ODISHA POWER GENERATION CORPORATION LIMITED

BANHARPALI, JHARSUGUDA ODISHA 768234 INDIA

IB THERMAL POWER STATION 2 660 MW UNITS 3 & 4

Date: 30-01-2015
Reference: Letter Ref. No. OPGC-BOP-1313 DT 17-12-2014
Subject: Comments on: Plant instrument & Service air distribution P&ID.
Comment Resolution Sheet:

Sl.
No.

OPGCL / DCPL
Comments
Date: 02-05-2014

BGR
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OPGCL / DCPL
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Response
Resolut
Date: 19-06ion
2014
Date: 12-062014

BGR Replies /
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on
Date: 03-072014

OPGCL / DCPL
Response
Date: 16-07-2014

OPGCL / DCPL
Response
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Date: 08-09Resolution
2014
Date: 27-08-2014

BGR
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Date: 02-02Resoluti
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on
Date: 30-012015

Please note that

computing
Nm3/hr x 1.35
gives
FAD
of
compressor
at
site
condition
which is at inlet
condition. As per

Point closed.

DRAWING NO: GID-208-ME-SCB-XB-1564

1.

2.

3.

4.

5.
6.

Furnish basis on
arriving the total
air quantity.
There
are
multiple
interfacing points
with BTG. Please
refer BHELs P&ID
(PE-DG-391-555A003) and revise
the
P&ID
accordingly.

Please
refer
the attached Noted.
annexure-1

Point closed.

Noted
drawing
revised.

Noted.

Point closed.

Noted.

Point closed.

Noted.

Point closed.

Noted.

Point closed.

and

Noted
and
Tap for both CT
drawing
unit to be shown.
revised.
Tap of for AHP Noted
and
compressor
drawing
building to be
revised.
shown.
and
SA to FOPH & Noted
another line tap drawing
off for dyke area. revised.
Please
furnish Please
note
pipe sizing and that
the
pressure
drop instrument
calculation
for and
service
the
entire air lines are
network of IA & 50 NB only.
SA system.
Hence
no
need
to

BGR has to Pipe

size
furnish
back
selected is as
up calculation
per
the
for pipe size &
velocity
pressure drop.
criteria
Pipe
sizing
provided
in
shall
be
NIT Vol-II B/Srevised
I/Annexure-

Please check
the
pipe
size
calculation
once
again according to
velocity
criteria
and correct it.

Our

Noted.

DEVELOPMENT CONSULTANTS PRIVATE LIMITED

DEVELOPMENT CONSULTANTS HOUSE
BLOCK-DG/4, SECTOR-II, SALT LAKE, KOLKATA 700 091
Page 1 of 8

Comments Resolution Sheet: Continued.

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OPGCL / DCPL
Comments
Date: 02-05-2014

BGR
Replies
OPGCL / DCPL
/
Response
Resolut
Date: 19-06ion
2014
Date: 12-062014
furnish
the
based on the
pipe
sizing
velocity
and pressure
criteria
as
drop
provided
in
calculation.
NIT Vol-IIB/SI/Annexure1/page 14

BGR to state
the
pr.
availability at
each
consumption
point. BGR to
note that the
pressure
availability at
BTG terminal
point is about
6.5 to 7.0
kg/cm2
(g).
BGR
to
furnish
backup
pr.
drop
calculation
for each line
upto
the
consumption
point.
For
service

BGR Replies /
Resoluti
on
Date: 03-072014
1/page
14
only.
A
header of 50
NB is more
than
sufficient for
considering
the
Service
air flow of
633m3/hr
(472 Nm3/hr)
and
the
Instrument
air flow of
496m3/hr
(370 Nm3/hr)
and
the
minimum
velocity of 20
m/sec.
Please note
that flow in
the
other
branch lines
are very low
compared
with
total
flow of the
system and
we
have
considered
the minimum
line size of 25
NB.
Please note
that
the
instrument
and service
air lines are
50 NB, 40 NB

OPGCL / DCPL
Response
Date: 16-07-2014
comments on line
sizing for IA & SA
have been marked
separately
in
respective
dwgs.
Please check &
revise.

OPGCL / DCPL
Response
BGR Replies /
Date: 08-09Resolution
2014
Date: 27-08-2014

BGR
OPGCL / DCPL
Replies
Response
/
Date: 02-02Resoluti
2015
on
Date: 30-012015

standard
practice,
pipes
sized for outlet
condition of the
compressed air
at 7.5 Kg/cm2 (g)
only.
Please
refer
the
attached line size
calculation
(Annexure-I), in
which
the
calculated
line
size is more than
adequate
to
handle the air
flow.

CRS-VDT-BOP-0007
Page 2 of 8

Comments Resolution Sheet: Continued.

Sl.
No.

7.

8.

OPGCL / DCPL
Comments
Date: 02-05-2014

Please
indicate
each line utility
end
point
pressure & flow.

As per contract
document, Cl no.
4.19.00 of vol - II
H2/S-I no service
or instrument air
shall be supplied
by buyer from
mail
plant

BGR
Replies
OPGCL / DCPL
/
Response
Resolut
Date: 19-06ion
2014
Date: 12-062014
air, pipe size
shall be such
that at any
instant all the
service
stations for a
particular
area/building
are
in
operation to
get
the
required flow.
In
normal Please
refer
practice
reply
as
pressure and furnished
flow
against
sl.
parameters
no.6.
are
not
specified
in
the
air
distribution
P&ID.
Also
please
note
that there is
no
process
parameters
mentioned in
the
BHELs
P&ID (PE-DG391-555A003)
also.
Hence
need
not
to
be
shown.
Noted
and Noted.
drawing
revised.

BGR Replies /
Resoluti
on
Date: 03-072014

OPGCL / DCPL
Response
Date: 16-07-2014

OPGCL / DCPL
Response
BGR Replies /
Date: 08-09Resolution
2014
Date: 27-08-2014

BGR
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Response
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Date: 02-02Resoluti
2015
on
Date: 30-012015

and 25 NB
only. Hence
no need to
furnish
the
pipe
sizing
and pressure
drop
calculation.
Noted.
Please
refer
our reply as
furnished
against
sl.
no.6.

Point closed.

Noted.

CRS-VDT-BOP-0007
Page 3 of 8

Comments Resolution Sheet: Continued.

Sl.
No.

9.

10.

OPGCL / DCPL
Comments
Date: 02-05-2014
compressed
air
system to CHP
area.
Compressors and
other
facilities
including
compressor
house
required
for this purpose
shall be within
sellers scope.
As per contact
document,
Annexure I of Vol.
II B/S-V, the pipe
material for both
IA & SA systems
shall be stainless
steel as per ASTM
A-312 Gr.304 for
50 NB & below
pipe
size,
thickness shall be
schedule
40S
ANSI B36.19 &
fittings will be
socket weld.
*- thus marked
area provide PT
*- thus marked
area provide PG

BGR
Replies
OPGCL / DCPL
/
Response
Resolut
Date: 19-06ion
2014
Date: 12-062014

Noted
drawing
revised.

BGR Replies /
Resoluti
on
Date: 03-072014

OPGCL / DCPL
Response
Date: 16-07-2014

OPGCL / DCPL
Response
BGR Replies /
Date: 08-09Resolution
2014
Date: 27-08-2014

BGR
OPGCL / DCPL
Replies
Response
/
Date: 02-02Resoluti
2015
on
Date: 30-012015

and

As per tender
drawings
(K8B09-DWGM-001M-R1 &
K8B09-DWGM-001N-R1)
pressure
transmitters
and
the
pressure
gauges
requirements
are
not
envisaged for

Noted.

Point closed.

Please provide
pressure
gauges at all
terminal
consumption
point locations
for instrument
& service air
distribution
system.

As per tender
drawings
(K8B09-DWGM-001M-R1 &
K8B09-DWGM-001N-R1)
the
pressure
gauge
requirements
are
not
envisaged for
instrument
and service air
at
the

Instrumentation
shown in contract
flow
diagram
is
indicative only. BOP
contractor
is
responsible
for
developing detail P
& ID showing all
instrumentation for
increased reliability,
better performance
and uniformity of
hardware
and
efficient spare parts

As
per
tender
drawings (K8B09DWG-M-001M-R1
& K8B09-DWG-M001N-R1)
the
pressure
gauge
requirements are
not envisaged for
instrument
and
service air at the
terminals.
Please refer the
BHEL
P&ID
in
which they have
also not provided
the
pressure

BGR
is Provided
in Noted.
requested to the
revised
provide PG at drawing.
least to the
following five
locations
to
monitor
the
pressure:
Near
Ash
silo
Near FOPH
PTP
plant
area
CT area
Fire station

CRS-VDT-BOP-0007
Page 4 of 8

Comments Resolution Sheet: Continued.

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No.

OPGCL / DCPL
Comments
Date: 02-05-2014

BGR
Replies
OPGCL / DCPL
/
Response
Resolut
Date: 19-06ion
2014
Date: 12-062014
instrument
and
service
air
at
the
terminals.
Hence
not
provided.

BGR Replies /
Resoluti
on
Date: 03-072014

OPGCL / DCPL
Response
Date: 16-07-2014

terminals.
Hence
not
provided and
not
required
also.

management
meet
specification
requirement.

Noted.

Noted.

OPGCL / DCPL
Response
BGR Replies /
Date: 08-09Resolution
2014
Date: 27-08-2014

to gauge
the instrument
service air at
terminals.
Hence
provided and
required also.

BGR
OPGCL / DCPL
Replies
Response
/
Date: 02-02Resoluti
2015
on
Date: 30-012015

for
and
the
not
not

Comments dated 19.06.2014

11.

12.

13.

To get flow at
site conditions
a
multiplication
factor of 1.35
should
be
considered
this comment
applicable for
each line.
Please
note
that
a
separate
air
receiver
of
capacity
2
cum is being
supplied
as
loose items by
BTG
vendor.
BGR to install
the same and
connect
with
this piping.
Indicate
design
pressure.
It
shall be min.
10 kg/cm2(g)

Point closed

Noted
drawing
revised.

and Safety relief valve & Noted

and Noted.
pr. gauge shall be drawing revised.
provided by BGR.

Noted
drawing
revised.

and Noted.

Point closed.

Point closed.

New Comments
14.

Service air system:

a. Common
header shall
be min. 80

Pls refer our reply Noted.

for pt no. 6 and
Annexure I. Line
shall be based on

Point closed.

CRS-VDT-BOP-0007
Page 5 of 8

Comments Resolution Sheet: Continued.

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No.

OPGCL / DCPL
Comments
Date: 02-05-2014

BGR
Replies
OPGCL / DCPL
/
Response
Resolut
Date: 19-06ion
2014
Date: 12-062014

BGR Replies /
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on
Date: 03-072014

OPGCL / DCPL
Response
Date: 16-07-2014
NB as per
velocity
critera.
Pls
check.
b. Common line
shall
be
based
on
single
highest
demand (for
DM
plant
without
considering
usage factor)
(i.e
=
5*40*1.35=2
70cumhr.
Instrument
air
system:
a. Should
be
min. 65 NB
as
per
velocity
criteria.
b. Common line
should
be
min. 50 NB
as
per
velocity
criteria (flow150*1.35=20
2.5 cum/hr)
c. Should
be
min. 40 NB
as
per
velocity
criteria.
(flow=75*1.3
5=101.25
cum/hr).
d. Should
be

OPGCL / DCPL
Response
BGR Replies /
Date: 08-09Resolution
2014
Date: 27-08-2014

BGR
OPGCL / DCPL
Replies
Response
/
Date: 02-02Resoluti
2015
on
Date: 30-012015

highest demand
without
considering usage
factor.
However
multification
factor will not be
considered
as
refered in pt.no.
6.

CRS-VDT-BOP-0007
Page 6 of 8

Comments Resolution Sheet: Continued.

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No.

OPGCL / DCPL
Comments
Date: 02-05-2014

15.

16.

BGR
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OPGCL / DCPL
/
Response
Resolut
Date: 19-06ion
2014
Date: 12-062014

BGR Replies /
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Date: 03-072014

OPGCL / DCPL
Response
Date: 16-07-2014
min. 40 NB
as
per
velocity
criteria.
Check & furnish Pr.
Drop calculation for
each
line
from
cranes hand book
or
any
other
standard book.
Individual
lines
towards
building
shall be designed
considering
all
service stations are
operating at a time.
E.g.if there are 2
nos.of
service
stations the line
size of the same
shall be for a flow
of 108 cumhr. (i.e
2*40*1.35). Based
on velocity criteria
the line size shall
be of 40 NB. No
usage factor should
be considered for
individual building.
Common
header
shall be designed
based on higher
flow either of two
following criteria:
1) Minimum
flow in the
header shall
be
single
largest
building
demand

OPGCL / DCPL
Response
BGR Replies /
Date: 08-09Resolution
2014
Date: 27-08-2014

BGR
OPGCL / DCPL
Replies
Response
/
Date: 02-02Resoluti
2015
on
Date: 30-012015

Noted & attached

as Annexure - I

Noted.

In our opinion at
no point of time
all the service
lines will be used
simultaneously.
As per existing
practice and data
from
previous
projects only 10
15% of the total
terminal
points
will be operating
at a time.

Noted.
Noted.
However M/s
BGR
should
ensure
that
the pipe size
should
capable
of
providing
service air at
least
for
single service
station
demand (i.e.
40
nm3/hr)
for
each
building with
required min.
pressure.

CRS-VDT-BOP-0007
Page 7 of 8

Comments Resolution Sheet: Continued.

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No.

OPGCL / DCPL
Comments
Date: 02-05-2014

BGR
Replies
OPGCL / DCPL
/
Response
Resolut
Date: 19-06ion
2014
Date: 12-062014

BGR Replies /
Resoluti
on
Date: 03-072014

OPGCL / DCPL
Response
Date: 16-07-2014

OPGCL / DCPL
Response
BGR Replies /
Date: 08-09Resolution
2014
Date: 27-08-2014

BGR
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Date: 02-02Resoluti
2015
on
Date: 30-012015

considering
all
service
station
of
building are
working
without
considering
usage factor.
2) Minimum
flow
with
usage factor
when
there
are
more
than
five
branches
/
buildings
from
this
common
header.

CRS-VDT-BOP-0007
Page 8 of 8