Chemical

TENDER NO VOLUME
PSER:SCT:SDG-M1349:12. II SCOPE OF WORK, TECHNICAL SPECIFICATION, DRAWING ETC
JOB
DESIGN, ENGINEERING, MANUFACTURING/ SUPPLY, ERECTION, COMMISSIONING, HANDING OVER, ETC OF CW TREATMENT PLANT PACKAGE CAPACITY 2x500 MW UNITS PROJECT SAGARDIGHI STPP, WB.
BHARAT HEAVY ELECTRICALS LIMITED (A Govt Of India Undertaking) POWER SECTOR EASTERN REGION PLOT DJ 9/1, SECTOR II, SALT LAKE KOLKATA 700 091
WEST BENGAL POWER DEVELOPMENT COMPANY LIMITED, KOLKATA
2X500 MW, SAGARDIGHI TPP EXTN PROJECT, STAGE II, UNITS 3 & 4
TECHNICAL SPECIFICATION FOR
CW TREATMENT PLANT
SPECIFICATION NO: PE-TS-373-156-A001 VOLUME -IIB
BHARAT HEAVY ELECTRICALS LTD. POWER SECTOR PROJECT ENGINEERING MANAGEMENT NEW DELHI
TITLE: TECHNICAL SPECIFICATION FOR CW TREATMENT PLANT 2X500 MW, SAGARDIGHI TPP EXTN PROJECT, STAGE II, UNITS 3 & 4
SPEC. NO. PE-TS-373-156-A001
VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF
SECTION A B C C1 C2 C3 D1 D2 D3 D4 E F F1 F2 F3
SPECIFICATION NUMBER PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 ANNEXURE1 ANNEXURE2 ANNEXURE3 ANNEXURE4 ANNEXURE5 ANNEXURE6 ANNEXURE7 ANNEXURE8 ANNEXURE9 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PETS373156A001 PEDG373156A001 PEDG373156A002 PEDG373156A002
CONTENTS VOLUMEII(TECHNICALSPECIFICATION) REV. TITLE NO. 00 Scopeofenquiry 00 Projectinformation Specifictechnicalrequirements 00 Equipment/Systemstobesuppliedalongwithdesign engineeringrequirements 00 SpecifictechnicalrequirementforCWtreatmentplant 00 Annexures 00 ElectricalscopebetweenBHELandvendor 00 Documentdistributionschedule 00 Scheduleofdeviations 00 Formatforelectricalloaddata 00 PaintingRequirements 00 Listofsubvendors 00 PGtestprocedure 00 Informationtobefurnishedbythebidderalongwithbid 00 Informationtobefurnishedbythevendorafterawardof contract Designrequirements 00 Mechanical 00 Technicalspecificationforhorizontalcentrifugalpumps 00 Technicalspecificationforlowpressurepiping,valves& specialties 00 Technicalspecificationformetering pumps 00 Electrical 00 TechnicalspecificationforACandDCmotors 00 Controlandinstrumentation 00 SpecificC&Irequirements 00 PLCsystemconfigurationdiagram 00 SpecificationforC&IforAuxpackages 00 TechnicalspecificationsInstruments&system 00 DCSinterfaceforunidirectionaldrive,bidirectionaldriveand
solenoidvalve
PAGE NO 1 3 7 8 13 20 21 23 24 25 26 28 32 38 39
40 41 49 62 65 66 79 81 82 83 84 115 118 122 135 148 149 150 151
00 00 00 00 00 00
Typicalinstrumentinstallationdiagram QualityPlans Datasheet A&C Listofdrawings P&IDforCWtreatmentplant TentativeEquipmentlayoutforCWtreatmentplant MechanicalGAofCW/ACWandF/Wpumphouse
PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA
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SPEC. NO. PE-TS-373-156-A001
SECTION A SCOPE OF ENQUIRY
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SPEC. NO. PE-TS-373-156-A001
1.0
SCOPE OF ENQUIRY a) This specification is intended to cover design, engineering, manufacture, assembly, testing at manufacturer's works, forwarding, transportation, delivery to the site, unloading, handling, storage, in plant transportation at site, erection, commissioning, trial run, performance guarantee test and handing over in a flawless operating condition to Purchaser the entire CW treatment Plants complete with all accessories including startup, commissioning spares, chemicals (corrosion inhibitor, scale inhibitor and biocide required for six (6) months of operation of CW treatment plant at full load) for CW treatment Plant as per the technical specification number PETS373156A001 of 2X500 MW Sagardighi Thermal Power Plant, Stage II, Units 3 & 4. b) Items though not specifically mentioned but needed to make the system complete as stipulated under these specifications are also to be furnished unless otherwise specifically indicated as excluded. c) It is not the intent to specify all the details of the design & manufacture. However, the equipment shall be of proven design and conform in all respect to high standard of design, engineering & workmanship and shall be capable of performing the required duties in a manner acceptable to Purchaser / Enduser, who will interpret the meaning of drawing & the specification & shall be entitled to reject any work or material, which is not in full accordance herewith. d) In case of any deviation, the Bidder shall indicate the same clause by clause in the deviation schedule. In the absence of the same it will be construed that the bid conforms strictly to the specification. e) General terms & conditions, instructions to the tenderer & other attachments referred to elsewhere are made part of this specification. f) In case of any data/requirement stipulated in the drawings but not in the specification and vise versa, such data /requirement shall be deemed to be contained in the both. Contradictions between drawings and specifications, if any, shall be brought to the attention of the purchaser by the bidder and the correct requirement shall be obtained. In the event of any conflict between the various sections of the specification, bidder shall obtain necessary confirmation in writing from the purchaser. In case bidder fails to do so before ordering of contract, BHEL interpretation of the technical specification shall prevail.
g) For the purpose of this specification, the terms like Owner, Customer and/ or Enduser shall refer to WBPDCL or his appointed consultant DCPL.
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SPEC. NO. PE-TS-373-156-A001
SECTION B PROJECT INFORMATION
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DCPL-K8A07
VOLUME : IIA SECTION-III PROJECT SYNOPSIS AND GENERAL INFORMATION
1.00.00
INTRODUCTION The proposed 2 x 500 MW Sub-critical Extension (Unit 3 & 4) Sagardighi Super Thermal Power Project would be set up by West Bengal power Development Corporation Limited (WBPDCL) at a site, which falls under the villages Manigram in Murshidabad district of West Bengal, India. The Bidder shall acquaint himself by a visit to the site, if felt necessary, with the conditions prevailing at site before submission of the bid. The information given here in under is for general guidance and shall not be contractually binding on the Owner. All relevant site data/information as may be necessary shall have to be obtained / collected by the Bidder.
2.00.00
APPROACH TO SITE Sagardighi Super Thermal Power Station site is located at Manigram village, 13 KM north of Sagardighi town by the side of the SMGR (SagardighiManigram-Gankar-Raghunathganj) Road at a distance 20 KM from National Highway 34 in Murshidabad District, West Bengal and around 240 KM from Kolkata, India. The nearest rail station is Manigram adjacent to the site on Bandel - Barhawara branch line and 6.5 KM from Sagardighi Railway Station on Sainthia - Azimgunj line of Eastern Railway. From Sagardighi railway station a railway line will branch off to the site for material unloading and coal marshalling. The equipment will be normally transported by rail only and under exceptional cases by road. The material consignments shall be as per the restrictions of rail and road transportation prevailing in the country. Nearest Airport Kolkata. Nearest Seaport Kolkata/ Haldia
3.00.00
LAND The total land, approximately 706 hectares, has already been acquired for the present, proposed extension and future combined cycle units. The locations of various facilities and plant auxiliaries for Unit 1 & 2 under Phase-I and Units 3 & 4 for extension project with space provision for future combined cycle units will be as per the General Layout enclosed. About 456 acre of land has been kept for disposal of ash. The Bidder shall accommodate equipment offered under this specification generally within the spaces allocated for such equipment in the General Layout. Specific approval from Owner/Consultant shall be taken by the contractor prior to any revision or relocation.
(PCA.CD-003.M790LEA1)
V.IIA/S-III : 1
DCPL-K8A07
Except where stated otherwise, the plinth levels of all buildings shall be 300 mm above the corresponding developed grade level and the road level shall be 150 mm above the developed grade.
4.00.00
SOURCE OF COAL The Power Station has been linked to Jhanjra, Chitra and Sarpi mines of Eastern Coal fields (ECL) and Panchwara & Damagoria for extension units. Coal will be transported on broad-gauge line of Eastern Railways from the coal fields to the Power station in BOBRN rake loads. Fuel oil (HFO/LDO) will normally be transported by railway oil tankers from nearest oil depot.
5.00.00
SOURCE OF WATER The water requirement for the Power station will be met by drawing water from river Bhagirathi at a distance of 6 KM east of project site. The Power station will operate on closed cooling system using Natural Draft Cooling Towers. In addition, all water conservation and recycling measures will be adopted to minimize requirement of make up water. The Bidder shall include in his proposal all such conservation measures adopted.
6.00.00
ASH DISPOSAL AREA The ash disposal area for the station is located about 1 Km from the plant site. The Site Location Plan will give an idea of the locations of the site, colony, ash disposal area and rail and road connections.
7.00.00 7.01.00
SALIENT CLIMATOLOGICAL AND DESIGN DATA Unless otherwise specified, the following design conditions shall be considered for the equipment offered: a) Design ambient dry bulb temperature Maximum relative humidity Average relative humidity Highest wet bulb temp. : 50 C maximum, 5 C minimum
b) c) d)
: : :
84% 73% 26.9 C
V.IIA/S-III : 2
DCPL-K8A07
e) f)
Average annual rainfall Seismic zone
: :
1389 MM Zone-III as per IS-1893 latest revision In accordance with IS-875 for a basic wind speed of 47 m/sec upto a height of 10 metres above mean ground level. For further details refer Volume II-G of this specification. 34M above MSL.
g)
Wind load
h)
Altitude
V.IIA/S-III : 3
SPEC. NO. PE-TS-373-156-A001
SECTION C SPECIFIC TECHNICAL REQUIREMENT
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SPEC. NO. PE-TS-373-156-A001
SECTION C1 EQUIPMENT / SYSTEMS TO BE SUPPLIED ALONG WITH DESIGN ENGINEERING REQUIREMENTS
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SPEC. NO. PE-TS-373-156-A001
GENERAL: This specification is intended to cover design, engineering, manufacture, assembly, testing at manufacturer's works, forwarding, transportation, delivery to the site, unloading, handling, storage, in plant transportation at site, erection, commissioning, trial run, performance guarantee test and handing over in a flawless operating condition to Purchaser the entire CW treatment Plantscompletewith all accessoriesincludingstartup,commissioningspares,chemicals(corrosion inhibitor,scaleinhibitorandbiociderequiredforsix(6)monthsofoperationofCWtreatmentplant atfull load)forCWtreatmentPlantasperthetechnicalspecificationnumberPETS373156A001 of2X500MWSagardighiThermalPowerPlant,StageII,Units3&4. A) MajorMechanicalscope: 1. One (1) number skid of Corrosion inhibitor dosing system complete with piping, valves and instruments as indicated in the P&ID for CW treatment plant BHEL Drg. No. PEDG373156A001 includingpipinguptoCWforbayunit3&4. 2. One (1) number skid of scale inhibitor dosing system complete with piping, valves and instruments as indicated in the P&ID for CW treatment plant BHEL Drg. No. PEDG373156A001 including pipinguptoCWforbayunit3&4. 3. One (1) number skid of biocide dosing system complete with piping, valves and instruments as indicatedintheP&IDforCWtreatmentplantBHELDrg.No.PEDG373156A001includingpiping uptoCWforbayunit3&4. 4. One (1) set of sulphuric acid storage and dosing system complete with piping, valves and instruments as indicated in the P&ID for CW treatment plant BHEL Drg. No. PEDG373156A001 includingpipinguptoCWforbayunit3&4. 5. Onenumberofeyewashcumsafetyshower. 6. Suitable number of diffusers (minimum three diffusers for each of the four dosing systems, i.e. minimum12nos.ofdiffusers)forpropermixingofchemicalsinCWforbay. 7. Six months of maximum consumptive process requirement of corrosion inhibitor, scale inhibitor & biocide. 8. Complete electrical, instrumentation, control and PLC based control panel etc complete with controlcablesandtubing. 9. All integral and interconnecting piping and also piping up to dosing point including pipe, fitting, valves,pipesupportsetc. 10. Biddershallincludeinhisscope120m25NBMS(IS1239heavygrade)pipeforpipeheaderfrom sulphuric acid dosing pump at CW treatment plant to diffusers in CW forebay and 100 m 25 NB SS 316 (ASTM A 182) pipe from pump discharge header of each of scale inhibitor dosing system, corrosioninhibitordosing systemandbiocidedosingsystem(total300mpipe)todiffusersinCW forebay in the base price (routing shall be done tentatively as indicated in Equipment layout of chlorination plantBHEL drawing PEDG373156A002 enclosed with the technical specification. Necessary supports and fixing arrangement, flanges & fittings of pipe up to CW forebay shall be included by the bidder in his scope. Bidder shall quote unit prices as erected per meter length of 25 NB IS 1239 heavy grade pipe and 25 NB ASTM A 182 GR TP 316 pipe inclusive of all taxes and duties for addition or deletion in length during detailed engineering from the length specified in the equipment layout diagram. Unit rate shall be payable/ recoverable for addition / deletion of pipe(overandabove10%variation). 11. Bidder shall include in his scope necessary support/platform /ladder/hanger /anchor bolts as requiredforsatisfactoryerection/commissioning&operationofplant. 12. Start up and commissioning spares for installation, testing and commissioning of equipments, pipe work,instrumentationandcontroletc.coveredunderthisspecification.
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SPEC. NO. PE-TS-373-156-A001
13. First fill of all lubricants, servo fluids and all chemicals except H2SO4. The consumption during the trial operation and final filling / topping up after the trial operation shall also be included in bidders scope. Bidder shall furnish separate containers quantity not less than 10% of the full charge of each variety of lubricants, servo fluids and chemical used. B) Electrical scope: 1. The scope of electrical works, equipment and services shall be as per table for electrical scope between BHEL and vendor enclosed in annexure 1, section C3 of technical specification. 2. The other electrical design requirement shall be as specified in section D2 of technical specification. C) Control and instrumentation scope: 1. The control of CW treatment plant shall be dual processor based PLC system, PLC unit shall be provided with two processors (main processing unit with memories) one for normal operation and one as hot standby. 2. The PLC system shall be provided with necessary interface hardware and software for dual fiber optic connectivity and interconnection with station wide LAN (In BHELs scope) for twoway transfer of signal for information sharing only of CW treatment plant. The plant information shall be made through Ethernet link following TCP / IP standard. The system shall be OPC compliant. The dual fiber optic communication cable between bidders control panels and employers DDCMIS is excluded from bidders scope. 3. Bidder to include light interface units, converter, Ethernet switch, accessories at PLC end for connectivity to other systems. The bidder terminal point shall be LIU in case of fiber optic medium for connectivity to plant DDCMIS. 4. Two numbers of online pH analyzer transmitters as per P&ID for CW treatment plant BHEL Drg. No. PEDG373156A001 including piping up to CW forbay unit 3 & 4. Transmitters shall be installed in the CW pump discharge header of unit 5 and unit 6. Bidder shall provide one number Ph meter on each control panel. 5. The other control and instrumentation design requirement shall be as specified in section D3 of technical specification. D) Civil scope: 1. All civil works including building & foundation of equipment are excluded from bidders scope. However, all steel inserts, plates, bolts/foundation bolts, nuts, sleeves and all other embedding components etc as required to grout in purchasers civil works and to hold / support the equipments being supplied under this specification for the chlorination plant shall be in the scope of bidder. 2. Pedestals for pipes from CW treatment plant building to CW forebay are excluded from bidder scope. 3. Bidder shall furnish all applicable civil inputs details during detailed engineering. E) START UP AND COMMISSIONING SPARES All the necessary start up and commissioning spares for installation, testing and commissioning of all equipment, pipe work, instrumentation and control etc. covered in the this specification shall be considered by bidder as a part of base offer. F) RECOMMENDED SPARES Bidder may submit the list of recommended spares for 3 years of operation & maintenance along with the offer for our reference only.
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SPEC. NO. PE-TS-373-156-A001
G) QUALITY ASSURANCE PLANS Bidder to note the minimum Quality assurance requirement shall be inline with the section D4 of technical specification. However, detailed QP, inspection checklist, category of inspection etc. for each subvendor shall be decided during detailed engineering. All inspection & testing etc. shall be carried out accordingly. Any changes/additional tests insisted upon by BHEL/Enduser during detailed engineering shall be accepted by bidder without any commercial implication to BHEL/Enduser. H) SUB VENDOR: Bidder to note that all the subvendor shall be selected from the list of subvendors attached as Annexure 6 section C3 in the technical specification. Bidder to note that all the subvendor indicated in the Annexure 6 Section C3 are acceptable to BHEL subject to approval of enduser during detailed engineering. In case of newly proposed sub vendor over and above specified in Annexure 6 Section C3, it shall be subjected to approval from BHEL/customer during detailed engineering without any commercial or delivery implication to BHEL. I) PG TEST: Bidder shall perform the guarantee parameters as per the Annexure 7 section C3 of technical specification requirement to the satisfaction of BHEL/Enduser. The exact modalities of verifying guarantee for the parameters indicated in the specification shall be finally agreed with the Enduser during detailed engineering & mutually agreed between bidder, BHEL & Enduser. The Bidder shall arrange all the monitoring gadgets / instruments / equipment required for performing guarantee parameters (returnable after PG test). Site facility as available or as extended by Enduser shall only be provided. J) TERMINAL POINTS (Refer P & I Diagram enclosed) TP 1: Chemical solution discharge line: Bidder shall terminate chemical solution (H2SO4, scale inhibitor, corrosion inhibitor, biocide) discharge line at diffuser (to be fixed by bidder at CW forebay of BHEL) outlet. TP 2: Service water: Bidder to note that the service water for CW treatment plant building shall be terminated at 10 meter from the CW treatment plant building at a pressure of 2 kg/cm2(g) and further distribution for use in chlorination plant shall be done by bidder. TP 3: Electrical terminal point: Bidder to note that electrical scope and terminal points shall be as per annexure 1, section C3 of technical specification. TP 4: Connection to DDCMIS: Bidder terminal point shall be LIU at his PLC for further connection to DDCMIS by BHEL. Further cabling up to DDCMIS shall be in BHEL scope. TP 5: Online pH analyzer: A stub connection shall be provided by BHEL at each of the two CW pump discharge header for the bidder to install his two online pH analyzers (one for each CW pump discharge header). Isolation valve for each online pH analyzer shall be in bidder scope.
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SPEC. NO. PE-TS-373-156-A001
TP 6: Drain: All drains from equipments shall be led by bidder to the nearest drain trench. All drainscarryingsulphuricacidshallbeledtonearestdrainafterneutralizinginlimepit. TP 7: Sulphuric acid solution: Bidder shall supply one number unloading manifold with two numbers 30 m long type2 80 NB HDPE hose as per IS 7654/1989 (as per P&ID) for further connectionofendusersH2SO4tanker. K) Painting: Bidder to note that painting shall be as per the painting specification enclosed with the Annexure 5 sectionC3oftechnicalspecification. L) DRAWINGS/DOCUMENTATION Bidder to note that the number of hard/soft copies/CD of documents required shall be as stated in annexure2,sectionC3oftechnicalspecification. Biddertonotethatallthedrawings/documentsincludingProcess&instrumentationdiagram,layout, piping, equipment data sheet, foundation drawing, control & instrumentation, general arrangement drawings, field quality plan, quality plan, erection drawings, O&M Manual, PG Test procedure, plant control philosophy etc. as per document list enclosed in the specification shall be submitted for approval of BHEL/Enduser during detailed engineering. In case any change is suggested by Enduser to meet the system/specification requirement, the same shall be incorporated / carriedout without anycommercial/deliveryimplicationtothesatisfactionofEnduser/BHEL. M) Any item/work either supply of equipment or erection material which have not been specifically mentioned but are necessary to complete the woks for trouble free and efficient operation of the plant shall be deemed to be included within the scope of this specification. The bidder without any extra chargeshallprovidethesame.
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SPEC. NO. PE-TS-373-156-A001
SECTION C2 SPECIFIC TECHNICAL REQUIREMENT FOR THE CW TREATMENT PLANT
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SPEC. NO. PE-TS-373-156-A001
1.0
SCOPE This section covers the basis of design, system philosophy, equipment selection and control philosophy for Circulating Water (CW) Conditioning system, which shall comprise of Scale Inhibitor dosing System, Corrosion Inhibitor dosing System, Biocide dosing System and H2SO4 dosing System for 2X500 MW SAGARDIGHI TPP. DESIGN PHILOSOPHY: The treatment shall be designed to minimize the formation of scale and growth of micro organisms and to prevent fouling and corrosion of the condenser and heat exchanger. Scale/Corrosion inhibitor, biocide and H2SO4 dosing Systems have been designed to dose required quantity of chemical at CW fore bay to maintain quality of circulating water. CAPACITY SELECTION: Acid Dosing (98% H2SO4) Malkalinity in makeup water Desired Malkalinity in makeup water COC Makeup water flow Acid dosage rate
2.0
3.0
= = = = = = = = = = = = = = = = =
Specific Gravity Acid dosage rate Acid Dosing Pumps (selected) Effective capacity of H2SO4 Day Tank for 24 Hrs (required) Effective capacity of each H2SO4 Day Tank for 24 Hrs ( Selected) Effective capacity of H2SO4 Storage for 30 days (required) Effective capacity of H2SO4 Storage Tank for 30 days (Selected)
190.75 ppm as CaCO3 150 ppm as CaCO3 5.0 2900 m3/hr (as per BHEL PID for CW and ACW system: PE DG373165N001, Rev 01) [Makeup MAlkalinity(Desired MAlkalinity in Circulating water/5)] X Make up water X 24/1000 [190.75(150/5)] X 2900 X 24/1000 11188.2 kg/day 466.175 kg/hr 475.7 kg/hr (98% H2SO4) 1.84 475.7/1.84 LPH. 258.53 LPH 300 LPH (2W+1S). (considered so that 2 pumps working at 50% stroke length can suffice the requirement) 6204.72 Litre. 7000 Litre. 186141.6 Litre Four tanks each having effective capacity of 50000 Litre Each tank shall have 7 days capacity.
Rated capacity of H2SO4 unloading = 10 m3/hr pumps Scale inhibitor /corrosion inhibitor/Biocide dosing Scale inhibitor and corrosion inhibitor are a proprietary chemicals and level of its dosage in CW & ACW depends upon the recommendations of chemical manufacturer and based upon plant operation. However, the system will be designed for minimum 10 ppm dosage for both scale inhibitor and corrosion inhibitor and for minimum 3 ppm dosage for biocide.
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SPEC. NO. PE-TS-373-156-A001
Scale inhibitor /corrosion inhibitor dosing Blow down = Drift loss = Dosing rate = = = = = = = =
Specific gravity Chemical dosage rate of 100% Solution. Chemical dosage rate Considered. Chemical Injection Pump (selected) Effective capacity scale/corrosion inhibitor days (required) Effective capacity scale/corrosion inhibitor days (selected) Biocide dosing Flow rate
573 m3/hr (as per PEDG373165N001, Rev 01) 7 m3/hr per unit (Blow down + drift loss) (m3/hr) X dosage (ppm) /1000 (573+2X7) X 10/1000 kg/hr of commercial grade solution 5.87 kg/hr of commercial grade solution 1 (approx) 5.87/1 LPH (Approx) 5.87 LPH 6 LPH (Approx) 7.5 LPH (2W+1S). (considered so that 2 pumps working at 50% stroke length can suffice the requirement) 2160 Litre (considering 6 lph dosage rate)
of each = Tank for 15 of each = Tank for 15
2500 Litre
= = = = = = = = = = = =
Holding time (assumed) Holding volume (assumed) Biocide required for one dose
Specific gravity Chemical dosage rate of 100% Solution. Biocide per dose Considered. Twice the chemical dosage rate Chemical Injection Pump (selected)
[ 200 + 2 X {(2X29175) + 3159} ] m3/hr 123218 m3/hr 30 minutes 61609 m3 Hold up volume (m3) X dosage (ppm) /1000 61609 X 3/1000 kg of commercial grade solution 184.827 kg of commercial grade solution 1 (approx) 184.827/1.0 184.827 Liter 200 Litre 400 LPH 400 LPH (2W+1S) (Considered as per spec requirement that rated capacity of pump should cater to twice chemical required at 50% stroke length). 1 hour in a week 400 Litre 1000 Litre
Time of Biocide dosing = Effective capacity of each biocide Tank = for 15 days (required) Effective capacity of each biocide Tank for 15 days (selected) Note:
Bidder to note that the parameters selected above shall be the minimum capacity of tanks & pumps required. In case chemical manufacturer recommends more dosage, the capacity of tanks and pumps shall be increased by bidder in line with the calculation given above.
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SPEC. NO. PE-TS-373-156-A001
4.0 BRIEF SYSTEM DESCRIPTION Scale inhibitor /corrosion inhibitor /biocide dosing system: The chemical is dosed in CW fore bay to control scaling and corrosion and to prevent bio growth in the system. For this purpose one (1) number of skid mounted scale inhibitor, one (1) number of corrosion inhibitor, one (1) number of biocide dosing system has been provided. Further three numbers diffusers shall be supplied for each of the three skids along with piping to interconnect the diffusers and their respective dosing skid terminal points. Each of the three skids shall mainly consist of the following equipment: x Two (2) Nos. Solution Preparation cum metering tank with accessories. x Three (3X50%) Nos. Dosing pumps. x All necessary piping, valves, fittings, instrumentation etc. Solution Preparation cum Metering tank (2 Nos.) Two (2) numbers solution Preparation cum metering tank shall be provided to prepare the dilute solution. Both the tanks shall be provided with accessories like funnel connection with valve, level gauge and low level switch as indicated in P&ID. The solution shall then be dosed to the required point with the help of dosing pumps. Dosing Pumps (3 nos.) Three (3X50%) numbers positive displacement hydraulic diaphragm type dosing pumps with motor and external pressure relief valves shall be provided. Y type strainer (1 x100%) shall be provided at pump suction for each of the three dosing pumps and pulsation dampeners (1 x100%) shall be provided at pump discharge for each of the three dosing pumps. NOTES: 1. Individual drains of each skid (scale inhibitor, corrosion inhibitor & biocide dosing) shall be connected by an 80 NB ASTM A 312 GR TP 316 Sch 10 pipe and each of the three drain headers shall be led to plant drain. 2. All the three dosing skids shall be located indoor inside the CW treatment building. H2SO4 DOSING SYSTEM: H2SO4 is dosed to control the pH in the cooling water cycle. For this purpose one (1) number H2SO4 dosing system has been provided. The H2SO4 dosing system shall consist of the following: x Four Nos. Bulk Acid storage tanks with accessories as per P&ID x Two (2X100%) Nos. Acid unloading pumps with motor x One number hose station with 2 nos. HDPE hose connections of 80 NB and two numbers 30 m long 80 NB HDPE hose x Two (2X100%) Nos. Acid day tanks x Three (3X50%) H2SO4 Dosing pumps with motor and pressure relief valves x All necessary piping, valves, fittings, instrumentation, etc. Y type strainer (1 x100%) shall be provided at pump suction for each of the two unloading pumps. Y type strainer (1 x100%) shall be provided at pump suction for each of the three dosing pumps and pulsation dampeners (1 x100%) shall be provided at pump discharge for each of the three dosing pumps.
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SPEC. NO. PE-TS-373-156-A001
NOTES: 1.Provision shall be kept to transfer sulphuric acid from one bulk storage tank to the other tanks. 2.Flow of sulphuric acid from bulk storage tanks to acid day tanks shall be by gravity. 3.Drains from Sulphuric acid bulk storage tanks and day tanks, effluent from flushing line of pumps, and other effluents from Sulphuric Acid handling area shall be led to Lime Pit. 4.Silica Gel Breather shall be provided for sulphuric acid storage tanks. 5.One number safety shower shall be provided near Sulphuric acid handling area. 6.Sulphuric acid bulk storage tanks shall be located outdoor without any cover and sulphuric acid unloading pumps shall be located outdoor and covered on top by canopy. This storage area (comprising of storage tanks and unloading pumps) shall be surrounded by 1 m high dyke wall and covered by acid proof tiling/lining. Sulphuric acid day tanks and dosing pumps shall be located inside the CW treatment plant building. 7.Two numbers (one per unit) pHAT (pH Analyzer cum Transmitter) shall be provided at CW Pump common discharge header line. 5.0 Plant Operation and Control The CW treatment system shall have its dedicated PLC with two OWS which shall be housed in the common control room for CW treatment and CW chlorination system. The control of Dosing of Scale Inhibitor, Corrosion Inhibitor and Biocide shall be manual (local or remote) and the operation of Sulphuric Acid dosing system shall be auto, remote manual and local manual. The Control circuit shall be designed to operate the CW treatment Plant in a smooth and safe manner and with minimum of operator interference. The tripping of the plant in case of emergency shall be automatic based on interlocks provided. Starting & normal stopping of the plant shall be done manually. The chemical feed rates shall be set manually by the operator depending on the desired doses rate and based chemical manufacturers recommendations. The interlocks, controls, alarms/annunciations shall be builtin the dual processor based PLC system. PLC unit shall be provided with two processors (main processing unit with memories) one for normal operation and one as hot standby. Interconnection between CW treatment PLC and DDCMIS is not envisaged. The operation of the plant shall be possible from either of the two OWS. One OWS may also be used as engineering work station. The manual operation of CW treatment plant shall be possible in either Remote or Local mode. The Auto/local manual/remote manual selector switch (soft) in case of sulphuric acid dosing system and local/Remote selector switch (soft) for all three other dosing systems shall be provided at the PLC OWS. In remote mode, starting and stopping any motorized drive shall be possible from the OWS. Local manual operation shall be possible using the START/ EMERGENCY STOP push buttons provided locally at the vicinity of each drive. START push buttons shall be routed through the PLC while the EMERGENCY STOP push buttons (lockable type) shall be directly wired to the MCC. Starting any drive locally shall be possible only when local mode is selected. However, local stopping shall be possible through the EMERGENCY STOP push button irrespective of whether the local mode is selected or the remote mode is selected. All three phase loads shall be driven directly from MCC and single phase loads from LCP. The ON/OFF/TRIP status of all drives shall be displayed in the OWS. Provision shall be given in OWS for annunciation in case of all alarms (based on level switch signals) and trip conditions. The feed rate control of Sulphuric Acid Injection Pumps shall be possible in three modesauto, remote manual and local manual. In the auto mode, the stroke shall be adjusted by sensing pH of Circulating Water. During normal operation, Sulphuric Acid Injection Pumps will operate in the automode and inject sulphuric acid to maintain the pH of circulating water at a desired level so that scale deposition or corrosion can be avoided. For this purpose two number pH analyser transmitters shall be supplied and one number each shall be installed at each of the two CW discharge headers. Adjustment of stroke shall
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SPEC. NO. PE-TS-373-156-A001
also be possible manually from OWS in remote manual mode as well as local manually using the micrometer dial/knob mounted in the pump. The start/stop/dosing rate control of Scale Inhibitor Injection Pumps, corrosion inhibitor pumps and biocide dosing pumps shall be possible through OWS in remote manual as well as from START/EMERGENCY STOP local push buttons and the stroke adjuster knob provided on each individual pump. The auto stroke controllers of each dosing pump shall be provided in the local PLC panel. The stroke position & adjustment in remote mode will be done from OWS & Local PLC panel and the stroke controller shall be suitable for accepting 420 mA DC signals. The dosing pumps shall be provided with 24 V DC, 2 wire LVDT Type Position feedback transmitter to generate 420 mA DC signals to indicate stroke position in OWS. Monitoring equipment with reference to scale formation, corrosion and biological growth will be provided. The tank selector switch (soft) for all the dosing system in the CW treatment system shall be provided in the OWS. Normally two (2) pumps will be in service, one dedicated for each unit and one (1) pump will be there as common standby which will be used separately for both the units by selection through a selector switch (soft) provided in the OWS. The following interlocks shall be provided as minimum in the PLC: 1. Tripping of sulphuric acid unloading pump at high level in bulk acid storage tank 2. Tripping of scale/corrosion/biocide/sulphuric acid dosing pump at low level of the respective dosing tank in operation. 3. Dosing rate control of sulphuric acid dosing pump based on feedback from pH analyser transmitter installed in each of the CW discharge pump header. The following condition shall act as start permissive for the starting of dosing pump (applicable for sulphuric acid/scale inhibitor/corrosion inhibitor/biocide dosing systems): 1. Tank level in the selected tank for that dosing pump driveNOT LOW The following alarms with annunciation shall be provided as minimum in the PLC: 1. 2. 3. 4. 5. 6. High level in bulk storage tanks Low level in bulk storage tanks Low level in dosing day tanks Tripping of any drive High pH value in either of the two pH analyser transmitter Low pH value in either of the two pH analyser transmitter 6.0 Guarantee: The following guarantees shall be given by the CW treatment plant bidder and the same shall be demonstrated during performance guarantee test also: Corrosion Rate On MS < 3.0 mpy On Cu < 0.5 mpy On SS (304) < 0.5 mpy
1. x x x
PAGE:
18
SPEC. NO. PE-TS-373-156-A001
2. 3. x x 4.
5.
Scaling < 15 mg/dm2/day Micro/Bio fouling conditions Total Viable Count (TVC) < 1x105 Counts/ml Sulphate reducing bacteria (SRB) < 1x105 Counts/100ml NiCr mesh should be clean when visually inspected. Pitting corrosion rate on MS/Brass < 20 mpy
PAGE:
19
SPEC. NO. PE-TS-373-156-A001
SECTION C3 ANNEXURE
PAGE:
20
SPEC. NO. PE-TS-373-156-A001
Annexure1 ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR

PROJECT: 2 X 500 MW SAGARDIGHI SL.N DETAILS O 1 415V MCC
DATE: 10.12.2011
PACKAGE: CW TREATMENT PLANT REMARKS
SCOPE SUPPLY BHEL
SCOPE E&C BHEL
2 3
Local Push Button Station (for motors) Power cables, control cables and screened control cables for a) both end equipment in BHELs scope b) both end equipment in vendors scope c) one end equipment in vendors scope
BHEL
BHEL
BHEL BHEL BHEL
BHEL Vendor Vendor
Any special type of cable like compensating, coaxial, prefab, MICC, fiber optical etc. Cable trays, accessories & cable trays supporting system where one end equipment is in BHELs scope Cable glands and lugs for equipments supplied by Vendor
Vendor
Vendor
1. 415V, 3 ph power supply feeder shall be provided by BHEL based on vendors load requirement. Any other voltage level required by vendor shall be drawn by vendor. 2. Power supply equipment (battery, battery charger, UPS etc) required for the PLC/control panel (as applicable) for the system shall be supplied by vendor. 3. Interposing relays (RE 302 of Jyoti make or equivalent), if required for PLC and microprocessor based systems, shall be provided by BHEL in MCCs. Requirement of these relays shall be furnished by vendor during detailed engineering stage. Located near the motor. 1. Sizes and quantity of cables required shall be informed by vendor at contract stage (based on inputs provided by BHEL). Finalization of cable sizes shall be done by BHEL. Vendor shall provide lugs & glands accordingly. 2. Termination at Vendor equipment terminals by Vendor (except fiber optic cable between bidders PLC and BHELs DDCMIS)
BHEL
BHEL
Vendor
Vendor
Cable trays, accessories & cable tray supporting system
BHEL
BHEL
1. Double compression NiCr plated brass cable glands 2. Solder less crimping type heavy duty tinned copper lugs for power cables 3. Solder less crimping type heavy duty copper lugs for control cables. In case cables are routed through conduits, the supply & E&C of the same shall be in the scope of vendor. Conduits shall be medium duty, hot dip galvanized cold rolled mild steel
PAGE:
21
SPEC. NO. PE-TS-373-156-A001
SL.N O
DETAILS
SCOPE SUPPLY
SCOPE E&C
REMARKS
rigid conduit as per IS: 9537. Makes of conduits shall be subject to BHEL approval at contract stage. 8 9 10 11 Above ground Equipment earthing Below grade grounding & lightning protection LT Motors with base plate and foundation hardware a) Input cable schedules (C & I) b) Cable interconnection details for above c) Cable block diagram Equipment layout drawings BHEL BHEL Vendor Vendor Vendor Vendor Vendor BHEL BHEL Vendor Makes shall be subject to BHEL approval at contract stage. Cable listing for C & I systems for vendor supplied equipment shall be furnished during detail engineering by vendor in soft copies in the BHEL cable schedule format. For ensuring cabling requirements are met, vendor shall furnish layout drawings (both in print form as well as in AUTOCAD) of the complete plant (including electrical area) indicating location and identification of all equipments requiring cabling, and shall incorporate cable routing details marked on the drawing as per PEM interface comments. Electrical equipment layout drawing shall be to BHEL approval. For necessary interface review.
12
13
Electrical Equipment GA drawing
Vendor
NOTES: 1. Make of all electrical equipments/items supplied shall be reputed make & shall be subject to approval of BHEL after award of contract. 2. All QPs shall be subject to approval of BHEL after award of contract without any commercial implication.
PAGE:
22
SPEC. NO. PE-TS-373-156-A001
Annexure 2 Drawing/document distribution schedule
Sl. No. 1 2 3 4
First Submission BHEL Subsequent submission to BHEL First Submission DCPL/WBPDCL Subsequent submission DCPL/WBPDCL After approval DCPL/WBPDCL
Soft copy to 1 copy (in through email) re 1 copy (in through email) to 1 copy (in through email) re 1 copy (in to through email) by Not required
Hard Copy .pdf 1 copy .pdf Not required .pdf 5 copies .pdf Not required
CD Not required Not required Not required Not required
6 copies for formal approval by stamping & distribution Asbuilt drawing, O&M 1 copy (in .pdf As required, exact Manual & distribution through email) quantity to be informed drawings later
Not required
As required, exact quantity to be informed later
Note: 1.0 AutoCAD copy of equipment layout, cable trench/tray/routing layout & foundation drawings as well as cable schedule in MSEXCEL format shall be submitted along with soft copy in .pdf format. 2.0 Date of submission of hard or soft copy, whichever is later, shall be considered as date of submission for the purpose of calculation of delay analysis. 3. Bidder to note that BHEL reserve the right for drawing/document submission through web based Document Management System (DMS). Bidder would be provided access to the DMS for drg/doc approval and adequate training for the same. Detailed methodology would be finalized during the kickoff meeting. Bidder to ensure following at their end. x Internet explorer version Minimum Internet Explorer 7 x Internet speed 2 mbps (Minimum preferred) x Pop ups from our external DMS IP (124.124.36.198) should not be blocked x Vendors Internal proxy setting should not block DMS applications link (http://124.124.36.198/wrenchwebaccess/login.aspx)
PAGE:
23
SPEC. NO. PE-TS-373-156-A001
ANNEXURE 3 SCHEDULE OF DEVIATIONS All deviations from the Technical Specification shall be filled in by the bidder clause by clause in this schedule. VOLUME SECTION CLAUSE NO. PAGE NO. SPECIFICATION REQUIREMENT DEVIATION REASONS FOR DEVIATION
The bidder hereby certifies that the above mentioned are the only deviations from the PURCHASERs technical Specification for this enquiry. The bidder further confirms that in the event any other data and information presented in the bidders proposal and accompanying documents including drawings, catalogues, etc., are at variance with the specific requirements laid out in the PURCHASER's Technical Specifications, then the latter shall govern and will be binding on the BIDDER for the quoted price.
PAGE:
24
RATING (KW / A)
Nos. CABLE
LOAD TITLE REMARKS RUNNING NAME PLATE NOs SIZE CODE
UNIT (U)/STN (S)
STANDBY
VOLTAGE CODE*
FEEDER CODE**
EMER. LOAD (Y)
CONT.(C)/ INTT.(I)
STARTING TIME >5 SEC (Y) LOCATION
9 10
11
12
13
14
15
BLOCK CABLE DRG. No.
MAX. CONT. DEMAND (MCR) BOARD NO. CONTROL CODE 16 17 18
LOAD No.
19
ANNEXURE 4
NOTES:
1. COLUMN 1 TO 12 & 18 SHALL BE FILLED BY THE REQUISITIONER (ORIGINATING AGENCY); REMAINING COLUMNS ARE TO BE FILLED UP BY PEM (ELECTRICAL) : * VOLTAGE CODE (7):- (ac) A=11 KV, B=6.6 KV, C=3.3 KV, D=415 V, E=240 V (1 PH), F=110 V (cc): G=220 V, H=110 V, J=48 V, K=+24V, L=-24 V : ** FEEDER CODE (8):- U=UNIDIRECTIONAL STARTER, B=BI-DIRECTIONAL STARTER, S=SUPPLY FEEDER, D=SUPPLY FEEDER (CONTACTER CONTROLLED)
2. ABBREVIATIONS
JOB NO. PROJECT TITLE SYSTEMS DEPT.- SECTION
LOAD DATA (ELECTRICAL)
373 2X500 MW SAGARDIGHI STPP STAGE II UNITS #3 & 4 CW TREATMENT PLANT MAX - WC
ORIGINATING AGENCY NAME SIGN. SHEET 1 OF 1
PEM (ELECTRICAL) DATA FILLED UP ON REV. 00 DATA ENTERED ON DES SIGN. & DATE
25
SPEC. NO. PE-TS-373-156-A001
Annexure 5 PAINTING REQUIREMENTS
PAGE:
26
SPEC. NO. PE-TS-373-156-A001
Paint Reference Scheme
Surface Preparation Grade / Surface Profile Blast clean to Sa 21/2
Primer Coat Premier Paint No. of Coa ts 1
Intermediate Coat DFT in Intermedi Microns ate Paint No. of DFT Coats in Micro ns 1 50 Finish Paint (See Note)
Finish Coat No. of Coats
Total DFT DFT in in Microns micr ons 35 per coat 155
Various type of equipment/v alve, LP Piping/ structural/ Vessels, etc. (Temp. up to 90o) Equipment with (Temp. up to 250o) Equipment in corrosive areas like CPU (regeneratio n) Dosing skid, etc. Elect. / Control Panels, etc.
Red oxide zinc chromate as per IS:2074 (alkyd medium)
35 per coat
HB MIO
Synthetic enamel (alkyd med.) as per IS:2932
- do -
Heat resistant Al paint Epoxy resin based zinc phosphate primer
20 per coat
Heat resistant Alpaint
20 per coat
80
Blast clean 1 to Sa 2 /2
35 50 Epoxy per coat based TiO2 pigmente d paint
50 per Polyamid coat e cured Epoxy finish coat
25 35 135 per coat 170
Seven tank process
Zinc phosphate (alkyd Medium)
25 35 per coat
Synthetic enamel (alkyd med.) as per IS:2932
20 25 90 per coat 120
Notes: 1. Surface preparation shown is as per Swedish Standards SIS 055900. Degreasing will be as per Standard SSPCSP1. 2. In case of insulated surfaces, only primer coats shall be applied. 3. GM/SS items with piping and G.I. pipes will not be painted. However these items carrying under Fire Fighting System shall be painted Fire Red as per TAC guidelines. Further SS/GI piping shall be given necessary color banding for identification as per color scheme. 4. All instruments shall be painted as per manufacturer standard practice. 5. All structural steel items shall be painted at site. Piping shall go with primer coating & finish paint shall be applied at site. Equipment shall be finish painted at shop. 6. Method of painting application shall be as per paint manufacturers recommendation. 7. Based on above painting schedule, detailed painting schedule will be prepared by chlorination plant vendor and the Same shall be subject to WBPDCL/DCPL approval during detailed engineering.
PAGE:
27
SPEC. NO. PE-TS-373-156-A001
Annexure 6 LIST OF SUBVENDORS
PAGE:
28
SPEC. NO. PE-TS-373-156-A001
LISTOFSUBVENDORS
SNO. 1 2 3 ITEM TANK HORIZONTALCENTRIFUGAL PUMP METERINGPUMP/PRV/ PULSATIONDEMPENER/AUTO STROKECONTROLLER YSTRAINER STEELGATE/GLOBE/NR VALVE STEELBALLVALVES NEEDLEVALVE(IS:3224) VALVEMANIFOLD FITTINGS APPROVEDSUPPLIERS BELCOPOLLUTIONCONTROLPVTLTD FANTECH TECHNOFAB KIRLOSKARBROS.LTD. MATHER&PLATTPUMPS LTD KSBPUMPSLTD SAMTURBOINDUSTRYLTD VOLTASLTD SULZERPUMPSINDIALTD PLACE GREATERNOIDA PUNE NEWDELHI PUNE PUNE PUNE COIMBATORE MUMBAI
METACHEM SWELORE VKPUMPS MILTONROYINDIA

OTOKLIN JAYPEE GREAVESCOTTON MULTITEX WEIRVALVES&CONTROLSM.E. BABCOCKBORSIGESPANA,S.A. BDKENGINEERINGINDUSTRIESLTD LEADERVALVESLTD KIRLOSKARBROTHERSLTD KSBPUMPSLTD FOURESSENGG.INDIALTD VAGVALVESINDIA VAASAUTOMATIONPVTLTD FLOWCHEMINDUSTRIES BDKENGINEERINGINDUSTRIESLTD LEADERVALVESLTD KIRLOSKARBROTHERSLTD KSBPUMPSLTD FISHERSANMARLIMITED VAGVALVESINDIA FOURES KSB HITECH BALDOTA METPRESSENGG. FLOWTECH BHARATFORGE RELIANCEFORGE
MUMBAI AHMEDABAD NASIK CHENNAI

MUMBAI NEWDELHI MUMBAI NEWDELHI HUBLI JALANDHAR COIMBATORE CHENNAI HUBLI JALANDHAR COIMBATORE AHMEDABAD KOLKATA KOLKATA PUNE
4 5 6 7 8 9
PAGE:
29
TITLE: TECHNICAL SPECIFICATION FOR CW TREATMENT PLANT 2X500 MW, SAGARDIGHI TPP EXTN PROJECT, STAGE II, UNITS 3 & 4 10 11 12 13 14 15 16 17 18 19 FLANGES PAINT NRV(CI,CIRL) CS/MSPIPING(IS:1239) SAFETYSHOWER&EYEWASH LTMOTORS PRESSUREGAUGE/DPG LEVELGAUGES FLOATTYPELEVELSWITCHES LOCALCONTROLPANEL
SPEC. NO. PE-TS-373-156-A001
EBY SIDDARTH&GAUTAM MSFITTINGS PRADEEPMETALSLTD TUBEPRODUCTINCOROPORATION PRADEEPMETALSLTD TUBEPRODUCTINCOROPORATION RELIANCEFORGE BERGERPAINTS ASIANPAINTS SHALIMARPAINTS JENSON&NICOLSON KSB FOURESS BDK JINDALTUBES SAIL TISCO UNICARE JAYCO SIEMENS KIRLOSKARELECTRICCOLTD. CROMPTONGREAVESLTD ABB BHARATBIJLEE ALSTOM CGL MARATHON NGEF SWITZER(FORDPGAUGES) ANINSTRUMENTS MANOMETERINDIA GENERALINST GLUCKINDIA FORBESMARSHALL BUDENBERG SIGMAINSTRUMENTS LEVCON SBELECTROMECHANICAL TECHTROL(FLOAT&BOARDTYPE) GENERALINSTRUMENTS LEVCON SIGMAINSTRUMENTS NIVOCONTROL SBEM LEVCONINST INDSUSTRIALSWITCHGEAR&CONTROL POSITRONICS ECS SWITCHINGCIRCUIT
MUMBAI FARIDABAD KOLKATA MUMBAI BARODA MUMBAI BARODA KOLKATA MUMBAI KOLKATA KOLKATA MUMBAI MUMBAI BANGALORE CHENNAI KOLKATA MUMBAI INDORE PUNE MUMBAI BARODA NOIDA KOLKATA
PAGE:
30
TITLE: TECHNICAL SPECIFICATION FOR CW TREATMENT PLANT 2X500 MW, SAGARDIGHI TPP EXTN PROJECT, STAGE II, UNITS 3 & 4 20 21 220VDCLEADACIDBATTREIS 220VDCBATTREYCHARGER
SPEC. NO. PE-TS-373-156-A001
CONTROL&SCHEMATICS GEPOWER SIEMENS C&S PYROTECH JOVEMULTISYSTEMS EDAFUTURETECH L&T EXIDEINDUSTRIESLTD CHHABIELECTRICALSPVT.LTD. CALDYNEAUTOMATICSLTD. HBLPOWERSYSTEMLTD AMARRAJAPOWERSYSTEMPVTLTD.
HYDRABAD BANGLORE NOIDA MUMBAI
Note: 1. Allsubvendormentionedaboveshallbesubjecttocustomerapprovalduringdetailed engineeringwithoutanycommercial/deliveryimplicationtoBHEL. 2. AnyothersubvendornotspecifiedinabovesubvendorlistshallbesubjecttoBHEL/customer approvalduringdetailedengineeringwithoutanycommercial/deliveryimplicationtoBHEL.
PAGE:
31
SPEC. NO. PE-TS-373-156-A001
Annexure 7
PG TEST PROCEDURE
PAGE:
32
GENERAL TECHNICAL REQUIREMENT FOR PERFORMANCE GUARANTEE OF CW DCPL-K8A07 TREATMENT PLANT (For other specific Performance Guarantees, please refer clause 6 section C2 of this technical specification)
maintainability of the equipment proposed. The Owner reserves the right to evaluate the parameters quoted by the Bidder based on his experience and published material available.
1.04.00
The liquidated damages shall be calculated prorata for the fractional parts of the unit unless stated otherwise. The turbine generator, boiler, auxiliaries, and all other plant equipment and system shall perform continuously without exceeding the values of noise level (individual or collectively) exceeding the values specified in respective equipment specification over the entire range of output and operating frequencies. Performance/Acceptance Tests The performance/acceptance tests for various equipment and systems shall be carried out as specified under the respective equipment specifications and those specified below shall be specifically applicable. All the guarantees shall be tested together as far as practicable. The performance guarantee tests shall be conducted for both the units and shall be covered in price schedule. In case of systems with stand-by equipment the liquidated damages for non-performance will be levied for normal operating number of equipment only. However, for this purpose all the equipment including standby equipment shall be tested and average values arrived at. For instrument in-accuracies during PG Test, refer subsequent clauses of this section. For Total Auxiliary Power Consumption of Main Plant Package, the transformers listed under the respective clauses, shall be taken together for purposes of guarantee and not individually.
1.05.00
1.06.00 1.06.01
1.06.02
1.06.03
1.06.04
1.06.05
2.00.00
START-UP, INITIAL OPERATION, TRIAL OPERATION AND PERFORMANCE TESTS The Contractor shall provide commissioning & start-up supervisory engineering staff specially identified for the period commencing with start-up and extending through initial & trial operation and all performance tests. During this period, the Contractor shall furnish the calibration devices, special test instruments, etc. required to prepare for and conduct the performance tests. The Owner will associate his operating personnel and necessary supporting staff and shall make available fuel, and the system electrical load. Contractor's commissioning, & start-up supervisory engineering personnel shall conduct training for the Owner's personnel prior to and during this period and shall train them so that they will be able to operate and maintain the new equipment satisfactorily after acceptance by the Owner.
2.01.00
V.IIA/S-IX: 2
33
DCPL-K8A07
2.02.00
The Owner proposes to carry out in association with the Contractor, the following field inspections and tests in the sequence detailed below, and the successful performance and completion of all the tests taken together shall constitute the Owner acceptance tests. The Contractor shall provide supervisory services during field inspection and tests. Inspection and Checking of the Units After completion of erection and/or installation, and before being put into operation, the unit and all its appurtenances shall be thoroughly cleaned and then inspected, for correctness and completeness of installation and acceptability for placing in operation. All piping system shall be flushed, chemically cleaned; steam blown, air blown as required and cleanliness demonstrated using acceptable industry standards. Procedures to accomplish this work shall be subject to Owner's approval. The checkouts during the pre-commissioning period should be programmed to follow the construction completion schedule. Each system, as it is completed by construction and turned over to the commissioning (start-up) engineer(s), should be checked out and cleaned. The checking and inspection of individual systems should then follow a prescribed schedule. Also refer specification clause on commissioning management specified elsewhere. On completion of inspection, checking and after the pre-commissioning tests are satisfactorily over, the complete equipment shall be placed on Initial Operation during which period the complete equipment shall be operated integral with sub-systems and supporting equipment as a complete plant. When the equipment is operating properly, its characteristics shall be recorded on the start-up report sheets. Copies of typical start-up report shall be given to the Owner. Start-up reports for all equipment shall be completed before the start of the trial operation period.
2.02.01
2.02.02
Initial Operation, Reliability Run/Trial Run The plant shall be on Trial Operation during which period all necessary adjustments shall be made while operating over the full load range enabling the plant to be made ready for performance and guarantee tests. The duration of Trial Operation of the complete equipment, systems, subsystems in the automatic position of control system including demonstration of CMC shall be fourteen (14) days out of which at least seventy two (72) hours shall be in continuous operation on full load or any other duration as may be agreed to between the Engineer, and the Contractor. The Trial Operation shall be considered successful, provided such item of the equipment can be operated, continuously at the specified operating characteristics for the period of Trial Operation.
V.IIA/S-IX: 3
34
DCPL-K8A07
For the period of Trial Operation, the time of operation with any load shall be counted; minor interruptions not exceeding four (4) hours at a time caused during the continuous operation shall not affect the total duration of trial operation. However, if in the opinion of the Owner, the interruption is long, the Trial Operation shall be prolonged for the period equivalent to the duration of interruption. A trial Operation report comprising observations and recordings of various parameters to be measured, in respect of the above Trial Operation shall be prepared by the Contractor. This report besides recording the details of the various observations during trial run shall also include the dates of start and finish of the Trial Operation and shall be signed by the representatives of both the parties. The report shall have sheets, recording and print out of all the details of interruption occurred, adjustments made, any minor repairs done during the Trial Operation. Based on the observations, necessary modifications/ repairs to the plant shall be carried out to the full satisfaction of the Engineer to enable the later to accord permission to carry out Performance and Guarantee Tests on the plant. However, it is the prerogative of the Owner to grant permission for aforesaid test with minor defects, which do not endanger the safe operation of the equipments. Should any major failure or interruption occur in any portion of the plant due to or arising from faulty design, materials, workmanship or omissions or incorrect erection, sufficient to prevent safe and full commercial use of the plant, the reliability run shall be considered void and the reliability test period of 14 days shall recommence after the Contractor has remedied the cause of defect to the satisfaction of the Owner. 2.02.03 Performance and Guarantee Test a) The final tests as to the performance and guarantees shall be conducted at site, by the Contractor with full involvement of the Owner. The necessary operating inputs shall be provided by the Owner. The Contractor's engineering staff for commissioning and start-up shall ensure that the equipment are ready for such tests. The Owner shall associate his necessary supporting staff with the Contractor to carry out the various activities related to P-G tests. The necessary labour/supporting staff etc. shall be provided by the Contractor. Such tests will be conducted within a period of three (3) months after the successful completion of Trial Operation. Any extension of time beyond the above three (3) months shall be mutually agreed upon. b) These tests shall be binding on both the parties of the Contract to determine compliance of the equipment with the declared performance guarantees.
V.IIA/S-IX: 4
35
DCPL-K8A07
The Contractor shall submit the test procedure for Owner's approval within thirty six (36) months from the date of letter of award of the contract. The test shall be carried out by the test grade instruments as stipulated in the applicable test code. These instruments shall be calibrated by the Contractor in a laboratory duly approved by Owner. Batch calibration will not be acceptable. The available instrumentation and control equipment in the plant if found suitable could also be used with the prior approval of the Owner after calibrations in the plant/outside laboratory. The tests will be conducted at the specified load points, and as near the specified cycle conditions as practicable. Proper corrections in calculations to take into account the conditions which do not correspond to the specified conditions will be applied in the test report as brought out under the respective sections of the specification. c) All special test grade instruments, equipment, tools and tackles, required for the successful completion of the Performance and Guarantee Tests shall be brought for the purpose of test, free of cost by the Contractor. The guaranteed performance figures of the equipment shall be proved by the Contractor during these Performance and Guarantee Tests. The Contractor shall submit a detailed test report in the manner, already agreed to within one (1) month time of completion of the test, for Owner's approval. Should the Owner's assessment of these tests show any deterioration from the guaranteed values the Contractor shall modify the equipment as required to enable it to meet the guarantees to the satisfaction of the Owner. In such case Performance and Guarantee Tests shall be repeated after one (1) month, from the date the equipment is ready for retest and all costs for modifications including labour, materials and the cost of additional testing to prove that the equipment meets the guarantees, shall be borne by the Contractor. The specific tests to be conducted on equipment have been brought out in the technical specifications. The procedure to be submitted by the Contractor should include the detailed methodology to conduct these tests/verify the guarantees offered by the Contractor notwithstanding whether these attract liquidated damages or not. Instrument accuracies shall be in accordance with the relevant test codes. All instrument in-accuracies if applicable shall be computed as per the code and values will be corrected to the advantage of the Owner. No negative tolerance will be allowed. For example, if the inaccuracy of instrumentation has been worked out to be 1%, the measured values will be assessed to be 1% inferior for purpose of LD.
d)
e)
f)
V.IIA/S-IX: 5
36
DCPL-K8A07
g)
The Bidder shall establish the following modes of operation to the satisfaction of the Owner before acceptance test: i) ii) Operation of each system by remote manual control. Operation of the entire system in integrated manner on auto control. Operation of the entire plant with auto-control loops fully implemented including different modes of load control with the help of control system. Demonstration of CMC.
iii)
iv) h)
Ten (10) copies of the test reports are to be furnished by the Contractor to the Owner backed up with jointly signed data sheets.
V.IIA/S-IX: 6
37
SPEC. NO. PE-TS-373-156-A001
Annexure 8 INFORMATION TO BE FURNISHED BY THE BIDDER ALONG WITH BID DOCUMENTS TO BE FURNISHED IN THE OFFER (4 SETS): 1. Bidder to specify the deviations from the specification, if any, in the schedule of deviations enclosed as annexure 3, section C3 of technical specification. In the absence of duly filled in schedule, it will be presumed that the offer confirms to the specifications in all respects. Electrical load data duly filled in the format for electrical load is enclosed as annexure 4, section C3 of technical specification. List of spares for: Recommended spares (optional for BHEL reference only) Signed and stamped copy of the electrical scope sheet. Signed and stamped copy of Unpriced price schedule
2. 3. 4. 5.
PAGE:
38
SPEC. NO. PE-TS-373-156-A001
ANNEXURE 9 INFORMATION TO BE FURNISHED BY THE VENDOR AFTER AWARD OF CONTRACT x x x x x x x x x x x x x x x x Bar chart and schedules for drawing submission, manufacturing, erection and commissioning P and I Diagram including pipe sizes and terminal points. Equipment layout showing building details, headroom, equipment, piping layout inside and outside chlorination plant. GA drawing of dosing all skids Fabrication drawing of all tanks Foundation Design drawings indicating foundation design, load data, anchor bolt location, pocket details etc. Electrical load data. Wiring and schematic drawings for PLC based control panels. Control philosophy. Data sheet & general arrangement drawings for all the equipments showing dimensions and detail of materials of construction. Data sheet, GA & Characteristic curves for pumps and motors. Electrical equipment layout, Cable trench layout, cable routing and cable schedules. Manufacturing Quality plans and field quality plans. As built drawings Operation and maintenance manual Any other drawing required to make the system complete & as required for erection, commissioning & inspection purpose.
PAGE:
39
SPEC. NO. PE-TS-373-156-A001
SECTION D1 DESIGN REQUIREMENTS MECHANICAL
PAGE:
40
DCPL-K8A07
VOLUME : IIH SECTION-II HORIZONTAL CENTRIFUGAL PUMPS
1.00.00 1.01.00
GENERAL INFORMATION This section presents the general guidelines and details of horizontal centrifugal pumps to be procured under the scope of Main Plant Package and shall not be limited to the pumps specified under clause no. 3.00.00 below. For other horizontal centrifugal pump in the scope of Main Plant Package, these general guidelines as specified hereinafter shall be followed.
2.00.00 2.01.00
CODES AND STANDARDS The design, manufacture and performance of the horizontal centrifugal pumps as specified hereinafter, shall comply with the requirements of the following codes and standards and shall include all the latest amendments subsequent to the year of publication as mentioned below. IS-6595 Part-2/ 1993 IS-5120/1977 : : Horizontal Centrifugal pumps for clear, cold and fresh water. Technical requirements for Rotodynamic special Purpose pumps. : : : : Pumps for handling chemicals & corrosive liquids. Pumps for process water. Pumps for handling volatile liquids. Code for acceptance tests for centrifugal, mixed flow and axial flow pumps - Class 'C'.
2.01.01
2.01.02
2.01.03 2.01.04 2.01.05 2.01.06
IS-5639/1970 IS-5659/1970 IS-6536/1972 IS-9137/1978
2.01.07
ISO 3555/1977 BS 5316/1977 Part 2
Acceptance tests for centrifugal, mixed flow and axial flow pumps - Class 'B' tests.
2.01.08
ISO 2548/1973 BS 5316/1976 Part 1
- Do - Class 'C' tests.
(PCA.CD-003.M794ACW1)
V.IIH/S-II : 1
41
DCPL-K8A07
2.01.09 2.01.10 2.01.11 2.02.00
API-610/1989
Centrifugal pumps for general refinery services.
Standards of the Hydraulic Institute of USA (1983). PTC 8.2/1965 : Power Test Codes - Centrifugal pumps.
In case of any contradiction with the above standards and annexures, the stipulations in the annexures shall prevail and shall be binding to the Contractor.
3.00.00 3.01.00 3.01.01
SCOPE OF WORKS Scope of Supply The scope of supply under this section shall be as below. Items specifically not mentioned but deemed necessary by the Tenderer for making the system completely reliable and efficient shall also be included. a) Equipment i) DMCW Pumps Turbine Island : Six(6) nos. Horizontal Pumps and drives pumps complete with all accessories as specified in this section and in the annexures attached to this section. Four(4) nos. Horizontal Pumps and drives complete with all accessories as specified in this section and in the annexures attached to this section. Three(3) nos. Horizontal Pumps and drives complete with all accessories as specified in this section and in the annexures attached to this section. Two (2) nos. Horizontal Pumps and drives complete with all accessories as specified in this section and in the annexures attached to this section.
ii)
DMCW Pumps Boiler Island :
iii)
DMSW Pumps
iv)
SG Fill Pumps :
v)
Any other horizontal centrifugal pump included by the Tenderer within the scope of Main Plant Package.
V.IIH/S-II : 2
42
DCPL-K8A07
b)
Equipment Accessories Each pump set for all the above groups shall be supplied with the following accessories : i) Couplings of approved design to connect pump shaft directly with the motor shaft. Sets of base plates, support plates, grounding pads, lifting lugs, eye bolts, nuts etc for each pump and motor set. Slip-on type drilled steel flanges of proper rating for both suction and discharge connections of each pump set. All the counter-flanges shall be complete with requisite number of bolts, nuts, gaskets etc. Air release cocks and drain plugs for each pump set. Discharge line pressure gauge and suction line pressure/vacuum gauges complete with isolating cocks for each pump set. All internal/integral piping with valves, fittings, and pressure gauges for lubrication, cooling and sealing, wherever applicable, shall be tapped of directly from respective pump discharge.
ii)
iii)
iv) v)
vi)
3.02.00
For details regarding scope of services and works Volume IIA of this specification shall be referred to.
4.00.00 4.01.00
PERFORMANCE REQUIREMENT Performance requirements for the pumps shall be as guided in Section-I of this volume and by the Annexure enclosed with this section. Pumps shall be designed such that the maximum efficiency lies within a tolerance of 10% of the design flow. The pumps shall be suitable for continuous operation at any point within the "Range of Operation" as stipulated in the annexure attached with this section. Pumps shall preferably have a continuously rising head-capacity characteristics from the specified duty point towards shut-off point, the maximum being at shut-off to enable parallel operation. Under all circumstances, the 'range of operation' of the pumps shall exclude any unstable operating zone of the head - capacity curve.
4.02.00
4.03.00
V.IIH/S-II : 3
43
DCPL-K8A07 4.04.00 Wherever specified in the annexures attached to this section, pumps of each category shall be suitable for parallel operation. The head vs. capacity, the BHP vs. capacity characteristics etc. shall be identical to ensure equal load sharing and trouble-free operation of any pump when the other pump(s) working in parallel with it trip. The pump set along with the drive motor shall run smooth without undue noise and vibration. Acceptable peak to peak vibration limits shall be generally guided by the Hydraulic Institute Standards of USA. Vibration must be in good zone.
4.05.00
5.00.00 5.01.00 5.01.01
DESIGN AND CONSTRUCTION Pump Casing Pump casing shall be provided with adequate number of vents and priming connections with valves unless the pump is made self- venting and priming. Casing drain, as required, shall be provided complete with drain valves. Pump design must ensure that the nozzles are capable of withstanding external reactions not less than those specified in API-610. In cases where an expansion joint is located at pump discharge, the pump assembly will be subjected to an additional thrust which will be transmitted to the foundation. This additional thrust shall be taken into the consideration of pump design. Impeller The rotor assembly shall be dynamically balanced and designed with critical speed substantially above the operating speed. Wearing Rings Replaceable type wearing rings shall be furnished to prevent damage to impeller and casing. Shaft Shaft size shall be selected considering that the critical speed shall be away from the operating speed as recommended in applicable Code/Standard. The critical speed shall also be at least 10% away from runaway speed. Shaft Sleeves Renewable type fine finished shaft sleeves shall be provided at the stuffing boxes/mechanical seals. Length of the shaft sleeves must extend beyond the other faces of gland packing or seal end plate so as to distinguish between the leakage past shaft and shaft sleeve and that past the seals/glands.
5.01.02
5.01.03
5.02.00 5.02.01
5.03.00 5.03.01
5.04.00 5.04.01
5.05.00 5.05.01
V.IIH/S-II : 4
44
DCPL-K8A07 5.05.02 Shaft sleeves shall be properly fastened to the shaft to prevent any leakage or loosening. Shaft and shaft sleeve assembly should ensure concentric rotation. Bearings Bearings shall be easily accessible without disturbing the pump assembly. A drain plug shall be provided at the bottom of each bearing housing. Heavy duty sleeve/ball/roller type bearings shall be provided to take care of the radial loads. In case of sleeve type radial bearings, axial thrust shall be absorbed in suitable hydraulic devices and/or thrust bearings. Bearings and hydraulic devices (if provided for balancing axial thrust) shall be of adequate design for taking the entire pump load arising from all probable conditions of continuous operation, as specified in the annexures. Life of the bearings shall be guided by the design standard of the pump or as specified in annexures. Thrust bearing shall be capable of running continuously at maximum load. The bearings shall be oil/grease lubricated. Suitable lubricating arrangement for the bearings shall be furnished with the pump complete all accessories like pump, filters, pipings, fittings, valves, interlocking and supervising instruments etc. as necessary and specified in the Annexures. The design shall be such that the bearing lubricant does not contaminate the liquid being pumped. Stuffing Boxes Stuffing box design shall permit replacement of packing without removing any part other than the gland. Stuffing boxes shall be sealed/cooled by the fluid being pumped/external clear water, as specified in the Annexures. All necessary pumps, piping, fittings, valves, instruments etc. as required for safe and trouble-free operation of the pumps and as specified in the Annexures shall be included in the scope of supply. Mechanical Seals Mechanical seals shall be provided if specified in the Annexures. The pump supplier shall co-ordinate with the seal maker in establishing the circulation rate for maintaining a stable film at the seal face in the chamber. The seal piping system shall form an integral part of the pump assembly. When handling liquids near their boiling point, suitable arrangement for external cooling shall be provided so as to prevent flashing at the seal faces. For the seals under vacuum service, the seal design must ensure sealing against atmospheric pressure, even when the pumps are not operating. V.IIH/S-II : 5
5.06.00 5.06.01
5.06.02
5.06.03
5.06.04
5.06.05
5.07.00 5.07.01
5.07.02
5.08.00 5.08.01
5.08.02
5.08.03
45
DCPL-K8A07
5.09.00 5.09.01
Drive Unit The pumps shall be driven by electric motor directly coupled or through a gear box, as specified in the Annexure. A heavy duty coupling along with coupling guard shall be provided between the pump and drive unit. Unless otherwise specified in Annexure, drive unit power rating shall be the maximum of the following requirements. a) b) 15% margin over the pump shaft input power at the rated duty point. 10% margin over the maximum pump shaft input power required within the 'Range of Operation' at 500 C ambient. Pump shaft input power required considering the overloading of the pump assuming single pump operation in the event of tripping of one or more of the pumps operating in parallel.
5.09.02
c)
6.00.00 6.01.00
INSPECTION AND TESTING The Contractor shall carry out the following specific tests and inspections to ensure that the equipment furnished lies in strict conformance with the specification and also in accordance with applicable codes/standards and good engineering practice. a) Identification and Testing i) All materials used for pump construction shall be of tested quality. Material shall be tested as per the relevant standards and test certificates shall be made available to the Owner. Tests for each pump included under this section shall include but not be limited to the following : The entire surface of the impeller castings shall be subjected to Dye Penetration Test as per ASTM Specification no.: E165-65. Shaft shall be subjected to Dye Penetration and Ultrasonic Tests. Wearing rings shall be subjected to Dye Penetration Test. Verification of material, witnessing of pouring, casting and inspection of finalised fabricated/cast castings. Inspection of finished castings for impeller and verification of materials. Inspection of pump shaft and verification of material. Witnessing of NDT/review of NDT reports. V.IIH/S-II : 6
ii)

46
DCPL-K8A07
Static balancing test for impeller and dynamic balancing of complete rotating parts as per ISO- 1940. Complete Inspection of assembled pump.
b)
Hydrostatic Testing The pump casing shall be hydrostatically tested at 150% of the shutoff pressure. Pressure shall be maintained for a period of not less than one (1) hour. While arriving at the above values maximum suction pressure shall be taken into account.
c)
Performance Test at Shop i) Each pump shall have to be tested to determine the performance curves of the pumps. These tests are to be conducted in presence of Owner's representative as per the requirements of the Standards of Hydraulic Institute of USA (ASME-Power Test Code PTC 8.2/BS-599) or any other equivalent standard specified in the specification but the tolerances on head discharge and power shall be as specified in HIS, USA. Performance tests are to be conducted to cover the entire range of operation of the pumps. These shall be carried out to span 130% of rated capacity upto pump shut-off condition. A minimum of five combinations of head and capacity are to be achieved during testing to establish the performance curves, including the design capacity point, shut-off point and the two extremities of the range of operation as specified in the annexures. After completion of performance test, all pumps shall be stripped down for inspection of internals. Tests shall be conducted with actual drive motors being furnished. NPSH tests are to be conducted on one pump of each type at 3% head drop conditions, if specified in the pump Annexures. Mechanical run test shall be carried out on all pumps to determine the vibration levels, noise levels etc. This test shall be conducted at site also. However, test value at site shall be used for the acceptance of the equipment.Pump vibration must be in good zone as per respective code and standard.
ii)
iii)
iv)
v)
7.00.00 7.01.00
DRAWINGS, DATA, CURVES AND INFORMATION The Bidder shall submit the following along with his formal proposal besides the different information plate required as indicated elsewhere in this section. Drawings V.IIH/S-II : 7
7.01.01
47
DCPL-K8A07
a)
General arrangement drawings showing the principal dimensions, weight and location of the suction and discharge connections of the pumps offered. Details of lubrication and sealing arrangement shall be included. Typical cross-section drawing showing various components of the pumps offered, materials of construction etc.
b)
7.01.02
Data and Curves a) Determination of pump total dynamic head and rated capacity as per guidelines specified in Section-I of this Volume. Detailed calculations shall be shown by the Bidder. Anticipated performance curves showing the following characteristics : i) ii) iii) iv) v) c) Capacity vs. head Capacity vs. power Capacity vs. efficiency Capacity vs. NPSH required System resistance curves
b)
Speed vs. torque curve of the pump corresponding to recommended mode of pump starting superimposed on speed vs. torque curves of the drive unit corresponding to 80%, 90%, 100% of the rated voltage (applicable only in the cases of pumps with drive motor power rating of 100 KW and above). Completely filled-in Technical particulars enclosed under Volume-III of this specification.
d)
7.02.00
The successful Bidder shall furnish the following drawings/data for Purchaser/Engineer's approval after award of the contract. Final versions of all the drawings, documents as specified in clause no. 7.01.00 above. Pump foundation details along with all design loads, direction and points of application. Test reports, test certificates and other particulars. All other applicable drawings and documents as specified in Volume IIA of this specification.
7.02.01
7.02.02
7.02.03 7.02.04
V.IIH/S-II : 8
48
DCPL-K8A07
VOLUME : IID SECTION-II LOW PRESSURE PIPING, VALVES AND SPECIALTIES
1.00.00
GENERAL INFORMATION This section covers all the low-pressure piping up to 400mm NB size, associated valves and specialties that include but is not limited to the following systems.
1.01.00
Service Air System - shall consist of distributions terminated at hose valves for general house keeping on the different floors of Power House, boiler galleries and equipment cleaning of main plant package. Distribution scheme shall also include some continuous and intermittent requirement of boiler and Turbine-generator islands. The service air shall be supplied by the Owner at a single point as mentioned under Terminal Point of the specification (Vol. IIA) Instrument Air System - shall comprise of distribution of instrument quality air to pneumatically operated instruments/ valves/dampers of the Main Power House, boiler, . The instrument air shall be supplied by the Owner at a single point to be mutually agreed with the Bidder.as mentioned under Terminal Point of the specification (Vol.IIA) Supply of DM water from condensate storage tank to different required points under Main Plant Package. Demineralised Water closed cycle Cooling shall include supply of DMW make up from Condensate Storage tank to DMCW make up tank via DMSW pumps and also closed DM cooling system of the boiler and turbine area coolers. Any other low pressure piping as found necessary during detail engineering shall also be included.
1.02.00
1.03.00
1.04.00
1.06.00
2.00.00 2.01.00
CODES AND STANDARDS In addition to the requirements spelt out in Volume II, the design, manufacture, inspection and testing of the piping, fittings, valves and specialties covered under this specification shall conform, in general, to the standards and codes (latest edition) mentioned below:
(PCA.CD-003.M799PCP2)
V.IID/S-II : 1
49
DCPL-K8A07 2.01.01 IS-1239 [Part-I & II] IS-3589 : Mild steel tubes, tubular and other wrought steel fittings. Electrically welded steel pipes for water, gas and sewage (150 to 2000 mm nominal diameter) Dimensions for pipe threads where pressure tight joints are required on the threads. Hexagonal head bolts, screws and nuts (size range M5 M36) Precision and Semi-precision hexagon bolts, screws, nuts and lock nuts (diameter range 6 to 39 mm) Hexagon bolts & nuts (M42 to M150) Swing check type reflux (non-return) valves. Colour code for the identification of pipelines. Plain washers Compressed asbestos fiber jointing Steel pipe flanges and flanged fittings Wrought steel Butt welding flanged Forged steel fittings, Socket-welding and Welded and Seamless Wrought Steel Pipe Stainless Steel Pipe Steel gate valves Class I Arc welding of ferrite steel pipe work for carrying fluids. Specification for steel pipes and specials for water and sewage. Specification for Ball valves. Threaded.
2.01.02
2.01.03
IS-554
2.01.04
IS-1363 [Part-I & II] IS-1364
2.01.05
2.01.06 2.01.07 2.01.08 2.01.09 2.01.10 2.01.11 2.01.12 2.01.13 2.01.14 2.01.15 2.01.16 2.01.17
IS-3138
IS-5312/EN/DIN: IS-2379 IS-2016 IS-2712 : : :
ASME B-16.5 : ASME B-16.9 : ASME B-16.11 : ASME B-36.10 : ASME B-36.19 API-600/EN/DIN: BS-2633 :
2.01.18
BS-534
2.01.19 2.01.20
BS-5351
AWWA-C-504 /EN/DIN : AWWA-C-208 :
Specification for Butterfly valves. Dimension for fabricated steel water pipe fittings.
2.01.21
V.IID/S-II : 2
50
DCPL-K8A07
3.00.00 3.01.00
SCOPE OF WORK The equipment and materials to be supplied shall include but not be limited to the following: a) Supply of all low pressure piping including bends, elbows, tees, branches, laterals, crosses, reducing union, couplings, caps, saddles, shoes, flanges, blank flanges, Y-pieces etc. as required for the piping system under the scope of this section. Matching pipes, matching pieces like reducers/enlargers etc., counter flanges with bolts, nuts, washers, temporary and permanent gaskets, threaded union etc. for all terminals of other packages as required. Supply and machining work of flanges, pipe spools and matching pipes to connect flow measuring orifices/nozzles with the main pipe work. All isolating and regulating valves, non-return valves, steam/air traps, relief/safety valves (wherever applicable), strainers, pressure reducing orifices etc. complete with the counter flanges and matching connecting pieces as required within the terminal points of entire low pressure piping system. Anchors, hangers and supports, etc. as required. Any platform necessary for maintenance and operation of valve and equipment located 1.5 m above any permanent floor or platform including access ladders, supporting structures etc. All secondary structural steel members required for pipe supports from building steel structures and from embedded steel wherever provided including pipe supports in trenches. However, trench piping should be avoided to the extent possible. Funnels, tundishes for drips and drains including all miscellaneous drain piping and drain piping from tundish outlet up to drain points. All drain and vent lines shall be conveniently terminated to floor drain points/permanent drain trenches of the Power Station. Flanges, counter flanges, blank flanges, bolts, nuts, washers, temporary and permanent gaskets, fasteners caps etc. as required for interconnecting piping, valves & fittings as well as for terminal points. Cleaning and Painting of all piping, valves & specialties at manufacturer's shop.
b)
c)
d)
e)
f)
g)
h)
i)
3.02.00
Following general requirements shall however be provided a) Instrument Connections including instruments, root valves, sensing lines etc.
V.IID/S-II : 3
51
DCPL-K8A07
b)
Pipe stubs and blanking plates etc. required for chemical cleaning and hydro testing.
For conducting acceptance test, the required pressure, temperature, flow measurement points shall be provided. 3.03.00 3.04.00 3.04.01 All miscellaneous instruments Terminal Points For Service Water System, DM water supply for main plant package make up, terminal points for supplying the above from the Plant Water System shall be. as mentioned under Terminal Point of the specification (Vol.IIA) For Supply of Service and Instrument Air to the main plant package shall be one single terminal point. as mentioned under Terminal Point of the specification (Vol.IIA)
3.04.02
4.00.00 4.01.00 4.01.01
GENERAL DESIGN AND CONSTRUCTION General Considerations The piping systems included in this section shall be designed to operate continuously without replacement during the plant service life of 30 years. The piping system shall be complete in every detail and in accordance with the highest standard of workmanship. Any item of the section on which the contractor is in doubt shall be referred to the Owner for clarification. All design and fabrication shall be in accordance with codes/standards specified. No pipe work shall be run in trenches carrying electrical cables. Pipe size above 50 NB shall be shop fabricated and of size 50 NB and below shall be field run. All piping shall be identified by means of colour strips and by adequate lettering, conveniently spaced and located. Identification colours and lettering shall be as approved. Air release and drain branches shall be provided wherever necessary depending upon the layout and arrangement so that the drains and air release valves are located for easy operation. Unless otherwise specified, all pipe work shall be suitable for a minimum pressure of 10.0 kg/sq. cm(g) at 80 deg. C or as required by the design of the different piping system, if higher.
4.01.02
4.01.03
4.01.04 4.01.05
4.01.06
4.01.07
4.01.08
V.IID/S-II : 4
52
DCPL-K8A07
4.01.09
Drain Pipe work a) Low pressure drains shall have an isolating valve at the point of take-off from the pipe or vessel to be drained, or as near as possible for conventional operation. Unless otherwise stated, all drain piping shall be of 25 mm NB minimum and all vent pipings shall be of 15 mm NB size minimum. For CS pipes up to 50mm NB, pipe wall thickness shall be as per schedule 80 of ASME B36.10 and for SS pipes up to 50mm NB, pipe wall thickness shall be as per schedule 40S of ASME B36.19. Unless otherwise stated, wherever a main or branch of any pipeline is terminated with a valve, such terminal valve shall be provided with a blank flange/blanking cap at the free end.
b)
c)
4.01.10
Specification of pipes used in different services included in the L.P piping section has been detailed in Annexure-I. Material Specification Materials for pipes and fittings shall be as stipulated in Annexure-I. In case bidder wants to offer alternative piping material, same may be accepted by the Purchaser depending on the merits of alternative material. Pipe attachments for supports, anchors and restraints, which are coming in direct contact with pipes, shall have similar materials as the piping concerned. All other materials of supports, anchors and restraints shall be of tested quality and as per manufacturer's standards. Fabrication Except where otherwise specified all piping shall have butt-welded connections with a minimum of flanged joints necessary for maintenance. Where flanges are adjacent to welded fittings, weld neck flanges shall be used. Branches shall, in general, be formed by welding. Standard fittings may be used in positions and for sizes where approval has been given in detail drawings. Pipe bends and tees shall be truly cylindrical and of uniform section. all welded branches shall be reinforced where needed as per the applicable codes/regulations.
4.02.00 4.02.01
4.02.02
4.03.00
4.03.01
Piping shall be fabricated in the shop in the largest transportable sections to minimize the number of field weld joints. The choice of field weld joints locations shall be based on the traverse of the pipe through walls, floors, sleeves or other restrictive areas. Support attachments for major piping shall be done at shop.
V.IID/S-II : 5
53
DCPL-K8A07
4.03.02
All pipes bends shall be made true to angle with no negative tolerance and shall have a smooth surface free of flat spots, crease and corrugations. A cross section through any bent portion of the pipe shall be true in diameter, within plus or minus 3% of the pipe diameter. Pipe bends shall be made from straight pipe pieces of sufficiently higher thickness so that after thinning, the minimum thickness of bends shall not be less than the minimum thickness required for the straight pipe. Thinning allowance shall be considered as per the relevant code. For bends in pipes straight piece of pipes shall be bent by the contractor to required bend radius. However, forged bends (Bend radius = 1.5 x pipe diameter) wherever required shall be provided at no extra cost. The ends of Pipe and welded fittings shall be bevelled according to details shown in the relevant piping code. All welding shall be made in such a manner that complete fusion and penetration are obtained without an excessive amount of filler metal beyond root area. The reinforcement shall be applied in such a manner that it shall have a smooth contour merging gradually with the surface of adjacent pipe and welded fittings. Backing rings shall not be used on any pipe welds, unless otherwise approved by the Engineer. Cutting and Bevelling a) Carbon steel piping - End preparation for butt welding shall be done by machining/flame cutting. Socket welding - Socket weld and preparation shall be done by saw or machine cutting.
4.03.03
4.03.04
4.03.05
b)
4.04.00
Hangers, Supports, Anchors Normally pipe supports and anchors shall be selected at those points in the buildings where provision has been made for the loads imposed. The cutting of floor/roof beams or the reinforcement in slabs will not be permitted. Piping attached to a plant item shall be supported in such a way that the weight of the piping is not taken by the plant item.
4.04.01
Support spacing shall be as per good engineering practice. However in no case it shall be less than support spacing stipulated in ASME B31.1. Accurate weight balance calculations shall be made to determine the required supporting force at each hanger location and the pipe weight load at each equipment connection. All large pipes and all long pipes shall have at least two supports each arranged so that any length of pipe or valve may be removed without any additional supports being required.
4.04.02
4.04.03
V.IID/S-II : 6
54
DCPL-K8A07 Support steel shall be of structural quality. Perforated strap, wire or chain shall not be used. Support components shall be connected to support steel by welding, by bolting or by beam clamps. Boltholes shall be drilled, not burned. Support components may be bolted to concrete using approved concrete anchors. Valves and Accessories General Requirements a) All valves shall be of approved make and type and shall have cast/forged bodies with covers and glands of approved construction and materials as specified in Annexure-II & III. The valves shall be provided with electric motors/solenoids and actuators as required. Valves and specialties to be supplied under this specification will be used for various air and water services and will be located indoor/outdoor and on horizontal/vertical runs of the pipelines. However, mounting of valves in vertical pipe runs should be avoided as far as possible. All valves shall, unless otherwise stated, have the internal diameter same/as the internal diameter of the pipes to be joined. All valves shall receive tests at manufacturer's or contractor's works in accordance with the specific requirements of the approved Codes of Practice. Valves shall be rising stem or otherwise as approved by the Purchaser. Gate valve and Ball valve have been specified with the intention of achieving isolation and tight shut-off. In full open condition, these valves should offer minimum of resistance to fluid flow. Globe valves have been specified with the intention of achieving good control of fluid passing. The plug and seat will have therefore suitable profiles for obtaining such controlling action. Check valves have been specified in order to prevent reverse flow through them. All valves shall function smoothly without sticking, rubbing or vibration on opening or closing and shall be suitable for most stringent service conditions i.e. flow, temperature and pressure under which they may be required to operate. Material, design, manufacture, testing etc. for all valves and specialties along with the accessories shall conform to the latest editions of codes.
4.04.04
4.05.00 4.05.01
b)
c) d)
e)
f)
g)
h)
i)
V.IID/S-II : 7
55
DCPL-K8A07
j)
By pass valves shall be provided for larger size valves as per standards followed and as felt necessary for smooth and easy operation, even though not specifically mentioned in the specification. All flanged valves and specialties to be supplied under this section shall be provided with two (2) counter flanges, bolts, nuts, washers, gaskets etc. All valves shall be of approved design and manufacture. Where valves are of similar size and type they shall be interchangeable with one another. Valves shall have welded or flanged connections subject to the Purchaser's approval. All valves shall have outside screwed spindles and screwed thread of spindle shall not pass through or into the stuffing box. Where valves are exposed to the weather, protective covers shall be provided for the spindles, which shall be subject to approval. Gate, Globe and Ball valves shall be provided with the following accessories in addition to other standard items: i) ii) iii) Hand wheel with embossed open and shut directions. Local position indicator. Motorised operation as specified .
k)
l)
m)
n)
o)
Gate valves, in addition shall be provided with following extra features i) ii) iii) Bypass valve for larger valves Draining arrangement Enclosed Gear operators for valves 300 mm size and above for ease in operation. Motorised operation as specified .
iv) p) q)
All gate and globe valves shall be rising stem type. All valves shall be provided with hand-wheels, chain, operator, extended spindle and floor stand wherever required so that they can be operated manually by a single operator from the nearest operating floor either at a lower or higher elevation as the case may be. If such a valve is provided with integral bypass then similar arrangement shall be done for the bypass valve also. All valves and specialties shall be provided with brass Tag Discs indicating Tag numbers and nomenclature of the valve including duty or service intended and the function of the valves specialties. V.IID/S-II : 8
r)
56
DCPL-K8A07 s) Stems shall preferably be arranged vertically with gland at the top, however, in no circumstances must the stem be inclined downward from horizontal or gland be at the bottom. Globe valves shall be installed with the pressure under the disc. Valves shall not be fitted in inverted position. Where necessary, for accessibility, grease nipples shall be fitted at the end of extension piping and where possible these shall be grouped together and mounted on a common panel situated at a convenient position. A separate nipple shall be provided to lubricate each point. The Bidder shall supply the first fill of oil or grease for these parts. The Bidder shall supply a suitable manually operated grease gun for the standard type of nipple provided. The spindles for all valves for use outside the building shall have weatherproof protection covers of approved construction. All valves shall be fitted with indicators so that it may be readily seen whether the valves are open or shut. In the case of those valves fitted with extended spindles, indicators shall be fitted both to the extended spindles and to the valve spindles. Plastic or bakelite valve hand wheels will not be accepted. All valves shall be closed by rotating the hand wheel in a clockwise direction when looking at the faces of the hand wheel. The face of each hand wheel shall be clearly marked with the words 'Open' and 'Shut' with arrows adjacent to indicate the direction of rotation to which each refers. Wherever practicable heavy valves of total weight including actuator, drive motor, integral by-pass etc., equal to or greater than 500 kg. shall be provided with suitable lugs to permit direct suspension by hanger rod or direct resting on bottom support, as applicable. Special attention shall be given to the operating mechanism for large size valves in order that quick and easy operation is obtained and maintenance is kept to a minimum. Eyebolts shall be provided where necessary to facilitate handling heavy valves or parts of valves. The Bidder shall supply with his bid and in addition during the course of the Contract, comprehensive drawings showing the design of valves, test pressure and working pressure/temperatures. They should include a parts list referring to the various materials used in the valve construction. All sampling and root valves shall be of integral body bonnet type.
t)
u) v)
w) x)
y)
z)
aa)
bb)
cc)
V.IID/S-II : 9
57
DCPL-K8A07 4.05.02 4.06.00 For Design Requirements for different valves refer Annexure-II & III. Safety/Relief Valves Safety/Relief valves shall be of direct spring loaded type and shall have a tight, positive and precision closing. All safety valves shall be provided with manual lifting lever. Valves used for air and any other compressive fluid shall be of pop type. Safety/Relief valves shall be constructed and adjusted to permit the fluid to escape without increasing the pressure beyond 10% above the set blow off pressure. Valve shall reset at a pressure not less than 2.5% and more than 5% of the set pressure. Releasing capacity of the safety/relief valves shall be as per the applicable codes and standards and shall be subject to the approval of the Owners Engineer/Consultant. The seat and disk of safety valves shall be of suitable material to resist erosion. The seat of valve shall be fastened to the body of the valve in such a way that there is no possibility of the seat lifting. 4.07.00 4.07.01 Hosepipe and Accessories Hose valves for service water system shall be Gate valves and service air system shall be Globe valves. Hose pipes with fittings for Service Water System: a) b) c) The water hose shall be as per IS-444 (Type-3). Length of each hose shall be 15 metres. For each hose, one end shall be fitted with M.S. female coupling with swiveling nuts and soft seating ring suitable for connection to male end of hose valve and other end shall be made threaded for joining with the swiveling nut of a second hose whereby two hose lengths may be joined.
4.07.02
4.07.03
Hose pipes with fittings for Compressed air System a) b) The compressed air hose shall be as per IS-911 (Type 2). The length and type of each end shall be similar to as specified in above clause no. (n) above.
V.IID/S-II : 10
58
DCPL-K8A07 5.00.00 5.01.00 DRAWINGS, DATA, INFORMATION & MANUALS Drawings, data, Information to be furnished by the Bidder besides those already mentioned in volume : II with the offer. A complete list of all piping and fittings of various sizes with their quantities and details e.g. nominal size, O.D., I.D. (as applicable) thickness, design pressure, design temperature, material of construction/code/standards etc. A complete list of all valves with their type, quantities & ratings. Manufacturer's catalogue indicating complete range of available size and rating of pipes & fittings. Descriptive literature on the manufacturing process and quality control procedures highlighting the manufacturing, fabricating and testing facilities available in the shop. After Award of Contract Detail drawings including fabrication drawings of all shop fabricated piping system indicating design parameters and complete bill of material (Relevant Standards and grades to be indicated) and information/data pertaining to the hydrostatic and non-destructive test requirements to be submitted progressively. 5.02.01 Detail dimensioned drawing of each valve, specialties, indicating tag no., pressure rating, manufacturing standard, the bill of materials and hydrostatic test pressures. The drawing shall include the end preparation details and shall indicate the position of the hand wheel/operator. Technical particulars of motor operators wherever applicable shall also be indicated. General arrangement drawing for each hanger/support/anchor etc. indicating identification number, auxiliary supporting structural details, other details & information as required in the specification. Wiring diagram for all limit switches of motor operated valves. The loading data required for design of structures shall be furnished well in advance to suit Purchaser's time schedule.
5.01.01
5.01.02 5.01.03
5.01.04
5.02.00
5.02.02
5.02.03 5.02.04
6.00.00
BROAD GUIDELINES FOR ERECTION AND INSTALLATION OF LP PIPING All fittings like "T" pieces, flanges, reducers etc. shall be suitably matched with pipes for welding. The valves will have to be checked, cleaned or overhauled in full or in part before erection, after chemical cleaning and during commissioning.
6.01.00
V.IID/S-II : 11
59
DCPL-K8A07 6.02.00 Adjustments like removal of oval ties in pipes and opening or closing the fabricated bends of high pressure piping to suit the layout shall be considered part of work and the Erection contractor is required to carry out such work as per instruction of Contractor/Owner, which shall include specified heat-treatment procedures, etc. also wherever required. Certain adjustments in length may be necessary while erecting high pressure pipelines and the Erection contractor should remove the extra lengths to suit the final layout after preparing edges afresh and adopting specified heat treatment procedures. Suspension for piping, pressure parts, etc., will be supplied in running lengths, which shall be cut to suitable sizes and adjusted as required. All the valves, lifting equipments, actuators, power cylinders, etc., shall be serviced and lubricated to the satisfaction of Owner before erecting the same and also during pre- commissioning. Even after commissioning, the equipments, if there are problems in the operation, they have to be attended to by the Bidder during the tenure of the contract. Welding or jointing of extension spindle for valves to suit the site conditions and operational facility shall be part of erection work. All tubes and pipes shall be cleaned and blown with compressed air and shown to the engineer before lifting. Bigger size pipes should be cleaned with flexible wire brush, wherever necessary. After cleaning is over the end caps shall be put back in tube openings till such time they are welded to other tubes. Fine fittings, drain piping, oil systems & other small bore piping have to be routed according to site conditions and hence shall be done only in position. As such, layout of small-bore piping shall be done as per site requirement. There is a possibility of slight change in routing the above pipelines even after completion of erection, which shall be carried out by the Contractor without any extra cost to the Owner. Work shall also include fabrication of small bends at site from straight lengths to suit the site conditions. No temporary supports shall be welded on the pressure parts. Welding of temporary supports, cleats, etc., on the building columns shall also be avoided. In case of absolute necessity, Erection contractor shall take prior approval from Contractor/Owners Engineer. Further, any cutting or alteration of member of the structure or platform or other equipments shall not be done without specific prior approval of Owners Engineer/Consultant. Wherever piping erected by the Erection Contractor is connected to piping or equipment erected by some other agencies the joint at the connecting point shall be considered under this specification.
6.03.00
6.04.00
6.05.00
6.06.00
6.07.00
6.08.00
6.09.00
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DCPL-K8A07 6.10.00 a) All piping shall be grouped wherever practicable and shall be routed to present a neat appearance. The piping shall be arranged to provide clearance for the removal of equipment for maintenance and for easy access to valves, instruments and other piping accessories required for operational maintenance. Piping shall be routed above ground unless otherwise specifically indicated/ approved by the Owners Engineer/Consultant. In such special case, the piping may be arranged in trenches, or buried and properly protected as per AWWA Standards. Overhead piping shall have a minimum overhead clearance of 4 meters above walkways and working areas and 6 meters above roadways unless otherwise approved by the Owners Engineer/Consultant Drains shall be provided at all low points and vents at high points as per actual layout regardless of whether some have been shown in respective drawings or not. The pipelines shall be sloped towards the drain points.
b)
c)
d)
e)
6.11.00
All drips and drains for piping and equipment whether shown in the drawings or not shall terminate on the ground floor up to station drain unless otherwise specified. Leading such drains up to station drainage is also the responsibility of the Contractor.
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TITLE: TECHNICAL SPECIFICATION FOR CONDENSATE POLISHING UNIT 2X500 MW, SAGARDIGHI TPP EXTN PROJECT, STAGE II, UNITS 3 & 4
SPEC. NO. PE-TS-373-155-A001
TECHNICAL SPECIFICATION FOR METERING PUMPS
PAGE:
62
SPEC. NO. PE-TS-373-156-A001
1.00.0 GENERAL 1.01.01 Specification cover the design, material, construction features, manufacture, inspection, testing the performance at the vendor's/subvendor's works, delivery to site, erection, commissioning and testing of metering pumps. 2.00.0 GENERAL DESIGN FEATURES
2.00.01 Pumps shall be simplex positive displacement hydraulically operated diaphragm design, driven by squirrel cage induction motor through suitable speed reduction unit. Maximum pump stroke speed shall not exceed 100 per minute. 2.00.02 The stroke shall be continuously adjustable to give a capacity variation 0100% range while the pump is running or stopped. Adjustment of capacity shall be done by manual control facility (micrometric adjusting type) to be provided locally for each of the pump. The stroke shall be continuously adjustable to give a capacity variation 0100% range while the pump is running or stopped. Adjustment of capacity shall be done by manual control facility (micrometric adjusting type) to be provided locally for each of the pump. Capacity variation may be effected by changing eccentricity of the driving crank or by suitable hydraulic circuit. Pump accuracy shall be industry standard 1% of capacity setting. Pumps shall be provided with an integral relief valve, spring operated to release pressure when delivery line blockage occurs. Crankcase shall be constructed of high quality cast iron, which will also house the gearbox and guides of cross head. Guided, controlled travel, doubleball check valves or equivalent, shall be provided both on the suction and discharge side. Material of construction of the various parts shall be as per the details furnished elsewhere in the specification. However all parts coming in contact with acid shall be of Haste alloy 'B' and for alkali it should be of SS316 only. Suitable gland seal shall be provided to prevent leakage. Electric drive motor particulars should follow enclosed electrical chapters.
2.00.03
2.00.04
2.00.05
2.00.06
2.00.07
2.00.08
2.00.09 2.00.10
3.00.00 TESTING 3.01.00 Testing and Inspection at Manufacturer's Works 3.01.01 The manufacturer shall conduct all tests required to ensure that the equipment furnished conforms to the requirements of this Specification and is in compliance with requirements of the applicable codes. The particulars of the proposed tests and the procedures for the tests shall be submitted to Owner for approval before conducting the tests.
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SPEC. NO. PE-TS-373-156-A001
3.01.02 The Owner's representatives shall be given full access to all tests for which the Manufacturer shall inform the Owner allowing adequate time so that if the Owner so desires, his representatives can witness the test. 3.01.03 All materials and castings used for the equipment shall be of tested quality. The test certificates shall be made available to Owner. 3.01.04 The pump casing shall be hydraulically tested at 200% pump operating pressure or 150% of design pressures whichever is higher. The test pressure shall be maintained at least for an hour. 3.01.05 The rotating parts of pump drive shall be subjected to static balancing. 3.01.06 All pumps shall be tested at the shop for capacity, volumetric accuracy, repetitive accuracy, power and volumetric efficiency. The tests are to be done according to the requirements of API 675. 3.01.07 The pump accessories e.g. gear box, speed reduction unit etc. will be subjected to tests as per manufacturer's standards. The test results shall be furnished to the Owner. 3.01.08 The combined variation of the pump and motor should be restricted within limits specified by Hydraulic Institute Standard, USA when the pump operated singly or in parallel. 3.01.09 All pumps shall be subject to strip down examination visually to check for mechanical damages after performance testing at shop. 3.01.10 Diaphragm of the metering pump shall be type tested as per applicable code/standard. 3.01.11 Performance test shall be carried out for the setting of pressure relief valve. 3.01.12 Test reports and certificates of all the abovementioned tests to ensure satisfactory operation of the system shall be submitted to the Owner for approval before dispatch. 3.02.00 Test at Site After erection at site, pumps, as detailed under different groups, shall be operated to prove satisfactory performance as individual equipment as well as a system. If the performance at site is found to be not to the requirements, then the equipment shall be rectified or replaced by the Vendor at no extra cost to the Owner.
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SPEC. NO. PE-TS-373-156-A001
SECTION D2 DESIGN REQUIREMENTS ELECTRICAL
PAGE:
65
DCPL-K8A07
VOLUME : IIF/1 SECTION-II TECHNICAL SPECIFICATION FOR A.C. & D.C. MOTORS
1.00.00 1.01.00
SCOPE This section covers the general requirements of all the HT & LT AC drive motors and DC motors for Main Plant auxiliary equipments. Motors shall be furnished in accordance with both this general specification and the accompanying driven equipment specification. In case of any discrepancy, the driven equipment specification shall govern.
1.02.00
1.03.00
2.00.00 2.01.00
STANDARDS All motors shall conform to the latest applicable IS, IEC and CBIP Standards/Publications except when otherwise stated herein or in the driven equipment specification. Major standards, which shall be followed, are listed below other applicable Indian Standards for any component part even if not covered in the listed standards shall also be followed: IS-325 IS-12615 (Efficiency Class eff 1) IS-3177 IS-4722 IS-2148 IEC-34
2.02.00
3.00.00 3.01.00
SERVICE CONDITIONS The motors will be installed in hot, humid (relative humidity 95%) and tropical atmosphere, highly polluted at places with coal dust and/or fly ash.
(PCA.CD-003.E803ELE2_MOTOR)
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DCPL-K8A07 3.02.00 Unless otherwise noted, electrical equipment/system design shall be based on the service conditions and auxiliary power supply given in the annexure to this specification. For motor installed outdoor and exposed to direct sunrays, the effect of solar heat shall be considered in the determination of the design ambient temperature.
3.03.00
4.00.00 4.01.00 4.01.01
TYPE AND RATING A.C. Motors Motors shall be general purpose, constant speed, squirrel cage, three/single phase, induction type. Crane duty motors shall be slip ring type induction motor. All motors shall be rated for continuous duty. They shall also be suitable for long period of inactivity. However, crane motors shall be rated for S4 duty i.e. 40% cyclic duration factor. The motor name-plate rating at 50qC shall have at least 10% margin over the input power requirement of the driven equipment at rated duty point and also covering the maximum load demand of the driven equipment under entire operating range, including voltage and frequency variations, unless stated otherwise in driven equipment specification or in general electrical specification. The motor characteristics shall match the requirements of the driven equipment so that adequate starting, accelerating, pull up, break down and full load torques are available for the intended service. D.C. Motors D.C. motor provided for emergency service shall be shunt/compound wound type rated for 220V DC and shall be fed DC starter panel. Motor shall be sized for operation with fixed resistance starter for maximum reliability.
4.01.02
4.01.03
4.01.04
4.02.00 4.02.01
4.02.02
5.00.00 5.01.00 5.01.01
PERFORMANCE Running Requirements Motor shall run continuously at rated output over the entire range of voltage and frequency variations as given in the annexure. The motor shall be capable of operating satisfactorily at full load for 5 minutes without injurious heating with 75% rated voltage at motor terminals.
5.01.02
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DCPL-K8A07 Starting Requirements Motor shall be designed for direct on line starting at full voltage. Starting current shall not exceed 6 times of full load current plus IS tolerance for all auxiliaries except for motors rated above 200 kW and up to 1500kW which are to be fed from purchasers 3.3 kV System . For motors rated above 1500 kW, which are fed from purchasers 11kV system. The starting current for 11 kV & 3.3 kV voltage motors shall not exceed 4.5 times full load current plus IS tolerance. For D.C. Motors the starting current shall be limited to 2 times full load current. 5.02.01 The motor shall be capable of withstanding the stresses imposed if started at 110% rated voltage. All Motors except mill motors shall start with rated load and accelerate to full speed with 80% of rated voltage at motor terminals for motors upto 4000 kW & 75% of rated voltage for motors above 4000 kW. Mill motors shall start with rated load and accelerate to full speed with 85% of rated voltage at motor terminals for motors above 1000 kW & 90% of rated voltage for motors below 1000 kW. 5.02.03 a) The motor shall be capable of three equally spaced starts in an hour, the motor initially being at a temperature not exceeding the rated load operating temperature. The motor shall be capable of two starts in succession with coasting to rest between starts and the motor initially at rated operating temperature.
5.02.00
5.02.02
b)
5.02.04
Pump motor subject to reverse rotation shall be designed to withstand the stresses encountered when starting with non-energized shaft rotating at 125% rated speed in reverse direction. All motors shall be designed to ensure that maximum in rush currents and locked rotor as well as pull out torque developed by them at extreme voltage & frequency variations is not detrimental to the motor and its driven equipment. Stress During Bus Transfer The motor may be subjected to sudden application of 150% rated voltage during bus transfer, due to the phase difference between the incoming voltage and motor residual voltage. The motor shall be designed to withstand any torsional and/or high current stresses, which may result, without experiencing any deterioration in the normal life and performance characteristics.
5.02.05
5.03.00 5.03.01
5.03.02
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DCPL-K8A07 Locked Rotor Withstand Time The locked rotor withstand time under hot condition at 110% rated voltage shall be more than motor starting time by at least 2.5 seconds for motors upto 20 seconds starting time and by 5 seconds for motor with more than 20 seconds and upto 45 seconds starting time. For motors with starting time more than 45secs. at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be more than starting time by at least 10% of the starting time. Speed switches mounted on the motor shaft shall be provided in cases where above requirements are not met. 5.04.02 Starting time mentioned above is at minimum permissible voltage of 80% rated voltage. Hot thermal withstand curve shall have a margin of at least 10% over the full load current of the motor to permit relay setting utilising motor rated capacity. Torque Requirements a) Accelerating torque at any speed with the lowest permissible starting voltage shall be at least 10% motor full load torque. Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall be 275% for crane duty motors.
5.04.00 5.04.01
5.04.03
5.04.04
b)
6.00.00 6.01.00 6.01.01
SPECIFIC REQUIREMENTS Enclosure All motor enclosures shall conform to the degree of protection IP-54 for indoor motors and IP-55 for outdoor, unless otherwise specified. Motor for outdoor or semi-outdoor service shall be of weather-proof construction. A separate Canopy shall be provided for motors located in outdoor & semi-outdoor areas. The degree of protection for cable box shall be IP-54 for indoor area and IP-55 for outdoor area.
6.01.02
Motors of large output ratings, located indoor and not directly exposed to coal dust or fly ash, could have screen protected drip proof enclosure conforming to IP23. For hazardous area approved type of increased safety enclosure shall be furnished with flameproof construction conforming to IS 2148 as detailed below:
6.01.03
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DCPL-K8A07 a) b) Fuel oil area Hydrogen generation plant area : : Group IIB Group IIC (or Group-I Div-II as per NEC)
6.02.00 6.02.01
Cooling The motor shall be self ventilated type, with TEFC / CACA / CACW/ TETV cooling, depending on requirement and rating. For large capacity motors rated 3000kW or above, closed air circuit water cooled (CACW) may be considered for acceptance.
6.02.02
6.02.03Temperature Rise i) Air cooled motors 70C by resistance method for both class 130(B) and 155(F) insulation. Water cooled motors 80C over inlet cooling water temperature, by resistance method for both class 130(B) and 155(F) insulation.
ii)
6.03.00 6.03.01 6.03.02
Winding and Insulation All insulated winding shall be of copper. 11000V and 3300V motors shall have class 155(F) insulation but limited to class 130(B) temperature rise. They shall be capable of withstanding 1.2 / 50 sec switching surges of (4U + 5) kV, where U = Rated Voltage. The coil interturn insulation shall be as per IEC-60034 Part 15 followed by 1 min power frequency high voltage test of appropriate voltage on inter turn insulation. All other motors shall have class B insulation. Any substitution of class B insulation must be submitted to the Owner for approval. Windings shall be impregnated to make them non-hygroscopic, flame resistant and oil resistant. Tropical Protection All motors shall have fungus protection involving special treatment of insulation and metal against fungus, insects and corrosion. All fittings and hardwares shall be corrosion resistant. Bearings Motor shall be provided with antifriction bearings, unless sleeve bearings are required by the motor application.
6.03.03
6.03.04
6.04.00 6.04.01
6.04.02 6.05.00 6.05.01
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DCPL-K8A07 6.05.02 Vertical shaft motors shall be provided with thrust and guide bearings. Thrust bearing of tilting pad type (Mitchel or Kingsbury) is preferred. Bearings shall be provided with seals to prevent leakage of lubricant or entrance of foreign matters like dirt, water etc. into the bearing area. Sleeve bearings shall be split type, ring oiled, with permanently aligned, close running shaft sleeves. Grease lubricated bearings shall be prelubricated and shall have provisions for in-service positive lubrication with drains to guard against over lubrication. Oiled bearing shall have an integral self cooled oil reservoir with oil ring inspection ports, oil sight glass with oil level marked for standstill and running conditions and oil fill and drain plugs. Forced lubricated or water cooled bearing shall not be used without prior approval of Owner. Lubricant shall not deteriorate under all service conditions. The lubricant shall be limited to normally available types with IOC equivalent. For motors above 1000 kW, Bearings shall be insulated to prevent shaft current and resultant bearing damage. Noise & Vibration Noise level and vibration shall be limited within the limits prescribed in IS: 12065 and IS: 12075 respectively. The peak amplitude of the vibration shall be within IS specified limits. Motor Terminal Box Motor terminal box shall be detachable type and located in accordance with Indian Standards clearing the motor base- plate/ foundation Terminal box shall be capable of being turned 360 Deg. in steps of 90 Deg., unless otherwise approved. The terminal box shall be split type with removable cover with access to connections and shall have the same degree of protection as motor. The terminal box shall have sufficient space inside for termination/connection of XLPE insulated armoured aluminium cables. Terminals shall be stud or lead wire type, substantially constructed and thoroughly insulated from the frame.
6.05.03
6.05.04
6.05.05
6.05.06
6.05.07
6.05.08
6.05.09
6.06.00 6.06.01
6.06.02 6.07.00 6.07.01
6.07.02
6.07.03
6.07.04
6.07.05
V.II-F1/S-II: 6
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DCPL-K8A07 6.07.06 The terminals shall be clearly identified by phase markings, with corresponding direction of rotation marked on the non-driving end of the motor. The terminal box shall be capable of withstanding maximum system fault current for a duration of 0.25 sec. For 11000V and 3300V motor, the terminal box shall be either dust tight phasesegregated double walled type (metallic as well as insulated barrier) or elastomould terminations with protective cover and trifurcating sleeves. The neutral leads shall be brought out in a separate terminal box (not necessarily phase segregated type) with shorting links for star connection. Motor terminal box shall be furnished with suitable cable lugs and double compression brass glands to match the approved standard cable used. Removable gland plates of thickness 3 mm (hot/cold rolled sheet steel) or 4 mm (non magnetic material for single core cables) shall be provided in case of cable boxes. Grounding The frame of each motor shall be provided with two separate and distinct grounding pads on opposite sides complete with tapped hole, GI bolts and washer. The grounding connection shall be suitable for accommodation of ground conductors as follows: Motor above 90 KW Motor above 30 KW up to 90 KW Motor above 5 KW up to 30 KW Motor up to 5 KW 6.08.03 6.09.00 : : : : 50 x 6 mm GS Flat 35 x 6 mm GS Flat 25 x 3 mm GS Flat 8 SWG GI Wire
6.07.07
6.07.08
6.07.09
6.07.10
6.08.00 6.08.01
6.08.02
The cable terminal box shall have a separate grounding pad. Rating Plate In addition to the minimum information required by IS, the following information shall be shown on motor rating plate : a) b) c) d) Temperature rise in Deg.C under rated condition and method of measurement. Degree of protection. Bearing identification no. and recommended lubricant. Location of insulated bearings. V.II-F1/S-II: 7
72
DCPL-K8A07 7.00.00 7.01.00 ACCESSORIES General Accessories shall be furnished, as listed below, or if otherwise required by driven equipment specification or application. 7.02.00 7.02.01 Space Heater Motor of rating 30 KW and above shall be provided with space heaters, suitably located for easy removal or replacement. The space heater shall be rated 240 V, 1 phase 50 Hz and sized to maintain the motor internal temperature above dew point when the motor is idle. Temperature Detectors All11000 V and 3300 V motors shall have at least two numbers duplex type temperature detectors for each phase of stator winding. Each 11000 V and 3300 V motors bearing shall be provided with dial type thermometer with adjustable alarm contact and two numbers duplex type temperature detector. The temperature detector mentioned above shall be resistance type, 3 wire, platinum wound, 100 Ohms at 0qC. Leads of all duplex type motor winding RTDS and motor bearing RTDS shall be wired up to respective switchgear metering & protection compartment. From which one set of RTDS will be connected to numerical protection relay and another set shall be connected with DCS/Common Control Consoles. Indicator/Switch Watertight (IP 65) microprocessor based LCD/digital indicator with alarm contacts shall be provided for the following: a) b) 11000 V and 3300V motor bearing temperature. Hot and cold air temperature of the closed air circuit for CACA and CACW motor.
7.02.02
7.03.00 7.03.01
7.03.02
7.03.03
7.03.04
7.04.00 7.04.01
7.04.02
Flow switches shall be provided for monitoring cooling water flow of CACW motor and oil flow of forced lubrication bearing, if used. Motors with heat exchangers shall have dial type thermometer with adjustable alarm contacts to indicate inlet and outlet primary air temperature. Alarm switch contact rating shall be minimum 0.5 A at 220V D.C. and 5A at 240V A.C.
7.04.03
7.04.04
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DCPL-K8A07 7.05.00 7.05.01 Current Transformer for Differential Protection Motor above and including 2000 KW shall be provided with three differential current transformers of PS class on each phase mounted over the neutral leads in a separate neutral terminal box within the enclosure. The arrangement shall be such as to permit easy access for C.T. testing and replacement. Current transformer characteristics shall match with the requirements of differential protection relay. The bidder shall include additional CT for differential relay of identical characteristics to be supplied as loose for motor rating including and above 2000 kW. Accessory Terminal Box All accessory equipment such as space heater, temperature detector, current transformers etc., shall be wired to and terminated in terminal boxes, separate from and independent of motor (power) terminal box. Accessory terminal box shall be complete with double compression brass glands and pressure type terminals to suit for cable connections. Drain Plug Motor shall have drain plugs so located that they will drain the water, resulting from the condensation or other causes from all pockets of the motor casing. 7.08.00 Lifting Provisions Motor weighing 25 Kg. or more shall be provided with removable type eyebolt or other adequate provision of lifting. 7.09.00 Dowel Pins The motor shall be designed to permit easy access for drilling holes through motor feet or mounting flange for installation of dowel pins after assembling the motor and driven equipment. 7.10.00 Painting Motor including fan shall be painted with corrosion proof paints as per RAL 5012 (Blue).
7.05.02
7.06.00 7.06.01
7.06.02
7.07.00
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DCPL-K8A07 8.00.00 8.01.00 TESTS The bidder shall carry out type tests for H.T. motors as per clause 8.03.00. The type tests shall be carried out in presence of Owners representative, for which minimum fifteen (15) days notice shall be given by the bidder. The bidder shall obtain owners approval for the type test procedure prior to performance of tests. The type test procedure shall specify test set-up, instruments to be used, acceptance norms, recording of various parameters , interval of recording, precautions to be taken etc .Upon completion, each motor shall be subject to standard routine tests as per IS. In addition, any special test called for in the driven equipment specification shall be performed. Type test certificate not more than 5 years old for all Motors shall be furnished for approval. Type test certificate on any equipment, if so desired by the owner, shall be furnished. Otherwise, the equipment shall have to be type tested, free of charge, to prove the design. The following type tests shall be performed on a representative sample of 11000V and 3300V motor of each type & rating, even if type test certificates of these tests are submitted by the Bidder for Purchaser's approval: a) Measurement of stator resistance (and rotor resistance on slip ring motors). No load running of motor and reading of voltage, current, power input and speeds. Locked rotor reading of voltage, current, power input and values of torque of motor. Full load reading of voltage, current, power input and slip. Temperature rise test. During heat run test, bearing temperature, winding temperature, core temperature, coolant flow and its temperature shall be recorded. In case temperature rise test is carried at any load other than rated load, specific approval for test procedure and method has to be obtained.
8.02.00
8.03.00
b)
c)
d) e)
Type test certificates for tests other than those specified above, and as per relevant IS / IEC has to be furnished for owners review. 8.04.00 Upon completion, each motor shall be subject to standard routine tests as per IS. In addition, any special test called for in the driven equipment specification shall be performed.
V.II-F1/S-II: 10
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DCPL-K8A07 9.00.00 DRAWINGS, DATA & MANUALS Drawings, data & manuals for the motors shall be submitted as indicated below : 9.01.00 Along with the bid a) b) c) d) 9.02.00 List of the motors Individual motor data sheet as per format of the proposal data sheets. Scheme & write up on forced lubrication system, if any Type test report
After Award of the Contract a) b) c) d) e) f) g) h) i) Dimensional General Arrangement drawing Foundation Plan & Loading Cable end box details Space requirement for rotor removal Thermal withstand curves hot & cold Starting and speed torque characteristics at 80% & 100% voltage Complete motor data Erection & Maintenance Manual Test reports
V.II-F1/S-II: 11
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DCPL-K8A07 ANNEXURE-A
DESIGN DATA
1.0
SERVICE CONDITIONS Refer Clause no 3.00.00 of Sec-I, Vol-II F of Specification.
2.0
AUXILIARY POWER SUPPLY Supply H.T. Supply Description 11000 V, 30 / , 3W, 50 Hz non-effectively earthed Consumer Motors above 1500 KW and also LT Transformer (11kV / 433 V) Motors above 200 KW and upto 1500 KW
3300 V, 30 / , 3W, 50 Hz non-effectively earthed Fault level 40 KA symm. for 1 second.
11kV & 3.3kV system shall be earthed through resistance to limit the current to 300A or high resistance grounding through artificial earthing transformer and resistance.
L.T. Supply
415V, 30 / , 3W, 50 Hz effectively earthed Fault level 50 KA symm. for 3 seconds.
Motors above 200W to 200 KW
240V, 10 / , 2W, 50 Hz effectively earthed
Motors up to 200W, Lighting, space heating, A.C. control & protective devices D.C. alarm, control
D.C. Supply
220V, 2W, unearthed & protective devices Unearthed system Fault level 25* KA for 1 second.
Indicative only; actual value to be decided by the bidder and to be substantiated by calculation.
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DCPL-K8A07 ANNEXURE-A RANGE OF VARIATION A.C. Supply Voltage : 6 % for 11kV & 3.3kV 10 % for 415V + 3% and 5 % 10 % (absolute sum)
3.0
Frequency Combined Volt & frequency
: :
During starting of large motor, the voltage may drop to 80% of the rated voltage for a period of 60 seconds. All electrical equipment, while running, shall successfully ride over such period without affecting system performance. D.C. Supply Voltage : 198 to 240 Volt
V.II-F1/S-II: 13
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SPEC. NO. PE-TS-373-156-A001
SECTION D3 DESIGN REQUIREMENTS CONTROL AND INSTRUMENTATION
PAGE:
79
C&I SPECIFICATION FOR CW TREATMENT PLANT FOR 2 X 500 MW SAGARDIGHI
80
SPECIFIC REQUIREMENTS:
1) The control for CW TREATMENT PLANT shall be realized in Hot redundant PLC based control system (in vendor scope). 2) The valve actuator shall be without Integral starter. 3) All instruments shall be terminated on JB/LCP in field and both instrument and JB/LCP are in vendor scope. 4) For scope of cables, refer electrical section of specification. 5) The solenoid valve shall have limit switches for open/close feedback. 6) The junction boxes for termination of instruments /actuators LS/Solenoid valve LS and any other local panel or remote I/O Panel required are in vendors scope. 7) Vendor shall furnish all C&I related engineering documents mentioned in next page during detail engineering stage. 8) Relevant Pages of drive control philosophy are enclosed in the document as reference for interfacing of PLC with various drives. 9) For details of the control system (including requirements of HMI) and configuration diagram refer to the Control and operation of the CW TREATMENT Plant section of the specification. 10) Suitable DCS interface for monitoring shall be provided by Vendor. Fibre optic cable for DCS connectivity is excluded from Vendors scope. However, necessary hardware for interfacing (LIUs etc.) at PLC end shall be in vendors scope.
81
82
FORM NO. PEM-6666-0
SPECIFICATION NO.:
SPECIFICATION FOR CONTROL & INSTRUMENTATION FOR AUX PACKAGES
VOLUME
II B
SUB SECTION D1 REV. NO. SHEET DATE : OF
GENERAL REQUIREMENT 1.0 Bidder shall provide complete and independent control & instrumentation system with all
accessories, auxiliaries and associated equipments for the safe, efficient and reliable operation of auxiliary systems
2.0 The quantity of instruments for auxiliary system shall be as per tender P &ID wherever provided
of the respective system as a minimum, for bidding purpose. However, Bidder shall also include in his proposal all the instruments and devices that are needed for the completeness of the plant auxiliary system/ equipment supplied by the bidder, even if the same is not specifically appearing in the P & ID. During detail engineering if any additional instruments are required for safe & reliable operation of plant, bidder shall supply the same without any price implication.
3.0 Measuring instruments/equipment and subsystems offered by the bidder shall be from reputed
experienced manufacturers of specified type and range of equipment, whose guaranteed and trouble free operation has been proven. Further all the instruments shall be of proven reliability, accuracy, and acceptable international standards and shall be subject to employers approval. All instrumentation equipment and accessories under this specification shall be furnished as per technical specification, ranges, makes/ numbers as approved by the employer during detail engineering
4.0 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve manifold and
all the other accessories required for mounting/ erection of these local instruments shall be furnished, even if not specifically asked for, on as required basis. The contacts of equipment mounted instruments; sensors, switches etc for external connection including spare contacts shall be wired out to suitably located junction boxes.
83
DCPL-K8A07
VOLUME : IIE SECTION-VI TECHNICAL SPECIFICATION INSTRUMENTS AND SYSTEMS
1.00.00
FIELD INSTRUMENTS This section provides general guidelines for field instruments and equipment to be supplied under this specification. All measuring instruments/equipment and subsystems offered by Bidder shall be from reputed experienced manufacturer of specified type and range of equipment, whose guaranteed and trouble free operation has been established. All instruments/equipment shall be of proven reliability, accuracy, repeatability requiring a minimum of maintenance and comply with the acceptable international standards. All instruments/equipment and accessories shall be supplied as per technical specifications, ranges, make as approved by Owner during detailed engineering. i) Bidder shall provide a dedicated and standalone PC based HART Management system with suitable interface to DDCMIS system for each of the units for centralised configuration, maintenance, diagnostics & record-keeping for all electronic transmitters.
ii) The analog input modules in the Control System will use 4-20 mA analog signals and segregate the superimposed digital signal to be used in the PC based system referred above. The PC based system shall access these information either through the system bus or through any dedicated network as per Bidder's standard practice. iii) Bidder shall provide following facilities as a minimum through software: a) Constant scanning to monitor faults of changes to instrument configuration. b) Owner-defined and standard calibration and configuration procedures for all transmitters. c) Constant signal data collection facilities to maintain continuously updated records. d) Automatic tracking of configuration changes made in the field, such as may be introduced by hand-held communicator. All configuration function associated with hand-held communicators shall be available in the system. e) Event and log reports on screen as well as on printer. f) Any addition/deletion of transmitter will be reported on printer and logged in hard disk.
(PCA.CD-003.I801CI6)
V.II-E/S-VI : 1
84
DCPL-K8A07
09.
Accessories
Slip-on orifice plate of 316-SS and taps of CS / SS as per application. Applicable CS / SS Isolation valves and SS Range Orifice - for bypass type rotameters. IP- 55.
10. 1.08.00
Housing protection class
PRESSURE GAUGE AND DIFFERENTIAL PRESSURE GAUGE 01. 02. 03. 04. 05. 06. Type MOC Sensing & Socket Movement Material Case Material Dial Size Scale : : : : : : Bourdon/Bellows/Diaphragm AISI-316 SS AISI-304 SS Stainless steel. Enclosure IP-55. 150 mm Black lettering on white background in 270 Deg. arc. Shatterproof glass Normal process pressure 50 ~ 70 % of range (approximately). 125% of maximum range by internal stop. External stop at zero Micrometer screw for zero adjustment. Internal micrometer screw for range adjustment. External zero adjustment for glycerine filled gauges. Argon welding 1/2" NPT(M) Bottom connection for local mounting, back connection for panel mounting. Accuracy of r 1.0 % of span or better. 0 - 50OC Blow out disc./diaphragm at the back a) Snubbers and Glycerin filled for pulsating fluid applications and at pump discharge.
07. 08.
Window Range Selection
: :
09.
Over-range Protection
10.
Adjustment
11. 12.
Element Connection Process Connection
: :
13. 14.
Performance Operating ambient temperature Safety Feature Accessories
: : :
15. 16.
V.II-E/S-VI : 10
85
DCPL-K8A07 b) Stainless steel Diaphragm seals for corrosive, viscous and solid-bearing or slurry type process fluids. 3-Way stainless steel Gauge cock for pressure gauges. Prcoess connection NPT. 5-valve SS316 manifold constructed from barstock for differential pressure gauge. Process connection NPT. Union, nut & tail piece and other Installation accessories as required. Syphons for steam and hot water services.
c)
d)
e) f) 17. 18. 1.09.00 Applicable standard Nameplate : :
IS-3624 / 1996 Tag number, service engraved in stainless steel tag plate
TEMPERATURE GAUGE 01. 02. 03. 04. 05. 06. 07. 08. Type Sensing Element Material Capillary Armoring Movement Material Bulb / Stem Diameter Bulb / Stem Material Capillary Thermometer connection to well Case Material Dial Size Scale : : : : : : : : Mercury or gas filled remote mounting system. Bourdon - AISI-316 SS Stainless steel flexible AISI 304 SS 12 mm AISI 316 Stainless Steel NPT
09. 10. 11.
: : :
Stainless steel 150 mm in general (100 mm for SWAS gauges) Black lettering on white background in 270 Deg. arc. Surface/Panel 125 % of range or more Bottom connection for local mounting and back connection for panel mounting.
12. 13. 14.
Mounting Over range Protection Instrument connection
: : :
V.II-E/S-VI : 11
86
DCPL-K8A07 03. 04. 05. 06. Bulb Material Capillary Movement Material Case material : : : : AISI SS-316 Stainless steel armoured AISI SS-304 Epoxy coated steel plate or die-cast aluminum alloy with neoprene gasket and clear glass where applicable cover conforming to IP-55. (Explosion proof for NEC Class-1, Division 1 area). Black lettering on white background 120 % Bottom Two SPDT 240V, 5A AC/220V, 0.5A DC Snap acting, shock and vibration-proof. Internal Set point adjustable over span range Plug in socket a) Capillary compensation with invar wire throughout the capillary length. Case compensation
07. 08. 09. 10. 11. 12. 13. 14. 15.
Scale Over range Protection Instrument connection Switch configuration Switch rating Switch type Adjustability Elect connection Compensation
: : : : : : : : :
b) 16. Performance : i) ii) iii) 17. Scale Accuracy Repeatability Response time : : : :
r 1.0 % of full scale < 0.5 % of full range Less than 40 seconds with thermowell 5 meters (minimum) for local mounting/15 meters for local panel mounting. Tag number, service engraved in stainless steel tag plate Thermowell from SS barstock, accessories, NPT cable gland. Mounting
Capillary length
18.
Nameplate
19.
Accessories
1.15.00
LEVEL SWITCH 01. Type : External cage float operated. Magnetically coupled.
V.II-E/S-VI : 18
87
DCPL-K8A07 02. Float Material 03. Other wetted parts 04. External Cage : : : AISI-316 stainless steel or better AISI-316 stainless steel or better Carbon steel / Stainless steel or better as per process requirements, welded type / flanged construction. Cage pressure rating shall equal or exceed the rating of the main vessel.
05.
External cage mounting
Side-Side.
06.
External cage connection Switch housing
: :
25 NB socket welded. Epoxy coated die-cast aluminum alloy with neoprene gasket conforming to IP-55. (Explosion proof for NEC Class-1, Division 1 area). 2 SPDT (two nos.) 5A, 240V/AC, 0.25A, 220V DC a) b) c) d) e) Counter flange, nuts & bolts, suitable gasket etc. Steel globe type drain valve. NPT cable gland Stainless steel alpha-numeric engraved for service and tag. Globe drain valve
07.
08.
Type of switch configuration Contact rating Accessories
: : :
09. 10.
11. 12. 1.16.00
Preferred feature Mounting
: :
Switch operating point marked on cage On standpipe
CONDUCTIVITY TYPE LEVEL SWITCH 01. Type : : : : : Conductivity discrimination. Drain pots viz. on CRH line Flanged on external cage. Stainless steel with high purity ceramic. > Maximum design pressure of vessel.
02. Application 03. 04. 05. Mounting Probe MOC Probe rating
V.II-E/S-VI : 19
88
DCPL-K8A07 08. Accessories : Flanges, gaskets, nuts & bolts, root valves (1 316 SS globe) jack screw, meter run pipe, Drain & vent hole as per application etc.
NOTE: One flow element of each type shall be calibrated in the test laboratory for validation of computed flow calculations.
1.23.00
FLOW NOZZLE 01. 02. 03. 04. 05. Application Design Standard Tapings Diameter Ratio Material : : : : : High fluid velocity flow measurement ASME PTC 19.5 D and D/2 ( Numbers as required plus one additional pair of taps) Between 0.4 and 0.7 316 SS (321 SS for high temperature)
05. 06. 07. 08.
Thickness Document Meter run pipe Accessories
: : : :
Suitable for the application Beta ratio calculation, assembly drawing and Flow vs. DP curve. Same as pipe material Meter run pipe, nipples and root valves (1 316 SS globe).(Inspection port assembly for nozzles used in plant performance purpose)
NOTE: One flow element of each type shall be calibrated in the test laboratory for validation of computed flow calculations. 1.24.00 GAUGE GLASS 01. 02. 03. 04. 05. 06. Type Glass Body material Pressure rating Temperature rating Bolts and nuts : : : : : : Reflex Toughened borosilicate. Resistant mechanical and thermal shocks. to
Carbon steel / stainless steel- As per process requirements (Flanged Connection) Twice the maximum working pressure 300O C Rust proof alloy steel
V.II-E/S-VI : 25
89
DCPL-K8A07 07. Accessories : Suitable ball check valves of SS-304/316 body, gaskets, companion flange etc.
1.25.00
LEVEL GAUGE (FLOAT & TAPE)
01. 02. 03. 04. 05. 06. 07.
Type Float & Tape MOC Pulley material Guide wire Accuracy Indication Rating
: : : : : : :
Float and Tape AISI 316 Aluminium SS 316 Stainless steel +/- 2 mm On circular or vertical dial Twice the design pressure
1.26.00
POWER CYLINDERS (PNEUMATIC) 01. Mounting Type : : 02. Control Signal : a) b) Fixed position mounting (End mounting). Trunnion mounting
4-20 mA DC to smart positioner with HART protocol for modulating purposes. 24V/48VDC operated solenoid valve operating on pneumatic line for open & closing purpose of on & off drive. 0-7 Kg / Cm2. Based upon thrust / torque, stroke length, angular movement, full-scale travel time, repeatability, space factor etc. Provision for air-to-open and air-to-close operation. IP-55. a) Air lock relay b) Hand wheel. c) Air filter regulator with gauge. d) Volume Booster. e) Limit Switches. f) Smart Positioner with integral I-P convertor, feedback position Transmitter (4-20 mA DC
03. 04.
Supply Air Selection
: :
05. 06.
Casing Accessories (as required)
: :
V.II-E/S-VI : 26
90
DCPL-K8A07 06. Binary Output 07. : Contact relay outputs, 2 NO + 2 NC for alarm RS 232 C digital Hand held terminal port Flow meter with LCD screen backlight based local display and keypad. If required, transmitter shall be suitably located away from the sensor for better access and visibility.
Communication ports :
08.
Display/Indication
09.
Recording / Totalizing / Logging Facilities :
Yes. Should be able to compute cumulative flow over intervals selectable by Owner i.e., daily, weekly, monthly etc. The data shall be stored in the memory of flow computer for access in future. Compensation for any cross path errors Programming, configuration, shall be possible from front panel. False signal tolerance , power supply failure etc IP-65 or better, Weather protection against direct sunlight, rain etc for Flow meter and suitable for Cooling water for Transducer. 1% Plug and socket Underground All mounting hardware required like clamping fixtures, mechanism to remove the transducers online, interconnecting cables etc. All weather canopy for protection from direct sunlight and direct rain. Material of all fittings shall be SS 316
10.
Software features
11.
Diagnostics
: :
12. Protection Class
13. 14. 15. 16.
Accuracy
Electrical connection : Pipe location Accessories : :
f)
Bidder shall submit certified flow calculation and differential pressure Vs. flow curves for each element for Owners approval. Sizing calculation, precise flow calculation for all the flow elements, fabrication and assembly drawings and installation drawings shall be submitted for Owners approval.
1.40.00
UPS (for offsite & plant auxiliary system) 01. Type : Packaged Unit, Solid-state SCR/ Transistor & Microprocessor controlled. power
V.II-E/S-VI : 37
91
DCPL-K8A07 02. 03. Duty Enclosure : : Continious Sheet steel, IP-42
04. 05. 06.
Transformer Inverter Inverter Capacity
: : :
Ferro-resonant Solid state pulse width modulated To be decided by the bidder on load calculation. 25% extra capacity margin to be considered. Microprocessor based. 220 Volt, Ni-Cd vented type, pocket plate high discharge battery of adequate capacity to meet the requirement of UPS, generally confirming to IS-10918 < 2% 400% Better than 5% Better than 3% 3000 : 1 Self correcting > 0.95 Frequency, Battery, input, output voltage & % load ON, on battery, low battery, self diagnostic malfunction alarm with SPDT potential free contacts rated at 230 VAC, 5A for each alarm.
07. 08.
Control Battery
: :
09. 10. 11. 12. 13. 14. 15.
Total harmonic distortion Harmonic attenuation Line regulation Load regulation Spike attenuation Power factor Metering display
: : : : : : :
16.
Status display
17.
Output a) Voltage b) Frequency c) Load Power factor d) Wave form Input a) Voltage b) Frequency c) Power Factor Battery back-up capacity
: : : :
240 V A.C, 50 Hz,1-phase +/- 1.0% 50 Hz(+/- 0.5%) 0.8% Sinewave
18.
: : :
180 V to 270 V A.C 45 to 60 Hz 0.92
19.
60 Minutes at full load
V.II-E/S-VI : 38
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DCPL-K8A07
20. 21. 22. 23
Charger Static switch Quantity Rating / Capacity
: : : :
Built-in Built-in As required 125% of System powering capacity
2.00.00 CLOSED CIRCUIT TELEVISION (CCTV) SYSTEM 2.01.01 Closed Circuit Television (CCTV) System with all equipment and accessories shall be installed for the purpose of surveillance of major Equipment & Plant areas e.g. Boiler Feed Pumps, ID Fans, FD and PA fans, Mills, Condensate Extraction Pumps and critical areas like Turbine hall, Firing floor, CW/ACW Pump House, Unit equipment room, AVR room, LT & HT switchgear rooms, Switchyard, Transformer yard, Central Control room (common for both units) at the Technical building, ESP Switch Gear Room,Owners Ash Handling Plant areas etc. so that, by and large, all important areas & equipment can be brought under surveillance. Also, cameras shall be installed at the Main Gate and other common auxiliary plants. Bidder shall make a detailed study of the system and submit his proposal. The CCTV system shall meet the specific functional & design requirements towards collecting live video information from the various operational areas of the power plant and displaying that information at respective control room DCS OWS and LVS cubes. Bidder shall include Digital Server based Video Manager, Camera unit, Video Streamer, Optical fiber network cables, Network hard wares , DCS connectivity hardwares & all other accessories including design / engineering, testing, erection & commissioning etc. for complete functioning of the system. Bidder shall consider licensed version of all application and system software required for the system. The Digital Video Server based CCTV System to be offered by Bidder shall be of proven design and of reputed make. Bidder shall furnish a proof indicating functioning of identical system in large fossil fired thermal power plants or in dust laden large industrial installation. Bidder shall also have to give warranty against satisfactory performance of the equipment under stipulated variations of voltage and frequency. Similar type of equipment shall be of same make & model; mixing of different make & model is not acceptable. Bidder shall submit block schematic of Power distribution and wiring diagram, CCTV network architecture drawing, hardware & software detail and other information as necessary along with the bid.
2.01.02
2.01.03
2.01.04
2.01.05
2.01.06
2.01.07
V.II-E/S-VI : 39
93
DCPL-K8A07 4.12.00 TESTS All valves shall be tested in accordance with the Quality Assurace Programme (QAP). Bidder shall submit QAP for Owners approval. The tests shall include but not be limited to the following : 01. Non destructive test as per ANSI B 16.34. 02. Hydrostatic shell test as per ANSI B 16.34 prior to seat leakage test. 03. Valve closure test and seat leakage test as per ANSI B 16.34 and as per the leakage class 04. Functional test : The fully assembled valves with actuator and all accessories shall be functionally tested to demonstrate from open to close position and vice versa. Valve lift shall be checked at 5 points at 0, 25, 50, 75 and 100% in both the directions with increasing and decreasing inputs. Performance of the valve with Positioner shall be as follows : a. b. c. d. e. f. Linearity : +/- 1% Hysteresis : +/- 1% Sensitivity : +/- 0.5% Deadband : +/- 1% Reproducibility : 0.3% of total stroke Overall accuracy : +/- 1%
05. CV test : Cv test shall be carried out as type test on each size, type and design of the valves as per ISA 75.02 standard and test report shall be submitted for Owners approval.
5.00.00 5.00.01
CONTROL DESK / PANEL / RACK Three dimensional Architectural design/ drawing of Central Control Room shall be developed by the owner on priority basis; bidder shall furnish above mentioned relevant drawings / data / documents well in advance for review & approval and necessary incorporation The material and construction details of the control desk/panels shall be as per the actual requirements and shall be finalized during detailed engineering. Convenient and logical approach to operational interfaces shall be considered to enhance aesthetics in the overall view of the control room..
5.00.02 5.00.03
For items susceptible to vibration, suitable rubber gaskets or padding shall be provided to prevent damage or malfunction. All items like MCB, Terminals, instruments, lamps etc. inside the panels/cabinets shall be neatly arranged with easy access/ maintenance approach to avoid undue disturbing the wiring. Power supply feeders shall be duplicated, so that a single failure shall not affect the operation of the unit. Required isolation & protection through MCB shall be provided in all cases. Alarm shall be provided against failure of a single power supply. V.II-E/S-VI : 71
94
5.00.04
DCPL-K8A07 5.00.05 5.00.06 5.00.07 5.00.08 Desk / panel shall be provided with interior illumination lamp with door switch, space heater with thermostat and 5A, 3 Pin receptacle with plug. Lamp, heater and receptacle circuits shall be suitable for available AC supply and furnished with individual ON-OFF switch. Panel / Desk shall have gland plate at cable entry to panel. Thickness of gland plate shall not be less than 3 mm. Panels / enclosure shall be provided with 20% spare terminals. In addition, the spare hot on rail mounted input output channels /modules shall be in fully wired & terminated condition for system cabinets. Wire shall be routed/laid in the covered PVC cable trough/tray. Nameplate a) b) c) d) 5.01.00 5.01.01 Nameplate shall be furnished for each instrument or device mounted on the panel/desk. The material shall be laminated phenolic, 3 mm thick with white letters on black background. The nameplates for panels / consoles shall be provided both on the front and the rear. Nameplates for all devices shall be located adjacent to the respective devices.
5.00.09 5.00.10
UNIT CONTROL DESKS All devices mounted on the control desks shall be flush type. Instruments / devices shall be so mounted that the removal and replacement can be accomplished individually without interruption of services to others. Aesthetic, argronomy and room illumination shall be considered while positioning of the desk, large video screen and panels in control room. Control desk shall be free standing floor mounting type table top design for placing computer monitor and other hardwares. Desk shall be of latest technology aesthetic design and constructed from aluminium with high density fiber. All operators TFTs & keyboards, emergency push buttons like MFT, Turbine trip & Unit trip, alarm annunciation PBs shall be mounted on the desk. Desk shall be arranged in arc like shape. Exact profile & shape shall be finalized during detailed engineering. The detailed technical specification of the control Desk shall be as per Cl. No. 5.01.08 Crating of the desks shall be suitable for protection against shock, vibration, inappropriate handling and inclement weather conditions during transportation and warehousing and all panel mounted equipment shall have adequate protection against damage during handling, transit and storage. Suitable desiccant shall be used inside the packing case. Suitable Pockets for placing telephone set and intercom set shall be provided on the desk.
5.01.02 5.01.03
5.01.04
5.01.05
V.II-E/S-VI : 72
95
DCPL-K8A07 5.01.06 Bidder shall provide permanent Modular type power receptacles of ISI standard each having five Plug points (15Amps rated) with individual isolation switches for powering the each OWS & other application terminals mounted on the Unit Control Desk. Temporary power spike busters are non-acceptable. Permanent I/O receptacles shall be provided in the Control desks for each of the HMI A minimum of two set of Alarm Accept/Reset Push Button shall be provided on each Control Desk. Technical Specification of Unit Control Desk i) The frame / structure should be minimum 2mm thick Powder Coated Extruded Aluminum profile. ii) The Table Top / Work Surface shall be 36mm thick, Medium Density Fiber (MDF) board with high pressure laminate or Acrylic Plastic Solid Surface (APSS).Top surface shall be finished with anti-scratch material. iii) The curvilinear angles shall be 4 - 10 degree.. iv) Foot extension shall be of Cast Aluminum & painted. v) Foot Leveler shall be injection molded glass filled nylon foot with steel insert. vi) END Caps & Extruded PVC Caps shall be provided where required. vii) Front edge shall be extruded PVC or rounded post-formed laminate viii) Concealed cable tray shall be powder coated steel. ix) Provision shall be made for keeping Multi-media speakers.. x) Design shall include Earthing bolts on left side end and right side end of the Workstation Desk / Rack. xi) Design should include cutouts for Push buttons, Public Address System and Function Keyboard mounting on the Furniture. 5.02.00 5.02.01 BACK UP PANEL / ELECTRICAL PANEL UCP shall be of free standing type vertical panel with doors at the back. Construction shall be made from sheet steel of thickness not less than 3mm with mosaic grid structure of approximate size 24 X 48 on the front surface. Grid shall be heat resistant, flame retardant, self extinguishing, shrinkage free, non reflecting type. Finish shall be mat type without flaring. Emergency start & stop PB and Lamp indications of critical drives; valves & dampers, critical meters /indicators /ammeters, conductivity type EWLI for Boiler drum, electromatic safety valve controls etc. shall be mounted on the panel. Electrical Panel construction & design shall be similar to back up panel. Required control switches, meters, indicators, synchronizer, excitation control switch, annunciation window etc. alongwith associated mimic diagram shall be provided for manual synchronization of generator. Crating of the panels shall protect against shock, vibration, inappropriate handling and inclement weather conditions during transportation and warehousing. Mounted equipment shall have protection against damage during handling, transit and storage. Suitable desiccant shall be used inside the packing case.
5.01.07 5.01.08
5.02.02
5.02.03
V.II-E/S-VI : 73
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DCPL-K8A07 5.03.00 CABINETS / ENCLOSURE / PANELS 01. 02. Material of construction Thickness of Sheet : : Cold rolled steel sheet a) b) 03. Construction : 3.0 mm for faces instruments / terminals. supporting
2 mm for other sides and top.
Welded throughout as per (metallic parts) approved National Standards. 2300 mm (approx) 7 mm inner radius
04. 05.
Panel height i) ii) Corners Dimensional Tolerances
: :
a) b) c)
In height & length - 3 mm In height between adjacent sections 2 mm. Total for a group - 6 mm
06.
Doors i) ii) iii) iv) Thickness of Sheet Hinges Door latches Door gaskets
: : : : :
Double, recessed, turned back edges 2 mm Stainless steel Three point type Neoprene rubber on fixed frame to result dust proof/weatherproof enclosure. Outward With removable wire mesh to ensure dust and vermin proof. Brilliant white RAL 7032 (Approval shall be accorded by Owner during engineering) Epoxy powder coated or better Removable 3 mm thick (bottom) Bottom a) Anti vibration pad- 15 mm
v) Opening of the doors vi) Louvers
: :
07. 08.
Color of interior Colour external
: :
09. Painting 10. 11. 12. Gland plates Cable entry Hardware
: : : :
V.II-E/S-VI : 74
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DCPL-K8A07 b) c) d) Predrilled base channel ISMC - 100 or equivalent for all sides. Stainless steel buff- finished 2 mm thick kick plate for all sides. Stainless steel scratch strips along desk edges fixed with pan-head recessed screws. Rubber strips to ensure air tightness between kick plate and finished floor. Lifting hook / Eye bolt Drawing pocket Door switch, lamps, heaters and fans thermostat,
e) f) g) h)
13.
Enclosure Protection
As per environment condition of the area of installation. Refer section-I of this vol.
5.04.00
LOCAL INSTRUMENT RACKS & ENCLOSURE Transmitters and switches located in the field shall be grouped together and shall be installed in the enclosure (Closed Transmitter Racks) in case of outdoor area such as Boiler area etc. and in Open Type Rack in case of covered area. Racks shall be factory prefabricated & painted and complete with internal tubing, manifold valve, isolation valves, integral junction box with outside access door, illumination etc. Racks used for furnace, flue gas and air application shall be provided with intermittent & continuous air purging.
5.04.01
Closed Type Transmitter Racks a) b) Required number of transmitter racks shall be furnished to house transmitters, switches and converters by grouping them suitably, area-wise / function-wise. The transmitter enclosures shall be constructed of 3 mm thick steel plate. The enclosures shall preferably be of modular construction and with two end plate assembly bolted to the frame. The enclosure shall approximately be 1200 millimeters wide, 1000 millimeters deep and 2200 millimeters high to allow easy access to the internals. Racks shall be reinforced as required to ensure true surfaces and to provide adequate support for instruments and equipment mounted therein. Double interlocking doors shall be provided and shall be arranged for maximum possible access to the interior. Center posts or any member which would reduce access shall not be provided. Doors shall have concealed quick removal type pinned hinges and locking handles. Doors locks shall accept the same key all over the plant. Gaskets shall be used between all mating sections to achieve dust proof enclosure V.II-E/S-VI : 75
98
c)
d)
DCPL-K8A07 rating for the modules and a IP-65 waterproof and dust tight rating on the terminal boxes. All enclosures shall have access doors on front side. e) Bulkheads, especially designed to provide isolation from process line vibration shall be installed on modular bulkhead plates of the transmitter enclosures to meet the process sensing line connection requirements. Removable top and bottom plates shall be furnished. All internal wirings and/or data bus connections, if any, between the transmitters and terminal junction box shall run through flexible dust tight conduits connected to the terminal box hub. No exposed wirings within transmitter racks, both open and closed type, is admissible. All racks shall have a common closed drain trough to connect transmitter drain points to a common header after suitable pressure breaking. Covered funnels shall be used for saturated liquid and steam service, whereas, open funnels may be used for cold liquid services. The trough shall be suitably sloped and shall have one end flanged and extending beyond the rack for connection to plant drain header. Vibration dampeners shall be installed for supporting each enclosure. The loading at each corner of the enclosure shall be determined by actual test weighting when construction is complete to determine the correct length of each dampener for proper loading of the dampener in accordance with manufacturer's recommendations. Service Power and Lighting i) Each enclosure shall be provided with one receptacle, one light fixture with wire guard and one lighting switch. Lighting switches may be door actuated & mounted inside the panel. Outlet box, switch box and device covers shall be of galvanized stamped steel. Light switches and receptacles shall be installed inside the enclosure on the wall near the latch side of the enclosure door. Light fixtures shall be installed on the ceilings of the enclosures. Power supplies for miscellaneous devices shall be provided with MCB located within the enclosures. MCB shall be mounted in fuse blocks. Nameplates shall be furnished above the MCB blocks, identifying the devices being served.
f)
g)
h)
i)
ii)
j)
Control Air i) A control air supply header shall be furnished in each enclosure having pneumatic devices. The header shall be 25 mm NB brass header stock drilled and tapped for 8 millimeter valves. A valve with double compression end fittings shall be installed in each tap. Not less than three spare connections shall be furnished in each enclosure. The air header shall originate at a bulkhead penetration or fitting located in one of the bulkhead plates. Each pneumatic instrument shall have an individual air shut-off valve.
ii)
V.II-E/S-VI : 76
99
DCPL-K8A07 iii) Pressure reduction shall be achieved by air filter regulator sets. One filter regulator shall be furnished for each group of components making a system.
k)
Service Air A 15 mm NB service air header shall be furnished in each enclosure housing draft and coal mill instruments. The header shall be furnished complete with a pressure regulating valve, pressure gauge and valved quick disconnect connections. A hose for connecting each header to the draft instrument line four-way valves shall be furnished. The hose shall be self-storing nylon tubing having a burst pressure 15 Kg/Sq. cm. The service air header shall originate at a bulkhead penetration or fitting located on one of the bulkhead plates.
l)
Power Supplies Contractor shall supply all required transformers, regulators and other power supply equipment to adapt sources of power to the requirements of the enclosure mounted equipment. This shall include but not be limited to internal instrument illumination transformers. The circuits shall be separately isolated with MCBs.
m)
Equipment Installation Special attention shall be given in the piping layout to avoid air traps in liquid filled piping, or water pockets in piping.
n)
Impulse Piping /Tubing i) Transmitter enclosures shall be complete with impulse piping & tubing, valves from enclosure bulkhead connection to all instruments and necessary drain / blow down connections. The type, size, material and pressure class of pipes/tubes, fittings, valves etc. shall be suitable for the intended applications. Blow down piping / tubing may be shared, but individual instrument piping / tubing and valves shall be furnished. Piping / Tubing material within enclosures shall conform to the application requirements. The final flexible connection to each instrument shall be fabricated with a double offset so that it may readily be disconnected to permit "in situ" calibration of the instrument. Bulkhead connection shall be used when instrument piping/ tubing enters the enclosure. For instrument lines which enter through the bottom of the enclosure, the primary process line from the instrument valve shall be neatly installed, anchored and terminated at approximately 150 millimeters above the floor of the enclosure. The enclosure shall have a removable, gasketted floor plate to provide an effective seal around the incoming field primary process line. An angle shall be installed 600 millimeters above the floor, running the length of the enclosure for anchoring of incoming field process lines. Pulsation dampeners shall be furnished wherever required. V.II-E/S-VI : 77
100
ii)
iii)
iv)
DCPL-K8A07 v) vi) Drain pots shall be furnished for instruments measuring flue gas parameters and vacuum. All liquid filled blow down lines, except those measuring vacuum shall be connected to a header extended through one end of the enclosure and turned downward for directing the blow down into drain. Gas filled lines and lines equipped with drain pots shall not be connected to the blow down header. The connection between the blow down valve and blow down header shall be constructed so that it can be removed to permit the connection of test instruments to the blow down valves. The draft instrument line four-way valves shall be installed so that the quick disconnect fitting is readily accessible for connection with the service air hose. Pipe and stainless steel tube welding shall comply with the provisions of the latest applicable ANSI Code for Pressure Piping. Instrument piping and tubing shall be hydrostatically tested at one and one-half times the maximum system pressure for that instrument except for low pressure and vacuum measurement the test pressure will be as per piping standard.
vii)
viii) ix)
o)
Instrument Tubing i) Pneumatic tubing shall be installed in a neat workmanlike. It shall be supported frequently enough that it does not shake when subjected to vibration. All tubes which enter or leave the enclosure shall be terminated on bulkhead fittings in the bulkhead plate. Pneumatic tubing material shall be 6 mm OD stainless steel tubing, unless otherwise specified. Flareless tubing fittings shall be used for tubing connections smaller than one inch. Tubing shall be stretched before installation to assure straightness. Special tools shall be used for all bending and forming operations. Tubing shall be carefully handled to avoid flat spots, kinks, and short bends. All piping and tubing shall be air blown after erection and before attachment to equipment at either end.
ii)
5.04.02
Open Type Transmitter Racks a) Open type transmitter racks may be provided for mounting transmitters, switches, gauges, converters and other accessories in rooms, buildings and closed areas like the power house building. The open type racks may be shop or site fabricated. Transmitters, switches, converters and transducers of enclosure class IP-65 or better can be directly mounted on open racks. However, enclosures not conforming to the above protection standard shall have to be housed in enclosures conforming to IP-65 class prior to mounting them on open structures.
b)
V.II-E/S-VI : 78
101
DCPL-K8A07
c)
Racks shall be constructed on structural members of adequate strength and rigidity to ensure proper support to the mounted instruments and equipment. Racks shall be of welded construction throughout. Major load-bearing posts shall be suitably supported by gusset plates or moment members. Suitable fenders grill shall be welded to the end-posts of the rack to outline a boundary beyond which no mounted equipment shall project to protect instrument from accidental contact during personnel movement. Each rack shall be provided with a canopy to protect the instrument from dripping water or falling objects. For operational convenience, the open type racks shall be used for mounting pressure and temperature gauges and switches and the local operating stations for electrical drives in the vicinity. Gauges mounted in racks shall be bottom connected and secured by double lock nuts. All gauges shall be located within 1500 mm from the floor for easy readability. The structural design shall be such that no item shall interfere with maintenance and removal of instrument, equipment and their accessories. Service Power and Lighting i) Each rack shall be provided with one receptacle, one light fixture with wire guard and one lighting switch. Outlet box, switch box and device covers shall be galvanized stamped steel. Light fixtures shall be installed on the canopy of the rack. Power supply for receptacles and lighting shall be arranged. Power supplies for miscellaneous devices shall be provided with MCB located within the rack JB. MCBs shall be mounted in blocks. MCB ratings will be given on electrical schematic diagrams. Nameplates shall be furnished above the MCB blocks, identifying the devices being served.
d)
e)
f)
ii)
g)
Control Air Same as for closed type transmitter rack. Refer 5.01.01 (j) above
h)
Service Air Same as for closed type transmitter rack. Refer 5.01.01 (k) above
i)
Power Supplies
Same as for closed type transmitter rack. Refer 5.01.01(l) above j) Equipment Installation Contractor shall prepare rack fabrication and piping drawings indicating the layout of each instrument. The drawings shall clearly indicate Contractor's piping arrangement for the sharing of process connections between two or more instruments. Special attention shall be given in the piping layout to avoid air traps in liquid filled piping or water pockets in piping intended to be dry.
V.II-E/S-VI : 79
102
DCPL-K8A07 k) Impulse Piping / Tubing Same as for closed type transmitter rack. Refer 5.01.01 (n) above l) Instrument Tubing Same as for closed type transmitter rack. Refer 5.01.01 (o) above 5.04.03 Wiring of the Racks a) A fully enclosed IP 65 type junction box shall be provided in each rack for housing the terminal blocks connectors, power supply fuses and other electrical accessories, as required. Junction boxes for modular enclosures shall be fabricated externally on one end of each enclosure assembly to accept field wiring/cabling through the top or bottom of the junction box. A hinged door shall give access to the interior of the junction box. All electrical connections between instruments and the junction box terminal blocks shall be made. In addition all utility wiring for lighting and service power shall be installed. All wiring used within the enclosures shall conform to NEC /IEC standards. All wiring shall run though flexible or rigid conduits and shall be terminated at suitable terminal blocks. Sufficient clearance shall be provided for all control and instrument leads and all incoming and outgoing leads shall be connected to terminal blocks suitably located for connecting external circuits. High impedance circuits shall be connected using shielded or coaxial wire suitable for the service. Conduits shall be supported properly at regular intervals with suitable conduit clamps. Wire shall be neatly arranged and routed/laid in PVC trough/tray.
b)
c)
d)
e) f) g) 5.04.04
Junction Box Junction boxes shall be of metallic construction. a) Junction box shall be provided with front opening type cover. Junction box shall be of sheet steel construction with thickness not less than 2 mm. Junction box shall be complete with DIN rail mounted terminals, MCB, receptacles and earth bar. Earth bar shall be made of tinned copper of 25 X 6 MM size. Earth stud shall be furnished for safety grounding. Terminals shall be screwless cage-clamp type and 20% spare terminals shall be furnished.
b)
V.II-E/S-VI : 80
103
DCPL-K8A07 6.00.00 PROGRAMMABLE LOGIC CONTROLLER (PLC)
6.00.01
Programmable Logic Controller (PLC) based control system shall be complete with a configuration of 1:1 hot redundancy. Each PLC having Central Processing Units (CPUs) of word length of 32 bits minimum, redundant communication processors, redundant memory modules, redundant rack power supply units, redundant bulk IO power supply units, redundant IO communication modules, IO modules, redundant data highway and redundant 10/100Mbps data network connecting operator stations. Two CPUs shall operate on fault tolerant mode with continuous self and crossmonitoring facility. Failure of the active CPU shall not affect the operation of the plant. In the event of failure of active CPU, tasks shall be transferred to the standby CPU bumplessly within fastest possible transfer time without causing any output to drop during the transfer period. The bumpless change over shall be accomplished within one Scan-cycle.Transfer speed shall not be less than 2 Gbit/sec.CPU Redundancy shall be achieved through dedicated hardwared Synchronised Link between active and standby CPU. In the event of both the CPU failure, the system shall revert to the fail-safe mode. CPUs shall not be loaded over 60% of the individual capacity even under worst data loading conditions. It shall be possible to make a manual transfer from the active to the back-up CPU from engineering station and as well as from the front panel of CPU module. Module shall have adequate status and diagnostic indication on the front panel and as well as on the engineering station.
6.00.02
The system shall be of modular construction and expandable by adding hardware modules and incorporating them in the address register. Bidder shall provide at least 20% or minimum one number, whichever is higher, spare channels as hot-onrail spares in each configured cards/modules. In addition to this 10% or minimum one number, whichever is higher, extra assigned complete spare modules mounted on rails in racks for each type of I/O modules shall also be provided. The spare channel and cards shall be fully wired and terminated. The memory unit of the CPU shall be field expandable. The memory capacity shall be sufficient for complete system operation and shall have the capability for future expansion at least to the tune of 25%. The application program/sequence logic etc. shall be stored in nonvolatile memory (EEPROM). However, all the dynamic memories shall be provided with battery back up at least for 360 hours. The batteries shall be lithium or Ni-Cd type. The number of input / output points per card shall not exceed 16 (sixteen) for digital and 8 (eight) for analog/thermocouple/RTD. Individual input channels shall have galvanic isolation. Output points shall also have optical/galvanic isolation. Merely fusing of individual or a group of channels is not acceptable. The data communication system of the PLC shall not be limited to the following:
6.00.03
6.00.04
6.00.05
V.II-E/S-VI : 81
104
DCPL-K8A07 a) b) Bus and data network loading shall in no case be more than 60% of its capacity. Redundant communication controller shall be provided for the purpose of communication between the I/O modules (including remote I/Os if any) and the PLC as well as in between PLC and the operators work stations. The communication system design shall ensure that any single point failure on the system bus/media shall not disrupt more than single message and disrupted message shall be automatically retransmitted. Failure or physical removal of any station/modules connected on the system bus shall not lead to any loss of communication. Diagnostics message on fault detection. Bus change over from active bus to stand by bus, during failure of active bus shall be performed automatically and bumpless. Such event shall be suitably logged or alarmed. Noise immune high-speed serial link optical fiber cable between CPUs and remotely located remote I/O modules with standard communication protocol shall be provided. Main data network shall be noise immune high-speed communication link with bit rate in the range of 10 / 100 MB/sec and shall comply with the International Standard IEEE-802.3 (Ethernet) for data exchange and communication.
c)
d) e) f)
g)
h)
6.00.06
All PLC based controls shall have interface with DCS. The PLC system shall be open protocol at both layers(OPC compliant) i.e. Supervisory layer (between PLC & MMI) and Control Layer (between PLC & I/O). Supervisory level Ethernet must be unmodified with non-proprietary application layer. Communication for selected data transfer with DCS shall be through OPC soft link. Bidder shall furnish the necessary connectivity, optical fiber cables & interface for transmitting data from the redundant PLC ports.
6.00.07
Operator work station shall be complete with PC and latest windows version operating system. 22 colour TFT monitors, membrane KB, mouse, colour laser printer shall be provided as peripherals. In addition to PC based operator cum engineering station, LAPTOP loaded with engineering software shall be furnished. For specification of operator / engineering station Bidder shall refer to clause no.7.11.00 of this section. Operator workstation shall comprise of A3 & A4 size color laser graphic printer.
6.00.08
MMI function of PC based operators station shall not be limited to the following: a) b) Selection of auto/Manual, open/close operation, sequence auto, start/stop operation etc. Dynamic Mimic display depicting the entire process for control and monitoring purpose.
V.II-E/S-VI : 82
105
DCPL-K8A07 c) d) 6.00.09 Alarm monitoring, report generation, logs, calculations and printing of logs, reports, trends etc. On-line / historical trending, historical storage and retrieval of data.
Annunciation System a) For PLC controlled area / plant, window based annunciation wherever required shall be an integral part of the PLC system. Sequence for annunciation shall be configured in PLC and shall conform to ISA sequence. Window lamps will be driven by PLC. For the systems where only monitor & keyboard based operator workstation has been envisaged, alarm/ annunciation will be displayed in the operator workstation. The window lamps for the system shall be driven through output modules of the PLC. Each window shall have removable lamp box. The window shall have black lettering inscription on white background. However, for trip application red background shall be provided. Each of the annunciation windows shall be backlighted with minimum two groups of clustered LED lamps with minimum readable distance of 3 Meter. The window design shall be such that the lamp replacement can be done easily from the front. Audible device shall be provided with the annunciation system. The devices shall have in built electronic tone generator with adjustable sound level and intensity controls.
b)
c)
6.00.10
Software a) All the necessary software for fulfilling the complete implementation of the control logics, operational displays & logs, data storage, retrieval and other functional requirements as indicated in this specification, shall be provided. Offered PLC system must use Tag based addressing structure. Tags must be inherent in the controller not in the MMI. The MMI shall support directly by referring the Tags resident in the controller. Licensed version of required software including configuration and MMI software shall be provided. operating system,
b)
c) d)
e)
Programming language shall be user friendly. Detail documentation on the all programming softwares shall be furnished by Bidder and this shall be a part of the O&M Manual. Contractor shall provide software locks and passwords to Owners engineers at site for all operating and application software so that Owners engineers can take back up of these software and are able to do modifications at site.
6.00.11
Control & Power Supply Scheme Bidder shall provide two nos. redundant 240V AC 1% UPS (Uninterruptible Power Supply) Power feeders for the PLC system from the unit UPS systems. The PLCs which shall be common to both the unit shall be powered by two independent UPS sources taken from each unit UPS system . All required hardware/ equipment etc. for conversion and/or stabilization of the power source to all other levels which may
V.II-E/S-VI : 83
106
DCPL-K8A07 be necessary for meeting individual requirements of equipment/ systems shall be furnished by the bidder. . Separately mounted I/O racks, shall be provided with separate power supplies. . Power supply module shall be of ample capacity to feed all the modules. In addition 20% spare capacity for future shall be provided. All the drives shall be switched ON/OFF through 24 V DC interposing relays to be located in HT/LT SWGR panels. All other interposing relays for solenoid drives etc.shall be mounted in a separate cabinet or a separate section of the cabinet. Power supply distribution to all the consuming points shall be in the scope of Bidder. The exact power supply scheme shall be submitted by Bidder during detailed engineering stage for Owners approval. Bulk power supply units for interrogation, relay and solenoid voltage shall be separate from system power supply units and shall be redundant in all cases. Each set of PC along with TFT monitor, Printer shall be provided with smart type line interactive UPS with software and hardware for remote management along with features of surge suppression and AVR facility by Contractor. The UPS shall be of sufficient capacity of at least 30 minutes back up at machine load. The battery shall be Ni-Cd type battery with long life and shall be able to provide a back up for at least one hour at full load of the completed control system. 6.00.13 The system shall have high MTBF and shall be hot maintainable. The system hardware shall be designed to be `fault avoidant' by selecting high-grade components of proven quality and properly thermally de-rated design. The network shall have extensive fault monitoring, self-surveillance & on-line self-diagnostic capability so that failure up to module/card level is immediately detected. Each of the modules shall have its self-diagnostic system. The operator workstation located at the local area control room shall be used for fault data presentation and monitoring purpose. The system shall have capability to automatically check & correct gain & drift for ADCs on-line. Data exchange in a bus shall be fully monitored and checked for validity. Transfer of data from Remote I/O modules with PLC module shall be done through serial link as per standard protocol. Input scan periods shall be equal to or less than: a) b) c) d) 6.00.18 OLCS & sequence control inputs CLCS inputs Monitoring analog parameters Monitoring digital parameters : : : : 100 ms. 250 ms. 500 ms. 100 ms.
6.00.14 6.00.15 6.00.16 6.00.17
Following operations will be performed on I/Os, as required: a) Square root extraction V.II-E/S-VI : 84
107
DCPL-K8A07 b) c) d) e) 6.00.19 Pressure & temperature compensation Reasonability check of all inputs (analog specially), validate and quality tagging like good, bad, suspect etc. Channel wise engineering unit conversion Contact bounce filtering with adjustable time constant.
All controllers shall be freely configurable with respect to requisite control algorithms. An extensive library of macros shall be included for the purpose. Adequate software capability shall be provided to implement closed loop control functions as follows: a) b) c) d) PID control and their variations. On-off control Cascade control Ratio and bias control
6.00.20
Features for Open Loop Control shall not be limited to following: a) b) Logic functions like AND/OR/NOT gates, timers (on-delay, off-delay), shift registers, counters, latches, flip-flops, mono-shots etc. The automatic sequence control to ensure sequential start up and shutdown of auxiliaries/equipment. Sequence control shall be performed in groups initiated by command from operators console. A sequence shall be made of steps executed in predetermined order according to logic criteria. For each step there shall be a provision for `waiting time' and `monitoring time', and it shall output an action on the process. System shall have the capability to bypass a step if desired by the operating personnel from the operator workstation. Such action however shall be registered as an exception or alarm. Increase the reliability and availability of the plant as a whole, for example, by timely and correctly switchover to standby drives etc. Basic interlock and protection logic related to safety of individual drive and plant equipment. All inputs required for protection system shall be on high priority basis. In the event of either loss of control power or control signal input to the drive, the drive shall remain in its last position unless specifically required otherwise. The system shall be designed such that no upset occurs either to process or to the drive when the power is restored.
c) d)
6.00.21
Interface of the system with MCC/Switchgears shall be in the form of potential free contacts via interposing relay modules mounted in the respective MCC/Switchgear unit. All other interposing relays for solenoid drives etc.shall be mounted in a separate cabinet or a separate section of the cabinet. 10% wired additional interposing relay modules shall be provided as installed spare. Freewheeling diodes shall be provided across the coil of DC solenoid and contactors/relays. For AC solenoids and contactors directly driven from output cards, arc suppressors shall be provided across the coil. Each RIO rack shall have 10% spare rack space for future up gradation.
V.II-E/S-VI : 85
108
DCPL-K8A07 6.00.22 6.00.23 The operators station shall be responsible for handling all commands as well as in generating desired displays and print outs. Programming shall be with an easily understandable high-level language. Programming shall also be permissible by drawing Ladder or Boolean Diagram. Single programming instruction/command shall be sufficient to delete a program rung from memory. Similarly, any rung can be inserted into the existing program. The active and the stand-by CPU programs shall equalize automatically, once the new program is permitted to RUN. Updating time and reaction time (system's response to an operator's command) for operator stations shall be as follows: a) b) c) d) 6.00.25 Calling up a mimic Updating status signal in mimic Updating variables in a mimic : : : 2 sec or better 1 sec or better 1 sec. or better
6.00.24
Issuance of command to output : 1 sec. or better (without considering travel time and process lag)
Programmable Controller shall be responsible for real time process parameter monitoring, storage & display. Basic requirements are (i) Operator Interface, (ii) Basic Calculation, (iii) Alarm Monitoring with display & audio & Reporting, (iv) Display generation, (v) Logs, (vi) Trend Recording & (vii) Historical Storage & Retrieval. The displays at the operator console shall be classified into overview display, group display, point display and trend display. a) b) c) d) e) Overview display - This display is to enable the operator to set an overview of the entire plant section. Group display - The group display page shall display several sub-sections & present status information. Point display - Along with the specified parameter value, this page should indicate historical trend of the parameter. Trend display - This display include real time/historical trend display facility including Dynamic Graphic Display & Bar Graph Display. Alarm Message Display - It shall be possible to display process as well as system alarms for operator's attention and action. Alarm shall appear immediately on the operator workstation as and when they occur on priority basis. In addition to alarms appearing on different displays, the system shall also be able to display alarm summary and alarm history listing the date and time of occurrence, tag number, point description, type of alarm (absolute value or deviation), serial number of alarm in the sequence of occurrence etc. Alarm shall disappear from display only when they are acknowledged and cleared. Abnormal condition in the system shall be displayed as system alarm message on the operator workstation irrespective of display selected. In all cases occurrence of an alarm shall be logged. V.II-E/S-VI : 86
109
6.00.26
DCPL-K8A07 d) e) f) g) h) Memory capacity Common processor Battery back up for RAM Watch dog timer Diagnostic feature : : : : : : 25% spare capacity after full Expandable in multiples of 16 K. Integral / Separate Ni-Cd / lithium type, at least for 360 hrs continuous operations during power failure. Periodical reset. Alarm and interruption, if not reset within stipulated time. Periodic, automatic self-diagnostic. available at the operator workstation. LAN-supporting multidrop. Result utilization.
h) Communications 6.00.30
The salient features of the Input / Output modules are as follows. a) All modules 1. Ambient temp. 2. Surge withstand capability b) Digital General 1. No. of channels / module 2. Interrogation voltage 3. Status indicator 4. Isolation c) Digital Input Module 1. Contact bounce filtering 2. Diagnostic d) Digital Output Module 1. Output protection 2. Diagnostic 3. Rating e) Analog General 1. No. of channels / module 2. Isolation f) High level Analog Input Module 1. Type of input : V.II-E/S-VI : 88
110
: :
0-50O C IEC-255.4
: : : :
16 24V DC or 48 V DC LED type. Optical
: :
Adjustable time constant of 15 m. sec. Module fault
: : :
Short ckt. Proof & Individual fuse Module fault To switch ON/OFF interposing relays of approx. 3 VA at 24 VDC.
: :
08 Galvanic/Optical
4-20 mA DC / 1-5V DC
DCPL-K8A07 2. A/D Converter 3. Accuracy 4. Diagnostic 5 g) Powering of transmitter : : : : 11 bits + Sign (or better) 0.1% or better Module fault 24 V DC 2 Wire type
Low Level Analog Input Module 1. Type of input 2. C-J-C 3. Accuracy 4. A/D converter 5. Diagnostic : : : : : Pt-100; T/C(As required) On Module 0.1% or better 15 bits + Sign (or better) Module fault
h)
Analog Output Module 1. Type of output 2. Accuracy 4. A/D Converter 5. Load 6. Diagnostic : : : : : 4-20 mA DC + 0.1% or better 11 bits + Sign (or better) 500 Ohm Module fault
6.00.31 7.00.00 7.01.00 7.01.01
Termination & Relay cabinet shall be separate from the system and RIO cabinets. DISTRIBUTED CONTROL SYSTEM (DCS) SYSTEM FUNCTIONAL DESCRIPTION Integrated functionally & geographically distributed hierarchical Control System (both binary and modulating) including data acquisition, historization and Management Information System (MIS) system synthesized from one general family of identical interchangeable multifunction hardware with adequate redundancy has been envisaged for the plant. The system shall be unit-wise and connectivity with other plant control system & Management Information System (MIS) network has been envisaged. Bidder shall provide Remote Input Output as a data concentrator for acquisition of non critical monitoring parameters like Boiler metal temperature. RIO shall be located in air conditioned environment. Controls of some plant auxiliaries and off site plants such as CW & ACW Pumps and Fuel oil heating & pressurizing system controls shall be realized in the Remote Processing Unit (RPU). RPU consisting of CPU and input / output with their local operator stations shall be located in the respective air conditioned local area control V.II-E/S-VI : 89
111
7.01.02 7.01.03
7.01.04
DCPL-K8A07
13.02.04 13.02.05 13.02.06 13.02.07
Vibration test as per IEC-68-2-6. Electrostatic discharge tests as per IEC 801-2 or equivalent. Radio frequency immunity test as per IEC 801-6 or equivalent. Electromagnetic immunity as per IEC 801-3 or equivalent. Test listed at clause no. 13.02.05, 13.02.06 & 13.02.07 above are applicable for front end cards only as defined under clause no. 13.02.01 above.
13.03.00
SL. NO. 01. 02. 03. 04. 05. 06. 07. 08.
TYPE TEST REQUIREMENT FOR C&I SYSTEMS

TEST TO BE ITEM NARROW CHART RECORDER MULTI-POINT RECORDER VERTICAL INDICATORS ELECT. METERING INSTRUMENTS TRANSDUCERS THERMOCOUPLES RTD C.J.C. BOX TEST REQUIREMENT AS PER STANDARD AS PER STANDARD AS PER STANDARD AS PER STANDARD AS PER STANDARD DEGREE OF PROTECTION TEST AS PER STANDARD DEGREE OF PROTECTION TEST AMBIENT TEMP.
EFFECT AS PER STANDARD
APPROVAL
REQUIRED ON TEST CERTIFICATE
STANDARD IS-9319 IS-9319 IS-9319 IS-1248 IEC-688, IS12784 IS-2147 IEC-751 IS-2147 APPROVED PROCEDURE BS-6447 / IEC-770 MFR. STANDARD IS-2147
SPECIFICALLY CONDUCTYED
REMARKS
NO NO NO NO NO NO NO NO NO NO NO NO YES
NO NO NO YES YES NO NO YES YES YES YES YES YES
09. 10. 11. 12.
ELECTRONIC TRANSMITTER E/P CONVERTER DUST EMISSION MONITOR INSTRUMENTATION CABLES TWISTED & SHIELDED A) CONDUCTOR
AS PER STANDARD DEGREE OF PROTECTION TEST
B)
INSULATION
RESISTANCE TEST DIAMETER TEST TIN COATING TEST (DRAIN WIRE) LOSS OF MASS AGING IN AIR
OVENS
VDE-0815 IS-10810
VDE-0472 VDE 0472 **
** AS PER VDE 0207 FOR TEFLON

INSULATED
V.II-E/S-VI : 193
112
DCPL-K8A07
SL. NO. TEST TO BE ITEM TEST REQUIREMENT TEST ACID GAS GENERATION TEST CONTINUITY TEST SHIELD THICKNESS OVERLAP TEST NOISE INTERFERENCE FLAMMABILITY NOISE INTERFERENCE DIMENSIONAL CHECKS CROSS TALK MUTUAL CAPACITANCE HV TEST DRAIN WIRE CONTINUITY DEGREE OF PROTECTION TEST TEMPERATURE INTERFERENCE TEST IS 10810 STANDARD
APPROVAL
REMARKS
IEC-754-I
F)
AL-MYLAR SHIELD
G)
OVERALL CABLE
IEEE TRANSACTIONS IEEE 383
13. PRESSURE GAUGE
VDE 0472 VDE 0472
IS-2147
NO
NO
IS-3624
NO
NO
14. 15.
TEMPERATURE GAUGE PRESSURE & DIFFERENTIAL PRESSURE SWITCH
DEGREE OF PROTECTION TEST DEGREE OF PROTECTION TEST AS PER STANDARD
IS-2147 IS-2147
NO NO
NO NO
BS 6134 IS-2147
IS-2147 IS-2147
NO NO
NO NO
NO NO
YES YES
16.
17. 18.
LEVEL SWITCH
CONDUCTIVITY LEVEL SWITCH BATTERY CHARGER (INCLUDING CHARGERS OF UPS)
DEGREE OF PROTECTION TEST

DEGREE OF PROTECTION TEST DEGREE OF PROTECTION TEST
SHORT CIRCUIT CURRENT CAPABILITY TEMP. RISE
IEC-146-2
NO
YES
Approved
YES
YES
V.II-E/S-VI : 195
113
DCPL-K8A07
SL. NO. TEST TO BE ITEM TEST REQUIREMENT STANDARD
APPROVAL
REMARKS
21.
VOLTAGE STABILIZERS
OVERLOAD TEST TEMPERATURE RISE TEST WITHOUT REDUNDANT FANS INPUT VOLTAGE VARIATION TEST
Approved Procedure Approved Procedure
NO NO
YES YES
Approved Procedure
NO
YES
22.
FLOW NOZZLES & ORIFICE PLATE
CALIBRATION
ASME PTC, BS-1042
YES
NO
23.
PLCs
ALL TESTS AS PER IEC-1131
IEC-1131
24.
DDCMIS a) b) c) I/O MODULES OTHER MODULES CLCS SYSTEMS CMRR & NMRR VERIFICATION CMRR & NMRR VERIFICATION MODEL TEST Mfr. standard Mfr. standard Approved Procedure IS-2147 NO NO YES YES YES YES
25.
LIE / LIR / JUNCTION BOX FLUE GAS O 2 ANALYZER FLUE GAS CO 2 ANALYZER FLUE GAS SO 2 ANALYZER FLUE GAS NO X ANALYZER MASTER SLAVE CLOCK
DEGREE OF PROTECTION TEST DEGREE OF PROTECTION TEST DEGREE OF PROTECTION TEST DEGREE OF PROTECTION TEST DEGREE OF PROTECTION TEST CURRENT / POWER EFFICIENCY
YES
YES
26.
IS-2147
NO
YES
27.
IS-2147
NO
YES
28.
IS-2147
NO
YES
29.
IS-2147
NO
YES
30.
Approved Procedure IEC146
NO
YES
V.II-E/S-VI : 197
114
115
116
117
118
119
120
121
SPEC. NO. PE-TS-373-156-A001
SECTION D4 QUALITY PLANS
PAGE:
122
MANUFACTURER'S NAME&ADDRESS:
ITEM: CWTREATMENTPLANT SUBSYSTEM:
QUALITYPLAN(FORTANKS,SKIDS,PUMPS,VALVES,PIPES,FITTINGS,FLANGES) QP.NO: PEQP373156A001 REV.: 0 DATE: 30/04/10 PAGE: 1OF3 ACCEPTANCENORMS 8
PROJECT PACKAGE CONTRACTNO. MAINSUPPLIER FORMATOF RECORDS 9
2X500MWSAGARDIGHISTII CWTREATMENTPLANT
S.NO COMPONENTS/OPERATION CHARACTERISTICSCHECKED . 1 2 3 1.0 WELDER'SQUALIFICATION WELDINGPROCEDURE 1.1 SPECIFICATION(WPS) CORRECTNESS WELDERPERFORMANCE& PROCEDUREQUALIFICATION WELDSOUNDNESS&WELDING 1.2 RECORD PERFORMANCE 2.0 TANKS 2.1 RAWMATERIAL: 2.1.1 PLATE 2.1.2 PIPEFORNOZZLE CHEMICAL.&PHY.PROPERTIES IGCTEST CHEMICAL.&PHY.PROPERTIES IGCTEST HYDROTEST CHEMICAL&PHYPROPERTIES
CATEGORY 4 MA
TYPE/METHODCHECK 5
EXTENTOF CHECK 6
REFERENCEDOCUMENT 7
AGENCY** M B C 10
REMARKS 11
SCRUTINY
100%
ASMEIX
ASMEIX
QW482
MA
PHYSICALTEST
ASMEIX
ASMEIX
ASMEIX
QW483&QW484
MA MI MA MI NA MA
CHEM&.PHYTEST IGCTEST CHEM.&PHY.TEST IGCTEST LEAKAGE CHEM&PHYTEST MEASUREMENTWITH TEMPLATE DPTEST MEASUREMENT VISUAL WATERFILLFOR2HR
1/PLATE 1/PLATE REFERNOTE5 REFERNOTE5 100% REFERNOTE5
ASTMA240GR.TP304 ASTMA262PR.'E' ASTMA312GR.TP304 ASTMA262PR.'E' NOLEAKAGE ASTMA182GR.F304
ASTMA240GR.TP304 ASTMA262PR.'E' ASTMA312GR.TP304 ASTMA262PR.'E' NOLEAKAGE ASTMA182GR.F304
MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC/IR MGF.TC/LABREPORT
P P P P P
V V V V/W V
V V V V V
IDENTIFICATIONBY BHEL
REFERNOTE2
2.1.3 FLANGESFORTANKS 2.2 INPROCESS 2.2.1 DISHEDENDS
2.3
DIMENSIONS SURFACEDEFECTSON WELDMENTS FINALASSEMBLYFORTANKS: DIMENSIONS& ORIENTATION LEAKAGE
MA
100% 100% 100%
APPD.DWG.(BYBHEL) ASTME165 APPD.DWG.(BYBHEL) APPD.DWG.(BYBHEL) N.A.
APPD.DWG.(BYBHEL) NOSURFACEDEFECTS APPD.DWG.(BYBHEL) APPD.DWG.(BYBHEL) NOLEAKAGE
MFG.TC./LABREPORT MFG.TC MFG.TC/INSPREPORT MFG.TC/INSPREPORT MFG.TC/INSP.REPORT
P P P P P
V V W W W
V V W TOBEOFFERED W ALONGWITHFINAL SKIDASSEMBLY W INSPECTION.
MA MA MA **LEGEND:
2.3.1
100%
MANUFACTURER/ SUBCONTRACTOR SIGNATURE
MAINSUPPLIERBHEL
M:MANUFACUTRER/SUBCONTRACTOR/SUBVENDOR B:BHEL/NOMINATEDINSPECTIONAGENCY "P"PERFORM, "W" WITNESS,AND "V" VERIFICATION
C:CUSTOMER SIGNATUREOFAPPROVALBYCUSTOMER
123
QUALITYPLAN(FORTANKS,SKIDS,PUMPS,VALVES,PIPES,FITTINGS,FLANGES) QP.NO: PEQP373156A001 REV.: 0 DATE: 30/04/10 PAGE: 2OF3 ACCEPTANCENORMS 8 BHELAPPD.DATASHEET REF.NOTE#1 NOSURFACEDEFECTS API675 API675 API675 BHELAPPD.DATASHEET
NO LEAKAGE
PROJECT PACKAGE CONTRACTNO. MAINSUPPLIER FORMATOF RECORDS 9 MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC/LABREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT
S.NO . 1 4.0 4.1 4.1.1
COMPONENTS/OPERATION 2 METERINGPUMP: RAWMATERIAL: WETTEDPARTS
CHARACTERISTICSCHECKED 3 CHEM&PHY.PROPERTIES SURFACETEST
CATEGORY 4 MA MI
TYPE/METHODCHECK 5 CHEM.&PHY.TEST UTONBAR>25MMDIA DPONM/CSURFACE PERFORMANCE SHOPTEST SHOPTEST MEASUREDATWORK HYDROTEST MEASUREMENT MEASUREMENT MEASUREMENT
EXTENTOF CHECK 6 1/BAR 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
REFERENCEDOCUMENT 7 BHELAPPD.DATASHEET ASTMA388 ASMEE165 API675 API675 API675 BHELAPPD.DATASHEET @1.5XDESIGNPRESSURE BHELAPPD.DATASHEET/DWG
AGENCY** M B C 10
REMARKS 11
P P P P P P P P P P P
V V V W W W W W W W W
V V V V V V V V V V V
4.2 FINALINSPECTION 4.2.1 PUMPWITHMOTOR
LINEARITY STEADYSTATEACCURACY REPEATABILITY POWERDRAWN@100%STROKE LEAKAGE DIMENSIONS NOISE VIBRATION
MA MA MA MA MA MA MA MA
BHELAPPD.DATASHEET/DWG <85dbAAT1MRADIUS 45MICRONS(PEAKTOPEAK)
SHALLBETESTED WITHEITHERJOB MOTORORSHOP MOTOROFSIMILAR FRAMESIZE
6.0 6.1.0 6.1.1 6.1.2 6.1.3 6.1.4 6.2 6.2.1
CENTRIFUGALPUMPS RAWMATERIAL: CASING&COVER IMPELLER WEARRING SHAFT&SHAFTSLEEVE FINALINSPECTION PUMPWITHMOTOR PERFORMANCE
CHEM&PHY.PROPERTIES CHEM&PHY.PROPERTIES CHEM&PHY.PROPERTIES CHEM&PHY.PROPERTIES
MA MA MA MA
CHEM&PHY.PROPERTIES CHEM&PHY.PROPERTIES CHEM&PHY.PROPERTIES CHEM&PHY.PROPERTIES
REFERNOTE5 REFERNOTE5 REFERNOTE5 REFERNOTE5
BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET
BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET
FOUNDRYTC. MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC/LABREPORT
P P P P
V V V V
V V V V
7.0
PRESSURERELIEFVALVE
DYNAMICBALANCING DIMENSIONS QvsH,QvsN,QvsP EFFICIENCY LEAKAGE STRIPDOWNTEST NOISE VIBRATION POWERDRAWN@RATED CAPACITY&HEAD SET&RESETPRESSURE. DIMENSIONS LEAKAGEDURINGPERFORMANCE TEST MA MA MA
MA MA MA MA MA MA MA MA MA MA MA MA
MEASUREMENT PERFORMANCE PERFORMANCE HYDROTEST VISUAL MEASUREMENT MEASUREMENT MEASUREMENT PERFORMANCE MEASUREMENT VISUAL CHEM.&PHYTEST HEATTREATMENT CHEM.&PHYTEST HYDROTEST PNEUMATICTEST MEASUREMENT
100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% REFERNOTE5 1/HTBATCH REFERNOTE5 100% 100% 100%
ISO1940GR6.3 BHELAPPD.DATASHEET BHELAPPD.DATASHEET/IS5120 BHELAPPD.DATASHEET @1.5XDESIGNPRESSURE AFTERPERFORMANCETEST BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET&APIRP520 BHELAPPD.DATASHEET/DWG NOLEAKAGE BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET/DWG
ISO1940GR6.3 BHELAPPD.DATASHEET BHELAPPD.DATASHEET/IS5120 BHELAPPD.DATASHEET NOLEAKAGE NOWEAR&TEAR <85dbAAT1MRADIUS BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET&APIRP520 BHELAPPD.DATASHEET/DWG NOLEAKAGE BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET NOLEAKAGE NOLEAKAGE BHELAPPD.DATASHEET/DWG
MFG.TC INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT MFG.TC MFG.TC MFG.TC MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC/LABREPORT MFGTC MFGTC MFGTC
P P P P P P P P P P P P P P P P P P
V W W W W W W W W V V V V V V V V V
V V V V V V V V V V V V V V V V V V
SHALLBETESTED WITHEITHERJOB MOTORORSHOP MOTOROFSIMILAR FRAMESIZE
8 VALVES(GATE,GLOBE&NRV) 8.1 RAWMATERIAL: 8.1.1 BODY,BONNETCOVER CHEM.&PHYPROPERTIES HEATTREATMENT 8.1.2 TRIMMATERIAL CHEM.&PHYPROPERTIES 8.2 ASSEMBLY LEAKAGE(BODY&SEAT) LEAKAGE(SEAT) DIMENSIONS MANUFACTURER/ SUBCONTRACTOR SIGNATURE MAINSUPPLIERBHEL
**LEGEND: M:MANUFACUTRER/SUBCONTRACTOR/SUBVENDOR B:BHEL/NOMINATEDINSPECTIONAGENCY "P"PERFORM, "W" WITNESS,AND "V" VERIFICATION
C:CUSTOMER SIGNATUREOFAPPROVALBYCUSTOMER
124
QUALITYPLAN(FORTANKS,SKIDS,PUMPS,VALVES,PIPES,FITTINGS,FLANGES) QP.NO: PEQP373156A001 REV.: 0 DATE: 30/04/10 PAGE: 3OF3 ACCEPTANCENORMS 8 ASTMA182GR.TP304 ASTMA182GR.TP304 ASTMA262PR.'E' BHELAPPD.DATASHEET/DWG/ANSIB BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET NOLEAKAGE ASTMA312GR.TP304 ASTMA312GR.TP304 ASTMA262PR'E' NOLEAKAGE BHELAPPD.DATASHEET/DWG NOLEAKAGE APPDDWG/PAINTING
PROJECT PACKAGE CONTRACTNO. MAINSUPPLIER FORMATOF RECORDS 9 MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC MFG.TCLABREPORT MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC MFG.TC MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC/LABREPORT MFG.TC/IR INSPECTIONREPORT INSPECTIONREPORT INSPECTIONREPORT
S.NO COMPONENTS/OPERATION 1 9.0 9.1 9.2 10.0 10.1 10.2 10.3 11.0 11.1
CHARACTERISTICSCHECKED
CATEGORY 4 MA MA MI NA MA MA MA MA
TYPE/METHODCHECK 5 CHEM.&PHYTEST HEATTREATMENT IGCTEST MEASUREMENT PHY.&CHEM.TEST CHEMICAL MEASUREMENT MEASUREMENT HYDROTEST CHEMICAL MECHANICALTEST IGCTEST LEAKAGE MEASUREMENT
2 3 FITTING/FLANGESFORPIPING: RAWMATERIAL CHEM.&PHYPRPERTIES HEATTREATMENT IGCTEST FINALINSPECTION DIMENSIONS STRAINERS: RAWMATERIALFORBODY PHY.&CHEM.PROPERTIES SCREEN CHEMICAL MESHSIZE FINALINSPECTION DIMENSIONS LEAKAGE PIPE(SEAMLESS) MATERIAL CHEMICAL MECHANICALTEST IGCTEST HYDROTEST DIMENSIONS&ORIENTATION LEAKAGE,CHECKONWELDMENTS PAINTING
EXTENTOF CHECK 6 REFERNOTE5 100% 1/HTBATCH 100% 1/BAR 1/SIZE 1/SIZE 100%
REFERENCEDOCUMENT 7 ASTMA182GR.TP304 ASTMA182GR.TP304 ASTMA262PR.'E' BHELAPPD.DATASHEET/DWG/ANSIB BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET BHELAPPD.DATASHEET 1 BHELAPPD.DATASHEET ASTMA312GR.TP304 ASTMA312GR.TP304 ASTMA262PR'E' NOLEAKAGE BHELAPPD.DATASHEET/DWG DISCH.PIPING1.5xDISCHPR.OF PUMP,SUCTIONPIPING10KG/CM2 BHELAPPDPAINTINGSCHEME
10 P P P P P P P P P P P P P P P P V V V V V/W W W W V V V V V V V V V V V V V W W W V V V V V V V V
11
MA MA MI MA CR
1/HEAT 1/HTBATCH 1/HTBATCH 100% 100%
IDENTIFICATIONBY BHEL.REFERNOTE2.
12.0 COMPLETESKIDASSEMBLY:
MA
VISUAL&HYDROTEST 100% VISUAL&MEASUREMENT 100%
NOTE1)Duringevaluationanydefectechoshallnotbemorethan20%ofFSHorlossofbackwallechoaccompaniedwithdiscontinuityechoshallnotbemorethan20%ofFSH. NOTE2)FORPIPESPURCHASEDDIRECTLYFROMMANUFACTURER'SORAUTHORIZEDDEALERS,APARTFROMTCREVIEW,CHECKWILLBEASPERCLAUSE2.1.2AND10.0;HOWEVERFORHYDRAULICTEST,MANUFACTURERTCSHALLBEREVIEWED.INCASEONIMPORTEDPIPES PURCHASEDFROMOPENMARKET,TESTSHALLBEPERFORMEDASPERCLAUSE2.1.2AND10.0(INCLUDINGHYDRAULICTEST). NOTE3)FORRAWMATERIAL(BARS/PIPES/CASTINGS/FORGINGS)WHEREHEATTREATMENTARECARRIEDOUTBYMATERIALPRODUCERSONBULKQUANTITIES,THEIRTESTCERTIFICATESHALLBEREVIEWED(EXCEPTTIMETEMPERATURECHART) NOTE4)NDTREQUIREMENTONWELDING(TANK,PIPE,BREATHER)SHALLBEASA)ONBUTTWELD25%DP&25%RTFORPUMPSUCTIONSIDE&100%DP&100%RTFORPUMPDISCHARGESIDE.B)ONFILLETWELD100%DPTEST NOTE5)ALLCHEMICALTESTSSHALLBE1/HEATANDALLPHYSICAL/MECHANICALTESTSSHALLBE1/HEAT/HTBATCHUNLESSSPECIFICALLYMENTIONEDOTHERWISE.
**LEGEND: MANUFACTURER/ SUBCONTRACTOR SIGNATURE MAINSUPPLIERBHEL M:MANUFACUTRER/SUBCONTRACTOR/SUBVENDOR B:BHEL/NOMINATEDINSPECTIONAGENCY "P"PERFORM, "W" WITNESS,AND "V" VERIFICATION C:CUSTOMER SIGNATUREOFAPPROVALBYCUSTOMER
125
CUSTOMER : TITLE QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. TYPE/ METHOD OF CHECK P W V : NUMBER :
PROJECT
SPECIFICATION : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS
SL. NO.
SHEET 1 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK
QUALITY PLAN NUMBER PED-506-00-Q-006/0 ITEM AC ELECT. MOTORS BELOW 75KW (LV) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD
1
1.SHADE MA VISUAL SAMPLE MANUFR'S SPEC/BHEL SPEC./RELEVANT STANDARD MANUF'S SPEC MFG. DRG./ MFG. SPEC. MFG.SPEC./ RELEVANT IS MFG. DRG./ MFG. SPEC. MFG.SPEC. RELEVANT IS MANUF'S SPEC -DO-DOBHEL SPEC. SAME AS COL.7 LOG BOOK 3
9
-
10
-
11
1.O
PAINTING
2.0 2.DIMENSIONS MA -DO-DO-
ASSEMBLY
1.WORKMANSHIP
MA
VISUAL
100%
3 3
3.CORRECTNESS COMPLETENESS TERMINATIONS/ MARKING/COLOUR CODE 1.ROUTINE TEST INCLUDING SPECIAL TEST AS PER BHEL SPEC. 2.OVERALL DIMENSIONS & ORIENTATION MA MEASUREMENT & VISUAL 100% MA -DO100% IS-325/ BHEL SPEC./ DATA SHEET
MA
VISUAL
100%
-DO-
3.0
TESTS
SAME AS COL.7
TEST REPORT
2,1
2,1
NOTE -1
APPROVED DRG/DATA SHEET
APPROVED DRG/DATA SHEET & RELEVANT IS
INSPN. REPORT
BHEL
PARTICULARS NAME SIGNATURE DATE
BIDDER/VENDOR
BIDDER'S/VENDORS COMPANY SEAL
126
CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. TYPE/ METHOD OF CHECK P W V :
SL. NO.
SHEET 2 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK
PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-006/0 ITEM AC ELECT. MOTORS BELOW 75KW (LV) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD
SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS
1
3.NAMEPLATE DETAILS MA VISUAL 100% IS-325 & DATA SHEET IS-325 & DATA SHEET INSPN. REPORT
9
3
10
1 -
11
NOTES:
2 3
ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON WHERE EVER CUSTOMER IS INVOLVED IN INSPECTION, (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER. FOR EXHAUST/VENTILATION FAN MOTORS OF RATING UPTO 1.5KW , ONLY ROUTINE TEST CERTIFICATES SHALL BE FURNISHED FOR SCRUTINY.
BHEL
PARTICULARS NAME SIGNATURE DATE
BIDDER/VENDOR
BIDDER'S/VENDORS COMPANY SEAL
127
128
129
130
131
QUALITY PLAN NO.: PE-QP-999-145-I036___
STANDARD QUALITY PLAN FOR PROGRAMMABLE LOGIC CONTROLLER
VOLUME IIB SECTION D REV. NO. 00 SHEET 5 OF DATE: 23.03.2005 7
FACTORY ACCEPTANCE TEST (FAT) PROCEDURE This document covers procedure to conduct/witness PLC system functional tests in order to demonstrate conformity to purchase specifications and related engineering documents. The test shall be conducted at the system suppliers works. The system supplier shall conduct all functional tests before commencing FAT and test results shall be made available during FAT. Vendor must furnish following relevant drawings, duly approved by BHEL Engineering, for reference during FAT. a) Technical Specification of PLC. b) PLC System Configuration c) General Assembly Drawings. d) Panel Wiring Diagrams. e) Bill of Quantity for PLC System. f) Logic Diagram.
g) HMI Schematics. h) Input / Output List. Further the vendor shall furnish applicable product specification, datasheets, catalogues, test-certificates, and internal inspection records to enable FAT. Vendor shall also submit, for approval, his standard test procedure, for clauses given below; where vendors standard practice has been referred.
APPLICABLE TEST PROCEDURE:
1.
Input/Output Functional Verification. Check for correctness of addressing of racks, slots and I/O modules as per applicable PLC configuration diagram. Appropriate signal generators shall be used to simulate Inputs and outputs to check operation and SCAN time.
2.
Processor Verification PLC Configuration drawing to be referred for ascertaining i) ii) Redundancy Type (Hot or Cold) of redundancy
132
Module,PLAN Processor, Communication Module, Power Supply module etc VOLUME IIB STANDARD QUALITY from the running system and verify the corresponding system diagnostic SECTION D FOR messages. REV. NO. 00 DATE: 23.03.2005 PROGRAMMABLE LOGIC CONTROLLER
SHEET 7 OF 7
6.
Control Panel /Desk Verification i) PLC driven annunciation system should be checked by alarm signal simulation. Push Button and selector switch operation should be checked by verification of corresponding change of status of Data Base point. Indicating lamp / MIMIC should be checked by corresponding Data Base point simulation.
ii)
iii)
7.
Software Verification i). Control Logics: Software switches, lamps and Analog sources shall be used for simulation of field conditions .Control logics shall be checked for its correct functionality as per approved logic schemes Engineering features:a) Online changing of parameters, set points. b) Online modification in Control Logic Diagrams. c) Online configuration of Graphics, Trends, Logs, HSR. HMI features:Check for configuration & operation of Graphics, Trends, Logs, HSR and Alarms, in the form of Displays and Printouts, by simulation of Inputs as per approved documents.
ii).
iii).
8.
Burn in test i). PLC Modules are kept at 50 Deg C under continuous energized condition for 48 hours. Equipment is kept under continuous energized condition for 120 hours at ambient temperature. Temperature rise in the panels should be below 10 Deg C above ambient.
ii).
133
STANDARD QUALITY PLAN FOR PROGRAMMABLE LOGIC CONTROLLER
VOLUME IIB SECTION D REV. NO. 00 SHEET 6 OF DATE: 23.03.2005 7
Both the processors are to be checked for healthiness in case of redundant configuration as per vendors standard practice. In case of hot redundancy, switchover of control from primary processor to standby processor shall be demonstrated for uninterrupted control and data processing as per vendors standard practice. Switchover shall be witnessed, by manual power off or resetting the Primary CPU or simulating failure of primary processor. Checking should be by witnessing the lighting up of Processors LEDs as per manufacturers product standard. Vendor shall demonstrate, as per Vendors standard practice, adequate Loading (Spare Capacity) of Processors, as mentioned in contract specs. This shall be done, by simulating worst load operation of fully integrated PLC system.
3.
Power Supply Module Verification Check if PSM is in redundant mode as per specification. Check the healthiness of power supply from both the modules lamp indication/measurement. Simulate failure of one PSM and verify that standby PSM has taken over without any interruption.
4.
Communication System Verification Communication system has to be in line with approved PLC Configuration Diagram. Verify that both the communication buses are intact and connected. Communication between PLC processors, I/O rack, OWS etc. is to be checked through simulation of input data. Simulate the bus failure by disconnection of working bus. Check that the communication continues without interruption or loss of data. Following response times are to be demonstrated as per vendors standard practice for conformance to contract specifications: 1. 2. 3. 4. Screen update time I/O scan time SOE resolution time Data transfer time with third party system using Communication Protocol as per Contract specification and as per quantum of data as per approved signal exchange list.
5.
Diagnostic Verification Product Catalogue/Literature shall be referred for checking of all diagnostic features. Hardware failure to be simulated by removing an I/O
134
SPEC. NO. PE-TS-373-156-A001
SECTION E DATA SHEET A & C
PAGE:
135
SPEC. NO. PE-TS-373-156-A001
DATA SHEET A EFFECTIVE CAPACITY OF EACH TANK SHALL BE CALCULATED UPWARDS FROM THE LOW LEVEL SET POINT. Sl. no. Description Parameters 1.0 SULPHURIC ACID STORAGE TANK 1.1 Numbers Four (4) 1.2 Type Horizontal cylindrical with dished ends. 1.3 Type of fluid to be handled 98% Sulphuric Acid. 1.4 Effective capacity for each tank, in m3 50 m3 1.5 Minimum Free Board 300 mm 1.6 Manhole Two (2) on shell Each of minimum 450 mm NB 1.7 Design Temperature C 80 1.8 Material of Construction 1.8.1 Shell Carbon steel as per IS 2062 or ASTM A 515 Gr.70. 1.8.2 Dished Ends Carbon steel as per IS 2002 or ASTM A 515 Gr.70. 1.9 Thickness 10 mm 1.10 Design Code ASME SECVIIIDIVI /IS 2825 1.11 Accessories Fume absorber, platform with fixed ladder shall be supplied for each tank. 2.0 SULPHURIC ACID UNLOADING PUMPS 2.1 Number Two (2) [1W+1S]. 2.2 Location Outdoor. 2.3 Fluid to be handled 98% w/w Commercial Sulphuric Acid. 2.4 Service To unload Concentrated Sulphuric Acid from Tank Car to Sulphuric Acid Storage Tank. 2.5 Type of Pump Horizontal Centrifugal Non Clog type 2.6 Design standard As per IS5120 / IS5639. 2.7 Type of Impeller Semi Open or Open 2.8 Service temperature, in oC 80 maximum. 2.9 Rated Capacity, in m3/hr 10 m3/hr. 2.10 Range of operation 20 % 120 %. 2.11 Head to be developed at rated capacity Shall be decided during detailed engineering as per system requirement (10 mlc min) 2.12 Duty Intermittent and to be suited in parallel operation 2.13 Suction Condition Flooded 2.14 Material of construction 2.14.1 Casing Cast Iron 2.14.2 Impeller Alloy20 2.14.3 Shaft EN8 to BS970 2.14.4 Mechanical Seal Alloy20 2.14.5 Strainer Y type Carbon Steel (1X100 % for each pump) MOC of body: CI to IS 210 FG 260 Strainer: Strainer shall be of suitable material for Sulphuric Acid Service and size BWG30 mesh. Other requirements: Blowing arrangement shall
PAGE:
136
SPEC. NO. PE-TS-373-156-A001
2.14.6 2.14.7 2.15 2.15.1 2.15.2 2.15.3 2.15.4 2.16 2.17
Common Base plate Nut & bolts Type of drive Rated speed (RPM) Voltage, Phase & Frequency Type of coupling between Pump Motor Noise level (for complete set of Pump & Motor) Hose Hose manifold
be provided with removable plug at the outlet. Screen opening area shall be at least 6 times pipe crosssectional area. Fabricated Steel as per IS 2062 Alloy20 Electrical Motor 1500 (Sync.) maximum 415 V (+10%), 3 Phase, 50 HZ Flexible Spacer. Not more than 85 db (At a distance of 1.0 m from the outer surface of Motor). Two (2) nos., each 80 mm NB and 30 m long type2 HDPE hose as per IS 7654/1989. Hose manifold of ERW CS pipe to ASTM A53 GR B/ IS 1239 part I, heavy grade shall be provided.
3.00 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.7.1 3.7.2 3.8 3.8.1 3.9 3.10 4.0 4.1 4.2 4.3 4.4 4.5 4.6
SULPHURIC ACID DAY TANKS Numbers Type Type of fluid to be handled Effective capacity of each tank, in litres Minimum Free Board, in mm Design Temperature, C Material of Construction Shell Dished Ends Thickness Design Code Manhole Accessories SULPHURIC ACID INJECTION PUMPS Number Location Fluid to be handled Service Duty Type of Pump
Two (2) (1W+1S) Vertical cylindrical with dished bottom and bolted flat top flange cover 98% Sulphuric Acid. 7000 300 80 Carbon steel as per IS 2062 or ASTM A 515 Gr.70 Carbon steel as per IS 2062 or ASTM A 515 Gr.70 6 mm IS 803/2825 or Equivalent Not required Fume absorber, platform with removable type of cat ladder shall be supplied for each tank. Three (3) [2W+1S]. Indoor. 98% w/w sulphuric acid. To inject concentrated sulphuric acid into CW Fore bay. Continuous and suitable for parallel operation The chemical Injection pumps shall be positive displacement, reciprocating type, simplex, constant speed, variable stroke hydraulic diaphragm type. 300 LPH for 100% solution Local manual through micrometer dial/knob,
4.7 4.8
Rated Capacity, in LPH Facility for Capacity Adjustment
PAGE:
137
SPEC. NO. PE-TS-373-156-A001
4.9 4.10 4.11 4.12 4.13 4.13.1 4.13.2 4.13.3 4.13.4 4.13.5 4.13.6 4.13.7 4.13.8 4.14
Range of Capacity Adjustment Head to be developed at rated capacity Suction Condition Service temperature, in deg C Material of construction Housing Pump head Plunger Worm Worm Wheel Shafts Base plate Foundation bolts Strainer
remote manual from control panel & OWS and auto. 0 % 100 %. Shall be decided during detailed engineering as per system requirement (10 mlc min) Flooded. 80 Cast Iron Alloy20 Alloy20 Manganese Bronze / Cast Iron Manganese Bronze / Cast Iron Hardened Steel (EN 19 / ASTM A 276 Gr.410) MS Alloy20 Y type Carbon Steel (1X100 % for each pump) MOC of body: CI to IS 210 FG 260 Strainer: Strainer shall be of suitable material for Sulphuric Acid Service and size BWG30 mesh. Other requirements: Blowing arrangement shall be provided with removable plug at the outlet. Screen opening area shall be at least 6 times pipe crosssectional area. Electrical Motor 1500 (Sync.) maximum. 415 V (+10%), 3 Phase, 50 HZ Flexible Spacer. Not more than 85 db (At a distance of 1.0 m from the outer surface of Motor). Shall be provided for at each pump discharge API 675 Two (2) (1W+1S) Vertical cylindrical with dished bottom and bolted top flange cover. Commercial Scale Inhibitor Solution. 2500 Liter (each) 300. SS304 Not less than 5 mm. Shall be provided over the top cover to feed Scale Inhibitor Solution. Not required As per P&ID
4.15 4.15.1 4.15.2 4.15.3 4.15.4 4.16 4.16.1 4.17 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10
Type of drive Rated speed (RPM) Voltage, Phase & Frequency Type of coupling between Pump Motor Noise level (for complete set of Pump & Motor) Accessories Pulsation Dampener Design & test code SCALE INHIBITOR TANKS Numbers To be provided Type Type of fluid to be handled Effective capacity, in litres Minimum Free Board, in mm Material of Construction Thickness Feed Funnel Agitator Instruments
PAGE:
138
SPEC. NO. PE-TS-373-156-A001
5.11 5.12 5.13 6.0 6.1 6.2 6.3 6.4 6.5 6.6 6.7
Manhole Design Temperature, C Dissolving basket SCALE INHIBITOR INJECTION PUMPS Number Location Capacity Service Duty Fluid to be handled Type of Pump
Not required 60 Not required Three (3) [2W+1S] Indoor. 7.5 LPH (each) for 100% solution To inject Scale Inhibitor Solution into CW fore bay Continuous and suitable for parallel operation Commercial Scale inhibitor The chemical Injection pumps shall be positive displacement, reciprocating type, simplex, constant speed and variable stroke hydraulic diaphragm type. Local manual through micrometer dial/knob, remote manual from control panel & OWS 0 % 100 %. Flooded. Shall be decided during detailed engineering as per system requirement (10 mlc min) 60 Cast Iron SS316 SS316 Manganese Bronze / Cast Iron Manganese Bronze / Cast Iron Hardened Steel (EN 19 / ASTM A 276 Gr. 410) MS Electrical Motor 1500 (Sync.) maximum 415 V (+10%), 3 Phase, 50 HZ Flexible Spacer Not more than 85 db (At a distance of 1.0 m from the outer surface of Motor) Shall be provided for at each pump discharge Y type Carbon Steel (1X100 % for each pump) MOC of body: CI to IS 210 FG 260 Strainer: Strainer shall be of suitable material for Sulphuric Acid Service and size BWG30 mesh. Other requirements: Blowing arrangement shall be provided with removable plug at the outlet. Screen opening area shall be at least 6 times pipe crosssectional area. SS 316
6.8 6.9 6.10 6.11 6.12 6.13 6.13.1 6.13.2 6.13.3 6.13.4 6.13.5 6.13.6 6.13.7 6.14 6.14.1 6.14.2 6.14.3 6.14.4 6.15 6.15.1 6.16
Facility for Capacity Adjustment Range of Capacity Adjustment Suction Condition Head to be developed at rated capacity Service temperature C Material of construction Housing Pump head Plunger Worm Worm Wheel Shafts Base plate Type of drive Rated speed (RPM) Voltage, Phase & Frequency Type of coupling between Pump Motor Noise level (for complete set of Pump & Motor) Accessories to be provided Pulsation Dampener Strainers
6.17
Foundation Bolts
PAGE:
139
SPEC. NO. PE-TS-373-156-A001
6.18 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.11 7.12 7.12 7.13 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7
Design & test code CORROSION INHIBITOR TANKS Numbers Type Type of fluid to be handled Effective capacity, in litres Minimum Free Board Material of Construction Thickness Feed Funnel Agitator Instruments Manhole Design Temperature, C Dissolving Basket CORROSION INHIBITOR INJECTION PUMPS Number Location Rated Capacity, in LPH Service Duty Fluid to be handled Type of Pump
API 675 Two (2)(1W+1S) Vertical cylindrical with dished bottom and bolted top flange cover. Commercial Corrosion Inhibitor Solution. 2500 liter (each) 300 mm SS 304 Not less than 5 mm Shall be provided over the top cover to feed Scale Inhibitor Solution. Not required As per P&ID Not required 60 Not required Three (3) [2W+1S] Indoor. 7.5 LPH (each) for 100% solution To inject Scale Inhibitor Solution into CW fore bay Continuous and suitable for parallel operation Commercial Scale inhibitor The chemical Injection pumps shall be positive displacement, reciprocating type, simplex, constant speed and variable stroke hydraulic diaphragm type. Local manual through micrometer dial/knob, remote manual from control panel & OWS 0 % 100 %. Shall be decided during detailed engineering as per system requirement (10 mlc min) Flooded. 60 Cast Iron SS316 SS316 Manganese Bronze / Cast Iron Manganese Bronze / Cast Iron Hardened Steel (EN 19 / ASTM A 276 Gr. 410) MS Electrical Motor 1500 (Sync.) maximum 415 V (+10%), 3 Phase, 50 HZ
8.8 8.9 8.10 8.11 8.12 8.13 8.13.1 8.13.2 8.13.3 8.13.4 8.13.5 8.13.6 8.13.7 8.14 8.14.1 8.14.2
Facility for Capacity Adjustment Range of Capacity Adjustment Head to be developed at rated capacity Suction Condition Service temperature, in deg C Material of construction Housing Pump head Plunger Worm Worm Wheel Shafts Base plate Type of drive Rated speed (RPM) Voltage, Phase & Frequency
PAGE:
140
SPEC. NO. PE-TS-373-156-A001
8.14.3 8.14.4 8.15
Type of coupling between Pump Motor Noise level (for complete set of Pump & Motor) Strainers
8.16 8.17 8.17.1 8.18 9.0 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10
Foundation Bolts Accessories to be provided Pulsation Dampener Design & test code BIOCIDE TANKS Numbers Type Type of fluid to be handled Effective capacity, in litres Minimum Free Board Material of Construction Thickness Feed Funnel Agitator Instruments
Flexible Spacer Not more than 85 db (At a distance of 1.0 m from the outer surface of Motor) Y type Carbon Steel (1X100 % for each pump) MOC of body: CI to IS 210 FG 260 Strainer: Strainer shall be of suitable material for Sulphuric Acid Service and size BWG30 mesh. Other requirements: Blowing arrangement shall be provided with removable plug at the outlet. Screen opening area shall be at least 6 times pipe crosssectional area. SS 316 Shall be provided for at each pump discharge API 675 Two (2) [1w + 1S] Vertical cylindrical with dished bottom and bolted top flange cover. Commercial Biocide Solution. 1000 Ltrs 300 mm SS 304 Not less than 5 mm Shall be provided over the top cover to feed Biocide Solution. Not required As per P & ID.
9.11 9.12 10.0 10.1 10.2 10.3 10.4 10.5 10.6
Manhole Service temperature, in degree C Dissolving Basket BIOCIDE INJECTION PUMPS Number Location Fluid to be handled Service Duty Type of Pump
Not required 60 Not required Three (3) [2 W+1S] Indoor Commercial Biocide Solution To inject Corrosion Inhibitor Solution into CW fore bay Continuous The chemical Injection pumps shall be positive displacement, reciprocating type, simplex, constant speed and variable stroke hydraulic diaphragm type. 400 LPH (each) for 100% solution Local manual through micrometer dial/knob, remote manual from control panel & OWS
10.7 10.8
Rated Capacity, in LPH Facility for Capacity Adjustment
PAGE:
141
SPEC. NO. PE-TS-373-156-A001
10.9 10.10 10.11 10.12 10.13 10.13.1 10.13.2 10.13.3 10.13.4 10.13.5 10.13.6 10.13.7 10.14 10.14.1 10.14.2 10.14.3 10.14.4 10.15 10.15.1 10.16
Range of Capacity Adjustment Suction Condition Service temperature in oC Head to be developed at rated capacity Material of construction Housing Pump head Plunger Worm Worm Wheel Shafts Base plate Type of drive Rated speed (RPM) Voltage, Phase & Frequency Noise level (for complete set of Pump & Motor) Type of coupling between Pump Motor Accessories to be provided Pulsation Dampener Strainers
0 % 100 % Flooded 60 Shall be decided during detailed engineering as per system requirement (10 mlc min) Cast Iron SS316 SS316 Manganese Bronze / Cast Iron. Manganese Bronze / Cast Iron. Hardened Steel (EN 19 / ASTM A 276 Gr. 410). MS. Electrical Motor 1500 (Sync.) maximum. 415 V (+10%), 3 Phase, 50 HZ Not more than 85 db (At a distance of 1.0 m from the outer surface of Motor). Flexible Spacer. Shall be provided for at each pump discharge. Y type Carbon Steel (1X100 % for each pump) MOC of body: CI to IS 210 FG 260 Strainer: Strainer shall be of suitable material for Sulphuric Acid Service and size BWG30 mesh. Other requirements: Blowing arrangement shall be provided with removable plug at the outlet. Screen opening area shall be at least 6 times pipe crosssectional area. SS 316 API 675
10.17 Foundation Bolts 10.18 Design & test code Piping, Valves & Diffusers Sl. No. Equipment 11.01 11.02 Pipe MOC Fittings/flanges MOC
11.03 11.04 11.05 11.06 11.07
Nuts & bolt Valve type Valve MOC Ball valve(full bore type as per BodyCI to IS 210 FG 260 API 6D) Ball and wetted partsCI Check valve (flap type) BodyCI to IS 210 FG 260 Wetted partsCIRL (fully rubber lined with 3mm thick
Scale/corrosion/biocide inhibitor dosing system ASTM A53 Gr B/ IS 1239 Part ASTM A 312, GR TP 316, I, heavy grade schedule 10 Mild Steel ASTM A 182, GR TP 316, dimensions as per ASME B 16.11 SW Alloy 20 SS 316 As shown in P&ID As shown in P&ID Body ASTM A 182, GR TP 316 Ball and wetted partsSS 316 Body ASTM A 182, GR TP 316 Wetted partsSS 316 Endsas per ANSI B 16.11
Sulphuric acid dosing system
PAGE:
142
SPEC. NO. PE-TS-373-156-A001
11.08
Saunders Diaphragm Valve (Weir type) as per BS 5156 (for valves located at inlet of filling connection of tank and at drain line of tank as per P&ID).
11.09 11.10 11.11 11.12 11.13
Gate Valve (in service water line) Needle valve Pressure relief valve DiffusersQuantity DiffusersMOC
hard rubber (hardness 8590 on shore A) Endsas per ANSI B 16.11 125 class, FF, full face rubber lined BodyCI to IS 210 FG 260 Wetted partsrubber lining 3 mm thick as per IS 4682 (hardness 8590 on shore A) DiaphragmNeoprene Endsas per ANSI B 16.11 125 class, FF, full face rubber lined BodyCI to IS 210 FG 260 Wetted partsCast Iron SS 316 Cast Iron 3 numbers Alloy 20
Body ASTM A 182, GR TP 316 Wetted partsSS 316 DiaphragmNeoprene Endsas per ANSI B 16.11
BodyCI to IS 210 FG 260 Wetted partsCast Iron SS 316 SS 316 3 numbers per dosing system SS 316
NOTE: 1. Size of all pipes shall be as per P&ID.
PAGE:
143
DATA SHEET A FOR CW TREATMENT PLANT
SL.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
PARAMETERS MOTOR DESIGN AMBIENT TEMP VOLTAGE SUPPLY AND VARIATION FREQUENCY WITH VARIATION COMBINED VOLTAGE & FREQUENCY VARIATION MAX ACCEPTABLE RATING OF MOTOR AT 415 V SYSTEM FAULT LEVEL AND ITS DUARTION SUTABILITY OF TERMINAL BOX FOR FAULT LEVEL AND DURATION CLASS OF INSULATION & TEMP RISE LIMITED TO MIN. STARTING VOLTAGE MOTOR RATING FOR SINGLE PHASE SUPPLY MAXIMUM LOCKED ROTOR CURRENT ACCEPTABLE NOISE LEVEL TYPE OF STARTER PROVIDED IN MCC DOP OF ENCLOSURE SPACE HEATER REQUIREMENT PAINT SHADE SPECIAL REQUIREMENT
UNIT DEG. C VOLT Hz
SAGARDIGHI 50 415V, + 10% 50(+ 3% to - 5%)
10% (absolute)
KW KA (Upto) 200 KW 50kA sym for 3sec 50 KA, 0.25 sec Class-F and temp rise limited to 70 DEG C 80% 0.2 kW & Below % OF FLC DB 600% with of IS tolerance. as per IS 12065 DOL IP-55 & IP-54 for outdoor & indoor resp. 30KW & ABOVE RAL - 5012 TYPE TEST REPORTS MORE THAN 5 YEARS OLD ARE NOT -
ENERGY EFFICIENT
144
TITLE
SPECIFICATION NO.
MOTOR
VOLUME SECTION D 1 OF
II B
DATA SHEET - C
REV NO. 00 DATE 29/08/2005 SHEET 2
S. No. A. 1 2 3 4 5 6 7 B. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description General Manufacturer & country of origin Motor type Type of starting Name of the equipment driven by motor & Quantity Maximum Power requirement of driven equipment Rated speed of Driven Equipment Design ambient temperature Design and Performance Data Frame size & type designation Type of duty Rated Voltage Permissible variation for a b c) Voltage Frequency Combined voltage & frequency
Data to be filled by successful bidder
Rated output at design ambient temp (by resistance method) Synchronous speed & Rated slip Minimum permissible starting voltage Starting time in sec with mechanism coupled a) At rated voltage b) At min starting voltage Locked rotor current as percentage of FLC (including IS tolerance) Torque a) Starting b) Maximum
16 17 18 19
Permissible temp rise at rated output over ambient temp & method Noise level at 1.0 m (dB Amplitude of vibration Efficiency & P.F. at rated voltage & frequency a) At 100% load c) At 75% load
NAME OF VENDOR REV. NAME SIGNATURE DATE SEAL
145
TITLE
SPECIFICATION NO.
MOTOR
VOLUME SECTION D 2 OF
II B
DATA SHEET - C
REV NO. 00 DATE 29/08/2005 SHEET 2
S. No. c) At starting C. 1 2 3 4 5 6 Constructional Features
Description
Data to be filled by successful bidder
Method of connection of motor driven equipment Applicable Standard DOP of Enclosure Method of cooling Class of insulation Main terminal box a) Type b) Power Cable details (Conductor, size, armour/unarmour) c) Cable Gland & lugs details (Size, type & material) d) Permissible Fault level ( kArms & duration in sec)
7 8
Space heater details (Voltage & watts) Flame proof motor details (if applicable) a) Enclosure b) suitability for hazardous area i Zone ii Group O / I / II IIA / IIB / IIC
9 10 11 12 13 14 15 16 D.
No. of Stator winding Winding connection Kind of rotor winding Kind of bearings Direction of rotation when viewed from NDE Paint Shade & type Net weight of motor Outline mounting drawing No (To be enclosed as annexure) Characteristic curves/ drawings (To be enclosed for motors of rating t 55KW) a) Torque speed characteristic b) Thermal withstand characteristic c) Current vs time d) Speed vs time
NAME OF VENDOR REV. NAME SIGNATURE DATE SEAL
146
FORM NO. PEM-6666-0
SPECIFICATION NO.: VOLUME II B D 02 DATE: 19.07.2008
DATA SHEET FOR PLC SYSTEM
SECTION REV. NO. SHEET
1 OF 1 Data Sheet No.: PES-145-36-DS2-0
Data Sheet C
DATA SHEET C (TO BE FILLED BY BIDDER AFTER AWARD OF CONTRACT) PROJECT
GENERAL*
SERVICE QUANTITY LOCATION
PLC EQUIPMENT
MAKE / MODEL NO.
PROCESSOR DATA BUS (HMI) DATA BUS (I/O - CPU) DATA BUS (REMOTE I/O - CPU) FIELD CONTACTS INTERROGATION VOLTAGE LOCATION OF COUPLING RELAYS DESKTOP OWS QUANTITY DESKTOP MONITOR TYPE PRINTER (A4) - QUANTITY PRINTER (A4) - MODEL PROGRAMMING / CONFIGURATION FACILITY SAFETY STANDARD COMPUTER FURNITURE QUANTITY CLASS OF PROTECTION REMOTE I/O PANEL PANEL COLOUR BACK-UP DESK MIMIC CONTROL HARDWARE COMMUNICATION TO OTHER SYSTEM HARDWIRED PURPOSE MEDIUM TIME SYNCRONIZATION SIGNAL FORMAT SOFTLINK SERIAL LINK
POWER SUPPLY INPUT FEEDER
PLC PANEL REMOTE I/O PANEL
147
SPEC. NO. PE-TS-373-156-A001
Section F LIST OF DRAWINGS (P&ID OF CW TREATMENT PLANT & TENTATIVE EQUIPMENT LAYOUT OF CW TREATMENT PLANT)
PAGE:
148
149
150
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PSER:SCT:SDG-M1349:12. II SCOPE OF WORK, TECHNICAL SPECIFICATION, DRAWING ETC

WEST BENGAL POWER DEVELOPMENT COMPANY LIMITED, KOLKATA

TECHNICAL SPECIFICATION FOR

SPECIFICATION NO: PE-TS-373-156-A001 VOLUME -IIB

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

40 41 49 62 65 66 79 81 82 83 84 115 118 122 135 148 149 150 151

Typicalinstrumentinstallationdiagram QualityPlans Datasheet A&C Listofdrawings P&IDforCWtreatmentplant TentativeEquipmentlayoutforCWtreatmentplant MechanicalGAofCW/ACWandF/Wpumphouse

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

SECTION A SCOPE OF ENQUIRY

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

SECTION B PROJECT INFORMATION

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

VOLUME : IIA SECTION-III PROJECT SYNOPSIS AND GENERAL INFORMATION

84% 73% 26.9 C

Average annual rainfall Seismic zone

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

SECTION C SPECIFIC TECHNICAL REQUIREMENT

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

SECTION C1 EQUIPMENT / SYSTEMS TO BE SUPPLIED ALONG WITH DESIGN ENGINEERING REQUIREMENTS

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

SECTION C2 SPECIFIC TECHNICAL REQUIREMENT FOR THE CW TREATMENT PLANT

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

of each = Tank for 15 of each = Tank for 15

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA

SPEC. NO. PE-TS-373-156-A001

VOLUME II-B SECTION REV. NO. 0 DATE: SHEET OF

PS-PEM-MAX PPEI BUILDING, PLOT NO 25, SECTOR 16A, NOIDA