded stone metal) coping continuous alround over
supply of M.S./TOR reinforcement including its cutting, bending positioning and
binding with 16 gauge of M.S. binding wire (This includes the cost of M.S.

Page 27 of 46
from shown in the drawings shall be paid separately, under item rate.
top slab as per standard Drg.:
1.17.5 Handling, installing of 5 KL tank above ground on existing brick masonry chairs
as per standard :
the tank.

Page 28 of 46
site Engineer.
bushes/flanges.

decanting point.

Page 29 of 46
PIPELINES, FITTINGS, VALVES & OTHER EQUIPMENTS
CONTENTS
SR.NO. DESCRIPTION PAGE NO.
1. SUPPLYING HEAVY DUTY MS ERW PIPE (PLAIN END) AS PER

SPECIFICATION 25
2. SUPPLYING HEAVY DUTY MS ERW PIPE (SCREWED) AS PER IS

SPECIFICATION 25
3. SOIL CLASSIFICATION 2
4. BAILING OUT WATER 2
5. SHORING 2
6. TANK FOUNDATIONS 2
7. DOPING OF TANKS 3
8. LOWERING OF TANKS 3
9. BACK FILLING 3
10. INSTALLATION OF SUPPLIED 10 KL TANK AS PER SPECIFIED

DRAWINGS AND AS PER WORK DESCRIPTION 4


13. INSTALLATION OF SUPPLIED 50/70 KL TANK AS PER SPECIFIED

14. INSTALLATION OF CORPORATION SUPPLIED DISPENSING PUMP 23
15. INSTALLATION OF UNDERGROUND TANK IN EXISTING PIT/

FOUNDATION 23
16. LOADING / UNLOADING CHARGERS FOR 15/20/50/70 KL TANKS 23

Page 30 of 46
2.1 SUPPLYING HEAVY DUTY MS ERW PIPE (PLAIN END) AS PER SPECIFICATION:
2.1.1 Supplying heavy duty (Class ‘C’) MS ERW pipeline (plain end) of approved make as
per IS.1239 (part 1), 1979 and as per specifications given in Table 1 & 2 in Annexure-
I.
2.1.2 The CONTRACTOR shall supply all piping materials like pipes, fittings, flanges (along
with gaskets, bolts, nuts), valves, pipe supports, anti corrosive treatment, paints, etc.,
as mentioned in this tender specification. Supports shall include all accessories like U-
bolts, clamps, rods etc., and all steel structure required for proper supporting of the
pipe.
2.1.3 Scope of supply shall also include weather hoods for bare pipes crossing ceilings and
walls.
2.1.4 Any other materials or items required to complete the work shall also be supplied by
the CONTRACTOR at no extra cost to the CORPORATION whether specifically listed
or not.
2.2 SUPPLYING HEAVY DUTY MS ERW PIPE (SCREWED) AS PER IS

SPECIFICATION:
2.2.1 Supplying heavy duty (Class ‘C’) MS ERW pipeline (screwed) as per IS specification
No.1239 (part 1), 1979 and as per specifications given in Table 1 & 2 in Annexure-I.
2.2.2 The item includes the works as specified in 3.2, 3.3, 3.4, 3.6 etc., above
2.3 HANDLING & LAYING UNDERGROUND HEAVY DUTY MS ERW PIPELINE

(SCREWED) AS PER IS SPECIFICATION:
2.3.1 Laying threaded pipeline in trenches excavated in the required alignment along with
fittings and making all connections including those at tank and pumps and with swing
joints at all bends. Union/flanged joints are to be provided after the check valve. The
suction pipe from tank to pump shall be laid sloping towards the tank. The joints are
to be made leak proof by using jointing materials like litharge, glycerin, shellac, hold
tight etc.
2.3.2 Cleaning and scrapping, with wire brushes & abrasives, the outside surface of the
pipeline.
2.3.3 The rate includes excavation for trenches for the above work.
2.3.4 The pipe line laid shall be tested hydrostatically

Page 31 of 46
2.3.5 COATING:
2.3.5.1 The underground pipeline shall be protected by coating ( brush application ) with 3
coats (at an interval of 24Hrs between each coat) of SHALIMASTIC (shalismatic –
HD Thixotropic) or equivalent(as approved by the Engineer-in-charge), cold
applied anticorrosive treatment for a total DFT of 600 microns after preparing the
surface as per Manufacturer specification and as directed by the Engineer-in-
charge.
2.4 HANDLING & LAYING ABOVE GROUND HEAVY DUTY MS ERW PIPELINE
(SCREWED) AS PER IS SPECIFICATION:
2.4.1 Laying threaded pipeline in the required alignment along with fittings and making all
connections including those at tank and pumps and with swing joints at all bends.
Union/flanged joints are to be provided after the check valve. The suction pipe from
tank to pump shall be laid sloping towards the tank. The joints are to be made leak
proof by using jointing materials like litharge, glycerin, shellac, hold tight etc.
2.4.2 All the civil works involved in the item such as masonry support, plastering shall be
paid separately under item rate.
2.4.3 The pipe line laid shall be tested hydrostatically.
2.5 HANDLING, LAYING, WELDING, TESTING & PAINTING OF SUPPLIED MS ERW

PIPELINES:
2.5.1 Underground Pipeline:
Handling, laying underground, welding & testing to a pressure of 7 Kg/sq.cm. of MS

pipeline of specified diameter in tank farm, manifold & yard area including fabricating
necessary fittings such as tees, bends, elbows, spools, reducers etc. from supplied
MS pipes as per IOC drawings, specification etc. complete. Item includes doping the
pipeline ( brush application ) with 3 coats(at an interval of 24Hrs between each coat)
of SHALIMASTIC (Shalimastic-HD Thixotropic) or equivalent (as approved by the
Engineer-in-charge) cold applied anticorrosive treatment for a total DFT of 600
microns after preparing the surface as per Manufacturer specification and as directed
by the Engineer-in-charge.
All the civil works involved in the item such as masonry support, plastering shall be
paid separately under item rate.

Page 32 of 46
2.5.2 Above Ground Pipeline:
Handling, laying above ground, welding & testing to a pressure of 7Kg/sq.cm of MS

pipeline of specified diameter in tank farm, manifold & yard area including fabricating
necessary fittings such as tees, bends, elbows, spools, reducers etc. from supplied
MS pipes as per our drawings, specification etc. complete, including dismantling of
existing brick masonry walls for passing pipeline wherever required and repairing the
same as per direction of Engineer.
2.6 SUPPLY OF CLASS 150 MS FLANGES AS PER DRG. NO.ENG/425:
Supplying of steel flanges class 150 as per IOC drawing, including transportation of
the same to the work site. Material for SORF/ BLRF flanges to conform to ASTM A-
105 classs 150 for sizes upto 300mm. Flanges shall conform to ASME B16.5.
All flanges shall have raised serrated faces finished to 125 AARH. The bore of SORF
Flanges shall match the OD of the attached pipe. The rate includes all cost for
delivering the flanges at site
A. Slip on flanges
B. MS Blind flanges
2.7 WELDING OF CORPORATION SUPPLIED FLANGES
Welding of Corporation supplied flanges to MS pipelines with two runs of weld outside
and one run of the weld inside the flanges including painting / doping as per IOC
specifications complete.
2.8 MAKING FLANGED JOINTS (WELDED/BLIND):
Making flanged joints (welded / blind flanges) including supplying and fixing of gaskets
3mm thick CAF, permanite oil conforming to IS 2712 Gr O/1 and nuts, bolts, washers
etc. complete as per specifications.
2.9 SUPPLYING THE CS GATE / BALL VALVES:
Supplying CS Gate / Ball Valve as per the following specifications.

CAST STEEL GATE VALVES:
Rating : 150 class as per ANSI B 16.34
Ends : Flanged RF conc. Serrated , 150 class
Body Bonnet : ASTM A 216 gr WCB
Trim : 13 % Cr steel
Disc : Solid welded for gate valves
Swing type for check valves

Page 33 of 46
BALL VALVE:
Rating :
150 class as per ANSI B 16.34
Ends :
Flanged RF conc. Serrated, 150 class
Body Bonnet :
ASTM A 216 gr WCB
Ball :
SS 304
Seats & Seals :
25 % glass reinforced PTFE
Port :
Reduced port
Antistatic device : Required
Fire safe design : Required
Operation : Lever FM sizes ≤ 100 mm
Gear FM sizes ≥ 150 mm
2.10 SUPPLYING THE CS CHECK VALVE:
Supplying CS check valve as per the following specifications.

CAST STEEL SWING CHECK VALVES:
Rating : 150 class as per ANSI B 16.34

Ends : Flanged RF conc. Serrated , 150 class
Body Bonnet : ASTM A 216 gr WCB
Trim : 13 % Cr steel
Disc : Solid welded for gate valves
Swing type for check valves
2.11 HANDLING, ALIGNING & FIXING OF SUPPLIED FLANGED FITTINGS : GATE

VALVE / CHECK VALVE / BOX STRAINERS:
Handling, aligning & fixing corporation supplied gate valve / check valve / box strainer
etc. in pipeline sections including jointing with specified. Item also includes supplying
& fixing necessary gasket 3mm thick CAF, PERMANITE OIL conforming to IS 2712 Gr
O/1, approved Make nuts & bolts, washers etc.
2.12 SUPPLYING & FIXING OF CI BODY WITH GUN METAL SEAT OF APPROVED
MAKE – SCREWED/ ANGULAR TYPE
Supplying and fixing the approved Make check valve in pipelines including jointing
with specified materials
2.13 HANDLING, ASSEMBLING, INSTALLING, ALIGNING OF SUPPLIED PUMPING

UNIT WITH MOTOR:
Handling, assembling, installing, levelling, aligning, painting and commissioning of

Page 34 of 46
corporation supplied PUMPING UNIT WITH MOTOR over existing cement concrete
1:2:4 foundations, along with FLP starters/push button stations complete as per
drawing and actual dimension of pump. Item includes supplying and grouting of
16mm dia & 300mm long foundation bolts & nuts, supplying and installing ‘BEWARE’
400 VOLTS DANGEROUS’ sign board etc. (pump foundation will be paid separately
under item rates). Item also includes supplying and filling of required quantity of
lubricating oil at the time of commissioning and colour coding the pump with synthetic
enamel paint.
2.14 HANDLING, ALIGNING, INSTALLING CORPORATION SUPPLIED FLOW METER

IN PIPELINE SYSTEM:
Unpacking, handling, assembling, aligning, installing the Flow meters in pipeline

system including making flanges joint on inlet/outlet ends. The required support for
Flow meters will be provided of brick masonry / angle iron for which, separate
payment will be made under item rate. The job includes testing and commissioning
the Flow meter.
2.15 SUPPLYING AND FIXING PRESSURE / COMPOSITE GAUGE 0-15 KG/SQ.CM

RATING OF I.S. APPROVED MAKE:
Providing and fixing pressure gauge composite gauge 0-15 Kg/cm2 rating on pipeline.
Item also includes providing, fixing and welding socket in pipeline and providing and
fixing 12mm dia GM isolator valve complete as directed by Engineer.
2.16 PROVIDING LOCKING ARRANGEMENT FOR FILL & DIP PIPES AS PER
DRAWING NO.ENG/303-1/2 INCLUDING THE FOLLOWING ITEMS OF WORKS:
2.16.1 With clamp and lock (Approved Make) 7 Lever 50mm size:
2.16.1.1 Supply of approved make lock.
2.16.1.2 Providing & fabricating arrangement and fixing with nut, bolt or welded to the fill
and dip pipe.
2.16.1.3 Supplying and fixing in locking-clamp approved Make (or) equivalent approved
make pad-lock of size 50mm with duplicate keys.
2.16.2 With lock only (approved make) 7 Lever 50mm size:

2.16.2.1 Same as Item No. 2.16.1.3

Page 35 of 46
2.17 SUPPLYING AND FIXING OF TANK FITTING - DWG. NO.ENG/303-1/2&2/2 &

ENG/320-2/2:
Supplying and fixing of tank fitting, items listed in Item No.24 A to J of Capex as per
specifications and approval of site engineer.

Page 36 of 46
AIR COMPRESSORS, GAUGES, ETC.
3.1 SUPPLYING AND INSTALLATION OF APPROVED MAKE AIR COMPRESSOR

WITH ACCESSORIES
3.1.1 Air Compressors 1.5HP (110 litres tank capacity), 3HP(160 litres tank capacity) &
5 HP(220 litres tank capacity)
3.1.1.1This includes supplying air compressor of approved make, which shall be provided
with air gauge, high-pressure releasing valve and safety valve. A three phase 440V,
AC induction motor approved Make shall be coupled with air compressor. High-
pressure valve switch shall be connected to motor control circuit in starter.
3.1.1.2A three phase, 440v, 50 Hz AC relevant capacity of approved make DOL starter
(direct on line) shall be connected to motor.
Note: Installation to carried out as per manufacturer’s specification, drawings or as

directed by Engineer
3.2 AIR GAUGE AND INFLATORS :
3.2.1 Supplying And Installing Air Tower With Air Gauge For Filling Station as per
manufacturer’s specification, drawings or as directed by Engineer.
3.3 PROVIDING AND FIXING FOLLOWING FIXTURES FOR FUELLING POINTS AT

RAILWAY CONSUMER DEPOTS:
3.3.1 Fabricating and installing fueling box of size 450 x 600 x 900 mm notional size made
of 40 x 40 x 5 mm angle iron skeleton frame & 18 gauge MS sheet welded, including
open able door on one side with internal Harrison lock, outside locking, painting
outside and inside with two coats of zinc Phosphate primer and two coats of specified
synthetic enamel paint including making IOC monogram 300mm dia on two faces of
the box. The box will be fixed on suitable brick masonry / CC pedestal. The payment
for the pedestal shall be made separately under item rates of this schedule as per
actual measurements. The job also include making hole in roof of the box for passing
fuelling pipe and also providing hold fast in the bottom of the box. The bottom of box
shall not be covered with MS sheet. The size of box may vary according to site
conditions at different RDIs. The variation in surface area of MS sheet and lent angle
iron will be proportionately paid / directly based on the item rates available under the
schedule.
3.3.2 The nipple shall be made out of 60mm dia solid MS bar by machining / making purlins
on outer surface so as to make suitable for entry into 50mm dia rubber hose and
cutting the iron bore of minimum 40mm dia. The length of the nipple shall be
minimum 200mm and shall be welded on one end to the flange fixed to fuelling point
outlet. The cost includes only for the nipple and its welding.

Page 37 of 46
AIR COMPRESSORS, GAUGES, ETC.
3.3.3 a, b & c Supplying and fixing of 20/25/50mm dia braided Dunlop/Swastik Make rubber
hose:
Supplying & fixing of rubber hose of approved make 20/25/50mm dia of best quality,
suitable for petroleum products, at RCD including transportation and enroute taxes,
labour for fixing at site, the length of hose pipe (average length of one hose pipe is
likely to be 6m). The contractor may be required to supply and fix one or more hose
pipe at any RCD in the zone. The rates for the items will be payable on running meter
basis.
3.4 SUPPLYING AND FIXING OF HOSE FOR AIR GAUGE:
3.4.1 Supplying and fixing of hose for Air gauge shall be as per manufacturer specification.

Page 38 of 46
TRANSPORTATION OF EQUIPMENTS
4.1 TRANSPORTATION OF EQUIPMENT INCLUDING LOADING & UNLOADING

FROM ONE LOCATION TO ANOTHER INCLUDING ENROUTE ALL TAXES, LEVIS
AND UNLOADING, BY A SUITABLE VEHICLE EXCLUSIVELY FOR THIS
PURPOSE (TANK SHALL BE LOADED BY THE TANK FABRICATION
CONTRACTOR):
The above item includes the following item of works:
(i) Handling, loading, unloading and transportation of 15/20/50/70 KL Tank with

fittings dispensing pump, air compressor, other pumps and engineering
materials from one location to another in Southern Region area.
(ii) The dispensing pump/air compressor/all the pumps transported by number

basis.
(iii) No extra payment shall be made for loading / unloading the tank, pump etc.
with chain pulley block or any other mechanical method, staging, ramps etc.
(iv) Octroi if paid, shall be reimbursed on production of receipt.
(v) Transporter shall be responsible for any damages and losses during loading /
unloading and transporting of material. If the materials are required to be
insured for “Transit Insurance” the actual expenses so incurred shall be borne
by the Contractor.
(vi) Contractors may be asked to pack the materials and in that event, packing
charges shall be paid extra on mutually agreed rates.
(vii) The item includes taking delivery of material from the prescribed location,
transporting and delivery of the same at destination as per the instruction of
dispatch location.
(viii) The payment shall be made on the basis of shortest distance between two
locations and the kilometerage shall be given on the basis of Corporation
working and the contractor shall be bound by the same.
(ix) Payment shall be made on production of MRN only, along with bills.
(x) The transportation of IOC material will be done by the vehicle exclusively for
IOC job and no other material of any outside party will be loaded in the vehicle.

Page 39 of 46
TESTING AND CLEANING OF TANKS / PIPELINES
5.1 HYDROSTATIC TESTING OF MS PIPELINE INCLUDING CLEANING, SCRAPPING

ETC. COMPLETE :
(i) Exposing the underground pipeline from all sides by excavating the pipeline
trench up to required depth and back filling the same after the testing of
pipeline or doping is complete.
(ii) Item includes costs for rent for hydraulic pump, supply of water for testing, etc.
(iii) Filling water in the pipeline.
(iv) Removal of product from pipeline to be tested in the barrels, flushing etc.,
before undertaking testing.
(v) Testing pipeline at 7 Kg/sq.cm, keeping it for 6 hours and rectifying the leakage
if any.
(vi) Removal of water & its disposal outside the RO/CP.
(vii) Item includes cleaning and scrapping the pipeline complete
5.2 HYDROSTATIC TESTING OF 15/20/50/70 KL TANK:
(i) Removal of product (dead stock) if any / or sludge etc., by manual labour.
(ii) Opening the tank & making it gas free.
(iii) Supply of water and filling the same in the tank for testing.
(iv) Testing the tank to a pressure of 0.75 Kg/Sqcm.
(v) Rectifying leaks if any, however it shall be paid separately depending upon the
quantum of work.
(vi) Removal of water from the tank & its disposal outside IOC premises.
(vii) Cleaning the tank thoroughly from inside with Gunny bags, soft cloth etc. &
reconnecting the pipe line, fittings including replacement of packing nuts and
bolts etc., if required for commissioning the tank.
(viii) After testing the tank hydrostatically, the gasket used in the manhole cover has
to be replaced with new one.

Page 40 of 46
TESTING AND CLEANING OF TANKS / PIPELINES
5.3 DOPING OF 15/20/50/70 KL TANK AND PIPELINE:
a. The item includes removing the existing doping (in case of existing tank /
pipeline), etc. and the surface shall be completely cleaned.
b. The surface shall be made totally dry and free from moisture, oil, etc. before the
commencement of the application of the anticorrosive paint, Shalimastic – HD
or equivalent.
c. The Shalimastic – HD or equivalent paint shall be properly stirred first and then
cold applied over the prepared surfaces in three coats with brush. There shall
be an interval of 24Hrs between each coat. The minimum DFT per coat shall be
200 microns and the total DFT shall not be less than 600 microns.
d. The above mentioned entire application shall be carried out as per the
Manufacturer specifications and as directed by the Engineer-in-charge.
5.4 CLEANING OF 15/20/50/70 KL TANKS:
Item includes following jobs:
(i) Removal of dead stock from the tank and collecting the same in IOC/consumer
supplied empty barrels and handing over the same to the owner.
(ii) Degassing the tank by filling the water in tank upto the manhole till it overflows
and removing the water from the tank.
(iii) Removing the sludge from the tank and dumping the same at the place
indicated by Engineer-in-charge/Location-in-charge of IOC or the consumer.
(iv) Cleaning the inner surface of the tank with soap water solution and hessian
cloth and removing all foreign matter from the tank. The cleaning process shall
be carried to the full satisfaction of IOC representative / consumed.
(v) Reaffixing the manhole cover with new 3mm thick permanite oil packing and
also replacing defective nuts and bolts for manhole cover as well as pipeline
connection to the tank including connecting/ jointing all pipelines to tanks.
(vi) Back filling the manhole chamber and clearance of site including removal of
malba, if any.
(vii) Additional manholes, if required, shall be opened with cold cutting and welding
the manhole after gas freeing. The rate for cutting and welding shall be paid
separately.

Page 41 of 46
DISMANTLING TANKS AND PIPELINES
6.1 EXHUMING OF UNDER GROUND TANKS WITH FITTINGS:
6.1.1 From earth pit without RCC blocks/rafts:
The item includes the following works:
(i) Dismantling of tanks with fittings, its pipeline connections, manhole cover plate,
if any and stacking the same within the RO/CP premises.
(ii) Degassing the 15/20/50/70 KL Tank as per the approved procedures as per the
direction of Engineer-in-charge.
(iii) Removing dead stock, sludge oil trace and storing them in barrels at safe place
as per the direction of Engineer-in-charge.
(iv) Exhuming the tank from the pit, including necessary earth work and excavation
upto the bottom most level, lifting the tank by manual or mechanical means,
including dismantling earthing provisions, etc. complete.
(v) Stacking the 15/20/50/70 KL Tank within the premises.
(vi) Back filling the pit upto ground level with excavated and imported earth in
200mm layers well watered and consolidated upto the top most level with earth
rammer, etc. as directed by Engineer-in-charge.
6.1.2 From masonry pit with RCC blocks/rafts:
The item includes:
(i) Same as item (i) to (vi) under 6.1.1.
(ii) Dismantling of RCC blocks/rafts and disposal of debris outside the RO/CP
premises as per the directions of site in charge.
(iii) Dismantling of Anchor bolts straps etc. and stacking the same within the
RO/CP premises.
(iv) Excluding brick masonry walls, if required to be dismantled shall be paid under
separate item of this schedule.

Page 42 of 46
DISMANTLING TANKS AND PIPELINES
6.2 DISMANTLING OF MS/GI PIPELINE (SCREWED/WELDED) WITH FITTING, VALVES

ETC.:
This item includes the following item of works:
6.2.1 Above Ground:

(i) Dismantling of all pipelines, fittings like flanges, check valves, elbows, bends,
sockets union nipples etc, including cutting, if required, as per site conditions.
(ii) Stacking of all the above material within the RO/CP premises and handing over
the material to the Engineer.
(iii) Any other facilities/equipment (which is not required to be dismantled), if

damaged while carrying out the above job shall be made good at contractors
cost.
6.2.2 Underground:
(i) Same as item No. (i) to (iii) under above item 6.2.1.
(ii) Excavation in trenches, in all types of soil (upto 2m maximum), WBM/Asphalted

area etc.
(iii) Uplifting the pipe from the trenches, cutting the same in appropriate lengths
after dismantling the sockets/flange joints.
(iv) Back filling the trenches with the excavation or imported earth, watering and
consolidating with hand roller.
6.3 DISMANTLING OF EQUIPMENT INCLUDING ALL ACCESSORIES:
(i) Disconnecting the accessories, pipeline, airline, connection etc.
(ii) Dismantling the equipment from the existing foundations including opening of
foundation bolts, nuts, all connected pipes etc.
(iii) Removing of all electrical connection, cable etc, upto a safety point complete.
(iv) Handling and stacking the dismantled equipment at a safe place within the
RO/CP premises and handing over the same to the Engineer or dealer.

Page 43 of 46
PAINTING OF PIPELINES
7. PAINTING OF ABOVE GROUND MS PIPELINES :
7.1 Synthetic Enamel Finish
Scrapping and painting of the outer surface of the pipelines with 2 coats of red oxide
Zinc Phosphate primer to a DFT of 30-35 micron per coat and two coats of approved
make synthetic enamel finish paint to a DFT of 20-25 microns per coat. In case of old
pipeline, the Contractor will have to scrap the old primer & paint before applying the
fresh primer & paint without any extra cost to Corporation.
7.2 Aluminium Paint Finish
Scrapping and painting of the outer surface of the pipelines with 2 coats of red oxide
Zinc Phosphate primer to a DFT of 30-35 micron per coat and two coats of approved
make Aluminium finish paint to a DFT of 15-20 microns per coat. In case of old
pipeline, the Contractor will have to scrap the old primer & paint before applying the
fresh primer & paint without any extra cost to Corporation.

Page 44 of 46
ANNEXURES
ANNEXURE - I
Specifications for the Pipelines and Fittings:
TABLE – 1
(Service: For various petroleum products like petrol, kerosene, diesel, at retail outlets
only) (sizes < or = to 150 mm)
SR. ITEM DIMENSIONAL

NO MATERIAL STANDARD
SPECIFICATION
1 PIPES,ERW, ONE CARBON STEEL, BLACK IS1239 PART I ,
END SCREWED & HEAVY CLASS,
OTHER END THREADING AS PER
SOCKETED IS 554(TAPER)
2 FITTINGS CARBON STEEL, BLACK, IS1239 PART II , TO
SCREWED SCREWED ENDS AS PER SUIT HEAVY CLASS
(ELBOWS, TEES, IS 554
REDUCERS,UNION TAPER.
S)
3 PLATE FLANGES IS 2062 GR A ANSI B 16.5,150
SCREWED AS PER CLASS, RF,
IS554 SERRATED FINISH
4 GASKETS CAF, PERMANITE OIL, IS ANSI B 16.21, 150
2712, GR 0/1 CLASS,
3 mm THICK
5 MACHINE BOLTS & IS 1367 ,CLASS 4.6/4 IS 1363, TO SIUT 150
NUTS CLASS FLANGES
6 VALVES - GATE & REFER PARA 5.0, CL 5.1 REFER PARA 5.0 ,CL
CHECK (SPECIFICATION FOR 5.1 (SPECS FOR
BRONZE VALVES) BRONZE VALVES)
TABLE – 2
(Service: For various petroleum products like petrol, kerosene, diesel, LDO & FO at
Consumer depots, Taluka kerosene depots, Terminals, Depots and Aviation fuelling stations)
(Sizes 80 mm TO 200 mm)

1 PIPES , ERW, BE, API 5L Gr A / API 5L Gr B API 5L
WELDED
2 FITTINGS ASTM A234 Gr WPB, ANSI B16.9 (SEE TABLE-6
(ELBOWS,REDUCE SEAMLESS FOR SIZES FOR THICKNESS)
RS) 80NB TO 150NB. ASTM
A234 Gr WPBW WELDED
WITH 100%

Page 45 of 46
ANNEXURES

RADIOGRAPHY FOR SIZE
200NB
3 PLATE FLANGES IS 2062 GR A ANSI B 16.5 , 150 CLASS
SLIP-ON RF, SERRATED
2712 GR O/1 CLASS,3mm THICK
5 MACHINE BOLTS & IS 1367 , CLASS 4.6/4 IS 1363, 150 CLASS
NUTS
6 VALVES – GATE, REFER PARA 5.0 , CL 5.2 REFER PARA 5.0,CL 5.2&5.3
BALL& & 5.3 (SPECIFICATION (SPECS FOR VALVES)
CHECK,FLANGED FOR VALVES)
7 HOSES REFER PARA 6.0 REFER PARA 6.0 (SPECS
(SPECIFICATION FOR FOR HOSES)
HOSES)
TABLE – 3
(Service: Compressed Air and Water at all locations, SIZES < or = 80 NB)

1 PIPES ,ERW , CARBON STEEL, IS1239 PART I , HEAVY
SCREWED,ONE GALVANISED CLASS
END SOCKETED
2 FITTINGS CARBON STEEL, IS1239 PART 2 , HEAVY
SCREWED GALVANISED CLASS
3 PLATE IS 2062 Gr A, GALVANISED ANSI B 16.5,150#,RAISED
FLANGES,SCREW FACE,SERRATED FINISH
ED

2712 Gr O/1, CLASS
3 mm THICK ,
5 MACHINE BOLTS IS 1367 , CLASS 4.6/4 IS 1363, 150 CLASS
& NUTS
6 VALVES - GATE & REFER PARA 5.0, CL 5.1 REFER PARA 5.0 ,CL 5.1
CHECK (SPECIFICATION FOR (SPECS FOR BRONZE
BRONZE VALVES) VALVES)

Page 46 of 46
ANNEXURES
TABLE – 4 (Welding electrodes)
SR. BASE WELDING

NO MATERIAL FILLER MATERIAL PROCESS
ROOT FILLER
PASS PASS
1 CARBON E-6010 E-6013 SHIELDED METAL
STEEL ARC WELDING
TABLE – 5 (API 5L Pipe Thickness)
SR. SIZE(mm) WALL THICKNESS(mm)

NO (minimum)
1 80 4.7
2 100 4.8
3 150 6.3
4 200 7.9

Specifications
for
Electrical
Electrical Works
Indian Oil Corporation Ltd. SHEET 1 OF 67
(Marketing Division)
STANDARD SPECIFICATIONS
SPECIFICATION DESCRIPTION
NO.
1 GENERAL CONDITIONS
2 CABLE
3 CABLE SYSTEM INSTALLATION WORK
4 CABLE ACCESSORIES
5 DISTRIBUTION BOARD
6 SWITCHES, STARTERS, CONTACTORS, FUSES
7 LIGHTING SYSTEM EQUIPMENT
8 LIGHTING FIXTURES AND ACCESSORIES
9 STREET LIGHTING POLES
10 DIESEL GENERATOR SETS
11 EARTHING AND LIGHTNING PROTECTION
12 TRANSFORMER , H-POLE, EB METER
13 MISCELLANEOUS ITEMS
Contractor’s Signature & Seal: Date:

1.GENERAL CONDITIONS
1.0 General :
The entire electrical installation work shall be carried out in accordance with
approved drawings and in general conformity with the requirements of the Indian
Electricity Act 1910, the Indian Electricity Rules 1956, the relevant IS codes of
practice as amended to date, wherever applicable and the regulations of the local
licensing bodies/ C.E.I.G etc., and where such installations are subject to inspection
and approval of Fire insurance and Explosive Authorities, the installation shall be
planned and executed conforming to their regulations/ rules.
2.0 Workmanship:
First class workmanship and neat appearance are the essential requisites for
compliance with these specifications.
3.0 Materials and Makes:
All materials, equipment, fittings, fixtures, appliances, accessories, etc., to be used in

the installation shall conform to the relevant Indian Standard Specifications and
generally shall be as per approved make given in the SOR/specification.
The tenderer will specify the makes, which he proposes to use from the list of
approved makes of electrical goods. If he specifies more than one make, in any
category, the Clients shall be entitled to assume that the best of the different makes
so specified will be used by the Contractor on the works.
4.0 Service connection:
Contractor has to obtain the necessary service connection from the Electricity board
and electrical licencing board by paying the statutory payment. The payment made
shall be reimbursed on production of cash bill by the client.
• For all the fabricated items, namely MV panel, SSB, transformer etc., the general
arrangements / Fabrication drawings are to be prepared and approval obtained from
consultant/ Company, before commencing fabrication.

2. CABLE
1.0 SCOPE
1.1 This specification covers the requirements of 1100V grade Power, Control, Lighting,
Cables with general purpose insulation and sheaths.
2.0 CODES AND STANDARDS
2.1 The design, construction, manufacture and performance of cables shall comply with
all currently applicable statues, regulations and safety codes in locality where
cables will be installed. Nothing in this specification shall be construed to relieve the
CONTRACTOR of this responsibility.
3.0 SPECIFICATIONS
3.1 The following aspects are applicable for all types of cables covered in this
specification.
(a) Construction, Performance & Testing:
· Construction, Performance and testing of Power and Control cables shall conform
to IS: 1554. Part - 1 (PVC insulated heavy duty electric cables for working voltages
upto and including 11000V).
· Construction, Performance & Testing of 1100 V grade lighting, Misc./Light duty
unarmoured cables shall conform to IS: 694 (PVC insulated cables for working
voltages upto & including 1100V).
· Recommended current ratings for cables shall conform to following IS :
IS:3961 (PART II) 1967 : PVC insulated & PVC sheathed heavy duty cables.
IS:3961 (Part V) 1968 : PVC insulated light duty cables.
· Armouring shall conform to IS:3975-1979 (Mild steel wires, strips & tapes for
armouring of cables - first revision).
(b) Conductor
i) Plain aluminium conductor, solid / stranded, grade H4, Class I or 2 (as applicable), as
per IS 8130 (conductors for insulated electric cables and flexible cords).
ii) Plain annealed, high conductivity Copper Conductor solid / stranded, Class 1
or 2 (as applicable), as per IS 8130. Conductor shall be tinned when
indicated.
• The conductor shall be clean, reasonably uniform in size and shape, smooth & free
from harmful defects.
• Power cables shall be with Cu./Al conductors. Power cables upto and including 4 sq.
mm shall be with copper conductor. All power cables above 4 sq. mm shall be with
aluminium conductor. Control cables shall be with copper conductor only.
• Cables upto 6 sq mm shall be with solid/stranded conductor, but all cable including
and above 10 sq mm shall be with stranded conductor.

(c) Insulation
• Insulation for cables shall be PVC Type A as per requirement indicated herein and
shall conform to the properties covered in the following applicable standards.
IS 5831 - PVC insulation and sheath for electric cables
• The insulation shall be so applied that it fits closely on the conductor and it shall be
easily possible to remove it without damage to the conductor.
(d) Core Identification
Colour coding shall be acceptable for all cables upto 5 cores, Cables with more
than 5 cores shall have printed numerals on each core.
(e) Inner Sheath
• It shall be so applied that it fits closely on the laid up cores & it shall be possible to
remove it without damage to insulation. It shall be ensured that the inner sheath is as
circular as possible
• Inner sheath shall be of PVC and applied either by extrusion and shall be compatible
with the insulation provided for the cables.
(f) Armour
• Armouring is given for mechanical strength I protection of cables from external
damage. This shall comprise galvanised steel in the form of round wires or strips.
These shall be of following types:
W - Galvanised single steel wire.
F - Galvanised single steel strip
• Armouring is applied over insulation in case of single core cables and over inner
sheath in case of multicore cables. The direction of lay of the armour shall be left
hand.
(g) Outer Sheath
• The outer sheath shall be of an extruded layer of PVC compatible with the specified
ambient and operating temperature of the cables & conforming to the requirement of
IS 5831 as follows :
Type ST1 : General purpose sheath intended for use in Cables operating at a
maximum rated conductor temperature 70C.
Type ST2: Heat resiting sheath intended for use in cables operating at a
maximum rated conductor temperature of 90 Deg C
• The sheath shall be resistant to water, ultra violet radiation, fungus, termite and
rodent attacks. The colour of the outer sheath shall be black unless otherwise

specified. The sheathed cables shall be weatherproof, suitable for indoor / outdoor
use.
• The outer sheath shall be applied over armouring in case of armoured Cables.
FRLS CABLES
The FRLS cables shall be generally as per the above specification except the outer
sheath shall be of Extruded FRLS PVC. These Cables shall meet the requirements
related to flame retardance, low smoke emission, and low acid and toxic gas
emission as per applicable standard.
(h) Cable Code
The following code shall be used for designating the cable.
Constituent Code letter
Al conductor A
PVC insulation Y
Steel wire armour W

Steel strip armour F
Steel double wire armour WW
Steel double strip armour FF
PVC outer sheath Y
(i) Identification
Manufacturer’s Identification
The manufacturer’s name or trademark, Voltage Grade, Year of manufacture and
type of Insulation shall be indented, printed or embossed throughout the length of
the cable at every 1 meter length on the outer sheath.
Cable Identification
In order to distinguish electric cable from telephone cables, the word ‘ELECTRIC’
shall be indented, printed or embossed throughout the length of the cable on the
outer sheath.
Cable ends shall be sealed with non-hygroscopic sealing caps.
(j) Test and Test Equipment
• Cables shall be subjected to routine and acceptance tests in accordance with
standards specified. Test methods shall conform to IS 10810 (Methods of Test for
Cables).
• CONTRACTOR shall ensure use of calibrated test equipment having valid calibration
test certificates from standard laboratory traceable to National Standards.

Supplying and laying of 3 x 2.5 Sq. mm copper flat type submersible cable (For
submersible pump)
A relevant capacity of 3 core submersible flat type copper cable from submersible
pump to motor starter shall be provided. Waterproof jointing material shall be used
for cable jointing between motor and starter cable under the water surface.
Supplying and laying 3 x 4 Sq.mm copper flat type submersible cable (For
submersible pump)
Supply & Installation of Point Wiring for Street and Flood Lighting
Supply and installation of cables required between LDB and junction box mounted
on street lighting pole/flood lighting tower and also between junction box mounted
on food light tower to metal enclosed control gear box located near flood light
fixture, supply and installation of all the termination accessories, termination, testing
and commissioning of cables. CONTRACTORs scope of work also includes
excavation, preparation of riddled soil bedding. supply and installation of protective
covers over the cable, backfilling, ramming. supply and installation of route markers,
supply and installation of pipes for road crossing, supply and installation of
necessary cleating arrangement for cabling on flood light tower, supply of labour,
supervision, welding equipment, all tools and tackles and testing equipment as
required. Earthing of street light pole/ flood light tower lighting fixtures, etc. is
included under point wiring.
Telephone Points :
a) Providing & laying 19mm dia., 2mm thick PVC rigid conduit pipe with 2 pair telephone
cable 0.61mm tinned copper, for telephone points.
b) Supplying and fixing of 2 pin telephone socket modular type shall be paid under
separate item of work.
TV Points:
a) Providing & laying 19mm dia., 2mm thick PVC rigid conduit pipe with copper TV
cable for TV points.
b) Supplying and fixing of TV socket modular type shall be paid under separate item of
work.


3. CABLE SYSTEM INSTALLATION WORK
1.0 SCOPE
1.1 This specification covers the requirement of Cabling System Installation Work. The
installation, testing and commissioning of the complete cabling system (i.e. cables,
cable carrier system, terminations and all accessories required to make the system
complete) shall be carried out in accordance with this specification.
1.2 The installation work shall include unloading at site, receipt of materials from IOCL’s
stores / storage yard, transportation to contractor’s stores / yard / workshop, storing
in contractors stores / yard (All these activities are applicable if the cables are
supplied by IOCL), erection, jointing / termination, testing, commissioning and any
other work items necessary for completing the job
1.3 The CONTRACTOR shall furnish all supervision, labour, tools, welding equipment,
tackles and testing equipment as required for installation, testing and
commissioning work. All incidental hardware and miscellaneous items such as
saddles, spacers, nuts/bolts/washers, anchor fasteners, cable route and joint
markers and protective covers for buried cables, earthing as required for the cabling
installation shall be deemed to be included by the CONTRACTOR as part of the
installation work.
1.4 Major Civil Works like construction of cable trenches, cable tunnels and duct banks
are in Contactor’s scope but the same shall be paid separately. The required
embedment plates shall be provided by the Contractor by using anchor fasteners if
the same are not provided by others. However, minor civil works such as making
holes / grooves in floor slab/wall, and patching up in an approved manner any holes
made in the walls / floors, embedment of short lengths of conduits, plates in floors
walls, etc. shall be deemed to be included in the scope of work.
1.5 The CONTRACTOR shall ensure workmanship of good quality and shall assign
qualified SUPERVISORS / ENGINEERS and competent labour who are skilled, and
experienced in their trades.
2.0 CODES AND STANDARD

The cabling system installation work shall comply with the latest applicable
Standards, Electricity Rules, Fire Insurance Regulations and Safety Codes of the
locality where the installation is carried out.
3.0 CABLE LAYING

3.1 The cables shall be laid in build up trenches, directly buried in ground, vertical
raceways, clamped on structures / walls / ceiling, pulled through pipes and
conduits, etc.
3.2 The scope of cable laying shall include laying, pulling cables as above, proper
dressing of cables, supply and installation of cable fixing saddles, spacers and
metallic cable clamps as required.
4.0 CABLE INSTALLATION

4.1 The Installation rates shall include supply and installation of accessories like cleats,
clamps, identification tags and associated hardware.
5.0 DIRECTLY BURIED CABLES
PROVIDING & CONSTRUCTING UNDERGROUND BRICK DUCT 600 MM
BELOW GROUND LEVEL FOR CABLE LAYING AS PER DRG. NO.
IOCL/ENGG/E/808
I) Excavation in all types of soil including WBM Asphalting/CC/RCC/Brick

Masonry/Hard &Soft rock for making trenches upto a depth of 600 mm below.
ii) Supplying and spreading dry river sand 100 mm thick cushion over the entire
area of excavated trench and also filling in between the brick lining so as to
embed the cable as per drawing
iii) Supplying and laying dry brick or stone patties duct on the sides and top of
the cable shown in the drawing.
iv) Back filling the trench with excavated or imported earth free from all foreign
matters, including consolidated and disposal of surplus earth beyond the
premise.
6.0 CABLE FIXING ON WALL, COLUMN OR ABOVE GROUND :
Cable shall be clamped on wall/column with necessary clamp using zinc coated
/Cadmium plated screws and nuts when the cable is run above ground level.
7.0 CABLE TERMINATION

7.1 The scope of termination at each end shall include dressing, and connecting all the
cores of the cables. It shall also include :
a) Making the requisite holes on the gland plate of the switchgear/any other panel, fixing
glands, terminating the cables in the cable boxes, earthing the cable armour,

crimping of cable lugs on each core, neatly clamping the cable inside switchgear /
panel cable alleys, connecting the cable to the terminals and proper tightening of
terminals. The cable and core identifying tags and core identifying ferrules shall be
supplied and installed by the CONTRACTOR as a part of cable termination work.
7.2 Cost of supplying cable glands and cable lugs shall be included under unit rates for
cable termination.
7.3 Control cables/cable cores entering control panel / switchgear / MCC / miscellaneous
panels shall be neatly run in PVC channels / trough or bunched, clamped and tied
with cable ties to keep them in position.
7.4 The CONTRACTOR shall tag /ferrule all control cable cores at all terminations. The
panels where a large number of cables are to be terminated and cable identification
may be difficult, each core ferrule shall include the complete cable number as well as
the terminal number.
7.5 Spare cores shall be similarly tagged / ferruled / cross ferruled with a suffix letter ‘’S’’
along with cable numbers and coiled up after end sealing.
7.6 All cable entry points shall be sealed and made vermin and dust protected. Unused
openings shall be effectively sealed.
8.0 CABLE JOINTING IN HAZARDOUS AREA :

Cable jointing in hazardous area shall be through FLP junction box of minimum 80
mm dia JB with 4 way terminal block suitable for minimum 16 sq mm stranded cable.
Job includes supplying, installation, testing & commissioning at site of flameproof
junction box of approved make, cable termination FLP cable gland, earthing through
4 sq flexible stranded Al. cable. (Cable termination shall be paid extra)
9.0 CONDUITS / PIPES INSTALLATION
9.1 The CONTRACTOR shall install all conduits / pipes (inclusive of all accessories)
required for the cable work. Conduit shall be of 50 mm dia GI pipes
9.2 Conduits / pipes shall be laid buried in ground, laid along the walls / structural
members, along floors and ceilings. Conduits and pipe sleeves which are required to
be embedded in walls, roof slabs, floors, trench and tunnel walls, under roads and
tracks etc shall be installed by the CONTRACTOR. All conduits / pipes shall have
their ends closed by caps until cables are pulled.
9.3 Water-proof sealing shall be done for all outdoor to indoor conduit/pipe sleeves by
means of bell mouth termination pieces and bitumen based cold set water-proof
compound.
10.0 CABLE JOINTS
10.1 Jointing of cables shall be made in accordance with relevant codes of practice and
MANUFACTURER’s special instructions. Cables shall be firmly clamped and
supported within 300 mm from the joint to avoid mechanical stresses on the joint.

When two or more cables are laid together, joints shall be arranged to be staggered
by about 3 meter.
10.2 The CONTRACTOR shall plan and cut the cables in such a way that joints are
avoided as far as possible and also the wastage of cable is limited to a minimum.
Joints shall not be permitted in control cables. However, in long runs of power cables,
joints shall be permitted at an accessible location which shall be chosen in
consultation with IOCL before work is taken up.
10.3 The straight through jointing method and its application technique shall be of
thoroughly proven type. Jointing kits shall be suitable for the type of cable and for
underground buried /overhead cable installation. The CONTRACTOR shall offer cast
resin type jointing kits, complete with insulating materials, stress grading/relieving
materials, plastic mould, resin, tinned copper lugs and necessary accessories to
make a complete joint in all respects. Unit rate quoted for outdoor straight through
joints/Jointing kits shall include erection of temporary shelter and safeguarding
against ingress of moisture.
10.4 Jointing kits shall conform to IS 13573/VDE specification with test certificate.
11.0 CABLE TAGS AND MARKERS
11.1 Each cable shall be tagged with numbers that appear in the cable schedule.
11.2 The tag shall be aluminum with the number punched on it and securely attached to
the cable/conduit by not less than two turns of 20SWG GI wire conforming to IS:280.
Cable tags shall be of rectangular shapes for cables.
11.3 Location of cables laid directly underground shall be clearly indicated with cable
marker made of galvanised steel plate.
11.4 Location of underground cable joints shall be indicated with cable marker with an
additional inscription “Cable Joint”.
11.5 The price of cable tags and markers shall be included in the installation rates for
cable/conduits quoted by the Contractor.

4. CABLE ACCESSORIES
1.0 SCOPE
This specification covers the supply and installation of cable accessories like glands
and lugs.
2.0 CABLE GLANDS
2.1 The CONTRACTOR shall quote for supply of double compression type cable
glands. Cable glands shall be heavy duty and shall be of robust construction
capable of clamping the cable and armour rigidly without injury to insulation and
provide dust/leak proof termination. All cable glands shall be heavy duty brass/steel
chrome casting, machine finished and Nickel plated except skid washer & sealing
devices. Rubber components used in cable glands shall be of neoprene and of
tested quality. Cable sizes shall be marked on the cable glands for easy
identification. Each gland shall comprise the following
a) Gland body
b) Nipple with cone for clamping armour and neoprene compression ring. Nipple
shall have external threads.
c) Check nut and 2.3 to 3 torn thick neoprene washer
d) Metallic compression ring having internal taper to match with armour wire
diameter and outside diameter of cone.
e) Compression nut having internal threads to fix to the nipple body.
f) Compression nut with neoprene compression ring for outer sheath of cable.
g) Flame-proof (FLP) glands shall be similar to double seal cone grip type glands
described above except that construction shall be suitable for installation in
hazardous areas. Cable gland shall be as of specified make and CMRS
certification number and size shall be embossed on the gland. Approval
certificate of relevant authority on flameproof apparatus shall be furnished.
3.0 CABLE LUGS
Cable Lugs shall be of tinned copper/Aluminium, solderless crimping type of
reputed make confirming to relevent standards suitable for aluminium or copper
conductor cable connections. Copper lugs shall be used for copper cable and
Aluminium lugs shall be used for Aluminium lugs.

5. DISTRIBUTION BOARD
1.0 SCOPE
1.1 This standard covers the technical requirements of design, manufacture, testing at
works and delivery in well packed condition of sheet steel distribution boards.
2.0 STANDARDS TO BE FOLLOWED
2.1 The design manufacture and testing of the equipment shall comply with the latest
issue of the following Indian Standard unless otherwise specified.
IS : 8623 - Specification for low voltage switchgear and control gear assemblies.
IS : 13947 - General requirement for switchgear and control gear for voltage not
exceeding 1000 V AC and 1200 V DC.
IS : 5578 - Guide for marking of insulated conductors.
IS : 10118 - Code of practice for selection, installation and maintenance of

switchgear and control gear.
2.2 Various components housed in the distribution board shall conform to the Indian
Standard specification and shall be as per approved make.
2.3 The design and operational features of the equipment offered shall also comply with
the provisions of the latest issue of the Indian Electricity Rules and other Statutory
acts and Regulations. The supplier shall wherever necessary, make suitable
modifications in the equipment to comply with the above.
3.0 DESIGN AND CONSTRUCTIONAL FEATURES
3.1 Mounting : Floor / Wall as per site requirement.
3.2 Enclosure : Sheet steel (CRCA) Minimum 14 gauge (2mm)
3.3 Minimum Degree of protection : IP42.
3.4 Painting : All the sheet metal work shall be degreased, pickled, phospated
and then applied with two coats of zinc chromate primer and two coats of epoxy
paints Both the primer and the final paint shall be stoved. Both inside and outside
final paint shall be epoxy. Outside shade 630 as per IS 5 and inside white.
3.5 Busbar :

Switchgear shall be provided with three phase or three phase and neutral bus-bars
as indicated in the Technical specification / single line diagram. Except as noted
bus-bars shall be of high conductivity aluminium. Bus bars shall be provided with at
lest the minimum clearances in air as specified IS 5082 grade 63, 40% fault with
stand capacity 50 KA per seconds. All bus-bars, bus-taps shall be insulated with
close fitting sleeve of hard, smooth, dust and dirt free heat shrunk PVC insulation of
high dielectric strength to provide a permanent high dielectric non ageing and non-
tracking protection, impervious to water, tropical conditions and fungi.
The insulation shall be non-inflammable and self-extinguishing and in fast colours to

indicate phases. The joints shall be insulated in such a way to provide for
accessibility of contact bolts for maintenance. The dielectric strength and properties
shall hold good for the temperature range of 0 to 90 degree centigrade. If the
insulating sleeve is not coloured, bus bars shall be colour coded with coloured bands
at suitable intervals.
All bus-bar joints and bus-tap joints shall be silver faced. Bus-bar joints shall be of
the bolted type and shall be insulated. Spring washers shall be provided to ensure
good contact at the joints. Bus bars shall be thoroughly cleaned at the joint locations
and a suitable contact grease shall be applied just before making a joint.
Bus-bars shall be located in air insulated enclosures. Direct access to, or accidental
contact with bus-bars and primary connections shall not be possible. All apertures
and slots shall be protected by baffles to prevent accidental shorting of busbars by
the entry of maintenance tools. To provide a tight seal between cubicles, bushings or
insulating panels shall be provided for bus bars crossing from one cubicle to another.
Positive / live terminal or busbar shall be located at the top or on the left for two pole,
vertical and horizontal layout respectively. Sequence of red, yellow, blue phases and
neutral for four pole equipment shall be left to right and top of bottom, for horizontal
and vertical layouts respectively.
3.6 Indication Lamp : LED lamps for ON & OFF shall be provided at incomer and also at
outgoing feeders with current rating more than 63 Amp.

3.7 All the external hardware shall be cadmium plated/zinc passivated. The hardware for
fixing the removable parts shall be provided with retaining devices.
3.8 The doors and removable covers shall be provided with non deteriorating neoprene
gaskets.
3.9 All the components shall be accessible for inspection and maintenance without the
necessity for removal of the adjacent ones.
3.10 Adequate arrangement for earthing shall be provided to safeguard the operator or
other personnel from electric hazard under all conditions of operation.
3.11 The meters, switches and lamps shall be flush mounted.
3.12 Minimum clearance between two live conductors or between conductor and body
shall be minimum 20 mm.
3.13 All metal parts other than those forming part of an electrical circuit shall be
connected to a copper earth bar run along the inside bottom of the terminal cabinet
and extended at both ends for external connection. The minimum section of the earth
bar shall be (20 mm x 3mm) in case of copper bus and 25x3 mm in case of Al. bus.
4.0 CONTROL WIRING
4.1 The switchboard shall be completely factory wired and ready for external
connections.
4.2 The wiring shall be carried out with stranded PVC insulated copper conductor cables
of 1100 volts grade. Minimum size of wire shall be 1.5 sq mm. Numbered ferrule shall
be provided at both ends of each wire.
4.3 Panel wiring shall be securely supported, neatly arranged and easily accessible.
Wiring gutters, troughs, channel with covers, shall be used for this purpose. Extra

flexible wires (with 19 strands) shall be used where flexible cables are laid across
hinges to devices mounted an doors.
4.4 Size of wires for CT connection not less than 2.5 mm2
Size of wires for VT connections not less than 1.5 mm2
Other circuits not less than 1.5 mm2.

4.5 Wiring termination shall be made with solderless crimping type tinned copper lugs.
Insulation sleeves shall be provided at all terminations.
4.6 Core identification with plastic ferrules Marked with wire numbers shall be provided
at both ends.
4.7 Trip circuit wires shall be distinguished by an additional red coloured ferrules.
4.8 Generally only one wire shall terminate on a terminal, except in case of jumpering,
wherein maximum of two wires is permitted.
5.0 INSTRUMENTS AND METERS
5.1 All instrument shall be flush mounting type with square face and shall be tropicalized
and dust tight.
5.2 All meters shall have 0-240 degree scale moving iron spring controlled type of class
1.5 accuracy as per IS : 1248. The meters shall be of 96 x 96 mm size
6.0 DRAWING AND DOCUMENT
6.1 GA drawings showing the overall dimensions with layout of the major components
and bill of materials with rating and make of the components shall be submitted for
approval after placement of order..
6.2 All drawings and documents shall have description written boldly like Name of Client,
Enquiry/Order No./Project Name etc.

6. SWITCHES, STARTERS, CONTACTORS, FUSES
This standard covers supply and fixing of different components like switch, fuse, contactors,
MCCB, MCB, ELCB etc in new or existing panels.
1.0 AIR BREAK SWITCHES
1.1 Air break switches shall be of heavy duty, group operated load break, fault make
type and of required continuous rating complying with applicable standards.
1.2 Whenever solid links are used for connection between switches and fuses, such link
shall be fitted with insulating sleeves. Whenever the links are of less than 100 mm
length and sleeves can not be provided, taping shall be provided.
1.3 All live parts be switches shall be shrouded.
1.4 Switch operating handle shall be suitable for padlocking in OFF position. It shall be
possible to open the door only when the switch is in OFF position. The defeat
interlock facility shall also be provided.
2.0 FUSES
2.1 Fuses shall generally be of HRC cartridge fuse link type having a certified rupturing
capacity not less than 80 KA at 440 Volt.
2.2 Fuses shall be provided with visible indication to show that they have operated.
2.3 Fuses shall preferably be mounted in moulded plastic carriers and shall be complete
with fuse base.
2.4 Wherever it is not possible to mount fuses on carriers, fuse shall be directly mounted
on plug in type of base.
3.0 CONTACTORS
3.1 Motor starter contactor shall be of the electromagnetic type rated for un interrupted
duty as defined in applicable standard.
3.2 Class of co-ordination for starter module shall be class Z as per IS : 8544.
4.0 DIRECT ON LINE (DOL) STARTERS
Direct on line starters shall be suitable for class AC 3 utilisation category as
specified in applicable standards.
5.0 THERMAL OVERLOAD RELAYS
5.1 The thermal overload relay shall be complete with a three element, positive acting,
ambient temperature compensated, time lagged with adjustable settings and built in
single phase preventer. The setting range shall be properly selected in accordance
with the rating of the motor.
5.2 Thermal overload relays shall be hand reset type, unless otherwise indicated.
5.3 Stop push button of the starter and hand reset device shall be separate from each
other.

5.4 Overload relay hand reset push button shall be brought out on the front of the
compartment door.
6.0 MOULDED CASE CIRCUIT BREAKER (MCCB)
6.1 MCCBs in AC circuit shall be 4 – Poole construction arranged for simultaneous four
pole manual closing and opening. Operating mechanism shall be quick make, quick
break and trip free type. The ON, OFF and TRIP positions of the MCCB shall be
clearly indicated and visible to the operator. Operating handle shall be provided for
operation from door of the board.
6.2 The MCCB shall confirm to IS 13947 (Part II) – 1993 IEC 947 (Part II) breaking
capacity of 36 KA with earth fault realese and under voltage release with
electromagnetic tripping mechanism is provided.
6.3 The thermal and instanteous tripping element adjustable over a wide band make
these MCCB and confirm to IEC 947 (Part II) IS 13947 (Part II).
6.4 The thermal over load setting can be adjusted between 70 to 100 % of the rated
current on site depending on the load requirement also the breaker should be
capable of feature increasing in load requirement.
6.5 The mechanical interlocking arrangment should be made with the MCCB suitable
phase bearer and necessary external terminal connected to the main bus bar
chamber.
7.0 MINIATURE CIRCUIT BREAKERS

Miniature circuit breakers shall comply with the requirement of applicable standards
and shall have fault interrupting capacity of 10 KA.
8.0 EARTH LEAKAGE CIRCUIT BREAKER

Supplying and fixing of relevant capacity of 4 pole earth leakage circuit breaker
(ELCB) 300 MA sensitivity and breaking capacity of 10 KA as approved make shall
be provided as incomer of MCB DB as per IS specification.
9.0 CHANGE OVER SWITCH WITH MECHANICAL INTER LOCKING DRG. NO. IOC
/M & A / E / 302. :
9.1 Supply, Erection, testing and commissioning of wall mounted type change over
switch board (off lead with mechanical inter locking) shall be 1.6mm thick CRCA plain
black shut steel dust and vermin proof enclosure as per Drg. No. M&A / E / 302.
9.2 A relevant capacity of fuse switch unit with HRC fuses as a incomer of both supply
(EB and DG set) with relevant capacity of Tinned copper Bin bar (current rating of Bin
bar is not less than 1.5A / Sqmm) shall be connected both supply main source as
well as outgoing.

9.3 Two lock with one key mechanical inter locking arrangements shall be provided on
incomer of fuse switch unit to avoid parallel operation of both supply at a time.
9.4 This board also incorporated with 96 Sqmm Voltmetre, Ammetre (CT operated) and
selector switch for Voltmetre, Ammetre, 3 Phase indicator lamp with 6A control fuse-
3 Nos. relevant capacity of current transformer (CT) for measuring current level in
this board as per IE rules.
10.0 Supplying and fixing of four pole change over switch with necessary
connections as per Drg. No.IOC/ENGG/E/302. :
10.1 Supply, erection, testing and Commissioning, of wall mounted MCB Distribution shall
be 1.6 mm thick CRCA plain blank sheet steel dust and Vermin proof enclosure as
per Drg. No. IOC/ENGG/E/302 with relevant capacity of MCB’s are incorporated with
the board.
10.2 The lighting and power distribution MCB DB shall be provided with relevant capacity
MCB (SP,DP,TP version) and isolator, ELCB as per IS 12460-1988. The breaking
capacity MCB is 10KA, the double pole (DP) MCB shall be connected to pump and
TP MCB connected to 3phase Power as per IS 8828-1928.
11.0 Circuit breakers:

415 V Circuit breakers shall be of the air break type.
11.1 Circuit breakers operating mechanism:
The circuit breaker shall be manually operated spring charging type of mechanism as
specified in the technical particulars.
The tripping spring shall be charged by the closing action, to enable quick tripping.
Closing of the circuit breaker shall automatically initiate recharging of the springs to
enable the mechanism to be ready for the next closing stroke. Charging time for the
springs shall not exceed 30 seconds. It shall be possible to manually charge the
springs in an emergency. Transfer from motor to manual charging shall automatically
disconnect the charging motor. The charging mechanism shall be provided with
mechanical indicators to show "charged" and "discharged" conditions of the spring.
Failure of any spring, vibration or mechanical shock shall not cause tripping or
closing of the circuit breaker.
Only one closing operating of the circuit breaker mechanism shall result from each
closing impulse (manual or electrical), even if the breaker trips while the control
device (manual or electrical) is being held in the "close" position.
The circuit breaker mechanism shall make one complete closing operation, once the
control switch has been operated and the first device. In the control scheme has

responded, even though the control switch is released before closing operation is
complete, subject to the condition that there is no counter impulse for tripping.
Means shall be provided to manually open and close the breakers slowly when the
operating power is not available, for maintenance and adjustments.
All operating mechanisms shall be provided with "ON" - "OFF" mechanical indicators.
A local manual trip device shall be provided on the operating mechanism. Closing
coils and other auxiliary devices shall operate satisfactorily at all voltages between
85-110% of the control voltage. Trip coils shall operate satisfactorily between 70 -
110% the rated control voltage.
11.2 Interlocks:
Interlocks for metal clad switchgear shall comply with the following requirements:
It shall not be possible to plug in or isolate a closed circuit breaker. Attempted

isolation shall not trip a circuit breaker. It shall not be possible to close a circuit
breaker unless it is fully plugged in or fully isolated. Isolating devices, if provided
shall be interlocked with circuit breakers to prevent their making or breaking current.
Slow operation of circuit breakers shall be possible only in the circuit breaker fully
"drawn out" position.
It shall not be possible to close the circuit breaker in service position, without
completing the auxiliary circuits between fixed and moving position. Where key
interlocking is employed, tripping of closed circuit breaker shall not occur if any
attempt is made to remove the trapped key from the mechanism.
11.3 Test Operation facilities:

Metalclad switchgear shall be provided with testing facilities to test the operation of
circuit breaker. A separate test position of the circuit breaker shall be provided in the
cubicle / module.
11.4 Locking facilities:

Drawout circuit breakers shall be provided with padlocking facilities for locking the
circuit breaker carriage in the "fully drawn out", "earth and test" and "fully plugged in"
positions.
11.5 Safety shutters:

Switchgear shall be provided with safety shutters operated automatically by the
movement of the circuit breaker carriage, to cover the stationery isolated contacts
when the breaker is withdrawn. Padlocking facilities shall be provided for locking the
shutters positively in the closed position. It shall however, be possible to open the
shutters intentionally against the spring pressure for testing purposes.
Bus bars shutters shall be coloured "signal red" colour 537 to BS:381C labelled
"Busbars" in large white letters. Circuit shutters shall be coloured "lemon" colour 355
to BS:381C. shutters in bus section units shall be coloured "Signal Red" and shall be
labelled with a large white arrow pointing in the direction of the section of bus bars to
which the isolating contacts are connected. 415 V switchgear switch and starter
modules shall be provided with laminated insulating sheet partitions, to cover the
stationery contacts when the modules is withdrawn.
11.6 Circuit breaker alignment:

Circuit breaker moving portion shall be fitted with positive guides so as to ensure
correct alignment of the isolating contacts in both circuit or earthing position.

7.LIGHTING SYSTEM EQUIPMENT
1.0 SCOPE
This specification covers the supply, installation, testing and commissioning of
lighting system equipment such as lighting distribution boards and panels, lighting
wires, ceiling fans, conduits and other similar items necessary for lighting system.
2.0 STANDARDS
The items of supply shall comply with the latest applicable standards. Where no
standards are available, the supply items shall be backed by test results, shall be of
good quality and workmanship. Any supply items which are bought out by the
CONTRACTOR shall be procured from approved manufacturers acceptable to the
IOC.
3.0 LIGHTING DISTRIBUTION BOARD AND LIGHTING PANELS

3.1 Constructional Features
i) Boards shall be sheet steel enclosed, fully dust & vermin proof with degree of
protection equivalent to IP52 as per IS : 13947. The boards shall be with busbars
and incoming and outgoing feeding compartment. The boards shall be with hinged
doors.
ii) Busbars shall be of copper and supported on suitable DMC/SMC insulated
supports. They shall be provided with minimum clearances in air as per applicable
standards for 415 V, 3 phase system. The bus bars shall be arranged and colour
coded according to IS:5578/11353.
iii) All terminals shall be of bolted type and shall be identified for phase and neutral
circuit.
iv) All internal wiring shall be with copper wires, PVC insulated and shall not be less
than size 2.5 mm2
v) All cables shall be terminated through lugs only. Shrouds shall be provided on the
power and other terminals to prevent accidental contact during the maintenance.
vi) The depth of the enclosure or modules of Main Lighting Distribution Boards or
sub-lighting distribution Boards, when made of sheet steel shall not be less than
250 mm. The minimum height of the module shall be 200 mm for better availability
of working space for maintenance.
vii) Painting shall be powder coated as per IS-5 and shade to be 630.
viii) Separate earthing terminals one inside and two outside shall be provided.
ix) Adequate interior cabling space & suitable removable cable entry plates shall be
provided for top/bottom entry of cables through glands and or conduits.
x) For out door location degree of protection shall be IP-55 and shall be with a canopy.

3.2 Internal Wiring

3.2.1 Panels/boards shall be supplied completely wired, ready external connections at
terminal blocks. Engraved identification ferrules marked to correspond with the
wiring diagram shall be fitted at both ends of each wire.
3.2.2 All wiring shall be terminated on terminal blocks. Terminal blocks shall be one piece
moulded, suitable for 650 V, of reputed make preferably stud type for higher current
ratings such that wires are connected by cable lugs and complete with nuts and
washers. Terminals shall be adequately rated for the circuit current, the minimum
rating shall be 20A.
3.3 Labels & Diagram Plate
3.3.1 All door mounted equipment as well as equipment mounted inside the
boards/panels shall be provided with individual labels with equipment
designation/rating. Also the boards/panels shall be provided on the front with a label
engraved with the designation of the board/panel as furnished by the
PURCHASER.
3.3.2 Labels shall be made of non rusting metal.
3.3.3 Inside the door of lighting panels a circuit diagram/description shall be fixed for
reference and identification.
4.0 CEILING FANS

4.1 Ceiling fans shall be suitable for operation on 240 V, 1 phase, 50Hz supply and
shall be complete with standard mounting accessories such as suspension rods,
top and bottom caps etc. The fans shall be supplied with appropriate speed
regulators.
4.2 The fans shall generally conform to the applicable standards. Details regarding blade
sweep and suspension requirements shall be as per price schedule.
5.0 EXHAUST FANS

5.1 These shall be of Propeller type giving axial flow conforming to IS 2312.
6.0 LIGHTING WIRES
6.1 The wires for wring in lighting system shall be 1100 V, 1 core PVC insulated,
unarmoured with stranded copper conductors, unless otherwise specified. The
wires shall conform to the applicable standards specified.
6.2 The minimum area of conductors shall be 2.5 sq.mm for light fittings and 5A
receptacles and 4 sq.mm for receptacles rated 15A.
6.3 The wires shall be coded white for phase/positive of DC and black for
neutral/negative of DC.

7.0 POINT WIRING

Wiring of lighting fixtures and their associated control switches, regulators of fans, &
switches of receptacle units shall be on point wiring basis. Job includes the following
:
7.1 Cutting of brick masonry/plastered/C.C. surface with chisel & hammer to provide
suitable PVC 15mm – 25mm dia. 2mm thick recessed conduit pipe or PVC conduit
pipe, and making the surface to original after laying conduit pipe.
7.2 Providing necessary clamps for fixing conduit pipe on the structure etc.
7.3 Providing & laying PVC 19mm. dia. 16 Gauge recessed conduit pipe or PVC conduit
pipe to accommodate 1.5sq.mm. multi stand PVC Wire.
7.4 Providing & laying PVC insulated copper conductor wire IS approved in conduit pipe
with 1.5 sq mm copper wire for earthing and providing end connections etc.
7.5 Providing inspection bends, junction boxes, 14 Gauge GI boxes of required size to be
embedded in walls.
7.6 Providing ordinary type or plate type modular switches of approved make for each
point.
7.7 All conduit wiring concealed or exposed wiring shall have provision for easy
inspection. Exposed wiring when run along wall shall be as near the ceiling as
possible. Where cable wiring is specified, cable shall be cleated on to the wall as
close to the ceiling as possible. In all types of wiring, due consideration shall be
given for neatness and appearance.
7.8 Wherever lighting system has three phase distribution, separate conduits shall be
used for different phases.
7.9 For long conduit wiring runs, inspection /pull boxes shall be provided at intervals not
extending 10m. Such facilities shall also be provided at conduit bends.
7.10 Each final sub-circuit from a lighting panel shall be controlled by a single pole switch
connected to the live conductor.
8.0 JUNCTION BOXES
8.1 Junction boxes with terminals shall be supplied for branching and terminating
lighting cables wherever required for outdoor areas, 3 phase receptacles etc.
8.2 The junction boxes shall be dust and vermin proof of outdoor /weatherproof
construction(IP55) and shall be made of from cats iron / cast aluminium and shall
be complete with all accessories. They shall be provided with gasketed front door
hinged at one end and fixed with captive screws at other end. Paint shade shall be
630 as per IS 5.
8.3 The boxes shall have provision for wall, column, pole or structure mounting and
shall be provided with cable/conduit entry knock cuts, terminal blocks as per the
requirement.

8.4 The terminal blocks, with specified number of terminals, shall be mounted securely
on brackets welded to the back sheet of the box. The terminals block shall be rated
for 1100V and 15A, one piece construction complete with terminals, insulation
barriers, galvanised nuts, bolts and washers etc. and provided with identification
strips of PVC. The terminals shall be made of copper alloy and shall be of box
clamp or clip on type. The terminals shall be suitable for terminating 2 nos. 2.5 sq
min stranded copper conductors on each side. At least two terminals in each box
shall be suitable for terminating 4 sqmm conductors
8.5 The boxes shall be hot dip galvanized or painted with one coat of red oxide zinc
chromate primer followed by a finishing coat of paint (Shade 630 as per IS: 5).
8.6 Junction boxes shall be of flameproof type for zone-1 & II areas. Flameproof
junction boxes shall be of approved make and shall be approved by competent
certifying authority regarding their suitability for use in hazardous areas.
9.0 TESTS AND TEST REPORTS

9.1 Test certificates for all equipment and for installation work shall be produced for
IOC’s review and records.
10.0. SUPPLYING AND FIXING OF WEATHER PROOF JUNCTION BOX FOR

EMBELAMPOLE, SINGLE AND DOUBLE ARM LIGHT POLE:
a) Supplying and fixing of FLP junction Box/ weatherproof junction box wherever
necessary.
b) Weatherproof junction box shall be 3mm thick 100mm square type and FLP junction
box shall be of 125 mm dia. The JBs shall be of 3 or 4 way.
c) 4 Way 6A B type connector shall be fixed inside the junction box over a Hylam
sheet.
d) Two coat of synthetic enamel paint over a coat of red oxide primer.


8. LIGHTING FIXTURES AND ACCESSORIES
1.0 SCOPE
This specification covers supply, installation, testing and commissioning of lighting
fixtures and their associated accessories.
2.0 STANDARDS
The lighting fixtures and their associated accessories such as lamps tubes,
reflectors, housings, ballasts, etc. shall comply with the latest applicable standards as
indicated below. Where no standards are available. the supply items shall be backed
by test results, shall be of good quality and workmanship. Any supply items which are
bought out by the CONTRACTOR shall be ISI certified and from approved make.
A. Lighting Fixture
1. Code of practice for Industrial Lighting IS : 6665
2. Code of Practice for interior illumination IS : 3646
(Part I, II)
3. Luminaires for street lighting IS : 2149
4. Decorative lighting outfits IS : 5077 -1969
5. Luminaires, general and safety requirements IS : 1913
6. Photometric testing of incandescent type IS : 7678 - 190075
7. Industrial luminaire with metal reflectors IS : 1777 - 1978
8. Flood Light IS : 1947 - 1980
9. Electric lighting fittings for Zone 2 areas IS : 8224 - 1976
10. Dust proof electric lighting fittings IS 4012 - 1967
B. Lamps & Lamp Accessories
11. Ballasts for fluroescent Lamps for Switch IS : 1534
start circuit
12. Ballasts for HPMV lamps IS : 6616
13. HPMV Lamps IS : 9900 (Part I to IV)
14. High pressure Sodium vapour lamps IS : 9974 (Part I&II)
15. Capacitors for use in lamp circuits IS : 1569
3.0 LIGHTING FIXTURES (LUMINAIRES) - GENERAL REQUIREMENTS
3.1 Luminaires shall be designed for continuous trouble-free operation under
atmospheric conditions prevailing at site without reduction in lamp life or without

deterioration of materials and internal wiring. Outdoor fittings shall be weather-proof

and water-proof type.
3.2 All luminaires shall be supplied complete with lamps suitable for operation on a
supply voltage and the variation in supply voltage and frequency prevailing at site.
3.3 Fluorescent type, mercury vapour, sodium vapour and metal halide type luminaires
shall be complete with accessories like lamps, ballasts, power factor imprvement
capacitors, starters etc. These shall be mounted as far as possible in the luminaire
housing only. If these can not be accommodated integral with the luminare then a
separate metal enclosed control gear box shall be included to accommodate the
control accessories together with a terminal block suitable for loop-in, loop-out
connections. Outdoor type fixtures shall be provided with outdoor weather-proof
box with minimum degree of protection IP 54.
3.4 Fluorescent type luminaires with more than one lamp shall be provided with
capacitors connected in lead-lag circuit for correction of stoboscopic effect.
3.5 Each luminaire shall have a terminal block suitable for loop-in, loop-out and T-off
connection by 1100 V, I core PVC insulated copper conductor wires upto 6 sq.mm
in size. In outdoor corrosive and hazardous areas the termination at the luminarie
shall be suitable for 1100 V, PVC insulated copper/ aluminum conductor, armoured
cables of sizes upto 6 sq.mm conductor. Terminals shall be of stud or clamp type.
The internal wiring shall be completed by the MANUFACTURER by means of
stranded copper wire of minimum 1.5 sq.mm size and terminated on the terminal
block. Terminal blocks shall be mounted with minimum two fixing screws.
3.6 Mounting facility and conduit knock-outs for the luminaires shall be provided.
3.7 All hardware used in the luminaire shall be suitable plated or anodised and
passivated for use in chemical, industrial and power plants.
3.8 Earthing.
3.8.1 Each luminaire shall be provided with an earthing terminal suitable for connection to
the PURCHASER,s earthing conductor of 1.5 sq mm stranded PVC wire or unless
otherwise specified.
3.8.2 Where separate control gear box is provided for housing the accessories, the same
shall be provided with an earthing terminal suitable for connecting external earthing
conductor.
3.8.3 All metal or metal enclosed parts of the luminaire / control gear box shall be bonded
and connected to the earthing terminal so as to ensure satisfactory earthing
continuity.
3.9 Painting / Finish
3.9.1 All surfaces of the luminaire / control gear box housing accessories shall be
thoroughly cleaned and degreased. It shall be free from scale, rust, sharp edges
and burrs.
3.9.2 The luminaire housing shall be stove-enamelled / epoxy stove enameled / vitreous
enamelled or anodised as indicated under various types of fittings. Aluminium paint
on flame proof fittings is prohibited.

3.9.3 The surface shall be scratch resistant and shall show no sign of cracking or flaking
when bent through 90 deg, over 12.5 mm die mandrel.
3.9.4 The finish of the luminaire shall be such that no bright spots are produced either by
direct light source or by reflection.
3.9.5 External control gear box provided for housing accessories shall be painted or
galvanised
4.0 LUMINAIRES:
4.1 Fluorescent Luminaires
4.1.1 Decorative Type
1. Mounting rail type
The fixtures shall be suitable for 2 X 36/40W fluorescent lamp, provided with CRCA
sheet steel mounting channel, good quality acrylic opal diffuser of non yellowing
type and high impact polyesterene black end plates. The mounting channel shall be
provided with a reflector plate to hold the diffuser so that the same shall not come
out when the end plates are removed.
Decorative luminaires with mercury vapour / sodium vapour / metal halide lamps
shall be generally outdoor weather-proof type with degree of protection IP - 55
suitable for conduit mounting.
2. Recess Mounted Type
The fixture shall be suitable for 2 x 36/40W fluorescent lamps and recess mounting
on the false ceiling. The fixture have CRCA sheet steel housing accommodating all
the accessories, reflector plate and good quality non-yellowing type opal acrylic
diffuser. It shall be possible to have access to lamp and other accessories from
below.
The housing and the reflector plate shall be stove enamelled.
4.1.2 Industrial Type
Fluorescent lamp fixtures shall be suitable for 2 x 36/40 w fluorescent lamps. The
fixture are provided with CRCA sheet steel, mounting channel containing all the
accessories suitably covered with reflector stove enamelled for general industrial
application and vitreous enamelled for humid atmosphere. Hose proof fixture shall
be suitable for 2 x 36/4OW fluorescent lamps totally enclosed type, suitable for
outdoor installation having IP-55 degree of protection.
All external hardware used shall be of stainless steel.
4.2 Incandescent/HPMV/Sodium vapour/MLL Blended/Metal halide Luminaire
4.2.1 High, Medium and Low Bay Luminaires
4.2.1.1 High and medium bay luminaires shall be with cast alummium / stove enamelled
housing, anodised aluminium mirror polished reflector, canopy with eye bolt for
suspension, cooling fins. Glass cover shall be provided if specified.

The luminaire shall be suitable for mercury vapour lamps / sodium vapour lamps /
metal halide lamp upto 400W. The control gear accessories shall be mounted
integral with the luminaire.
4.2.1.2 Low bay luminaires may be with sheet steel / cast aluminium enclosure, wide angle
distribution type polished reflector, acrylic cover and wire guard complete with
neoprene gaskets, mounting bracket etc.
The lummaire shall be suitable for mercury vapour lamps upto 125W and sodium
vapour lamps upto 70W. The control gear accessories shall be mounted integral
with the luminaire.
All luminaires used with metal halide lamps shall be of enclosed type.
4.3 Flood Light
4.3.1 The fixtures shall be of weatherproof construction and shall be suitable for HPMV /
Sodium Vapour lamp upto 400W and comprise of epoxy stove enamelled, cast
alummium alloy body, a clear heat resistant flat toughened glass, an anodised
mirror polished aluminium reflector and a focussing device. The fixtures shall have
an arrangement of rotation on both horizontal and vertical planes and locking in any
desired position.
Neoprene gaskets shall be provided where necessary to make the fixture suitable
for outdoor installation. The complete unit shall be mounted on a structural platform.
A separate control gear box suitable for the rating of the lamp specified shall be
supplied alongwith fixture.
4.4 Street Lighting
4.4.1 The fixtures shall be totally enclosed type with gaskets to prevent ingress of dust,
moisture and insects inside the fixture. They shall be of outdoor weatherproof type.
All external hardware such as bolts, and screws, toggle lever, hinge pin etc. shall be
stainless steel.
Control gear box can be integral or supplied separately suitable for mounting on the
pole or structure.
4.4.2 Fluorescent Luminaires
The luminaire shall be of semi-cut off or non-cut off type, with CRCA sheet steel
housing, vitreous enamelled, plain or corrugated clear acrylic cover, complete with
integral mounted control gear, neoprene gaskets, side pipe entry or top
suspension type.
The luminaire shall be suitable for 1 x 40 / 36 watts or 2 x 40/36W fluorescent
tubes.
4.4.3 Mercury vapour and Sodium vapour Luminaire
The luminaire shall be of semi-cut off or cut-off type, with cast aluminium housing,
acrylic or prismatic cover, polished aluminum reflectors, complete with integral
mounted control gear, neoprene gaskets and with rear pipe entry. The luminaires
shall be suitable upto 25OW mercury or sodium vapour lamps.

5.0 ACCESSORIES FOR LUMINAIRES

5.1 Reflectors
5.1.1 The reflectors shall be made of CRCA sheet steel I aluminium / silvered glass /
chromium plated sheet copper as indicated for above mentioned luminaires.
5.1.2 Reflectors made of steel shall stove enamelled / vitreous enamelled / epoxy coating
finish. Aluminium used for reflectors shall be anodized / epoxy stove enamelled /
mirror polished.
5.1.3 Aluminium paint on the reflectors of flame proof lighting fittings is prohibited.
5.1.4 Reflectors shall be free from scratches or blisters and shall have a smooth and
glossy surface having an optimum light reflecting coefficient such as to ensure the
overall light output specified by the MANUFACTURER.
5.1.5 Reflectors shall be readily removable from the housing for cleaning and
maintenance without disturbing the lamps and without the use of tools. They shall
be securely fixed to the housing by means of positive fastening device of captive
type.
5.2 Lamp / Starter Holders.
5.2.1 Lamp holders shall comply with relevant standards. They shall have low contact
resistance, shall be resistant to wear and shall be suitable for operation at the
specified temperature without deterioration in insulation valve. They shall hold the
lamps in position under normal condition of shock and vibration met with under
normal installation and use.
5.2.2 Lamp holders for the fluorescent lamps shall be of the spring loaded bi pin rotor
type. The lamp holder contacts shall provide adequate pressure on the lamp cap
pins when the lamp is in working position.
5.2.3 Lamp holders for incandescent, MLL blended, metal halide, mercury vapour and
sodium vapour lamps shall be of Edison Screw (E.S.) type.
5.2.4 Starter holders for fluorescent lamps shall conform to relevant standards. All
material used in the construction of the holder shall be suitable for tropical use.
5.3 Ballasts
5.3.1 The ballasts shall be designed, manufactured and supplied in accordance with the
relevant standards. The ballasts shall be designed to have a long service life and
low power loss.
5.3.2 Ballasts shall be mounted using self locking, anti-vibration fixings and shall be easy
to remove without demounting the fittings. They shall be in dust tight, non
combustible enclosures.

5.3.3 The ballasts shall be of the inductive, heavy duty type copper wire wound, filled
with thermosetting, insulating, moisture repellent polyester compound filled under
pressure or vacuum. Ballasts shall be provided with taps to set the voltage within
the range specified in project information. End connections and taps shall be
brought out to a suitable terminal block rigidly fixed to the ballast enclosure.
Ballasts shall be free from hum and such of those which produce hum shall be
replaced by CONTRACTOR free of cost.
5.3.4 Separate ballast for each lamp shall be provided in case of multi lamp luminaires,
except in the case of 2 x 20 watts luminaires.
5.3.5 Electronic Ballast.
Electronic ballast shall be suitable for 1 x 36 W/40 W, 2 x 36 W/40 W fluorescent
lamp and shall be energy saving, warm start type having a power factor better than
0.96, having an optimum wattage delivery to the lamp. The choke shall be suitable
for 180-270 V AC for operation at ambient temperature range of -150C to +50 C.
5.4 Starters
5.4.1 Starters shall have bimetal electrodes and high mechanical strength. Starters shall
be replaceable without disturbing the reflector or lamps and without the use of any
tool. Starters shall have brass contacts and radio interference capacitors.
5.4.2 The starters shall generally conform to the relevant standards.
5.5 Capacitors
5.5.1 The capacitors shall have a constant value of capacitance and shall be connected
across the supply of individual lamp circuits.
5.5.2 The capacitors shall be suitable for operation at supply voltage as specified and
shall have a value of capacitance so as to correct the power factor of its
corresponding lamp circuit to the extent of 0.95 lag or better.
5.5.3 The capacitors shall be hermetically sealed preferably in a metal enclosure to
prevent seepage of impregnant and ingress of moisture.
5.6 Lamps
Lamps shall be capable of withstanding small vibrations and the connections at lead
in wires and filaments / electrodes shall not break under such circumstances.
Lamps / tubes shall conform to relevant standards specified and shall be suitable
for supply voltage and frequency specified in project information.
5.6.1 Incandescent lamps
a) General lighting service (GLS) lamps shall be tungsten filament incandescent
type. The filament shall be coil type rated for 230-250 volts, single phase AC.
b) Lamps shall be with Edison Screw metal lamp caps to prevent pilferage.
c) Lamps shall be milky white for diffused, soft, glare free lightning rated upto
100watts.
d) Unless otherwise specified lamps shall be clear type for rated upto 500 watts

5.6.2 Halogen Lamps

a) Halogen lamps shall be tungsten halogen type suitable for fitment in flood light
luminaires.
b) Lamps shall be rated 250 volts single phase AC upto 1000watts
5.6.3 Gas Discharge Lamps
5.6.3.1 Fluorescent Lamps
a) Fluorescent lamps shall be low pressure mercury vapour type with low wattage
consumption and high efficiency and longer burning life (about 7500 hours).
b) Lamps shall be of warm white or cool day light type with triband phosphor
coated, type suitable for operation on 24OV. single phase AC in standard
lengths of 2 and 4 feet.
5.6.3.2 Compact Fluorescent Lamps
a) These compact fluorescent lamps shall be of low pressure, low wattage type
with integral glow switch starter with separate/inbuilt ballast. Suitable for
operation on 240 V, single phase AC with burning life (about 7500 hours).
b) Lamps shall be rated 7 W, 9W, 11 W for compact fluorescent (PL) type and
ratings upto 25 W for bulb (SL) type.
5.6.3.3 High Intensity Discharge Lamps
These lamps include the high pressure mercury vapour blended lamp, high
pressure mercury vapour lamp and the high pressure sodium vapour lamp.
a) High pressure mercury vapour blended lamps shall be direct replacement for
incandescent lamps of higher wattages and shall be with in built control gear,
burning life (about 5000 hours). Lamp is available in standard rating of 160 W
& 220 W.
b) High pressure mercury vapour lamps shall be with quartz discharge tube,
internal coated shell, quick restrike time (of within 5 minutes) and with burning
life (about 5000 hours) in standard ratings upto 1000 watts
c) High pressure sodium vapour lamps shall be with polycrystalline translucent,
coated discharge tube, coated shell, quick restrike time (of within 5 minutes)
and with burning life (about 10,000 hours) in standard ratings upto 400 watts.
d) Metal halide lamps shall be single ended or double ended as required. The
lamps shall be with quartz discharge tube and transparent/internal coated
shell, quick restrike time (of within 5 minutes) with burning life (upto 5000
hours) in standard ratings upto 2000W. The colour rendering index of these
lamps shall be very high. These lamps shall be used only in enclosed
luminaires (lamps without protective coating).
5.6.3.4 Low Pressure Sodium Lamps.

These lamps are high efficiency discharge lamps. with restrike time (of within 11
minutes) and with burning life (about 10,000, hours) in standard ratings of 18 W and
35 W.
6.0 Installation of Lighting Fixtures

The installation of lighting fixtures shall be based on the mounting arrangement as
required at site. Unit rate for lighting fixtures shall include cost of installation of
control gear box wherever applicable.
6.2 Cost of supply and installation of necessary hardware shall be included in the unit
rates quoted for installation of fixtures.
6.3 Fixing the newly supplied electrical fittings in position, including making end
connections wherever required with electrical fittings.
6.4 Supplying and laying of cable, gland shall be paid under separate item.
7.0 TESTS AND TEST REPORT
7.1 The MANUFACTURER’s routine test certificates shall be submitted for scrutiny and
record for the fixtures and accessories.


9. STREET LIGHT POLES

SCOPE OF WORK
This specification covers the requirements of supply and installation of street
lighting poles & Decorative Poles, junction box for pole lights and wiring for pole
lights.
Lighting poles for street lights and flood lights shall be of stepped tubular/swaged
type construction as per applicable standard & IOC’s drawings. The steel poles
shall be coated with bituminous preservative paint on the inside as well as
embedded outside surface. Exposed outside surface of steel poles shall be painted
with two coats of red lead oxide primer. After completion of installation two coats of
aluminium paint shall be applied.
The supply of poles shall be complete with fixing bracket/necessary pipe reducer for
fixing the fitting and also include the necessary associated pole mounted junction
boxes. The poles shall be complete with internal wiring between junction box to
fixing bracket.
Supply and Installation of Lighting Poles and Decorative Poles for Outdoor
Lighting (Street and Flood Lighting)
Supply and installation of street light poles and decorative poles including
associated junction boxes, links and terminals for junction boxes near each flood
light fixtures of following types.
1.0 Supply, erection, painting of light poles of L-pole & Y-pole type of different height
(5M, 7M, 9M) as per relevant standard.
2.0 Supplying of Single/Double arm Decorative poles:
• Supplying, fabricating flood light pole with single or double arms decorative as
per design, specification and drawing enclosed.
• Painting the pole with two coats of red oxide primer and two coats of synthetic
enamel paint of approved make and shade after scrapping the surface with wire
brushes, abrasive etc.
3.0 Fixing of Single/Double arm poles & Decorative poles
i) Fixing of supplied Single arm pole & Single arm decorative pole as per drawing.
ii) Fixing of supplied Double arm pole & Double arm decorative pole as per drawing.

Detail specifications of Galvanized Octagonal poles.
Design The Octagonal Poles shall be designed to withstand the maximum

wind speed as per IS 875. The top loading i.e. area and the weight of
fixtures are to be considered to calculate maximum deflection of the
pole and the same shall meet the requirement of BS: 5649 Part VI
1982.
Pole Shaft The pole shaft shall have octagonal cross section and shall be
continuously tapered with single longitudinal welding. There shall
not be any circumferential welding. The welding of pole shaft shall be
done by Submerged Arc Welding (SAW) process.
All octagonal pole shafts shall be provided with the rigid flange plate
of suitable thickness with provision for fixing 4 foundation bolts. This
base plate shall be fillet welded to the pole shaft at two locations i.e.
from inside and outside. The welding shall be done as per qualified
MMAW process approved by Third Party Inspection agency.
Door opening The octagonal Poles shall have door of approximate 500 mm length at
the elevation of 500 mm from the Base plate. The door shall be
vandal resistance and shall be weather proof to ensure safety of
inside connections. The door shall be flush with the exterior surface
and shall have suitable locking arrangement. There shall also be
suitable arrangement for the purpose of earthing.
The pole shall be adequately strengthened at the location of the door

to compensate for the loss in section.
Material Octagonal Poles HT Steel Conforming to grade S355JO.
Base Plate Fe 410 conforming to IS 226 / IS 2062
Foundation Bolts EN.8 grade

Welding The welding shall be carried out confirming to approved procedures

duly qualified by third party inspection agency. The welders shall also
be qualified for welding the octagonal shafts.
Pole sections The Octagonal Poles shall be in single section (upto 11 mtr). There
shall not be any circumferential weld joint.
Galvanization The poles shall be hot dip galvanised as per IS 2629 / IS 2633 /
IS 4759 standards with average coating thickness of 70 micron. The
galvanizing shall be done in single dipping.
Fixing Type The Octagonal Poles shall be bolted on a pre-cast foundation with a
set of four foundation bolts for greater rigidity.
Top Mountings The galvanized mounting bracket shall be supplied along with the
Octagonal Poles for installation of the luminaries.
Manufacturing The pole manufacturing & galvanizing unit shall be ISO 9001: 2000 &
ISO 14001 certified to ensure consistent quality & environmental
protection.

10. DIESEL GENERATOR SETS

This specification covers supply, installation, testing and commissioning of DG sets and
aquastic chamber for DG set.
1.0 Supply, erection, testing and commissioning of 10 to 50KVA Three phase Air
cooled silent type Generator (excluding the cost of cable, glands and earthing)
The diesel generator shall be complete with Base, Disel engine, Alternator, Fuel
Tank and Control panel and the Aquostic Enclosure. The DG shall be air-cooled type
with 6 Nos. of heavy duty Dunlop Make anti vibration mounting pads. The capacity of
engine in withstanding the full load current carrying of power requirement shall be as
per IS 10002, BS 5514, DIN 6271 and ISO 3046. Anti vibration mounting will be
supplied by Contractor. The DG set shall be installed 150mm above floor level on a
concrete (PCC 1:2:4) platform. The DG set shall be provided along with following :
a) Engine control panel consisting of / on / off / start / key, lube oil pressure gauge and
Ammeter for battery current.
b) Engine protection system for high cylinder head temperature and low lube oil
pressure, V-belt and over speed mechanical shutdown devices for blower belt failure.
c) One No. 12 Volt, 150 AH lead acid battery Exide / Amco make copper lead and
fixing copper socket.
d) Residential type exhaust silencer with thermal insulation shall be provided.
e) 200 ltrs. capacity diesel tanks square type with level indicator.
f) Alternator shall be provided with brush less type, AVR (Automatic Voltage Regulator)
control.
g) 4 pole MCCB with short circuit protection and earth leakage protection of relevant
capacity, ammeter of relevant rating with selector switch, voltmeter with selector
switch, indication lamps for DG ON, DG on LOAD shall be provided in the alternator
control panel.
h) Supply and laying of relevant capacity of UG cable of approved make for DG panel to
set and change over switch to DG panel (Cost of cable and gland will be paid
separate item of work)
i) Supplying and providing three nos. of earth pit as per IS:3043/1986. One for
Generator Neutral, one for Generator body earth and other for common (Neutral and
body earth) cost of earth pit shall be paid under separate item of work.

First filling of 200 litres diesel shall be provided for initial running, testing and
commissioning and approval getting from CEIG also included in the scope of work.
2. Supply, erection, testing and commissioning of 5 to 20 KVA Single phase Air

cooled Generator (excluding the cost of cable, glands and earthing)
A single-phase air-cooled diesel generator shall be provided with suitable nos. of

heavy duty Dunlop Make, anti vibration mounting. The capacity of engine in
withstanding the full load current for the required power shall be as per IS 10002, BS
5514, DIN 6271 and ISO 3046. Anti vibration mounting shall be supplied along with
DG set. The DG set shall be installed 150 mm above floor level on a concrete (PCC
1:2:4) platform.
The DG set shall have the following provisions.
a) Engine control panel consisting of on / off key, lube oil pressure gauge and
ammeter for battery current
b) Engine protection system for high cylinder head temperature and low lube oil
pressure, v-belt and over speed mechanical shutdown devices for blower belt
failure.
c) One no. 12V, 20 AH lead acid battery Exide/Amco Make, copper wire with
copper socket.
d) Residential type exhaust silencer with thermal insulation shall be provided.
e) 100 ltrs. Capacity diesel tanks - square type with level indicator.
f) Alternator shall be provided with brushless type AVR (Automatic Voltage
regulator) control.
g) A relevant capacity of 72 Sqmm ammeter for measuring current and group
control double pole MCCB with protections, set run indication lamp and volt
meter shall be provided with control panel.
h) Supply and laying relevant capacity UG cable (approved make) from DG set
to control panel and change over switch. (Cost of cable, gland shall be paid
under separate item of work)
i) Providing three nos. of earth pit as per IS: 3043/1986 one for Generator
Neutral, one for Generator body earth and other for common (Neutral and
body earth) (Cost of earth pit shall be paid under separate item of work).

The tank shall be filled with 100 litres of diesel for the initial running. Testing,
commissioning and obtaining approval from CEIG are also included in the scope of
work.
INSTRUCTIONS TO TENDERERS
1. The DG set shall be indoor type and shall be installed on foundation inside sub
station room. Bidders shall submit detail dimensional drawing of the DG set
and Control Panel along with offer.
2. The DG set and Control Panel shall be designed / manufactured / tested at

works and despatched in well packed condition as per technical specification
and latest standards and codes.
3. The successful bidder shall submit the list of drawings/documents for

approval.
4. Every component, material, hardware used in the equipment shall be as per

relevant codes/standards.
5. Any deviation from the specification shall be clearly spelt out.
6. Aquastic Enclosure
The entire DG set shall be mounted in aquastic enclosure to have a sound note
more than 75 db at a distance of 1 M from set as per latest environmental
requirement.
7. Tenderer shall quote the delivery of the DG Set at site and shall stick on the same.

The intent of this specification is to broadly define the scope & requirement for design, manufacture,
testing and commissioning of 10 to 50 KVA DG set alongwith control panel, required by IOCL.
Standards :
The design, manufacture, erection, testing, commissioning and performance of DG set shall comply
with this specification and all relevant specifications, code of practices of BIS/BSS wherever
applicable, as also to the following.
-Indian Electricity Rules & Act

- Fire insurance regulation
- Regulation laid down by Chief Electrical Inspector of the state
- Regulation laid down by Chief Inspector of explosive
- Regulation laid down by Factory inspector or of the state
SPECIFICATION
1.0 General Description : DG set comprises the diesel engine coupled to a self regulated brush
less AC generator by means of a coupling & mounted on a common base plate.
2.0 The DG set is to be used in conjunction with the control panel, battery & fuel tank. The
general requirement of above items shall be as follows :
3.0 Description of Diesel Engine :
The diesel engine shall be Air cooled type, totally enclosed, compression ignition, four
stroke suitable to give rated BHP at 1500 RPM, generally in accordance with ISO-3046/DIN-
6217/IS-10000/BS-5514,. The engine shall be capable of taking an overload of 10% for one hour
during any 12 continuous hours running. The following items are to be included :
a) Suitable turbo charger driven from exhaust gas.
b) 12 Volt electric starting system complete with starter gear ring, starter motor, battery charging
alternator with in built regulator.
c) Instrument panel provided with the followings :
i) Start & stop push button
ii) Lube oil pressure gauge
iii) Tacho- cum -hour meter.

d) Fly wheel without flywheel housing.
e) Coupling guard
f) Gear type Lube oil pump, Lube oil filter and lube oil cooler.
g) Fuel Oil Filter, MICO Fuel Injection System complete with injector pump, nozzles, & governor
h) Exhaust Manifold (uncooled)
i) Engine cooling fan with fan cowling
j) Standard Fuel Tank for 12 hours continuous running. The fuel tank shall be fitted with a vent
pipe, having provision for extension of the pipe and fuel level indicator.
k) AVM Pads
l) First fill lube Oil
m) Set of Standard Tools.
n) Standard oil resistant flexible hoses connection for fuel systems.
o) Exhaust flexible pipe with necessary flanges/connections.
p) Set of Batteries and connecting leads.
q) Any other material required to complete the set.
4.0 AC Generator :
a) AC Generator shall be brushless type, SPDP, with IP 23 degree of protection, of 10 to 50

KVA rating (as per requirement), 3 phase 50 Hz, 415 Volts, 4 wire, not less than 0.8 power
factor, self regulated, self excited, fitted with end shield, ball /roller bearings. Alternator shall
generally confirm to BS 2163/IS 4722, Class F insulation, with temperature rise limited to
class B, The excitation to be provided by an over hung exciter of rotating armature type
with rotating diode assembly in conjunction with a static automatic voltage regulator (AVR).
b) Technical particulars of AC Generator :
i) Power factor : 0.8 (lag)
ii) Governing specification : IS 4722
iii) Type of enclosure : IP 23 (Minimum)
iv) Insulation class : F with temperature rise limited to class B.
v) Speed in rpm : 1500

vi) Frequency : 50 cycles
vii) Rated Volts : 415 Volts
viii) No. of phases : Three
xi ) 50 % of over load capacity : 15 second.
xii) Minimum 10% of overload for 1 hour for every 12 hours of operation.
xiii) Direction of rotation : Anti clockwise when viewed from non driving end.
xiv) Method of lubrication : Grease
xv) Type of excitation units : Brush less
xvi) Terminal box : suitable for termination of 1 No. three and half core power PVC- A- PVC Al.
cable, as per DG rating
xvii) Earthing terminal : 2 Nos. external.
5. BASE FRAME :
The engine and alternator shall be coupled on a sturdy channel steel base through a flexible
coupling.
6. ACOUSTIC ENCLOSURE :
The engine and alternator set shall be housed within a five sided canopy, approved by authority
like ARAI. The sound level shall be maximum 75 db at 1 Meter from the enclosure under free
field condition as per applicable CPCB norms. The fuel tank and control panel shall be housed
outside the enclosure. The enclosure shall have made up of 16 guage sheet with other
requirements. The detail specification of acoustic enclosure is given separately.
7. SPECIFICATION OF CONTROL PANEL:
The control panel shall be of fabricated sheet metal construction, dust & vermin proof,
floor mounting type, suitable for indoor use having cable entry from the bottom. The
components & other details shall be as per the data sheet attached.
a) Construction
i) Mounting : Floor
ii) Enclosure : Sheet steel (CRCA) Minimum 14 gauge (2mm). The front & the rear
doors shall be hinged type.
b) Degree of protection IP 54

c) Painting : All sheet metal work shall be degreased, pickled, phosphated and then
applied with two coats of zinc chromate primer and two coats of epoxy paint. Both the
primer and the final paint shall be stoved. Both inside and outside final paint shall be epoxy.
Outside shade 630 as per IS 5 and inside white.
d) Components for Control Panel :
i) MCCB : L & T/Siemens/GE make, 4 Pole, 415 V with static releases for O/C, E/F and
under voltage.
ii) AC Voltmeter with selector switch : 0-500 V
iii) AC ammeter with selector switch : As per DG rating
iv) Frequency meter : Reed type.
v) KW meter
All the above instruments shall be flush mounting type of size 72x72 mm
vi) CT & PT for protection and metering : As required
vii) Indication lamp (LED) :
ACB ON : Red
ACB OFF : Green
ACB tripped : Amber
viii) Fuses, auxiliary contactor and other control switches: As required
ix) ANNUNCIATION: The following annunciation to be provided in the panel
e) Battery Charger in Control Panel :
i) An automatic constant voltage battery charger shall be incorporated for charging the battery
of cranking motor for keeping the battery under trickle charge when the engines are not
running.
ii) The inter lock between the charger and the engine starting switch shall be so provided that
when the engine is being started or running the battery charger shall be in off condition.
iii) The charger shall be mounted in the lower half / front of the DG panel. The charger shall
consist of following :
- Transformer rectifier unit

- DC Ammeter 15-0-15 A
- DC voltmeter 0- 30 V
- OFF/Trickle/Boost
- Auto manual switch
- Indicating lamps (LED)
- Charger- ON
- Boost- ON
- Trickle Charger ON
f) TERMINALS & ACCESSORIES :
i) CABLE SIZE : Incoming -1 Nos. 3.5 C Power cable, Al.conductor, PVC insulated cable
from Generator to Control panel.
ii) Outging - 1 Nos. 3.5 C Power cable, Al.conductor, PVC insulated cable
ii) For Battery charger : 3 x 2.5 sq. mm (cu) cable.
iii) Gland Plate : 3 mm thick MS gland plate undrilled shall be provided in the panel
8.0 GENERAL NOTES ON GENERATOR & CONTROL PANEL :
a) The terminal box of the Generator shall be liberal in size for cable connection. The gland to
terminal distance shall be 500 mm or more for ease of cable connections. The terminal stud
diameter shall suit the cable socket bolt dia. hole diameter for proper connection.
b) The cable entry shall be from the bottom of the terminal box so that the cables are
conveniently connected on the terminal studs or bus bar links.
c) Panel size shall be liberal and all equipment/components shall be mounted logically, to
have free access for maintenance, tightening of connections and visual inspection.
d) Bus Bars/ link shall be made of Aluminium/Copper of adequate cross section, to

accommodate fully and properly the cable lugs for the required cable sizes.
f) A minimum of 20 mm clearance shall be available between phase to phase and phase to

earth of all power terminals and bus bars/extension links.
g) All bus bars shall be with heat shrunk PVC sleeves.
h) All power terminals shall be properly shrouded for accidental contacts.
i) Terminals/ Neutral links and components are to be so located that after cable termination,
accessibility to the components and other parts is not impaired.
j). All doors rear/front shall be of hinged type with stopper for positive locking in open position.

k). Each component inside shall have a distinct label as per the wiring diagram.
l). GA drawings showing the overall dimensions with layout of the major components and bill of
materials with rating and make of components shall be submitted with the offer.
RECOMMENDED MAKE OF COMPONENTS FOR 1 X 50 KVA DG SET.
1. DIESEL ENGINE : CUMMINS / INTAC(TIL)/ GREAVES/Ashok Lylend.
2. AC GENERATOR : JYOTI / KEL /KEC/Stamford/Crompton Greaves
3. MCCB WITH STATIC RELEASES : L&T/ SIEMENS/GE
4. SWITCHES : L&T/ SIEMENS/GE
5. FUSES : AS ABOVE
6. METERS : AEP/IMP
7. KWH METER : GEC ALSTHOM/ EQUIVALENT
8. CT/PT : PRECISE/SIEMENS/AEP
9. LED : BINAY/ EMCO
10. CONTROL TERMINALS : ELEMEX/CONNECTWELL
ACOUSTIC ENCLOSURE
Acoustic enclosure for DG set shall be designed for sound reducing level 70 db ± 2
db at a distance of 3m and built aesthetically. The enclosure apart from reducing the
noise, also provides good ventilation, easy access for operation and maintaining
good lighting.
Acoustic enclosure shall be 16 SWG corrugated plain black sheet steel enclosure.
These sheets shall be treated chemically to ensure that they withstand harsh tropical
environment (as per the drawing no.: IOCL/ENGG/E/805 & 806).
Bonded rock wool (100mm thick, with a high density of 48 kg/m3) shall be used
inside the Acoustic enclosure. This rock wool shall be fire resistant type, which can
be accommodated with 20 SWG aluminium perforated sheet and this material shall
be covered by tissue cloth. Hamerstone silver gray paint shall be used for the inner
surface of the enclosure.
Acoustic enclosure shall be provided with a sliding / hinged door for easy access to
all components from outside. The roof sheet shall be provided with 20° slope for

sliding of water and any other solid particles. Necessary hinges and lock shall be
provided. Powder coating (Siemens grey) shall be done as per the standard
engineering practice on outer surface of the enclosure. Control panel shall be fixed
outside the enclosure, preferably in the DG room.
Ventilation duct:
The natural drought ventilation duct with sound absorption with flatten shall be
provided to arrest sound leakage and to provide air circulation in the cabin. One
number of axial flow and two numbers of radial flow fan (Almonard or equivalent
approved make) shall be fitted for proper aspiration of DG set. Scaling materials and
base frames with spacer (70 x 40mm MS channel) shall be provided at the bottom of
the cabin to avoid any vibration and noise etc.
Proper supporting arrangements shall be made for exhaust pipe line with residential
silencer and the same shall be insulated with asbestos rope.
Electric system:
One number of tube light with wiring shall be provided inside the enclosure.
5.0 AMF PANEL (Automatic Mains Failure Panel) :
The AMF Panel shall house normal DG Control Panel along with facility for auto change over
from main to DG during normal power failure. The AMF Panel shall perform the following
additional compared to the normal DG control Panel in the event of Mains failure.
When mains power fails, AMF Panel shall sense the absence of mains voltage and initiate
automatic start of the DG set and simultaneously the Load shall be disconnected from the
mains. As the power generated by the DG set reaches the pre-determined voltage &
frequency, the Load shall be connected to the DG set within a pre set time.
If the DG set fails to start in three successive attempts and attain the operating speed, it
shall get disconnected and locked out automatically with annunciation to this effect.
When normal power restores to the normal voltage for a pre set time the electrical load shall
be automatically thrown back to the normal supply. The DG set shall run at full speed at no

load for a pre set time and then switched Off automatically if the normal power supply
continues to be healthy.
Incase the automatic operation is not required, provision for Manual start shall be available
on the AMF panel.
5.1 CONSTRUCTIONAL REQUIREMENT :
5.1.1 System : The AMF panel shall suitable for 415 Volt, 3 phase, 4 wire, 50 Hz system.
5.1.2 Mounting : Floor / Wall as per site requirement.
5.1.3 Enclosure : Sheet steel (CRCA) Minimum 14 gauge (2mm)
5.1.4 Minimum Degree of protection : IP42.
5.1.5 Painting : All the sheet metal work shall be degreased, pickled, phospated and
then applied with two coats of zinc chromate primer and two coats of epoxy paints
Both the primer and the final paint shall be stoved. Both inside and outside final
paint shall be epoxy. Outside shade 630 as per IS 5 and inside white
5.1.6 Bus Bar : Electrolytic grade Aluminium Bus bars insulated with coloured heat
shrinkable PVC sleevs and supported on SMC/DMC moulded supports with anti
tracking barriers.
5.1.7 Wiring : Wire used for internal wiring shall be of PVC insulated copper wire as per
current rating. Minimum wire size shall be 1.5 sq mm for AC circuit and 2.5 sq mm for
DC circuit. All wire used for internal wiring shall be suitable for 1.1 KV volatge grade
and shall be neatly dressed and supported.
5.1.8 The AMF panel shall have MCCB, power contactor, auxiliary contactor etc. of
approved make as per requirement.
5.1.9 Metering : Following meters of approved make shall be provided in the AMF panel.
Meter size shall be 72mmx72mm.
Ammeter suitable to read full load current with selector switch

Voltmeter 0-500 Volt range with selector switch
Frequency meter

KW meter
KWh meter
5.1.10 Annunciation : The AMF panel shall be provided with following annunciation.
Low Lube Oil Pressure
High Water Pressure
Engine Over Speed
Over Current & Earth Fault
5.1.11 Controls :
Circuit Breaker ON indication

Circuit Breaker OFF indication
Push Button for Engine start
Push Button for Engine stop.
Push button for Fault accept/reset
Facility for Speed raise/low
Facility for Voltage raise/low
5.1.12 Battery Charger :The AMF panel shall have a battery charging unit with Trickle/Boost
charge facility for charging the battery during idle condition of DG set.
5.1.13 Protection : The AMF panel shall have the protection to shut off the DG set on
occurrence of any of the following faults :
High Water Temperature

Over Speed
Low lube oil pressure
Earth fault
Overload on any one of the phase


11. EARTHING AND LIGHTING PROTECTION

1.0 SCOPE
This specification covers the requirements of supply, installation, testing and
commissioning of earthing and lightning protection systems.
2.0 CODES AND STANDARDS
The earthing and lightning protection system installation work shall conform to the
latest applicable electricity rules, all currently applicable standards, codes of
practice, regulations and safety codes of the locality where the installation is to be
carried out.
3.0 SCOPE OF WORK
3.1 The entire earthing installation shall be in accordance with the drawings,
specifications, and provisions of relevant standards. The entire installation shall
fully comply with the Indian Electricity Rules and Acts in force. The scope of
includes the following :
3.1.1 Earth work in excavation upto a depth of minimum 3.75 Meters or upto level of
moist soil in all types of soil.
3.1.2 Supplying and laying of earth pipe/plate and earthing conductor from main
board/equipment to earth pit, conductor size 25x6 mm GI strip.
3.1.3 Supplying and laying 2.7 m. long 50mm. dia G.I. ‘B’ class pipe with top funneling
arrangement or 3.8 M long 80 mm dia GI heavy duty pipe as per requirement/order.
3.1.4 Supplying and spreading required capacity of charcoal and of common salt in the
earthing pit.
3.1.5 Back filling the pit with excavated or imported earth, duly consolidated with water in
200mm thick layers and disposal of surplus earth to an un objected place.
3.1.6 Supply of earth conductors in outdoor areas, buried in ground, shall include
excavation of earth upto 500 mm deep, laying of conductor, brazing/welding/jointing
if required, of main grid conductor, joints as well as riser of length 500 mm above
ground at required locations and then backfilling.
3.1.7 Interconnection of all the earth pits using 50x6 mm GI strip to make a earth grid to
reduce the earth resistance of the system.
3.1.8 Connecting the earthing conductor with lighting and power main-circuit equipment.
3.2 The CONTRACTOR shall carry out the earthing of all equipment/panels/structures
etc. as per relevant industry practices. All welding brazing equipment, necessary
tools and testing equipment shall be furnished by the CONTRACTOR. All incidental
hardware & consumables including associated works shall be in CONTRACTOR’s
scope.
4.0 Flexible copper cable with Crocodile clip:
Supplying & laying of single core 50 sq.mm multi stand flexible copper wire with
suitable size of crimping socket on one end and other shall be crocodile clip. This

shall be installed near tanker unloading area. One end of the flexible cable shall be
terminated in the nearest earth strip.
5.0 Lightning Protection:

Supplying and laying of 35 x 6 mm thick GI strip or 25 x 3 mm copper flat from
individual earth pit to lightning arrester as per IS: 2309 – 1963 for protection of
buildings and allied structure against lightning. Job includes supply and installation
of air terminal at the top of the structure through the porcelain insulator.
Supplying and laying of 25 x 3 mm thick copper flat from LA air terminal to earth pit
shall be paid under separate item of work.
Earthing system of lightning protection must be independent of an equipment
earthing system as per IE rules.
6.0 Earthing Connection
6.1 All connections in the main earth conductors in earth/concrete and connection
between main earthing conductor and earth leads shall be of welded/bolted type.
6.2 Connection between earth leads and earthing terminal provided on the equipment
shall be bolted type unless specified otherwise.
6.3 Welding operations and fluxes shall be as per the approved standards.
6.4 All joints shall be made such that contact resistance is negligible.
6.5 All bimetallic connections shall be treated with suitable compound to prevent
moisture ingression
6.6 Metallic conduits and pipes shall be connected to the earthing system unless
specified otherwise.
6.7 Lightning protection system down conductors shall not be connected to any
earthing conductors above ground level.
7.0 TESTING OF EARTHING SYSTEM
The CONTRACTOR shall ensure the continuity of all conductors and joints.
Following tests shall be done after completion of entire earthing job.
7.1 Earth pit resistance measurement by earth meggar of 10 Ohm range. Earth pit
resistance for earth pits shall not be more than 1.0 Ohm. Incase earth resistance is
more than 1.0 Ohm, increase number of earth pit.
7.2 Earth continuity tests for all equipment by meggar.
7.3 Certificate for earth test shall be submitted by the contactor as per IE rules &
regulation.
7.4 The CONTRACTOR shall bear the cost of all such tests.
8.0 CONTRACTOR’S LICENSE

It will be the responsibility of the CONTRACTOR to obtain necessary

License/Authorisation permit for work from the Licensing Board of the locality/state
where the installation is to be carried out.
9.0 WORKMANSHIP
The CONTRACTOR shall ensure workmanship of good quality and shall assign
qualified supervisors/ engineers and competent welders/labour who are skilled and
experienced in their trades.
10.0 RECOMMENDED RRACTIES FOR EARTHING

10.1 Earth Resistance of the System should not exceed 1.OHM
10.2 Minimum Spacing between two electrodes shall be twice the length of the electrode
10.3 Earth Grid shall be 1.5 metre away from building column and to be buried at a depth
of 600 mm.
10.4 Interconnection of G.I. strips in the earth grid should be done by welding instead of
bolting, and the welded portion should be painted with zinc-rich paint (Epilux: -4 or
black bitumen paint to avoid rusting.
10.5 The connection of the grid strips with the earth electrodes shall be made by grouting
C type clamp on the side walls of the earth pit so that it shall be possible to isolate
the earth electrode and measure it’s earth pit resistance.
10.6 Down conductors of lightning arrestors shall be connected to the separate earthing
pits and not to the earthing grid directly.
10.7 All the earthing pits shall be interconnected with the earth grid so as to obtain the
minimum earth resistance of 1 ohm.
10.8 Equipment earthing should always be crimped in suitable lugs if done with cable/ GI
Wire ropes. Usage of solid conductor to be avoided, as it gives rise to loose
connection with crimped socket.
10.9 The earthing for UPS system and Computers shall be routed through insulated PVC
pipe
11.0 Recommended earthing conductor sizes for various equipment:
11.1 Earth Electrode - 50 NB GI pipe, length 3.0m
11.2 Interconnection of earth electrodes - 50 x 6 mm GI Strip
11.3 Distribution boards / Panels (415V) - 25 x 6 mm GI strip/25x3 mm Cu. strip
11.4 Lighting fixtures-6 sq mm Al or 2.5 sq mm Cu PVC insulated
11.6 Non-electrical equipment (storage tank / vessels) - 25 x 6 GI strip/25x3 mm Cu. strip

11.7 Oil Tankers - Two earth station connected with 10m long flexible single core 50 sq
mm copper PVC insulated cable with crocodile clip / welding clamp.
11.8 Lightning Protection - 35 x 6 mm GI strips or 25x3 mm Cu. Strip

12.TRANSFORMER,H-POLE,EB METER
1.0 SCOPE
This standard covers the technical requirements of design, manufacture, testing and
delivery of 11KV/433 Volt transformer of relevant rating, 2-Pole Structure, HT Cable,
and metering unit, all cable termination with necessary earthing arrangement etc as
per drawing no. IOC/ENGG/E/801 to extend supply of power to RO & JRO. A
relevant capacity of capacitor bank shall be provided for power factor correction with
respect local electricity board any approval and inspection to be done from Electrical
inspectorate or local electricity board is also included in the scope of work. The job
also includes providing Fencing around 2- Pole structure as per specification.
2.0 Location of HT/LT. Transformer and structure metering Unit :
This shall be as directed by IOC, depending on site condition.
a) 11KV/433V ONAN distribution transformer of 100 KVA or 160 KVA as per

requirement
b) H Frame & 11KV outdoor sub-station
3.0 POWER TRANSFORMERS
3.1 General:
The transformer tank shall be made from high-grade plate steel, suitably reinforced
by means of stiffeners made of structural steel sections. All seams, flanges, lifting
lugs, braces, and other parts attached to the tank shall be welded. The interior of the
tank shall be cleaned by shot blasting and painted with two coats of heat resistant
and oil insoluble paint. Adequately sized manholes shall be provided for easy
inspection and maintenance. All joints, which may have to be opened from time to
time in the course of operation shall be of a design to permit them to be made easily
oil tight in re-assembly. Steel bolts and nuts exposed to atmosphere, shall be
galvanized. The tank cover shall be suitably sloped so that it does not retain
rainwater.

Lifting lugs and eyebolts shall be so located that a safe clearance is obtained
between sling and transformer bushings, without the use of a spreader. When
transformers are provided with separately mounted radiators, flexible joints shall be
provided on the main oil pipes connecting the transformer tank to the radiator banks
to reduce vibration and facilitate erection and dismantling. The interconnecting pipes
shall be provided with drain plug and air release vents.
The transformer tank, radiators, and conservator shall be designed taking into
account the loss of thickness due to shot blasting. The transformer core shall be
constructed from high grade, non-aging, cold-rolled, grain oriented, silicon steel
laminations coated with insulation varnish. The steel laminations shall be of "core"
type. Each lamination shall be coated with insulation which is unaffected by the
temperature attained by the transformer during service. Inter-lamination resistance
shall be of the order 1000 ohms/sq.cm. Core laminations shall be annealed and burrs
removed after cutting. Cut edges shall be insulated.
Limbs and yokes shall be of stepped construction with interleaved mitred joints.
Maximum flux density in the core with the core excited to 110% rated voltage shall
not exceed 1.8 wb/sq. metre. The framework and clamping arrangements of core and
coil shall be securely earthed inside the tank by copper strap connection to the tank.
Windings shall be of suitably insulated copper wire or copper strip. Windings and
insulation shall be so arranged that free circulation of oil is possible between coils,
between windings, and between winding and core. The windings shall be fully
shrunk under vacuum before assembly. High voltage end windings shall be suitably
braced to withstand short circuit stresses and stresses set up by surges. All taps
shall be provided on the HV winding. The core and coil assembly shall be dried out
and impregnated under vacuum.
For transformers, viewed from the HV side of the transformer, with the HV bushings
in from of the viewer, the HV bushing sequence from left to right shall be R, Y & B
and the LV bushing sequence from left to right shall be R, Y & B. Wherever neutrals
are brought out, they shall be located to the left of the R phase bushing, when viewed

from the HV side. Transformer shall be designed for 110% continuous over fluxing
withstand capability.
3.2 Bushing:
Solid porcelain bushings with brown glaze shall be used upto 22 / 11 KV class
service. Solid bushings shall have characteristics specified in the latest edition of IS:
2099. Bushings rated 400 A above shall have non-ferrous flanges and hardware.
3.3 Cable termination:
Cable boxes shall have sufficient space for segregating the cable cores and to give
adequate clearance in air between bare conductors at the terminals. Cable boxes
shall be complete with necessary cable lugs and armor grips. All auxiliary wiring from
current transformers, buchholz relays, winding temperature indicators, etc., shall be
marshaled to a separate weatherproof and vermin proof marshalling box with an
independent access cover.
3.4 Standards Applicable:

All standards and code of practices referred to shall be the latest editions including all
official amendments and revisions.
Power transformer : IS 2026/IEC 76/BS 171
Transformer oil : IS 335 / IEC 296 BS 148
Bushing : IS 2099 / IEC 137 / BS 223
3.5 Technical particulars:

Rated output & quantity required:
Output - Qty
100 or 160 KVA - 1 No.
Transformer location - Outdoor
Degree of protection(As per IS:2147)- IP 55
No load transformation ratio - 11,000/433V
Number of phases - Three
Rated Frequency - 50 Hz
Impedance at principal tap
Upto and including 100 KVA - 4%
Above 100 KVA - 5%
Number of windings / Material of conductor - Two / Copper

Method of connection:
HV winding - Delta
LV winding - Star
Vector group - Dyn 11
LV Neutral - Solidly earthed
Insulation withstand:
Impulse - HV:75 KV (peak)
Power frequency - HV : 28 KV (rms)
- LV : 3 KV (rms)
Bushings
Voltage class
HV Line end - 12 KV
LV Line end & neutral - 1.1 KV
Impulse - HV:75 KV (peak)
Power frequency withstand
HV - 28 KV (rms)
LV - 3 KV (rms)
Minimum clearance in air
HV : phase to phase - 127mm
LV : phase to phase - 25.4mm
HV : phase to earth - 77mm
LV : phase to earth - 19mm
Minimum Creepage distance
HV - 276mm
LV - 25mm
3.6 Terminal connection:
LV Phase - Cable box suitable for 1.1 KV grade Aluminium conductor

PVC insulated flat steel armoured (AYFY) cable.
LV Neutral - One terminal inside cable box termination and another

outside through 1.1 KV class bushing for connection to station earthing
system. HV and LV cable box shall be covered with canopy.

Vacuum withstand capability of transformer main tank with bushings, radiators,

fittings, and accessories: 250mm of mercury.
Cooling - Oil naturally cooled i.e. ONAN.
Oil temperature rise by thermometer - 500c
Winding temperature rise measured by resistance method - 500c
Parallel operation - Suitable for momentary parallel
operation.
Tap changer - Full capacity off-circuit type on HV sidewith pad
locking facility
Tap range - +2.5% to - 10%
Tap step - 2.5%
Make - Approved
3.7 Test certificates:

a) Type / routine test certificates for all transformers shall be furnished.
b) Test certificates of all bought out items shall be submitted at the time of inspection.
3.8 Tolerance on performance guarantee:

The Permissible tolerances on the performance guarantees are as follows:
a) Voltage ratio at no load : + / - 5% of the declared ratio, or a
percentage equal to 10% of the
actual percentage impedance voltage
at rated load, whichever is smaller.
b) Impedance Voltage : + / - 5% on principal tap for 250 KVA
& below transformers
c) No load loss : + 10 %
d) Load loss : + 5%
e) Efficiency and regulation : In accordance with the tolerance on
impedance voltage and losses as
applicable
General arrangement drawings, showing the plan, front elevation and side elevation
complete with all accessories and fittings, detailed dimensions, net and shipping
weights, quantity of insulating oil, crane lift for untaking, size of lifting lugs and eyes,
clearances between HV terminals, between LV terminals, between HV and LV
terminals, between HV and LV terminals and ground etc. rating and terminal marking
plates, complete with polarity and vector group arrangements, control wiring diagram
for marshalling Kiosk.

4.0 H - Frame and 11 KV outdoor sub-station:
The work consists of providing 2 pole H - frame structure shall be ISMB 200 x 100
mm vertical rolled steel joist or equivalent size of RCC pole shall be 145 kg WL using
50 Tor steel 12mm dia, 4 Nos. with 8mm dia stirrups at 150mm c/c. The size of pole
is 300 x 125mm. Foundation size 450 x 450 x 1800mm PCC 1:3:6 mix (drawing
enclsoed). Cross channel shall be ISMC 100 x 50 mm, erection of this structure,
outdoor transformer, lightning arresters, isolators with drop out fuse, insulators and
hardware, ACSR conductors, outdoor termination etc. as per CEIG requirements and
chain link fencing, gates, filling up sub-station area with rubble of 80mm size to depth
of 100mm. The total structure shall be painted with two coats of synthatic Aluminium
paint over one coat of zinc phasphate primer.
4.1 APPLICABLE CODES:
The design, material, construction, manufacture, inspection and testing of all 11KV
outdoor sub-station equipment shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment will be installed.
The equipment shall conform to the latest applicable standards as given below. All
standards and code of practices referred to shall be the latest edition including all
official amendments and revisions.
a) Isolator : IS 9921, BS 3018, IEC 129
b) Air break switch : IS 2544
b) Lightning Arrester : IS 3070 (Part I), BS 2914, IEC 29
c) Current transformer : IS 2705, BS 3938, IEC 165
d) Voltage transformer : IS 3156, BS 3941, IEC 186
e) Bushings : IS 2099, BS 223, IEC 127
f) Insulator : IS 2544, BS 3297, IEC 168
g) Suspension Insulator : IS 731, BS 3297
h) Insulator fittings : IS 2486, BS 137
i) Fitting for aluminium and : IS 2121, BS 3288

steel cored aluminium
conductors

j) Electrical power connector : IS 5561, BS 159, IEC 305/383
k) ACSR conductor : IS 398
l) Hot dip galvanizing : IS 2629, 2633, BS 729
m) Wooden Ladder : IS 4435 – 1967
n) Rubber Gloves for electrical : IS 4770 – 1968

purposes
4.2 INSULATORS
General requirements:
i. Rated voltage - 11 kv
ii. Creepage distance total - 320mm
Porcelain used for the manufacture of insulators shall be homogeneous, free from
flaws or imperfections that might affect the mechanical or dielectric quality. They
shall be thoroughly vitrified, tough and impervious to moisture. The glazing of the
porcelain shall be of uniform brown colour, free from blisters, burns and other similar
defects. The porcelain shall be sound, free from defects, thoroughly vitrified and
smoothly glazed. Insulators shall have compression type glaze with a good luster
and of uniform brown colour. The glaze shall be unaffected by sudden changes in
temperature and by atmospheric pollution of ozone, acids, alkali, dust etc
4.3 ISOLATOR GENERAL REQUIREMENT :

a) Voltage : 12 KV
b) Frequency : 50 Hz
c) No. of phases : 3
d) Rated current : 200 A
e) Short circuit withstand rating at : 20 KA for 1 sec.

rated voltage for one second
f) Ambient temperature 45 Deg C
g) Impulse withstand voltage :
1. Across the isolating distance : 85 kv peak
2. Between poles and earth : 75 kv peak
i) One minute power frequency :

withstand voltage kv (rms)

1. Across, the isolating distance : 32 kv rms
2. Between poles and earth : 28 kv rms
j) Phase spacing (minimum) : 230mm
k) Type of Mounting
l) Height of mounting above ground :

level
m) Operating devices for isolator and : Manually operated

earthing switch
5.0 Fencing:
Fencing shall be rovided around H Pole structure with a gate with locking
arrangement. Fencing height shall not be less than 2.5m with 2 play GI barbed wire.
Spacing between RCC pole supporter shall be 2.5m and ground depth 600mm.
6.0 HT Power Cable :
A relevant capacity of 11 KV 3 core XLPE insulated confirmed to IS : 7098 (Part II)

shall be connected from departmental structure AB switch to HT metering unit(if
installed) and then to HT terminals of transformer.
Job also involves supply of suitable HT 11 KV XLPE cable termination kit assembly
for cable termination arrangements. Termination of cables shall be accordance with
relevant IS code and practice with manufacture special instructions. Material and
tools required for cable jointing work including cold setting bituminous compound
shall be supplied by the contractor. Cables carrying pipe (4”) shall be firmly clamped
using 40 x 60mm GI clamps on either side of the straight through joint. Before
termination of cable, insulation resistance value should be measured by megger.
Necessary cable route indicator shall be
provided with cable route marker along the cable routes. Cable shall be laid 1.0m
below the ground level.
7. EB METER BOARD:
Supply, Erection, testing and commissioning of wall mounting type dust and vermin
proof enclosed EB meter board as per drawing no. IOC/ENGG/E/304. 4mm thick clear

plain glass150sq.mm shall be fixed infront of EB meter, to see meter reading without
opening the door. 10mm thick hylum sheet (Required size) shall be used for fixing of
EB meter. 100A rewireable porcelin fuse carrier-3nos. shall be fixed with another
compartment. Additional space shall be provided for fixing of 125A TPN FSU(open
execution) for EB main controlling switch gear (cost of 125 A FSU shall be paid under
separate item of work.). Necessary loop wiring 3Cx25 sq mm copper shall be inter
connected between EB metre, fuse carrier and main switch.
8. FUSE CARRIER
Supplying and fixing of relevant capacity of fuse carrier kitkat rewirable type fixing in
required size of teakwood board on EB post as per local EB authority.
9 OVER HEAD LINE (EB INCOMING):

Supply, laying, testing and commissioning 4 runs of single core 6 sq mm Cu.
Insulated flexible wire for 3 phase & neutral power supply from over head line from
EB post to EB meter, stringing with 7/20 GI stay wire cum earthing conductor run
through 4 way reel insulator 600 to 750mm on regular interval.
A 50mm dia GI pipe (B class) with necessary Bend as per EB authority shall be fixing
on near to the EB meter board and erected necessary GI clamp with Grouting Bolt
and nut.

13. MISCELLANEOUS ITEMS

Scope of works involves supply and installation of following items.
1.0 Capacitor :
Scope shall be supply and installation of Capacitor bank of MPP type/All PP type of
approved make along with the cable termination. The capacitor bank may comprise
of suitable number of single phase units in series parallel combination. Capacitor
shall have inductive coil to take care of inrush current. The performance
characteristic of the capacitor banks shall be as per relevant IS. Capacitor bank shall
be connected by 3 core cable of relevant size from MV panel/DB.(Cost of cable, and
termination shall be paid separately)
2.0. Water Pump with Starter :
Supplying and fixing Water pump of approved make with starter of L&T or approved
including Supply and providing G.I. Sheet cover with locking arrangement. The
pump has to be installed as per manufacturer's specification.
3.0 Supplying and Installation of 0.5 to 2 HP Single phase Mono block Water
pump:
Supplying and Installation of 0.5 to 2 HP single phase mono block pump conforming
to IS 9079/1989 (maximum suction head 7.5 metre) with bronze impeller conforming
to IS318 to deliver water from open well with necessary foundation.
Supplying and fixing of relevant size foot valve with strainer and gate valve (as per
manufacturer’s recommendation), DOL starter of approved make for motor are also
included in the scope of work.
The cost of suction & delivery pipe, UG cable and gland shall be paid under separate
item of work.
4.0. Supplying and erection of submersible pump:
a) A submersible pump shall be provided with suitable total head and discharge to
meet the required capacity. The pump component shall be corrosion and
abrasion resistant, high grade engineering polymer/stainless steel with special
alloy as per IS:8034-1976. The submersible pump motor of approved make shall
be to suit wide voltage fluctuation and special PVC insulated copper winding.

b) A control panel of approved make shall be provided with single phasing preventor
and dry run preventor.
c) 3 Core relevant capacity of approved make submersible cable shall be used for
connecting pump and the control panel. Cost of cable shall be paid under
separate item of work.
d) A relevant capacity of TPN main switch shall be used for controlling incoming
power supply of submersible pumps.
e) DOL starter of approved make provided for pump is also included in the scope of
work.
10.0 3-Phase energy meter (KWH) - ordinary type:

Supply and fixing of 3 ph 4 wire (30 to 40 A) A/c energy meter
SIMPCO/BHEL/IMP/ALSTOM or equivalent make for calculating electricity utilized
from DG set supply on the existing MCB panel board with required size (10mm thick)
hylam sheet. Necessary inter connection (7/16 VIR copper conductor) between
energy meter and change over switch shall be paid under separate item of work.
11.0 Three Phase Energy Meter – Electronic type :

Supply and fixing of 3 ph 4 wire (30 to 40 A) A/c energy meter
SIMPCO/BHEL/IMP/ALSTOM or equivalent make for calculating electricity utilized
from DG set supply on the existing MCB panel board with required size (10mm thick)
hylam sheet. Necessary inter connection (7/16 VIR copper conductor) between
energy meter and change over switch shall be paid under separate item of work.
12.0 Constant Voltage Transformer (CVT):
Supplying and fixing of Constant Voltage Transformer of required capacity shall be

provided for MPD / DUO counter unit. The CVT shall deliver a constant output
voltage for an incoming voltage ranging between 170 to 290V.
13. Single Phase Servo Stabilizer:
Supply and fixing of 230V, Single phase, AC Servo voltage stabilizer of approved
makes for Individual dispensing pump shall be as per IE Regulation. The Servo
voltage stabilizer shall be high voltage and low voltage cut-off system, automatic
restart with time delay shall be 1 minute or less and fail safe circuit etc. (The supply

shall be bye passed in case of component failure inside the stabilizer). The servo
voltage stabilizer shall work for 140 to 260V with minimum no load power loss.
The above servo stabilizer shall indicate the following operations and caution
non-latching LED indication.
Input Present, Output normal, Input high, Input Low, Latching LED indication for cut
off system, output high, Output low, Output overloaded.
Manual and auto restart facility shall be provided with stabilizer.
14. Three Phase Servo Stabilizer:
Supplying and fixing of 3-phase air cooled auto load changer servo stabilizer for
balanced and unbalanced load shall be independent correction of each phase and as
per specification. The stabilizer have digital meter for voltage indication. The
Stabilizer shall have under voltage, over voltage protection with auto reset. In over
load protection the stabilizer shall have facility for manual reset. Degree of protection
shall be IP-55.
18. SUPPLYING & FIXING OF FOLLOWING ITEMS FOR ELECTRICAL SAFETY IN
SWITCH ROOM/GENERATOR ROOM ETC:
i) Supplying, laying in position on cable trenches, 6mm thick MS chequered plate

of IS approved Make in required size including cutting, grinding, smoothening of
edges etc.
ii) Providing 11KV tested rubber mat of superior quality at site conforming to
Indian Electricity Rules, for MCC rooms & Generator rooms.
i) Providing 11KV tested rubber hand gloves of superior quality at site confirming
to Indian electricity rules, for MCC rooms & Generator room.
ii) Supplying and affixed resuscitation chart both English and local language with
40mm thick wooden frame and 3mm thick along with plain glass covering.

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Specifications

SR.NO. DESCRIPTION PAGE NO.

1. TANK INSTALLATION FOR UNDERGROUND TANKS 2

4. BAILING OUT WATER 2

10. INSTALLATION OF SUPPLIED 10 KL TANK 4

11. INSTALLATION OF SUPPLIED 15 KL TANK 8

12. INSTALLATION OF SUPPLIED 20 KL TANK 13

13. INSTALLATION OF SUPPLIED 50/70 KL TANK 18

14. INSTALLATION OF CORPORATION SUPPLIED DISPENSING PUMP 23

15. INSTALLATION OF UNDERGROUND TANK IN EXISTING PIT/

16. LOADING / UNLOADING CHARGERS FOR 15/20/50/70 KL TANKS 23

17. INSTALLATION OF 5 KL TANK 23

CAPEX / SPECS / MECH / 07- 08 / REV 1

1.1 TANK INSTALLATION FOR UNDERGROUND TANKS

1.3 Soil Classification

1.4 Bailing out Water

1.6 Tank Foundations

CAPEX / SPECS / MECH / 07- 08 / REV 1

1.7 Doping of Tanks

1.8 Lowering of Tanks

1.9 Back Filling

CAPEX / SPECS / MECH / 07- 08 / REV 1

1.10 INSTALLATION OF SUPPLIED 10 KL TANK AS PER SPECIFIED DRAWINGS

1.10.1 In earth pit with RCC strip raft as per Drg.:

(1) Installation of New/Old tank with or without manhole.

(2) Detaching all inside/outside fittings from tank.

(7) Dressing / levelling & consolidation of the tank pit area.

CAPEX / SPECS / MECH / 07- 08 / REV 1

directed by the Engineer-in-charge, prior to testing of the tank. The contractor

CAPEX / SPECS / MECH / 07- 08 / REV 1

1.10.2 In Earth Pit with RCC matt raft as per Drg. :

(1) Item No. 1.10.1 (1) to (21), (23) & (24).

CAPEX / SPECS / MECH / 07- 08 / REV 1

(2) Item No. 1.10.2 (2) to (5) of the above.

(3) Item No. 1.10.3 (2) to (8) of the above.

1.10.5 Handling, installing of 10 KL tank above ground on existing brick masonry

(1) Item No. 1.10.1 (1) to (4) of the above.

CAPEX / SPECS / MECH / 07- 08 / REV 1

supervision of the Engineer-in-charge, prior to taking up the cleaning/repairs to

(10) Fixing, Corporation supplied, inside fill pipes including fixing/tightening of

1.11 INSTALLATION OF SUPPLIED 15 KL TANK AS PER SPECIFIED DRAWINGS AND

(2) Detaching all inside/outside fittings from tank.

CAPEX / SPECS / MECH / 07- 08 / REV 1

(7) Dressing / levelling & consolidation of the tank pit area.

CAPEX / SPECS / MECH / 07- 08 / REV 1

1.11.2 In Earth Pit with RCC matt raft as per Drg. :

CAPEX / SPECS / MECH / 07- 08 / REV 1

(1) Item No. 1.10.1 (1) to (21), (23) & (24).

CAPEX / SPECS / MECH / 07- 08 / REV 1

(2) Item No. 1.10.2 (2) to (5) of the above.

(3) Item No. 1.10.3 (2) to (8) of the above.

1.11.5 Handling, installing of 15 KL tank above ground on existing brick masonry

(12) Item No. 1.10.1 (1) to (4) of the above.

CAPEX / SPECS / MECH / 07- 08 / REV 1

(21) Fixing, Corporation supplied, inside fill pipes including fixing/tightening of

1.12.1 In earth pit with RCC strip raft as per Drg.:

(1) Installation of New/Old tank with or without manhole.

(2) Detaching all inside/outside fittings from tank.

(7) Dressing / levelling & consolidation of the tank pit area.

CAPEX / SPECS / MECH / 07- 08 / REV 1

CAPEX / SPECS / MECH / 07- 08 / REV 1

(23) In case of any hard rock (required chiseling/blasting), measurement shall be