Tce PG 72 Vol III A

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.
(APPDCL)
2X800 MW COAL FIRED POWER PLANT NEAR KRISHNAPATNAM, NELLORE DIST., ANDHRA PRADESH, INDIA STEAM GENERATORS & AUXILIARIES SPECIFICATION
VOLUME III
TCE CONSULTING ENGINEERS LTD 73/1, ST. MARKS ROAD BANGALORE 560 001 INDIA
November 2007
MAIN PLANT & AUXILIARIES SPECIFICATION
STEAM GENERATORS & AUXILIARIES
VOLUME IIIA
SPEC. NO.
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD 2X800 MW TPP NEAR KRISHNAPATNAM
VOLUME IIIA CONTENTS
TCE.5103A-C-510-01
STEAM GENERATORS AND AUXILIARIES
SHEET 1 OF 3
VOLUME III A CONTENTS

SECTIO N NO. SPECIFICATION NO. REV .NO. R0 R0 R0 R0 R0 R0 R0 R0 R0 TITLE
NO. OF SHEETS
D1 D1.1 D1.2 D2 D3
TCE.5103A-C-510-01 TCE.5103A-C-510-01 TCE.5103A-C-510-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 DATA SHEETS A
MECHANICAL DESIGN REQUIREMENTS SG & AUXILIARIES DESIGN REQUIREMENTS SPECIFIC PIPING REQUIREMENTS I & C DESIGN REQUIREMENTS ELECTRICAL DESIGN REQUIREMENTS 17 15 107 10
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21
TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.M4-203-01
DESIGN PARAMETERS OF SG AND AUXILIARIES UTILITY REQUIREMENTS STEAM GENERATOR PRESSURE PARTS REGENERATIVE AIR PREHEATER CENTRIFUGAL FANS AXIAL FANS SOOT BLOWING SYSTEM COAL BURNERS COAL MILLS FUEL OIL BURNERS AND IGNITORS FUEL OIL PUMPS ELECTROSTATIC PRECIPITATOR DUCT & DAMPERS CHAIN PULLEY BLOCK (HAND OPERATED) ELECTRICALLY OPERATED HOISTS POWER PLANT PIPING & VALVES STRAINERS SHELL AND TUBE HEAT EXCHANGERS THERMAL INSULATION FOR HOT SURFACES FLASH TANK INDUCTION MOTORS
5 1 1 1 1 1 1 1 1 1 1 2 1 2 2 9 2 2 2 1 5 ISSUE R0 TCE FORM 329 R3
R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R8
SPEC. NO.
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SHEET 2 OF 3
A22 A23 A24 A25 A26 A27
T CE.M4-203-02 TCE.M4-203-11 TCE.M4-203-06 TCE.M4-219-01 TCE.M4-219-11 TCE-M4-203-71 DATA SHEETS B
R8 R7 R4 R7 R6 R1
INDUCTION MOTORS -ADDITIONAL REQUIREMENT FOR HT MOTOR D.C. MOTORS
3 MOTOR OPERATED VALVE ACTUATORS 6 CONTROL CABINETS 2 LOW VOLTAGE SWITCH GEAR VARIABLE SPEED DC/AC DRIVES 6 9
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21
TCE.5103A-C-510-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 TCE M4-105-01 TCE.5103A-C-500-01 TCE.M4-113-54
R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R10 R0 R5
STEAM GENERATOR PERFORMANCE DATA HEAT RELEASE AND OTHER DATA STEAM GENERATOR PRESSURE PARTS REGENERATIVE AIR PRE HEATER STEAM COIL AIR PRE HEATER CENTRIFUGAL FANS AXIAL FANS SOOT BLOWING SYSTEM FUEL OIL BURNERS AND IGNITORS COAL BURNERS COAL MILLS ROTARY GEAR/SCREW PUMPS FUEL OIL HEATERS AIR AND FLUE GAS DUCTS AND DAMPERS ELECTROSTATIC PRECIPITATOR INSULATION/REFRACTORY SEPERATOR DRAIN RECIRCULATION PUMPS ATMOSPHERIC DRAIN TRANSFER PUMP HORIZONTAL CENTRIFUGAL PUMPS DRAWING AND DETAILS ELECTRICALLY OPERATED HOISTS
11 3 5 3 2 2 2 3 2 2 3 2 2 2 7 2 1 1 1 3 3 ISSUE R0 TCE FORM 329 R3
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SHEET 3 OF 3
B22 B23 B24 B25 B26 B27 B28
TCE.5103A-C-500-01 TCE-M4-219-11 TCE-M4-203-06 TCE-M4-203-11 TCE-M4-203-71 TCE-M4-219-01 TCE-M4-203-01
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FOUNDATION LOADING AT COLUMN BASES LOW VOLTAGE SWITCHGEAR MOTOR OPERATED VALVES ACTUATORS D.C. MOTORS VARIABLE SPEED DC/AC DRIVES CONTROL CABINETS INDUCTION MOTORS
1 8 2 2 4 1 5
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ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 2 X 800MW TPP NEAR KRISHNAPATNAM
VOLUME IIIA
TCE-5103A-C-510-01
STEAM GENERATORS & AUXILIARIES 1.0 MECHANICAL DESIGN REQUIREMENTS General 1.1
SECTION D1.1 SHEET 1 OF 17
The steam generator shall be designed for maximum continuous rating (SGMCR capacity) as specified in Data Sheet- A1. Bidder shall offer super critical pressure type once trough steam generators of proven design. The steam generators and its auxiliaries shall be designed for outdoor installation. The steam generator unit shall be capable of operating on sliding pressure /modified sliding pressure mode. The load range for the sliding pressure unit operation shall be from 40% steam generator maximum continuous rating (SGMCR) to 100% TGMCR. However it shall also be possible to operate the steam generator with modified sliding pressure mode, with constant pressure mode operation between 90% TGMCR to 100 % SGMCR. Steam generator shall be designed to meet the Indian Boiler Regulations (IBR) requirement. Wherever IBR is not specific about material, design, manufacture, inspection and testing requirements, ASME or equivalent reputed international code shall be used. Steam Generator Structure
1.2
1.3
1.4
1.5
The steam generator structure shall be designed to support all loads located on the structure including the load transferred from the furnace buck stays, seismic and wind loads. In addition, other loadings may be introduced on the structure from piping, enclosures, adjacent structures and equipment. Furnace
1.6
The furnace shall be designed such that the heat release rates shall not exceed the values specified in Data Sheet-A1 of Vol III. The distance between centre line of bottom most coal burner and furnace hopper working point shall be not less than 3 meters. The configuration of the furnace shall be such that flame impingement on any section of the furnace is avoided over the entire load range. The furnace shall be designed for a pressure as indicated in Data sheet-A1, to withstand pressure regimes without permanent deformations. The furnace shall be made of gas tight welded membrane walls and the tube panels bent, where required for openings of wall blowers, observation ports, access doors and instruments. To minimise the wear of membrane walls, geometry that causes notch effect shall be avoided. The furnace walls shall be either spiral wound and vertical tubes or vertical rifle tubes, as per the manufacturer s practice. Bending radius for tubes shall be as large as possible and minimum 1.5 times of external diameter. The furnace shall have hopper bottom with stainless steel seal plates suitable for connection to an ash hopper. A suitable sealing arrangement shall be
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provided for connecting to water impounded wet type bottom ash hopper. The clear width of the hopper throat shall not be less than 1100mm. The elevation of hopper bottom shall be not less than 9.0 m from ground level. 1. 10 All openings of wall blowers, observation ports, access doors and instruments shall be designed to prevent infiltration of air into the unit. Casing 1. 11 A gas tight enclosure shall be designed for the entire steam generator from the lower furnace to the economiser exit. In areas where welded wall construction is used, no skin casing is required, but skin casing of steel plates shall be used for all enclosures and behind all wide spaced tubes where refractory is used. Frames shall be furnished around all openings in the steam generator, designed to allow for expansion between the welded wall or inner skin casing and an outer aluminium lagging. Furnace Wall Evaporator and Steam System 1.12 The system shall be designed for a continuous operating capability as specified in Data Sheet-A1 of Vol III. Bidder shall clearly bring out the design features that individual evaporator tubes to have uniform temperature distribution, to minimize the peak tube metal temperature, unit temperature variation between adjacent enclosure tubes and prevent departure from nucleate boiling in evaporator sections. The Bidder shall also indicate about the precautions to be taken. The furnace wall system shall be of materials specified in the Data Sheet- A3 of Vol III. The Bidder shall enclose a calculation sheet for tubes, pipes and headers, stating dimensions, material, tolerance, design pressure and design temperature, design tension, operating pressure and operating temperature as well as fatigue factors and necessary wall thickness either with the bid or at contract stage. The furnace wall system shall be made of seamless tubes. A careful and safe fixing and suspension of tubes and tube banks shall be available to prevent misalignment and rubbing during operation. Design details shall be included in the Bid document. Suitable allowances shall be provided for all the water wall tubes and steam tubes to counter the erosion conditions. The furnace support system shall be so designed to transfer the weight of the entire furnace to the structural steel so as to accommodate inherent movement and expansions during operation without imposing any constraints. Further, construction of furnace walls shall be no way create differential thermal expansion on the furnace wall tubes. The bidder shall furnish details of furnace support system including systems of transfer of furnace wall loads and construction of steam generator support system in his bid.
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STEAM GENERATORS & AUXILIARIES 1.17
The furnace walls shall be equipped with buck stays arranged at suitable spacing to take up the forces due to positive and negative gas pressure expansions. The furnace buck stays design pressure shall be as specified in Data sheet A1 of Vol III. Separators , Storage Tank and Circulating Pumps
1.18
A watersteam separator system shall be provided with an adequately dimensioned collecting vessels and cyclone separators for use during steam generator start- up and low loads. The water / steam separators shall be arranged at the evaporator outlet and shall be so sized to ensure adequate steam separation. The water /steam mixture shall be fed into the separators by connecting pipe work which shall enter tangentially around the circumference at an inclined angle to ensure mixture moving spirally downwards and the water/steam separation is done by means of applied centrifugal force .The water shall be led downwards to the collecting vessel and the steam escapes centrally upwards to the connections towards the first superheater stage. A certain water level shall be maintained in the collecting vessel during low load operation and the surplus water volume must be drained off. The draining of the water shall be controlled. The water received in the separators shall be re-circulated to the economizer inlet via 1X100 % glandless hermitically sealed re-circulation (start up) pump .The water level in the collecting vessel shall be maintained by the provision of control valve(s) at the outlet of the re-circulation pump. Suitable arrangement shall be incorporated to provide adequate NPSH to the pump under all operating conditions during operation. At higher loads the recirculation pump shall not be in operation and the entire flow from the evaporator is directed to the superheater. It shall also be possible to start the steam generator without the re-circulation pump. The bidder shall provide detail construction features of the re-circulation pumps offered. To assure the adequate cooling of the furnace tubes of the evaporator during start-up or in low load operation, a minimum flow rate of approximately 40 % TGMCR shall be maintained. Since during the normal operating range the separator and the associated system are not in operation, an appropriate warm- up system shall be provided to switch over to the operation with separators, in case of such requirements. Bidder shall furnish complete details of start- up and low load operation system with separators and drain system and shall also provide detailed flow diagrams/ P & I diagrams for the system offered.
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STEAM GENERATORS & AUXILIARIES Atmospheric Flash Tank 1.26
To facilitate start-up of the steam generator, an atmospheric flash tank shall be provided. The flash tank shall receive excess water from the separator during start-up. The flashed steam shall be led to the atmosphere through a silencer above the boiler roof and the remaining condensate shall be led into a condensate collection tank. The condensate from the condensate collection tank shall then be transferred to the condenser by the provision of 2X100% condensate transfer pumps for minimizing the make-up water requirement. The flash tank shall also receive other start-up drains from : a) Economiser system b) Superheater system c) Reheater system d) Soot blower system e) Oil heating system f) Mill steam system The flash tank shall be adequately sized to take care of the total drain in the complete steam generator and power cycle piping system. Superheater(SH) and Reheater (RH)
1.27
1.28
1.29
The superheater and reheater shall be of proven design and shall be designed to maintain superheat and reheat steam temperatures at superheater and reheater outlet over the entire steam temperature control range (i.e. from 40% SGMCR to 100% SGMCR rating for SH and 60% TGMCR to 100% SGMCR rating for RH ) under the following conditions: With the steam generator heat absorption surface condition varying from clean up to normally expected and permissible fouling limits. With minimum possible use of de-superheating spray. With permissible and normally expected unbalance or stratification in flue gas flow. With all specified mode of fuel burning.
1.30
Only the proven material for long periods of operations for the required pressure and temperature conditions shall be adopted. Suitable allowances in tube thickness shall be provided considering erosion due to fly ash, laden flue gas. Bidders shall furnish satisfactory explanations with the list of experience for the materials of construction of SH and RH tubes used. Clearances between the tube elements shall be convenient for cleaning and maintenance. For horizontal tube bundles the arrangement shall be such as to permit free expansion without constraints.
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The superheater and reheater elements shall be arranged to ensure the uniform steam distribution and minimum steam temperature variation across the width of the steam generator at all operating conditions and loads. Bidder shall indicate the expected temperature variation. The attemperators are to be of spray type fitted with an inner removable lining, so arranged that the lining could be removed readily without recourse to extensive cutting of the construction welds. Ample provision shall be allowed to enable internal inspection of the vessel by means of the intrascope. Complete superheater and reheater temperature control system with necessary piping, block, control, isolation, drain, vent, check valves and instrumentation and controls shall be provided. In case of RH temperature control is by means of damper control of the flue gases or gas recirculation, the bidder shall furnish list of such installations where the systems installed by the Bidder are in operation. The superheater and reheater supports or hangers exposed to hot gases within the setting shall be of a heat-resistance material suitable for long life under the service condition. Auxiliary steam tap-off connection for soot blowing shall be either from intermediate superheater header or from cold reheat line or from auxiliary steam header. In case the steam is tapped off from the cold reheat line or from auxiliary steam header, CONTRACTOR shall furnish a list of installation where such systems are in vogue and also the same shall be reflected appropriately in the turbine cycle heat balance diagrams. Suitable allowance shall be provided for the super heater and reheater tubes to counter the erosion condition. Economiser
1.34
1.35
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1.37
1.38
It shall be ensured that the economiser design pressure exceeds the steam generator design pressure by an amount of at least equal to the pressure drop (friction and static) through the economiser at the 100% SGMCR condition. The economiser shall be of non-steaming and bare tube type. The tube banks shall be of in line design. The design of the economiser shall be such that the tube elements can be easily replaced when necessary. Suitable allowance shall be provided for economizer tubes to counter the erosion. In order to achieve high boiler availability, all tubes in the economiser, HP superheaters and reheaters shall be easily replaceable. Bidder shall submit the procedure for the replacement for the PURHSER/ENGINEERS review during detailed engineering stage. Headers
1.39
1.40
All headers in high temperature gas path shall be located outside the gas path.
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The header vents, drains, pressure gauges, water and steam safety valve connections shall be of weld-end type. Instruments as required including test connections shall be provided. All headers shall be thoroughly cleaned and be free of scale by shot blasting inside. All connections of pipes to headers for field welding shall be made by means of welding transition piece between headers and piping. In case pipe and header end covers are of flat type design, end cover thickness and welding should be considered appropriately and bidder shall obtain prior approval from the PURCHASER/ENGINEER. All valves that require operation during start-up or shutdown of the steam generator shall be electric motor operated, except as specifically stated otherwise. All motor actuators shall be designed to meet the torque requirement due to maximum differential pressure. In addition to these motorised valves, any other service which calls for motor operation shall be motorised and those motorised valves shall be listed in the bid. Drains from all headers shall be fed to the atmospheric flash tank. Field welds in large diameter thick walled headers or pipes shall be avoided to the extent possible Preservation of SG either by N2, dry air or treated water shall be considered by the Bidder. The requirement of dry air / treated water and its qualities for filling shall be indicated in the Bid. The preservation system shall include all the piping, valves, vents and drains, pipe supports and instruments etc to make the system complete. Air and Flue Gas System
1.42
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1.44 1.45
1.46 1.47
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The air and flue gas system shall be designed to meet the requirements of 100% SG MCR conditions and for the fuels specified in Project Information in Section B, Volume II. The entire flue gas system including the SG flue gas passes shall cope with explosions and/ or implosions, which might occur even at typical or extreme conditions. The air and flue gas system shall consist of two (2) 50% capacity FD fans of axial blade pitch controlled, two (2) 50% capacity PA fans of axial blade pitch controlled, two (2) 50% capacity centrifugal ID fans with variable frequency drives and inlet guide vane control or axial fan with blade pitch control mechanism. 2 x 50% capacity trisector regenerative air preheater (RAPH), with associated drive motors, cold air, hot air, tempering and flue gas ducting and dampers to handle the steam generator requirements. Alternatively BIDDER may offer 2x50% bisector RAPH for primary air system and secondary air system separately. The air preheater shall be provided with air motors with air receiver for coasting down operation. The air receiver capacity shall be such that during black out condition the air receiver shall be
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able to supply adequate air for safe shutdown of RAPH. Bidder shall make provision for installing the 2X50% steam coil air preheaters (SCAPH) in the bypass air duct so that same can be installed, if required, in future. 1.49.1 The air preheaters shall be of regenerative type with vertical main shaft, counter flow, enclosed in a gas tight insulated casing. The design shall ensure that the air preheaters shall be capable of operating for extended periods of time without blockage of flow areas between heating element plates. All the element sections shall be basketed with cold end elements suitable for replacement. Provision shall be made for ease of adjustment of seals externally without need for working from inside. An adequate number of access doors for inspection and maintenance and observation ports with vapour proof lighting shall be provided. The structure shall be strong and light in weight and shall be sufficiently flexible to operate without difficulties under conditions of large temperature gradients through the rotor in the axial direction. The heat transfer plates used in different layers shall be of differing material combination depending upon suitability to withstand extremes of temperature condition. Use of corrosion resistant materials shall be considered to avoid corrosion at the back end. A suitable structural steel framing for handling the heater element basket shall be provided. This shall include a trolley beam extended beyond the platform to enable lowering of elements to the ground floor. A hoist and trolley shall also be furnished. The air heater design shall be such that on-load cleaning by suitable steam soot blower is feasible. The location of the blower shall be on the flue gas side. For off-load cleaning, water washing spray nozzles on an extended fixed arm on both hot and cold ends shall be provided. The locations can be either on air or flue gas side. The general design requirements for the fans shall be as follows : The rotor shall be over speed tested at least 10% above maximum operating speed and shall be dynamically balanced. The fan shafts are to be supported in bearings on either side independent of the casings. All constants speed fans shall be designed for under frequency operation upto 47.5 Hz without any reduction in its performance. Forced oil lubrication system (if offered) for the fans and motors shall consist of 2 x 100% oil pumps each with motor, 2 x 100% oil coolers and filters; one (1) oil tank and electric heater with thermostat etc.
1.49.2 1.49.3
1.49.4
1.49.5
1.49.6
1.49.7
1. 49.8
1.50 1. 50.1
1. 50.2 1. 50.3
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STEAM GENERATORS & AUXILIARIES 1. 50.4 1. 50.5
Flow induced pulsation should be avoided by suitable design of fan and connecting duct work. Suitable design of shaft sealing shall be provided to prevent ingress of atmospheric air. Each bearing is to be provided with oil pressure indicator and a screwed drain plug. Adequate sealing arrangement shall be provided at each end of the bearing housing to prevent leakage of lubricating oil. Silencer shall be provided at the inlet of FD and PA fans with weather hood and inlet screen. An adequate number of interconnecting, isolating and control dampers with drives shall be provided on all cold air, hot air, seal air and flue gas ducting before and after equipment on these systems to permit proper operations. The control dampers shall be pneumatically operated and isolation dampers shall be electrically operated. Alternatively Bidder can supply electrically operated control dampers if it is cost effective. Bidder shall submit the basis of selection in their Bid The gas and air ducts shall be designed for wind loads as specified for the steam generating unit proper and their own weight including fly ash load which may get deposited at the duct bottom, insulation and lining. The top of the ducts shall be crowned to ensure proper drainage. The duct work shall be free to expand, but it shall be rigid against wind and seismic disturbances. Adequate provision shall be made for all expected expansion or contraction. All gas and air ducts consist of turning vanes / baffle plates, stiffening devices, expansion joints, interior bracings, access doors and brackets, support structures and hangers as necessary. Aerofoils shall be provided in the air ducts for the measurement of total air flow. Locking devices shall be provided to dampers to permit locking in both open and shut positions. Electrically operated guillotine type isolation dampers along with drives shall be provided as specified in Data Sheet-A12. The inlet dampers for ID fans shall be located in horizontal duct of main inlet duct to avoid fly ash build up when in closed position. Flue gas duct layout shall be designed considering the following aspects: The change of direction of flue gas duct shall be gradual to avoid ash collection at the bottom of the duct and also to prevent erosion by local concentration of fly ash.
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The number of direction changes of the flue gas duct shall be minimal to minimise the ash collection points. However, the air preheater, economiser and duct hoppers shall have provision for removal of fly ash during maintenance period when the steam generation is out of operation. To facilitate such fly ash removal, a 100% gas tight isolation gate near the hopper bottom shall be provided. The hopper bottom shall be blanked with a blind chute suitable for unloading fly ash from all the above mentioned hoppers.
Dust Precipitation and Collection System 1.61 One electrostatic precipitator (ESP) shall be provided for the steam generator. The electrostatic precipitator shall be designed to limit the dust concentration as specified in Data Sheet A12. ESP shall be complete with supporting structural frames, collecting and discharge electrodes, shaft insulators, bush insulators, independent rapping system for collecting and discharge electrodes with automatic rapping controls, high voltage transformers, rectifiers, bus sections with sectionalising and grounding switches and controls, fly ash collecting hoppers with accessories etc. An Energy Management System (EMS) shall be provided to optimise the power consumption. The Bidder shall furnish the details of EMS. For personnel protection, key interlocks shall be provided to prevent the opening of any inspection and/or access doors until after de-energising of all high voltage equipment that can be reached and/or made contact with, through the inspection and/or access door. Each hopper shall be provided an arrangement to facilitate emergency poking. The hoist with supporting structure/beams to permit easy removal of each transformer-rectifier from its operating position to grade level shall be provided. The rapping system shall be designed for selective remote automatic or manual operation at adjustable intervals. Necessary rapping arrangement with controls shall be provided for perforated gas distribution plate at inlet to the ESP. Electrical System of ESP Transformer Rectifier Equipment 1. 67.1 These shall be suitable for indoor/outdoor installation. Key interlocking shall be provided on access door or cover to the links required for changing the high voltage connections or the high voltage switch operating mechanism to prevent access while the transformer-rectifier is energised.
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STEAM GENERATORS & AUXILIARIES 1. 67.2
Primary taps shall be included on the transformer. The transformer shall have suitable shielding of the high voltage coil to accomplish proper voltage division in the transformer to take care of surge conditions. Each output leg of each transformer-rectifier set shall serve one bus section and both bus sections served by each transformer-rectifier set shall be in the same field. Transformer rectifier assemblies shall be mounted in a heavy gauge welded steel tank designed for a minimum of 0.5 Kg/cm2 test pressure and full vacuum. All silicon rectifier cells shall be conservatively rated for compatibility with maximum circuit load and demands requirements. In the event of arcing, the filter voltage shall be switched off for several half cycles to ensure a satisfactory extinction of the arc. Supporting insulators shall be located in heated compartments that are maintained above the dew point of the flue gas. They shall be located out of the dirty gas stream. These shall be protected from weather by either a common top housing or individual compartments. Each compartment shall be pressurised and ventilated by heated filtered air furnished by one or motor driven blowers. Control Cubicles
1. 67.3
1. 67.4
1. 67.5 1. 67.6 1. 67.7
1.67.8
Automatic control cubicles shall be furnished for indoor mounting. The automatic controls shall have full control from 10% of the power set rating to full rating. The control system should be capable of: a) b) c) d) e) Evaluating sparking by intensity and wave shape. Regulate power at the threshold of sparkling. Break a power arc within around ten- (10) milli sec of its occurrence. Automatically control the arc response so that power is restored within around one hundred twenty (120) milli secs. And Modify the current wave shape permitting greater power input prior to reaching spark over threshold.
1. 67.9
Adequate numbers of indicating instruments and alarms shall be provided on the control cubicles.
1. 67.10 Rapper control system for each bus section or pairs of bus sections served by a single transformer-rectifier shall :
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STEAM GENERATORS & AUXILIARIES a) b)
Provide manual adjustments of the timing and frequency of operation and the rapping intensity from the control cabinets, Provide rapper diagnostic system including miniature indicating lights, digital indicators, etc.
Motors 1. 67.11 Drive motors of the rapping mechanism for collecting and discharge electrodes and fans shall comprise 415V, 3 phase, 50 Hz, rated direct-online induction motors with IP-55 enclosure. In general, motors shall conform to Specification as specified elsewhere in this specification. 1.67.12 The storm water drain piping shall be provided up to the grade levels for ESP. Start-up/Warm-up and Support Oil System 1.68 1.68.1 The start-up/warm-up and flame stabilization oil system shall be as described under. Warm up oil system shall be designed for burning light diesel oil (LDO).This system design capacity should be sufficient to raise steam parameters of the steam generator to meet auxiliary steam for fuel oil heating / atomising in the shortest possible time to enable quick changeover to heavy fuel oil ( HFO) firing. However, this system shall have minimum capacity of 7.5% of MCR rating of one steam generator. LDO will also be utilised as flushing medium for flushing out fuel oil pipe lines and headers during long unit outages. The system shall be common for both SG units and shall consist of two (2) 100% capacity LDO pressurising pumps (1 working + 1 standby) common for both units, suction strainers, compressed air atomised burners, LDO and air piping, valves and fittings, instrumentation, safety and control systems. The LDO pressuring pumps shall be located in fuel oil pump house (FOPH). Support Oil System 1.69 1.70 The support oil system shall use heavy fuel oil (HFO) /LSHS/ HPS as specified for start up/warm-up and flame stabilization. The fuel oil burning system shall consists of 3 pressuring pumps common for two units ( 2 working + 1 stand by ), suction piping , valves and fittings, filtration units, fuel oil heaters and matching pressure filters, steam atomised burners, fuel oil safety and burner shut off valves, fuel oil pressure and temperature control valves, fuel oil metering units, fuel oil atomising and blow-off steam headers at burners, atomising steam pressure control valves, piping and valves necessary for bypass and isolation, fuel oil burner header recirculation control valve, recirculation piping with valves upto the fuel oil tanks, as identified in the enclosed sketch. The fuel oil pressuring pumps shall be located in FOPH.
ISSUE R0
1.68.2
SPEC.NO.
VOLUME IIIA
TCE-5103A-C-510-01
The oil burning system shall be designed for 25 % SG MCR rating. The fuel oil burners shall be positioned to provide support to any of the coal burners at low loads for flame stabilization as and when required. All pumps, strainers and / or pump strainer assembly units shall be provided with drip pans. Drain oil connection and pumping system shall be provided in steam generator area and in fuel oil pump house. An oil drain header of size not less than 150 NB shall be provided to collect drain oil from pans, strainers, pumps, pipes, etc. and return the same to the drain oil tank. The drain header shall be laid just above the ground and shall be generously pitched towards the drain tank. All oil drain lines shall have a size not less than 25 NB and shall be electrically traced. The drain oil pump suction and delivery lines shall have a size not less than 25 NB and shall be electrically traced. The drain oil tank shall be provided with heating coil and accessories/instruments. The suction and discharge filters, the fuel oil pumps and the fuel oil pipes shall be equipped with electric heat tracing. The atomising / blow off steam system and steam oil heaters will be supplied with auxiliary steam from auxiliary steam system.
1.72 1.73
1.74
The screw type pressurising pumps (if required) shall be provided with a spring loaded relief valve and it shall be built-in with the pump, the discharge end of the valve being connected to the pump s suction side. The relief valve shall be capable of allowing the full discharge of the pump through it. The relief valve set pressure shall be adjustable. The pressurising oil pumps and the fuel oil pipes shall be equipped with electric heat tracing. Flexible hoses (armoured type) shall be provided for oil and steam connections The complete oil supply system shall meet the requirements of Indian Petroleum Rules. Specific approval from Chief Controller of Explosives shall be obtained by the CONTRACTOR. Ignition System
1.75
1.76
High Energy Arc (HEA) igniters shall be provided to ignite LDO and HFO. One HEA ignitor for each fuel oil gun shall be provided. The igniter system offered shall be of well proven design of reputed make. Ignition system shall be complete with all electrical gadgets viz., transformer control cabinets, igniters, cabling, etc. to make the system complete by itself and shall be integrated with BMS. Adequate number of flame scanners shall be provided for fuel oil and coal firing. Two (2) 100%, one AC and one DC motor driven scanner air fans shall be provided for the flame scanner cooling.
1.77
The heavy fuel oil from the storage tank shall be drawn by the fuel oil pumps through suitable suction strainers and shall be pumped through heaters of requisite capacity to raise the oil temperature to the level
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TCE FORM NO. 329 R4
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TCE-5103A-C-510-01
required for satisfactory operation of the burners. The oil shall be taken to the steam generator units and recirculated back to the storage tanks. Arrangement of the fuel oil system including oil recirculation system shall be such to avoid cold zone in any part of the system. 1.78 Drain oil connection and pumping system shall be provided both in steam generator area and in fuel oil pump house. In the fuel oil pump house area, an oil drain header of size not less than 150 NB shall be provided to collect drain oil from pans, strainers, pumps, pipes, etc. and return the same to the drain oil tank. The drain header shall be laid just above the ground and shall be generously pitched towards the drain tank. All oil drain lines shall have a size not less than 25 NB and shall be electrically traced. The drain oil pump suction and delivery lines shall have a size not less than 25 NB and shall be electrically traced. The drain oil tank shall be provided with heating coil and accessories/instruments. The oil burners shall be provided with their discriminating flame sensing devices so that the admission of oil may be automatically shut off and oil gun withdrawn in case of flame failure. The flame sensing devices shall be self contained and shall be unaffected by dirt, oil film and ambient conditions. The oil firing scheme shall incorporate automatic purge interlock to facilitate restarting after such conditions. Automatic ignition system to initiate the flame in the furnace shall be included. However, facility for the manual operations shall also be provided. Ignition system shall be complete with ignitors suitable for ignition of heavy oil directly. Necessary piping, valves, control and instrumentation and all other equipment necessary for the completeness of this system shall be provided. Coal Pulverising and Firing System 1.80 The coal firing system shall be designed to meet the requirement of steam generator at 100% SG MCR condition, with blended coal from domestic coal and imported coal, the proportion of which will be normally about 70: 30. The range of domestic and imported coals are furnished in Section B, Volume II. The coal pulverising and firing system shall consist of medium speed coal mills with drives, coal feeders with drives, coal isolation gates at bunker outlet, feeder inlet, coal piping with flexible couplings from mill outlets to coal burners, coal burners with shut-off gates and drives, air registers with drives, coal mill hot air and coal / air discharge isolation gates and drives, two (2) x 100% seal air (SA) fans complete with air ducting to all coal mills/feeders, isolation, interconnecting and control dampers on seal air ducting as required, insulation, supports and hangers etc. The coal mills shall be designed for direct firing of crushed coals. The coal mills and bunker bays shall preferably be arranged on the steam generator front or rear. Bidder shall ensure equal distribution of the pulverised fuel among the burners from the coal mill as much as possible in order to have low NOx.
1.79
1.81
1.82 1.83
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1.84
Forced oil lubrication system for the coal mills and motors shall consist of 2 x 100% oil pumps each with motor, 2 x 100% oil coolers and filters etc. with necessary piping and valves. The number and capacity of coal mills and feeders shall be selected based on the following : (a) With one mill as standby and other mills running at 90% of their MCR, the system shall be able to meet 100% coal firing rate using worst coal. Also, with two mills as standby, 100% TGMCR shall be met using design coal. Minimum three mills shall be in operation for load range of 60% TGMCR to 100% SGMCR Each coal mill shall be provided with a separate coal feeder and its capacity shall not be less than the capacity of the coal mill
1.85
(b)
(c)
1.86
Dampers shall be provided on coal pipes at mill outlet, on cold air and seal air ducts and gates on hot air to coal mills. These dampers shall be pneumatically operated where as gates shall be electrically operated. The CONTRACTOR shall quantify the operating hours between major overhauls of the coal mill and the coal throughput in tonnes, when handling worst blended coal. Sealing air (SA) fans shall deliver air into a common seal air header from where each coal mill and feeder set shall be supplied with the seal air. For drawing coal samples (iso kinetic sampling of coal) for testing the fineness of the ground coal, a minimum of four tapping points at right angles to each other shall be provided on the straight length of pipe at each coal mill outlet. Compressed air purging connections shall be provided at the tapping points to clear the opening prior to sample collection Two coal isolation gates shall be provided at each bunker outlet. The gates shall be of dust-proof, rack and self-cleaning type pinion with all parts in contact with coal of minimum type 410 weldable stainless steel. The gate at the outlet of the bunker shall pneumatically / electric motor operated; where as the gate nearer the feeder shall be manually operated. The down spout from feeder outlet to mill inlet shall be provided with pneumatically / electric motor operated isolation gate Two isolation gates shall also be furnished in each coal burner pipe one nearer to the coal mill and the other nearer to the furnace / wind-box (if applicable) for facilitating on-line maintenance work of coal piping/coal mill. The gate nearer to the coal mill shall be pneumatically / electric motor operated, and the following gate shall be manually operated.
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1.87
1.88 1.89
1.90
1.91 1.92
TCE FORM NO. 329 R4
SPEC.NO.
VOLUME IIIA
TCE-5103A-C-510-01
The coal feed pipe from the coal mills to the coal burners shall be of wear resistant, weldable steel and of minimum thickness not less than 12 mm on straight length and 20 mm (but not less than one and a half times the straight pipe thickness) at outer radius of bends. The bends shall be basalt lined or ceramic lined to prevent erosion. Each pipe between bunker outlet and feeder inlet shall be provided with a flanged filler piece for connection of an angle type diverter chute to permit emergency dumping of coal from the bunkers. One carbon steel diverter chute connection piece with flanged outlet shall be furnished. A dresser or equal coupling shall be provided on each feeder inlet to permit bunker and feeder expansion movements. The inner ring shall be of stainless steel. Adequate and suitably located poke holes shall be provided to clear the feed pipes to the mills when they get choked. Soot Blowing System
1.94
1.95
1.96
1.97
The soot blowing system shall consist of motor operated steam soot blowers of the rotary and retractable type, with drives, pressure reducing, isolation and relief valves, steam traps, thermal drain valves, complete piping, supports and hangers, insulation, motor control centers and soot blower instrumentation and control system. The system shall be of self-draining type. Bidder can consider either conventional type of soot blowing system or Smart soot blowing system (lower consumption of steam and less erosion, software based, selective soot blowing) and furnish the details of the same along with his bid. The soot-blowers shall be suitable for remote automatic sequential and local operation. Auxiliary Steam System
1.98
1.99
Auxiliary steam system shall consist of piping, valves etc required for supplying auxiliary steam to the equipment covered under bidder s scope of works. Auxiliary steam shall be tapped off from auxiliary steam header. Refractory and Insulation
1.101
The refractory shall be selected appropriately at various locations in the furnace (viz., bottom ash hopper, burner zone, goose neck, cage roof, pent house etc.) considering the gas temperature, oxidising /reducing atmosphere and erosion. CONTRACTOR shall substantiate the basis of selection of refractories in the bid document. Thermal insulation and cladding shall be provided for the entire steam generator, flue gas / air ducting, etc. The insulation selected shall meet the requirement specified.
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1.102
TCE FORM NO. 329 R4
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VOLUME IIIA
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The steam generator shall be provided with 1.2mm corrugated aluminum cladding and the ducts shall have plain aluminum cladding Auxiliary Cooling Water
1.104
The auxiliary cooling water system shall be supplied for each SG unit. The system shall consist of complete piping to all equipment requiring cooling water. Each cooler / bearing shall be supplied with isolating valves at the inlet and throttling type valves at the outlet. Vibration and Noise Levels
1.105
The design of steam generator and its auxiliaries shall ensure maintenanceof vibration and noise levels within the limits specified in the following paragraphs over the entire operating range and during load fluctuations: The gas path design shall prevent the generation of excitation forces conducive to resonant vibration. Constant speed fans shall be supported on conventional block foundations. However STG, BFP & Mill foundation shall have vibration isolation system Coal mills, ID, FD, PA, and GR fans (if applicable) vibrations at the bearings shall meet the requirements of ISO 10816 Part 3. The ducting shall be adequately stiffened to absorb pressure pulsations. Guide vanes shall be provided at bends as required to prevent turbulence. Guide vanes in the gas duct shall be properly designed to minimise erosion. Fan induced duct vibrations shall be avoided. The measured noise level produced by any rotating equipment shall not exceed 85 dBA at a distance of 1.5 m from its boundary in any direction under any load condition. The noise produced in valves and piping associated with handling compressible and incompressible fluids shall be attenuated to 85dBA at a distance of 1.5 m from the source by the use of low noise trims, baffle plate silencers/line silencers, acoustic lagging (insulation), thick-walled pipe work as and where necessary. All pipes and valves downstream of pressure control valve (including pressure control valve) shall be one schedule higher than needed by pressure considerations to attenuate the noise. For safety relief valves the allowable noise level shall not exceed 115 dBA for one quarter hour or less per day. The CONTRACTOR shall outline the methods adopted to limit the vibration and noise levels within specified values. Safety Provisions
1.106 1.107 1.108 1.109
1.110
1.111
1.112
The Safety valves shall be provided on superheater and reheater headers and its number and capacity shall conform to the code requirements. Bidders shall furnish details in his bid as to how the design capacity of various safety valves are selected meeting the code requirements. ISSUE
R0
TCE FORM NO. 329 R4
SPEC.NO.
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In addition to the safety valves required by the code, electromatic relief valve of 10% capacity for remote operation shall be provided on superheater outlet header or on superheater outlet pipe. The valve shall also be capable of automatic operation on rise in pressure to a value corresponding to a pressure setting lower than that of the superheater safety valve. Each valve shall be complete with controller, solenoid, pilot valve and piping with two shut-off valves. All steam safety valves shall be provided with adequately sized atmospheric relief to 1.0 m above the steam generator roof. Weather shields shall be provided at points where the relief pipes pass through the roof. The electromatic relief valve, first spring loaded safety valve and start up vents in super heater shall be provided with silencers. Staircases on either side of mills, and ESP with walkways and galleries shall be provided so that all areas of mills and ESP are safely and conveniently accessible for operation and maintenance. Staircases shall be provided at front and rear of steam generators to quickly approach various floors. All staircases / platforms shall be provided with 2 rail safety handrails of 100 cm high and made of 32 mm GI pipe. The minimum width of staircase shall be 1000 mm and the minimum width of platforms shall be 750 mm. The minimum width of interconnecting walkway between mill maintenance platform and the steam generator gallery shall be 1200 mm. All platforms and staircases shall be provided with gratings and only operating floor (burner floor) shall be provided with chequered plates. Actuators for remote operation of shut-off gates at the air inlets to coal mills and shut off gates at outlet of coal mills shall be provided to allow positive shut-off in the event of fire in the mills. Control Valves For System
1.114
1.115
1.116
1.117
1.118
1.119
All control valves shall be sized such that the valves are controllable over entire operating regime viz. low load to full load. Those control valves, which require to be operated during cold, warm, and hot start conditions shall also be controllable during this mode of operation. To meet the above requirements if the CONTRACTOR provides more than one control valve, the controllable ranges of the control valves shall overlap to ensure bump less transfer from one control valve to other. For other requirements of the control valve refer relevant C and I section. Burner Blow out System
1.120
The fuel oil and atomising steam pressure shall be such that there should not be any oil traces entering the atomising steam system. The BIDDER shall explain in his bid the special features provided on this aspect.
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TCE FORM NO. 329 R4
SPEC. NO.
TITLE
VOLUME: IIIA SECTION D1.2 SHEET 1 OF 15
TCE-5103A
SPECIFIC PIPING REQUIREMENTS 1. SPECIFIC PIPING REQUIREMENTS
This Section covers the basic requirements for the all the piping systems, valves and specialities and thermal insulation to be provided for the power plant. 1.1 1.1.1 LINE SIZING Sizes of pipelines shall be selected such that the velocity of fluid in pipes does not exceed the following limits under conditions of maximum possible volumetric flow: Steam Superheated steam Saturated steam Wet steam/Exhaust steam Water Pump suction Pump delivery Boiler feed pump discharge Service/Potable water Oil LDO Air Compressed air 1.1.2 15 m/s 2 m/s 1.5 m/s 3.0 m/s 6.0 m/s 1.5 m/s 75 m/s 40 m/s 30 m/s
Lower values of velocities than those stated above shall be used to determine line size if dictated by considerations of pressure drop, NPSH, surges, water hammer, etc. The design flows considered in line sizing shall not be less than the rated capacities of equipment to which the piping is connected such as pumps, blowers, compressors, valves, flow limiting orifices, etc., or, the system heat and/or mass balance diagrams. Sizes of Boiler feed pump suction piping shall be selected to meet the NPSH requirements of the pumps under transient conditions prevailing on loss of steam supply to feed water tank. Similarly for all pumps, NPSH requirements shall be satisfied in line sizing.
1.1.3
1.1.4
ISSUE R0 CONSULTANTS: TCE Consulting Engineers Limited TCE FORM NO. 329 R4
SPEC. NO.
TITLE
TCE-5103A
SPECIFIC PIPING REQUIREMENTS 1.2 MATERIALS
The material specifications of pipelines of various systems shall be as specified in Data Sheet - A attached to this specification. 1.3 1.3.1 WALL THICKNESS The calculation of wall thickness required for pipelines subject to internal and/or external pressure shall be based on the formulae and recommendations as given in the applicable codes. Adequate allowances shall be made towards thinning due to bending, weakening at branch connections, threading, commercial tolerances on pipe wall thickness, corrosion and erosion, etc. and the same shall be subject to approval by ENGINEER. In any case a minimum corrosion allowance of 1.0 mm shall be considered while selecting the thickness. In case of carbon steel materials, the nominal wall thickness of pipeline shall be not less than the minimum acceptable values given below:
1.3.2
--------------------------------------------------------------------------------------------------------NB mm 15 20 25 32 40 50 65 80 100 125 (inch) (1/2) (3/4) (1) (1 1/4) (1.5) (2) (2.5) (3) (4) (5) --------------------------------------------------------------------------------------------------------Min. 3.2 3.2 3.6 3.6 3.6 3.6 3.6 4.0 4.5 5.4 thickness, mm ---------------------------------------------------------------------------------------------------------NBmm 150 200 250 300 350 400 450 500 600 (inch) (6) (8) (10) (12) (14) (16) (18) (20) (24) ---------------------------------------------------------------------------------------------------------Min. 5.4 6.35 6.35 6.35 7.1 7.1 7.1 8.0 8.0 thickness, mm ---------------------------------------------------------------------------------------------------------> NB 600 mm to NB 950 mm - 10.00 mm > NB 950 mm to NB 1200 mm - 12.00 mm Sizes of NB 32(11/4 ), NB 65(21/2 ), and NB 125(5 ) shall not be used in the piping system. 1.4 1.4.1 FLEXIBILITY ANALYSIS Formal flexibility analysis calculations shall be carried out in case of pipelines subjected to restrained thermal expansions or contractions. The following piping systems shall be analysed : (a) Pipelines with a maximum operating temperature equal to or greater than 150? C
SPEC. NO.
TITLE
TCE-5103A
SPECIFIC PIPING REQUIREMENTS
(b)
Regardless of their operating temperatures, all pipelines connected to sensitive rotating equipment such as turbines, feed pumps etc. for which limiting values of pipe reaction have been specified by the equipment manufacturer Any other pipeline which in the opinion OWNER/ENGINEER requires a formal analysis. of the
(c) 1.4.2
If it is deemed necessary by the boiler or turbine vendor, a surge analysis shall be carried out by the Contractor to evaluate the effect of closure of valves that are hydrostatically or pneumatically actuated. The pressure rise in the pipeline, additional forces and moments at terminal points and additional stresses shall be calculated. If the stresses or the forces and moments exceed the allowable value, suitable shock absorbers shall be provided by the Contractor. LAYOUT AND DETAILING All pipelines with size greater than NB 50 mm are considered as shop fabricated piping and detailed piping layout drawings shall be prepared for all such pipelines. The drawings shall be to scale and shall be prepared as plan & sections and shall carry the following minimum details:
1.5 1.5.1
1.5.1.1 Fully dimensioned layout with locating dimensions referred to plant axes and coordinates 1.5.1.2 Details of all stub connections and other welded attachments as required for anchors, restraints, hangers supports, etc. 1.5.1.3 Slope, drains and vents, all vents and drain lines shall be extended to nearest drain
1.5.1.4 Edge preparation details of weld ends 1.5.1.5 Mounting and orientation of valves and specialities and maintenance space requirements 1.5.1.6 Location and tag numbers of hangers, supports, restraints, anchors, etc. 1.5.1.7 Location and magnitude of cold cuts, if any 1.5.1.8 Pipe sizes, materials, requirements 1.5.1.9 Insulation details design parameters, shop and field test
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1.5.1.10 Tolerances, if any 1.5.1.11 Any specific requirements on shop fabrication and/or field erection 1.5.1.12 Any other detail considered necessary by the Owner / Owner s representative. 1.5.2 Pipelines with a size of NPS 50 mm or smaller are regarded as field routed. CONTRACTOR shall however indicate any specific requirements he may have in regard to the routing of these pipelines. Detailed bills of material shall be prepared for all piping systems. In case of shop fabricated piping, the bill of material shall correspond to the layout drawing prepared. While routing piping, the following requirements shall be taken into account:
1.5.3
1.5.4
1.5.4.1 All piping shall be routed so as to avoid interference with other pipes and their hangers and supports, electrical cable trays, ventilation ducting, structural members, equipment, etc. Adequate clearances shall be ensured with respect to the above to accommodate insulation and pipe movements. 1.5.4.2 All piping shall be grouped where practicable and shall be routed to present a neat and aesthetic appearance. 1.5.4.3 The piping shall be arranged to provide clearance for the removal of equipment requiring maintenance and for easy access to valves and other piping accessories required for operation and maintenance. Layout drawings shall indicate valve orientations and availability of access to valves and specialities. Layout of all piping shall ensure that all valves including motor operated valves are located as to be accessible conveniently for operation. Valves for operation and maintenance shall have 1.0 m clear approach space. If any of the valves are not accessible, suitable access platform shall be provided by the CONTRACTOR. 1.5.4.4 Piping shall generally be routed above ground but, where specifically indicated/approved by the ENGINEER the pipes may be arranged in trenches or buried. Pipes at working temperatures above the ambient shall however not be buried. 1.5.4.5 Where steel piping is required to be buried, the pipe work shall be protected from soil corrosion by suitable anti-corrosive treatment as specified.
SPEC. NO.
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TCE-5103A
1.5.4.6 Overhead piping shall have a minimum vertical clearance of 2.3 metres above walkways and working areas and 7.0 metres above roadways unless otherwise approved by the ENGINEER. 1.5.4.7 Drains shall be provided, at all low points and vents at all high points as per actual layout regardless of whether the same have been shown in the flow diagrams or not. Pipelines shall be sloped towards the drain points. 1.5.4.8 Besides at low points, tell tale drains shall be provided at other points as necessary to remove on-line valves and specialities from piping for repair and replacement. Wherever spray water is introduced into steam piping, at a suitable location downstream, drain pots shall be envisaged along with motor operated drain valves and high and low level switches. The drain valves shall be interlocked with the level switches for automatic operation. For operating temperatures of greater than 400oC, drip leg with drains, operated by a motor operated valve shall be provided. At all other drain locations (operating temperatures less than 400oC) traps shall be provided. All traps shall be provided with strainers, isolating, bypass and free blow valves. Traps shall be thermodynamic type. 1.5.4.9 Provision shall be made while preparing piping layout to accept control valves, flow measurement element and any other on-line speciality or equipment. Sufficient upstream and downstream lengths shall be provided for flow measuring devices, control valves, desuperheaters and other specialities as required by the respective equipment manufacturer. 1.5.4.10 At all the screwed valves and screwed connections on equipment, unions shall be provided to facilitate disassembly. Likewise, unions shall also be provided at suitable points on straight length of screwed pipelines. 1.5.4.11 At all points where pipes pass through concrete floors or brick or other walls, suitable floor collars or wall boxes shall be provided. The CONTRACTOR shall design and furnish the details of the floor collars to the ENGINEER/OWNER. 1.5.4.12 In the case of flanged pipe work, boxes shall be large enough to permit the passage of the flange. 1.5.4.13 All pipe racks shall be provided with walkways of 750 mm wide. 1.5.4.14 All pipe bends shall have a radius of five nominal pipe diameter unless otherwise specified by the Owner / Engineer 1.5.4.15 All oil piping shall be arranged such that these shall be below of away from the high temperature steam pipes or other heated surfaces.
SPEC. NO.
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TCE-5103A
1.5.4.16 All bearing oil drain lines and cooler outlet water flow lines shall be provided with visual indicator with rotational wheel (if possible) for observation of flow from a local platform or operating floor. 1.5.5 Hangers and Supports
1.5.5.1 All piping supports, guides, anchors, turnbuckles, rod hangers, spring hangers, rollers, with incidental structural subframing shall be designed by the CONTRACTOR. 1.5.5.2 The hangers and supports shall be spaced in accordance with standard engineering practice as outlined in applicable codes and standards. 1.5.5.3 The CONTRACTOR shall ensure that the location of the hangers and supports shall not increase the forces and moments on the equipment beyond their allowable values. 1.5.5.4 If severe vibration of piping is encountered in systems over which the CONTRACTOR has control or if the piping system is to be subjected to shock loading, hangers shall be supplemented by vibration-control equipment of an approved design. 1.5.5.5 At locations where lateral or axial movement is expected, the hangers shall be provided with suitable linkages to permit swing. All hangers shall be designed to be vertical in the hot position unless otherwise approved by the ENGINEER. 1.5.5.6 In order to minimise any horizontal force components of the dead weight or any binding of the pin or rocker joints used on the hangers, the hanger rods should be as long as possible. In critical piping systems, the length of the hanger assembly capable of swinging shall not be less than 20 times the maximum expected pipe movement in the horizontal plane at the hanger location. It is recommended in case of main steam piping to provide for a hanger rod length of atleast 5-6 metres wherever feasible. 1.5.5.7 Constant support type of hangers shall be adopted at all locations on critical piping excepting where the smallness of vertical movements of pipe justifies the use of variable spring hangers. 1.5.5.8 As far as practicable, connections of hangers to supporting structure shall be achieved without welding to structural members. If welding is inevitable, adequate factor of safety shall be considered in the design and specification of the weld. 1.5.5.9 The attachment of support brackets to brick walls shall be avoided as far as possible and where this is not possible, details of the attachment shall
SPEC. NO.
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TCE-5103A
be furnished to the ENGINEER for his approval. Under unavoidable circumstances, when medium or heavy brackets are bolted to walls, back plates of adequate size and thickness shall be furnished to distribute the load against the wall. Where the use of a back plate is not practical, the brackets shall, be fastened to the wall in an approved manner. 1.5.5.10 Diameter of hangers for piping NB 50 mm and smaller shall not be less than 10 mm and for piping with size NB 65 mm and larger shall not be less than 13 mm. 1.5.5.11 All components for hangers such as turn buckles, clamps, etc. shall be of forged steel. 1.5.6 Fittings and Flanges
1.5.6.1 Branch connections in piping shall be made by the use of wrought or forged seamless fittings such as tees, laterals and crosses. Small stubs as may be required for instrument, drain and vent connection may be provided in the form of weld outlet fittings or forged couplings. Intersection welds are acceptable only in the event of non-availability of fittings. 1.5.6.2 Wherever pipe bends are employed for change of direction the same shall be to a radius of 5 times the pipe diameter. 1.5.6.3 Mitred bends may be adopted for piping systems upto a design pressure 10 bar (g) only. Mitre angle shall not exceed 22.5 degrees. 1.5.6.4 Slip-on type of flanges may be only upto a maximum pressure rating of ANSI 300 lbs. In case of higher pressure ratings, weld-neck type of flanges shall be employed. 1.5.7 Dimensional Standards
1.5.7.1 Uniform dimensional standards for all piping components shall be employed to ensure compatibility with each other. 1.5.7.2 Nominal pipes sizes and pipe outside diameters shall generally be as per ANSI B36.10. In case of deviation CONTRACTOR shall bring it to the specific attention of ENGINEER for prior approval stating reasons for the deviation. 1.5.8 Instrument Connections
1.5.8.1 Unless otherwise called for by OWNER all thermowell stubs shall have an internal threading to M33 x 2.
SPEC. NO.
TITLE
TCE-5103A
1.5.8.2 All stubs for pressure or flow measurement for pipelines with a maximum working pressure equal to or above 62 bar(g) or with a maximum working temperature equal to or above 350? C shall be NPS 25 mm and double root valves shall be used. 1.5.8.3 Stubs for pressure or flow measurement on pipelines with a maximum working pressure less than 62 bar (g) and a maximum working temperature less than 350? C shall be of NPS 15 mm size and single root valves can be used. 1.5.8.4 Measurement stubs on fuel oil lines shall be of NPS 25 mm size and provided with two root valves. 1.5.9 Drain and Vent Connections
1.5.9.1 Drain and vent connections on pipelines shall be atleast of NPS 25 mm size. 1.5.9.2 For pressure and temperature conditions as defined in Clause 5.8.2, double isolating valves shall be used on drain and vent lines. For pressure and temperature conditions as defined in Clause 5.8.3, single isolating valves are considered adequate. Where with single root valve, instrument and root valve are not accessible, double root valve shall be provided with one root valve near the tap off and the second root valve with instrument at accessible point. For fuel oil drain and vent lines double isolation valves shall be provided irrespective of the pressure and temperature. 1. 6 WELDING AND HEAT TREATMENT All heat treatment, welding, post and pre weld temperatures shall be as per the code ASME B31.1. 1.7 1.7.1 INSPECTION & CLEANING All pipes shall be hydrotested at shops for pressures as per standards and all erected piping shall be tested 1.5 times the design pressure. All other inspection requirements shall be as per the enclosed data sheet A1. All hot bent, forged formed, fabricated and straight pipes shall be chemically cleaned, pickled or wire brushed and punged with air blast or shot/grit blast to remove all sand and scale from the inner surface as applicable. The Contractor shall carryout the following cleaning after hydrotest.
1.7.2
1.7.3
SPEC. NO.
TITLE
TCE-5103A
SPECIFIC PIPING REQUIREMENTS (a) (b) (c) (d) (e) (f) 1.7.4 1.7.5
All piping shall be mass flushed, in addition to the specific cleaning operations as described below, as required. Main steam, HP bypass piping shall be steam blown. Extraction steam, condensate, boiler feed suction and discharge, heater drains and vents shall be alkaline flushed. Auxiliary steam piping and associated steam lines, heavy fuel oil piping shall be steam blown. Compressed air piping shall be blown by air. Turbine lubricating oil piping shall be pickled
Contractor has to arrange chemicals, pumps, piping, valves, dummy devices, oil etc for acid cleaning, steam blowing, alkali boil out, oil flushing etc., Weld repair in valve shall be done as per the standard welding practice. Major weld repair record of critical valve shall be made available. PAINTING AND CORROSION ON PROTECTION All uninsulated piping systems, hangers and supports shall have two coats of red oxide Zinc Chromate primer (conforming to IS 2074) with minimum dry film thickness (DFT) of 25 microns per coat and two coats of finish paints using enamel paint to give a minimum total DFT of 100 microns (after two coats of primer and two coats of finish paint). Shades shall be as per IS 5 or as indicated by Owner /Engineer. Service of the pipe/line designations shall be painted on all pipes at visible locations. Before application of paint, Contractor shall clean the pipes of all mill scale, dirt dust, soot, grease, rust etc. All pipe lines, piping components shall be adequately protected against corrosion during manufacture, fabrication, shipment and storage by appropriate protective paint. UNDERGROUND PROTECTION Where pipelines are buried, underground protection shall be provided for the piping system as indicated any one of the methods given below: (a) Coal tar primer, coal tar enamel, inner wrap of fibre glass, final outer wrap of enamel impregnated fibre glass. Total thickness of coating shall not be less than 4.0 mm. With anti-corrosive tape of 4 mm thick conforming to IS10221 and AWWA C 203-93.
1.8.0 1.8.1
1.8.2
1.8.3
1.9 1.9.1
(b) 1.9.2
Pipe surfaces shall be cleaned by shot or sand blasting before application.
SPEC. NO.
TITLE
TCE-5103A
1.9.3
Tests to be carried out after application (a) (b) Bond/Adhesion test Holiday test SPECIFIC REQUIREMENTS OF PIPING SYSTEMS These shall be as detailed out in data Sheet A
1.10
1.11 1.11.1
THERMAL INSULATION CONTRACTOR shall provide thermal insulation for all hot piping and equipment with fluid temperatures greater than 60? C. Specific requirements of thermal insulation are detailed out in Data Sheet-A. Further, the insulation thickness indicated in Data Sheet - A shall be regarded as minimum acceptable thickness. These minimum acceptable thickness are OWNER s estimate based on use of mineral wool blankets as insulating material with a surface temperature of 60? C or less over the insulation finish and Contractor is advised to ensure that the thickness envisaged by OWNER are adequate to guarantee a surface temperature measured over the finish of not greater than 60? C. In case the Contractor estimates that higher insulation thickness are required, the same shall be included and clearly indicated in the offer under the Schedule of Technical Deviations of this specification. If Contractor is adopting calcium silicate insulation, the thickness shall be calculated with maximum thermal conductivity as given in IS-8154 and temperature shall be over the finish (aluminium cladding). Contractor shall submit with his offer a schedule of insulation thickness proposed by him along with supporting calculations. The calculations shall be based on thermal conductivity values certified and guaranteed by the insulation supplier who shall base his guarantee on actual tests conducted by recognised test houses. Calculation of insulation shall be based on standard BS 5970/IS 3677. No credit would be claimed by the insulation manufacturer over and above those actually recognised by international standards. However, if the CONTRACTOR is offering insulation material with superior thermal conductivity this value shall be suitably substantiated by tests. CONTRACTOR shall demonstrate to the OWNER/ENGINEER the surface temperature of the insulation at site. For indoor piping, the temperature shall be measured at the middle of one segment of pipe run at different points. These temperatures shall be taken as representative temperatures for that length of piping. If the temperature measured is
1.11.2
1.11.3
1.11.4
SPEC. NO.
TITLE
TCE-5103A
higher than that guaranteed, the whole length shall be replaced or additional thickness added to meet the surface temperature. Two measurements shall be taken at the measuring points (one at the top and another at the bottom). 1.11.5 Contractor should take care while fixing the insulation mats, no welding shall be permitted on HP/LP cylinder & steam chests for fixing nuts, bolts, lugs, for their mats. The strip on the casing, stop valves, where provided and instructed by manufacturer shall be used to weld the insulation pins for thermal insulation. VALVES Design And Construction Features The following design and construction features of valves shall be complied with. 1.12.1.1 All gate and globe valves shall be of rising stem, outside screw and yoke type. The design of valves shall ensure a streamlined passage and gate valves shall have low pressure drop. The seats and discs shall be easily renewable and/or shall be suitable for easy refacing and grinding. Valve discs shall be of such design as to keep the seats tight when the valve body is subjected to pressure, temperature variations and piping stresses. Gate valves shall close in both flow directions. 1.12.1.2 All globe valves shall be capable of being closed against pressure. 1.12.1.3 All valves end details shall be as specified in data sheets. In the case of all end-welded valves, the stub ends of the valves shall project from the valve body a sufficient amount to ensure that the welding process will not distort the valve body and internal parts. 1.12.1.4 Valves for regulating duties shall be of the globe type with tapered plug type disc. 1.12.1.5 Hardness of disc seating surface shall be minimum of 350 BHN and a minimum differential hardness of 50 BHN shall be provided between disc and seat to prevent galling. This is not applicable for stellited seats. 1.12.1.6 Check valves of sizes 400 mm NB and larger shall have dash pot arrangement. 1.12.1.7 All gate and globe valves shall have back-seating arrangement facilitate easy replacement of packing with the valve in service. to
1.12 1.12.1
SPEC. NO.
TITLE
TCE-5103A
1.12.1.8 All valves shall be so designed that the hand-wheel moves in a clockwise direction to close the valve. The face of the hand-wheel shall be clearly marked with the words 'OPEN' and 'CLOSE' and an arrow to indicate the direction for opening. All hand-wheels shall be fitted with name plate. 1.12.1.9 Piston lift check valves shall have accurately guided pistons so that the pistons are cushioned in their cylinders as they move up. 1.12.1.10 All gate, globe, Y-type and angle valves intended for manual operation and falling under the following categories shall be equipped with a gear operator for ease of operation and to ensure fast and tight closure: VALVE SIZES FOR WHICH GEAR OPERATOR IS REQUIRED -------------------------------------------------------------------------------Class 300 and below 350 mm and larger Class 600 and above 200 mm and larger -----------------------------------------------------------------------------------------------1.12.1.11 All gate valves falling in the following categories shall be provided with integral bypass valve. Bypass size shall conform to MSS-SP-45 as a minimum standard unless otherwise specified in data sheet. The bypass valve shall be hand operated unless otherwise specified in data sheet. Pipe for bypass shall be at least Schedule 80 seamless and of a material of the same nominal chemical composition and physical properties as that used for the main line. Orientation of bypass arrangement shall be subject to the approval of OWNER/ENGINEER. VALVE SIZES FOR WHICH BYPASS IS REQUIRED ---------------------------------------------------------------------------Class 600 and over 200 mm and larger Class 300 & 150 350 mm and larger -----------------------------------------------------------------------------------------------1.12.1.12 All gate valves of ANSI pressure rating class 150 and 300 shall have solid or flexible wedge and ANSI pressure rating class 600 and above shall have flexible or parallel slide type of wedge. 1.12.1.13 Valves with flexible wedge shall have provision for relieving the pressure in the neck of the valve when the valve is in the closed position. 1.12.1.14 All valves of ANSI pressure rating upto class 600 shall have bolted bonnet construction and class 900 and above shall have bonnet ANSI PRESSURE RATING ANSI PRESSURE RATING
SPEC. NO.
TITLE
TCE-5103A
construction of the pressure seal type. Pressure seal valves shall have stainless steel inlay in the gasket area and silver-plated gaskets or other acceptable proven features. 1.12.1.15 All carbon steel valves of ANSI pressure rating upto class 150 and 300 shall have stainless steel trim (13% Cr) unless otherwise specified in Data Sheet and ANSI pressure rating class 600 and above shall have stellited trim. 1.12.1.16 All alloy steel valves shall have stellited seats. 1.12.1.17 All valves of ANSI pressure rating upto class 900 and higher shall have yoke with anti-friction bearing arrangement. 1.12.1.18 Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be provided with a non-detachable locking arrangement. The locking arrangement provided shall be subject to approval by the OWNER. 1.12.1.19 Valves operating under vacuum conditions shall have glands with water sealing. The inlet and outlet connections shall be NB 15mm. The CONTRACTOR shall indicate the maximum and minimum sealing water pressure and the required flow rate. 1.12.1.20 Motor actuators for motor operated valves shall meet requirements indicated elsewhere in the specification. 1.12.1.21 All HP valves of size 50- NB and blow shall be of minimum class 1500 welded bonnet type irrespective of design requirements. 1.12.1.22 All the valves in the turbine extraction line shall be selected for one rating higher than the design requirement. 1.12.2 Cleaning Prior to factory inspection, all manufacturing waste, such as metal chips and filings, welding rods and stubs, rags, debris and all other foreign matter shall be removed from the interior of each valve. All mill scale, rust, oil, grease, chalk, crayon, paint marks and other deleterious material shall be removed from the interior and exterior surfaces. At the time of shipment, valves shall be clean inside and outside. 1.12.3 1.12.3.1 Inspection and Tests Inspection and tests shall be as per the relevant section.
SPEC. NO.
TITLE
TCE-5103A
SPECIFIC PIPING REQUIREMENTS 1.12.3.2
Defects in excess of acceptance standards shall be removed by suitable means. If removal of surface defects does not result in reduction in wall thickness below 5% of intended thickness of metal at that location, the area shall be blended smoothly into the surrounding surface. Where defect removal results in a wall thickness below the above, resultant cavity may be repaired by welding. The procedure and operator shall be qualified as per applicable standards. Major weld repairs shall be stress relieved or heat treated in accordance with ASME Section VIII Division I-UCS 56. The required area shall be re-examined and the acceptance standards shall be as in the original examination. Weld repairs made as a result of radiographic examination shall be radiographed after welding. Repairing a particular area more than 2 times is not permitted and the component shall be rejected. The acceptance standards for welds shall be as per ASME Boiler and Pressure Vessel Code, Section VIII, Division I, UW - 51. Prior approval shall be obtained from the OWNER/ENGINEER before taking up major weld repairs (major weld repair - when depth of repair exceeds 20% of thickness or 1 inch whichever is smaller). Mapping of major weld repairs is also required. All valves shall be tested hydrostatically for strength, tightness of seats and tightness of back seating at the pressures indicated in data sheets, in accordance with MSS-SP 61, "Hydrostatic Testing of Steel Valves". Water used for hydrostatic testing of valves with stainless steel components shall not have chloride content exceeding 20 ppm. Clean potable water may be used for testing of all other valves. All valves except check valves shall be tested for seat tightness by air at a pressure of 6 bar (g) on both sides of seat. All check valves shall also be hydrotested at 25% of the seat hydro test pressure. All valves shall be checked for correctness in respect of specified end details as per applicable standards. Painting and Corrosion Protection Two coats of primer of thickness 35 microns for each coat shall be applied to all steel and cast iron exposed surfaces as required to prevent corrosion, after release has been given for painting and before despatch. The use of grease or oil, other than light grade mineral oil, for corrosion protection is prohibited. Bores of all valves shall be
1.12.3.3 1.12.3.4
3.12.3.5
1.12.3.6
1.12.3.7 1.12.3.8
1.12.3.9 1.12.4
SPEC. NO.
TITLE
TCE-5103A
covered immediately after testing, draining and drying with suitable plastic end covers to avoid ingress of foreign materials. 1.12.5 Temporary piping and accessories All temporary piping, fitting, accessories, valves, specialities etc. required for the various erection and commissioning activities such as chemical cleaning, steam blowing, hydraulic test etc shall be in the scope of the bidder.
SPEC NO. TCE. 5103A-C-51001
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD TITLE 2 X 800 MW TPP AT KRISHANAPATNAM
VOLUME: IIIA SECTION: D 2 SHEET 1 OF 1
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM CONTENTS
SUB SECTION D 2.1 D 2.2 D 2.3 D 2.4 D 2.5 D 2.6
TITLE SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SCOPE AND TERMINAL POINT-SYSTEM / EQUIPMENT / SERVICES DESIGN, PERFORMANCE AND FUNCTIONAL REQUIREMENTS SPECIFICATION FOR DCS / INSTRUMENTS TO BE SUPPLIED TESTS AND INSPECTION FOR INSTRUMENTATION AND CONTROL EQUIPMENT OTHER SERVICES LIST OF TABLES
NO.OF SHEETS 6 9 27 19 3 2
SUBSECTION TABLE - 1 TABLE - 2 TABLE- 3 TABLE- 4 TABLE- 5 TABLE- 6 TABLE- 7 TABLE- 8 TABLE- 9 TABLE10
TITLE AVAILABILITY REQUIREMENTS LAYOUT AND MAINTENANCE REQUIREMENTS ERECTION, TESTING AND COMMISSIONING REQUIREMENT CODES AND STANDARDS LIST OF ESSERNTIAL SPARES TRAINING TO BE PROVIDED FOR OWNERS PERSONNEL TESTS FOR I & C SYSTEM EQUIPMENT INSTRUMENT INSTALLATION DATA TO BE FURNISHED WITH BID DATA TO BE FURNISHED AFTER AWARD OF CONTRACT
NO. OF SHEETS 1 2 6 5 4 1 14 2 1 5
ISSUE R0
CONSULTANTS : TCE CONSULTING ENGINEERS LIMITED
TCE FORM 329 R3
VOLUME: IIIA SECTION: D 2.1 SHEET 1 OF 6
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY
1.0 1.1
SYSTEM DESCRIPTION The instrumentation and control (I&C) system for the project will be a comprehensive system integrating the functions of plant monitoring, control and protection to facilitate the task of integration, co-ordination and autonomous operation of the plant sub systems/equipment namely Steam Generators (SG), Steam Turbine Generator (STG) and their associated auxiliaries, balance of the plant equipment / systems like plant electrical system, utility plants like coal handling plant, Ash handling plant, DM water plant and compressed air plant etc.. The plant I&C system is envisaged to be configured by interfacing main plant control system namely DCS interfaced with other different plant control systems namely SG Integral control system, STG Integral control system and other utility and auxiliary plant control systems (both unit specific and plant common systems) and provided with different special plant monitoring and analysis systems to provide supervisory and reporting facilities to plant personnel and management. The plant I&C system is envisaged to permit centralised operation and monitoring of the power plant from the central control room (CCR) being described subsequently in detail. The system will consist of a functionally distributed microprocessor based system (DCS) with facility for VDU (Video Display Unit) / Keyboard & Large Video Screen based operation, control and monitoring. The overall I & C system design objective is to ensure the following: (a) (b) (c) (d) (e) Maximise safety for the plant personnel and equipment Safe, reliable, efficient and easy operation of the plant under all operating conditions Maximise availability and efficiency of the plant through system redundancy. Consistent control & instrumentation philosophy usage of standard functional modular hardware and software design. Ability to operate under all specified conditions (start-up, normal operation, disturbances and shut down) automatically and/or by remote manual control from relevant control room. Malfunction of any component or loss of supply leading to fail-safe condition Provide accurate and reliable information to the plant operators and management. Provide the operators the following facilities: (i) Complete information for plant equipment status / abnormal and critical conditions.
1.2
1.3
1.4
(f) (g) (h)
ISSUE R0
TCE FORM 329 R3
(ii) (iii) (iv) 1.5
Alarm notification. Logging of equipment/component failure duration and data availability for failure analysis. Historical data storage and retrieval facility for long term monitoring of plant equipment performance.
Special plant monitoring and analysis systems being envisaged will include the following: (a) (b) (c) (d) (e) (f) (g) Vibration monitoring and analysis system Performance analysis, diagnostics and optimisation system Computerised maintenance management system Security and surveillance system Management Information System (MIS) Flame Monitoring & Analysis System Boiler Tube Leak Detection System
2.0 2.1 2.1.1
PLANT OPERATION PHILOSOPHY OPERATION FROM CENTRAL CONTROL ROOM (CCR) All equipment associated with main plant viz. SG, STG and their associated auxiliaries, balance of plant equipment systems and other different utility and auxiliary systems will be operated /monitored from VDU/Keyboard based Operator stations (OS) mounted on Unit Control Desk (UCD) in CCR. The OS will be table top mounted type. Operation from OS will permit to call for the various types of displays for all parameters as required on the screen and to carry out all types of operations. CCR operation/ monitoring facility through OS/LVS will include the following as an additional facility, which will be primarily operated and monitored from respective utility plant located local control room: (a) (b) (c) (d) (e) Limited Operation & Complete monitoring of plant common Coal Handling Plant. Limited Operation & Complete monitoring of plant common DM water plant & effluent treatment plant etc. Limited Operation & Complete monitoring of plant common Ash Handling Plant. Complete operation and monitoring of plant common Switchyard system. Complete operation and monitoring of unit specific Electro-Static Precipitator.
ISSUE R0
TCE FORM 329 R3
(f) (g) (h) 2.1.2
Complete operation and monitoring of unit specific Mill reject Handling system. Limited Operation & Complete monitoring of unit specific DG Set. Complete monitoring of unit specific A/C & Ventilation System.
In addition to VDU/KB operation from OS, limited back up operation/ monitoring facility will be provided on the Unit Control Panel (UCP) in CCR, for safe operation/shutdown of the power plant. UCP operation/ monitoring facility to include but need not be limited to the following: (a) (b) (c) (d) (e) (f) Emergency stop push buttons for boiler, STG and all HT & major auxiliaries for safe shutdown of the plant in the event of failure of VDU/KB based OS equipment. Audio-Visual window based hardwired annunciation for system / equipment faults. Push buttons associated with hardwired annunciation system located both on UCD & and in UCP. Digital Display Unit for selected important plant parameters. Large Video Display Screen suitable for both operation and monitoring. PA system and telephone sets.
2.1.3 2.2 2.2.1
Operation, control and monitoring requirement of Station Electrical system / equipment are detailed in Section D 3, Volume IIIA. LOCAL OPERATION OPERATION FROM LOCAL CONTROL ROOM (CCR)
2.2.1.1 The utility and auxiliary systems viz., Coal handling plant / Ash handling plant / Switchyard plant / DM Water plant & Effluent treatment plant / A/C & Ventilation System etc., will be primarily operated & monitored locally from respective utility plant located local control rooms (LCR). However, facility for operation and monitoring from CCR as detailed above in Clause 2.1.1, Section D 2.1 above are also envisaged. Utility plant operation / monitoring will be primarily through VDU/ KB based OS mounted on Control Desk (CD). The OS will be table top mounted type. Operation from OS will permit to call for the various types of displays for all parameters as required on the screen and to carry out all types of operations. Control Desk shall also accommodate PA & Telephone sets. 2.2.1.2 Two (2) no.s OS will be provided for each utility plant local control room. 2.2.1.3 In addition to VDU/KB based OS, Large Display screen are also envisaged for both CHP & AHP local control room.
ISSUE R0
TCE FORM 329 R3
2.2.1.4 In addition to VDU/KB operation from OS, back up operation/ monitoring facilities will be provided in the Back Up Control Panel for both CHP and AHP local control room(s). Back up Control Panel operation/ monitoring facilities to be provided will include the following: (a) (b) (c) (d) (e) (f) (g) Coloured Mimic diagram Push buttons with lamps for all major plant equipments. Audio-Visual window based hardwired annunciation for system / equipment faults. Push buttons associated with annunciation system. Digital Display Units for selected important parameters. Large Video Display Screen suitable for both operation and monitoring. PA system and telephone sets.
2.2.1.5 DG set will be primarily operated and monitored from DG set control room with facility for remote start/stop operation with status/alarm monitoring in CCR. 2.2.1.6 Switchyard will be operated and monitored from Switchyard building. All operation /monitoring from Switchyard building will be through VDU/Keyboard based OS. 2.2.1.7 In general, for no auxiliary and utility plant system/equipment, local control panel based operation and monitoring is envisaged. Any specific deviation in this regard shall be subject to OWNERs approval. 2.2.1.8 For ESP control system, VDU/KB based operation /monitoring facility may be provided if felt needed by Bidder. However, primary operation /monitoring facility will be from DCS based OS from CCR. 2.2.2 Local Operation From Field
2.2.2.1 In addition to the control room operation / monitoring facility, local start/stop operation from local pushbuttons (LPB) shall be provided for all uni-directional drives as a testing and maintenance facility. The local pushbuttons for various drives shall be hooked up to control system as indicated below: (a) (b) (c) All emergency stop pushbuttons shall be wired directly to MCC/Switchgears. Status of all emergency stop pushbuttons for unidirectional drives (pump/fan etc) shall be monitored into the respective control system. Local start pushbuttons (for pump/fan etc.) commands shall be connected to the control system to ensure interlock/protection requirement.
ISSUE R0
TCE FORM 329 R3
2.2.2.2 Local / remote operation location selection will be carried out from control room through OS. 3.0 3.1 PLANT CONTROL PHILOSOPHY The control requirements of the main power plant comprising SG, STG with associated auxiliaries (except for SG & STG Integral control systems) , balance of plant system/equipment like CW/ACW/Misc. water systems, plant electrical system, compressed air system etc. to be implemented in microprocessor based Distributed Control System (DCS) being provided by Purchaser. SG Integral control system will include Burner Management System (BMS) & Boiler protection system and will be an independent microprocessor based control system. BMS & Boiler Protection system will be a fail-safe type system conforming to SIL 3 with certification from authorised agency. STG Integral control system will include STG Governing Control & Turbine protection system and will be an independent microprocessor based control system. BMS & Boiler Protection system will be a fail-safe type system conforming to SIL 3 with certification from authorised agency. PLC based control systems are envisaged for all other unit specific and plant common utility and auxiliary plants like detailed below which are not covered in DCS based control systems. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (j) Plant Common Coal Handling Plant. Plant Common Ash Handling Plant Plant Common Switchyard system Plant Common DM water plant Plant Common Effluent treatment plant etc. Unit Specific ESP Control system (If DCS based control is not provided) Unit Specific Mill reject system (If DCS based control is not provided) Unit Specific DG Set Unit Specific Fire Protection & Detection system Unit Specific A/C & Ventilation system Any other plant system/equipment not covered in plant DCS system.
3.2
3.2
3.3
ISSUE R0
TCE FORM 329 R3
3.4
SG Integral Control system (For BMS & Boiler protection system) and STG Integral Control System (For STG Governing Control & Turbine Protection) will be interfaced with plant DCS through redundant bi-directional OPC link with Ethernet based TCP-I/P protocol. However for time critical signals hardwired interfacing is envisaged. All PLC based utility plant control systems will be interfaced with plant DCS through redundant bi-directional OPC link with Ethernet based TCP-I/P protocol. In general, no plant system/equipment will have relay based control system. CCR operation / monitoring of equipment/systems under SG and STG Integral control systems, utility plants / plant common systems detailed above will be through plant DCS system OS /LVS. All different plant control systems like SG /STG Integral Control systems, plant DCS, PLC based control systems for utility plant/systems and other special monitoring and analysis systems like CMMS, MIS etc. are interfaced through redundant interfacing for proper functioning. Each unit Turbo Supervisory System to be interfaced with respective unit plant DCS. A common time synchronisation system is envisaged (by Purchaser) for time synchronising of all programmable control systems like SG / STG Integral control system, plant DCS, PLC control systems etc. for the whole station.
3.5 3.6 3.7
3.8
3.9 3.10
ISSUE R0
TCE FORM 329 R3
SPEC. NO
VOLUME: IIIA SECTION:D 2.2 SHEET 1 OF 9
TCE 5103A-C-510-01
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM SCOPE OF WORK / TERMINAL POINTSYSTEM/EQUIPMENT/SERVICES
1.0
INSTRUMENTATION & CONTROL EQUIPMENT SYSTEM / EQUIPMENT/SERVICES TO BE FURNISHED The Scope includes design, manufacturing, supply, erection, testing and commissioning of specified Instrumentation and Control System Equipment complete with all hardware, software and accessories and other services including the following, to operate the steam generator plant and auxiliaries efficiently, reliably and safely as detailed in this section and also under System description/Operation philosophy in Section-D 2.1, Design philosophy in Section D 2.3, relevant technical specification in Section D 2.4 and Testing requirements in Section-D 2.5 with enclosed Tables. The offer shall comply with the latest applicable codes and standards as prevailing on the date of submission of the bids. (i) SG Integral control system for Burner Management System (BMS) & Boiler Protection System. The system shall be fail-safe type conforming to SIL 3 with certification from authorised agency and implemented in an independent microprocessor based system (either TMR type or any other approved configuration by IEC). Furnace Flame Monitoring and Analysis System for each unit. Boiler Tube Leak detection system System cabinets and Marshalling cabinets Field Instruments including pipe mounted items and accessories within battery limits. Final control elements within battery limits. Supply, laying & termination of complete Instrumentation, Control, Compensating, Special cables, Pre-fabricated cable etc., together with preparation of all cabling related engineering documents like Cable Schedule, Inter-connecting Schedule etc. as specified. Auxiliary Power Supply System Maintenance and Erection Tools and Tackles Essential Spares Erection, Field Testing And Commissioning Including Erection Hardware Inspection and testing of I&C system equipment included in Bidders scope. Engineering Documentation Training Of Owners Personnel
ISSUE R0
(ii) (iii) (iv) (v) (vi) (vii)
(viii) (ix) (x) (xi) (xii) (xiii) (xiv)
TCE FORM 329 R3
SPEC. NO
TCE 5103A-C-510-01
(xv) (xvi) 2.0 2.1 2.2 2.3 2.4 2.4.1
Provision of Performance Guarantee Test Instrumentation Co-ordination with other Vendors
SG INTEGRAL CONTROL SYSTEM HARDWARE I/O Modules: As required considering the requirements detailed in Section D 2.3 Distributed Processing Units (Controllers): As required considering the requirements detailed in Section D 2.3 Engineering Station: 1 no for program development and modification unit complete with VDU unit and keyboard / mouse. Plant DCS Interfacing Requirement One (1) no independent redundant bi- directional OPC link with Ethernet based TCP- I/P protocol for interfacing SG Integral Control System with plant DCS. Interfacing cable as required with accessories are included in Bidders scope. Independent redundant bi- directional OPC link for interfacing numerical protection relays under Bidders scope of supply with plant DCS. Interfacing cable as required with accessories are included in Bidders scope. [@-] OPC link shall be of latest version suitable for time stamped data transfer for alarm and events. @- Communication protocol will be decided during detail engineering stage. It is the Bidders responsibility to offer communication link with protocol suitable for communication between DCS & Bidder supplied numerical relays. BOILER TUBE LEAK DETECTION SYSTEM A microprocessor based Boiler tube leak detection system complete with all hardware, software and accessories shall be provided for each unit. The requirements are detailed in Section D 2.4 of this specification.
2.4.2
2.4.3 2.4.4
3.0
4.0
FURNACE FLAME MONITORING SYSTEM Furnace flame monitoring and thermo graphic flame analysis system complete with all hardware, software and accessories including display arrangement in CCR (central control room) shall be provided for each unit. The system is detailed in Section D 2.4 of this specification.
5.0
SYSTEM CABINETS AND MARSHALLING CABINETS
ISSUE R0
TCE FORM 329 R3
SPEC. NO
TCE 5103A-C-510-01
System cabinets and Marshalling cabinets for control/ monitoring systems under Bidders scope of supply shall be complete with all instruments and control equipment duly mounted and pre-wired. The specification for these items are given in Section-D 2.4 of this specification.. 6.0 FIELD INSTRUMENTS AND ACCESSORIES All primary elements, field mounted instruments and accessories, racks, field termination cabinets / junction boxes, etc. as required for the services detailed below shall be supplied. The guidelines for provision of these items and technical specification for the same are detailed in Section 2.3 & D 2.4 respectively of this specification. (a) (b) (c) All pipe mounted primary element within Bidders scope as required for the complete plant I&C system. All primary sensors / instruments as required for the I&C system under Bidders scope. All primary sensors / instruments integral to Bidders equipment such as pipe/tube metal temperature elements, fuel feeder flow sensing etc. (examples are indicative and not exhaustive) required for monitoring /control in Purchasers DCS. Stubs / tapping points with root valves etc. for all pipe / equipment mounted measuring points for all primary sensor / instruments required for monitoring /control in Purchasers DCS. Exact requirement of all such stubs / tapping points with root valves will be decided during detail engineering stage and Purchasers decision towards the same will be final.
(d)
7.0
FINAL CONTROL ELEMENTS All final control elements as required are included in Bidders scope. The technical requirements are detailed in Section D 2. 3 & 2.4 of this specification.
8.0
INSTRUMENTATION AND SPECIAL CABLES Supply, laying & termination of complete Instrumentation, Control, Compensating, Special cables, Pre-fabricated cable, Fibre optic cable etc., together with preparation of all cabling related engineering documents like Cable Schedule, Inter-connecting Schedule etc. The technical requirements of cables are covered in Section D 2.4 of this specification. Governing rule for Bidders cabling scope will be all I&C cables between the equipment where both the end equipments are in Bidders scope of supply. This will include but limited to the following applications: (a) (b) Between Sensor / Instruments under Bidders scope and Junction Box Between Bidders scope Junction Box and Control/ Marshalling cabinets.
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(c) (d) (e) (f)
Between Bidders scope Control cabinets and Switchgear / MCC for command & feedback for Uni-directional Drives. Between Bidders scope Control cabinets and Motorised Valve actuators for command & feedback. Between Bidders scope Local Push Button and Control/ Marshalling cabinets / Switchgear / MCC All power supply distribution cables between Bidders scope Power Distribution Box and Individual I &C equipment (All incomer cables to Bidders Power Distribution Box by Purchaser). All power supply cables for powering of solenoid valves under Bidders scope.
(g) 9.0 9.1
AUXILIARY POWER SUPPLY SYSTEM 230 V AC UPS and 24 V DC power supply for total plant I&C system equipment will be provided by Purchaser. The details of the above power supply system are covered in Section D 3- Electrical section. Bulk power supply through redundant feeders will be provided for Vendors application. Bidders scope involves complete distribution of power supply required for I&C equipment under Bidders scope. 24V DC or 220 V DC supply system shall be utilized for equipment like trip valves / equipment used for trip/ safety circuit application. All other solenoid valves shall be of either 24 V DC or 230 V AC. + 24V DC supply shall be utilized for all the control equipment of I&C system. Power supply monitoring shall be provided in the Purchasers DCS. MAINTENANCE AND ERECTION TOOLS AND TACKLES The Bidder shall include in his offer all special maintenance and erection tools and tackles as required for the system being offered. The details shall be furnished.
9.2
9.3 9.4 10.0
11.0
ESSENTIAL SPARES Bidders scope of supply includes I&C system essential spares as detailed in Section D 2, TABLE-5.
12.0 12.1
ERECTION, FIELD HARDWARE
TESTING
AND COMMISSIONING INCLUDING ERECTION
The CONTRACTOR shall erect, test and commission all Instrumentation and Control Equipment supplied under the scope of this specification to the complete satisfaction of the PURCHASER. The requirements are covered in Section D 2, TABLE3 of this specification.
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12.2
Impulse pipes, fittings and air supply and signal piping/tubing shall be supplied for all the instruments under the scope of this specification. The guidelines for selection of size, material & rating depending upon service conditions and instrument installation are specified in Section D 2, TABLE-8. INSPECTION AND TESTING FOR I&C SYSTEM EQUIPMENT The Purchaser or Purchasers representative reserves the right to inspect and approve the material, equipment and workmanship at all stages of manufacturing of all the main I&C equipment including the SG Integral Control System. Contractor shall call for inspection / witnessing the conductance of test of the equipment well in advance (minimum 21 days) to the Purchaser. Purchaser will indicate his preference regarding the inspection of the equipment. It is Contarctors responsibility to schedule the inspection & testing of different equipment / systems in a properly phased manner. Inspection and testing requirements for different I&C system equipment (as applicable) are tabulated in Section D 2.5 and Section D 2, TABLE-7 of this specification. Testing requirements not explicitly specified for any equipment but required for establishing the satisfactory performance / functioning of the equipment / system are deemed to be included in the scope of work of Contractor. The following minimum equipment shall be considered for Inspection (witness) at manufacturers works (Contractors and sub suppliers) by Purchaser as specified: (a) (b) (c) (d) (e) BMS & Boiler Protection System All control valves / control dampers Flame Monitoring And Analysis System Boiler Tube Leak Detection System Transmitters
13.0 13.1
13.2
13.3
13.4
The Contractor shall conduct site tests for following equipment / systems: (a) Site Acceptance tests including Trial Operation, Performance Guarantee Test & Availability Guarantee Test for BMS & Boiler Protection System. The CONTRACTOR shall prove the guarantee of the system and equipment supplied. Flame monitoring & Analysis System Boiler Tube Leak Detection System
(b) (c) 14.0 14.1
ENGINEERING DOCUMENTATION Bid data to be submitted are detailed in Section D 2, TABLE-1 of the specification.
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14.2
CONTRACTOR shall prepare and submit various engineering documents for OWNER / CONSULTANT review and approval. These are detailed in Section D, TABLE-2 of the specification. TRAINING OF OWNERS PERSONNEL The CONTRACTOR shall provide training to Owners personnel as specified in Section D 1.6 and Section D, TABLE-6 of the specification.
15.0
16.0
PERFORMANCE GURANTEE TEST INSTRUMENTATION The CONTRACTOR shall provide plant PG test instrumentation as specified in Section D 1.6 of the specification.
17.0
CO-ORDINATION WITH OTHER VENDORS Vendor shall co-ordinate interactions are required. with Vendors of other equipment wherever technical
18.0 18.1 18.1.1
GENERAL Uniformity of Hardware To provide smooth and optimal maintenance, easy interchange ability and optimal spare parts management of I&C instruments/equipment, the bidder shall ensure that all the similar equipments shall be of the same make, series and family of hardware Following equipments shall be of same make, series and family of hardware at minimum: (a) (b) Pressure and Temperature Gauges All pressure, Differential pressure, level & flow transmitters of differential pressure type & Temperature transmitter.
18.1.2
18.2
All the systems in the Bidders scope shall work satisfactorily taking into account all the required interconnections. Measurement and control equipment offered shall be complete in all respects and any equipment / accessories not explicitly indicated in this specification, but considered essential for proper functioning of equipment and process shall be included in the Bidders scope of work and supply. Any I&C equipment required during any stages for the efficient / safe / reliable operation of the plant either during detailed engineering / commissioning / after commissioning shall be installed and commissioned by the Bidder with in the quoted price. Before taking over the plant by the Owner, all the instruments, system and auto control loops shall run satisfactorily for at least one month at varying loads without disturbing any adjustment. During this period, supervision and maintenance of total instrumentation
ISSUE R0
18.3
18.4
TCE FORM 329 R3
SPEC. NO
TCE 5103A-C-510-01
equipment shall be the scope and responsibility of the Contractors personnel. 18.5 Availability of Spares & Services Spares and services for SG Integral Control System shall be available for 15 years from the date of handing over of plant by the Contractor. Bidder shall furnish the guarantee for the same in the bid offer. The guarantee shall be re-confirmed by Contractor on post contract execution phase from respective equipment / system vendor. The guarantee shall be absolute and shall be a criteria for vendor selection by Contractor. 19.0 TERMINAL POINTS Area / System 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 19.9 19.10 19.11 Plant DCS BMS / Boiler Protection SER System By Owner Complete system Complete system Complete system NIL NIL Within battery limits of scope. NIL Cabinets / Panels-Within battery limits of scope As specified-within limits of scope. battery By Contractor
Time Synchronisation Complete system System Control Desk, Cabinets, NIL Panels Field Instruments and Outside Bidders scope accessories Final control elements SWAS System Analysers Gas Analysers Erection hardware accessories Outside battery requirement
limit Complete requirement within battery limits of scope. NIL NIL As specified-within limits of scope. NIL battery
with Complete system Complete system & Outside Bidders scope
Unit Control Panel with Complete system panel mounted hardware / instruments Hardware Annunciation Complete system System Large Screen Display Complete system
19.12 19.13
NIL NIL
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System 19.14 19.15 Boiler Tube Leak NIL Detection System Complete System
Smart Transmitter Complete system except for Provision of HART protocol Maintenance Facility Bidders scope signal from Bidders scope transmitters from Marshalling cabinet Vibration Monitoring & Complete system except for Provision of vibration pad on Analysis System Bidders scope equipment bearing within battery limit. Furnace Flame NIL Monitoring & Analysis System PADO System CMMS System Complete system Complete system Complete System
19.16
19.17
19.18 19.19
NIL Provision/ arrangement of equipment data for equipment outside battery limit. NIL NIL
19.20 19.21 19.22 19.23 19.24 19.25 19.26 19.27 19.28 19.29
MIS System I&C Cables Furniture
Complete system Complete system
Complete system except for For Engg. Station for I&C Bidders scope equipment in Bidders scope. within Bidders for
Auxiliary Power Supply Complete system except for Distribution System Bidders scope scope. Maintenance & Erection Outside Bidders scope tools Laboratory Instruments & Test Complete system Other than Bidders scope. Complete system
Complete requirement Bidders scope. NIL As specified NIL Complete requirement Bidders scope. Complete requirement
Essential Spares Consumables
Erection, Field Testing Other than Bidders scope. & Commissioning Inspection & Testing Other than Bidders scope.
for for
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SPEC. NO
TCE 5103A-C-510-01
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM SCOPE OF WORK / TERMINAL POINTSYSTEM/EQUIPMENT/SERVICES Bidders scope.
19.30 19.31
Training of personnel
Owners Outside battery requirement
limit Complete requirement Bidders scope. Complete requirement
for
Power Plant PG Test NIL Instrumentation
ISSUE R0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD 2 X 800 MW TPP AT KRISHANAPATNAM
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS
1.0
BASIS FOR PROVISION OF INSTRUMENTS / TAPPING POINTS Pressure indicators shall be provided wherever indicating type Pressure transmitters are not envisaged. The applications include: (a) (b) (c) Suction and discharge lines of pumps / fans, including on header section, if two or more pumps are employed for the same service. All input and output lines of process equipments. Inlets and outlets of heat exchangers (both the fluid media) and de-super heaters.
1.1
1.2
Pressure Switches shall be avoided as far as possible and in place, smart pressure transmitters with soft limit value monitoring in DCS shall be provided. The applications will include the following: (a) (b) (c) (d) On all process lines / Equipments where parameter abnormality / status including pre trips alarms to be communicated to the operator in control room. For all permissives and protection conditions governed by safety operation of the equipments. e.g. pr. adequate, pr. very high / very low conditions. For all interlock conditions, governing starting of standby equipment or subsequent equipments for safety operation of the system. Inlet and outlet of filters / strainers.
1.3
Differential Pressure Switches (indicating type) shall be provided for the following applications: (a) (b) Across filters/strainers for remote monitoring Across condenser for remote monitoring and interlocks.
1.4
Smart Pressure Transmitter shall be provided for all control applications included in Bidders scope and as demand by the process. Pressure stubs with isolating valves shall be provided for mounting Pressure Transmitters. Differential Pressure Transmitter shall be provided for all the requirements of Diff. pressure, flow, level measurement. Pressure stubs with isolating valves shall be provided for mounting differential Pressure Transmitters. Temperature indicators (Thermometers) shall be provided (a) On all process lines where local indication is warranted by the system either for monitoring or testing.
1.5
1.6
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(b) (c) 1.7
On the inlet/outlet equipments such as desuper-heaters, Heat Exchangers & Coolers for both the fluid media. Differential temperature indicator shall be provided across BFP suction and discharge service.
Temperature Elements: Thermocouples / RTDs shall be provided for casing metal temperature monitoring and bearing temperature monitoring of 6.6 kV drives/motors. (a) (b) All thermocouples and RTDs as required for implementation of control & monitoring in Bidders system, shall be supplied. The elements shall be duplex type with integral thermowell (except for metal thermocouples). K Type Thermocouples shall be used for all temperature measurements wherever possible. However, for high temperature flue gas services R or S type thermocouple shall be provided. For metal thermocouples suitable MS pads, clamps, flexible extension lengths etc. shall be provided. Temperature elements in boiler and air ducts shall be in protective tubes. All temperature elements shall be supplied with associated junction box. Compensating cable shall be provided with all thermocouples for terminating to the control system eg. DCS. Six nos. (2 nos. per phase) Resistance temperature detectors (RTDs) shall be provided for all 6.6 kV motors, for winding temperature monitoring. Each element shall be 3 wire type, duplex with thermowell assembly. RTDs shall be terminated in the external terminal box, for connection to DCS system. 1 no. duplex PRT-100 type RTD shall be provided for each bearing of HT equipment and its driving equipment (motor). All RTDs shall be PRT-100 type with each element being 3 wire type, duplex with thermowell assembly. RTDs shall be terminated in the external terminal box, for connection to DCS system. For process temperature up to 200 degree C, RTD shall be used. Beyond 200 degree C temperature thermocouple to be used.
(c) (d) (e)
(f) (g)
(h) 1.8
Level gauges shall be provided on all tanks and the maximum length of one gauge glass shall not exceed 1 meter. The gauge glasses shall be stacked to cover the complete height of the tanks including over flow level. There shall be an overlap of minimum 100mm, when more than one level gauge is required. Level switches: The instrument shall be provided for the following applications: (a) On all equipments (storage vessel) where parameter abnormality/status has to be communicated to the operator in the control room.
1.9
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(b) (c)
All permissive, interlock and protection conditions governed by the safety operation of the equipment. The instrument shall be external cage type with SW connection with isolation facility for surface mounted tanks and top mounted with still pipe for all sumps. Still pipes shall be provided with adequate supports. Conductivity type level switches shall be used for all heaters and drain pots. Radar type level switches shall be used for bulk material bunkers.
(d) (e) 1.10
Level Transmitters Stubs with impulse pipes, root valves for mounting Level transmitters shall be provided on process equipments where continuous remote monitoring and/or control of level is envisaged. Wherever necessary standpipes or float chambers shall be provided and also makeup line for filling up the constant level vessel shall be provided. (a) The instrument shall be displacement type for all low pressure and vacuum applications involving two phase media viz: condenser, hotwell and LP heaters level measurements. Optionally, radar type shall be used. The instrument shall be differential pressure type or torque tube type for other applications. Radar type level transmitter shall be used for fuel oil storage tanks. Admittance or Radar type shall be for sludge and slurry applications. and shall be employed
(b) (c) (d) 1.11
Flow Glasses shall be provided at the outlet of the pipe lines under the following conditions: (a) (b) (c) Coolers
The instrument shall be rotary type with glass mounted for indication Upto 6 inch on-line flow glasses shall be supplied and above 6 inch bypass type flow glasses shall be provided.
Sight flow and variable flow indicators shall be used for low pressure and low temperature applications. 1.12 1.13 1.14 Speed Measurement shall be provided, where variable speed drives are to be controlled from remote (e.g. BFPs, feeders, ID fans etc). Flow elements shall be provided as detailed in Table-3. Digital Display Unit (DDU) shall be provided for main steam pressure, temperature, fuel flow, MW Export, MW Target, MVAR and frequency, condenser vacuum, Instrument air pressure, GPS Time, Weather Report (Room Temperature, Humidity, Barometer, Air purity etc).
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1.15 1.15.1
Pneumatically Operated Control Valves Pneumatically Operated Control Valves shall be provided for all control application. If the process demands any other control, then control valves shall be provided for those applications also. Where a single control valve can not meet the turn down ratio as dictated by the process, control valves with split range application shall be provided. All bypass valves of control valves shall be motor operated valves suitable for inching operation provided with position transmitters. All integrated bypass valves shall be motor operated. Electro-pneumatic positioners shall be used for all pneumatic control valves. Pressure test points & drains shall be provided across each control valve. In case during detailed engineering, pneumatic control elements get converted to electrically operated items, thyristor reversing unit based electronic power positioner (EPP) are in Bidders scope. In case, for these EPPs, power supply other than what is available if required, the same shall be supplied, by the Bidder. The pneumatically operated control valves shall be provided with Smart Positioners, diagnostics and HART compatibility. Control Valve diagnostics shall be transmitted through this HART Protocol to DCS. Solenoid Valves shall be provided for all pneumatic control valves hooked up with process interlock requirements and where direct tripping is involved. All solenoid valves shall be uniformly rated for 24VDC or 220V DC. The number of ways for solenoid valve shall be provided as indicated below : (a) (b) On line two (2) way solenoid valves shall be provided, where process line of less than 2 inch with low pressure & temperature application is involved. Three (3) way solenoid valves shall be provided commonly, where the pressure is admitted or exhausted from a diaphragm valve or single acting cylinder. E.g.: Pneumatic operated spray water block valve. Four (4) way solenoid valve shall be provided for operating double acting cylinders (If applicable). E.g.: Pneumatically operated on-off type dampers. Dual coil, latch, unlatch type Solenoid valves shall be supplied for equipment trips/critical applications. Five-way, dual coil solenoid valves shall be used for Oil guns.
1.15.2
1.15.3
1.16
(c) (d) (e) 1.17 1.18
Position Transmitters shall be provided for all motorised inching valves .Position transmitters shall be 24 VDC, 2 wire, non-contact type. Electro-Pneumatic positioners shall be provided for all pneumatically operated control valves, power cylinders etc., for converting controller output of 4-20 mA to appropriate pneumatic signal.
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1.19
Air Filter Regulators along with gauges shall be provided in each of the: (a) (b) (c) Air supply line to valve positioners /power cylinders Air supply line to pneumatic interlocked block valves Transmitter Racks
1.20
Interposing relay (To be mounted in Control room cabinet) for interface to the following: (a) (b) (c) Solenoid valve (two relays per valve) - Relays with contact rating of 2 Amps. DC Starter (two relays per drive) - Relays with contact rating of 0.2Amps. Hardwired signal exchange as required.
1.21
Analytical Instruments-Withdrawable Type Conductivity Analyser; (a) Provision for mounting the above analyzer shall be made at the condenser hot well along with necessary mounting arrangements/ accessories as required. For other analytical measurements, the sampling tapping points as called for, shall be provided.
(b) 1.22
Vibration Monitoring system: For all HT rotating equipment bearings and for steam turbine bearings
1.23 1.23.1
Junction Boxes/Field termination cabinet: All JBs /FTCs shall be SS. Junction Boxes shall be provided for (a) (b) (c ) Termination of all sensors located equipment wise. Termination of Duplex Thermocouples / RTDS Termination of limit switch, torque switch, position transmitter and control demand, independently for each valve.
1.23.2
FTCs shall be provided for: (a) (b) Connecting group of JBs area wise. FTC shall be designed to provide multiple units in Boiler and Turbine areas. FTCs reduce the number of cables entering the control room. Depending on the size of the multi core cable, one or two cables shall link to marshalling cabinet in the control room.
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SPEC NO. TCE. 5103-C-51001
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS and
1.24
Instrumentation & control cables treatment shall be supplied to: (a) (b) (c) (d)
Prefabricated Cables with Anti-Rodent
Connect field instruments to field junction boxes/Local Panels. For switches, both the SPDT contacts of switches shall be wired upto the J.B. Connect limit switches, torque switches and position transmitters to their respective field junction boxes. Compensating cable shall be supplied for connection between the element and the respective junction boxes / system cabinets as per guidelines. Prefabricated cable for connecting between system cabinets, marshalling cabinet to system cabinet, system cabinet to Relay Rack, system cabinets to Operator work stations , system cabinets to Engineering work stations etc. shall be in Bidders scope. Entire I&C cable within the battery limits.
(e) 1.25
Auxiliary Power Supply System (APSS) The power supply system shall conform to the requirements indicated in Electrical portion of this specification. The power requirements of the various systems in the scope shall be consolidated and power supply shall be envisaged. A list indicating the loads to be connected to different voltages shall be furnished. Bidder shall distribute the power for his I&C system. All power supply in the cabinets shall be redundant and have auto change over facility or diode auctioneering.
1.26
Instrument Air Supply System Dry instrument air shall be distributed to various equipments of I&C system like control valves, Analyzer purging, Transmitter racks, pneumatic On-Off dampers. The Bidder shall supply total Instrument air requirement Calculations, and design of Air compressor system along with the Bid.
1.27
Impulse pipes/tubes & fittings Impulse pipes, fittings and air supply and signal piping/tubing shall be supplied for all the instruments under the scope of this specification. Instrument piping shall be designed for maximum design pressure and temperature of the process. Pressure measurement connection shall be or 12mm pipe connection. Instrument on Vacuum system at CEP inlet should have vent lines connected to high point in the condenser. Instrument air tubing shall be copper, PVC coated to avoid oxidation at the surface of the tubing.
1.28
Instruments for Performance Testing
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SPEC NO. TCE. 5103-C-51001
All instruments required for performance testing to prove the guaranteed performance of the plant shall be supplied by the BIDDER for the Performance Test. These test instruments shall have test certificates from reputed test house, valid for the duration of the performance test. 1.29 1.30 2.0 System cabinets & marshalling cabinets shall be provided for all the systems in Bidders scope. Stand pipes required for hot well, deaerator, heaters, GSC, drain pot, etc. shall be provided by Bidder. SELECTION OF RANGES FOR INSTRUMENTS The ranges of the instruments shall be selected based on the following philosophy indicated below: For pressure and draft measurements, the maximum operating pressure will be within 70 to 80% of the maximum scale range. All pump suction measurement and steam pressure measurements in extraction steam and in heaters will cover the negative pressure range also and all draft gauges will cover the negative pressure as well as the positive pressure as the case may be. For temperature measurement, the maximum operating temperature will be within 80 to 90% of the maximum scale range. For pressure switches and temperature switches, the set points shall fall within 40% to 70% of the scale range selected. For level measurement, the maximum of the range will cover the overflow point or six inches from the top of the vessel and the minimum of the range will be six inches above the bottom of the vessel. Also, the gauge glasses will be stacked with overlap to cover permissive, alarm and trip levels. For flow measurement, the maximum range shall be fixed at about 10 to 15% above the maximum operating flow. For electro-chemical measurements (conductivity, pH, dissolved O2, Silica etc.), the maximum range will be around 10 to 15% higher than the recommended alarm settings. For gas analysers (if included in scope), the maximum range will be around 10 to 15% higher than the recommended alarm settings. PG TEST POINTS Pressure, temperature and flow test points shall be provided in line with latest performance test code requirements. In addition, pressure and temperature test points shall be provided for the following
ISSUE R0
2.1 2.2
2.3 2.4 2.5
2.6 2.7 2.8

3.0
3.1 3.2
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
services: (a) (b) (c) (d) 3.3 3.4 4.0 At the discharge of all pumps and fans At the inlet and outlet of the heat exchangers for the fluid media involved Adequate number at the Combustor at different zones At the inlet and outlet of each control valve
Pressure test points shall be complete with root valves and shall terminate with a nipple. Temperature test points shall be provided with thermowell with a cap and chain. SIZE OF TAPPING POINT STUB, NO. AND SIZE OF ROOT VALVES FOR DIFFERENT TYPE OF MEASUREMENTS Sl. No Qty. Of Root Stub & Root Valve Service Conditions Valves Size
A. Pressure & Differential Pressure Measurement (i) (ii) 2 1 25 NB 15 NB >=62 bar OR 425 degree C < 62 bar AND425 degree C.
B. Level Measurement B1-Level Gauge And Switch (i) 2 25 NB (ii) 1 15 NB
>=62 bar OR 425 degree C < 62 bar AND 425 degree C.
B2-Level Transmitter (Displacement Type) (i) (ii) 2 1 40 NB 40 NB >=62 bar OR 425 degree C < 62 bar AND 425 degree C.
B3-Standpipe For Level Measuring Instrument (i) (ii) 2 1 80 NB 80 NB >=62 bar OR 425 degree C < 62 bar AND 425 degree C.
C-Flow Measurement
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SPEC NO. TCE. 5103-C-51001
(i) (ii)
2 1
25 NB 25 NB
>=62 bar OR 425 degree C < 62 bar AND 425 degree C.
D. Sampling System Measurement (Steam & Water Service) (i) (ii) 5.0 2 1 25 NB 25 NB >=62 bar OR 425 degree C < 62 bar AND 425 degree C.
SPECIFIC INSTRUMENTATION REQUIREMENTS FOR STEAM GENERATOR Redundant speed sensor shall be provided with each coal feeder and shall provide an output to the feeder speed control. All feeder speed sensor tachometer-feedback circuits shall be suitably shielded from any electrical and mechanical interference. A no-coal flow detector complete with amplifier and pick-up located at the outlet of each coal feeder shall be provided to detect no-coal flow. Coal flow measurement with the help of conveyor speed and active load cells shall be provided for each feeder. The coal flow rate along with the integrator shall be made available in plant DCS. Super-heater tube metal thermocouples shall be provided on every fourth tube connected to the intermediate super-heater outlet headers, the intermediate reheat outlet headers & the final super heater/ reheater outlet header. Furnace gas temperature probes on each side of furnace for monitoring of gas temperature at the furnace outlet. The probes shall be moveable type. Furnace flame monitoring system with UV type flame scanners. The system shall conform to NFPA requirements. Digital Flame Scanners (microprocessor based) shall be supplied to cover 100% Oil and coal firing .The scanner electronics shall be mounted in Control room and shall include the following signals to Purchasers DCS: 4-20 mA output for Flame intensity. 4-20 mA output for Flame Quality Serial MODBUS connection to the DCS SG INTEGRAL CONTROL SYSTEM PHILOSOPHY MEASUREMENT SYSTEM (MS) The MS shall have the following features:
5.1
5.2 5.3
5.4
5.5 5.6
5.7
6.0 6.1 6.1.1
ISSUE R0
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SPEC NO. TCE. 5103-C-51001
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS Linearisation for temperature measurement i.e. mv Vs Deg. C
(a) (b) (c) (d) (e) (f)
Square root extraction for flow measurement, where the measurement is in differential pressure. Integration for totalising the flow measurement, whenever applicable. Compensation for variation in pressure or temperature or density for flow / level measurement. E.g.: Feed water flow / Boiler drum level. Limit value monitor for generation of contacts for alarm/interlock purpose. E.g.: Boiler Tube metal, Bearing, winding temperature measurements Each of the analog transmitters shall be Smart type with the following: (i) (ii) 4-20mA DC signal with 24V DC interrogation. HART protocol based digital communication
(g)
All these Transmitters shall be hooked up to a PC based Centralised Calibration system, which shall have Diagnostic and Configuration software. This system shall be located in MEE room. All contact inputs shall be interrogated with 24 / 48 V DC.
(h) 6.2
CONTROL SYSTEM-DESIGN FEATURES (a) (b) (c) (d) (e) No single random fault in the entire automation and control system will cause a load loss, forced outage or unit trip. No two simultaneous faults shall lead to or potentially cause damage to plant Safety related instrumentation and control shall be designed with a fail- safe mode. No single fault shall jeopardise the functioning of the entire system. The control and automation system and the field instruments and actuators as well as its support systems, power supplies and data networks shall be immune to the electromagnetic interference and shall conform to the internationally accepted standards. To meet the operational and safety requirements, the control system hardware and software shall conform to a modular, hierarchical architecture.
(f) 6.3 6.3.1
CLOSED LOOP CONTROL SYSTEM (CLCS) The CLCS shall control the process variables automatically both under steady state and dynamic conditions with in the limits specified under guarantee clauses over the entire
ISSUE R0
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SPEC NO. TCE. 5103-C-51001
operational range of the equipment/system. 6.3.2 The CLCS shall have the following features: (a) (b) Provision of predictive and/or adaptive controls in addition to PID controls as required by the system. Set point adjustments and indication from operating CRTs for process variables which need to be changed during load changes, start-up, shutdown, normal or under any other emergency conditions. Fixed set point at the software level/hardware level (only changeable by the maintenance engineer) and indication for those process variables which need not be changed with respect to load or otherwise. Bias adjustment with indication where a single controller is controlling more than one final control element (control valve, control damper, speed drive etc.) to maintain the same process variable. Auto and manual control facility shall be transferable in both directions without bump of the value of the process variable to control the parameter during manual operation. Both master Auto Manual station and Auto / Manual station for individual control element shall be provided in CRTs. Manual control facility will include operation from Back Up Control Panel also in addition to operation from operator station. Characterisation of final control element to suit the various applications with respect to load or otherwise as dictated by the process. Function generator to provide necessary characterisation or variation of set points with respect to load, speed or any other requirement. Soft Auto /Manual station interlocks to drive the final control elements to a suitable position for safe plant operation in the event of process/equipment abnormal conditions. Blocking/Interlocking function as dictated by process/equipment. Monitoring of loop failures or any hardware failure in the loops. Fail safe operation of final control elements in case of failure of motive power or signal.
(c)
(d)
(e)
(f) (g) (h)
(i) (j) (k) 6.4 6.4.1
OPEN LOOP CONTROL SYSTEM (OLCS) Protection, interlock and sequence controls constitute OLCS. This system shall enable the operator for safe start up and shutdown and carryout normal operation both from control room and local areas. Protection and Interlock shall be provided for all the equipment and system to safeguard the equipment against abnormal conditions which
ISSUE R0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
may result in the failure and less utility of the equipment and protect the operating personnel. Controls shall be provided to start/shutdown various systems and/or any equipment with associated auxiliaries and to operate the Unit on line with optimum number of operations and higher safety. 6.4.2 The OLCS shall have the following features as a minimum: Features-General Requirements (a) The logic and sequence control shall be Digital distributed and programmable. icroprocessor based
6.4.2.1
(b)
Enable the operator to start/stop various unidirectional motors, to open/close various valves and dampers and carry out inching operation of bypass valves or any other similar equipment both from control room and local areas. The system shall be designed based on the philosophy of command to energise a relay or solenoid valve. Where there is more than one pump or fan for the same service (say 2 pumps), auto standby features shall be provided to select the standby unit and this standby unit shall start automatically on failure of running pump or on applicable process criteria (say low discharge pressure) with an annunciation. All the contacts of the sensors used in protection circuit shall be monitored. Triple redundant sensors shall be provided when used in protection circuits for major critical equipment and 2 out of 3 logic shall be derived for further use in protection circuit
(c)
(d)
(e) (f)
6.4.2.2
Features-Interlock Requirements (a) Permissive conditions for a equipment start shall be provided. The permissive conditions within the equipment are bearing temperature normal, winding temperature normal, adequate suction pressure, bearing vibrations normal, bearing lubrication oil pressure normal, switchgear in service, switchgear not in test, no protection trip command persisting (as applicable) etc. The permissive conditions from a process system related equipment are establishment of free path for the flowing medium under all start-up, emergency and shutdown conditions, closure of discharge valve for the starting of first of the identical pumps/fans and then opening the valve after the operating condition is established etc. Selection of standby equipment and starting the equipment automatically on the tripping of running equipment and/or desired process parameter conditions (say loss of discharge pressure or low level in the discharge tank etc.)
ISSUE R0
(b)
(c)
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
(d) (e)
Isolation of the tripped equipment from the main process. Any other conditions for safe starting and shutting down the equipment.
6.4.2.3
Features-Sequence Control Requirements Sequence control shall be provided to start and stop the equipment and the associated auxiliaries. The sequence control shall have the following features: (a) Once the start-up or shutdown of an equipment is initiated either manually or automatically from the system, the control of associated auxiliaries shall be automatic with facility for manual operation at each stage (step). Criteria check up for each stage of operation with monitoring and displaying. Bypass facility for each criteria when only the feedback signal/display is incorrect but the actual condition is fulfilled. This activity shall be logged and annunciated in control system (DCS). Adequate time delay between the steps as dictated by the process to establish an operating parameter or healthiness of an equipment. Normally, the auxiliaries of the standby equipment should be running (as applicable) so that the standby equipment is started without loss of time.
(b) (c)
(d) (e)
6.4.2.4
Features-Protection Control Requirements The following minimum protection shall be provided for the various equipment/system as applicable to trip the equipment. (a) (b) (c) Any condition which endangers the safety of the plant personnel Any of the permissive conditions becoming abnormal thereby producing a dangerous condition in operating the equipment. The conditions from process such as dry flow conditions, flashing conditions or any other conditions that may create cavitation.
6.5
REDUNDANCY AND AVAILABILITY REQUIREMENTS Measurement system (MS), Closed Loop Control System (CLCS) and Open Loop Control System (OLCS) shall all be configured with redundancy at processor modules, communication modules, data bus and power supply modules. For Measurement System, redundancy at sensor level and I/O module level is not required
ISSUE R0
6.5.1
6.5.2
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
6.5.3
Both CLCS & OLCS shall be configured with I/O channels redundancy for each sensor/signals. Where redundant sensors are provided redundant I/O channels shall be provided for each sensors/signals. For all CLCS loops triple redundant sensors shall be provided. This will include sensors provided for compensation also. Similarly for critical protection logic requirements triple redundant sensors for 2 out of 3 logic shall be provided to avoid spurious tripping. SENSOR REDUNDANCY- PHILOSOPHY Two out of three measurements philosophy shall be adopted for the control of all closed and critical open loop variables for reliability of operation. The control system shall select the median value for the normal control purpose. In case of deviation of one transmitter output from the other two, the same shall be automatically isolated and average output of the remaining transmitters shall be fed to the control and measurement system and the control loop in this case shall be maintained on auto, with an alarm on the operators monitor as well as maintenance engineers monitor. In case of failure of the two remaining transmitters in circuit, deviation of one transmitter output is more than the preset limit compared to the other transmitter, there shall be automatic bump less transfer and changeovers shall have suitable alarms. For signal compensations, separate signals from separate transmitters shall be used for measurement and control. Sensor Redundancy For OLCS All sensors for the following causes of trips shall be triple. (a) (b) (c) (d) Unit trips, Boiler trips, Turbine trips Trip of any auxiliary which will lead to substantial (50%) loss of unit availability.
6.5.4
7.0
7.1
7.2
7.3 7.4 7.4.1
7.4.2
All sensors for the following causes of trips shall be dual (requirement specified at Clause 10.8.1 will have priority of application). (a) (b) All HT equipment trips. All LT equipment trips.
7.4.3
Single sensors shall be provided for the following:
ISSUE R0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS Alarm Permissive Measurement
(a) (b) (c) 7.4.3 8.0 8.1 8.1.1
Sensor Redundancy For CLCS: Triple redundant sensors shall be provided. SG INTEGRAL CONTROL SYSTEM EQUIPMENT / SYSTEM FUNCTIONAL REQUIREMENT DISTRIBUTED PROCESSING UNIT (DPU) Processor will be minimum 32 bit with floating point arithmetic capability. It will have adequate capacity of volatile memory to store dynamic plant data, control programmes and self- diagnostic routines. Also it will have adequate capacity of non- volatile memory to store programmes, standard software to perform control data acquisition and diagnostic functions. Battery back up (if applicable) for duration not less than 50 hours shall be provided. Memory expandability of 150% of offered capacity shall be provided. Processor shall have the following functional capabilities as a minimum: (a) (b) (c) Mathematical Functions: To meet the functional requirement of the control system and provision to add more algorithms by the purchaser. Logic Functions : For performing Boolean operations and time delay requirements Control Techniques: Shall include Multivariable, feed forward, feedback, cascade, auto tracking, ratio and bias, dynamic dead band, proportional, integral, derivative and their combinations, auto inching, auto limits, blocks, runups, run downs, over rides, analogue hold and any other techniques as may be necessary. Point Status and Quality feed back.
8.1.2
(d) 8.1.3 8.1.3.1
INPUT/OUTPUT MODULES Digital Input Modules shall have the following features: (a) (b) (c) (d) Signal isolation (optical) Fuse protection Contact bounce protection Field cable monitoring
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TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS Short circuit protection Configurable as status input, latched input Alarming of abnormal state The interrogation voltage for digital inputs shall be 24 V DC
(e) (f) (g) (h)
The number of channels per DI module shall be maximum 32 8.1.3.2 Digital output Modules shall have the following features: (a) (b) (c) (d) (e) (f) Individually fused Individual contact suppression Configurable as momentary, latched or pulse-width modulated outputs Individually definable default state Output read back verification Short circuit protection
The number of channels per DO module shall be maximum 32 8.1.3.3 Analog Input Modules shall have the following features: Analog inputs can be 4-20 mA DC, RTD ( Pt 100 ) , Thermocouple (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Signal isolation (Galvanic/ Opto-coupler) Fuse protection and fuse failure detection Transmitter power supply at 24 V DC Input filtering for noise level Cold junction compensation for thermocouples Transmitter monitoring for parity, wire break and limit values Monitoring of A/D conversion Conversion to engineering units Test for normal or extended range Detection of open circuit for thermocouples
ISSUE R0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS Detection of open circuit for thermocouples
(k) (l)
Alarm limit testing for high, high-high , low, and low-low substituted values
The number of channels per AI module shall be maximum 16 8.1.3.4 Analog Output Modules shall have the following features: (a) (b) (c) (d) Analog outputs shall be 4-20 mA DC Direct or reverse operation Loop check back of output Default options upon failure
The number of channels per AO module shall be maximum 16 8.2 8.2.1 Design Features/Requirements of Process Controllers (DPU) Microprocessor based multiloop controllers with input/output ports/cards shall be used with configuration and control software. All open/close control loops shall be easily configurable using user-friendly software. Controllers shall be able to operate in either manual, auto, cascade mode. Mode changeover in either direction shall be bumpless. The controller shall also have facility for slow and fast ramping of set point and output. The controller should be capable of implementing complex and advanced control strategies through the use of exhaustive set of control algorithm/software blocks. These shall include PID, adaptive, feed forward, dead time, lead-lag compensation, high-low signal selection, curve fitting, real time computational capability etc. In addition the controller shall be able to perform batching, sequencing, interlocks and logic functions. Failure of one loop shall not result in failure of other loops. The distributed processing unit shall be provided with redundant floating power supply. The power supply modules, which are vital to the systems continuous operation, shall have the means to receive power from two (2) independent power sources. Suitable battery back up shall be provided for protection of volatile memory (for 72 hours). The system shall have 1:1 redundancy with respect to the processor modules, power supply modules, communication modules and network interface. The system shall be designed in such a manner that in the event of failure of the primary controller, the entire configuration of the failed controller shall be instantaneously and automatically transferred to the back-up controller without operators intervention. Mode changeover in either direction shall be bumpless. Simultaneously, a message should appear on the video-monitors of the Operator' s/Engineer' s work station indicating the failure. The system shall be capable of accepting commands from Purchasers DCS system OS and shall be capable of sending the feedback to DCS OS through MMI system of DCS.
8.2.2
8.2.3
8.2.4
8.2.5
ISSUE R0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
8.3
ENGINEERING STATIONS (ES) (a) (b) To generate control software through logic diagrams with out any programming knowledge To generate graphic display and control displays, facility to change/enter all the attributes of analog and digital I/O points, calculated and Boolean variables and constants like scan rate, process range To test, configure/reconfigure process interface modules/cards CLCS tuning To accumulate I&C faults to analyse downtimes and time to repair To run offline system diagnostic programmes On- line fault detection through diagnostics Other maintenance Engineer' s functions.
(c) (d) (e) (f) (g) (h) 8.4 8.4.1
DCS SYSTEM PERFORMANCE REQUIREMENTS DCS System performance requirement (Under worst loading conditions) shall be as follows: (a) (b) (c) (d) (e) (f) (g) (h) Scanning rate of analog signals Scanning rate of digital signals Scanning rate of pulse signals Loop execution time for CLCS Loop execution time for OLCS Controller output update for CLCS Controller output update for OLCS Controller Loading Maximum 1 sec for measurement Maximum. 50 ms Max. 50 ms Maximum 250 ms (For all Loops) Maximum 50 ms (For all Loops) Every 250 ms (For all CLCS Loops) Every 50 ms (For all OLCS Loops) Max. 50 %
8.4.2
Worst Loading Conditions for SG Integral Control System: The worst loading condition shall include the following tasks: (a) All process inputs scanning and processing is in progress and all the data is
ISSUE R0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS transmitted over the main data bus every one second.
(b) (c) (d) (e) (f) 8.5 9.0 9.1
All closed loop controls in operation All open loop controls in operation All output devices are in operation with rated performance/speed. Control/information request is initiated on control VDU. In burst mode operation, 100 digital alarms are generated per second for a period of 10 seconds.
DCS System Reliability / Availability Requirement shall be as per the standard specified in code. BMS AND BOILER PROTECTION SYSTEM A microprocessor based independent fail safe fault tolerant control system shall be provided for BMS & Boiler protection system. System shall be fail-safe type with minimum Safety-Integrity Level 3 as defined in IEC 61508 and independent for each boiler. BMS & Boiler protection shall be either of TMR (triple modular redundant) type or any other approved configuration as approved by the IEC code. The system shall be certified from an authorised agency. Copy of certification with all conditions specified shall be submitted by Bidder with Bid offer. System shall be provided with redundant power supply modules with power supply provided through redundant feeders. System shall have an integrated sequence of event recording and alarming facility with a resolution of 1 mili-second for all input signals. The system shall be able to provide fault diagnostics covering up to 99% on all the possible internal failure of hardware. System shall be able to carry on-line modification of application programme. Necessary tools for engineering modification shall be provided. Protection system output shall be directly hardwired to field control elements. Where the same field sensor signal is used for both Boiler protection and plant DCS, field sensor shall be directly connected to the protection system and the input signal to plant DCS shall come as an output from protection system. TRUE TMR FEATURES
ISSUE R0
9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9
10.0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
10.1
True TMR configuration essentially means that there shall be three parallel processing channels each with dedicated Input modules, Controller, Output modules, Communication modules, power supply modules, and relay. The outputs from the relays shall be finally wired out, in 2 out of 3 mode. The communication Buses, Sensors and Power supply shall also be triple. There shall be extensive, on-line, software validation between the three processing channels such that the system availability is 99.7%. The three processing channels shall be physically located in three separate cabinets. There shall be continuous hardware cyclic checking upto the relays and suitable diagnostics to identify any faults and annunciate. SPARE PHILOSOPHY FOR SG INTEGRAL CONTROL SYSTEM I/O CHANNELS: (a) Spare I/O Channels: All types of I/O modules shall be provided with 10 % spare channels. Spare channels shall be wired and shall be distributed among the control processors. 10% hot spare I/O modules (installed) shall be provided. 10% spare slots for I/O modules distributed among the control processors.
10.2 10.3 10.4 10.5
11.0
(b) (c) 12.0 12.1
SPECIFIC DESIGN REQUIREMENTS VALVE ACTUATOR / CONROL SYSTEM / MCC INTERFACE All the On-Off valves of SG Package shall be provided with integral actuators. The required actuator power supply shall be from the switchgear. The actuators shall accept potential-free contact command signals from Control system (eg. DCS) and following feed back signals (potential) shall be provided to control system (eg.DCS): (a) (b) (c) (d) (e) (f) Open Position Close Position Open Torque actuation Close Torque actuation Actuator trouble Actuator ready to start
12.2
UNI-DIRECTIONAL LT DRIVES/ CONTROL SYSTEM / MCC INTERFACE

ISSUE R0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
LT drives like Pumps and Fans shall have the following interface with Control system and MCC (a) (b) 24 V DC Logic level On-Off commands from control system to MCC Feed backs from MCC to control system shall include: (i) (ii) (iii) (iv) 12.3 12.4 12.5
On/Running Off/Stop Trip MCC Ready
All motorised bypass valves & Bypass Dampers shall be inching type and shall be provided with non-contact type position Transmitters. For all the variable frequency drives, all the analog and digital signal exchanges with Purchasers DCS / control system shall be provided, as required. Local Stop push button (Shrouded type) shall be provided for all HT and LT drives for emergency stopping of the drives. The contact pf the push button shall be wired directly to MCC to initiate trip. All such contacts shall be suitably connected to control system for reporting of local operation. Two Emergency trip push buttons with front covers, for each Boiler shall be provided in the control room in UCP. All field instrument, local panel / cabinet enclosures shall be IP-65 Individual (one for each transmitter) purging line connected to the impulse line before the root valve with required accessories shall be provided for all Air and Flue gas transmitters impulse lines. ACTUATORS for control valves: All regulating type final control elements shall have actuators of pneumatic type excepting LP/HP bypass and Turbine governor valve, which shall be hydraulic type. Actuators shall be provided with air failure lock to obtain the required fail safe condition, control contacts as warranted, adjustable minimum / maximum stops, local position indication and two (2) wire electronic position transmitters with solenoid valves wherever necessary and air filter regulator. Fail safe action of the final actuator shall be as follows: (a) (b) Modulating controlStay put
12.6 12.7 12.8
12.9 12.9.1
ON/OFF control -Move to safe-end-position

ISSUE R0
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
12.9.2 12.10 12.10.1
All actuators shall be provided with hand wheel for local operation. CONTROL VALVES: The control valves shall be capable of handling at least 130 percent of required maximum flow at full open condition. Control valves shall be provided with manual isolating and bypass valves for facilitating maintenance wherever alternative flow paths are not available. SMART Positioners shall be used for all regulating services. Two wire electronic position transmitters and limit switches shall be provided on the valve wherever required depending upon the system requirement. SMART Positioners shall be provided with HART protocol and Diagnostic features. All the cables in the Hot Zone (combustor region) shall be fire survival cable conforming to IEC 331standard.The cables in other areas shall be FRLS, conforming to IEC 332 standard. For coal Feeders, three (3) number Feed Rate signals shall be provided from each Feeder Cabinet to DCS. Feeder calibration is very critical and Bidders shall envisage a scientifically correct Feed rate signal computation method and a proven method of calibration. The Owner / Project Manager personnel have to be trained specially on this. KKS Tagging philosophy is to be followed uniformly. The Test Position of each DC starter shall be monitored and alarmed in DCS. GENERAL TECHNICAL REQUIREMENTS The general engineering and calculations shall be made as per prevailing Indian, International standards acceptable to Owner / Project Manager. Wherever such standards are not available, they shall be as per the best practice in India and abroad. All measurements shall be in metric units All the electronic circuitry shall be built-up with plug in modules providing maximum flexibility and easy servicing. Anti-vibration mountings and shock absorbers shall be provided for cabinets, desk and panels. The cabinets surface shall be thoroughly degreased, smoothed, filled and painted with rust resistant primer to present a smooth and flat finish. Front of cabinets shall be primed and filled as required at least two coats of primer and minimum two coats of final colour above the primer coating to present a smooth and mat finish. SS Legend plates shall be provided on the cabinet front and back, desk face, unit control
ISSUE R0
12.10.2
12.11
12.12 12.13
12.14 12.15 13.0 13.1
13.2 13.3 13.4 13.5
13.6
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
panel, local panels, junction boxes, transmitter racks, FTCs, Remote I/O rack, instruments, Control valves etc., for all items supplied to identify the equipment. Overall dimensions of the nameplates shall be decided by the text of legend, maintaining overall consistency and clarity and avoiding size variations. 13.7 The cabinets shall be upright; floor mounted, front open type with removable door and shall have ventilation with steel mesh. The outside colour of all instrumentation cabinets, control desks, consoles, local cabinets, marshalling cabinets, system cabinets, junction boxes, Transmitter racks, FTCs etc. shall be of light grey shade no. 631 of IS: 5, 1978 or equivalent international code. The inside colour of all these cabinets shall be brilliant white. The cabinets shall be made from CRCA Steel sheet with a minimum thickness of 2 mm. Removable eye lifting lugs shall be furnished and installed on all cabinets. All Critical control valves shall be provided with anti-cavitation trim. Control valves / dampers shall be supplied with all accessories including non-contact type position transmitters and E/P Positioners. Combination of I/P + Pneumatic positioner is not acceptable. All inching valves shall be supplied with position transmitters integral with the valve positioner. All Temperature sensors shall be Duplex type and field mounted temperature transmitter shall be provided for all temperature measurement for control applications. This will include equipment bearing temperature measurements also. Switches (pressure, temperature, level & flow etc.) shall be provided only for critical equipment trip such as BFP/ CEP trip etc. Wherever possible, transmitters shall be provided with required redundancies for all other purposes. Where multiple functions like monitoring /control/alarm etc. are sought to be performed based on a parameter value, in minimum dual sensor shall type be provided. All outdoor field equipment shall be provided with epoxy painting. Individual continuous purging shall be provided for all Air and Flue gas transmitters. The tap points for these services shall be Y shaped. The purging line shall be shall be connected near the root valve only and not at the Transmitter end. All local cabinets / utility plant control panels with bottom cable entry shall be provided with suitable pedestals for easy cabling. The panels shall be designed for ease of operation of operating hardware and monitoring the indicators. All local panel indicating lamp/indicating type Push button should be of cluster LED type only. All local panels shall be of double door type instead of double leaf type to avoid ingress of dust in dust prone areas. All motorised bypass valves shall be inching type and shall be provided with position transmitters of non-contact type.
ISSUE R0
13.8
13.9
13.10
13.11
13.12 13.13 13.14
13.15
13.16
13.17
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
13.18 13.19 13.20 13.21 13.22 13.23 13.24
Conductivity type dedicated level switches shall preferably be used for heater level applications. Spring-loaded terminals shall be used for termination of instrumentation cables at field JBs, FTCs and local panels. Instrumentation cables shall be laid in separate cable trays. Cable number tags and markings will be provided at every 30 meters along the entire length of cable. All JBs, FTCs and similar equipment in Boiler, STG and other areas shall not have top entry to avoid dust entry. No equipment shall have top entry for cables. All the switches, wherever provided shall be provided with 2nos. changeover contacts and both shall be wired upto Junction Boxes. The Instrumentation & Control (I&C) equipment/system offered shall be of proven system The models of all instruments, field sensors, final control elements, flow elements, control system equipment and monitoring system equipment as covered in this section shall be field proven, i.e. installed, commissioned and successfully operating for a minimum period of 3 years. The Bidder shall furnish list of installations and users certificates to prove the same and shall be subjected to Purchaser' s approval. All the systems in the BIDDERs scope shall work satisfactorily taking into account all the required interconnections. Any other control and instrumentation / equipment not specifically included but required for plant operation/performance, along with the scope shall be identified. Grouping of instruments in JBs in Vendor scope is subject to Purchasers approval. All stubs, root valves, within Bidders battery limits are included in Bidders scope. Suitable expanders shall be provided for small diameter pipes to enable mounting of temperature instruments to have minimum immersion lengths of 3 inches. Vendor shall furnish set points for all instruments mounted on his pipe/equipment. Vendor shall size the control valves/flow elements in his scope as per latest applicable standards. Vendor shall provide dedicated sensors for all pre-trip alarms. Vendor shall provide sensors for fault monitoring and alarming for the equipment within the scope. Technical features of instrument types not covered in Section D 2.4 shall be subject to
ISSUE R0
13.25 13.26 13.27 13.28 13.29 13.30 13.31 13.32 13.33
TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
Purchaser/Consultants approval.
13.34
IBR certificates as applicable for control valves, flow elements, thermowells, etc., shall be furnished. Signal Exchange Between Bidders Equipment / System (a) (b) and Purchasers System
13.35
All the signals required for interlock / alarm / SER purpose (to be implemented in the Purchaser' s DCS) shall be hardwired. All binary outputs provided from Bidders cabinet/local panels/sensors for connection to Purchasers system shall be potential free contacts with a rating of 0.2 amps at 220 V DC or 5 amps at 240 V AC. All check backs to Purchasers system shall only be potential free contacts. All analog outputs provided from Bidders cabinet / local panels/sensors for connection to Purchasers system shall be isolated 4-20 mA DC. Command outputs from Purchasers control system (DCS) to Bidders motorised valve actuator integral starter will be logic level signal (24 V DC) and necessary interposing relays suitable to accept 24 V DC logic level command signal shall be provided in Bidders MOV actuator.
(c) (d)
14.0 14.1
CODES AND STANDARDS All equipment, systems, software and services covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. All codes and standards referred in this specification shall be understood to be the latest version on the date of offer made by the Bidder, unless otherwise specified. If such standards are not existing for any equipment or system, the same shall comply with the applicable recommendations of the following professional institutes: (a) (b) (c) (d) (e) (f) (g) (h) National Electricity Manufacturers Association (NEMA) The Institute of Electrical and Electronic Engineers (IEEE). Instrumentation Systems and Automation Society (ISA). American National Standards Institute (ANSI). Deutsche Industries Norman (DIN). International Electrochemical Commission (IEC). International Consultative Committee on Telephone and elegraphy (CCITT). Verin Deutschar Eisecnhuttenleutte (VDE)
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TCE FORM 329 R3
SPEC NO. TCE. 5103-C-51001
(i) 14.2
Indian Standard Institute (ISI).
Standards not indicated in the specification are acceptable (subject to approval by the Owner / Owners Representative) if they are established to be equal or superior to the standards indicated in the specification. The VENDOR shall furnish English translation of all standards to which the equipment and systems offered conform to. The specific codes and standards applicable are listed in Section C, TABLE-5.
14.3 14.4
ISSUE R0
TCE FORM 329 R3
SPEC. NO TCE 5103A-C-51001
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TECHNICAL SPECIFICATION
1.0 1.1
SPECIFICATIONS FOR INSTRUMENTS TO BE SUPPLIED ARE AS FOLLOWS. Pressure Indicators/DP indicators Direct reading, pipe mounted Pressure gauges of die-cast aluminium body, with 6 inch(150mm) phenolic dial (white dial with black numerals), 316 SS/304 SS Bourdon tube for high pressure application and 316SS Diaphragm/bellow for low pressure applications, AISI 304 movements and micrometer type adjustable aluminium pointer an accuracy of +/-1.0% of span including accessories like siphons for steam services, snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services and name plate, etc. Material of accessories shall be SS. IP65 or equivalent degree of protection for enclosure. Over range protection shall be 50% above maximum pressure. Armoured capillary of 10 M shall be provided as required. Process connection shall be NPT (F).
1.2
Pressure Switches/DP Switches Non indicating type, field mounted Pressure Switches of aluminium casing (epoxy coated), and 316 SS element and repeatability of +/-1% of span, including accessories like siphons for steam services, snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services, name plate & mounting brackets. Material of accessories shall be SS. Auto reset micro switch with internal adjustment for set values with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or equivalent degree of protection for enclosure. Over range protection 50% above maximum pressure. Scale for setting shall be provided. Piston actuated for high pressure applications and diaphragm/bellows for low pressure/vacuum. Process connection NPT (F).
1.3
Pressure Transmitters/DP transmitters/DP type (SMART)
Transmitters/Flow
transmitters(DP
type/Level
Micro-processor based 2 wire indicating type (LCD display), rack mounted with accuracy of +/-0.075% of span, external zero and span adjustment, self diagnostics, temperature sensor for compensation. Power supply 24 V DC; output signal of 4-20 mA DC. IP 65 or equivalent degree of protection. Aluminum housing with epoxy coating, Accessories like snubbers for pump discharge applications and chemical diaphragm. 10 m PVC covered SS armoured capillary for corrosive and oil services, three way manifold, nameplate etc. Material for accessories shall be SS. Turn down ration 30:1. Load impedance 700 ohm (min).Process connection-1/2NPT (F). 2 valve manifold for absolute pressure, 3 valve manifold for gauge/vacuum and 5 valve manifold for DP/level/flow measurements. For HFO, LFO applications, SS capillary with ANSI RF flanged ends shall be provided. 1.4 Thermometers Mercury in steel below 450 deg. C. and inert gas actuated for above 450 deg.C. of SS
ISSUE R0
TCE FORM 329 R3
bulb and capillary. Body material-Die-cast aluminium. Dial size-150 mm with white dial and black numerals and process connection-1/2NPT (F). Accuracy-+/- 1% of span. IP 65 protection class. Accessories include nameplate, mounting brackets and SS Thermo well. Process connection-3/4NPT (F). 1.5 Thermo wells Pipe/equipment mounted temperature test wells of 316 SS with a process connection of M33x2 thread or 150 RF flanged. Accessories like name plate, plug with chain, etc. shall be provided. Material of accessories shall be SS. Thermowell shall be hex head of barstock assembly. In case flanged wells are required for any specific application, the same shall be supplied as required. The thermo well construction shall meet the ANSI 19.3 (latest) requirements. Thermo well shall be designed such that the resonant frequency is above the exciting frequencies generated by vortex shedding in the process fluid. All Test thermo well shall have the plug of SS316. 1.6 Thermocouple Assembly Duplex, K Type, 16 AWG or R type, 24 AWG with accuracy as per IEC-751/ANSI-C96.1, ungrounded type depending on operating temperature range. Response time of 2 to 6 sec, Spring loaded mineral insulated thermocouple assembly with 316 SS thermo well housed aluminium casing (epoxy coated) having a process connection of M33 x 2 thread. Material of accessories (name plate, etc.) shall be SS. IP 65 or equivalent degree of protection for enclosure. Thermo well with hex head (with screwed cover & SS chain) bar stock assembly with ungrounded junction. For metal temperature measurement, thermocouple pads weldable to M.S pipes shall be provided with 15 m thermocouple extension wires. Element size shall be 18 AWG. Insulation resistance at 540 Deg C shall not be less than 5 M ohms. Temperature devices provided with thermo wells shall be calibrated with the associated thermo well as an assembly. The thermo well construction shall meet the ANSI 19.3 (latest) requirements. All pent house thermocouples shall be supplied with 15mts flexible extension length. Thermowell material for abrasive process application like coal air mixture, flue gas etc. shall have tungsten carbide coating. For high temperature flue gas applications such as platen super-heater and de-super heater inlet / outlet etc. T/C shall be provided with ceramic assembly. 1.7 Resistance Temperature Detectors (RTD) Duplex type, PT 100, with accuracy of +/-0.5% of span, response time 1-2 seconds; Spring loaded mineral insulated three (3) wire RTD assembly with 316 SS Thermo well housed in aluminium casing (epoxy coated) having a process connection of M33 x 2 thread or 150 RF flanged. IP 65 or equivalent degree of protection for enclosure. Material of accessories (name plate, etc.) shall be SS. Thermo well with hex head with screwed cover & SS chain, barstock assembly. Element lead size shall be 18 AWG. The insulation resistance at 540 Deg C shall not be less than 5M ohms. Repeatability over full range shall be better than 0.02%. RTDs shall be ungrounded. RTD shall be supplied as an assembly complete with thermo wells meeting ANSI 19.3
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TCE FORM 329 R3
(latest) requirements. 1.8 Level Gauges Tubular type level gauges for low pressure up to 7 kg /sq.cm & reflex type for high pressure water & steam services & vacuum services with automatic ball check valves, illuminator (240 AC), pyrex / tempered toughened borosilicate glass, mica shield, brass guard rods & brass holders. Body material: Forged carbon steel/304SS. Accuracy- +/- 2% with vertical scale.4. Material of accessories (name plate, etc.) shall be SS. Tubular glass OD shall be 5/8. Vent & drain valves shall be provided. Connection shall be screwed or flanged (ANSI class 150 RF). 1.9 Level Switches External cage magnetic float operated level switches for tanks and vessels and top mounted level switches for sumps and underground tanks. The top mounted level switches shall be supplied with still tubes to suit the requirement. Micro switch with 2 SPDT contacts rated for 0.2 A, 220 V DC. Material of float & float chord shall be 316 SS & cage material shall be fabricated steel and the material of accessories shall be SS. IP 65 or equivalent degree of protection for enclosure. Accessories like name plate, drain valve for external case type level switches, mating flange, gaskets (asbestos), fasteners, bolts & nuts, etc. shall be supplied. Conductivity type electronic Probe type level switches shall be supplied for Drain pots. The required pressure vessel assembly for mounting probes are included in the scope. 1.10 Displacement type Level Transmitter Displacer type level switches shall be provided for level measurements of the vessel under vacuum or low pressure applications viz for condensate and feed water system. The displacer tube material shall be K-monel. The float movement shall be transmitted to the pivot mechanism by only torque device incorporating positive seal between float cage interior and the transmitting mechanism without the use of stuffing boxes. Accuracy including combined effect of linearity, hysterisis and repeatability shall be +/0.75% of span or better. Protection class shall be IP-65. Output-4 to 20mA signal superimposed with HART protocol. 1.11 Flow Glasses Online flow glasses for pipe size up to 6 with a rotary wheel (not a flapper type) suitable for installation on vertical or horizontal pipelines, material Pyrex tempered glass. Body material shall be carbon steel, rotor & wetted parts shall be bronze. The material of accessories shall be SS. IP 65 or equivalent degree of protection for enclosure. Upto 50 Nb size, connection shall be screwed & above 50 mm Nb size it shall be flanged - ANSI, 150 RF. Accessories like name plate, mating flanges with gaskets (neoprene), bolts & nuts, etc. shall be supplied.
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TCE FORM 329 R3
1.12
Flow Switches Indicating, Differential pressure, flapper type on line flow switches for line sizes up to 80 mm with an accuracy of +/-0.5% of span and dial size of min. 50 mm having 316 SS flapper/SS 316 bellows housed in die cast aluminium. Micro switch with adjustable range with 2 SPDT contacts rated for 0.2 A, 220 V DC. IP 65 or equivalent degree of protection for enclosure. The material of accessories shall be SS. Repeatability shall be +/-0.5% of span. Over range protection shall be 50% above maximum flow. Setting shall be tamper proof external adjustment & scale shall be provided for setting. Range spring & orifice plate shall be SS 316 for DP type. NPT for sizes below 2 & for sizes above 2 ANSI 150 RF shall be provided. Accessories like nameplate, mating flanges with gaskets, bolts & nuts, pipe assembly with orifice plate, etc. 5 way manifold, pipe, fittings (DP type), etc. shall be supplied.
1.13
Flow Elements 316 SS long radius, welded type flow nozzles as per ASME PTC 19.5 or BS-1042 for all steam and feed water services with D and D/2 pressure tappings; 316SS concentric orifice plate assembly as per ASME PTC 19.5 or BS-1042 for all water services with flange tap connections. Beta ratio of 0.34 to 0.7 for orifice and around 0.7 for flow nozzles. The material of accessories shall be SS. Refer to Table-5 for provision of flow elements. All the flow elements shall have 3 pairs of differential pressure tappings complete with root valves. Orifice plate shall be 3 mm thick for nominal pipe diameter up to 300 mm & 6 mm thick for pipe diameter > 300 mm. The thickness of the flow nozzle shall be as per the application. The flow elements shall be supplied as assemblies with High/low pressure tappings, root valves as required. Performance Guarantee flow elements shall be provided separately. Butt welded edges shall be prepared as per ANSI 16.25 & flanged connections shall be as per ANSI 16.5 standards. Orifice assembly complete with nipples & valves to be supplied by Bidder shall be one meter long with ANSI class 150 RF SS flanges at the ends including gaskets, bolts & nuts. Isolating valves shall have SW end connection. Accessories like nameplate, gaskets, bolts & nuts, reservoirs (condensing chambers), 6 nos. shut off valves per assembly, nipple, welding adapters, etc. shall supplied. Bidder shall submit assembly drawing and flow vs DP curve for each flow element.
1.14
Magnetic Flowmeter Inline type with indicating top mounted transmitter with flange connection. Accuracy: 0.5% of flow rate or volume flow. Repeatability 0.1% of flow rate/volume flow. Transmitter shall be smart with LCD display and superimposed HART on 4-20mA DC output. Data storage shall be in EEPROM. Shall have diagnostic capabilities. Touch control facility on the indicator for checking the rate/volume and diagnostic messages. Material: Case-Al.alloy with corrosion resistant, flow tube and extension pipe- Stainless steel (SS 304) and Lining-fluro carbon. The flow rate shall be available in DCS/PLC and flow integration shall be implemented in DCS/PLC to indicate volume flow.
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TCE FORM 329 R3
1.15
Anubar ( Impact Head Type) Element shall be tubular, insert type with minimum four impact ports facing upstream direction, located precisely for measurement of average flow velocity. The material of the sensor shall be SS 316. Accuracy shall be +/ - 1% of the actual value or better. Repeatability shall be + /- 0.1 of actual value or better. Online retracting facility and flushing arrangement shall be provided. The sensor shall be supplied with complete mounting hardware and support plugs and valve manifolds ( NPT) for DP transmitter connection. The specification of DP transmitter is specified elsewhere.
1.16
Pressure and Differential Pressure Transmitter Racks Open type transmitter racks to mount all pressure, differential pressure and flow transmitters with vibration dampener: air supply lines and header shall be provided with bulk head fittings to receive impulse lines; Also provided with blow down/drain header. The material of accessories shall be SS. Drains shall be connected upto suitable Owner / Project Managers drain header. The quantity shall be as required for the specified Pressure and Diff. Pressure transmitter.
1.17
Junction Boxes (JB) All JBs shall be Galvanised. Wall/column mounted junction boxes having 32 (2x16) terminals and cable entry only at the bottom and sealed with fireproof compound; Screwed terminal type; IP 65 or equivalent degree of protection for enclosure. Separate terminal blocks shall be used for analog and digital signal and also for signals with different voltages. Removable gland plate shall be supplied. JB shall have single lockable door with gasket, able to open side ways, with common keys. Painting inside shall be glossy white & outside - IS-5 shade 631. Shield bus for screw connection shall be provided. Terminal size shall be suitable for 0.5 sq. mm to 2.5 sq. mm wire. Terminal blocks shall be vertical. JB shall have provision to add 10% additional terminals. Accessories like metal tag (SS), clamps, fixtures, bolts (SS), nuts (SS), gaskets (neoprene), lock & key, fireproof compound for sealing, etc. shall be supplied. The grouping of instruments in JBs is subject to Owner / Project Managers approval. All the field Junction boxes shall have single doors and provision for locking. The doors shall not have screwed type of locking, but turnable hinge based. The JBs are subject to approval prior to manufacturing All JBs shall be provided with individual canopies to avoid ingress of water. All the TBs used shall be 6.6polymide to withstand corrosion and the metallic portion shall be coated against rust / corrosion.
1.18
Field Termination Cabinet (FTC) FTCs shall be galvanized, out door located, free standing vertical type with IP-65 enclosure and with 2 mm thick sheet metal of cold rolled steel; double door with neoprene gaskets; ant vibration pads of 15 mm thick; fluorescent lighting; fire detection for each cabinet; fire proof compound (50 mm thick) for sealing cable entry (bottom,
ISSUE R0
TCE FORM 329 R3
front, rear). The colour of the cabinets shall be indicated at detailed engineering stage. The type of terminal shall be made up of 6.6 polyamide and the metallic portions shall be coated against corrosion. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by Bidder, subject to approval by Owner / Project Manager/ Consultant. Door shall have concealed type hinges and swing of 180 Degree & lockable. The doors shall be provided both on the front and rear. Channels, bolts & nuts shall be zinc plated and passivated. Two coats of primer paint and black colour paint shall be applied. Fluorescent lamp of 40W shall be provided and shall be operated by the door switches as well as by manual switches. The marshalling cabinets, the terminal blocks, the terminals and the electronic hardware if any, shall have identification numbers. Each cabinet shall be provided with one each 3 pin receptacles for 240 V AC, 1P, 50 c/s and receptacles for +24V DC. Cabinet shall be delivered totally wired. Preparation of interconnection schedule (ICS) between FTC and marshalling cabinets is in Bidders scope and cabling will be by Owner / Project Manager. Cabling between FTCs & JBs is in Bidders scope. The format of ICS shall be given to the Bidder during detailed engineering stage. 1.19 Interposing Relays (IPR) Electro magnetic type IPRs with plug-in type connections, suitable for channel/rail mounting in cabinets; coil rating 24V D.C; 2 set of silver plated Change over contacts rated for 0.2A 220 V DC. Freewheeling diode across relay coil (copper) and self reset type status indicator flag (electronic) shall be provided. All relays shall be mounted in IPR cabinet & relay base (silver plated) internally wired to the external cabling termination block in IPR cabinet. Wiring connection shall be cage-clamp & termination shall be suitable for0.5 sq. mm to 2.5 sq. mm size wiring. Facility to simulate relay operation manually shall be provided. Relays of different contact interrogation voltages shall be separated by a barrier in IPR cabinet. Accessories like name plate (SS) with tag & service inscription, relay base mounting rail/channel, nuts & bolts, etc. shall be supplied. In each cabinet, a DC Voltmeter shall be provided to check the Field Interrogation voltage. 1.20 System Cabinets These cabinets shall house signal-conditioning cards, input/output cards, processor cards & associated power supply units. Indoor located, free standing vertical type system cabinets with IP-32 enclosure and with 2 mm thick sheet metal of cold rolled steel; double doors with neoprene gaskets; ant vibration pads of 15 mm thick; blower & louvers in each cabinet with brass mesh; fire proof compound (50 mm thickness) for sealing cable entry (bottom); fire detector for each cabinet. Beacon lamp shall be provided in each cabinet to indicate the cabinet having fault condition. The racks in system cabinets shall have provision along with plug in sockets/back plane to house accommodate the spare slots/modules as specified elsewhere. The colour of the cabinets shall be indicated at detailed engineering stage. Doors shall have concealed type of hinges and swing of 100o. to, on the side to help the operator.
ISSUE R0
TCE FORM 329 R3
Power supply distribution shall be provided on per cabinet basis with all associated MCBs, protections, etc. The system cabinets, racks in system cabinets, slots in the racks & the terminals shall have identification numbers. A stainless steel metal tag (plate) shall be fixed to the inside of the door & the layout of the racks, slots & details of the card type/service shall be inscribed on this metal tag. Each cabinet shall be provided with one each 3 pin receptacles for 240 V, 1P, 50 C/S and receptacles for +24V DC. Cabinet shall be delivered totally wired. All electronics shall be mounted & wiring connections at these hardware shall be terminated by Bidder. Quantity shall be as required. One of the doors shall be provided with folder to keep the relevant engineering document of the cabinet. All cabinets shall have common key for the locks. In each cabinet, a 24 VDC Voltmeter shall be provided to check the Field Interrogation voltage. 1.21 Marshalling Cabinets Indoor located, free standing vertical type marshalling cabinets with IP-32 enclosure and with 2 mm thick sheet metal of cold rolled steel; single/double door with neoprene gaskets; anti vibration pads of 15 mm thick; fluorescent lighting; blower & louver in each cabinet with brass mesh; fire detection for each cabinet; fire proof compound (50 mm thick) for sealing cable entry (bottom, front, rear). The colour of the cabinets shall be indicated at detailed engineering stage. The type of terminal shall be Phoenix / Weid ueller / WAGO. The terminal blocks shall be cage clamp type. Fused terminal blocks hinged at one end to facilitate easy isolation shall be provided wherever necessary. All cabinets shall be provided with spare terminals for the spare inputs/outputs as specified else where in the specification.. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by Bidder, subject to approval by Owner / Project Manager/ Consultant. Door shall have concealed type hinges and swing of 180 Degree & lockable. The doors shall be provided both on the front and rear. Channels, bolts & nuts shall be zinc plated and passivated. Two coats of premier paint and black colour paint shall be applied. Fluorescent lamp of 40W shall be provided and shall be operated by the door switches as well as by manual switches. The marshalling cabinets, the terminal blocks, the terminals and the electronic hardware if any, shall have identification numbers. Each cabinet shall be provided with one each 3 pin receptacles for 240 V AC, 1Ph, 50 c/s and receptacles for +24V DC. A system cabinet and associated cabinets shall be supplied on a skid to avoid outside interconnecting cables. Cabinet shall be delivered totally wired. Preparation of interconnection schedule (ICS) between marshalling cabinets & JBs/FTCs and JBs to Instruments is in Bidder scope. The format of Interconnection Cable Schedule (ICS) shall be submitted by the Bidder during detailed engineering stage for approval by Owner / Project Manager. All cabinets shall have common key for the locks. All the terminals shall have no screws and the cables shall be gripped by spring. Each terminal shall have LED indication with fuses to indicate and isolate earth faults.
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TCE FORM 329 R3
1.22 1.22.1
Local Panels Indoor/Outdoor located, free standing vertical type local panels with 2 mm thick sheet material of cold rolled steel; ant vibration pads of 15 mm thick; fluorescent lighting; Double doors with neoprene gaskets at every 1.5 m; blower & louvers in each section with brass mesh; fire proof compound (50 mm thick) for sealing cable entry (bottom); fire detector for each section; space heater with thermostatic control for each section (strip type). IP 65 degree of protection for enclosure. Removable cover plates with locking facility shall be provided along the bottom of the front desk continuously to facilitate maintenance work. The length of each cover plate shall not exceed 1 m. Fluorescent lamp of 40 W shall be provided from one end of the panel to the other end at continuous length and shall be operated by the door switches as well as by manual switches. Nameplates shall be provided for all instruments/inserts with Tag. No. & short description of service engraved. These shall be phenolic overlays (1.6 mm thick), black background with white lettering & shall be fixed to the panel by stainless steel screws (counter sunk). Each section of the panels shall be provided with one each 3 pin receptacles for 240V AC, 1P, 50 c/s & 230 V AC, 1P, 50 c/s. Panel shall be delivered totally wired. All instruments, inserts and annunciation windows shall be mounted & wiring connections at these hardware shall be terminated at site by Bidder. Quantity shall be as required. All the Terminal Blocks shall be rust proof and corrosive resistant for outdoor mounted panels. Terminal Blocks housing material shall be 6.6 polyamide and metallic portion shall be coated against rust/corrosion. In each Local Panel, a 24 V DC Voltmeter shall be provided to check the Field Interrogation voltage. 24V DC Distribution Board The function of the 24V DC distribution board is sub distribution of 24V DC power derived from 230V UPS to all the utilities viz., DCS cabinets, ISAS cabinets and all other 24V DC requirements. Redundant feeders shall be provided for each utility through diode auctioneering using diodes of high peak inverse voltage. The cabinets shall be free standing, vertical cabinets designed for indoor location. Material of construction shall be 2mm thick CRCA. Fluorescent lighting, fire detector and space heater shall be provided for each cabinet. Isolating switches and HRC cartridges fuses shall be provided for individual feeder isolation. Ammeter and voltmeter shall be provided for the incoming feeders to the distribution boards. Features for any other type of Distribution board to be supplied by Bidder shall be subject to Owner / Project Managers approval. Each terminal shall have LED indication with fuses to indicate and isolate earth faults.
1.22.2
1.22.3 1.23
1.24
Control Valves
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TCE FORM 329 R3
1.24.1
Balanced, modulating, globe type, cage guided, single ported, diaphragm type of actuator with hand wheel, SMART Pneumatic positioner, air filter regulator, air lock device, solenoid valve as applicable, limit switches and position transmitters completely tubed with junction box. Pneumatic positioner shall be suitable for accepting 4-20mADC signal. Pneumatic (PVC coated copper) tubing complete with accessories, fittings, If any up-gradation of the offered system is envisaged before completion of the job to meet the specified requirements, the same shall be incorporated in the system, with the approval of the OWNER without any additional cost. Positioner shall be provided with input/output/bypass gauges. Local position indicator & Non-contact type position transmitter with 2 wire, 4-20mA DC output. All limit switches/position transmitters, E/P converter signals etc., shall be wired out to external block of actuator and respective junction boxes. Control valves shall be sized to have an opening of 15% at minimum flow condition and 85% at maximum flow condition. Noise level shall not exceed 85 dB at a distance of about 1.5 M from the valve. In case of predicted noise level above 85dBA, suitable low noise trim shall be provided. Noise reduction shall be achieved through an inherent Trim design and not through external means. Leakage class for double seated valve shall not exceed 0.05%, and single seated valve shall not exceed 0.01%. Either extended type bonnet or cooling fin type bonnet shall be provided for service above 200 Degree C and for other service the bonnet type shall be standard. The end connections shall be socket welded for sizes below 50 NB and butt welded for sizes 50 NB and above. Flanged connection shall be provided for DM water services, with suitable rubber lined interfaces. Water seal shall be provided for valves that could be subjected to below atmospheric conditions. Generally stem and guide material(trim) shall be SS 316 stellited, and plug and seat material shall be 17-4 PH SS, except for specific applications like DM water, HP bypass services. Refer to enclosed table for selection of control valve body material and actuator type. The trims supplied shall be suitable for quick changing. Actuator housing shall be of pressed steel construction. Trim shall be designed such that trim exit velocity shall be limited to avoid cavitation. Feed control valves and Spray control valves shall have a leakage class of VI and all other valves shall have a leakage class of V. The action of valves on failure of operating media shall be determined by the process requirements with regard to safe operation and emergency shut down requirements. Control valve sizing shall be accompanied with data sheets. Following size calculation details shall be furnished for Control valves:
ISSUE R0
1.24.2
1.24.3 1.24.4 1.24.5
1.24.6 1.24.7
1.24.8
1.24.9 1.24.10
TCE FORM 329 R3
1.25
Pneumatic block valves Balanced, on off, plug type, single ported, gate valve. Body material shall be ASTM A 216 GR WCB with end connection socket welded for sizes 50 NB and below & butt welded for sizes above 50 NB and flow direction shall be horizontal. Bonnet: Std. type of material ASTM A 216 GR WCB & packing material GRAFOIL.
Trim : Cage guided, metal seated with flow characteristic of quick opening with stem, plug, seat and guide material of SS 316. phragm (Nitrile) type with handwheel & travel indicator and adjustable stop. It shall be sized for shut off differential pressure. Accessories like air filter regulator, solenoid valve, limit switch with Nema 4 enclosure, etc. shall be supplied. Actuators & accessories requiring tubing shall be mounted and tubed. 1.26 Control Damper Drives Pneumatic actuator type, located in flue gas/air area with damper shaft bearings mounted externally. Bearings are grease lubricated. Blades (SS) shall be linked together. Accessories like position transmitters (2 wire) with 4-20mA DC output, Local Position indicator, position locks, limit/torque switches, etc. shall be supplied, after integrating, calibrating & testing at works. Smart Positioners with all required accessories, required for the positioning of control damper drives shall be provided. Spare cams for accommodating any change in characteristic to achieve better process control during commissioning shall be supplied as required. All the field mounted Damper accessories ( position indicator, limit switches etc.,) shall comply to NEMA -4. 1. 27 1.27.1 SMART Positioners of Control Valves. Positioner shall be microprocessor based with digital communication by means of HART protocol. Positioner has to be 2-wire, 4-20 mA loop powered by the control system and capable of split ranging operation. The SMART positioner shall be suitable for both single acting and double acting actuators. The SMART positioner shall be fully modular in construction with Encapsulated printed wiring board and pressure gauges inside the positioner cover to protect from transit/site damage. SMART positioner shall preferably be of the same make as the Control Valve, to ensure repeatability in Calibration, serviceability and proper maintenance of the Control System. SMART positioner shall be a Double stage positoner. The first stage of the positioner shall be typically a flapper-nozzle that serves as a high-gain pre-amplifier. This sensitivity shall be maintained over a wide range of dynamic conditions. Second stage
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1.27.2
1.27.3
1.27.4
TCE FORM 329 R3
shall be a power amplifier that provides power to drive the actuator. Preferably this shall be a pneumatic relay. Spool Driven type SMART positioners are not preferred due to Higher Dead Band and Poor responsiveness. The SMART positioner shall have pressure sensors to measure the pneumatic outputs to the actuator. 1.27.5 The control algorithm for the positioner shall use feedback signal from the motion of the pneumatic relay beam instead of pressure feedback to minimize pneumatic related effects and for stable and smooth response of the control valve. The SMART positioner shall have user adjustable tuning sets to identify the optimum tuning for the total valve assembly. SMART Positioner with HART Communication facility shall communicate all the valve diagnostics to DCS. The electrical housing shall be designed to meet NEMA 4X,IEC 60529 IP66. Air Filter Regulator (AFR) Constant bleed type AFR with an accuracy of +/-0.1%, inlet pressure range of 5-8 kg /sq.cm and suitable spring ranges (AFR) for use with positioners in control valves, control damper, E/P converters and shut off valves, transmitter purging lines etc; Filtering particles above five microns having phosphor bronze filter element. Material of accessories shall be SS. Built in blow down valve shall be provided. AFR shall have automatic drain feature. All accessories shall be supplied. Degree of protection shall be IP65. 1.29 Position Transmitters 24VDC operated Non contact LVDT type with 4-20 mA DC 2 wire system with an accuracy of 1%; range adjustment and zero adjustment to be provided; IP65 degree of protection for casing. The output shall be linear. All accessories shall be SS. 1.30 Solenoid Valves Direct operated solenoid valves, pilot operated for higher sizes with shut off class (leakage) VI, body material of bronze, plunger material of 316 SS rated for continuous duty. IP 65 class for enclosure. Insulation class of ' F'for the solenoid. Body ratings shall suit the pressure and temperature conditions. 1.31 1.31.1 Cables Individual pair shielded & overall shield twisted pair copper cables shall be used for analogue signals & overall shielded cables shall be used for digital signals. All these cables shall be armoured. All the insulation including overall sheath shall be FRLS quality. The wire size shall be 0.5sq.mm. Ferruling indicating terminal numbers on termination side shall be followed. Colour coding shall be approved by Owner / Project Manager. Only sleeve type ferruling with printed terminal numbers shall be used. Cross ferruling shall be adopted.
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1.27.6 1.28
TCE FORM 329 R3
1.31.2
Instrumentation Cables Instrumentation cables shall be 1100 VAC grade, stranded high conductivity annealed, tinned copper, twisted pair (with min. 20 twists for meter) extruded PVC insulated with overall and / or individual screening, extruded PVC inner sheathed, galvanized steel wire armoured, extruded outer sheathed with FRLS PVC compound. The conductor size shall be minimum 0.5 sq.mm. Triplex cables similar to instrumentation cables can be used for RTDs. Instrumentation cables carrying digital signals shall have overall screening along with drain wire and analogue signal carrying cables shall have each pair screening and overall screening along with each pair drain wire and overall drain wire.
1.31.3
Control Cables Control cables shall be 1100V AC grade, multicore, minimum 1.5 sq.mm cross section, stranded copper conductor having 7 strands, PVC insulated, inner FRLS PVC sheathed of type ST-1, galvanized steel wire armoured and outer sheath made of FRLS PVC compound of type ST-1. In situations where accuracy of measurement or voltage drop in control circuit, warrant, higher cross sections as required shall be used. For all the CT & PT cables, minimum 2.5 sq.mm cables shall be used. Solenoid valve Power supply cables shall be minimum 2.5 sq.mm.
1.31.4 1.31.4.1
Compensating Cables All Compensating cables shall be single or multicore cable (ANSI type KK) twisted and multiple shielded thermocouple extension compensating cable and shall be of Flame Retardant Low Smoke type (FRLS). All Compensating cable ( Chromel - Alumel) of FRLS type shall conform to additional test to Prove the FRLS Characteristics as mentioned in the FRLS Instrument Cable specifications Compensating Cable: (a) (b) (c) Reference Conductor Insulation ANSI ISA 96.1 16 SWG shield alloy Insulated with heavy duty, self extinguishing type, PVC, cores colour coded, extruded PVC sheathing, insulation of each wire with high grade 0.6mm, 105 deg C PVC, Voltage grading of 1100V. Twisted pair with 75 mm maximum lay. Shielding shall be single pair-cable assembly only, Multiple pair-each pair and cable assembly 2.35MIL, Thick combination Aluminium Mylar tape and 7 strand 20 SWG tin
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1.31.4.2
(d) (e)
Lay Shielding
TCE FORM 329 R3
coated copper drain wire. Insulation, coverage shall be 100% and total shield isolation shall be such as to isolate from all other fields. 1.31.4.3 Thermocouple Extension Cable 1100V AC, twisted pair (20twist/meter), 1.5 sq.mm dia. Thermocouple extension wires, PVC insulated, aluminium Mylar tape shielded/PVC jacketed/ armoured & overall PVC jacketed/FRLS. Features such as colour coding, thermo electric characteristics, etc. shall be as per ANSI MC 96.1, 1975. Alternatively thermocouple extension wires with 1100 V AC twisted pair ,1.5 sq.mm, PTFE insulated copper braiding & PTFE outer jacket , shall be considered for turbine area. 1.32 1.32.1 1.32.2 Wiring, Termination and Accessories All the cables are to be treated with anti-rodent treatment properties, voltage grade shall be 1100V. Prefabricated Cable : Used for interconnection between system /marshalling cabinets. Used for panel external wiring, tinned copper conductor of 0.5 sq.mm cross section with seven strands twisted pair with 20 twists/meter. Insulation material shall be PVC, heat resistant with flame retarding properties with thickness not more than 0.5 sq.mm Voltage grade shall be 1100V AC. Each prefabricated cable shall have a minimum of 5 cores as spares and these shall not be connected to end connectors. 1.32.3 Terminal Block (TB): Cageclamp type , 600V V AC grade, vertically mounted, size of 0.5 sq.mm to 1.5 sq.mm for instrument wires and 100V AC 1.5 sq.mm to 2.5 sq.mm for control wires. Clearance between TBs shall be 150 mm and between TB and bottom plate shall be 250 mm, flame resistant, non-hygroscopic, decarbonised. Insulation between adjacent terminals or between terminals & framework shall be 2 KV RMS for 1 minute. Power supply and signal TB shall be separate. Signals shall be grouped in TBs in the same order as that in field junction box so as to provide neat cable layout and wiring. High voltage and low voltage signals shall be provided on separate TBs, which are mounted separately. TBs housing material shall be 6.6 polyamide and metallic portion shall be coated against corrosion. There shall be no double decker terminals. 1.33 Boiler Drum Level Gauge Bi-colour type (Red for steam & green for water) with tungsten halogen illuminator, local bicolour read out 2 nos., one at each end shall be provided for each drum. No. of ports shall be at least one for every 2 inches. Isolating & drum valves shall be provided with chain & pulley mechanism in addition to hand wheels. Material of body
ISSUE R0
TCE FORM 329 R3
- 316 SS, cover - carbon steel. Visible range covers alarm & trip levels recommended. Power supply for the illuminator shall be fed from 110 V AC, UPS. 1.34 1.34.1 Electronic Water Level Indicator (EWLI) Two (2) systems per boiler drum operating on the principle of resistivity; single pressure vessel at each end; 4-nos. isolating valves with limit switches per vessel & 2 nos. blow down valves with limit switches per vessel shall be provided. Thermal equilibrium shall be established with boiler drum. Vessel material shall be forged carbon steel of ANSI rating 2500. The size of the tapings at the drum & the isolating valves shall be the same. These tapings shall not be shared for any other instruments. No. of electrodes per vessel shall be such as probe to probe distance not to exceed 50 mm. Material of electrode-tip shall be titanium; body SS 316, insulation high purity ceramic, gasket monel-silver. Electrodes shall be arranged in 2 different rows staggered to provide maximum resolution. Solid state/micro processor based detector system and control unit with independent power supply for each unit; bicolour type display unit of 4 nos., two (2) nos. display shall provided at the control room and two (2) nos. display units at detector unit. Range of display to cover HH & LL trip levels. One set of alarm for high and low conditions and trip contacts for high high and low low conditions with adjustable settings. Self diagnostic features included. All the cables shall be provided by the Bidder. Alarm and trip contacts shall be fail-safe type. The detector unit shall house redundant power supply units and electronic cards connected to electrodes for measurement of boiler drum level. Alarm contacts (SPDT) rated for 0.2A, 220 V DC shall be provided low and high water level. For each pressure vessel, alarm settings shall be adjustable. The power supply shall be independent for each unit. A green lamp is illuminated for water and a red lamp for steam. The lamp rating is of 0.5 W. Each window shall have two lamps connected in parallel. Two (2) numbers display units shall be provided at the control room. Each drum shall have both fault lamp with reset push button and lamp test switch. The other two (2) number display units provided at the detector unit. Each shall have only lamp test switch. Bidder to supply EWLI of Owner / Project Manager approved make. Furnace Temperature Probe Duplex k-type thermocouple with mineral insulation & SS sheath located in furnace below SH panels; minimum of 2 nos. Probe housing shall be weather proof & corrosion resistant. Accuracy shall be +/-0.5% of span. The junction shall be ungrounded with response time of 2 to 5 seconds. Starter box shall be provided with IP65 enclosure & 3 mm thick sheet. Electric motor with chain drive shall be provided for the lance. The traverse of the probes from opposite sidewalls shall cover the full cross section of the furnace. Automatically controlled cooling system shall be provided for the lance. Loss of cooling water shall be detected & provided as a contact. Accessories like limit/torque switches position transmitters, etc. shall be provided.
ISSUE R0
1.34.2
1.34.3
1.35
TCE FORM 329 R3
All the field mounted accessories (limit switches etc.,) shall comply to NEMA-4 1.36 Electromatic Relief Valve (EMRV) Controller Electronic type with pressure high & low switches. One no. for each EMRV. Man/Auto/Off selection with lamps for auto/manual positions shall be provided. IP65 or equivalent degree of protection for enclosure. Enclosure material will be epoxy coated die cast aluminium. Power supply will be 220 V DC & output signal will be pressure high potential free contact for solenoid valve energisation. One no. solenoid valve (for each EMRV) of 220 V DC single coil with limit switches shall be supplied. Other features of solenoid valve shall be in line with that specified under Solenoid Valves in this section. Terminals in terminal block of the controller & solenoid shall accept cable of 0.5 to 2.5 Sq.mm. Switch contact rating shall be boosted using relays. 1.37 Colour Graphic Video Display Unit 21" (unless specified otherwise) colour TFT monitor with mouse / track ball facility shall be provided. Resolution shall be 1280 x 1024 pixels minimum. Number of characters per line shall be minimum 80 and number of lines per display page shall be minimum 48. Total number of characters shall be minimum 256 graphic characters + ASCII. Minimum Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. Main memory capacity shall be 8 MB with minimum 80 MB Hard disc capacity and shall have a DVD / CD RW drive. The system shall support Seven (7) types of audible alarms (3 Process related, 2 no system related and 2 keyboard related). The VDUs shall be table top mounted type. The VDU' s shall be fully assignable and functionally interchangeable. All VDU' s shall have dedicated keyboard. 1.38 Keyboard Flat Membrane type Keyboard shall be provided for operator interface with process for plant control and display functions to access plant data in conjunction with Operator station VDUs. The keyboard shall have a minimum of 80 configurable keys for assigning most frequently used displays. A minimum of Sixty-four (64) of those keys shall have two independently lit LED' s used for event-specific alarm annunciation. 1.39 Optical Disk Drive Unit / CD ROM drive (Read & Write) Optical disk drive unit shall be provided to store the required plant data and historical data in a reliable high performance medium for retrieval/archival whenever necessary. Type of disk shall be random access, re-writable magneto optical in nature with formatted capacity of 8 GB and minimum 19,600 tracks per second. Data transfer rate shall be minimum 5 MB per minute and seek time shall be 22 milli seconds or better. Data error check features of parity check, CRC check shall be included. Facility shall be provided for direct transfer of bulk data from BMU to optical disk drive unit. The approximate quantity shall be as follows:
ISSUE R0
TCE FORM 329 R3
1.40
Colour graphic printer: Shall serve as a hard copy device to copy diagrams from the colour CRTs for documentation and graphic diagram development functions. Minimum 7 colours to be provided. Multiplexer unit shall be provided to facilitate printing of graphics from any of the OS / ES VDUs. All printers shall be of A3 size. Noise levels for the Printers at 1 meter distance shall be < 45 dB.
1.41
Bulk Memory Unit (BMU) The BMU shall have the following features: (a) (b) (c) (d) (e) (f) Two discs in hard stand by mode Fixed disk drives with one controller per drive Disk capacity to meet functional requirements of the control system with a minimum formatted disk capacity of 80 GB. Data transfer rate shall be 1.5 MB/second Average access time shall be less than 40 milliseconds. Error checking and Error recovery feature
2.0 2.1 2.1.1
FURNACE FLAME MONITORING AND ANALYSIS SYSTEM FLAME MONITORING-GENERAL Furnace flame monitoring and analysis system shall provide analysis of flame conditions on continuous on-line basis and shall guide the plant operation personnel regarding the nature of flame and combustion process and the corrective action required. The system to be provided shall include all necessary hardware, software, firmware and interfaces required for implementing a fully functional system. Bidders offered system shall include but not limited to the details specified in subsequent paragraphs. Furnace flame monitoring and analysis system shall be independent for each unit. FLAME MONITORING-DESIGN AND FUNCTIONAL REQUIREMENT The flame monitoring and analysis system shall provide flame condition monitoring and thermo-graphic analysis of the flame in the furnace and also for each burner. The system shall be complete with video camera, signal conditioning cards, amplifiers,
ISSUE R0
2.1.2
2.1.3 2.2 2.2.1 2.2.2
TCE FORM 329 R3
special cables. etc. with all necessary equipment and accessories. 2.2.3 2.2.4 Sufficient number of cameras shall be provided so as to cover all burner flames so as to be able to carry out thermo-graphic analysis. Flame monitoring cameras shall be provided with advance/ retract facilities with cooling arrangement through water etc. Advance/ retract unit shall be designed for suspended use. Necessary protection for automatic camera retraction on loss of cooling medium etc. shall be incorporated. The analysis software should be capable of outputting direct message on video monitor of the exact nature of fault. The system shall have facility to store bulk data for 5 years duration with facility for retrieval of the same. The system shall have facility to share all the data in the hard disk/ back up media and provide user friendly utilities to retrieve and analyze stored data. The system shall be provided with redundant UPS power supply. The power supply provision shall be such that on failure of one power supply the other power supply shall cater to the requirement of the equipment so as never to hinder the functioning of the system in any manner due to power supply failure. FLAME ANALYSIS REQUIREMENT SYSTEM HARDWARE/ SOFTWARE/ INTERFACING
2.2.5 2.2.6 2.2.7
2.2.8
2.3 2.3.1
Each Furnace flame analysis system shall include all hardware and software as required for proper functioning of the system including but not limited to the following: (a) (b) (c) (d) (e) (f) (g) Video camera unit for each burner (with advance/retract facility mounted) One (1) no Server (With PC, Video Display Unit, Keyboard /Mouse) One (1) no user station (With PCs, Video Display Unit, Keyboard/ Mouse and Colour Laser Printer) Flame analysis software with all relevant users license. Bulk data storage and retrieval facility Redundant OPC communication link with all necessary hardware and software. System cables etc.
ISSUE R0
TCE FORM 329 R3
2.3.2 2.3.3 2.4 2.4.1
All software user licenses shall be valid for entire life of power plant. User should not have to pay any recurring license fee during the usage period of the system. It shall be possible to upgrade the installed system with the latest available version of the software model during the plant life. DESIGN DATA Server Unit (a) (b) (c) (d) (e) (f) (g) (h) Pentium latest model & version Memory-1024 MB RAM Hard Disk Drive-80 GB or Higher DVD / CD ROM Drive-50X DAT Drive-Required Network Interface- Required Server Operating System-Required External Modem- Required, 56 k V.90
2.4.2 2.4.3
User Station PC: Industrial grade PC of latest model / configuration with Owners/ Consultants approval. Video Display Unit (Server PC / User Station PC): 29" colour TFT LCD monitor with mouse / track ball facility shall be provided. Resolution shall be 1280 x 1024 pixels minimum. Number of characters per line shall be minimum 80 and number of lines per display page shall be minimum 48. Total number of characters shall be minimum 256 graphic characters + ASCII. Minimum Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. The VDUs shall be of table top mounting type. All VDU' s shall have dedicated keyboard. .
2.4.4
Colour laser printer : Colour laser printer shall serve as a hard copy device to copy diagrams from the colour VDU for documentation and graphic diagram development functions. Minimum 7 colours to be provided. Interfacing- RS 232C/ 422A. Size- A3. Noise levels for the Printers at 1 meter distance shall be < 45 dB.
2.4.5
Bulk data storage and retrieval facility as required.

ISSUE R0
TCE FORM 329 R3
2.5 2.5.1
SYSTEM IMPLEMENTATION System implementation shall take into account the stabilisation of fuel firing equipment characteristics while in service for some period (say plant commissioning period) and the varying characteristics coal being available in the plant. However, the system shall be user tested at site. It is the Contractors responsibility to demonstrate the proper functioning of the system to Users personnel. It is preferred that Contractors implementation team will involve ultimate users O&M personnel during system implementation. BOILER TUBE LEAK DETECTION SYSTEM Tube leak detection system for each unit shall be independent and shall consist of number of high grade audio electronic microphone type audio detectors with a display sound level range of 50 to 150 dB and head amplifiers with a maximum operating temperature of 90oC to be provided. The number of sensors shall be as required to cover complete boiler tube zones (but minimum 24 nos.) The measurement system shall have adequate number of channels corresponding to number of sensors and an accuracy of logarithmic conversion + 2% shall be provided. The display unit shall match the display unit in the CRT. The output shall be 4-20 mA / channel. The level of leakage shall be displayed in the form of bar charts and alarms shall be generated on occurrence of tube leakage. One speaker, power supply failure alarm and steam leak alarm shall be provided.
2.5.2 3.0 3.1
ISSUE R0
TCE FORM 329 R3
SPEC NO.
VOLUME: IIIA
TCE. 5103A-C510-01
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TEST AND INSPECTION FOR INSTRUMENTATION AND CONTROL EQUIPMENT
SECTION:D 2.5 SHEET 1 OF 4
1.0 1.1
TESTS AND INSPECTION FOR INSTRUMENTS After Manufacturing, all instruments shall be tested and calibrated at Factory. CONTRACTOR shall be responsible in obtaining test certificates related to calibration of all the Instruments and submit for Owner/Engineers approval. CONTRACTOR shall allow despatch of these instruments only after passing applicable Factory Acceptance test and approved by Owner/Engineer. The details of the tests to be carried out for the different instruments / field equipments/ Systems shall be as indicated in the Section D 2, TABLE-7 and any other tests as required by the Standards and Codes. TESTS AND INSPECTION FOR SG INTEGRAL CONTROL SYSTEM Tests will include the following: (a) Factory Acceptance Test (FAT): To be carried out at SG Integral Control system CONTRACTORs / SubVendors works and witnessed by Owner/Engineer, successful completion of which will be the basis for Authorisation for Shipment to Site. FAT shall be preceded by a pre-FAT inspection/test by Vendor. (b) Site Test (SAT): Involves tests for site commissioning, guarantee tests for system performance & availability to be conducted in the presence of Owner.
2.0 2.1
2.2 2.2.1
Factory Acceptance Test (FAT) FAT shall be a complete integrated test of the SG Integral Control system and carried out at CONTRACTORs / Sub-Vendors works on completion of manufacturing of the system. The test shall be performed with the completely assembled system and performing all the functions, it is expected to perform while in actual service. The various tests to be performed for the tootal system together with the guideline for Factory acceptance test (FAT) procedure are detailed in Section D 2, TABLE-7. The CONTRACTOR shall submit a detailed "Factory Acceptance Test Procedure" in line with the above specified guidelines for Owner / Consultant approval. FAT shall be preceded by a Pre- FAT Inspection/ Test to be carried out by Contractor/ Vendor. Pre-FAT inspection / test shall be carried out as per approved FAT procedure detailed above and shall submit Pre- FAT Inspection/ Test report for Owner/Consultants review and approval. Owner/ Consultant shall witness the actual FAT on the basis of successful completion of Pre- FAT Inspection/ Test. Site Test (SAT) Tests to be conducted at site will involve the following:
ISSUE R0
2.2.2
2.3 2.3.1
CONSULTANT: TCE CONSULTING ENGINEERS LTD.
SPEC NO.
VOLUME: IIIA
TCE. 5103A-C510-01
(a)
Site Pre-commissioning Tests comprising the following to be conducted by Contractor at site: (i) (ii) Calibration of monitoring and control equipment Integrated loop test wiring, Simulation input from site
(b) (c) 3.0 3.1
Trial Operation of the SG Integral Control system functioning. Performance Guarantee Test for SG Integral Control system.
TRIAL OPERATION OF THE DCS SYSTEM Trial operation test of SG Integral Control system shall be conducted on completion of installation as per specification requirements, checking and satisfactory precommissioning tests detailed at 2.3.1 (a) above. Test shall be conducted at site by Contractors personnel in the presence of the Owner / Consultant. Test duration shall be of 14 days out of which 72 hours shall be continuous operation performing all the specified functions. The trial operation shall be considered successful provided that each item of equipment can operate continuously at the specified characteristics for the period of trial operations. During this period, any modifications / repairs as required shall be carried out. If the total interruption period (outage time) is more than 4 hours, the trial operation duration shall be extended by the period of interruption. PERFORMANCE GUARANTEE TEST FOR I&C SYSTEM After successful trial operation, the OWNER shall conduct performance guarantee test for a period of 14 days in the presence of CONTRACTORs commissioning engineer. During the test, the system shall run with 100% availability. Contractor shall also furnish the guaranteed process parameters and the acceptable deviations before conducting the performance test. Following tests to be performed during the PG test: Redundancy checks for processor, communication, power supply and 1/O modules. This check shall be conducted in a sequence as mutually decided between the Client and the contractor. During each redundancy check, the plant operation shall not be disturbed and the control loops shall continue in auto mode. The trending of control parameters shall be in service during these checks and the over shoot / under shoot of the controlled parameters shall be less than 1%. These checks shall be logged
ISSUE R0
3.2 3.3 3.4
4.0 4.1
4.2 4.2.1
SPEC NO.
VOLUME: IIIA
TCE. 5103A-C510-01
(removal and relocation of modules/cables) in the system in addition to being made available to the operator in operator station. 4.2.2 4.2.3 4.2.4 4.3 4.3.1 Response time for each type of update as per the specification shall be checked on line by suitably recording each activity. Time synchronisation with master clock shall be tested. Specified communication links shall be established and proven. PG Test Methodology If the performance of the system deviates from the specification requirements, the contractor shall be given a maximum period of 3 days depending on the gravity of the defect as mutually agreed, to carryout the modification without disturbing the plant operation. Contractor shall declare the system fit for checking after completing the modification / rectification. The specific test shall be repeated for proper functioning. Contractor shall be given maximum of three attempts each not exceeding 3 days for any subsequent defects found. After 3 tests for each activity, if the system still deviates from the specified requirements, the warranty period may be extended depending on the gravity of the defect, during which period the contractor shall rectify / modify the system to meet the specified requirements. During the test, any modules / equipment fails, the contractor immediately within four hours shall replace the faulty module / equipment and the test shall be repeated after extended continuous running of 96 hrs. The total duration for the site acceptance tests i.e site pre-commissioning tests and Trial operation test together shall not exceed 30 days including the repetition of tests and duration for replacement / rectification. During all the above tests, Contractor shall ensure that the disturbance to the process is minimum. PG Test Result Interpretation The failure of any one of the hard or soft copy device shall not be taken as nonavailability of the system. However, the mean time to repair shall not exceed that specified by the CONTRACTOR. The PG test shall be repeated if the test results deviate from the guaranteed values. All the special equipment, tools and tackles required for the successful completion of the PG test shall be provided by CONTRACTOR as part of the total scope of services.
ISSUE R0
4.3.2 4.3.3
4.3.4
4.3.5
4.3.6 4.4 4.4.1
4.4.2
SPEC NO.
VOLUME: IIIA
TCE. 5103A-C510-01
Ready stock of all types of modules / PC boards shall be available as part of the total scope of services for immediate replacement during the period. 4.3 The SG Integral Control system PG test shall be carried out to Owners satisfaction. The last 5% of the total supply payment will be released only after successful completion of PG test.
ISSUE R0
SPEC NO. TCE. 5103A-C510-01
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM OTHER SERVICES
1.0 1.1
TRAINING OF OWNER'S PERSONNEL The CONTRACTOR shall at no extra to the OWNER, undertake to train engineers selected and deputed by the OWNER. These engineers shall be given special training in shop, laboratory and drawing office of the CONTRACTOR, where the Instrumentation and Control Equipment will be designed, and manufactured and in any other power plant where similar type of equipment designed, manufactured and supplied by them is under installation, test, operation or maintenance, to enable the engineers to become fully familiar with the equipment offered. The type of training with number of personnel to be trained and the duration of training to be provided for different I&C system equipment are detailed in Section D 2, TABLE- 6. CONTRACTOR's personnel at site, shall continuously and intensively instruct and train adequate number of the OWNER's operating and maintenance personnel at site during erection and commissioning of the equipment to enable them to take over the proper operation and maintenance of the equipment after commissioning. The CONTRACTOR shall include in his bid, the charges for providing training to purchaser's personnel as above. CONTRACTOR shall include in his bid a detailed description of the proposed training for the OWNER's personnel. INSTRUMENTS FOR PERFORMANCE TESTING All instruments required for performance testing to prove the guaranteed performance of the Instrumentation and Control Equipment as specified in Section-D 2.5 or for the Performance Guarantee test of the plant shall be provided by the CONTRACTOR for the duration of the Performance Test. These test instruments shall have test certificates, from reputed test house, traceable to International /National standards and shall be valid for the duration of the performance test.
1.2 1.3
1.4 1.5 2.0 2.1
3.0 3.1
QUALITY ASSURANCE
BIDDER shall furnish a detailed Quality Assurance/ Quality Control Plan (QA/QC) for each Instrument/System covered under this specification for OWNER / PROJECT MANAGER/ Consultant review and approval. The QAP shall be subject to Owner / Consultants approval. BIDDER shall offer for inspection as specified. PERFORMANCE GURANTEES The BIDDER shall guarantee that material and workmanship of all components in the
ISSUE R0
3.2 4.0 4.1
TCE FORM 329 R3
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM OTHER SERVICES
system cabinets, control units and instruments supplied shall be in accordance with his latest design practices, unless otherwise specified in this specification. 4.2 Bidder shall guarantee for proper functioning of all field instruments like local gauges / indicators, switches, transmitters etc., and control equipments like control valves/dampers etc. under Bidders scope of supply within specified accuracy / performance. Bidder shall guarantee for proper functioning of SG Integral Control System under Bidders scope of supply within specified performance condition. Bidder shall guarantee for proper functioning of Furnace Flame Monitoring and Analysis system under Bidders scope of supply. Bidder shall guarantee for proper functioning of Boiler Tube Leak Detection System under Bidders scope of supply.
4.3 4.4 4.5
ISSUE R0
TCE FORM 329 R3
VOLUME: IIIA SECTION: D2-T1 SHEET 1 OF 1
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 1: AVAILABILITY REQUIREMENTS
1.0 1.1 1.2 1.3
AVAILABILITY REQUIREMENTS All equipment and systems covered in this specification shall be designed for maximum reliability and availability. All equipment and systems shall be of proven design using material with well established physical and chemical properties and as appropriate to the service intended. To ensure high reliability of the trip circuit and to avoid spurious trippings of the plant, multiple input logic system, (e.g.,2 out of 3 logic) shall be provided for important and vital trip functions. Protection circuits shall be independent of other systems such as interlock, measurement, control, etc. From availability considerations, all circuits for the same type of equipment shall be housed in different cabinets. Adequate redundancy shall be built in at various levels to increase the system availability and reliability. BIDDER shall quote a highly reliable equipment/ configuration to perform the functional requirements as specified. The system shall be designed with extensive self-diagnostics and trouble shooting features. Adequate facility shall be provided for quick repair/maintenance and on-line replacement of faulty modules. This shall not result in spurious trips. Where a major equipment/ unit trips likely to be inhibited when the card is pulled out, it shall be identified by VENDOR during detailed engineering stage. In case of control system, auto and manual circuits shall be independent from each other in all respects, including power supply, so that in case of any fault in the auto circuit, the manual circuit shall always be available to control the plant. Components used in the equipment and systems shall be designed with higher rating than required for the normal operating conditions in order to have higher availability of the system. Control valves/dampers shall be driven to the fail safe position or stayput position in case of control system failure, as specified. This arrangement is necessary to avoid system upsets and subsequent loss of operation. Easy access shall be provided for all components in the equipment and systems offered to reduce the maintenance period. All components shall be subjected to a burn-in test before they are assembled. Completely assembled system shall be subjected to a continuous working test. This test will help in eliminating the weak components in the system, thus increasing reliability and availability.
ISSUE R0
1.4 1.5 1.6 1.7 1.8
1.9
1.10
1.11
1.12 1.13
TCE FORM 329 R3
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 2: LAYOUT AND MAINTENANCE REQUIREMENT
1.0 1.1
LAYOUT REQUIREMENTS All the cabinets supplied by Bidder shall have the same height, depth and colour. The VENDOR shall submit a layout drawing clearly indicating all the dimensions of the system cabinets, doors, knockout doors, floor opening required for cable entry, etc. Computer grounding will be separate from station grounding. Any specific recommendation regarding the location and limiting distances between the different equipment to be located in the annexe of the control room shall be detailed and the layout for the same shall be furnished during detailed engineering stage for PURCHASERs/ CONSULTANTs approval. The location of junction boxes will be finalised during the detailed engineering stage. Purchaser reserves the right to change the grouping of instruments in each junction box during detailed Engineering stage. The local panels to be supplied shall be mounted indoors and near the corresponding equipment. The exact routing of impulse pipes will be decided at site during erection depending upon the location of tap points. PURCHASER reserves the right to approve the suitable location of the field mounted junction boxes. All equipment and I&C equipment piping supplied by the VENDOR shall be supported adequately to prevent vibration and anchored sufficiently to prevent undue strains on the equipment. Hangers and supports shall be so installed as not to interfere with free expansion and contraction of the piping between anchors. Suitable spring hangers, vibration dampeners, etc. shall be provided wherever necessary. In addition, care should be taken that the arrangement of piping, and supports shall provide for safety under working stress and shall protect the piping from detrimental sagging, mechanical injury, abuse to unusual service conditions from sources other than those due to pressure, temperature and vibrations. Straight length requirement before and after control valves, flow element and desuperheater shall be provided as per latest applicable standard codes. The tapping point instruments shall be located at appropriate location to meet the purpose of the instrument provided for. Eg. The pressure switch to open a discharge valve of a centrifugal pumps after a pump start shall be located between pump and discharge valve; the stub for temperature sensing at a desuperheater outlet for temperature control shall be located after a straight run of min. three (3) meters to ensure through mixing of the fluids and temperature is measured at a location of laminar flow. MAINTENANCE REQUIREMENTS
ISSUE R0
1.2 1.3
1.4
1.5 1.6
1.7
1.8 1.9
2.0
TCE FORM 329 R3
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 2: LAYOUT AND MAINTENANCE REQUIREMENT
2.1
All equipment supplied by BIDDER shall be designed for ease-of-maintenance to help achieve a high meantime between-failures (MTBF). All equipment shall be of modular design to assure a short mean-time to repair (MTTR). The following specific provisions shall be made to achieve the above objective : (a) The Vendor shall furnish the details of the maintenance requirements of each equipment, indicating list of parts which require regular maintenance and frequency of maintenance for these parts. Based on VENDORs experience, documentation giving a recommended maintenance program to achieve a high MTBF for the equipment shall be furnished. The VENDOR shall furnish sufficient documentation to ensure efficient maintenance and trouble-shooting of equipment and modules. This shall include wiring diagrams and schematic diagrams of all electronic assemblies for the system cabinets supplied, supplemented with concise description of theory of operation of individual subsystems. Expected faults, trouble shooting hints, checkout lists and a list of sub-components prone to failure shall also be provided. All equipment shall have extensive self-diagnostic features, test points and clearly labelled error indicating lamps which help in speedy identification of faulty modules/components. Provision shall be made for isolation of subsystems/modules which are identified to be faulty, thus enabling on-line replacement without taking equipment off-line. Adequate number of test equipments, test sockets, test cables, digital voltmeters, 3-pen recorders, signal generators, card extenders, etc., shall be provided by the VENDOR to facilitate ease in maintenance. Necessary maintenance equipment tools and special erection tools which are not specifically mentioned in the specification but are normally required for ease in maintenance and to have minimum down time, shall be included in the BIDDERs scope. Components of same function shall be as far as possible interchangeable. Standardisation concept shall be used in setting the components for the systems. All the documentation shall be in English language. All documentation shall be provided on DVD-ROM in addition to the printed documents.
2.2
(b)
(c)
(d)
(e)
(f)
(g) (h) (i) (j)
ISSUE R0
TCE FORM 329 R3
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 3: ERECTION, TESTING AND COMMISSIONING REQUIREMENT
1.0 1.1
GENERAL The erection of instrumentation system shall be carried out generally conforming to sound engineering practices. However, the Bidder shall select and adopt methods and procedures for equipment erection to suit the nature of equipment and erection, involved according to the best modern practice and his own experience. SCOPE OF WORK FOR ERECTION The Bidder shall be required to erect all cabinets, consoles, desks, all cables, conduits, equipment of Programmable control systems (DCS/ PLC etc.) required for completion system covered in this specification. The Bidder shall provide all supervisory, skilled, semiskilled and unskilled labours including instrument tube fitters, licensed cable jointing mechanics etc., tools and tackles, consumable, erection materials required for the complete installation, transport vehicles, hydraulic jacks, welding sets, mobile cranes, blowers and other necessary equipment for timely efficient erection and testing. The Bidder shall maintain proper record of the materials at the place of storage for quick identification as and when required. The Bidder shall carry out all repairs to damages that might have suffered during transit or in subsequent storage and replacement of all lost parts. The Bidder shall furnish a detail erection schedule, which shall be finalised along with the offer keeping in view the overall erection and commissioning schedule. The erection schedule as agreed with the PURCHASER shall be strictly adhered to by the Bidder. The erection work shall include but not limited to the following: (a) (b) (c) (d) Transportation of the tested and calibrated equipment to the place of installation without any damage. Installation of DCS / PLC equipment as per bill of material and as per relevant approved G.A and disposition drawing. Installation of the necessary cable and racks with posts, brackets, and fasteners. Installation and termination of electrical, measuring, control, power supply, and signal lines, from the available / to be erected marshalling cabinets to I/O cabinets System cabinets as per relevant interconnecting and terminating drawings prepared by the successful Bidder. This includes laying of all control cables, compensating cables etc.
ISSUE R0
2.0 2.1
2.2
2.3 2.4 2.5
2.6
TCE FORM 329 R3
(e) (f) (g)
Supply, fabrication and erection of structural steel plates, angles, pipes required for supporting cable trays complete with bolts and nuts. Providing identification of cable by engraved Aluminium tag plates at both ends inside the cabinets, consoles as per cable schedule. Supervision of preparation of separate earthing pits as recommended by the DCS/ PLC etc. system supplier, laying and connection of the earthing cables from different equipment to the respective earthing pit.
3.0 3.1 3.1.1
ERECTION Cabinets and desk The Bidder shall arrange for the transportation and handling of cabinets and desks from stores to work site suitably without any damage. If any damage is observed before handling, this shall be brought to the notice of the PURCHASER. Before installation of cabinets and desks, the necessary openings and inserts required to be made on the floor by the Bidder shall be checked and then after proper alignment, the cabinets and desks shall be installed on the floor by the Bidder. All necessary civil work to be carried out for this shall be in Bidders scope of supply. The cabinets and desks shall be cleaned by blowing air to remove dust or foreign particles. The Bidder' s scope of work and supply shall also include tightening of wires, replacement of broken items and retouching of damaged painted surface of cabinets those has taken place during transport from store to work site and during installation. The Bidder' s scope of work and supply shall also include tightening of wires, replacement of broken items and retouching of damaged painted surface of cabinets those has taken place during transport from store to work site and during installation. Cables, cables trays and conduits All electrical work shall conform to the rules and regulations of Indian Electricity Act. All cables shall be tested for insulation level. Cable ends shall be properly cleaned. The entry to and exit from pipes shall be smooth and free from burr where cables are run through pipes. Cable shall be pulled into the pipes in such a way that there shall be no damage to the cables. Flexible conduits shall be provided wherever necessary.
3.1.2
3.1.3 3.1.4
3.1.5
3.2 3.2.1 3.2.2 3.2.3
3.2.4
ISSUE R0
TCE FORM 329 R3
3.2.5 3.2.6 3.2.7
Cable in hot areas shall have proper heat protection. A minimum distance of 300 mm shall be kept between instrument / signal cables and power cables. Each tray shall be filled with a maximum of three layers of cables (two for instrument and control cables and one layer for power cables for I&C equipment) providing 20% spare space in the number of layers specified. Instrument Cable Trays, shall be erected vertically as far as possible to avoid dust accumulation. All the cables laid shall be tied individually to the Tray. Thermocouple cables shall be run completely independent of all other cables with minimum separation as per relevant standard and with cross over at right angles. The cabling accessories shall include cage-clamp type terminal blocks, splicing materials, crimping tools, cable support grips, insulating tapes, GI flexible conduits, conduit fittings, GI perforated covered trays, supports, accessories, and cadmium plated trays & cable glands. SPECIFIC REQUIREMENTS FOR ERECTION, TESTING, CALIBRATION AND COMMISSIONING ERECTION REQUIREMENTS The actual location of transmitter racks, junction boxes and other instruments shall be decided by the Bidder depending on the site conditions considering the layout and maintenance aspects. The Bidder shall get prior approval as per approved quality assurance plan of the Purchaser / Purchasers Representative before any installation work starts. If any work is carried out by the Bidder before prior approval from Purchaser / Purchasers Representative and modification is sought by Purchaser / Purchasers Representative later, then the work shall be redone by Bidder without any cost / material implications to the Purchaser / Purchasers Representative. Impulse / sample piping, air supply and pneumatic tubing, cable trays and equipment shall be supported rigid enough to prevent vibration and anchored sufficiently to prevent strains on equipment installed. Supporting clamps shall be provided at-least at every one metre distance for better rigidity. Impulse / sampling piping shall be provided with adequate slope, (preferably 1:10). Hanger and supports shall be so installed as not to interfere with free expansion and contraction of the piping and tubing between anchors. Suitable vibration dampners, etc., shall be provided wherever necessary. In addition, care shall be taken that the arrangement of impulse / sampling piping, air supply and pneumatic tubing from detrimental sagging, mechanical injury, abuse due to unusual
ISSUE R0
3.2.8 3.2.9 3.2.10 3.2.11
4.0 4.1 4.1.1
4.1.2
4.1.3
TCE FORM 329 R3
service conditions from sources other than those due to pressure, temperature and vibrations. All impulse lines of joints shall be welded type unless otherwise specified. Argon arc welding shall be employed. 4.1.4 4.2 4.2.1 All the panels, desk, cabinets supplied by the Bidder shall be welded or bolted to the floor channel. TESTING REQUIREMENTS The Bidder shall set up his own instrument laboratory. The calibration equipment shall cover complete range and shall have the desired accuracy of not less than 0.1%. All the calibration equipment shall have the certification from National Physical Laboratory (NPL) or IDEMI for the duration of Contract Period. The Bidder shall follow the standard procedures for calibration of various instruments and as set by the manufacturer of instruments and as instructed by the Purchaser including any requirements of field calibration. First, the calibrations shall be carried out independently by the Bidder and later in the presence of Purchaser who shall certify the same. Proper documentation in this regard shall be maintained and handed over to the Purchaser. All the instruments shall be calibrated for the entire range of the instrument for which it is designed. Calibration shall include test for repeatability. After first commissioning, the instruments shall be tested for calibration again to check whether the instrument maintains its zero and maximum of the range. All instruments and control equipment shall be calibrated to read correctly to the satisfaction of equipment supplier / Purchaser. All switches shall be tested for the actuation of both normally open and normally closed contacts at the desired set points and also for the fixed / differential settings. All the float operated level switches shall be tested for the movement of the float and linkages to make to break the switch contacts by filling up with water before installation. For such tests, necessary testing set up required shall be arranged by the Bidder. All the conductivity type probes and switches shall be tested for performance before installation. Air leak tests shall be performed on all flue gas impulse / sample lines, air supply and pneumatic lines. Necessary equipment such as portable compressor, connecting pipes, materials, cables and test gauges shall be provided by the Bidder. Hydro test shall be performed for all other impulse lines / sampling lines. Necessary equipment such as hydro test pumps and temporary piping to the required point, fill pump etc., materials such as temporary gaskets, miscellaneous fasteners, etc. tools and tackles including test pressure gauges, etc. are to be provided by the Bidder.
4.2.2
4.2.3
4.2.4 4.2.5 4.2.6
4.2.7
4.2.8
ISSUE R0
TCE FORM 329 R3
4.2.9
For all electrical actuators of the valves, functioning, setting and performance of limit switches / torque switches of various positions shall be checked before and after installation of the actuators. The position transmitters for inching applications shall also be calibrated. Pneumatic actuators shall be calibrated at site for Vendor supplied valves. COMMISSIONING REQUIREMENTS Prior to taking the instruments in service, all impulse lines, sampling lines and air supply lines shall be blown as required with the establishment of adequate line pressure and temperature conditions to keep the lines thoroughly clean. On-line [i.e, without removing control valves from the pipe] calibration of the positioners and stroking of control valves/control dampers whether supplied by the VENDOR or by others and connected to the control systems (loops) supplied by the VENDOR shall be carried out as required by PURCHASER/SUPPLIER during control system tuning. Pre-commissioning checks, individuals loop checks, power initialisation, verification of system functioning, trouble shooting final solutions to application and / or instrument problems, etc., is Bidders responsibility. All the required software and hardware changes shall be incorporated as required for successful commissioning to Purchasers satisfaction. Any other tests as may be directed by the Purchaser/Purchasers Representative. After delivery of the equipment, the Bidder shall locate all the equipment including electronic cards in its final position, check all the power wiring, grounding and interconnection cables, all in accordance with manufacturers recommendations. The Bidder shall perform initialisation of system power, field loading of system configuration / software and data base, demonstration of system functionality to verify conformance with manufacturers instructions and specifications, tuning of control loops, implementation of any configuration changes including hardware, software and additional tappings / instruments, cabinets as required and providing general trouble shooting and final solutions to application and / or instrument problems. LOOP TESTING The action of the DCS / PLC controller is set as prescribed. Controller settings for various modes of operation (Proportional band, reset and rate action) are at nominal value. For current signals, 4 20 mA shall be injected and checked the loop for 0%, 25%, 50%, 75% and 100% of full scale inputs. For temperature loops with thermocouples, a known milli volt signal shall be injected and the output display shall be checked for input signals of 0%, 25%, 50%, 75% and
ISSUE R0
4.2.10 4.3 4.3.1
4.3.2
4.3.3
4.3.4 4.3.5
4.4 4.4.1
4.4.2 4.4.3
TCE FORM 329 R3
100%. 4.4.4 For temperature loops with RTDs, a known resistance shall be injected in the control cable through decade resistance box and output display shall be checked for 0%, 25%, 50%, 75% and 100%. For field mounted switches for alarms / interlocks, the action shall be simulated by disconnecting the wires / shorting the terminals and the function of the associated system shall be checked. Any equipment required by the Bidder for testing, calibration and commissioning shall be brought by the Bidder at site. The list of such equipment shall be furnished along with the offer. COMMISSIONING The Bidder shall take care to complete all pre-commissioning activities and simulation tests after erection to suit the over all start up of respective plant equipment. The pre-commissioning activities of the system shall be completed at least two (2) days in advance as per the schedule of plant start-up. The controllers shall be tuned as per the process requirement. The list of set points, alarms / interlocks, settings for the controllers shall be furnished in the standard format and handed over to the PURCHASER. Control loops shall be put in auto mode as per the operational requirement of different phases. Bus Worst loading conditions calculation shall be proved at the time of commissioning. Before taking over of the plant by the PURCHASER, all the system and auto control loops shall run satisfactorily for at least one month at varying loads without disturbing any adjustment. During this period, supervision and maintenance of the system shall be the scope and responsibility of the Bidder. The performance test shall be carried out for the system offered and certificates to these effects shall be approved by the PURCHASER.
4.4.5
4.4.6
5.0 5.1 5.2 5.3
5.4 5.5 5.6
5.7
ISSUE R0
TCE FORM 329 R3
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 4: CODES AND STANDARDS
SL. No
DESCRIPTION
CODE / STANDARD
1 2 3 4 5 6 7 8 9
Instrumentation Symbols And Identification. Graphic Symbols For DCS, Shared Display Instrumentation Logic & Comp. System Graphical Symbols for Diagrams, Binary Logic Elements Diagrams, Charts, Tables Industrial Measurement & Control Terms & definition Pressure, Vacuum And Differential Pressure Gauges Instrument And Apparatus For Pressure Measurement Instrument And Apparatus For Temperature Measurement Temperature Measurement -Thermocouples
ISA S 5.1 ISA S 5.3 IEC 617-12 IEC 113 IEC 902 IS-3624 / BS 1760 Class I ASME PTC- 19.2 ASME PTC- 19.3 ANSI ISA 96.1 / ASTM E 230-03 / IEC 751 IS: 2806 DIN 43760 / IEC 751 / IS 2848 ANSI ISA: 96.1 ISO 5167 IEC 534 ISA S 75.01 ISA S 75.02 ISA S 75.03 ANSI B 16.104
ISSUE R0
10 11
Temperature Measurement By Electrical Resistance Thermometers (RTD) Industrial Platinum- RTD Temperature Measurement- Thermocouples , Extension wires / cables Measurement Of Fluid Flow By Means Of Orifice Plates & Nozzles Industrial Process Control Valves Control Valve Sizing Control Valve Procedure Capacity Test Uniform Face Two Face Dimensions for Flanged Globe Style CV Bodies Valves Seat Leakage
12 13 14 15 16 17 18
TCE FORM 329 R3
SL. No
DESCRIPTION
CODE / STANDARD
19 20 21 22 23 24 25 26 27 28 29 30
Measurement & Control, Electrical sensors, Elec. Position Sensors & Signal Converters for IS Two Wire DC Systems. Vibration, Axial Position & Bearing Temperature Monitoring Systems Electronic Transmitters Compatibility Of Analog Signals For Electronic Industrial Process Instruments Electronic Equipment For Use In Electrical Power Installations Safety Requirement For Electrical And Electronic Measuring And Controlling Instruments Electromagnetic Susceptibility Of Process Control Instrumentation Dynamic Response Testing Of Process Control Instrumentation Electronic Equipment For Furnaces Electrical Indicating Instruments ( Direct Acting) Panel Mounted Indicating And Recording ElectricalInstruments, Dimensions For SWC ( Surge Withstand Capability) Test Annunciator Sequences And Specification. Specifications And Guides For The Use Of General Purpose Annunciators Environmental Conditions Basic Environmental Testing Procedures For Electronic And Electrical Items
DIN 19243 API 670 BS: 6447 ISA - S 50.1 / ANSI MC 12.1 VDE: 0160 ANSI C 39.5 - 1974 SAMA PMC 33.1 / IEC 801 ISA -S 26 VDE: 0116 Section 8.7 IS: 1248 IS: 2419 ANSI -C37.90.1 / IEEE - 472 / IEC 225-4 ISA S 18.1 ISA S 19.1 ISA S 71.04 IS- 9000 / IEC 16000
31 32 33 34
ISSUE R0
TCE FORM 329 R3
SL. No
DESCRIPTION
CODE / STANDARD
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Damp Heat Cycling Test Classification Of Hazardous Areas Classification Of Hazardous Areas For Electrical Installations Electrical Instruments In Hazardous Dust Locations Protection Class For Enclosures, Cabinets, Control Panels & Desks Types Of Enclosures Flame Proof Enclosure For Electrical Apparatus Intrinsically Safe Apparatus Purged And Pressurised Enclosure For Electrical Equipment In Hazardous Locations Contact Rating - AC Services Contact Rating - DC Services Edge Socket Connectors Racks, Panels & Associated Equipment Miniature Circuit breakers For Voltages Not Exceeding 1000 V Plain End Steel Tubes, Welded & Seamless General Table Dimensions & Masses / Length Pipe Threads Dimensions Of Fittings Material For Socket Welded Fitting Nomenclature For Instrument Tube Fittings Binary Logic Diagrams For Process Operation
IS -2106 NFPA 70, Article 500 IS : 5572 ( Part-1 ) ISA-RP 12.11 IS- 2147 / IEC 529 NEMA ICS Part-6 ( With Rev.14/80) IS : 2148 NFPA 496 NFPA Art. 496 NEMA ICS 2 , Part-2125 , A 6000 NEMA ICS 2 , Part-2125 , N 600 IEC 130 -11 ANSI C 83.9 IS: 8828 ISO 4200 ANSI B 2.1 ANSI B - 16.11 ASTM A-105 ISA-RP-42.1 ISA S 5.2
ISSUE R0
TCE FORM 329 R3
SL. No
DESCRIPTION
CODE / STANDARD
55 56 57 58 59 60 61
Preparation Of Function Chart For Control System Functional Diagramming Of Instrument & Control Systems Quality Control Standard for Control Process Control Security Requirements Boiler Safety Interlocks Turbine Water Damage Prevention Safety Requirements For Turbine Protection Water And Steam In Power Cycle Standard Methods Of Sampling System Submerged Helical Coil Heat Exchangers For Sample Coolers Hardware Testing of Digital Process computers Standard Digital Interface For Programmable Instrumentation IEEE Guide To Software Requirements Specifications Standard For Local Area Networks : Carrier Sense Multiple Access with Collision Detection CSMA-CD And Supplements A,B,C and E Standard For Local Area Networks-Token Ring Access Method And Physical Layer Separation Wiring Cables For Telecommunication And Information Processing System Conductors For Insulated Electrical Cables And Flexible Cords Rules For Testing Insulated Cables And Flexible Cables Colour Coding of Instrumentation Cables
IEC 848 SAMA PMS 22.1 ANSI FCI 70.02 IEC 62443 NFPA -85B & 85C ASME-TDP-1980 VDE: 0116 Section87 VDE: 0160 ASME PTC 19.11 ASTM D 1066-69 ASTM D 11 ISA RP-55.1- 1983 IEEE - 488.2 -1990 IEEE 830 IEEE 802.3 IEEE 802.5 VDE: 0815 IS: 8130 VDE: 0472 BS-5308 (Part-2) / IEC-189 (Part-2)
ISSUE R0
62 63 64 65 66 67 68 69 70 71 72 73
TCE FORM 329 R3
SL. No
DESCRIPTION
CODE / STANDARD
74 75 76 77
Guide For Design And Installation Of Cable Systems In Power Generating Stations (Insulation, Jacket Material) Instrumentation Cables And Internal Wiring Guide For Design And Installation Of Cable Systems In Power Generating Stations (Cable Trays, Support Systems, Conduits) Guide For Design And Installation Of Cable Systems In Power Generating Stations (Cable Trays, Support Systems, Conduits) Test Standards Requirement Of Vertical Tray Flame Tests UPS - Performance Testing Air Purge System
IEEE 422 IS- 1554 (Part-1) / IS-5831 IEEE 422 / NEMA VE-1 / NFPA-70 NEMA VE-1
78 79 80
IEEE 383 IEC - 146 ISA S 12.4 / NFPA 496
ISSUE R0
TCE FORM 329 R3
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 5: ESSENTIAL SPARES
SL. NO. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.12.1 1.12.2 1.12.3 1.13 2.0 2.1
ITEM/DESCRIPTION
QUANTITY / UNIT (NOTE-1, 2)
Field Instruments / Elements / Equipment (Gauges, Switches, transmitters etc.) Local Gauges Field Switches Transmitter Temperature Element (RTD) with Thermowell Temperature Element (T/C) with Thermowell Air Filter Regulator Junction Box. Flow Elements I/P Converter Position Transmitter Limit Switches Positive Displacement Flow Meter O rings Gaskets Measuring Mechanism Furnace Temperature ProbeThermocouple 2 no. of each size 2 no. of each size 1 no 1 no 10% for each type, size and range but minimum 2 no 10% for each type and range but minimum 2 no 10% for each type and range but minimum 2 no 10% for each type, range and Immersion length but minimum 2 no 10% for each type, range and Immersion length but minimum 2 no 10% for each type and range but minimum 2 no 10% for each size but minimum 2 no 2 no shut off valves for each flow element 10% for each type and range but minimum 2 no 10% for each type and range but minimum 2 no 10% for each type and rating but minimum 2 no
SG Integral Control System-BMS And Boiler Protection System (Each) Power Supply modules/Cards 10% for each type and range but minimum 2 no
ISSUE R0
TCE FORM 329 R3
SL. NO. 2.2 2.3 2.4
ITEM/DESCRIPTION Network Cards /Switches Communication Interface Cards All other electronic modules Controller card (For Integrated Controller card) / Processor Module for Controller I/O Cards (Each Type) Interposing Relay
QUANTITY / UNIT (NOTE-1, 2) 10% for each type and range but minimum 2 no 10% for each type and range but minimum 1 no 10% for each type and range but minimum 1 no
2.5
2 nos.
2.6 2.7 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9
10% for each type and range but minimum 2 no 10% of total quantity
Panels, local panels, System /Marshalling cabinets Fuses Miniature Ckt. Breaker (MCB) Male/ Female parts of pre-fabricated cables Space Heater Smoke Detector Terminal Blocks Terminals in Terminal blocks Cable clamps Blowers 50 nos of each type and rating 10 nos of each type and rating 10 nos. of each type 10% of total quantity but minimum 1 no 10% of total quantity but minimum 1 no 20% of total quantity. 10 nos of each type 5 nos of each type. 1no
ISSUE R0
TCE FORM 329 R3
SL. NO. 3.10 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5.0 5.1 5.2 5.3 5.4 6.0
ITEM/DESCRIPTION Cabinet Cooling Fans
QUANTITY / UNIT (NOTE-1, 2) 4 nos. of each type/rating
Control valves and Pneumatic Block valves (for each Valve) Plug and steam assembly Seat ring Packing and gaskets Pilot relay Actuator diaphragm O-rings Feedback linkage Control valves (Electrical operated- if supplied) Interfacing modules Control Dampers (for each damper) Actuator diaphragm O-rings Feedback linkage Packing and gaskets Solenoid Valve (For each valve)
ISSUE R0
1 no. of each type 1 no. of each type 2 sets. of each type 1 no. of each type 1 no. of each type 2 sets of each size for positioner 1 no of each type 1 no. or 10% of total qty. whichever is higher.
1 no. of each type 2 no. of each size for positioner 1 no of each type 1 no. of each type
TCE FORM 329 R3
SL. NO. 6.1 6.2 6.3 6.4 6.5 7.0 7.1 7.2 7.3 8.0 8.1
ITEM/DESCRIPTION Solenoid Valve Coil Solenoid Valve Plunger Seat Gaskets O-rings
QUANTITY / UNIT (NOTE-1, 2) 2 nos of each rating and insulation 1 no of each type 1 no of each type and size 2 sets of each type and size 5 sets of each type and size
Steam Tube Leakage Detection System 2 nos. or 10% of total quantity whichever is Sensor higher for each type and range. Each type of card Any other items 10 % of total quantity but minimum 1 no As per the manufacturers recommendation.
Flame Monitoring And Analysis System Camera 10 % of total quantity for each type but minimum 1 no As per the manufacturers recommendation for 3 years operation.
8.2
Other Spare parts
NOTES: 1. 2. 3.
Fractions are to be rounded-off to next higher integer. Qty. indicated is applicable for each unit. There are 2 units in the project. SPARES requirement for any equipment/system not specified above, the Contractor shall supply the spares for the supplied system/subsystem/instruments as per the manufacturers recommendation.
ISSUE R0
TCE FORM 329 R3
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 6: TRAINING TO BE PROVIDED FOR OWNERS PERSONNEL
SL. NO.
TYPE OF TRAINING
NO. OF PERSONS
DURATION OF TRAINING
1.0 1.1 1.2 1.3 1.4
SYSTEM MAINTENANCE TRAINING I&C Engineers In BMS/ Boiler Protection System Hardware & Software I&C Engineers In Furnace Flame Monitoring and Analysis System- Hardware, Software & Analysis I&C Engineers In Boiler Tube Leak Detection SystemHardware, Software & Analysis For All Other Instruments/ Systems 4 4 4 4 2 Weeks Each 1 Week Each 1 Week Each Adequate Training
ISSUE R0
TCE FORM 329 R3
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 7: TESTS FOR I&C SYSTEM EQUIPMENT
PART-A: TESTS FOR I&C SYSTEM EQUIPMENT SL. NO 1. 2. 3. 4. 5. 6. 7. 8. INSTRUMENT / EQUIPMENT Pressure indicators Pressure switches Pressure Transmitters Differential Pressure Indicators Differential Pressure Switches Differential Pressure Transmitters Thermometers Temperature switch TESTS TO BE CONDUCTED Calibration Hydro test (1.5 times max. Pr.) Calibration test /Hydro test/Contact rating test/ Accuracy test / Repeatability Test Calibration test /Hydro test/Leak test/Over range test / Accuracy test /Repeatability test. Calibration test /Hydro test/Leak test/Over range test / Accuracy test/Repeatability test. Calibration test /Hydro test/Leak test/Over range test/ Accuracy test/Repeatability test. Calibration test /Hydro test/Leak test/Over range test/ Accuracy test/Repeatability test. Calibration test /Material test//Accuracy test/Bore concentricity : 5% of wall thick/Hydrostatic test for TW (1.5 times max. pr.). Calibration test/Material test//Accuracy test/Bore concentricity : 1.5% of wall thick/Hydrostatic test for TW (1.5 times max. pr.)/Contact rating test. Calibration/Material test/Accuracy test/Bore concentricity test/Insulation test (<500 M at 500 V, DC) as per ISA, Hydro test for TW. Bore concentricity : 5% of wall thick, Accuracy test Calibration/Material test/Insulation test (<500 at 500 V, DC) as per ISA, Hydro static test (1.5 times max. pr.) More concentricity 5% of wall thick Calibration test/Accuracy test/Ambient temperature error test Material test /Bore concentricity : 5% of wall thick/ Hydrostatic test for TW (1.5 times max.pr) Functional test/temperature rise test/high voltage test/ limits of operation test/insulation test.
ISSUE R0
CONSULTANT: TCE CONSULTING ENGINEERS LTD. TCE FORM 329 R4
9.
Resistance temperature detector assembly Thermocouple assembly Temperature transmitters Thermowells Interposing relay
10.
11. 12. 13.
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 7: TESTS FOR I&C SYSTEM EQUIPMENT PART-A: TESTS FOR I&C SYSTEM EQUIPMENT
SL. NO 14. 15. 16. 17. 18. 19. 20. 21.
INSTRUMENT / EQUIPMENT Level gauges Level switches (magnetic) Level gauges (Probe) Flow switch Flow glasses Variable are flow metes Flow element Control valves
TESTS TO BE CONDUCTED Hydrostatic test/Material test/Seat leakage test / Ball check test Material test/Contact rating test/Hydro test / Calibration test Material test /Contact rating test /Hydro test / Calibration test Material test / Hydro test/ (1.5 time max. pr) / function test Material test /Hydro test/ (1.5 time max. pr) / function test Calibration test / Material test / Hydrostatic test (1.5 time max. pr) 100% Radiography test / Hydro test / Calibration test / IBR certificate (a) (b) (c) (d) (e) (f) (g) IBR certificate Form III C Hydrostatic test : IBR/MSS-SP-61/ANSI B 16.34 (Note 1) Seat leakage test : As per ANSI B 16-104 (Note-1) CV test : As per ISA procedure (Note 1) Magnetic particle test : As per ANSI B 16.34 special class (applicable for pr.> 70 bar & tem < 4000C Liquid penetration test : As per ANSI B 16.34 special class (applicable for pr > 70 bar & temp < 4000C Calibration and Hysteresis test (Note-1)
NOTE-1: These tests shall be witnessed by PURCHASER / CONSULTANT 22. Pneumatic Block Valves: (a) (b) (c) IBR certificate Form III C Hydrostatic test : ANSI B 16.34 (Note 1) Seat leakage test : As per ANSI B 16-104 (Note-1)
ISSUE R0
SL. NO
INSTRUMENT / EQUIPMENT
TESTS TO BE CONDUCTED (d) (e) (f) (g) (h) (i) CV test : As per ISA procedure (Note 1) Magnetic particle test : As per ANSI B 16.34 special class (applicable for pr.> 70 bar & tem < 4000C Liquid penetration test : As per ANSI B 16.34 special class (applicable for pr > 70 bar & temp < 4000C Radiography test : As per ANSI B 16.34 special class Calibration and Hysteresis test (Note-1) Actuator leakage test (Note-1)
Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT 23. Pressure Regulating Valves (a) (b) (c) (d) (e) (f) (g) (h) (i) IBR certificate Form III C Hydrostatic test : ANSI B 16.34 (Note 1) Seat leakage test : As per ANSI B 16-104 (Note-1) CV test : As per ISA procedure (Note 1) Magnetic particle test : As per ANSI B 16.34 special class (applicable for pr.> 70 bar & tem < 4000C Liquid penetration test : As per ANSI B 16.34 special class (applicable for pr > 70 bar & temp < 4000C Radiography test : As per ANSI B 16.34 special class Calibration and Hysteresis test (Note-1) Actuator leakage test (Note-1)
Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT 24. Position Transmitters Calibration/ Hysteresis and Accuracy test
ISSUE R0
SL. NO 25. 26. 27. 28. 29.
INSTRUMENT / EQUIPMENT I/P Converters Solenoid Valves Air Filter Regulators Junction Boxes Transmitter Racks
TESTS TO BE CONDUCTED Calibration test/Accuracy Test Hydro test/Seat leakage test/CV test/Coil insulation test Calibration test/Accuracy test Test for degree of protection/Material test Hydro test, Air leak test for tubing/Piping & fittings, IBR certificate required for impulse pipes, tubes and fittings of all steam & water services Verification of degree or protection. Test for enclosure type, Type tests & routine tests as per relevant Indian standards. Thermo-emf characteristic/Continuity test/Measurement on capacitance, inductance and loop resistance / insulation resistance /high voltage test as per latest IS/Tensile and elongation test/Oxygen index test /Any other test applicable Verification of degree of protection / Electrical tests as detailed under Wiring, Terminations & Accessories/Type tests & routine tests as per relevant Indian standards. Verification of degree of protection / Electrical tests as detailed under Wiring, Terminations & Accessories/Type tests & routine tests as per relevant Indian standards. Verification of degree of protection / Electrical tests as detailed under Wiring, Terminations & Accessories/Type tests & routine tests as per relevant Indian standards.
30. 31.
Transmitter Racks Compensating cable
32.
Local Panels
33.
Marshalling Cabinets
34.
System cabinets
35. 35.1
Wiring Termination and Accessories Routine test Conductor resistance test (*) / High voltage test (*)/Impulse dielectric test/Insulation test/Humidity test/Temperature rise tests on power circuits/Short time current tests on power circuits. Annealing test (*) / Test for insulation and sheath (*)/Flame retardance test (a) Oxygen index, (b) Flammability/Test for acid gas generation/Test for water absorption (*)/Wet dielectric test.
ISSUE R0
35.2
Type test
TCE FORM 329 R4
SL. NO 35.3
INSTRUMENT / EQUIPMENT Test for terminal blocks
TESTS TO BE CONDUCTED Note (*) As per IS-1554 Test for moulding for flame resistant, Non-hygroscopic and Decarbonised / Insulation test between terminals / Insulation between terminal block and frame
36 36.1
DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS Measurement & Control System (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Simulated Functional test for the complete system (As per FAT procedure. Note-1) System performance & tests for monitoring functions (As per FAT procedure. Note-1) Surge withstand capability test as per ANSI C37.9A / IEEE 4721 BE MMA 219 or equivalent. Damp heat cycling test as per is 2106, part 1I- 1962 or equivalent. Dielectric strength test (high pot tests as per NEMA ICSI. part ICS-109) ANSI C39.51/UL 508 or equivalent, Radio frequency interference test as per SAMA PMC 33.1 or equivalent. Immunity to noise test as per IEEE SWC test 587 or equivalent. Burn in test & temperature rise test for 120 hrs. Continuity test & short circuit test for current limiters. Under voltage and over voltage test (Note-1).
Note-1: Test to be witnessed by Owner or Owners representative. 36.2 Data bus system (a) Functional test for the complete system (Both hardware & software) simulating worst condition (As per FAT procedure. Note-1). Noise test-surge withstand capability test as per IEEE or equivalent.
ISSUE R0
(b)
SL. NO
INSTRUMENT / EQUIPMENT (c)
TESTS TO BE CONDUCTED Quality assurance and tests shall be as per latest BS5750 and ESS-1980 or equivalent.
Note-1: Test to be witnessed by Owner or Owners representative. 36.3 Central Processing Unit for Man Machine Interface (a) Main memory test of 12 hours duration to demonstrate the capability of memory Read-Write function under worst pattern at various voltage levels Main memory parity detection test of 12 hours duration to demonstrate that parity detection feature performs properly to the Owners satisfaction Logic tests for 12 hours duration to demonstrate the hardware commands, interrupt structures and hardware failure detection Count down registers and pulse counter test of 8 hours duration to demonstrate the accuracy of all time count down registers Bulk memory Data transfer test of 36 hours duration to demonstrate possible combinations of transfer from/to bulk memory including checks for illegal writing, reading and wrong transfer indications Voltage and speed variation checks Bulk memory parity detection test of 12 hours duration to demonstrate the proper functioning of parity detection feature Functional test for complete system (Both hardware and software) simulating worst conditions (As per FAT procedure. Note-1). Noise test-surge withstand capability test as per IEEE or equivalent. Quality assurance and tests shall be as per latest BS5750 and ESS-1980 or equivalent.
ISSUE R0
(b)
(c)
(d)
(e)
(f) (g)
(h)
(i) (j)
SL. NO
INSTRUMENT / EQUIPMENT
TESTS TO BE CONDUCTED (k) Design, construction, components, materials, finishes and testing of electronic equipment as per EES - 1980 (General specification of electronic equipment) or equivalent.
Note-1: Test to be witnessed by Owner or Owners representative. 37 Colour Graphic Video Display Unit (VDU) (a) (b) Functional tests (As per FAT procedure. Note-1). Test for capabilities of VDU including error detection for the complete system (Both Hardware & Software) simulating worst conditions Noise test Surge withstanding capacity as per IEEE or equivalent Quality assurance as governed by BS 5750 or equivalent. Design, construction, components, finishes and testing of electronic equipment as per EES-1980 (General specification of electronic equipment) or equivalent.
(c) (d) (e) (f)
Note-1: Test to be witnessed by Owner or Owners representative. 38 Keyboard (a) Test for satisfactory operation of keyboard controls, push buttons and all associated functions (As per FAT procedure. Note-1). Quality assurance as governed By BS5750 or equivalent for functional test for the complete system simulating worst conditions Design, construction, components Materials finishes and testing of electronic equipment as per EES-1980 (General specification for electronic equipment) or equivalent
(b)
(c)
Note-1: Test to be witnessed by Owner or Owners representative.

ISSUE R0
SL. NO 39
INSTRUMENT / EQUIPMENT Printers
TESTS TO BE CONDUCTED (a) (b) (c) (d) Noise level test for the printer Test of interlock performance and error detection feature, Quality assurance as governed by BS 5750 or equivalent Design, construction, components, finishes and testing of electronic equipment as per EES-1980 (General specification of electronic equipment) or equivalent Noise test
40
Floppy/Tape Drive Unit / Bulk Memory Unit / DVD, CD drive Unit / DAT Drive
(a)
(b) (c) (d)
Surge withstanding capacity as per IEEE or equivalent Quality assurance as governed by BS 5750 or equivalent Design, construction, components, finishes and testing of electronic equipment as per EES-1980 (General specification of electronic equipment) or equivalent Test of Control unit and drive for all features, Date checking features. Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
(e) 41 Vibration Monitoring & Analysis System (a) (b)
Note-1: Test to be witnessed by Owner or Owners representative. 42 Flame Monitoring & Analysis System (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative. 43 PADO System (a) Simulated Functional test (Note-1)
ISSUE R0
SL. NO
INSTRUMENT / EQUIPMENT (b)
TESTS TO BE CONDUCTED Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative. 44 CMMS System (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative. 45 MIS System (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative. 46 Security & Surveillance System (PSS) (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative. 47 Boiler Tube Leak Detection System (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
PART-B: GUIDELINES FOR FACTORY ACCEPTANCE TEST (FAT) FOR DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS 1 GENERAL REQUIREMENTS Factory acceptance test (Fat) procedure : Ref. Note -1 & 2
2
TEST REQUIREMENTS
ISSUE R0
PART-B: GUIDELINES FOR FACTORY ACCEPTANCE TEST (FAT) FOR DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS
(a)
Test shall be performed with the completely assembled system and also with complete i&c software and performing all functions expected out while in actual service and with system configuration as finalised. Process input / output conditions and other load on the system to be stimulated either by hardware / software. All system software & application software to be loaded and operational on the system prior to fat refer relevant sections.
(b)
(c)
TEST DOCUMENTS / DRAWINGS (a) (b) Total system configuration drawings Fat procedure consisting of : (i) (ii) (iii) (iv) (v) (vi) (vii) (c) Test equipment Test environment Test configuration Test procedure Test schedule Test venue Test reports- specimen copies
Function design specification for each eqipment / system
PRELIMINARY CHECKS (a) (b) (c) (d) (e) General appearance check & bill of mateirals check Construction check as per over all general arrangement drawings Dimensional check Labelling, terminal arrangement and equipment identification check Power supply voltage level check & power ' leds - on check
ISSUE R0
PART-B: GUIDELINES FOR FACTORY ACCEPTANCE TEST (FAT) FOR DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS (f) (g) 5 Cooling fan operation check Grounding network check
SYSTEM HARDWARE CHECKS (a) (b) (c) (d) (e) (f) Power supply under voltage and over voltage check ( 10%) Processor & main data bus network redundancy check , Communication coupler redundancy check Communication module of the controller to network redundancy check, Power supply redundancy check Hardware on-line maintainability check ,
CONTROLLER ENGINEER FUNCTIONAL CHECK (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Closed loop control simulation check Open loop control simulation check Control loop response check Bumpless auto manual transfer check VDU graphic overview check VDU- trend check VDU- real time trend check VDU- mimics check VDU- check for operating control directly from mimics VDU- function keys check VDU- touch screen function check VDU- analog control display check
ISSUE R0
PART-B: GUIDELINES FOR FACTORY ACCEPTANCE TEST (FAT) FOR DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS (m) (n) (o) (p) (q) (r) (t) (u) (v) (w) (x) (y) (z) (aa) (bb) 7 VDU- sequence control display check VDU- operator guidence message check VDU/ backpanel operation priority check VDU- alarm management function check VDU logging function check VDU / response / updating check Keyboard lock function check VDU interchangebility & assignability check Printer assignability & back-up function check Floppy disk / compact disk / optical disk unit storage & retrieval check VDU assignability check for hard copier function Plant performance calculation check Communication interface to others system simulation check Ser interface data dump function check Data bus distance building check (refer note- 3)
MAINTENANCE ENGINEER FUNCTION CHECK (a) (b) (c) (d) (e) Graphic display building function check Closed loop control system modification check Open loop control system modification check Alarm display prioritisation check System security check
ISSUE R0
PART-B: GUIDELINES FOR FACTORY ACCEPTANCE TEST (FAT) FOR DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS (f) (g) (h) (i) (j) 8 System alarm check System diagnostic function check Point detail configuration check Control loop tuning check System self documentation check
SYSTEM PERFORMANCE REQUIREMENTS (a) (b) (c) (d) (e) (f) (g) (h) (i) System response time Controller responsiveness Input off - normal detection responsiveness Operator crt responsiveness Command initiation Command formatting Command execution and data display for monitoring Printer responsiveness System accuracy requirements
AUTHORISATION TO SHIP TEST (a) (b) (c) (d) (e) (f) Includes all features of operation tests Simulation of inputs / outputs: to verify conversion accuracy, scan rates, operator panel functions, correctness of calculations. Operation test : to verify that the system performs all operations specified Power consumption test Power failure test : to observe the consequence of total power failure Accuracy and repeatability test
ISSUE R0
PART-B: GUIDELINES FOR FACTORY ACCEPTANCE TEST (FAT) FOR DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS (g) (h) (i) (j) Function test Format test : to verify printouts and display formats Manual & auto switch over from master to standby All diagnostic and s/w debug tests shall be performed in the presence of the owner / project manager / consultant representative with the system fully assembled and all parts interconnected together with simulated anolog / digital inputs. Surge withstand capacity test as per relevant standard Management information system function check
(k) (l)
NOTES: 1 The intent of the fat is to demonstrate and ensure that the I&C system meets all the functional requirements as intended in the specification / contract. A completed integrated test of the system shall be carried out at vendor' s works in the presence of owner / project manager / consultant, on completion of integration/manufacturing of the system. The shipment of I&C equipment to site will be effected only after the fat has been accepted by the owner / project manager / consultant. 2 3 4 5 6 Fat procedure shall be prepared by vendor and to be submitted for owner / project managers / consultant' s approval well in advance prior to the commencement of fat Fat shall be conducted with the distance between the processor and other supporting peripherals as per the final layout in the control room. Duration of fat shall be minimum three (3) weeks. the fat procedure shall be subject to owner / project managers approval. For closed loop controls vendor shall also demonstrate the performance using simulation software to cover the relative performance of the boiler and turbine parameters. During the course of fabrication the owner / project manager shall have access to the plant for inspection. at all times, the owner / project manager / consultant shall have the right to inspect for quality control. Pre-Shipment inspection The complete system shall be examined at the factory for workmanship, assembly and fat, mechanical safety, materials, wiring, connections, parts, finish, operation and strict conformance to this specification and approved design layouts and detail drawings . All tests including functional tests shall be conducted as per is and this specification.
ISSUE R0
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 8: INSTRUMENT INSTALLATION
1.0 1.1
IMPULSE LINE/TUBE FITTINGS & ACCESSORIES Nipple shall be provided for root valve size more than inch and nipple size shall be same as the root valve size. Reducer/adapter shall be provided to suit instrument connection, where nipple, root valve size is more than inch. Bulk head fitting socket welded type to be provided at instrument rack/ enclosure. All instrument impulse tube size should be ss. Impulse tube shall be tig welded from root valve to instruments. Anchor fasteners shall be provided for installation of standpipe whenever required.purge line shall be connected near root valve only. Purge rotameter, backpressure regulator, air filter regulator for purge air shall be located near instrument. FITTINGS All fittings except the last fitting connecting to the instrument shall be socket welded. The size of the fittings shall be same as the impulse line size. The fitting connecting to the instrument shall have a size and instrument connection. DRAIN Drain shall be provided for all water/steam and non-inflammable / non-corrosive fluids only. DRAIN VALVE Two numbers of globe drain valves shall be for process conditions of 425oc or 62 bar and higher. One number globe drain valve shall be provided for process conditions of less than 425oc and 62 bar. The valve size shall be same as impulse piping/tubing size. FUNNEL WITH DRAIN HEADER Funnel with drain header shall be provided in the racks for blowing/draining out the process fluid in the impulse tubings. The drain header of the rack shall be connected to the nearest floor level or plant drain. The size of the drain header shall be 1. thread to suit the
1.2 1.3
2.0 2.1 2.2 3.0 3.1 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3
ISSUE R0 CONSULTANTS : TCE CONSULTING ENGINEERS LIMITED TCE FORM 329 R4
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 8: INSTRUMENT INSTALLATION
5.4
When instruments are mounted local to the tapping point and are not mounted in the rack, or panel or enclosure. The drains shall be connected to the nearest floor level or plant drain. INSTRUMENT CONNECTION Type of the valve shall be needle valve with built in drain valve. Sizing of the valve shall be . Right/left threaded fittings shall be provided for installation/removal of instruments without disturbing the tubing/piping. A suitable adapter shall be provided to install the instruments on right-left threaded fitting A vent line with a isolation valve shall be provided in the instrument rack for air and compresible fluids or otherwise if the installation call for eg., for liquid service where the transmitter is located at a higher elevation than the tapping point. For air/flue gas measurement a drain pot with plug shall beprovided in place of drain valves. PURGING SYSTEM Purging system shall be provided for flue gas measurements Instrument air connection shall be provided at each instrument for air & flue service for continuous purging. One air filter regulator, purge rotameter and a blow down device per instrument shall be provided in the transmitter rack. The purge line shall be connected to each instrument through a isolating valve.
6.0 6.1 6.2 6.3 6.4 6.5
6.6 7.0 7.1 7.2 7.3 7.4
ISSUE R0 CONSULTANTS : TCE CONSULTING ENGINEERS LIMITED TCE FORM 329 R4
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 9: DATA TO BE FURNISHED WITH BID
TABLE-9: I&C DATA TO BE FURNISHED WITH THE BID
SL. NO 1.0
DATA TO BE FURNISHED P&ID (Process and Instrumentation drawings) indicating primary and secondary Instruments and the destination/functionality of the signals for main Plant and for each Utility package. Clause wise confirmation / deviation list with respect to I & C requirements specified in sections. Confirmation certificate for the latest version of software and hardware offered. Codes and applicable standards followed for the project. Letter confirming support of spares for 15 years for the offered I&C equipment Technical details of including configuration diagram with copy of certification from authorised agency for the offered BMS & of Boiler Protection System Technical details of including configuration diagram for the offered Flame Monitoring and Analysis system Technical details of including configuration diagram for the offered Boiler Tube Leak Detection System Heat load and power supply requirement for the offered I&C system equipment (Preliminary; Final after award of contract). Number of panels/ cabinets to be located in control room/ electronic cabinet room with dimensions. List of recommended control loops with a brief write up to be implemented in Purchasers DCS (Refer Note no 3, 4 & 5 of Section D 2, TABLE-10, Data to be furnished after award of contract).
2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0
ISSUE R0
TCE FORM 329 R4
VOLUME: IIIA SECTION: D2T10 SHEET 1 OF 5
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 10: DATA TO BE FURNISHED AFTER AWARD OF CONTRACT
SL NO 1.0
DATA TO BE FURNISHED Process & Instrumentation Diagram (PID) indicating primary sensors and secondary instruments, functional usage / destination reference (alarm, control etc) for SG Package systems. Purchase specification for all I&C equipment including BMS / Boiler Protection System BMS / Boiler Protection system configuration drawing / system architecture drawing indicating all elements. System Configuration Diagram with interfacing details for following analysis systems: (a) (b) Flame monitoring and Analysis system Boiler Tube Leak Detection System
Category A
2.0 3.0 4.0
A A A A A A A A A A
5.0 6.0 7.0 8.0 9.0 10.0
Hardware and software design manual for BMS / Boiler Protection system Input / Output list for BMS & Boiler Protection System Drive List for BMS & Boiler Protection System I/O Assignment for BMS & Boiler Protection System including nest loading. Hardware design manual for Flame monitoring and Analysis system & Boiler Tube Leak Detection System Bill of quantity for (a) (b) (c) BMS & Boiler Protection System Flame monitoring and Analysis system Boiler Tube Leak Detection System
I I I A A I
ISSUE R0
11.0 12.0 13.0
Factory Acceptance Test (FAT) procedure / Availability test procedure /PG test procedure for all C & I equipment. QAP for all equipments GA drawings of control panel / local panel with cabinet internal layout.
TCE FORM 329 R3
SL NO 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0
DATA TO BE FURNISHED
Category
List Of Panels/ Cabinets and Control Room Mounted Equipments Marshalling philosophy / cabling philosophy Wiring diagrams for panel, local panel, junction boxes, actuators, starters etc. List of JBs and FTCs. With locations and terminal details. Heat load and Power consumption data for I&C equipments Earthing Scheme Essential & start-up Spares list Cable List Interconnection cable schedule (ICS) and cable schedule between Jbs to Marshalling cabinets. O & M Manual for all I&C equipment : (a) (b) Field Instruments Systems (i) (ii) (iii) BMS / Boiler Protection System Flame monitoring and Analysis system Boiler Tube Leak Detection System
I A I I I
A I I I
I I I I A
24.0 25.0
Equipment wise vendor details including Address, Contact person, Telephone nos. Complete graphic diagrams for SG and its auxiliaries control and monitor at plant DCS operator consoles (Process mimics indicating Analog and digital parameters). Measurement Point Schedule Complete Input/Output signal list for Purchasers DCS tag database
26.0 27.0
A A
ISSUE R0
TCE FORM 329 R3
SL NO 28.0 29.0 30.0 31.0
DATA TO BE FURNISHED
Category
Drive List Solenoid Valve List List of Alarm And Trip Set Points Recommended Control Schemes with write up for (NOTE 3, 4 & 5) (a) (b) Modulating Control Schemes Interlock / Protection Logic Diagrams
A A A A
32.0 33.0 34.0 35.0 36.0 37.0 38.0
Actuator Wiring Diagram Standpipe details Control Valve Data Sheet & Sizing Details Inputs to Vendors system from PURCHASERS system with terminal details Outputs from Vendors system to PURCHASERS system with terminal details Flow Elements Data Sheet & Sizing Details. Equipment Location Details
A A A A A A I
NOTES: 1. 2. 3 All the drawings shall be submitted in both soft and hard copies. All engineering documents (item 9.0) formats shall be approved by Owner / Project Manager. Recommended schemes along with write-up for all the controls as deemed necessary for the steam Generator & auxiliaries, to be implemented in Purchasers DCS shall be furnished by Vendor. Recommended Analog Controls for Bidders Equipment/ implementation in Purchasers DCS : Systems for
3.1
ISSUE R0
TCE FORM 329 R3
3.1 (i)
This includes all auto controls like Furnace pressure, drum level, air/fuel flow, HPBP, windbox air damper, Auxiliary pressure reducing desuperheating station and SH steam temperature controls. Recommended schemes along with write up to be submitted by Vendor shall be Final Schemes for straightaway implementation, clearly indicating sensor tag nos. legend, interlock requirements, settings for time delays controller etc. Each block in the scheme shall be clearly explained in the associated detailed write-up. Each functional block in the scheme shall be accompanied by associated characteristic curve for implementation. All the control system requirements shall be clearly brought out with no Holds to avoid any future correspondence. Review of the schemes will not be done by Purchaser. Vendor shall account for any delays in implementation of these controls in Purchasers system for want of information/ clarification. Recommended logic diagrams for control systems to be implemented in Purchasers DCS for drives [ON/ OFF, inching, open/close, solenoid etc.] This includes controls of all HT drives, LT drives, motor operated valve, solenoid valves, protection & auto-standby of HT & LT drives Schemes shall be Final Schemes for straightaway implementation, clearly indicating sensor tag nos. legend, settings for time delays switches etc. Each block in the scheme shall be clearly explained in the associated detailed write-up. All the control system requirements shall be clearly brought out with no Holds to avoid any future correspondence. Review of the schemes will not be done by Purchaser. Vendor shall account for any delays in implementation of these controls in Purchasers system for want of information/clarification.
3.1 (ii)
3.2 3.2 (i) 3.2 (ii)
3.2 (iii)
3.3 3.3 (i) 3.3 (ii)
Sequence logic for boiler auxiliaries start up/shut down/load up/load down.
This includes controls like Furnace safeguard supervisory system (includes BMS system) for fuel control at boiler, Boiler protections and soot blower controls. Vendor shall furnish functional block diagram clearly identifying the various steps for the sequential and auto starting, sequential and auto shut down of the Boiler auxiliaries as demanded by turbine operational requirements at the different stages of operation. A detailed write-up clearly explaining the above shall also be furnished. Vendor shall ensure that the source instrument requirements indicated in the recommended schemes match exactly with the instruments indicated in the flow schemes and instrument list submitted by Vendor. Wherever source instruments are in Purchasers scope, the same shall match with the stubs provided as indicated in Vendor flow schemes.
3.3 (iii)
ISSUE R0
TCE FORM 329 R3
3.3 (iv) 4.0
All the required set points shall be indicated on the recommended schemes. The SG vendor shall list all the recommended control schemes and logic diagrams which are required for the protection and control of SG auxiliaries (which have to be implemented in Purchasers system) one below the other in a single place. Against each loop the Vendor shall clearly list the following under separate columns:(a) Tag Nos. along with service descriptions of sensors required for implementation of the loop, which have already been provided by SGV on his piping/equipment. Service descriptions for sensors/instruments to be provided by Purchaser on SG vendors piping. Service description for sensors/instruments to be provided by Purchaser on Purchasers piping. be functional block diagrams which can be easily
(b) (c) 5.0
The recommended schemes shall understood and implemented.
LEGEND: A- For Approval, I- For Information
ISSUE R0
TCE FORM 329 R3
SPEC. NO.
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD 2x800 MW TPP NEAR KRISHNAPATNAM
VOL-III A
TCE-5103A-C-510-01
STEAM GENERATORS & AUXILIARIES ELECTRICAL DESIGN REQUIREMENTS
SECTION: D3 SHEET 1 OF 10
3.0 3.1 3.1.1
Design Requirements Motors All the drive motors covered under this specification shall comply with the requirements of enclosed specification TCE.M4-203-01, TCE.M4-203-02 Section-D along with its data sheet-A All motors rated 160 kW and below shall be suitable for 400V or 415V, 3 phase, 50 Hz, AC supply. Motors rated 160 kW above upto and including 1500kW shall be rated for 3.3 kV, 3ph 50Hz system. Motors rated 1500kW above shall be suitable for 11kV, 3 ph 50Hz system. Referring to the specification TCE.M4-203-01, following may be noted. (a) Table I under clause no. 9.5 indicating the sizes of cables and terminal boxes etc. are only for guidance. Suitable double compression cable glands and terminal boxes shall be supplied based on the final cable sizes to be intimated to the VENDOR during detailed engineering.
3.1.2
3.1.3
3.1.4
With reference to specification TCE.M4-203-02 cl.no.4.2 following may be noted. For all HT motors, in addition to the thermometers specified for the bearing, duplex type thermocouple shall be provided for each bearing. The terminals of these thermocouples shall be brought to a junction box. All motors covered under the scope of this specification shall be designed to withstand atleast 5% harmonics in supply voltage. The minimum phase to phase and phase to earth clearances for 415V motors in the respective terminal boxes shall be as follows : Phase - Phase 25.4mm Phase - Earth 19.0 mm
3.1.5
3.1.6
3.1.7 Motors rated 1000 kW and above will be provided with differential protection. These motors shall be provided with star connected stator windings. Three numbers of current transformers for differential protection will be supplied by switchgear VENDOR, one
ISSUE R0
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
for each phase, shall be mounted in a separate compartment in the neutral side terminal box. The three phases will be connected to form the star point after they pass through the CTs. The CTs shall be of relay accuracy. The technical parameters of these CTs will be informed to the successful BIDDER during detailed engineering. 3.1.8 Maximum noise level measured at a distance of 1.0 m from the outer surface of any motor shall not exceed 85 db (A). 3.1.9 Cable boxes of all HT motors shall be of phase segregated type with a short circuit with stand capability of 40kA for 0.25 Sec. The cable box shall be suitable for either heat shrinkable type of terminating kit or other type of kits, the details of which will be informed to successful BIDDER. These cable boxes shall be provided with quick disconnecting type of terminal connectors to facilitate easy disconnection and removal of motors without requiring unsealing or disturbing the external cable connection. The type of cable for HT motors will generally be with Aluminium conductor, XLPE insulated and armoured. 3.1.10 Variable Frequency drive shall be provided for ID fans. When FD fans of centrifugal type is offered, the same shall be provided with VFD .The VFD shall be as per enclosed section-D, TCE.M4-203-71 and associated data sheets. 3.2 3.2.1 Motor operated valve actuators All the motor operated valve actuators and dampers along with their motors specified under this specification shall comply with the specification TCE.M4-203-06. All motor operated valves shall be provided with integral starters. PURCHASER will provide only switch fuse supply from the MCC for these valve motors. DC motors All the DC motors covered under the scope of this specification shall comply with the enclosed specification TCE.M4-203-11. Starter panel for DC motors Starters for motors of Generator auxiliaries such as JOP, EOP, Cooling system etc., shall be included by VENDOR. The necessary interlocks, protection, etc., for the operation of these motors are
ISSUE R0
3.3 3.3.1 3.4 3.4.1
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
included in VENDOR s scope. These auxiliaries are operated from DCS. 3.4.2 The constructional features of these panels shall comply with the requirements of specification TCE.M4-203-11, Section D. LT Switchgear MCCs for feeding the auxiliary loads of Boiler such as Boiler MCC, Boiler valve and Damper control MCC, soot blower MCC and ESP MCC shall be included in Bidder s scope. These MCCs shall be provided with suitable quantity and type of outgoing feeders for the auxiliary loads and any control panels envisaged in the SG system. Bidder shall furnish a list of drives requiring DC or emergency power supply so that feeders for the same can be arranged from Purchaser s DC / Emergency switchboards. The bus bars, incomer and bus coupler breakers shall be sized based on LV side current of the auxiliary transformer plus 20% margin rounded off to the next standard rating in the case of transformer fed switchboards and based on the full load current with 20% margin for all other switchboards. The incomers and bus couplers shall be ACB type for rating greater than 630A. In addition following feeders shall be provided in the each switchgear. (a) Spare feeders Minimum one no. feeder of each rating and type at the time of handing over the plant. Any additional quantity required for any increase/changes during detailed engineering stage shall also be duly considered. 240V, 1 phase motor space heating module - 1 No. on each bus section 240V, 1 phase panel space heating module - 1 No on each bus section 400/110V Test supply module 1 No. on each bus section (b) &(c) are applicable for switchgear with motor feeders. Bus VT module-1 No. on each bus section
3.5 3.5.1
(b) (c) (d) (e) 3.5.2
Two (2) nos. 100% 415/110V 1-ph transformers shall be provided in each switchboard for deriving control supply .Rating of each transformer shall be adequate to cater both the bus sections. Normally each transformer feed one bus section each. A changeover switch shall be provided for selection.
ISSUE R0
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
3.5.3
LT switchgear shall comply with the particulars indicated in section D, TCE.M4-219-11 and associated data sheets and typical control schemes enclosed. The incomer, bus coupler and outgoing breakers of LT switchboards will be controlled from DCS. Manual live changeover facility shall be provided between the two incomers of LTMSB for ESP, any other MCC with ACB incomers. When planned outage of one of the normal incoming supplies is required, the respective incomers shall be tripped automatically after the bus coupler breaker is closed manually after checking the synchronism between the two bus voltages. For this purpose synchrocheck relay shall be provided in the switchgear. Syncronisinng breaker selection and intended breaker selection will be from DCS. Thus depending on the selection, incomer-A/B will be tripped once bus coupler is closed manually .A timer shall be provided for annunciation of running breaker failed to trip. i.e. two sources paralleled beyond preset time. Then the last closed breaker is tripped based on synchronising selection from DCS. When normal supply has to be brought back into operation, the incomer breaker will be closed and bus coupler shall be tripped automatically. All hardware required for meeting the functional requirements stated above shall be included in the scope of supply.
3.5.4
3.5.5
3.5.6 Motors rated 150KW and above shall be controlled by Air circuit breakers and those below 150KW and above 50KW shall be controlled by MCCB, bi-metal relay and contactor and those rated 50KW and below shall be controlled by MPCB and contactor 3.6 3.6.1 Power supply distribution boards Power supply distribution boards for different voltages as required by the system are included in VENDOR s scope. The constructional features of these boards shall be as per enclosed specification TCE.M4-219-01, Section-D along with its Data Sheet A. PURCHASER will provide 100% duplicate feeders at one point for distribution by VENDOR. Necessary changeover arrangement shall be provided between the two incomers to the distribution boards. Required number of outgoing feeders with minimum of one(1) spare feeder of each rating shall be provided.
ISSUE R0
3.6.2
3.6.3
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
3.6.4
The BIDDER shall furnish the rating of all the power supplies required by him from the list above. BIDDER shall also indicate the proposed location of the distribution boards to enable the PURCHASER to arrange for the power supplies. The distribution panels are located in such a way that they are nearer to load centre. In view of this, if the requirement of distribution boards of any type is more than one, the quantity, distribution arrangement and tentative location proposed shall be furnished by the BIDDER in the bid. The distribution of power supplies shall include all the equipment under the scope of this specification viz. thermocouples or cold junction compensation boxes, lube oil system local JB or control panels, equipment handling systems, fans and their motor temperature gauges, bearing temperature gauges, motor speed switches etc. For the 110V AC, 1PH and 240V AC, 1 PH PURCHASER will arrange only two nos. 100%, 400V or 415V, 3PH AC supplies for each distribution board. BIDDER shall provide suitable step down transformers to obtain the necessary supplies required. Following details shall be furnished by the VENDOR during detailed engineering for PURCHASER s approval for all distribution panels. (a) General arrangement, foundation / fixing layout (b) Single line diagram (from both VENDOR and his SUB-VENDOR
3.6.5
3.6.6
3.6.7
3.6.8
3.7 3.7.1
Junction boxes (JBS) / Marshalling boxes(MBS)/Local push button stations( LPBs) The constructional features of JBs/MBs/LPBs shall be as per the details indicated in the enclosed specification TCE.M4-219-01, Section - D. The junction boxes are required for terminating the cables from field instruments, thermocouples etc., and for further cabling. The Junction Boxes and Marshalling boxes shall be selected such that at least 20% spare terminals are available in each of these boxes after all the cabling is completed.
ISSUE R0
3.7.2 3.7.3
TCE FORM NO. 329 R4
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
3.7.4 The Local push button stations shall be two push button type with START and STOP push buttons. STOP PB (NC) contact shall be directly wired to MCC, while START PB (NO) and STOP PB (NO/NC) shall be taken to DCS. Since contacts are taken for different circuits, separation shall be provided between these two contacts in the terminal block. 3.8 3.8.1 Cables LT Power cables pertaining to Boiler valves, ESP & soot blower system shall be included in Bidder s scope. Control and instrumentation cable scope shall be as per Vol-V The cables shall be as per specification described below: 3.8.2 LT Cables The LT cables shall be 1.1kV grade with single/multicore, stranded aluminium conductor, XLPE insulated, extruded PVC (type-ST-2) inner sheathed, aluminium round wire armourd for single core/galvanised steel round wire / strip armoured for multicore, extruded FRLS PVC (TYPE-ST-2) outer sheathed cables conforming to IS-7098 part-1. 3.8.3 Control Cables The control cables shall be 1100v grade, multi core of 2.5/4 sq.mm cross section stranded (7 strands) copper conductor, PVC insulated, inner PVC sheathed (type ST-1), galvanised steel wire / strip armoured and with FRLS PVC outer sheath conforming to IS1554 pt-1. 3.8.4 Instrumentation cables Instrumentation cable shall be suitable for the requirements of instrumentation system. Cable in general will be stranded annealed, tinned copper conductor, PVC insulated, twisted pair/triplets with overall screening for RTDs and digital signals, shall conform to each pair screened and overall screened for analog signals inner PVC sheathed, steel wire/strip armoured and outer sheath of FRLS PVC conforming to clause 2.8.3 below. The cables shall conform to IEC 189 Pt 1 & 2.
ISSUE R0
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
3.8.5
Outer sheath for FRLS cables shall meet the following test requirements related to flame retardance, low smoke emission, low acid and toxic gas emission. The BIDDERs shall have proper test apparatus to conduct all the relevant tests as per the applicable Standards mentioned herein.
3.8.5.1 Test for Flame Retardance (a) Oxygen Index The critical oxygen index value shall be minimum 29 when tested at 27+2oC as per ASTM-D-2863 and the temperature index value shall be minimum 250oC at oxygen index of 21 when tested as per NES 715/ ASTM-D-2863 (b) Flammability i. Cables shall pass test under fire conditions as per IS10810- Part-53. Cables shall also pass tests as per IS-10810 Part- 61 & Part-62. Cables shall also pass tests as per IEC-332-1 Fire survival cables in addition to tests (i) and (ii) above shall pass tests as per IEC-331.
ii. iii. iv.
3.8.5.2 Test for Smoke Generation The cables shall satisfy the tests conducted to evaluate the percentage obscuration by smoke in an optical system placed in the path of the smoke. The maximum smoke density rating shall not be more than 60% when tested as per ASTM-D-2843.
3.8.5.3 Tests for Acid Gas Generation The hydrochloric acid generation when tested as per IEC 754-1 shall be less than 20% by weight. 3.8.5.4 Tests for Resistance to Ultra Violet Radiation
ISSUE R0
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
This test shall be carried out as per DIN 53387. The retention values of tensile strength and ultimate elongation after the tests shall be minimum 60% of tensile strength and ultimate elongation before test. 3.9 Cable Sizing The LT Power cables shall be selected on the basis of current carrying capacity, permissible voltage drop during running of motor and permissible voltage dip during motor starting. a) Minimum LT Power cable size (aluminium conductors) shall be 4 sq.mm except for valve actuators for which 2.5 sqmm copper cable can be used. Minimum control cable size shall be 1.5 sq. mm copper. Power cables for motors controlled by switch fuse units and contractors shall be based on the maximum load current, derating factors for temperatures, laying & grouping and voltage drop during running as well as starting. Voltage dip during starting of any individual motor shall not exceed 15% and minimum derating factor for temperature, laying and grouping shall be 0.7. Voltage drop during running shall not exceed 5%. Additionally for motors controlled by Air circuit breakers, short circuit withstand time shall also be considered. The power cable sizes selected by the CONTRACTOR shall be subject to approval by PURCHASER. For this purpose, CONTRACTOR shall furnish necessary calculations during detailed engineering. Any change in cable size as decided by PURCHASER shall be accommodated without commercial / delivery implications. Space Heating LT motors of rating 30 kW and above- 4 sq.mm Al or 2.5 sq.mm copper.
b) c)
d)
e)
3.10
Cable Installation Cables shall be laid in Purchaser s cable trays in all areas except in Boiler platforms and ESP platforms, where Bidder shall supply & install cable trays along with supports. Vendor shall install, test and commission cables which are included in their scope. Bidder shall
ISSUE R0
TCE FORM NO. 329 R4
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
submit Cable tray layouts in Boiler and ESP platforms for Purchaser s review. 3.11 Cable glands and lugs Cable glands & lugs for all cables included in Bidder s scope shall be in Bidder s scope. All cable glands shall be of double compression brass type. All lugs shall be of tinned copper crimping type. 3.12 3.12.1 Cable termination All cable shall be terminated at both ends. Cables shall be additionally supported near the entry point of equipment in order to avoid the whole weight of the cables coming on to the gland plate / cable box. The scope of termination at each end shall include dressing and connecting all the cores of the cables. The following shall be included in the scope of work: (a) Making the requisite holes on the gland plate of the panels, fixing glands, terminating the cables in the cable boxes, earthing the cable armour, crimping of cable lugs on each, neatly clamping the cables inside switchgear and distribution board. The cable and core identifying tags and core identifying ferrules respectively shall be supplied and installed by the VENDOR as a part of cable termination work.
3.12.2
3.12.3
The VENDOR shall tag / ferrule all control cable cores at all terminations as instructed by the PURCHASER. For panels where a large number of cables are to be terminated and cable identification may be difficult, each core ferrule shall include the complete cable number. Spare cores shall be similarly tagged / ferruled / cross ferruled with a suffix letter S along with cable numbers and coiled up after end sealing. Cable tags and markers (a) Each cable shall be tagged with numbers. The scheme of numbering will be informed to successful BIDDER during detailed engineering.
ISSUE R0
3.12.4
3.13
TCE FORM NO. 329 R4
SPEC. NO.
VOL-III A
TCE-5103A-C-510-01
(b)
The tag shall be aluminium with the number punched on it and securely attached to the cable / conduit by not less than two turns of 20SWG GI wire confirming to IS: 280. Cable tags shall be a rectangular shape for cables. Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossings, on each duct / conduit entry and at every ten (10) metres.
(c)
3.14
Earthing and Lightning protection The main earth grid will be provided by Purchaser Two(2) nos GS risers will be provided from the main grid for Boiler and ESP platforms. The earthing of all equipment in Boiler and ESP platforms is in vendor s scope. The conductor sizes for the individual equipment earthing shall be in accordance with IS-3043 considering the appropriate ground fault current and the duration of the fault current. Calculation shall be submitted for Purchaser s review. Lightning protection of ESP platforms and Boiler platforms is included in Bidder s scope. The lightning protection shall be in accordance with IS-2309.The down conductors shall be connected to the main plant earth grid in the grade level through direct driven rods.
ISSUE R0
ISSUE NO R0
SPEC NO. TCE-5103A-C-51001
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD 2 X 800MW TPP NEAR KRISHNAPATNAM
VOLUME IIIA DATA SHEET A1 SHEET 1 OF 5
STEAM GENERATORS & AUXILIARIES DESIGN PARAMETERS OF SG AND AUXILIARIES UNITS 60 % TGMCR 4 80% TG MCR 5 100% TGMCR 6
SL. NO. 1
PARTICULARS
2 STEAM AND FEED WATER
TOP HEATER OUT OF SERVICE (100% TGMCR) 7
100% SG MCR 8
1. 2.
STEAM FLOW AT SH OUTLET PRESSURE AT MAIN STEAM STOP VALVE OUTLET PRESSURE AT TERMINAL POINT IN MAIN STEAM LINE STEAM TEMPERATURE AT SH OUTLET STEAM TEMPERATURE AT TERMINAL POINT STEAM FLOW AT RH OUTLET RH INLET PRESSURE AT TERMINAL POINT RH INLET TEMPERATURE AT TERMINAL POINT RH OUTLET PRESSURE AT TERMINAL POINT
t/hr bar (a)
1380*1 *2
1880*1 *2
2380*1 *2
Later *2 *2
2500
3.
bar (a)
160*1
214*1
242
242
242
4.
*2
*2
*2
*2
*2
5.
565
565
565
565
565
6. 7.
t/h bar (a)
Later Later
Later 49
1982 61
Later Later
2075*1 62.5*1
8.
Later
350*1
350*1
Later
350*1
9.
bar (a)
Later
45.6*1
57*1
Later
58.5*1
REV.NO. DATE REV. BY
RO
PPD. BY : CKD. BY : DATE :
JOB NO. TCE -5103A
CLIENT : APPDCL PROJECT: 2 X 800MW TPP NEAR KRISHNAPATNAM
ISSUE NO R0
STEAM GENERATORS & AUXILIARIES DESIGN PARAMETERS OF SG AND AUXILIARIES
SL. NO. 1 10.
PARTICULARS
UNITS
60 % TGMCR 4 593
80% TG MCR 5 593
100% TGMCR 6 593
2 RH OUTLET TEMPERATURE AT TERMINAL POINT FEED WATER FLOW TO ECONOMISER FEED WATER TEMPERATURE AT ECONOMISER INLET
3
0
TOP HEATER OUT OF SERVICE (100% TGMCR) 7 593
100% SG MCR 8 593
11. 12.
t/h
0
1394*1 263*1
1899*1 280*1
2404*1 293*1
Later Later
2575 295*1
Note : *1: Tentative values. Exact values will be furnished after finalization of TG contract *2: Bidder to indicate HEAT RELEASE RATE 13. 14. . VOLUMETRIC BASIS EFFECTIVE PROJECTED RADIANT SURFACE (EPRS) NET HEAT INPUT TO PLAN AREA (NHI /PA) BURNER ZONE GAS TEMP AT FURNACE OUTLET AT SGMCR FOR COAL kCal /m3/hr kCal/ m2/hr 100000
15. 16. 17.
kCal/ m2/hr kCal/ m2/hr

0
4.75X106 1.55X106 1100
RO
JOB NO. TCE -5103A
ISSUE NO R0
STEAM GENERATORS & AUXILIARIES DESIGN PARAMETERS OF SG AND AUXILIARIES UNITS 60 % TGMCR 4 80% TG MCR 5 100% TGMCR 6
SL. NO. 1
PARTICULARS
2 COMBUSTION AIR AND SITE DATA
TOP HEATER OUT OF SERVICE (100% TGMCR) 7
100% SG MCR 8
18.. 19. 20.
EXCESS AIR AT APH INLET AIR PREHEATER OUTLET TEMP UNBURNT COMBUSTIBLES AT ECONOMISER OUTLET AS % OF FLY ASH AMBIENT AIR TEMP. AND RELATIVE HUMIDITY ELEVATION ABOVE SEA LEVEL NOX EMISSION LIMITS FEED WATER pH DISSOLVED OXYGEN TOTAL DISSOLVED SOLIDS FUEL FOR STARTUP AND LOW LOADS
RO
%
0
20 140 3
21.
As per section B
22. 23. 24. 24.1 24.2 24.3 25.
As per section B < 200 gms/GJ of heat input
< ------------------------------ 8 - 9 PPM PPM
------------------------------ >
< ------------------------------0.007 ------------------------------ > Normal 0.5, Maximum during start-up / condenser leak 2.0 Fuel oil as per section B
JOB NO. TCE -5103A
ISSUE NO R0
STEAM GENERATORS & AUXILIARIES DESIGN PARAMETERS OF SG AND AUXILIARIES Coal as per section B
26.
MAIN FUEL
27. 27.1 27.2 27.3 27.4 27.5 27.6 27.7 27.8 27.9
CODES AND STANDARDS INDIAN BOILER REGULATIONS INTERNATIONAL ORGANISATION FOR STANDARDISATION AMERICAN SOCIETY FOR MECHANICAL ENGINEERS AMERICAN NATIONAL STANDARDS INSTITUTE AMERICAN NATIONAL STANDARDS INSTITUE AMERICAN WELDING SOCIETY TUBULAR EXCHANGE MANUFACTURERS ASSOCIATION HEAT EXCHANGE INSTITUTE HYDRAULIC INSTITUTE
27.10 ANSI / ASME POWER TEST CODE 27.11 DEUTSCHE INDUSTRIE NORMEN 27.12 OTHER ESTABLISHED NATIONAL OR INTERNATIONAL STANDARDS EQUAL OR SUPERIOR TO THE ABOVE TESTED STANDARDS.
NOTES 1.0 1.1 FOLLOWING SHALL BE NOTED FOR CALCULATING HEAT RELEASE RATES THE NET HEAT IS THE EFFECTIVE HEAT IN THE FURNACE. THIS SHALL BE CALCULATED ON THE BASIS OF THE GROSS HEATING VALUE (GHV) OF THE FUEL, CORRECTED BY SUBTRACTING RADIATION LOSS, UNBURNT COMBUSTIBLE LOSS, LATENT HEAT OF WATER IN THE FUEL AND ADDING THE SENSIBLE HEAT IN BOTH THE FUEL AND THE COMBUSTION AIR ABOVE SPECIFIED AMBIENT TEMPERATURE.
RO
JOB NO. TCE -5103A
ISSUE NO R0
STEAM GENERATORS & AUXILIARIES DESIGN PARAMETERS OF SG AND AUXILIARIES
1.2
FURNACE NET HEAT RELEASE ON EPRS BASIS SHALL BE OBTAINED BY DIVIDING NET HEAT BY EFFECTIVE PROJECTED RADIANT SURFACE (EPRS) OF THE FURNACE WHICH IS THE TOTAL ENVELOPE MULTIPLIED BY APPROPRIATE EFFECTIVENESS FACTOR FOR THE VARIOUS WALL SURFACES. THE METHOD THAT VENDOR USES TO CALCULATE FURNACE EFFECTIVE RADIANT SURFACE AREA SHALL BE CLEARLY STATED. PLAN AREA SHALL BE OBTAINED BY MULTIPLYING THE WIDTH WITH THE DEPTH OF THE FURNACE AS SHOWN IN SH. 1 OF 3 OF DATA SHEET B2 of Vol IIIA. BURNER ZONE HEAT RELEASE RATE SHALL BE OBTAINED BY DIVIDING NET HEAT BY 2 X (FURNACE WIDTH + FURNACE DEPTH) X BURNER ZONE HEIGHT WHERE BURNER ZONE HEIGHT IS EQUAL TO (VERTICAL DISTANCE BETWEEN TOP AND BOTTOM ROW BURNERS + 3 METERS). COLUMNS LEFT BLANK SHALL BE SHALL BE FILLED BY THE BIDDER
1.3 1.4 1.5
1.6
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A-C-510-01
STEAM GENERATORS & AUXILIARIES UTILITY REQUIREMENTS
SL. NO. 1.0 1.1 1.2 2.0 2.1 3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 4.2 4.3 4.4
DESCRIPTION AUXILIARY STEAM Pressure Temperature COMPRESSED AIR Pressure CONDENSER COOLING WATER Quality Temperature at condenser inlet for performance guarantee (average temperature) Minimum temperature at condenser inlet Maximum temperature at condenser inlet Temperature rise across condenser limited to AUX COOLING WATER Quality Pressure (Design) Temperature (Max.) Maximum allowable pressure drop across VENDORS terminal point
UNIT
VALUE
bar (a)
0
19 305
Kg/cm2 (a)
7-8
Sea water
0
As per Section B 33 28 34 10
C C C C
0 0 0
Passivated DM water Kg/cm2 (a)

0
10 37 1.5 *
Kg/cm2
NOTE :
* vendor to arrange booster pumps (2 x 100%) to augment the inlet pressure in case pressure drop is more than 1.5 bar
PPD. BY : CKD. BY : DATE : JOB NO. TCE -5103A CLIENT : APPDCL PROJECT: 2 X 800MW TPP NEAR KRISHNAPATNAM
RO
STEAM GENERATORS & AUXILIARIES STEAM GENERATOR PRESSURE PARTS SR.NO. ITEM UNITS VALUES
1.1 1.8
Type of Steam generator Explosion force / Implosion
Once through reheat, radiant, dry bottom, balanced draft, outdoor Maximum of ( 650 mm WC or Shut off head of the ID and FD fan at Test Block condition and ambient temperature) IBR and ASME or other reputed international codes Membrane Seamless spiral plus vertical, or vertical rifle tubes m/s 10 (Average gas velocity). Bidder to indicate maximum expected flue gas velocity Medium carbon steel High temp. above 565 oC : Bidder to indicate. High temp. above 400oC & up to & including 550 oC: Alloy steel to ASTM A 335/ASTM A 213, P-11/T-11, P-22/T-22, P91/T-91,P-92/T-92 OR approved equivalent Low temp. upto 400oC: Carbon steel to ASTM 106 Gr B/C or SA 210 C or approved equivalent.
1.10 1.17 1.18 1.19
Code Furnace tube arrangement Type of furnace tubes and header for pressure parts Flue gas velocity in SG convection/ second pass MATERIALS OF CONSTRUCTION Furnace wall/Economiser Super heater /Reheater
1.20 1.20.1 1.20.3
Note: Bidder shall use proven materials for high temperature SH and RH Tubes. 1.20.1 Inspection /Access doors Heat resistant without water cooling
RO
JOB NO. TCE -5103A
STEAM GENERATORS & AUXILIARIES SR.NO. 1.1 1.2 1.3 1.3.1 Type On load cleaning medium Off load cleaning medium Air preheater leakage ITEM REGENERATIVE AIR PREHEATER UNITS VALUES
Trisector ( 2 X 50 %) / Bisector Steam Water Shall not exceed 10 % of total air requirement.
1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.5 1.5.1 1.5.2 1.5.3
Accessories to be provided Auxiliary air motor Hand operated barring device Seal plate adjustment Air receiver Air supply to air receiver MATERIALS OF CONSTRUCTION Hot end elements Cold end elements Rotor and intermediate elements Carbon steel or equivalent Corten steel or equivalent Corrosion resistant low alloy steel Yes Yes Automatic and external Adequate for safe coasting down without external air supply From station service air system
PO
JOB NO. TCE -5103A
CLIENT : IFFCO PROJECT : 2 X 800MW TPP NEAR KRISHNAPATNAM
STEAM GENERATORS & AUXILIARIES CENTRIFUGAL FANS SR.NO. 1.1 Designation ITEM UNITS VALUES Induced draft fan (ID fan) with VFD & IGV or Bidder can also offer blade pitch controlled axial fan with proven experience Two(2)
1.2 1.3 a) b) c) 1.4 1.4.1 1.5 1.6 1.7 1.8 1.8.1 1.8.2 1.8.3 1.8.4 1.8.5 1.8.6 1.8.7
Number Design parameters Capacity Head Temperature Speed First critical speed Blade type Flow control Fan / motor bearings MATERIALS OF CONSTRUCTION Fan scroll Suction chamber Casing Shaft Sleeves Regulating vane Diffusers and dampers rpm rpm
With two fans operating, shall be able to meet 115% SGMCR flow 30% over 100% SGMCR requirement 150C above maximum flue gas temperature 750 At least 15% above normal speed Backward curved, aerofoil type Electric motor with variable frequency drive and inlet guide vane control. Self aligning
Lined with abrasion resistant material IS 1079 / 73 SH. 34 IS 2062 SAE 1045 forged normalised and tempered steel High grade Babbit IS 1079/73 IS 2062
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A-C510-01
VOLUME IIIA DATA SHEET A6 SHEET 1OF 1
STEAM GENERATORS & AUXILIARIES AXIAL FANS

SR.NO.
ITEM
Designation Number Location Type Design parameters
UNITS
FD fan, PA fan
VALUES
1.1 1.2 1.3 1.4 1.5
2x50% for each type Outdoor Axial blade pitch controlled With two fans operating, it shall be able to meet 115% SG MCR flow 30 % over100% SGMCR requirement for FD fan & PA fan. 50C above maximum ambient temperature Clean air RPM 1500 At least 15% above normal speed Variable blade pitch Hydraulic Self aligning
a) Capacity b) Head c) Temperature d) Fluid to be handled 1.6 1.6.1 1.5 1.6 1.7 1.8 1.8.1 1.8.2 1.8.3 Speed First critical speed Flow control Blade pitch variation system Fan / motor bearings MATERIALS OF CONSTRUCTION Impeller blade Impeller hub Shaft
Cast aluminium alloy Forged steel or fabricated steel SAE 1045 or equivalent forged normalised and tempered steel
RO
JOB NO. TCE -5103A
STEAM GENERATORS & AUXILIARIES SOOT BLOWING SYSTEM

SR.NO.
ITEM
UNITS
VALUES
1.1
Designation
Wall blowers, Rotary blowers, long retractable blowers, short retractable blowers and air preheater blowers. Superheated steam Dual electric drive for traverse and rotary motion Yes Yes
1.2 1.3 1.4 1.4.1 1.4.2 1.5 1.5.1
Cleaning medium Drive Accessories Required Emergency hand crank for every soot blower Facility to adjust angular travel of short retractable soot blower MATERIALS OF CONSTRUCTION Lance / swivel tube in high temp. area in intermediate temp area in low temp. area Nozzle Bearing (in high temp. area) Bearing (in intermediate temp. area) Bearing (in low temp. area) Blowing head Feed Tube
High temp. chrome steel Steel with chromium surface coating Carbon steel 2.5% chromium, 12% Ni stainless steel Chrome alloy steel Chrome cast iron Alloy Cast Iron or Steel Stainless steel 304 Stainless steel 304
1.5.2 1.5.3 1.5.4 1.5.5 1.5.6 1.5.7
RO
JOB NO. TCE -5103A
STEAM GENERATORS & AUXILIARIES COAL BURNERS

SR.NO.
ITEM
GENERAL Combustion air DESIGN DATA Turn down ratio Coal fineness Excess air Mode of adjustment of combustion air MATERIALS OF CONSTRUCTION Coal burner nozzle Guide plates
UNITS
VALUES
1.0 1.1 1.2 1.2.1 1.2.1 1.2.3 1.2.4 1.3 1.3.1 1.3.2
Secondary / primary
To match with coal mills 70% through 200 mesh 20% at APH inlet Air damper
High chrome heat resistant High chrome heat resistant
RO
JOB NO. TCE -5103A
STEAM GENERATORS & AUXILIARIES COAL MILLS

SR.NO.
ITEM
ITEM Coal mills UNITS
UNITS
VALUES Medium speed vertical spindle; N +1 with worst coal and N + 2 with design coal [ N number of mills in operation] Pressurised 70% through 200 mesh Bidder to indicate Required as per ISO / ASME. One working and one as standby. Required Required To meet NFPA requirement Gravimetric Required
SR.NO. 1.1
1.2 1.3 1.4 1.5
Mill inside condition Output fineness Minimum stable load without oil support Coal sampling device for sampling coal from coal mill discharge with rigid accessible platform. Sampling connection & cock on coal pipe to each burner Coal mill inerting system Coal mill system safety Coal feeder Reverse rotation facility for coal feeder for bunker emptying MATERIALS OF CONSTRUCTION Lube oil system Grinding ring/race Shaft Coupling Drive transmission Coal feed pipe from bunker to feeder Coal feed pipe from feeder to coal mill
1.6 1.7 1.8 1.9 1.10 1.11 1.11.1 1.11.2 1.11.3 1.11.4 1.11.5 1.11.6 1.11.7
Integral Segmental Coupled / monoblock / mfg. Std. Flexible gear Gear SS SS
RO
JOB NO. TCE -5103A
VOLUME IIIA DATA SHEETA10 SHEET 1 OF 1
STEAM GENERATORS & AUXILIARIES FUEL OIL BURNERS AND IGNITORS
SR.NO. 1.1 1.2 1.3 1.4 1.5 1.6 1.6.1 1.6.2 1.6.3 Designation Fuel oil
ITEM
UNITS
VALUES Start up / low load flame stabilisation Light diesel oil for start-up, heavy fuel oil for flame stabilisation 4:1 HEA Air for LDO, steam for HFO
Turndown ratio of fuel oil burners Igniters Atomising medium MATERIALS OF CONSTRUCTION Oil burner spray plate mixing plate Diffuser Nozzle cap
Alloy steel Alloy steel Alloy steel
RO
JOB NO. TCE -5103A
STEAM GENERATORS & AUXILIARIES FUEL OIL PUMP

SR.NO.
ITEM
Designation Number required (common for 2 units) Type of bearing Design motor size of the pumps LIQUID DATA Liquid pumped MATERIALS OF CONSTRUCTION Casing Rotor Shaft Base plate
UNITS
HFP Pump 3 x 100%
VALUES
LDO Pump 2 x 100 %
1.1 1.2 1.3 1.4 1.5 1.5.1 1.6 1.6.1 1.6.2 1.6.3 1.6.4
Antifriction heavy duty and external Based on highest viscosity of oil plus 15% as margin HFO LDO
-------------Fabricated steel------------------BS 970 EN 9 or equivalent-------------BS 970 EN 9 or equivalent---------------------Fab. Steel / CI--------------
RO
JOB NO. TCE -5103A
STEAM GENERATORS & AUXILIARIES ELECTROSTATIC PRECIPITATOR SR.NO. 1.1 1.2 1.3 1.4 1.4.1 1.4.4 ITEM Number required per steam generator Duty Location Design & Construction Requirements Number of Gas Streams Dust concentration at outlet of ESP with design and worst coal range. - with worst coal and all fields in service - with worst coal and one field out of service Bulk ash density For hopper capacity For hopper strength kg/m3 kg/m3 800 1600 Compatible with furnace design pressure Not less than 6 mm 8 hrs. (minimum) By Bidder UNITS one Continuous Between air-preheater and ID fan VALUES
mg/Nm3
50 (max.) 75 (max)
1.4.5 1.4.6
Casing design pressure 1.4.7 Thickness of steel sheet Storage capacity of dust hopper with worst coal firing (To be measured 600 mm below electrodes) Plate angle of dust hopper Thickness of collecting electrode plate 1.4.8 1.4.9 1.4.10 1.4.11 No. of ESPs per boiler Spacing between collecting electrodes Specific collection area Flue gas velocity within ESP Items to be Provided Inlet and outlet gas isolation dampers/ gates Fly ash hoppers with panel type heaters, level indicators, outlet flange poke holes, access doors etc.
REV.NO. DATE REV. BY RO PPD. BY : CKD. BY : DATE : JOB NO. TCE -5103A
mm
degrees
Not less than 70 Not less than 18 gauge 4 (Minimum) 300 (Minimum) > 200 Not more than 1 Yes Yes
mm m /m /s m/s
2 3
STEAM GENERATORS & AUXILIARIES ELECTROSTATIC PRECIPITATOR SR.NO. 1.4.12 ITEM Thermal insulation aluminium cladding Weather-proof enclosure for insulator compartment with heaters, air blowers, filters, controls etc. Provision of water washing system (offload) Test connections of std. size for measuring pressure, temperature, velocity, dust loading at inlet and outlet of precipitator Interior access walkways minimum of 600 mm wide, exterior platforms, staircase on both sides , ladder, access doors and galvanised hand rails of 40 mm pipe etc. Opacity monitor 1.5.6 Elevation of hopper outlet flange M UNITS Yes Yes VALUES
Yes Yes
Yes
Yes EL (+) 3.0
RO
JOB NO. TCE -5103A
STEAM GENERATORS & AUXILIARIES SPECIFIC TECH REQUIREMENT OF SG & AUX DUCT & DAMPERS
SR.NO.
ITEM
Dampers Numbers Application Duty Installation Gas handled DESIGN AND CONSTRUCTION REQUIREMENTS Isolation damper
UNITS
VALUES
1. 1.1 1.2 1.3 1.4 1.5 1.6 1.6.1
As per functional requirement Isolation / Control Intermittent / Continuous Outdoor Flue gas / cold air / hot air mixed with particulate matter
Zero leakage guillotine type - ESP inlet and outlet - ID fan inlet - GR fan inlet and outlet (if applicable) - RAPH inlet and outlet (flue gas side)
1.7 1.7.1 1.7.2 1.7.3 2. 2.1
MATERIALS OF CONSTRUCTION Dampers frame Blades Linkage bolts and pins Duct Flue gas velocity - Upstream of ESP - Downstream of ESP m/s Not to exceed 15 Not to exceed 20 Heavy structural steel channels or plates not less than 10 mm thick Not less than 10 mm thick made up of 2x 5 mm thick plates Stainless steel
RO
JOB NO. TCE -5103A

CHAIN PULLEY BLOCK (HAND OPERATED) SR.NO. ITEM UNITS VALUES
1.0 1.1 1.2 1.3 1.4 1.5 Type
DESIGN CONDITIONS Spur As per IS 3832 Steel Forged alloy or carbon steel as per IS : 2758 / IS : 2759 / IS 3832 As per IS 3109 / BS 1663 / BS 3114 / IS 6216 As per BS 590 To suit load chain To suit hand chain Not less than 5 Cut from cast or forged steel, Spur and helical as per BS 436 Worm as per BS 721 Friction disc type to sustain load at any working position Ball and / or roller Wrought iron / cast iron / low alloy steel
Pulley block Frame made of Hook Load chain
1.6 1.7 1.8 1.9 1.10
Hand chain Load chain wheel Hand chain wheel Factor of safety Gears
1.11
Brake
1.12 1.13
Bearing Trolley wheels

RO

CHAIN PULLEY BLOCK (HAND OPERATED) SR.NO. 1.14 Lubrication ITEM UNITS VALUES Centralised grease lubrication with hand pump To be submitted for hook, chain, pulley block, etc. At works Yes At site Yes Yes
1.15
Material test certificates
1.16
Overload test with 150% of specified load Visual inspection and dimensional check
1.17
RO
JOB NO. TCE -5103A

ELECTRICALLY OPERATED HOISTS
SR.NO.
ITEM
DESIGN CONDITIONS Class of hoist Hoist speed Method of operation Speed control (hoist)
UNITS
VALUES
1.0 1.1 1.2 1.3 1.4
Class II, as per IS:807 2-3 m/min Pendant push button Single speed
1.5
MATERIALS OF CONSTRUCTION
1.5.1 1.5.2
Drums & sheave Hook
1.5.3 1.5.4 1.5.5 1.5.6
Bearing Shaft Wire rope Gear
Cast iron / cast steel / mild steel drum, grooving construction as per IS 3938 Forged alloy / carbon steel, as per IS 2758 / IS 2759 single hook provided with standard depress safety latch lock to prevent hook from swivelling Ball and / or roller Steel Construction 6 x 36 minimum ultimate strength 1.6 x 206 kN/m2 as per IS 2365 factor of safety as per IS 3938 Cut from cast / forged steel as per IS 436
1.5.7
Brake
Electro hydraulic type to hold 125% of the load torque

RO

SR.NO.
ITEM
UNITS
VALUES
1.5.8
Trolley
Gears and brakes same as for hoist
1.5.9
Lubrication
Centralised grease lubrication with hand pump
1.5.10
Trolley wheels
Heat treated carbon steel / low alloy steel / graded CI single flanged
1.6
Material test certificates
To be submitted for critical components such as hook, wire rope, drum, trolley, etc.
1.7
Overload test with 150% of specified load
At works : Yes At site : Yes
1.8
Visual inspection and dimensional check
Yes
1.9
Hoist motor shall be suitable for inching operation
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A
STEAM GENERATORS & AUXILIARIES POWER PLANT PIPING AND VALVES
SPECIFIC REQUIREMENTS FOR PIPING

SL. NO. 1.1 SERVICE STEAM TEMP. 550C AND ABOVE UPTO O 600 C SIZE NB 65MM & ABOVE PIPES ASTM A335 - P91 FITTINGS ASTM A234 WP91 FLANGES ASTM A182 F91 GASKETS SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 SPIRAL WOUND SS 316 GRAFOIL LINE JOINT BUTT WELDED
NB 50MM & BELOW 1.2 STEAM TEMP. ABOVE 510C AND UPTO 549C NB 65MM & ABOVE NB 50MM & BELOW 1.3 STEAM TEMP. 400C TO 510C NB 65MM & ABOVE NB 50MM & BELOW 1.4 STEAM BELOW 400C NB 65MM & ABOVE NB 50MM & BELOW NB 65MM & ABOVE NB 50MM & BELOW NB 65MM & ABOVE
ASTM A335 - P91 ASTM A335 - P22 ASTM A335 - P22 ASTM A335 - P11 ASTM A335 - P11 ASTM A106 Gr.B ASTM A106 Gr. B ASTM A106 Gr. C/B ASTM A106 Gr. C/B ASTM A106 Gr. B
ASTM A182 F91 ASTM A234 WP22 ASTM A182 F22 ASTM A234 - WP11 ASTM A182 - F11 ASTM A234 WPB ASTM A105
ASTM A182 F91 ASTM A182 F22 ASTM A182 F22 ASTM A182 - F11 ASTM A182 - F11 ASTM A105 ASTM A105
SOCKET WELDED BUTT WELDED SOCKET WELDED BUTT WELDED SOCKET WELDED BUTT WELDED SOCKET WELDED BUTT WELDED SOCKET WELDED BUTT WELDED
1.5
FEED WATER / CONDENSATE
ASTM A234 WPC / WPB ASTM A105 ASTM A234 - WPB
ASTM A105
ASTM A105 ASTM A105
1.6
LUBE OIL AND CONTROL / HYDRAULIC OIL (UPSTREAM OF FILTER)
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A

NB 50MM & BELOW NB 65MM & ABOVE ASTM A106 Gr.B ASTM A 312 TP 316 (SEAM LESS) ASTM A105 ASTM A 403 GR. WP316 ASTM A105 ASTM A182 F316 GRAFOIL GRAFOIL SOCKET WELDED BUTT WELDED
1.7
LUBE OIL & CONTROL / HYDRAULIC OIL (BEYOND FILTER)
NB50MM & BELOW 1.8 DEMINERALI-SED WATER NB 65MM TO 150
ASTM A 312 TP 316 (SEAM LESS) ERW, BLACK, IS 1239 (PT-1) Heavy class Rubber lined IS 1978 ERW OR API 5L GR.B Rubber lined ASTM A312 TP 304(ERW)
ASTM A 403 GR. WP316 ASTM A 234 GR. WPB RUBBER LINED
ASTM A182 F316 ASTM A 105 RUBBER LINED
GRAFOIL
SOCKET WELDED FLANGED
GRAFOIL
200 T0 350 NB 50MM & BELOW
A 182-F304
ASTM A 182 F304
GRAFOIL
SOCKET WELDED
1.9
AUXILIARY COOLING WATER (PASSIVATED DM WATER), SERVICE WATER SYSTEM (FRESH WATER APPLICATION), SERVICE AIR SYSTEM
NB 150
65 TO
ERW, BLACK IS 1239 Heavy class (PT-1) ERW, IS 1978 (OR) API 5L GR. B (OR) IS 3589 FABRICATED FROM IS 2062
ASTM A234 Gr.WPB
200 TO 450
ASTM A105 (A283GR-C FOR ABOVE NB 200 MM)
GRAFOIL
BUTT WELDED
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A

SL. NO. SERVICE SIZE 500 & ABOVE PIPES IS 3589 FABRICATED FROM IS 2062 PLATES ERW, BLACK, IS 1239 (PT-1) ERW, BLACK IS 1239 Heavy class (PT-1) Rubber Lined (5 mm thk) ERW, IS 1978 (OR) API 5L GR. B (OR) IS 3589 FABRICATED FROM IS 2062 Rubber Lined (5 mm thk) IS 3589 FABRICATED FROM IS 2062 PLATES Gunited with cement mortar ASTM A312 TP 304 (ERW) A 182-F304 ASTM A 182 F304 GRAFOIL SOCKET WELDED ASTM A105 ASTM A105 GRAFOIL SOCKET WELDED FLANGED FITTINGS FLANGES GASKETS LINE JOINT
NB 50 MM & BELOW 1.10 SEA WATER CONDEN SER COOLING WATER, AUXILIAR Y COOLING WATER (SECOND ARY CIRCUIT) NB 65 TO 150
ASTM A234 Gr.WPB Rubber Lined (5 mm thk)
NB 200 TO 800
ASTM A105 (A283GR-C FOR ABOVE NB 200 MM) Rubber Lined (5 mm thk)
GRAFOIL
NB 900 & ABOVE
NB 50MM & BELOW
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A

SL. NO. 1.11 SERVICE POTABLE WATER SYSTEM/ INSTRUME NT AIR SERVICE SIZE NB 65 TO 150 PIPES ERW, BLACK, IS 1239 Heavy class (PT-1), GALVANISED FITTINGS ASTM A234 Gr.WPB GALVANISED FLANGES ASTM A105 GALVANISED GASKETS GRAFOIL LINE JOINT FLANGED
200 NB TO 450
IS 1978, ERW(OR) API 5L GR.B (OR) IS 3589 FABRICATED FROM IS 2062 PLATES (A LL GALVANISED) ERW, BLACK, IS 1239 (PT-1), GALVANISED ASTM A 106 Gr. B ASTM A105 GALVANISED ASTM A 234 WPB ASTM A105 GALVANISED ASTM A105 GRAFOIL SCREWED
NB 50 MM & BELOW 1.12 LIGHT DIESEL OIL (LDO) / HEAVY FURNACE OIL (HFO) / HIGH SPEED DIESEL (HSD) NB 65MM & ABOVE (SEAM LESS)
TEFLON
BUTT WELDED
NB50MM & BELOW (SEAM LESS)
ASTM A 106 Gr. B
ASTM A 105
ASTM A105
TEFLON
SOCKET WELDED
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A
1. All mandatory tests shall be carried out as per ASME Boiler & Pressure Vessel Code ASME Section-II, 2. Each length of pipe shall be hydro-tested at shop as per the Codes/Standards. 3. Blind flanges on SS Pipe lines shall be to ASTM A 240-TP 316. Stub ends shall be used at flanged connections. 4. All branch connections shall be wrought (seamless) or forged steel based on the size and availability based on ASTM Standards. 5. Piping System under Sl. No.1.1, 1.2 ,1.3 & 1.4 shall have IBR Approval. Boiler feed discharge under item no.1.5 shall also be under IBR Approval. 6. All painting with primer coats (2 coats each) shall be provided for the piping and all hangers. 7. IS 1239, pipes
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A
SPECIFIC REQUIREMENT FOR VALVES
SL. NO. 1
SERVICE STEAM LINES O (TEMP >550 C O AND <600 C)
SIZE >65NB
BODY/ BONNET ASTM A217 C-12 ASTM A182 Gr.F-91 ASTM A217 WC-9 ASTM A182 Gr.F-22 ASTM A217 WC-6 ASTM A182 Gr.F-11 ASTM A216 Gr WCB ASTM A105
DISC ASTM A217 C-12 ASTM A182 Gr F91 ASTM A217 WC-9 ASTM A182 Gr F22 ASTM A217 WC-6 ASTM A182 Gr F11 ASTM A216 Gr WCB ASTM A182 Gr F6a
STEM ASTM A182 Gr. F6a ASTM A182 Gr.F6a ASTM A182 Gr. F6a ASTM A182 Gr.F6a ASTM A182 Gr. F6a ASTM A182 Gr.F6a ASTM A182 Gr F6a ASTM A182 Gr F6a
HAND WHEEL ASTM A47 G Gr. 32510 ASTM A97 Gr.32510 ASTM A47 G Gr. 32510 ASTM A97 Gr.32510 ASTM A47 G Gr. 32510 ASTM A97 Gr.32510 ASTM A47 Gr 32510 ASTM A47 Gr 32510
VALVE ENDS BUTT WELDED. SOCKET WELDED BUTT WELDED. SOCKET WELDED BUTT WELDED. SOCKET WELDED BUTT WELDED SOCKET WELDED
< 50 NB 2 STEAM LINES O (TEMP >510 C O AND <550 C) >65NB
< 50 NB 3 STEAM LINES O (TEMP>400 C O AND <510 C) >65NB
< 50 NB 4 STEAM LINES O (TEMP<400 C), CONDENSATE BLOW DOWN, BOILER FEED SUCTION LINE >65NB
< 50 NB
RO
JOB NO. TCE -5103A
SPEC NO. TCE-5103A

5 BOILER FEED DISCHARGE & RECIRCULATION SYSTEMS > 65 ASTM A 216 Gr. WCB/C ASTM A 105 ASTM A216 Gr WCB ASTM A105 SS 410 ASTM A 216 Gr. WCB/C ASTM A 182 Gr. F6a ASTM A216 Gr WCB ASTM A479 Type 410-2 SS 410 ASTM A 182 Gr. F6a ASTM A 182 Gr. F6a ASTM A479 Type 410-2 ASTM A479 Type 410-2 SS 410 ASTM A 47 Gr. 32510 ASTM A 47 Gr. 32510 ASTM A47 Gr 32510 ASTM A47 Gr 32510 ASTM A47 GR. 32510 ASTM A47 GR. 32510 ASTM A47 GR. 32510 BUTT WELDED SOCKET WELDED BUTT WELDED SOCKET WELDED BUTT WELDED SOCKET WELDED FLANGED FLAT FACE
< 50
6.
LUBE OIL, SLUDGE, OILY WATER DRAINS (UPTO FILTER)
>65NB
< 50 NB >65NB
7.
LUBE OIL & CONTROL OIL / HYDRAULIC OIL (BEYOND FILTER) CONDENSER COOLING WATER, AUXILIARY COOLING WATER, POTABLE WATER
<50NB >65
SS410 A126 CLASS B
SS 410 A126 CLASS B
SS 410 ASTM B 124 C 37700
8.
< 50
ASTM B62
ASTM B62
ASTM B 312 GR.A
ASTM A47 GR. 32510
SCREWED TYPE
RO
JOB NO. TCE -5103A

9 INSTRUMENT AIR >65NB ASTM A 216 GR.WCB ASTM A 105 ASTM A 126 CLASS B RUBBER LINED ASTM A 182 F316L ASTM A 216 GR. WCB 13% Cr Steel (Ball) ASTM A 126 CLASS B RUBBER LINED ASTM A479 Type 410-2 ASTM A479 Type 410-2 ASTM A47 Gr 32510 ASTM A47 Gr 32510 ASTM A47 Gr 32510 FLANGED RAISED FACE SCREWED TYPE FLANGED RAISED FACE
< 50 NB
ASTM A479 Type 410-2 ASTM A479 Type 410-2
10
DM WATER
>65NB
< 50 NB
ASTM A479 Type 410-2
ASTM A47 Gr 32510
SCREWED TYPE
RO
JOB NO. TCE -5103A
STEAM GENERATORS & AUXILIARIES POWER PLANT PIPING AND VALVES NOTES: 1. Testing of body, seat and back seat shall be as per ANSI B16.34
2. For water system covered under sl.no.8 for sizes 150NB and above and sl.no.10 for sizes 65NB and above, butterfly valves shall be used and shall conform to AWWA C-504. 3. Ball valves or plug valves shall be provided for oil systems. 4. All shut off valves on oil system shall have leakage ANSI B 16.104 class VI. 5. Ball valves shall be used for instrument air system up to 50NB size. 6. IBR approval for valves shall be included wherever applicable
RO
JOB NO. TCE -5103A
ISSUE NO RO
SPEC NO
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 2X 800 MW TPP NEAR KRISHNAPATNAM
VOLUME III A
TCE.5103A-C-50001
SPECIFIC TECH REQUIREMENT OF SG & AUX STRAINERS
DATA SHEET A17 SHEET 1 OF 2
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0
Tag Number Quantity Required Location Type Fluid Flow rate, kg/hr Operating pressure Kg/cm2 (g) Operating temperature 0C Design pressure Kg/cm2 (g) Design temperature 0C Fluid viscosity cP at Op. temp Fluid Sp. gravity at Op. temp. Max. permissible Pr. Drop at 50% clogging Screen / basket data (i) CA of perforations (ii) Min. Thickness mm (iii) Free straining area Steam jacket (a) Inlet pr. Kg/cm2(g) Op. / Desn. (b) Inlet temp. 0C Op. / Desn. End connections (a) Size NB mm (b) Type (c) Details / Standards Cover (a) Body (b) Cover (c) Screen basket (d) Bolts / Studs (e) Nuts (f) Gaskets ACCESSORIES BY VENDOR (a) (b) (c) For Bolts Diff. Pressure gauge Drain / Vent cock (Forged Steel)
2
Lube Oil & Fuel oil * * Duplex Lube oil * * * * * * * * * 1.5 4 times pipe cross sectional area. No
DESIGN DATA
15.0
16.0
MATERIAL
17.0 18.0
* Welded ANSI B 16.25 Quick opng./ Bolted Cast carbon steel ASTM A 216 Gr. B - do Stainless steel ASTM A 193 Gr. B7 ASTM A 194 Gr 2H Red rubber Full face wire inserted Yes Yes Yes * No Yes
CLIENT : APPDCL. PROJECT : 2x800MW TPP, KRISHNAPATNAM TCE FORM 330 R1
19.0
20.0
21.0 22.0
REV. NO. DATE REV. BY
Hydro static test Pr. Kg/cm (a) Shell side (b) Jacket side Vacuum test required Press. drop test required clean/50% clogged
PPD. BY CKD. BY JOB NO. 5103A
SPEC NO.
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD 2X 800 MW TPP NEAR KRISHNAPATNAM
VOLUME IV A
TCE.5103A-C-50001
SPECIFIC TECH REQUIREMENT OF STG & AUX STRAINER
1. 2. 3. 4. 5. 6. 7.
Duplex Filter shall be provided with Valves with a single handle or interlink so as to operate simultaneously. External valve position indicator shall be provided to indicate strainer housing in use. Strainer parts shall be replaceable without removing strainer housing from the line. Strainer housing covers shall be provided with Davit arm. Provision for equalising the pressure in standby housing before switching over should be provided. Acceptable leakage rates : NIL Strainers shall be skid mounted. VENDOR to furnish information in blank spaces
PPD. BY CKD. BY
JOB NO. 5103A
SPEC. NO.
VOLUME IV A
TCE.5103A-C-500-01
SPECIFIC TECH REQUIREMENT OF SG & AUX SHELL & TUBE HEAT EXCHANGER
DATA SHEET A 18 SHEET 1 OF 2
SL. NO. 1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Designation Capacity
ITEMS
UNITS By Bidder
VALUES 2 X 100% FOR EACH EQUIPMENT MATERIAL IS-2002 GR. 2A/SA-285 GR. C/OR EQUAL IS-2002 GR. 2A/SA-285 GR. C/OR EQUAL, SA 181 GR 1/OR EQ. IS-2002 GR. 2A/SA-285 GR. C/OR EQUAL. IS-2002 GR. 2A/SA-285 GR. C/ IS 1875 CL. B/ SA 181 GR 1/OR EQ. IS-1978 ST 25/SA-53 GR. B/OR EQUAL. IS-2002 GR. 2A/IS-1875 CL. B/SA 285 GR C/SA 181 GR 1/OR EQUAL IS-2002 GR. 2A/SA-285 GR. C/ OR EQUAL IS-2002 GR. 2A/IS 1875 GR B/ SA 285 GR C/SA 181 GR 1 OR EQUAL IS-2002 GR. 2A/IS-1875 GR B/ SA 285 GR. C/SA 181 GR. 1/OR EQUAL IS-1978 ST 25/SA-53 GR B/OR EQUAL IS-2002 GR 2A/IS 1875 GR B/SA 285 GR C/SA 181 GR 1/OR EQUAL SA-179/BS-3059 CDS 33/OR EQUAL
MATERIALS OF CONSTRUCTION COMPONENT Shell Shell Flanges Shell Cover Shell Cover Flange Shell Nozzles Shell Nozzles Flanges Channels Channel / Flanges Channel Cover Flange
3.10 3.11 3.12 3.13 3.14
Channel Nozzles Channel Nozzle Flanges Tubes Tube Sheets : i) Stationary ii) Floating Baffles : i) Longitudinal ii) Cross
IS-2002 GR 2A/IS-1875 GR B/SA 285 GR C/SA 181 GR 1/OR EQUAL. COMMERCIAL QUALITY STEEL COMMERCIAL QUALITY STEEL
JOB NO. 5103A CLIENT : APPDCL. PROJECT : 2x800MW TPP, KRISHNAPATNAM TCE FORM 330 R1
PPD. BY CKD. BY
SPEC. NO.
VOLUME IV A
TCE.5103A-C-500-01
SPECIFIC TECH REQUIREMENT OF SG & AUX SHELL & TUBE HEAT EXCHANGER
DATA SHEET A 18 SHEET 2 OF 2
3.15 3.16 SL. NO. 3.17 3.18 3.19 3.20 3.21 3.22 3.22.1 3.22.2 3.22.3 3.22.4 3.22.5 3.22.6 3.23 3.24
Support Plates Pass Partition ITEMS Impingement Plate Tie Rods Spacers Floating Tube Sheet Joint All Other Shell Side Joints Gaskets Shell Cover Channel Cover Fixed Tube Sheets Shell Side Fixed Tube Sheets Channel Side Floating Tube Sheet Shell Side Floating Tube Sheet Channel Side Saddle Supports / Brackets Jack Screws UNITS
COMMERCIAL QUALITY STEEL COMMERCIAL QUALITY STEEL VALUES COMMERCIAL QUALITY STEEL COMMERCIAL QUALITY STEEL COMMERCIAL QUALITY STEEL IS-1367-8.8, EN 24 T : SA 193-B-7STUDS IS-1367-B, EN 8 : SA 194-2H NUTS
ANNEALED STEEL JACKETTED COMP ASI ANNEALED STEEL JACKETTED COMP ASI COMP ASB ANNEALED STEEL JACKETTED COMP. ASB ANNEALED STEEL JACKETTED COMP. ASB ANNEALED STEEL JACKETTED COMP. ASB COMMERCIAL QUALITY STEEL MILD STEEL SA 193 B7 : IS-1367B, 8.8 : EN 24 T OR EQUAL
PPD. BY CKD. BY
JOB NO. 5103A
SPEC.NO
ISSUE NO R0
TCE.5103A-C-500-001
SPEC TECH REQUIREMENTS FOR SG & AUX THERMAL INSULATION FOR HOT SURFACES ITEMS UNITS
SL. NO. 1.0 1.2 2.0 3.0 3.1
VALUES Lightly bonded mineral wool / preformed calcium silicate All equipment as applicable except steam turbine No Aluminium as per IS737 31000, Gr.H3 i) Insulation outside dia above 450mm Sheet thickness 20 SWG. ii) Insulation outside dia 150 to 450mm Sheet thickness 22 SWG. iii) Insulation outside dia below 150mm Sheet thickness 24 SWG. i) Flues & ducts Sheet thickness 1.0mm ii) SG casing & rear wall enclosure Sheet thickness 1.6mm.
Insulation Material for Equipment Finishing Cement Sheathing Material For pipes
3.2
For Equipment
4.0
Design thicknes is / should be based on : a) b) Station ambient temperature Outer surface temperature on surface of sheathing Deg.C Deg.C 30 60 under still air condition Yes / (Refer sheet 2 of 2) IS 8183 IS 14164 BS 5970 IS-8154, BS 3958
5.0 7.0
Recommended thickness furnished (Applicable for calcium silicate also) Codes & Standards
8.0
Notes : 1. For insulation thickness calculation maximum thermal conductivity indicated in relevant BIS shall be considered
SPEC.NO TCE.5103A
VOLUME IIIA
THERMAL INSULATION FOR HOT SURFACES
Temp (0C) Pipe Dia

15 mm (1/2) 20 mm (3/4) 25 mm (1) 32 mm (1- /4) 40mm (1- /2) 50mm (2) 80mm (3) 100mm (4) 150mm (6) 200mm (8) 250mm (10) 300mm (12) 350mm (14) 400mm (16) 450mm (18) 500mm (20) 600mm (24) 625mm (25) 650mm (26) 700mm (28) 800mm (32) 900mm (36) 950mm (38) 1000mm (40) & above flat Surfaces
1 1
51 100
101150
151200
201250
251300
301350
351400
401450
451500
501550
551575
INSULATION THICKNESS IN mm. 25 25 25 25 25 25 25 40 40 40 40 40 50 50 50 50 50 50 50 50 50 50 50 50 25 25 40 40 40 40 40 50 50 50 50 50 65 65 65 65 65 65 65 65 65 65 65 65 40 40 40 40 40 40 50 50 50 50 50 65 75 75 75 75 75 75 75 75 75 75 75 75 40 50 50 50 50 50 50 65 65 65 65 75 75 75 75 100 100 100 100 100 100 100 100 100 50 50 65 65 65 65 80 80 80 80 90 90 90 90 90 115 115 115 115 115 115 115 115 115 65 65 80 80 80 80 90 90 100 100 115 115 115 115 115 115 115 115 115 115 125 125 125 140 80 80 90 90 90 100 100 115 115 125 125 140 140 140 140 140 140 140 150 150 150 150 150 170 90 90 100 100 115 115 125 125 140 140 150 150 165 165 165 165 175 175 175 175 175 175 175 215 100 100 115 115 125 125 140 150 165 165 175 190 190 190 190 200 200 200 200 215 215 215 215 250 115 125 125 140 140 150 165 165 190 190 200 215 215 215 225 225 240 240 240 240 240 240 240 300 125 125 140 140 150 165 170 190 200 215 215 225 225 240 240 240 250 250 250 300 300 300 300 350
Insulation thicknesses are calculated considering aluminium sheathing for the ambient temperature of 300C. The above values hold good for mineral wool insulating material only having the following densities. (a) (b) Temperature upto and including 4000C Temperature above 4000C 100 Kg/m3 150 Kg/m3
SPEC NO.
VOLUME III A DATA SHEETA20 SHEET 1 OF 1
TCE.5103A-C-510-01
SPECIFIC TECH REQUIREMENT OF SG & AUX FLASH TANKS

ITEMS UNITS
SL.NO. 1.0 1.1 1.2 2.0 2.1 2.2 2.3 2.4 2.5 3.0 GENERAL Number Location
VALUES FLASH TANK 1 Outdoor
DESIGN DATA Operating pressure Design pressure Operating temperature Design temperature Corrosion allowances MATERIALS OF CONSTRUCTION Shell and head Internal piping --------------Carbon steel------------------------ASTM-A106-Gr.B-------------------------ASTM-A106-Gr.B----------Kg/cm2(a) Kg/cm2(a)
o
Bidder to indicate * * * --------------3 (min.) --------------
C C
mm
3.1 3.2
3.3
Nozzle Note : * BIDDER to indicate
PPD. BY CKD. BY DATE
JOB NO. 5103A
CLIENT : APPDCL PROJECT: 2x800MW TPP, KRISHNAPATNAM FORM 330 R1
ISSUE NO. R8
SPECIFICATION No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED SECTION IIIA 2X 800 MW TPP NEAR KRISHNAPATNAM DATASHEET A21 TCE. M4-203-01 INDUCTION MOTORS SHEET 1 OF 5
SL.NO. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 GENERAL
DESCRIPTION
UNIT
TECHNICAL PARTICULARS
APPLICATION NUMBER OF UNITS TYPE OF MOTOR SUPPLY SYSTEM FAULT LEVEL SUPPLY NEUTRAL TYPE OF EARTHING COMPLIANCE WITH TCE.M4203-02 IS REQUIRED IF YES CLAUSES OF TCE.M4-203-02 WHICH ARE NOT APPLICABLE: RATING RATED OUTPUT: RATED VOLTAGE: NUMBER OF PHASES & FREQUENCY SUPPLY CONDITION (REF. CL.NO.4.1 OF TCE.M4203-01) SYNCHRONOUS SPEED DUTY TYPE OF DUTY (CLAUSE 9.2 OF IS:325 OR EQUIVALENT) POWER REQUIRED BY LOAD kW RPM kW V YES/NO MVA SQUIRREL CAGE/ WOUND ROTOR
2.0 2.1 2.2 2.3 2.4
I/II
2.5 3.0 3.1 3.2
JOB NO.
CLIENT
: APPDCL
TCE.5103A PROJECT : 2X800 MW TPP TCE.FORM NO.330R1
ISSUE NO. R8
SPECIFICATION No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED SECTION IIIA 2X 800 MW TPP NEAR KRISHNAPATNAM DATASHEET A21 TCE. M4-203-01
SL.NO. DESCRIPTION
INDUCTION MOTORS
UNIT
SHEET 2 OF 5
4.0
METHOD OF STARTING
D.O.L./STAR DELTA/ OTHER
5.0 5.1 5.2 5.3 5.3.1 5.3.2 6.0 6.1 6.2 6.3 7.0 7.1 7.2
INSULATION CLASS OF INSULATION REF. AMBIENT TEMPERATURE TEMPERATURE RISE OF WINDING BY THERMOMETER METHOD BY WDG RESISTANCE METHOD INSTALLATION LOCATION HAZARDOUS AREA DIVISION (IS: 5572 OR EQUIVALENT) ATMOSPHERE ENCLOSURE TYPE OF COOLING (IS 6362) DESIGNATION FOR DEGREE OF PROTECTION (IS 4691) CHEMICAL/DUSTY/SALT LADEN Indoor/Outdoor deg. C deg. C deg. C
8.0 8.1 8.2
MAIN TERMINAL BOX LOCATION AS SEEN FROM NONDRIVE END: RATINGS (a) SHORT TIME i. CURRENT : ii. DURATION: (b) DYNAMIC : kA (RMS) SECS. kA (PEAK) RIGHT/LEFT
0.25
JOB NO.
CLIENT
: APPDCL
ISSUE NO. R8
SL.NO. 8.3 8.3.1 8.3. 2 8.4 8.4.1 8.4.2 9.0 9.1 9.2
DESCRIPTION EXTERNAL CABLE DETAILS TYPE SIZE & NO OF CORES
UNIT
EARTHING CONDUCTORS MATERIAL SIZE MISCELLANEOUS REQUIREMENTS SHAFT ORIENTATION MOUNTING SYMBOL (IS: 2253 OR EQUIVALENT) TO BE FILLED IF MOTORS ARE BOUGHT SEPERATELY HORIZONTAL/VERTICAL/ HOLLOW VERTICAL
9.5
ROTATION AS SEEN FROM NON-DRIVE END TYPE OF BEARING DRIVE END NON DRIVE END WHETHER BED PLATE REQUIRED COLOUR SHADES OF PAINT WHETHER CTs FOR DIFFERENTIAL PROTECTION REQUIRED FOR MOTORS >1000 kW
CLOCKWISE/ANTI-CLOCKWISE
9.6 9.6.1 9.6.2 9.7 9.9 9.10
YES/NO
YES/NO
JOB NO.
CLIENT
: APPDCL
ISSUE NO. R8
SL.NO.
DESCRIPTION
UNIT
9.10.1
C.T. PARTICULARS: a) 3 CTs, ONE IN THE NEUTRAL LEAD OF EACH PHASE b) RATIO c) CLASS d) KNEE POINT VOLTAGE e) MAX. R.C.T. SECONDARY WINDING RESISTANCE f) MAX. EXCITING CURRENT AT 1/2 KPV g) CLASS OF INSULATION PS KPV OHMS
9.11
WHETHER VIBRATION PADS REQUIRED TEMPERATURE DETECTORS/ INDICATORS EMBEDDED TEMPERATURE DETECTORS FOR WINDING REQUIRED EMBEDDED TEMPERATURE DETECTORS FOR BEARINGS REQUIRED BEARING THERMOMETERS FOR DRIVING END & NON DRIVING ENDS REQUIRED
YES/NO
9.12 9.12.1
YES/NO
9.12.2
YES/NO
9.12.3
YES/NO
9.13
SPACE HEATERS FOR MOTORS REQUIRED
YES/NO
JOB NO.
CLIENT
: APPDCL
ISSUE NO. R8
NOTES
DRAWINGS SHOULD BE SUBMITTED FOR REVIEW AS FOLLOWS: 1) 2) GENERAL ARRANGEMENT WITHIN ___ WEEKS AFTER AWARD OF CONTRACT DETAILS MARKED THUS (*) WILL BE DECIDED AND INTIMATED BY THE BIDDER BASED ON DRIVEN EQUIPMENT CHARACTERISTICS.
JOB NO.
CLIENT
: APPDCL
SPEC. No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED TCE. M4-203-01 DATA SHEET-A21 INDUCTION MOTORS
SL.NO. BRIEF TITLE
SECTION IIIA SHEET 1 OF 2
REFERENCE NUMBER OF STANDARDS
1. 2. 3. 4. 5.
THREE PHASE INDUCTION MOTORS ROTATING ELECTRICAL MACHINES SINGLE PHASE INDUCTION MOTORS CODE OF PRACTICE FOR CLIMATE PROOFING DESIGNATIONS FOR TYPES OF CONSTRUCTION AND MOUNTING ARRANGEMENT OF ROTATING ELECTRICAL MACHINES TERMINAL MARKING & DIRECTION OF ROTATION FOR ROTATING ELECTRICAL MACHINERY DESIGNATION OF METHODS OF COOLING FOR ROTATING ELECTRICAL MACHINES DEGREES OF PROTECTION PROVIDED BY ENCLOSURE FOR ROTATING ELECTRICAL MACHINERY GUIDE FOR TESTING THREE PHASE INDUCTION MOTORS MEASUREMENT AND EVALUATION OF VIBRATION OF ROTATING ELECTRICAL MACHINES CLASSIFICATION OF HAZARDOUS AREAS FOR ELECTRICAL INSTALLATION DIMENSIONS OF SLIDE RAILS FOR ELECTRIC MOTORS PERMISSIBLE LIMITS OF NOISE LEVEL FOR ROTATING ELECTRICAL MACHINES GUIDE FOR TESTING INSULATION RESISTANCE OF ROTATING MACHINES
IS-325 IS-4722 IS-996 IS IS-2253
BS-4999 BS BS BS-6751 BS
IEC-34 IEC IEC IEC IEC-34-7
6.
IS-4728
BS-4999 -108 BSEN 60034 -6-1994 BS-4999 -105 BS BS-4999 142 BS
IEC-34-8
7.
IS-6362
IEC-34-6
8.
IS-4691
IEC-34-5
9. 10.
IS-4029 IS-12075
IEC-34 IEC-34-14
11.
IS-5572
IEC-79
12. 13.
IS-2968 IS-12065
BS-4999 -141 BSEN 60034 -9-1994 BS
IEC IEC
14.
IS-7816
IEC
JOB NO.
CLIENT
: APPDCL
SPEC. No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED TCE. M4-203-01 DATA SHEET-A21 INDUCTION MOTORS
SL.NO. BRIEF TITLE
SECTION IIIA SHEET 2 OF 2
15.
TANGENT DELTA & DELTA TANGENT DELTA TEST IMPULSE VOLTAGE WITHSTAND TEST
IS-13508
BS
IEC
16.
IS IS-12802
BS BS
IEC-34-15 IEC
17.
TEMPERATURE RISE MEASUREMENT OF ROTATING ELECTRICAL MACHINES TYPE OF DUTY AND CLASSES OF RATING ASSIGNED TO ROTATING ELECTRICAL MACHINES CBIP RECOMMENDATION FOR MOTORS
18.
IS 12824
BS
IEC
19.
NOTES 1. 2. EQUIPMENT, ASSOCIATED ACCESSORIES, COMPONENTS/PARTS, TESTS SHALL IN GENERAL CONFORM TO IS BS IEC RAW MATERIAL AND
OFFERS CONFORMING TO OTHER AUTHORITATIVE STANDARDS MAY ALSO BE CONSIDERED/ MAY NOT BE CONSIDERED.
JOB NO.
CLIENT
: APPDCL
SPEC. No. TCE. M4-203-01
TCE CONSULTING ENGINEERS LIMITED DATA SHEET-A2 INDUCTION MOTORS
SECTION
SHEET 1 OF 2
JOB NO.
CLIENT
: APPDCL
ISSUE NO. R8
SPEC. No. TCE. M4-203-02 DATA SH A22
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED VOLUME IIIA 2X 800 MW TPP NEAR KRISHNAPATNAM
INDUCTION MOTORS - HT
DESCRIPTION UNIT TECHNICAL PARTICULARS
SHEET 1 OF 5
SL.NO.
1.0 1.1 1.2 1.3 1.4 1.5
GENERAL APPLICATION NUMBER OF UNITS TYPE OF MOTOR SUPPLY SYSTEM FAULT LEVEL SUPPLY NEUTRAL TYPE OF EARTHING MVA SQUIRREL CAGE BY PURCHASER MEDIUM RESISTANCE EARTHED WITH CURRENT LIMITED TO 400AMPS SG AUXILIARIES
2.0 2.1
RATING RATED OUTPUT : kW BY BIDDER
2.2 2.3 2.4
RATED VOLTAGE : NUMBER OF PHASES & FREQUENCY SUPPLY CONDITION (REF.
11000 3PH,50 HZ VOLTAGE VARIATION:+/- 10%, FREQUENCY VARIAITON:+/- 5% COMBINED VARIATION:10%
2.5 3.0 3.1 3.2
SYNCHRONOUS SPEED DUTY TYPE OF DUTY (CLAUSE 9.2 OF IS: 325 OR EQUIVALENT) POWER REQUIRED BY LOAD
RPM
S1 kW *
JOB NO. TCE. 5103A
CLIENT
: APPDCL
PROJECT : 2x800 MW THERMAL POWER PLANT TCE.FORM NO.330R1
ISSUE NO. R8
INDUCTION MOTORS - HT SHEET 2 OF 5
SL.NO. 4.0 5.0 5.1 5.2 5.3 5.3.1 5.3.2 6.0 6.1 6.2 6.3 7.0 7.1 7.2
DESCRIPTION METHOD OF STARTING INSULATION CLASS OF INSULATION REF. AMBIENT TEMPERATURE TEMPERATURE RISE OF WINDING BY THERMOMETER METHOD BY WDG RESISTANCE METHOD INSTALLATION LOCATION HAZARDOUS AREA DIVISION (IS:5572 OR EQUIVALENT) ATMOSPHERE ENCLOSURE TYPE OF COOLING (IS 6362) DESIGNATION FOR DEGREE OF PROTECTION (IS 4691)
UNIT D.O.L
CLASS-F deg. C 50
deg. C deg. C
N.A 70
INDOOR NON HAZARDOUS DUSTY
TETV/CACW /CACA IP-54
8.0 8.1 8.2
MAIN TERMINAL BOX LOCATION AS SEEN FROM NONDRIVE END: RATINGS (a) SHORT TIME i. CURRENT : ii. DURATION: (b) DYNAMIC : kA(RMS) SECS. kA(PEAK) 40 0.25 100 LEFT
JOB NO. TCE. 5103A
CLIENT
: APPDCL
ISSUE NO. R8
SL.NO.
DESCRIPTION
UNIT
8.3 8.3.1 8.3. 2 8.4 8.4.1 8.4.2 9.0 9.1 9.2
EXTERNAL CABLE DETAILS TYPE SIZE & NO OF CORES ALUMINUM COND.,XLPE INSULATED LATER
EARTHING CONDUCTORS MATERIAL SIZE MISCELLANEOUS REQUIREMENTS SHAFT ORIENTATION MOUNTING SYMBOL (IS:2253 OR EQUIVALENT) TO MATCH WITH THE PUMP * GS BY BIDDER
9.5
ROTATION AS SEEN FROM NON-DRIVE END TYPE OF BEARING DRIVE END NON DRIVE END WHETHER BED PLATE REQUIRED COLOUR SHADES OF PAINT WHETHER CTs FOR DIFFERENTIAL PROTECTION REQUIRED FOR MOTORS >1000 kW
TO MATCH WITH THE PUMP
9.6 9.6.1 9.6.2 9.7 9.9 9.10
* * * SHADE 631 OF IS-5
BY SWITCHGEAR VENDOR
JOB NO. TCE. 5103A
CLIENT
: APPDCL
ISSUE NO. R8
SL.NO. 9.10.1
DESCRIPTION C.T. PARTICULARS: a) 3 CTs, ONE IN THE NEUTRAL LEAD OF EACH PHASE b) RATIO c) CLASS d) KNEE POINT VOLTAGE e) MAX. R.C.T. SECONDARY WINDING RESISTANCE f) MAX. EXCITING CURRENT AT 1/2 KPV g) CLASS OF INSULATION
UNIT
LATER
PS KPV OHMS
9.11
WHETHER VIBRATION PADS REQUIRED TEMPERATURE DETECTORS/ INDICATORS EMBEDDED TEMPERATURE DETECTORS FOR WINDING REQUIRED EMBEDDED TEMPERATURE DETECTORS FOR BEARINGS REQUIRED BEARING THERMOMETERS FOR DRIVING END & NON DRIVING ENDS REQUIRED
YES
9.12 9.12.1
YES 6 NOS. DUPLEX/12 NOS. SIMPLEX (PRT-100) ONE NO.DUPLEX RTD (PRT-100) FOR EACH BEARING YES
9.12.2
9.12.3
9.13
SPACE HEATERS FOR MOTORS REQUIRED
YES
JOB NO. TCE. 5103A
CLIENT
: APPDCL
ISSUE NO. R8
NOTES
DRAWINGS SHOULD BE SUBMITTED FOR REVIEW AS FOLLOWS: 1) 2) 3) DETAILS MARKED THUS (*) WILL BE DECIDED AND INTIMATED BY THE BIDDER BASED ON DRIVEN EQUIPMENT CHARACTERISTICS. THE MAXIMUM NOISE LEVEL MEASURED AT A DISTANCE OF 1 M FROM THE OUTER SURFACE OF THE MOTOR SHALL NOT EXCEED 85 dB(A) VIBRATION PICKUP AND MONITOR SHALL BE PROVIDED AT BOTH DE AND NDE OF MOTOR AT BOTH X AND Y DIRECTION.
JOB NO. TCE. 5103A
CLIENT
: APPDCL
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED

VOLUME IIIA DATA SH A 22 SHEET 1 OF 2
SL.NO.
BRIEF TITLE
1. 2. 3. 4. 5.
THREE PHASE INDUCTION MOTORS ROTATING ELECTRICAL MACHINES SINGLE PHASE INDUCTION MOTORS CODE OF PRACTICE FOR CLIMATE PROOFING DESIGNATIONS FOR TYPES OF CONSTRUCTION AND MOUNTING ARRANGEMENT OF ROTATING ELECTRICAL MACHINES TERMINAL MARKING & DIRECTION OF ROTATION FOR ROTATING ELECTRICAL MACHINERY DESIGNATION OF METHODS OF COOLING FOR ROTATING ELECTRICAL MACHINES DEGREES OF PROTECTION PROVIDED BY ENCLOSURE FOR ROTATING ELECTRICAL MACHINERY GUIDE FOR TESTING THREE PHASE INDUCTION MOTORS MEASUREMENT AND EVALUATION OF VIBRATION OF ROTATING ELECTRICAL MACHINES CLASSIFICATION OF HAZARDOUS AREAS FOR ELECTRICAL INSTALLATION DIMENSIONS OF SLIDE RAILS FOR ELECTRIC MOTORS PERMISSIBLE LIMITS OF NOISE LEVEL FOR ROTATING ELECTRICAL MACHINES GUIDE FOR TESTING INSULATION RESISTANCE OF ROTATING MACHINES
IS-325 IS-4722 IS-996 IS IS-2253
BS-4999 BS BS BS-6751 BS
IEC-34 IEC IEC IEC IEC-34-7
6.
IS-4728
BS-4999 -108 BSEN 60034 -6-1994 BS-4999 -105 BS BS-4999 142 BS
IEC-34-8
7.
IS-6362
IEC-34-6
8.
IS-4691
IEC-34-5
9. 10.
IS-4029 IS-12075
IEC-34 IEC-34-14
11.
IS-5572
IEC-79
12. 13.
IS-2968 IS-12065
BS-4999 -141 BSEN 60034 -9-1994 BS
IEC IEC
14.
IS-7816
IEC
JOB NO. TCE. 5103A
CLIENT
: APPDCL

VOLUME IIIA DATA SH A 22 SHEET 2 OF 2
SL.NO. 15.
BRIEF TITLE TANGENT DELTA & DELTA TANGENT DELTA TEST IMPULSE VOLTAGE WITHSTAND TEST TEMPERATURE RISE MEASUREMENT OF ROTATING ELECTRICAL MACHINES TYPE OF DUTY AND CLASSES OF RATING ASSIGNED TO ROTATING ELECTRICAL MACHINES CBIP RECOMMENDATION FOR MOTORS
REFERENCE NUMBER OF STANDARDS IS-13508
BS
IEC
16. 17.
IS
IS-12802
BS BS
IEC-34-15
IEC
18.
IS 12824
BS
IEC
19.
NOTES 1. 2. EQUIPMENT, ASSOCIATED ACCESSORIES, COMPONENTS/PARTS, TESTS SHALL IN GENERAL CONFORM TO IS BS IEC OFFERS CONFORMING TO OTHER AUTHORITATIVE STANDARDS MAY RAW MATERIAL AND
ALSO BE CONSIDERED
JOB NO. TCE. 5103A
CLIENT
: APPDCL
ISSUE NO R7
SPECIFICATION NO.
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED 2X800 MW TPP NEAR KRISHNAPATNAM
VOLUME IIIA
TCE-M4-203-11
D.C. MOTORS
DATA SH A23 SHEET 1 OF 2
1.0 1.1 1.2 1.3 1.4
GENERAL Application Supply System Fault Level Type of Supply Earthing Supply Voltage Variation % of Rated Voltage kA SG AUXILIARIES 20 ( However will be confirmed during Detailed engineering) UNEARTHED +10%/-15%
2.0 2.1 3.0 3.1 4.0 4.1 4.2 5.0 5.1 6.0 6.1 6.2
RATING Rated Voltage DUTY Type of Duty STARTING Method of Starting Starting Current INSULATION Class of Insulation TERMINATIONS Terminal Box Rotation External Cable Details a) Armature b) Field c) Others AL conductor,XLPE insulated,Armoured 360 deg. in steps of 90 deg. CLASS-F Reduced Voltage Not greater than 2.5 times full load current CONTINUOUS V 220
6.3
Earthing Conductor a) b) Material Size mm GS By bidder
7.0 7.1 REV. NO. DATE REV. BY
INSTALLATION Location PPD. BY : CKD. BY : DATE : JOB NO. TCE. 5103A Indoor CLIENT : APPDCL PROJECT : 2x800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO R7
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-203-11
D.C. MOTORS
7.2
Hazardous Area Classification a) Division / Zone b) Gas Group IIA/IIB/IIC c) Temp. Classification T1 to T6
N.A
7.3 7.4 8.0 8.1 8.2 9.0 9.1 9.2 9.3
Atmosphere Treatment Against Corrosion Required ENCLOSURE Type of Enclosure Designation for Degree of Protection OTHERS Thermometer and Temperature Relay for Alarm Space Heaters Suitable for 1 ph, 240V, 50 Hz supply Paint Finish
Dusty No
TEFC IP-54
Required Required Grey Enamel Paint-shade 631 as per IS-5
9.4
a) Starter Panel b) Starter Control Wiring Diagram Enclosed (If Yes, mention drawing No.)
Required No
9.5 10.0 10.1 10.2
Field Rheostat as per Cl.11.0 of Sec.D TESTS Routine Tests Type Tests
Required
All tests as per Applicable Standards Not Reqd. Copy of Test certificates shall Be furnished
JOB NO. TCE. 5103A
CLIENT : APPDCL PROJECT : 2x800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO R7
SPECIFICATION NO. TCE-M4-203-11
IFFCO CHHATTISGARH POWER LIMITED (ICPL) 2X500/600 MW TPP NEAR PREMNAGAR, SARGUJA DIST
D.C. MOTORS
VOLUME IIIA DATA SH A22/2 SHEET 1 OF 1
1.0
APPLICABLE STANDARDS
1.1
Rotating Electrical Machines
IS 4722
BS-4999, BSEN-60034-1
IEC-60034
1.2
Vibrations
IS 12075
BS 4999-142
IEC-60034-14
1.3
Climate Proofing
IS
BS
1.4
Tests
IS 4722
BS 4999
IEC-60034
1.5
Degree of Protection
IS 4691
BS 4999-105
IEC-60034-5
1.6
Hazardous Area Classification
IS 5572
BSEN 60079 -10
IEC-60079-10
1.7
Mounting of Motors
IS 2253
BSEN-60034-7
IEC-60034-7
1.8
Terminal Markings
IS 4728
BS 4999-108
IEC-60034-8
1.9
Methods of Cooling
IS 4362
BSEN 60034 -6
IEC-60034-6
1.10
Flame Proof Enclosure
IS 2148
IEC-60079-1
1.11
Guide for selection of Electrical Equipment for Hazardous Areas
IS 5591
BSEN 60079
IEC-60079
2.0 2.1
NOTES Equipment, accessories, components/parts, raw materials and tests in general shall conform to IS JOB NO. TCE. 5103A BS CLIENT : APPDCL PROJECT : 2x800 MW THERMAL POWER PLANT TCE FORM 330 R1 IEC
ISSUE NO.: R4
SPECIFICATION NO. TCE-M4-203-06 1.0
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED 2X 800 MW TPP NEAR KRISHNAPATNAM
MOTOR OPERATED VALVE ACTUATORS
VOLUME IIIA DATA SH A24 SHEET 1 OF 4
Application
2.0
Degree of Protection & Sealing (for motor actuators and starter enclosure) Explosion proof Type of Actuator (As per IS 9334) Direct temperature sensing thermostats to be provided in motor winding (2 Nos.) Switching capacity of contacts Motor duty Motor starting Power Supplies Main Power Supply Control supply Variation in supply voltage and frequency from rated values Supply voltage Supply frequency Combined voltage and frequency variation Integral motor starter to be provided Remote position transducer Potentiometric type / Others Position Transmitter giving signal output of 4 20 mA dc If transducer indicated in 10.2 provided, it shall have 2 wire output / 4 wire output to match the remote indicator / controller Auxiliary supply for transducer
IP
IP 67, O ring sealed
3.0 4.0 5.0 5.1 6.0 7.0 8.0 8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 9.0 10.0 10.1 10.2 10.3
As applicable Type 1 A Required 5A, 230 V AC As per IS 9334 DOL
400V or 415V, 3 - phase, 3 wire 50 Hz Effectively Earthed 110 V,1 Phase, 50 Hz
o/o o/o o/o
10 5 10 Yes Required Non contact type 24 VDC Yes 2 wire output
10.4
V, AC/DC
Loop powered
PPD. BY: CKD. BY: DATE:
JOB NO. TCE 5103A
CLIENT: APPDCL PROJECT: 2x 800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO.: R4
SPECIFICATION NO. TCE-M4-203-06 11.0 12.0 12.1 12.2 12.3 13.0 13.1 13.2 14.0 15.0 15.1 15.2 16.0 17.0
MOTOR OPERATED VALVE ACTUATORS Yes
Supply monitoring device with contact output for remote annunciation, required. Torque switch Number Close direction (min) Open direction (min) Additional switch Switching capacity Limit switch Number & contact development Switching capacity Blinker relay & lamp required Two (2) interposing relays required for receiving remote command signal Coil voltage rating Burden Additional contact of local / remote switch required for remote switch indication. Remote commands shall comprise Open Stop Close Volts VA Amp. Close Open Nos. Nos. Nos. Nos.
1 1 1 1 As per IS 9334
As per following table (Sh 4) showing limit switch contact requirement. As per IS 9334 Yes Yes ( 24V DC relay suitable to accept 24V DC logic level remote command signal) 24 V DC
Yes
Yes No Yes Yes
18.0
Drawings TCE.M2-EL-CW-S-2625 & 2626 enclosed with specification. (Required only for valve Actuators with integral starters) Terminal box Terminals for motor Gaskets Cable glands / lugs PPD. BY: CKD. BY: DATE: JOB NO. TCE 5103A
19.0 19.1 19.2 19.3 REV. NO. DATE REV. BY
Separate terminal box shall be provided for power and control wiring. Stud type with plain washers, spring washers and check nuts Neoprene Required CLIENT: APPDCL PROJECT: 2x 800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO.: R4
SPECIFICATION NO. TCE-M4-203-06 19.4
MOTOR OPERATED VALVE ACTUATORS Brass Tinned copper
If yes to 19.3 a) Glands b) Lugs c) Cable size i) Power ii)Control Paint and Finish Primer Finish
Sq.mm
3CX 2.5 sq.mm 0.5 sq.mm screened cable
20.0 20.1 20.2
One coat 2 coats of grey enamel paint (Shade 631 as per IS.5)
JOB NO. TCE 5103A
CLIENT: APPDCL PROJECT: 2x 800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO.: R4
TORQUE AND LIMIT SWITCH CONTACT REQUIREMENT FOR PURCHASERS USE
Switch Designation
Full Open
Intermediate
Full Close
Non- Integral Starter Not applicable
Integral Starter
Requirement
Torque switch open Torque switch close Limit switch Open Limit Switch close (Adjustable type from 0 to 50 % position) (Adjustable type from 50 to 100% position)
2 NO + 1 NC
YES
2 NO + 1 NC
YES
2 NO + 1 NC
YES
2 NO + 1 NC
YES
2 NO + 1 NC
YES
2 NO + 1 NC
YES
ISSUE NO.: R4

1.
Factory built assemblies of switchgear and control gear for voltages upto and including 1000 V AC and 1200 V DC. Air break switches H. R. C Cartridge fuses Contactors Starters Control switches / push buttons Relays Degree of Protection Code of practice for installation and maintenance of switchgear Climate proofing of electrical equipment Electrical motor operated actuators Flame proof enclosure
IS:8623
BS-EN-60439
IEC:60439
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
IS:13947-3 IS:9224 IS:13947-4 IS:13947-4 IS:6875 IS:3231 IS:2147 IS:
BS-EN-60947-3 BS-88
IEC-60947-3
IEC-60269 IEC-947-4 IEC-947-4-1 IEC : IEC : 60255 IEC :60529 IEC :
BS-E-N-60947-4 BS-EN-60947-4-1 BS: BSBSBS:
IS: IS:9334 IS:2148
BSBSBS-
IEC: IEC: IEC:
Note : Equipment, accessories, component parts, raw materials and tests shall in general conform to : IS BS IEC
JOB NO. TCE. 5103A
CLIENT: APPDCL PROJECT:2X800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO R7
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-219-01 1.0 1.1 1.2 1.3 1.4 1.5 GENERAL PATICULARS DESIGNATION LOCATION
CONTROL CABINET
DATA SH A 25 SHEET 1 OF 1
LOCAL CONTROL PANELS/DC MOTOR STARTERS INDOOR / OUTDOOR

0
DESIGN AMBIENT TEMPERATURE TYPE OF MOUNTING CABLE ENTRY A) TOP / BOTTOM B) GLANDS / CONDUITS -SIZE C) GLANDS IF REQUIRED
50 FLOOR/COLUMN/WALL MOUNTED AS REQUIRED GLANDS(BY VENDOR) DOUBLE COMPRESSION BRASS YES GS STRIPS BY BIDDER
1.6
EARTHING CONDUCTOR BY VENDOR A) MATERIAL B) TYPE C) SIZE
1.7
PAINTING: A) COLOUR FINISH OUTSIDE INSIDE B) EPOXY PAINT REQUIRED Yes/No YES, Ref .No SHADE 631 OF IS-5 GLOSSY WHITE NO TO BE FURNISHED BY BIDDER
1.8
CONTROL SCHEME & BILL OF MATERIAL, ENCLOSED If NO, TO BE FURNISHED BY VENDOR VOLTAGE POWER DEVICES, MOTOR DRIVES, ETC. A) SUPPLY VOLTAGE B) DUPLICATE FEED
2.0 2.1
400Vor 415V AC, 3-PHASE, 4-WIRE
400Vor 415V, 3PH, 50Hz REF. SEC-C V, AC/DC REQD/ NOT REQD. 110V AC REQUIRED FOR DERIVING 110V AC
230V AC , 1-Ph, 50 Hz (TO BE DERIVED BY VENDOR FROM 415V ,3PH,4 WIRE SUPPLY BY SUITABLY RATED TRANSFORMER)
2.2 2.3 2.4 3.0 3.1 3.2 REV. NO. DATE REV. BY
CONTROL VOLTAGE CONTROL TRANSFORMER SPACE HEATER/LIGHTING SUPPLY VOLTAGE OTHER PARTICULARS WHEN APPLICABLE STARTERS TYPE CONTACTOR RATED DUTY (AS PER IS:2459 & 8544) PPD. BY: CKD. BY: DATE:
DOL/RE VY
DOL AC3-NON REVERSIBLE DRIVES, AC4FOR REVERSIBLE DRIVES CLIENT:APPDCL PROJECT: 2x800 MW THERMAL POWER PLANT TCE FORM 330 R1
JOB NO. 5103A
ISSUE NO R7
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-219-01 1.0 APPLICABLE STANDARDS 1.1 1.2 SWITCHGEAR GENERAL REQUIREMENTS
CONTROL CABINET IS-4237 IS-8623
DATA SH A 25 SHEET 1 OF 1 BSEN-60947 BS-5486 IECIEC-60439-1
FACTORY BUILT ASSEMBLIES OF SWITCHGEAR AND CONTROL GEAR FOR VOLTAGES UPTO AND INCLUDING 1000V. A.C. & 1200 V. D.C. AIR BREAK SWITCHES MINIATURE CIRCUIT BREAKERS H.R.C. CARTRIDGE FUSES D TYPE FUSES CONTACTORS STARTERS CONTROL SWITCHES/PUSH BUTTONS CURRENT TRANSFORMERS POTENTIAL (VOLTAGE) TRANSFORMERS RELAYS INDICATING INSTRUMENTS ARRANGEMENT FOR BUS BARS, MAIN CONNECTIONS AND ACCESSORIES A.C. ELECTRICITY METERS DEGREE OF PROTECTION THE PERFORMANCE OF A.C. CONTROL GEAR EQUIPMENT RATED UP TO 660V FOR USE ON HIGH PROSPECTIVE FAULT CURRENT SYSTEM CODE OF PRACTICE FOR INSTALLATION AND MAINTENANCE SWITCHGEAR CLIMATE PROOFING OF ELECTRICAL EQUIPMENT CODE OF PRACTICE FOR PHOSPHATING IRON & STEEL WROUGHT ALUMINIUM & ALUMINIUM ALLOYS FOR ELECTRICAL PURPOSES NOTES EQUIPMENT, ACCESSORIES, COMPONENT PARTS, RAW MATERIALS AND TESTS SHALL IN GENERAL CONFORM TO
1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17
IS-13947 IS-8828
BSEN 60947-3 BS-3871
IEC-60405 IEC- (PI)
IS-13703 BS-88 IEC-60269-1 & IEC 60269-2 & IEC-60269-4 IS-8187 IS-13947 IS-13947 IS-13947 IS-2705 IS-3156 IS-3231 IS-1248 BSBS-775 BSEN-60947 BSBS-60044-1 BS-7625 BS-142 BS-89 IEC IEC-947-4-1 IEC-947-4-2 IECIEC-60185 IEC-60186 IEC-60255 IEC-60051 BS-159 IECIEC-60947-1 IEC-
IS-5578 & IS11353 IECIS-722 IS-13947 ISBS-5685 BSBS-
1.18 1.19 1.20 1.21 2.0 2.1
IS-10118 IS-3202 IS-6005 IS-5082
BSBSBS-3189 BS-2898
IECIECIECIEC-114
IS-
BS-
IEC-
JOB NO. 5103A
CLIENT:APPDCL PROJECT: 2x800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO. R6
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-219-11 1.0 1.1 1.2 1.3 1.4
LOW VOLTAGE SWITCHGEAR
SWITCHGEAR & BUSBAR RATING RATED VOLTAGE, PHASES & FREQUENCY SYSTEM NEUTRAL EARTHING : (EFFECTIVELY/NON EFFECTIVELY) MAXIMUM SYSTEM VOLTAGE ONE MINUTE POWER FREQUENCY VOLTAGE A) POWER CIRCUITS B) CONTROL CIRCUITS C) AUX. CIRCUITS CONNECTED TO SEC. OF CTS CONTINUOUS CURRENT RATING OF BUSBARS UNDER SITE REFERENCE AMBIENT TEMPERATURE REFERENCE AMBIENT TEMPERATURE MAXIMUM TEMPERATURE OF BUSBARS, DROPPERS AND CONTACTS AT CONTINUOUS CURRENT RATING UNDER SITE REFERENCE AMBIENT TEMPERATURE SHORT CIRCUIT WITHSTAND FOR BUSBARS AND DROPPERS A) SHORT TIME (1 SEC.) AT 415V B) DYNAMIC RATING KA(RMS) KA (PEAK) 50 105 AS PER DATA SHEET-A2 C C 400V OR 415V, 3 ph, 50 Hz. Effectively 440 V
VOLTS VOLTS VOLTS
2500 1500 2000 REFERE ITEM-2 BELOW AND DATA SHEET-A3 50 85
1.5
1.6 1.7
1.8
1.9 2.0
STANDARD APPLICABLE SWITCHGEAR PARTICULARS:

DESIGNATION BUSBAR DETAILS AMP CU/ AL TP/ TPN
SINGLE/ DOUBLE/ (SF/DF)
FULLY /SEMI DRAWOUT/ FIXED (FD/SD/F)
CABLE ENTRY TOP (T) BOTTOM (B) POWER CONTROL
1.Refer sec-C2 2. 3. 4. 5. 6. NOTE: FEEDER DESIGNATION, RATINGS & MODULE TYPES REFER DATA SHEET A3 & ENCLOSED DRAWINGS. REV. NO. DATE REV. BY PPD. BY : CKD. BY : DATE: JOB NO. TCE. 5103A CLIENT : APPDCL PROJECT : 2x800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO. R6
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-219-11 3.0 3.1
SWITCH GEAR CONSTRUCTIONAL REQUIREMENTS THICKNESS OF SHEET STEEL COLD ROLLED HOT ROLLED DEGREE OF PROTECTION AS PER IS:13947 COLOUR FINISH SHADE AS PER IS:5 INTERIOR EXTERIOR EARTHING BUS MATERIAL SIZE PURCHASER'S EARTHING CONDUCTOR CLEARANCES IN AIR OF LIVE PARTS METAL ENCLOSED BUSDUCT/BUS TRUNKING ENTRY TO CUBICLES IF REQUIRED STARTERS TYPE CONTACTOR RATED DUTY AS PER IS:13947 UTILISATION CATEGORY AS PER IS:13947 CONTROL SCHEME & BILL OF MATERIAL ENCLOSED CONTROL TRANSFORMER : A) SEPARATE FOR EACH MODULE B) COMMON FOR EACH SWITCHGEAR SECTION WITH 100% STANDBY SINGLE PHASING PREVENTOR REQUIRED STANDARD APPLICABLE THERMAL OVER LOAD RELAY RESET
MM MM
AS PER SECTION D 2.0 FRAME, 1.6 DOORS, 1.6 COVERS 2.5 FRAME, 2.0 DOORS, 2.0 COVERS IP-52 FOR SWGR. RATING UPTO 1600A. IP-42 FOR SWGR. RATED ABOVE 1600 A GLOSSY WHITE LIGHT SEMI GLOSSY SHADE : 631 GS BY BIDDER BY BIDDER PHASE TO PHASE : 25.4 MM PHASE TO EARTH : 19.4 MM A) TOP B) INDOOR/OUTDOOR
3.2 3.3
3.4
MM MATL. SIZE
3.5 3.6 3.7
4.0 4.1 4.2 4.3 4.4 4.5
DOL/REV/Y- / ANY OTHER AC3
YES/NO
IF YES, REF.NO. SEE ENCLOSED DWG LIST IN SECTION-C YES NO YES AS A PART OF BIMETAL RELAY AS PER DATA SHEET-A2 AUTO
YES/NO YES/NO YES/NO
4.6 4.7 4.8
PPD. BY : CKD. BY : DATE:
JOB NO. TCE. 5103A
ISSUE NO. R6
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-219-11 5.0 5.1 5.2 5.3 5.4 BREAKERS
CIRCUIT BREAKER TYPE VOLTAGE, FREQUENCY & NO. OF PHASES RATED BREAKING DUTY RATED BREAKING CAPACITY A) MVA B) KA(RMS) AT 415V 0-25 P.F. SHORT CIRCUIT WITH STAND CURRENT FOR 1 SEC. DURATION RATED MAKING CURRENT RATED CURRENT AT SITE REFERENCE AMBIENT TEMPERATURE TYPE OF OPERATING MECHANISM KEY INTERLOCKING REQUIRED SHUNT TRIP REQUIRED PROTECTION REQUIRED : A) RELAYS/SERIES RELEASES B) RELAY TYPE & SETTINGS C) UNDER VOLTAGE RELEASE REQUIRED MINIMUM NO. OF AUXILIARY CONTACTS CONTROL VOLTAGE A) FOR SPRING CHARGING MOTOR B) FOR CLOSING/TRIPPING EMERGENCY MANUAL OPERATION REQUIRED IN ADDITION TO ELECTRICAL OPERATING DEVICES: A) FOR SPRING CHARGING & CLOSING B) FOR TRIPPING ANNUNCIATOR REQUIRED STANDARDS APPLICABLE YES/NO YES/NO KA KA (PEAK) A 400V or 415V, 50 HZ, 3PH, 3 WIRE B-3 MIN-MB3 MIN-MB 36 50 50 100 SEE DATA SHEET-A3 MOTOR WOUND SPRING CHARGED NO YES NO NO NO 6 NO+6 NC 230 V AC 220V DC
5.5 5.6 5.7 5.8 5.9 5.10 5..11
5.12 5.13
YES/NO SETTING V, AC/DC
5.14
YES/NO YES./NO YES/NO
YES YES NO AS PER DATA SHEET-A2
5.15 5.16
JOB NO. TCE. 5103A
ISSUE NO. R6
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-219-11 6.0 6.1 MCCBS
MOULDED CASE CIRCUIT BREAKERS TO BE PROVIDED A) FOR MOTOR CONTROL CIRCUITS B) FOR OTHER CIRCUITS VOLTAGE, FREQUENCY & NO. OF PHASES RATED OPERATING DUTY RATED BREAKING CAPACITY (AT 415V 0.25 P.F.) RATED MAKING CURRENT RATED CURRENT AT SITE REFERENCE AMBIENT TEMPERATURE ON/OFF OPERATION : MANUAL REMOTE POWER OPERATED RELEASES REQUIRED : OVERLOAD INVERSE TIME UNDER VOLTAGE STANDARD APPLICABLE
YES/NO YES/NO
YES YES 400V or 415V, 50 HZ, 3PH, 3 WIRE
6.2 6.3 6.4 6.5 6.6 6.7
KA (RMS) KA (PEAK)
50KA 100KA TO SUIT MOTOR CONTROL CIRCUITS SEE DATA SHEET A3
YES/NO YES/NO YES/NO YES/NO
MANUAL
6.8
YES YES AS PER DATA SHEET A2
6.9
7.0
ESSENTIAL SPARES DESCRIPTION A) COMPLETE BREAKER WITH OPERATING MECHANISM AND RELEASES WHERE SPECIFIED ESSENTIAL SPARES TO BE FURNISHED 1 NO. OF EACH RATING
B) COMPLETE POLE OF BREAKER REV. NO. DATE REV. BY PPD. BY : CKD. BY : DATE: JOB NO. TCE. 5103A CLIENT : APPDCL PROJECT : 2x800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO. R6
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-219-11
2 NOS OF EACH RATING
C) CLOSING & TRIPPING COILS D) SPRING, CHARGING MOTORS, ALONG WITH CLOSING & TRIPPING SPRINGS IN CASE OF SPRING OPERATED BREAKERS E) FIXED MOVING CONTACT ASSEMBLIES OF EACH BREAKER F) BREAKER CONTROL SWITCHES, AUX. SWITCH ASSEMBLY, LIMIT SWITCHES, LOCAL / REMOTE SELECTOR SWITCH, OTHER SWITCHES G) BUS BAR SUPPORT INSULATORS H) PROTECTIVE RELAYS i)51 ii)51N I) CLUSTERED LED INDICATING LAMPS J) CURRENT TRANSFORMERS i) ii) iii) iv) v) vi) vii) K) VOLTAGE TRANSFORMERS i) ii) iii) iv) v) M) INSTRUMENTS : i) AMMETER FOR 1A OPERATION ii) VOLTMETER FOR 110V OPERATION iii) KW METER
2 SETS OF EACH RATING 2 NOS
2 SETS OF EACH RATING 5 NOS. EACH
10 NOS. 1 NO 1 NO. 10 NOS. OF EACH COLOUR 2 NOS. OF EACH RATIO & TYPE
2 NOS. OF EACH RATIO & TYPE
1 NO. OF EACH TYPE EACH RATING 1 NO. 1 NO.
JOB NO. TCE. 5103A
ISSUE NO. R6
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-219-11
N) CONTACTORS, RATING : POWER & AUXILIARY i) CONTACTOR ii) iii) iv) O) BI-METALLIC THERMAL ELEMENTS TO SUIT MOTORS OF FOLLOWING RATINGS : P) POWER FUSES TO SUIT CIRCUITS OF FOLLOWING RATINGS : Q) CONTROL CIRCUIT FUSES R) TRANDUCERS OF EACH TYPE & RATING
5 NOS. OF EACH RATING
1 NO. OF EACH RATING
10 NOS. OF EACH RATING 10 NOS. OF EACH RATING 2 NOS.
JOB NO. TCE. 5103A
SPEC NO.

TITLE
Volume IIIA
TCE-M4-219-11
DATA SH A 26
SHEET 1OF 2
APPLICABLE STANDARDS: 1. 2. 3. SWITCHGEAR GENERAL AC CIRCUIT BREAKERS FACTORY BUILT ASSEMBLIES OF SWITCHGEAR AND CONTROL GEAR FOR VOLTAGES UPTO AND INCLUDING 1000V A.C. & 1200 V D.C AIR BREAK SWITCHES MINIATURE CIRCUIT BREAKERS HRC CARTRIDGE FUSES D TYPE FUSES CONTACTORS 1 9. 10. 11. 12. 13. 14 15. 16. 17. 18. STARTERS CONTROL SWITCHES/PUSH BUTTONS CURRENT TRANSFORMERS VOLTAGE TRANSFORMERS RELAYS INDICATING INSTRUMENTS ARRANGEMENT FOR BUSBARS MAIN CONNECTIONS AND ACCESSORIES AC ELECTRICITY METERS DEGREE OF PROTECTION THE PERFORMANCE OF AC CONTROL GEAR EQUIPMENT RATED UPTO 600 V FOR USE ON HIGH PROSPECTIVE FAULT CURRENT SYSTEM CODE OF PRACTICE FOR INSTALLATION AND MAINTENANCE OF SWITCHGEAR IS : 13947 BSEN: 60947 IEC IEC 947-2 IEC:439
IS:13118 BSEN 60947-2 BS:3871(PI) MCCB IS:8623 BS:5486
4. 5. 6. 7. 8.
IS:13947 IS:8828
BSEN:60947-3 BS:3871 BS:88
IEC-947-3 IEC: IEC-769 IEC: IEC:9474IEC:947IEC: IEC:185 IEC:186 IEC:255 IEC:51 IEC: IEC: IEC:947-1 IEC:
IS:13703(P2) IS:8187 IS:13947 BS:
BSEN-60947-1 BSEN-60947-4-1 BS: BS:7626 BS:7625 BS:142 BS:89 BS:159 BS:37 BS: BS:
IS:13947 4-1 IS:13947 IS:2705 IS:3156 IS:3231 IS:1248 IS:5578 IS:11353 IS:8530 IS:13947(PI) IS:
19.
IS:10118
BS:
IEC:
SPEC NO.

TITLE
Volume IIIA
TCE-M4-219-11
DATA SH A 26
SHEET 2OF 2
20.
CLIMATE PROOFING OF ELECTRICAL EQUIPMENT CODE OF PRACTICE FOR PHOSPHATING IRON AND STEEL WROUGHT ALUMINIUM AND ALUMINIUM ALLOYS FOR ELECTRICAL PURPOSES CONTROL TRANSFORMER FOR SWITCHGEAR AND CONTROL GEAR FOR VOLTAGE NOT EXCEEDING 110V AC NOTE : EQUIPMENT, ACCESSORIES, COMPONENT PARTS, RAW MATERIALS AND TESTS SHALL IN GENERAL CONFORM TO :
IS:
BS:
IEC:
21. 22. 23.
IS: 6005 IS:5082 IS:12021
BS: 3169 BS:2898 BS:
IEC: IEC: IEC:
ISSUE NO. R1
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-203-71
VARIABLE SPEED DC/AC DRIVES
(General Requirements) 1.0 1.1 1.2 1.3 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Type of Drive Rating of the drive Type of duty (cl. 3.5) Quadrants of operation Quantity Power supply Variation voltage Variation in Frequency Combined voltage and frequency variation Environmental Conditions Location a) Whether in air conditioned room b) If NO, Average ambient temperature Design ambient temperature Relative humidity Vibration 9.0 Type of cooling for drive panel If water cooled, is DM water required If yes, quantity of DM water 10.0 Cable a) Size and type b) Entry
Inverter controlled AC drives. Class I I
11 kV, 3ph, 50 Hz + 10 % 50 Hz + 5% + 10%
Indoor Yes. However Bidder to indicate their recommendation

0 0
C C % Natural cooling
------ litres/minute later Bottom

JOB NO. TCE. 5103A CLIENT:APPDCL PROJECT: 2x 800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO. R1
SPECIFICATION NO.
VOLUME IIIA
TCE-M4-203-71
11.0 12.0 12.1 12.2 12.3 12.4 12.5 13.0
Dimensions Types of Protection Instantaneous over current Motor overload protection Over voltage / under voltage Momentary power loss Stall prevention Control characteristics for both AC/DC a) Control Method b) Freq. control range c) Accelerate/decelerate time Harmonics Limitations a) Load side for AC drives b) Source side(with DC/AC drives) Current harmonics
By Bidder
required required Ride through with adjustable under voltage and time setting required required
Automatic with feedback To suit fan requirement To suit fan requirement
14.0
Maximum within 5% 5th . 7th THD <= 5% 11th .. 13th THD <= 5% Required Required Required Required Required Required As recommended by Bidder
15.0
Controls on Drive Panel a) Start / Stop b) Speed Raiser / Lower c) Auto / Manual d) Local / Remote e) DOL by-pass f) Emergency Stop g) Any other
JOB NO. TCE. 5103A
CLIENT:APPDCL PROJECT: 2x 800 MW THERMAL POWER PLANT TCE FORM 330 R1
ISSUE NO. R1
SPECIFICATION NO.
VOLUME IIIA
DATA SH A 27 TCE-M4-203-71 VARIABLE SPEED DC/AC DRIVES SHEET 1 OF 3
Inverter Controlled A.C. Drives 1.0 2.0 3.0 Application Quantity a) Starting/rated torque b) Type of converters c) Inverter capacity at specified pf d) Rated Current e) Load power factor f) Max. continuous current g) Rated voltage with number of phases h) Rated frequency i) Converter Bridge j) Single Quadrant/Two quadrant/ Four Quadrant 4.0 Control Characteristics i) Speed Control a) Rated speed b) Speed ratio c) Constant torque/constant power d) Speed accuracy e) Closed loop/open loop
REV. NO. DATE REV. BY PPD. BY: CKD. BY: DATE:
fans 2 By Bidder PWM By Bidder By Bidder By Bidder By Bidder By Bidder 50 Hz 6/12 pulse-By Bidder to limit THD to <= 5% Single
By Bidder By Bidder By Bidder 0.5% Closed loop

JOB NO. TCE. 5103A CLIENT APPDCL PROJECT 2x800 MW THERMAL POWER PLANT H TCE FORM 330 R1
ISSUE NO. R1
SPECIFICATION NO.
VOLUME IIIA
f) If tacho-generator used (for closed loop) g) Accel./Deccel. time h) Type of tacho-generator - If analogue, then reference signal mA/mV j) Is remote operation required - If yes, is it through k) Type of control ii) Braking a) Type of braking b) Braking Torque 5.0 Miscellaneous Soft-start Flying restart Auto restart Kinetic Buffering 6.0 Indication on Drive Panel (minimum) a) Motor running b) Motor stopped / trip c) AC mains ON d) System Ready to start e) VSD system fault Metering
Yes By Bidder Digital
Yes DCS Digital
By Bidder By Bidder
Yes Yes Yes Yes Required
7.0
Required
JOB NO. TCE. 5103A CLIENT APPDCL PROJECT 2x800 MW THERMAL POWER PLANT H TCE FORM 330 R1
ISSUE NO. R1
SPECIFICATION NO.
VOLUME IIIA
Digital Display of the following Minimum parameters on the Drive Panels:a) Input AC Voltage b) Input AC Frequency c) Input AC Current d) Output Voltage e) Output Current VSD/Bypass f) Output Frequency g) Motor speed Necessary transducers shall be Provided with 4-20mA output for indicating motor speed & current in DCS.
JOB NO. TCE. 5103A
CLIENT APPDCL PROJECT 2x800 MW THERMAL POWER PLANT H TCE FORM 330 R1
ISSUE NO. R1
SPECIFICATION NO.
VOLUME III A
TCE-M4-203-71
Specification for metal clad base materials for printed circuits for use in electronic and telecommunication equipment Specification of Transformers and Inductors (Power, Audio, Pulse and Switching) for Electronic Equipment Semiconductor rectifier equipment safety code for Specification for printed wiring Board Recommended practice for emergency and standby power systems for industrial and commercial applic. Semiconductor devices Essential rating & characteristics Basic climate for mechanical durability tests for electronic components Specification for metal-clad base materials for printed circuits for use in electronic and communication equipment Specification for transformers and inductors (Power audio pulse and switching) for electronic equipment Specification for printed wiring board Degree of protection provided by enclosures for low voltage switchgears and control gears
REV. NO. DATE REV. BY PPD. BY: CKD. BY: DATE:
IS:5921
IS:6297
IS 6619 IS:7405 IS : IEC : IEEE :446
IS: 3700
IEC:146
IS:9000
IS:5921
IS:6297
IS: 7405 IS:2147
JOB NO. TCE. 5103A
ISSUE NO. R1
SPECIFICATION NO.
VOLUME III A
TCE-M4-203-71
Environmental requirements of semiconductor devices and integrated circuits Ambient temp. of electronic equipment Environmental tests for electronic equipment Terminal for electronic equipment
IS:6553
IS:9676 IS:9000 IS:4007
Equipment accessories, component parts, raw materials and test shall in general conform to IS IEC Factory built assemblies of low Voltage Semiconductor rectifier assemblies And thyristor converters Busbars and Busbar connections Code of practice for earthing Control cabinet Current transformers Potential transformers Power transformers Indicating meters Wiring rectifiers Pulse transformer Semiconductor Converters IS: 4237 IS:3695 IS:4560 IS:5082 IS:3043 IS:4237 IS:2705 IS:3156 IS:2024 IS:1248 IS:2274 IS:6297 IEC:146 BS: BS:4417 BS:159 IEC:439 IEC:148 IEC:
BS:CP:1013 IEC: BS: BS:3938 BS:3941 BS:171 BS:89 BS: BS: IEC: IEC:185 IEC:185 IEC:75 IEC:51 IEC: IEC:
JOB NO. TCE. 5103A
ISSUE NO. R1
SPECIFICATION NO.
VOLUME III A
TCE-M4-203-71
Basic climate and Mechanical Durability Tests for Electronic Components Environmental tests for electronic and electrical equipment Low-voltage switchgear & control gear General Rules
IS:589
IS:9000 Parts 1 to 18 IS:13947
JOB NO. TCE. 5103A
SPECIFICATION NO.
VOLUME IIIA
SPECIFIC TECH REQUIREMENT OF SG & AUX

TCE-5103A-C-500-01
DATA SHEET B1 SHEET 1 OF 11
EQUIPMENT PERFORMANCE DATA

BIDDER
ENQUIRY /SPECIFICATION NO.

SR.NO. ITEM
1.1.0 1.1.1 1.1.2 1.1.3 1.1.4 1.1.4.1 1.1.4.2 1.1.4.3 1.1.4.4 1.1.4.5 1.2.0 1.2.1 1.2.1.1 1.2.1.2
GENERAL Manufacturer No. of units Type of units Fuels Fuel for initial warm up Fuel for start up/flame stabilisation Fuel for performance guarantee Fuel for load carrying Fuel for ignitors UNIT CAPABILITY DATA SG MCR Superheater flow Steam conditions at super heater header outlet a) Pressure b) Temperature bar(a) deg.C kg/s bar (a) deg.C kg/s
1.2.1.3 1.2.1.4
Reheater flow Steam conditions at reheater inlet a) Pressure b) Temperature
1.2.1.5
Steam conditions at reheater outlet a) Pressure bar (a)
NOTE TO BIDDER 1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE MARKED WITHIN ASTERISK(*) (DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS) 2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.
SIGNATURE OF BIDDER DATE
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
b) Temperature 1.2.1.6 Maximum allowable working pressure for - Superheater - Reheater 1.2.1.7 1.2.1.8 1.2.1.9 1.2.1.10 1.2.1.11 1.2.1.12 Feed water inlet temperature Fuel consumption Efficiency based on fuel GCV Excess air at furnace exit Excess air at outlet of air heater a) Flue gas temperature at APH outlet - Considering leakage in APH - Without considering leakage in APH b) Flue gas temperature at ID fan outlet 1.2.1.13 SG Water Volume - Furnace including economiser - superheater - reheater 1.3.0 1.3.1 1.3.1.1 ANTICIPATED PERFORMANCE FOR SLIDING PRESSURE OPERATION Steam flow : Steam quantity leaving final superheater outlet
deg.C
bar(a) bar(a) deg.C kg/s % % % deg.C
deg.C
m 3 m 3 m
40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR
kg/s 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
1.3.1.2 1.3.2 1.3.3 1.3.4 1.3.5 1.3.5.1 1.3.5.2
Steam quantity leaving final reheater outlet Steam generator efficiency based on the GCV of the fuel GCV of fuel as fired NCV of fuel as fired Fuel, air and gas flow : Fuel firing rate Combustion air requirement (without leakage) - Burner - Overfire air
kg/s % Kcal/kg. Kcal/Kg.
kg/s kg/s
1.3.5.3 1.3.5.4 1.3.5.5 1.3.5.6 1.3.5.7 1.3.5.8 1.3.5.9 1.3.6 1.3.6.1
Excess air Air handled by both FD fans Air leakage in RAPH Gas flow at economiser outlet Gas flow at air heater outlet (including air leakage if any) Feed water pressure at economiser inlet Fuel oil/gas pressure at burner inlet Temperatures: Gas -
% kg/s kg/s kg/s kg/s bar(a) bar(a)
a) Leaving furnace
deg.C
40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
b) Entering high temperature superheater c) Leaving high temperature superheater d) Entering reheater e) Leaving reheater f) Entering low temperature superheater g) Leaving low temperature superheater h) Entering economiser i) Entering air heater j) Leaving air heater k) At stack entrance 1.3.6.2 Air a) Entering steam coil air pre heater b) Leaving steam coil air pre heater c) Entering air heater d) Leaving air heater e) Entering burner windbox f) Entering coal mills 1.3.6.3 Feed Water a) Entering economiser b) Leaving economiser
deg.C deg.C deg.C deg.C deg.C deg.C deg.C deg.C deg.C deg.C
deg.C deg.C deg.C deg.C deg.C deg.C
deg.C deg.C 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR
1.3.6.4
Flue gas velocity at furnace exit
m/s
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
1.3.7 1.3.7.1
Pressure drops : Steam path: a) Superheater b) Superheater desuperheater c) Reheater d) Reheater desuperheater bar bar bar bar
1.3.7.2
Air pressure Lossess : a) Ducts b) Air preheater c) Across flow elements d) Burner registers e) Total loss through the system mmwc mmwc mmwc mmwc mmwc
1.3.7.3
Draft Losses a) Furnace suction b) Superheater c) Economiser d) Air preheater e) Flue gas duct upto stack mmwc mmwc mmwc mmwc mmwc 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR mmwc
f) Electrostatic precipitator including transition pieces
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
g) Total loss through the system 1.3.8 1.3.8.1 1.3.8.2 1.3.8.3 1.3.8.4 1.3.8.5 1.3.8.6 1.3.8.7 1.3.8.8
mmwc
Heat balance (based on GCV of fuel as fired): Heat to steam and water Heat loss in dry flue gases Heat loss due to moisture Heat loss due to hydrogen in fuel Heat loss due to moisture in air Unburnt fuel loss Manufacturers margin % % % % % % %
Radiation and unaccounted losses (radiation losses with a temperature differential of 28 deg.C between steam generator surfaces and ambient air) % Gross efficiency based on GCV of fuel Total heat loss Desuperheater Superheater desuperheaters Spray water pressure at inlet Spray water quantity Spray water system design capacity bar kg/s kg/s 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR % %
1.3.8.9 1.3.8.10 1.3.9 1.3.9.1 1.3.9.1.1 1.3.9.1.2 1.3.9.1.3
1.3.9.2
Reheater desuperheater (If the spray is for emergency condition, indicate the maximum spray water expected under abnormal condition)
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
1.3.9.2.1 1.3.9.2.2 1.3.9.2.3 1.3.10 1.3.10.1 1.3.10.2 1.3.10.3 1.3.10.4 1.3.10.5 1.3.10.6 1.3.10.7 1.3.10.8 1.3.11 1.3.11.1 1.3.11.2 1.3.11.3 1.3.11.4 1.3.11.5
Spray water pressure at inlet Spray water Quantity Spray water system design capacity Induced draft Fans: Volume of gas handled by each fan Temperature of gas at fan inlet Total draft loss Speed of Fan Fan efficiency Variable speed hydraulic coupling efficiency (if applicable) Driving motor efficiency Electrical power input to each motor Forced Draft Fans: Volume of air handled by each fan Temperature of air at fan inlet Total air pressure loss Speed of fan Fan efficiency
bar kg/s kg/s
Nm3/sec deg.C mmwc rpm % % % kW
Nm /sec deg.C mmwc rpm % 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR
1.3.11.6 1.3.11.7
Driving motor efficiency Electrical power input to each motor
% kW
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
1.3.12 1.3.12.1 1.3.12.2 1.3.12.3 1.3.12.4 1.3.12.5 1.3.12.6 1.3.12.7 1.3.13 1.3.13.1 1.3.13.2 1.3.13.3 1.3.13.4 1.3.13.5
Primary Air Fans: Volume of air handled by each fan Temperature of air at fan inlet Total air pressure loss Speed of fan Fan efficiency Driving motor efficiency Electrical power input to each motor Gas Recirculation Fans: Volume of gas handled by each fan Temperature of gas at fan inlet Total gas pressure loss Speed of fan Fan efficiency Nm3/sec. deg.C mmwc rpm % % kW Nm3/sec deg.C mmwc rpm % % kW
1.3.13.6 Driving motor efficiency 1.3.13.7 1.3.14 1.3.14.1 Electrical power input to each motor Coal Mills: No. of mills in operation with design coal
No. 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR
1.3.14.2 1.3.14.3 1.3.14.4
Load on each mill Output size Driving motor efficiency
kg/s % thru 200 mesh %
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
1.3.14.5
Electrical power input to each motor
kW
1.13.14.6Minimum stable load of SGMCR when required no. of coal mills are in operation with design coal without oil support 1.13.14.7Minimum stable load of SGMCR when required no. of coal mills are in operation with worst coal without oil support 1.4.0 1.4.1 MILL PERFORMANCE DATA Three coal mills in operation - Minimum stable load on each coal mill below which stopping of one mill is to be initiated 1.4.2 Two coal mills in operation - Minimum load on each mill at which oil stabilisation is necessary before taking out a mill 14.3 One coal mill in operation - Minimum load on the mill with stabilising oil burners 1.5.0 1.5.1 1.5.2 Mode of operation Steady state Load change between 40% TGMCR to 100% TGMCR Between 50% TGMCR to SH outlet pressure deviation SH outlet temp. deviation Load on each mill (% mill MCR) Load on SG (%SGMCR)
1.5.2.1
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
60% TGMCR at 3% per minute of sliding pressure operation a) For sliding pressure operation 1.5.2.2 Between 60% TGMCR to 90% TGMCR at 5% per minute for sliding pressure operation Between 90% TGMCR to 100% TGMCR at 3% per minute for constant pressure operation Step load change between 100% SG MCR and 60% TG MCR in case of run back due to loss of one FD/ID/PA fan or BFP or any other emergency Time required to shut down the unit from full load condition Restart capability of the unit immediately after full load rejection Maximum permissible rate of temperature change Superheater Reheater COLD AND HOT START PROGRAMMES Recommended periods to bring steam generator on load with HP-LP bypass (60% bypass) After cold start After thirty six hours shut down After twenty four hours shut down After twelve hours shut down hrs hrs hrs hrs
o
1.5.2.3
1.5.3
1.6.0 1.7.0
1.8.0 1.8.2 1.8.3 1.9.0 1.9.1
Start up Load change Shut down
1.9.1.1 1.9.1.2 1.9.1.3 1.9.1.4
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER

SR.NO. ITEM
1.9.1.5 1.9.1.6 1.9.1.7 1.10 1.10.1
After eight hours shut down After four hours shut down Hot restart after trip out (less than 1 hr shut down) Auxiliary steam consumption Steam conditions (a) Pressure (b) Temperature
hrs hrs hrs
kg/cm (a)
0
1.10.2 1.10.3
Fuel oil heating units Fuel oil atomizing
kg/s kg/s
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
HEAT RELEASE AND OTHER DATA

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO. ITEM
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO. 1.1 1.2 1.3 ITEM Maxim furnace exit gas temperature at furnace outlet Clearance between pendant platen surface and furnace arch (nose) - B Clearance between centre line of top coal burners (nozzles) and work point of furnace arch (nose) - C Clearance between centre line of bottom coal burners (nozzles) and work point of hopper - D a) b) 1.5 1.6 For front and / or rear wall firing For tangential firing
deg. C m
1.4
m m m deg
Angle ( alpha ) a) b) c) d) Height Width H W G H1
m m m m kcal/m /hr x10 2 kcal / hr/m

6 3
Depth Platen Height -
1.7 1.8
Volumetric heat release rate (Net heat input at SG MCR / WxGxH) Furnace plan area heat release rate (Net heat input at SGMCR / furnace width x depth) Burner zone heat release = Net heat input at SGMCR / burner zone surface Burner zone surface = (2 x (furnace width + furnace depth) x burner zone height Burner zone height = distance F + 3 m
1.9
x10 2 kcal /hr/m
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER
1.10
Effective projected radiant surface release rate (Net heat input at SG MCR / effective radiant surface) Detail calculations for the net heat Input value, utilised in arriving at Various heat release rate mentioned above. Maximum flue gas velocity through tube banks at design excess air at SG MCR Economiser tube banks arrangement Clearance centerline of burner to side wall Maximum width of furnace hopper opening - E
kCal/m
1.11
1.12 1.13 1.14 1.15
m/s BARE / FINNED; INLINE / TAGGERED
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
STEAM GENERATOR PRESSURE PARTS

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO. 1.1.0 1.1.1 1.1.2 1.1.1 ITEM GENERAL Design capacity Design pressure Design temperature - Economiser - Furnace wall - Superheater - Reheater Maximum safety valve set pressure for SH Maximum safety valve set pressure for RH FURNACE WALLS Furnace Outside diameter Pitch Thickness Design standard Material Total projected surface area of tubes Side Walls, Rear Walls & Roof Number Outside diameter Pitch Thickness Design standard mm mm mm m
2
kg/s bar(a)
Economiser Evaporator
SH RH
deg.C
1.1.1 1.1.4 1.2.0 1.2.1 1.2.1.2 1.2.1.3 1.2.1.4 1.2.1.6 1.2.1.7 1.2.1.8 1.2.2 1.2.2.1 1.2.2.2 1.2.2.1 1.2.2.4 1.2.2.6
bar (a) bar (a)
mm mm mm
Side Walls
Rear Walls
Roof
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO. 1.2.2.7 1.2.2.8 1.2.1 1.2.1.1 1.2.1.2 1.2.1.1 1.2.1.4 1.2.4 1.1.0 1.1.1 1.1.1.1 1.1.1.2 1.1.1.1 1.1.1.4 1.1.1.5 1.1.1.6 1.1.1.7 1.1.1.8 1.1.1.9 1.1.1.10 ITEM Material Total projected surface area of tubes Water Wall Headers Number of headers Outside diameter Thickness Length of each header Erosion/corrosion allowance for all water wall tubes SUPERHEATER AND REHEATER TUBES AND HEADERS Superheater Tubes Material Heating surface (effective) Total circumferential heating surface Gas flow path area Maximum metal temperature Outside diameter Tube thickness Effective length (per one tube) Gross length (per one tube) Number of elements/section m
2 2 2
mm mm mm
Radiant Section (FSH)
Convective Section (LTSH)
deg.C mm mm mm mm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO. 1.1.1.11 ITEM Tube pitch (Indicate for each type of superheater ) a) Parallel to gas flow (Longitudinal) b) Across gas flow (Transverse 1.1.1.12 1.1.1.11 1.1.2 1.1.2.1 1.1.2.2 1.1.2.1 1.1.2.4 1.1.2.5 1.1.2.6 1.1.2.7 1.1.2.8 Erosion/corrosion allowance Type of flow Superheater Headers Max. operating pressure Design pressure Construction Outside diameter Thickness Material Number of steam passes Erosion/corrosion allowance mm mm mm bar(a) bar(a) mm mm mm Parallel / Cross
1.1.1 1. 1.1.1 1.1.1..2 1.1.1.1 1.1.1.4
Reheater Tubes Material Heating surface (effective) Total circumferential heating surface Gas flow path area m
2 2
m m
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER bar(a) deg.C bar(a) mm mm mm mm
ENQUIRY /SPECIFICATION NO. SR.NO. 1.1.1.5 1.1.1.6 1.1.1.7 1.1.1.8 1.1.1.9 1.1.1.10 1.1.1.11 1.1.1.12 ITEM Maximum operating pressure Maximum metal temperature Design pressure Outside diameter Tube thickness Effective length (per one tube) Gross length (per one tube) Tube pitch (Indicate for each type of reheater) a) Parallel to gas flow (Longitudinal) b) Across gas flow (Transverse) 1.1.1.11 1.1.4 1.1.4.1 1.1.4.2 1.1.4.1 1.1.4.4 1.1.4.5 1.1.4.6 1.4.0 1.4.1 Type of flow Headers Construction Outside diameter Thickness Material Number of steam passes Erosion/corrosion allowance ECONOMISER Effective heating surface (water side) m
2
mm mm Parallel / Cross
mm mm
mm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER m
2 2
ENQUIRY /SPECIFICATION NO. SR.NO. 1.4.2 1.4.1 1.4.4 1.4.5 1.4.5.1 1.4.5.2 1.4.5.1 1.4.5.1 1.4.5.4 ITEM Effective heating surface (gas side) Gas flow path area Gas velocity at SG MCR Tubes Material Outside diameter Thickness Length Pitch a) Parallel to gas flow (Longitudinal) b) Across gas flow (transverse) 1.4.6 1.4.6.1 1.4.6.2 1.4.6.1 1.4.6.4 Headers Material Outside diameter Thickness Length mm mm mm mm mm mm mm mm
m/s
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
REGENERATION AIR PREHEATER

BIDDER Primary Air
ENQUIRY /SPECIFICATION NO. SR.NO. 1.1.0 1.1.1 1.1.2 1.1.3 1.1.4 1.2.0 ITEM GENERAL No. of air preheaters (APH) per steam generator Type Make Speed HEATER ELEMENTS rpm No. of baskets Height of Material elements (mm)
Secondary Air
1.2.1 1.2.1.1 1.2.1.2 1.2.1.3 1.2.2 1.2.3 1.2.1 1.2.1.1 1.2.1.2 1.3.0 1.3.1 1.3.1.1 1.3.1.2 1.3.2
Cold/middle/upper hot elements Cold end elements Middle elements Upper hot elements Casing thickness Total effective heating surface Pressure drop at SG MCR Air side Gas side SEALING Type of radial seals Hot end Cold end Type of circumferential seal mm m
2
mmWc mmWc
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO. 1.3.3 1.3.4 1.4.0 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.5.0 1.5.1 1.5.1.1 1.5.1.2 1.5.2 1.5.2.1 1.5.2.2 1.5.2.3 1.5.3 1.5.3.1 1.5.3.2 1.5.3.3 1.5.3.4 ITEM Type of axial seal Air leakage across seals (expressed as % of air flow at 100% SG MCR) AIR AND GAS DATA Gas velocity at 100% SG MCR Air velocity at 100% SG MCR Net free areas for air and gas flow Air flow rate Gas flow rate AIR HEATER DRIVES Electric motor drive Motor speed Motor rating Speed reducer Type Speed ratio Shaft power Emergency drive (Air motor drive) Type Shaft power Speed Air requirements a) Pressure bar(a) kW rpm kW rpm kW m/s m/s m
2
cu.m/s cu.m/s
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01

BIDDER
b) Flow rate 1.6.0 1.6.1 1.6.2 1.6.2.1 1.6.2.2 ROTOR AND BEARINGS Rotor material Bearings Type Type of lubrication
m /s
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
STEAM COIL AIR PREHEATER

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO. 1.1.0 1.1.1 1.1.2 1.1.3 1.2.0 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.7.1 1.2.7.2 1.2.7.3 1.2.8 1.2.8.1 1.2.8.2 1.2.9 1.2.10 1.3.0 1.3.1 ITEM GENERAL No. of steam coil air preheaters (SCAPH) per SG unit Type Manufacturer DESIGN CONDITIONS (Each SCAPH) Total air flow Temperature of air entering heater Temperature of air leaving heater Air velocity Air pressure drop across heater Corrosion allowance Heating steam requirement: Quantity Inlet pressure Inlet temperature Drain: Drain temperature Drain enthalpy Total surface area Heat transfer coefficient CONSTRUCTION FEATURES No. of sections per heater deg.C Kcal/Kg m
2
m /h deg.C deg. C m/s mmWc mm
kg/s bar(a) deg.C
Kcal/hr 2 m deg.C
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
STEAM COIL AIR PREHEATER

BIDDER
1.3.2 1.3.3 1.3.3.1 1.3.3.2 1.3.3.3 1.3.3.4 1.3.3.5 1.3.3.6 1.3.4 1.3.1 1.3.6
No. of tubes in each section Materials of Construction Tubes Fins Nozzles Casing Supporting plate Gasket Surface area of each section Tube diameter Tube thickness m
2
mm mm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
CENTRIFUGAL FANS
BIDDER
1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.3.1 2.3.2 2.4 2.5 2.6 2.7 2.8 2.8.1 2.8.2 2.9 2.10 2.11 3.0 3.1 3.1.1
GENERAL No. of fans per steam generator Type Manufacturer DESIGN PERFORMANCE Capacity Head Design margins over BMCR- DC Capacity Head Design temperature Flue gas density Draught loss at 100% SG MCR-DC Fan speed Fan critical speeds First critical speed Second critical speed Fan efficiency at MCR (DC) Motor efficiency at MCR(DC) Motor rating CONSTRUCTION FEATURES Casing Material rpm rpm % % kW % %
0
m3/s mmWC
kg/m3 mmWC rpm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
CENTRIFUGAL FANS
BIDDER mm
ENQUIRY /SPECIFICATION NO. SR.NO. 3.1.2 3.2 3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.4 3.4.1 3.4.2 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.6 ITEM Thickness Coupling Type Make Impeller Diameter Material Shaft Diameter Material Bearings No., make and type Bearing liner material Type of cooling Bearing lubrication type Shaft sealing arrangement mm mm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
AXIAL FANS
ENQUIRY /SPECIFICATION NO. SR.NO. 1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.3.1 2.3.2 2.4 2.5 2.6 2.7 2.8 2.8.1 2.8.2 2.9 2.10 2.11 3.0 3.1 3.1.1
ITEM
GENERAL Number of fans per steam generator Type Manufacturer DESIGN PERFORMANCE Capacity Total head Design margin Capacity BMCR (DC) Head - BMCR (DC) Design temperature Air density Draft loss at 100% SG MCR Fan speed Fan critical speeds First critical speed Second critical speed Fan efficiency at MCR Motor efficiency at MCR Motor rating CONSTRUCTION FEATURES Casing Material
BIDDER
m3/s mmWC
% %
0
Kg/m3 mmWC rpm
rpm rpm % % kW
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
AXIAL FANS
ENQUIRY /SPECIFICATION NO. SR.NO.
ITEM
BIDDER
3.1.2 3.2 3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.4.2 3.5 3.5.1 3.5.2 3.6 3.7 3.7.1 3.8 3.8.1 3.8.2
Thickness Coupling Type Make Impeller Diameter Blade material Hub material Shaft Diameter Material Bearings No., make and type Bearing liner material Shaft sealing arrangement Hydraulic serve drive No., make and type Lube oil system No. and type of pumps No. and type of oil coolers
mm
mm
mm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SOOT BLOWING SYSTEM

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO 1.1.0 1.1.1 1.1.2 1.1.3 1.2.0 1.2.1 1.2.1.1 1.2.1.2 . ITEM GENERAL Source of steam Steam pressure Steam temperature SOOT-BLOWERS Furnace, Radiant, Convective Sections Type and make Number of soot blowers - Radiant section - Convective section 1.2.1.3 Material of construction 1.2.1.4 1.2.1.5 1.2.1.6 1.2.1.7 1.2.1.8 1.2.2 1.2.2.1 1.2.2.2 Lance / swivel tube Nozzle Blower head Feed tube Bearing (in high temp. area) Compression hangers hr min. bar(a) Kg/hr Kg/h Economiser Air preheater Furnace Superheater Reheater bar(a) deg.C
Total time required for one complete cycle of soot blowing operation Duration of operation Operating pressure Steam consumption rate per cycle Rate of steam consumption per blower Economiser & Air preheater: Type and make Number of soot blowers
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SOOT BLOWING SYSTEM

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO 1.2.2.3 . ITEM Material of construction 1.2.2.4 1.2.2.5 1.2.2.6 1.2.2.7 1.2.2.8 1.3.0 1.3.1 1.3.2 1.3.3 1.3.4 7.3.5 1.3.5.1 1.3.5.2 1.3.5.3 1.4.0 1.4.1 1.4.2 Lance / Swivel tube Nozzle Blower head Feed tube Swivel joint min. bar(a) Kg/h Kg/h h
Duration of operation Operating pressure Steam consumption rate per cycle Rate of steam consumption per blower Total time required for one complete cycle of soot blowing operation PRESSURE REDUCING VALVES (Furnish data for all valves) Type and make Inlet pressure Outlet pressure Outlet temperature Material : Valve seat Body Stem SAFETY VALVES (Furnish data for all valves) Type and make Blowing pressure
bar(a) bar(a) deg.C
bar(a)
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SOOT BLOWING SYSTEM

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO . ITEM
1.4.3
Blowing capacity
t/h
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
FUEL OIL BURNER AND IGNITOR

BIDDER
ENQUIRY /SPECIFICATION NO. SR.NO. 1.1.0 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.7.1 1.1.7.2 1.1.7.3 1.1.8 1.1.8.1 ITEM FUEL OIL BURNERS Designation Number of burners per steam generator Type Make Capacity of each burner Turn-down ratio of burner Heavy oil pressure : Maximum Normal Minimum Atomising medium Atomising steam/air requirement of each burner i) Flow rate ii) Pressure 1.1.9 1.1.9.1 1.1.9.2 1.1.9.3 1.1.10 1.1.11 Scavenging steam requirement of each burner Flow rate Duration of cleaning Pressure Viscosity of oil at burner tip for good atomisation Air requirement of auto retract mechanism Kg/h min bar(a) Cst Kg/h bar(a) bar(a) bar(a) bar(a) Kg/h LDO HFO/LSHS/HPS
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
FUEL OIL BURNER AND IGNITOR

BIDDER
1.1.11.1
a) Quality b) Quantity/operation c) Pressure Nm

3
Service / instrument air
bar(a)
1.1.12 1.1.12.1 1.1.12.2 1.1.12.3 1.2.0 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.5.1 1.2.5.2 1.2.5.3
Material of construction: Oil burner Diffuser Nozzle cap IGNITORS Type Number Fuel Capacity of each ignitors Ignition gas pressure Maximum Normal Minimum Kg/h bar(a)
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
COAL BURNERS
BIDDER
SR.NO.
1.1.0 1.2.0 1.3.0 1.4.0 1.5.0 1.6.0 1.7.0 1.8.0 1.9.0 1.9.1 1.9.2 1.9.3 1.9.4 1.10 1.10.1 1.10.2 1.10.3 1.10.4 1.10.5 1.10.6
ITEM
Number of burners Type (Low Nox burner) Make Capacity of each burner Turndown ratio without oil support Coal/air mixture pressure before burner Velocity of the mixture at entry to burner Velocity of secondary air at entry to burner Material Coal burner nozzle Guide plate Support bearing inside wind box Drive mechanism for tilting (linkages etc. if provided) COAL FEEDER Type Manufacturer Capacity Speed Distance between centre line of inlet and outlet Inlet Diameter
Yes/No
Kg/h
mmwc m/s m/s
T/hr rpm
mm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
COAL BURNERS
BIDDER
mm kW
SR.NO.
1.10.7 1.10.8 1.10.9
ITEM
Belt width Motor rating Type of controls
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
COAL MILLS BIDDER
SR.NO. ITEM
1.1.0 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.13.1 GENERAL Make Type No of mills Manufacturer Capacity (Indicate for worst and design coal) t/h Method of feeding Input lump size max. Speed of rotation Guaranteed output at specified input size and moisture Output fineness Mode of adjustment of ball / roller Mode of adjustment of classifier vanes Material a) Grinding ring/race/cylinder b) Liner, if applicable 1.1.13.2 a) Rolls/balls b) Liner, if applicable 1.1.13.3 a) Housing grinding zone b) Liner, if applicable 1.1.13.4 a) Reject collection zone
mm rpm t/h
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
COAL MILLS BIDDER
SR.NO. ITEM
b) Linear, if applicable 1.1.13.5 1.1.13.6 1.1.13.7 1.1.13.8 1.1.13.9 1.1.14 1.1.15 1.1.16 1.1.17 Gear drive make Main drive shaft Worm shaft Classifier type Pressure springs Type of bearings and seals Method of lubrication of rotating parts Type of flexible coupling Power consumption per mill at 10% SG MCR - For design coal - For worst coal 1.1.18 1.1.19 1.1.20 1.1.21 1.2.0 1.3.0 Mill drive motor rating Wear parts life Grinding ring/race life Rolls / Balls life Expected no. of operating hours between major over-hauls of the coal mill Rate of coal mill rejects - When the mills are relatively new (Just started operation) - Considering worn out condition of
Kw
Kw
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
COAL MILLS BIDDER
SR.NO. ITEM
grinding parts 1.4.0 Any other Data - List items
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
GEAR/SCREW PUMPS BIDDER

LDO
SR.NO.
1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.12.1 1.1.12.2 1.1.12.3 1.1.12.4 1.1.12.5 1.1.12.6 1.1.13 1.1.14 1.1.14.1 1.1.14.2
ITEM
Designation Manufacturer Type No. of pumps Capacity Total dynamic head Suction head Efficiency Speed Type of coupling Packing type Materials of construction: Casing Rotor Shaft Shaft sleeves Base plate Wearing rings (if required) Type of bearing used Connections Suction size Discharge size
HFO/LSHS/HPS
m /h mlc mlc % rpm
Internal/external
mm mm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
GEAR/SCREW PUMPS BIDDER

bar(a)
SR.NO.
1.1.15 1.1.16 1.1.16.1 1.1.17 1.1.18
ITEM
Relief valve set pressure Motor Motor rating and speed Maximum allowable suction lift Any other Data - List items
kW/rpm mlc
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
FUEL OIL HEATERS BIDDER
SR.NO.
ITEM
1.0 2.0 2.1 2.2 2.3
Number provided Design Data for each heater Fluid circulated Flow rate (max) Operating temperature (a) (b) Inlet Outlet
0
Shell Side
Tube Side
kg/hr
C C
2.4 2.5 2.6 2.7 2.8 3.0 4.0
Pressure drop across heater Hydrotest pressure Corrosion allowance Fouling resistance No. of passes Total heat transfer area Tube details (a) (b) (c) (d) No. Outside dia Pitch Length
0
kg/cm2 kg/cm2(a) mm Hr.m2 C/kcal
m2
mm/BWG mm mm
5.0
Materials of construction (a) (b) Shell Tubes
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
FUEL OIL HEATERS BIDDER
SR.NO.
ITEM
(c) (d) (e) 6.0 7.0 8.0 Empty weight of heater
Tube sheets Baffles Gaskets tonnes tonnes mxmxm
Flooded weight of heater Assembled dimension of heater
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
AIR AND GAS DUCTS AND DAMPERS BIDDER
SR.NO.
1.1.0 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.5.1 1.1.5.2 1.1.6 1.1.7 1.1.7.1 1.1.7.2 1.1.7.3 1.2.0 1.2.1 1.2.2
ITEM
AIR DUCTS FD fan cold air intake duct size FD fan cold air discharge duct size PA fan cold air intake duct size PA fan hot air duct size Thickness of plate : Cold air Hot air Material Air velocity in : Cold air duct FD fan Cold air duct PA fan Hot air duct PA fan GAS DUCTS Size of ID fan discharge duct Size of common flue gas duct (after headering) Duct plate thickness Material Gas velocities : Suction side
mm x mm mm x mm mm x mm mm x mm
mm mm
m/s m/s m/s ID Fan mm x mm mm x mm GR Fan (If produced)
1.2.3 1.2.4 1.2.5 1.2.5.1
mm
m/s
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
AIR AND GAS DUCTS AND DAMPERS BIDDER
SR.NO.
ITEM
1.2.5.2 1.3.0 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.4.0 1.4.1 1.4.2 1.4.3
Discharge DAMPERS Type and make Location Service Type of drive Sealing efficiency Materials of construction Dampers frame Blades Linkage bolts and pins
m/s Isolation Control Guillotine
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
ELECTROSTATIC PRECIPITATOR BIDDER
SR.NO.
1.1.0 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7
ITEM
GENERAL INFORMATION Manufacturer Number of ESP / Steam generator Number of gas stream / ESP Number of electrical fields in series in gas path / stream Total active treatment length per stream Treatment time Corona power per ESP stream
m secs. watts per 3 1000 m per min.
1.1.8
No. of hours ESP can run at specified gas flow and dust loading without emptying any hopper With worst coal With design coal Dust conc. at the ESP outlet Worst coal firing All fields in service One TR set out of service mg/Nm mg/Nm
3 3
1.1.8.1 1.1.8.2 1.1.9 1.1.9.1
1.1.9.2
Guarantee coal firing All fields in service One TR set out of service mg/Nm mg/Nm
3 3
1.1.10
Total power input to the ESP per steam generator
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SR.NO.
ITEM
1.2.0 1.2.1 1.2.1.1 1.2.1.2 1.2.1.3 1.2.1.4 1.2.1.5 1.2.1.6 1.2.1.7 1.2.1.8 1.2.1.9 1.2.1.10 1.2.1.11 1.2.1.12 1.2.2 1.2.2.1 1.2.2.2 1.2.2.3 1.2.2.4 1.2.2.5
ELECTRODES & BUS SECTIONS Collecting Electrodes Type Material Electrode thickness Clear distance between collecting electrode plates Number of gas passages / stream Active length per electrode Cross sectional area of each passage Active height per electrode Specific collection plate area Total number of electrodes per SG Aspect ratio length / height Average gas velocity in the electrical field Bus Section Total numbers Number of bus sections in parallel in gas path Number of sections in parallel in gas path HT Voltage Total power on HT electrode kV (peak) kW m/s
2
mm mm
m m m
2 2 3
m /m /sec
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SR.NO.
1.2.2.6 1.2.2.7
ITEM
Ratio of collecting electrode area to bus sections Number of sections lost if one transformer is out of service
1.2.3 1.2.3.1 1.2.3.2 1.2.3.3 15.2.3.4 1.2.3.5 1.2.3.6 1.2.3.7 1.2.4 1.2.4.1 1.2.4.2 1.2.4.3 1.3.0 1.3.1 1.3.1.1 1.3.1.2 1.3.1.3
Discharge Electrode Type Material Number of electrodes per gas path Distance between effective distance electrodes in direction of gas flow Total number of electrodes / SG Electrode dimension height Effective length of electrode High Voltage Conductor Manufacturer Type Size RAPPING SYSTEM Collecting Electrodes Type Total number of rappers per SG Maximum number of electrodes rapped by a rapper at any one time m m m
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SR.NO.
1.3.1.4 1.3.1.5 1.3.1.6 1.3.1.7 1.3.2 1.3.2.1 1.3.2.2 1.3.2.3 1.3.2.4 1.3.2.5 1.3.2.6 1.4.0 1.4.1 1.4.1.1 1.4.1.2 1.4.1.3 1.4.1.4 1.4.1.5 1.4.2 1.4.2.1 1.4.2.2
ITEM
Percentage of plates rapped at one time Rapping acceleration force minimum / plate Average input rapping power to rapping system Rapper controller type Discharge Electrode Type Total number of rappers Percentage of electrodes rapped at any time Rapping energy of each rapper Average input power to rapping system Rapper controller type SUPPORTS High Tension Support Insulators Type Material Leakage distance Minimum flash over Location High Tension Conductor Support Type Material g
kW
% kgs. kW
mm kV
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SR.NO.
ITEM
1.4.2.3 1.5.0 1.5.1 1.5.2 1.5.3 1.5.3.1 1.5.3.2 1.5.3.3 1.5.3.4 1.5.3.5
Insulator TRANSFORMER RECTIFIER UNIT Total numbers Capacity - each Transformer Type of transformer Class of insulation Temperature rise of oil over ambient Class of bushing Rating of each set a) Input power b) Output power c) Output voltage d) Output current kVA kW kV (peak) mA Litres
0
kVA
1.5.3.6 1.5.4 1.5.4.1 1.5.4.2 1.5.4.3 1.5.4.4 1.5.5 1.5.5.1
Volume of oil Rectifier Type Half-wave / full wave Guaranteed life Rating-each Transformer Rectifier Control Unit Number offered
hours
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SR.NO.
ITEM
1.5.5.2 1.5.5.3 1.5.5.4 1.5.5.5 1.5.5.6 1.6.0 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.6.6 1.6.7 1.6.8 1.6.8.1 1.6.8.2 1.6.8.3 1.6.8.4 1.6.8.5 1.7.0 1.7.1 1.7.2
Type of cabinet Voltage control Arc suppression Protection Instrumentation provided as required POWER CONSUMPTION OF ESP PER SG Input power Output power from TR sets Output voltage Output current Total connected load Maximum power requirement Corona power available Auxiliary power Rapping system Seal air fan Seal air heaters (during start up) Seal air heaters (normal operation) Hopper heaters HOUSING Plate thickness Design pressure mm mmwg kVA kW kV mA kW kW Watts / m kW kW kW kW kW kW
2
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SR.NO.
1.8.0 1.8.1 1.8.2 1.8.3 1.8.4 1.8.5
ITEM
DUST HOPPERS PER SG Total numbers Plate thickness Material Hopper valley angle Electric heater a) Rating b) Number per hopper
mm
degrees
1.9.0 1.9.1 1.9.2 1.9.3
PERFORATED GAS DISTRIBUTION PLATE Type Material Location
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
DATA SHEET B16
INSULATION / REFRACTORY BIDDER
SHEET 1
OF 2
SR.NO.
1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11
ITEM
Insulation Area of application (separately furnish for SG, flue gas duct, hot air duct, ESP etc) Type of insulation Manufacturer Composition Thickness of insulation Density of insulation (for pourable / castable refractory indicate for dry condition) Thermal conductivity Maximum continuous withstanding temperature Code to which insulation / refractory is offered ? (Name, number and year of code) Finishing cement provided? If yes, (a) Thickness of finishing cement (b) Density of finishing cement
mm Kg /m
3
mW/cm C
0
mm 3 Kg/m
1.1.12 1.1.13 1.1.14 1.2 1.2.1 1.2.2
Sheathing material, type wherever applicable Thickness of sheathing material Is the insulating material corrosive to surface on which it is applied ? Refractory Area of application ( furnish separately for each area of application ) Type Value mm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
DATA SHEET B16
INSULATION / REFRACTORY BIDDER
SHEET 2
OF 2
SR.NO.
1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8
ITEM
Manufacturer Composition Density Thermal conductivity Maximum continuous Withstanding Temperature Code to which refractory material is offered
Kg/cm3 W/ m2 C Deg C
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
SEPERATOR DRAIN RECIRCULATION PUMPS BIDDER
SR.NO.
1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.10.1 1.1.10.2 1.1.10.3 1.1.10.4 1.1.11 1.1.17
ITEM
Manufacturer Type No. of pumps provided No. of pumps in operation during start up Capacity of each pump Total dynamic head Suction head Efficiency Speed Materials of Construction Casing Impeller Shaft Bearings Motor housing Motor rating / speed
m /h mlc mlc % rpm
INTERNAL / EXTERNAL kW / rpm
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
ATMOSPHERIC DRAIN TRANSFER PUMPS BIDDER
SR.NO.
14.1.1 14.1.2 14.1.3 14.1.4 14.1.5 14.1.6 14.1.7 14.1.8 14.1.9 14.1.1
ITEM
Manufacturer Type No. of pumps provided No. of pumps in operation during start up Capacity of each pump Total dynamic head Suction head Efficiency Speed Materials of Construction
m /h mlc mlc % rpm
14.1.10.1 Casing 14.1.10.2 Impeller 14.1.10.3 Shaft 14.1.10.4 Bearings 14.1.11 14.1.17 Motor housing Motor rating / speed kW / rpm INTERNAL / EXTERNAL
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
HORIZONTAL CENTRIFUGAL PUMPS BIDDER
SR.NO.
19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 19.9 19.10 19.11 19.12 19.13 19.14 19.15
ITEM
Service Number Offered Pump Make And Model Number Design Capacity TDH Shut-Off Head Number Of Stages Pump Efficiency At Duty Point Pump Speed Drive Motor Rating Method Of Lubrication Npsh Required Type And Make Of Mechanical Seal Type Of Coupling Minimum Capacity For Continuous
M /Hr Mlc Mlc
% Rpm Kw
Mlc
M /Hr
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
DATA SHEET B20
DRAWING AND DETAILS BIDDER
SHEET 1 OF 3
SR.NO.
1.0
ITEM
The dimensioned drawings / details and data listed below shall be submitted with the bid. The BIDDER shall note that these drawings are minimum requirement only and he must include sufficient drawings to give a clear and comprehensive indication of the plant offered. General Arrangement Steam generator area plan upto stack for both 1st and 2nd unit. Front elevation, side elevation, and cross-section of the steam generating unit showing location of headers and drums. Layout of interconnecting platforms and platforms meant for connecting the steam generator floors to the turbine operating floor. Flow Diagrams, Control Schemes And Performance Curves Scheme of steam and water showing instrument tap-off points Scheme of air and gas path with instrument tap off points Scheme of pulveriser system with instrumentation Scheme of fuel oil supply and burning system with instrumentation Cold start up, warm start up (Overnight shutdown) and hot start-up curves. Correction curves Draft Plant
1.1 1.1.1 1.1.2
1.1.3
1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.3
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
DATA SHEET B20
SHEET 2 OF 3
SR.NO.
1.3.1
ITEM
FD / SA and PA fans blade angle lines, stall line, equal efficiency line, system resistance line with all fans in service and with one SA and one PA fan out both at 50 Hz and 47.5 Hz respectively showing SGMCR & test block points, for both one fan and two fan operation as applicable. ID fan inlet vane angle / speed lines, stall line, equal efficiency line, system resistance line for normally fouled condition with both ID fans and electrostatic precipitator sections in service and also with one ID fan and one electrostatic precipitator section out both at 50 Hz and 47.5 Hz respectively showing SG MCR and test block points, for both one fan and two fans operations as applicable. Coal Burning System General arrangement of feeders, etc.. General arrangement of mill, etc. Description of coal feeders Description of coal mills Fuel Oil Burning System Description of supply and firing system with associated equipment drawings Ignition System Description of supply and firing system including associated equipment and drawings Soot Blowing System Scheme of soot blowing system Write-up on operation of soot blowing system
1.3.2
1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.5 1.5.1 1.6 1.6.1 1.7 1.7.1 1.7.2
SPECIFICATION NO.
VOLUME IIIA

TCE-5103A-C-500-01
DATA SHEET B20
SHEET 3 OF 3
SR.NO.
1.8
ITEM
Description of flame scanners used on ignitors and fuel oil guns and installation list covering the latest three year period of in-service experience
ISSUE NO. R5
SPECIFICATION NO.
VOLUME IIIA
TCE.M4-113-54
DATA SHEET B21
ELECTRICALLY OPERATED HOISTS ENQUIRY/ SPECIFICATION NO. TCE.

SL. NO.
SHEET :
1 OF 3
1. GENERAL 2. 3. 4. 5. HOIST 6. 7. 8. 9. 10. 11. 12. 13. 14. 14.1 14.2 ELECTRICAL REQUIREMENTS 14.3 14.4 15. 15.1 15.2 15.3 15.4 16. 16.1 16.2
ITEM DESIGNATION NUMBER OFFERED TAG NUMBERS CAPACITY MANUFACTURER MAKE MODEL NUMBER
BIDDER ELECTRICALLY OPERATED HOIST FOR
TROLLEY
MANUFACTURER MAKE MODEL NUMBER HOIST MOTOR : MAKE TYPE RATING SPEED TROLLEY MOTOR : MAKE TYPE RATING SPEED LIMIT SWITCHES FOR : HOISTING : MAKE, TYPE AND NUMBERS PROVIDED TRAVELLING: MAKE, TYPE AND NUMBERS PROVIDED KW RPM KW RPM MAIN CREEP MAIN CREEP
NOTES TO BIDDER 1. DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN REPRODUCED IN DATA SHEET-B. IN CASE OF DEPARTURE FROM DATA SHEET-A, BIDDER SHALL BRING OUT THE SAME IN SCHEDULE OF DEVIATIONS, FAILING WHICH IT SHALL BE CONSTRUED THAT BIDDER COMPLIES WITH THE REQUIREMENTS STIPULATED IN DATA SHEET-A.
SIGNATURE OF BIDDER
2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.
DATE
FILE NAME: DB11354R5.DOC
TCE FORM NO. 294 R1
ISSUE NO. R5
SPECIFICATION NO.
VOLUME IIIA
TCE.M4-113-54
DATA SHEET B22
ELECTRICALLY OPERATED HOISTS ENQUIRY/ SPECIFICATION NO. TCE. SL. NO. 17. ELECTRICAL REQUIREMENTS (CONTD.) 17.1 17.2 17.3 17.4 17.5 ITEM TYPE OF DOWN SHOP LEAD MAKE SIZE LENGTH SUPPORTING ARRANGEMENT IF CURVED MONORAIL, NUMBER OF CABLE TROLLEYS PROVIDED AND WIDTH OF EACH TROLLEY 18. 19. 20. 21. 22. MONORAIL IF PROVIDED BY VENDOR : INDICATE BEAM SIZE MINIMUM/ MAXIMUM SUITABLE FOR TROLLEY MOVEMENT 23. DIMENSIONS MONORAIL IF PROVIDED BY PURCHASER : IS SIZE SPECIFIED IN DATA SHEET A SUITABLE FOR TROLLEY MOVEMENT 24. DISTANCE BETWEEN HIGHEST HOOK POSITION TO BOTTOM OF MONORAIL IF MONORAIL IS CURVED, MINIMUM RADIUS TROLLEY CAN NEGOTIATE 26. 27.
MATERIALS OF CONSTRUCTION
SHEET :
2 OF 3
BIDDER
M NO./ mm
mm
ISMB
/ ISMB YES/ NO
IF NO, INDICATE SUITABLE SIZE ISMB
mm mm
25.
IF HOIST IS IN HAZARDOUS AREA : TROLLEY WHEELS ROPE DRUM AND SHEAVES GEARS AND PINIONS
27.1 27.2 27.3 28. 29.
NOTES TO BIDDER 1. DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN REPRODUCED IN DATA SHEET-B. IN CASE OF DEPARTURE FROM DATA SHEET-A, BIDDER SHALL BRING OUT THE SAME IN SCHEDULE OF DEVIATIONS, FAILING WHICH IT SHALL BE CONSTRUED THAT BIDDER COMPLIES WITH THE REQUIREMENTS STIPULATED IN DATA SHEET-A. 2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.
SIGNATURE OF BIDDER
DATE
ISSUE NO. R5
SPECIFICATION NO. FILE NAME: TCE.M4-113-54
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED 2X800 MW TPP NEAR KRISHNAPATNAM ELECTRICALLY OPERATED HOISTS
VOLUME IIIA TCE FORM NO. 294 R1 DATA SHEET B22 SHEET : 3 OF 3
ENQUIRY/ SPECIFICATION NO. TCE. SL. NO. 30. 31. 32. 33. 34. 35. ITEM WIRE ROPE DIAMETER WIRE ROPE BREAKING LOAD WEIGHT OF COMPLETE HOIST AND TROLLEY ASSEMBLY WEIGHT OF HOIST WHEEL LOAD WITH IMPACT AND WITHOUT IMPACT PRELIMINARY DIMENSIONED GENERAL ARRANGEMENT DRAWING OF ELECTRICALLY OPERATED HOIST ALONG WITH WHEEL STOP DETAILS TO BE FURNISHED 36. 37. 38. 39. WHETHER FURNISHED YES/ NO Kg Kg Kg / BIDDER mm KN
NOTES TO BIDDER 1. DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN REPRODUCED IN DATA SHEET-B. IN CASE OF DEPARTURE FROM DATA SHEET-A, BIDDER SHALL BRING OUT THE SAME IN SCHEDULE OF DEVIATIONS, FAILING WHICH IT SHALL BE CONSTRUED THAT BIDDER COMPLIES WITH THE REQUIREMENTS STIPULATED IN DATA SHEET-A.
SIGNATURE OF BIDDER
2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.
DATE
FILE NAME: DB11354R5.DOC
TCE FORM NO.294 R1
SPEC. NO. TCE.5103A-C-50001
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED 2X800 MW TPP NEAR KRISHNAPATNAM FOUNDATION LOADING AT COLUMN BASE BIDDER
UNIT W BM BM SF SF BM BM SF SF
XX YY XX YY
VOLUME IIIA DATA SHEET B22 SHEET 1 OF 1
ENQUIRY /SPECIFICATION NO. SR.NO.

SL. NO LOADS DUE TO BOILER PARTS AND SELF WEIGHT OF STRUCTURE ETC.
ITEM
KIND OF LOAD UNDER MAXIMUM LOADING CONDITIONS
COLUMN DESIGNATION
T TM TM T T T
XX YY
UNDER MINIMUM LOADING CONDITIONS
TM TM T T T
XX YY
ADDITIONAL LOADING DUE TO WIND
WIND ACTING ALONG LONG AXIS
W BM SF
YY
TM T T
YY
WIND ACTING ALONG TRANS AXIS
W BM SF
XX
TM T T
XX
SEISMIC FORCES SEISMIC FORCES ACTING ALONG ACTING ALONG LONG AXIS TRANS AXIS
ADDITIONAL LOADING DUE TO SEISMIC
W BM SF
YY
TM T T
YY
W BM SF
XX
TM T
XX
BM SF
XX XY
- B M ABOUT LONG AXIS, BM
YY
- B M ABOUT TRANS AXIS, W - VERTICAL AXIAL LOAD

XX
- HORIZONTAL SHER ALONG AXIS, SF
- HORIZONTAL SHEAR ALONG TRANS AXIS
TM - TONNE METRES, T - TONNE
C TRANS AXIS
2 BM YY BM XX
C
2 S XX
LONG AXIS OF BOILER S YY
SECTION .1 - 1
SECTION -2 - 2
PLAN
SIGNATURE OF BIDDER DATE TCE FORM 294 R1
ISSUE NO.R6
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED 2X800 MW TPP NEAR KRISHNAPATNAM LOW VOLTAGE SWITCHGEAR
ENQUIRY /SPECIFICATION NO. SR.NO. ITEM BIDDER
1.0 1.1 1.2 1.3 1.4 1.5 1.6.1 1.6.2 1.7
SPECIFIC PARTICULARS Switchgear designations Single front or double front Applicable Standard Fully drawout/semi drawout/Fixed Total dimensions of each complete switchgear L x W x D Width of each vertical section with cable alley Width of cable alley only Minimum clear space required a) In front b) Back mm mm kg FD/SD/F mm L W D mm mm SF/DF
1.8 1.9
Max. cubicle weight with components Have all the feeders and components specified in enclosed Drawings and Data Sheets A - 3 been provided ?
YES/NO
ISSUE NO.R6
2.0 2.1
GENERAL PARTICULARS Sheet steel a) Cold rolled/Hot rolled b) Thickness : i) Frames mm mm mm mm mm
ii) Door iii) Rear cover iv) Side and top covers v) 2.2 Panel partitions
Degree of protections provided by the enclosure (As per IS : 13947) Earth busbar size BUSBAR a) Material of busbars b) Section c) Continuous current rating under site conditions d) Whether busbars have been insulated e) Type of insulation f) Temperature rise over the reference ambient when carrying rated C Sq.mm A PH : Sq.mm GI/AL/CU AL/CU N:
2.3 2.4
YES/NO
ISSUE NO.R6
current g) Material of busbar supports h) Clearance in air : i) Between phases ii) Between phases earth i) Short time rating (One Sec.) j) Momentary rating (peak) CIRCUIT BREAKERS Makers name Makers type designation Applicable standards Circuit breakers type (air break and or MCCB) Rated voltage Rated operating duty Rated current Derating factor for operation under site conditions Rated symmetrical breaking current at rated voltage. (Indicate power factor) Rated peak making current Rated short time withstand rating (for 1 sec.) (For MCCB, BIDDER to indicate the time) Operating mechanism type Limits of voltage for satisfactory operation of the following devices as a % of normal voltage mm mm kA kA
3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13
V A
kA P.F. kA
ISSUE NO.R6
i) ii) 3.14 3.15 3.16
Operating mechanism Closing at normal voltage
% % % W W
iv) Trip coil Power required for closing at normal voltage Power required for tripping at normal voltage Spring charging motor details : i) Rating ii) Rated voltage
kW V, AC/DC Sec. YES/NO
3.17 3.18 3.19 3.20 3.21 4.0 4.1 4.2 4.3 4.4 4.5
iii) Spring charging Overload release provided Short circuit release settings and time delay features Undervoltage release setting Have electrical and mechanical antipumping features been provided Have type test certificates been enclosed ? AIR BREAK SWITCHES Make Type Rated Voltage Applicable standards Maximum prospective fault current withstand of composite unit of switch and fuse FUSES Make Type Applicable standards Rated voltage Rated current for individual circuits to be provided as per requirements of protection coordination CONTACTORS
YES/NO YES/NO
kA (peak)
5.0 5.1 5.2 5.3 5.4 5.5 6.0
V YES/NO
ISSUE NO.R6
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10
Make Rated duty Rated Utilisation Category Applicable standards Rated (thermal) current provided as per specification Rated voltage of auxiliary contacts Rated voltage of coil Rated breaking capacity Rated making capacity Limits of operation i) Supply voltage variation
YES/NO V V Factor of rated current Factor of rated current +% +% %
ii) Supply frequency variation for closing 6.11 iii) Drop out voltage No of auxiliary contacts : I) Normally open ii) Normally closed 7.0 7.1 8.0 8.1 8.2 8.3 9.0 9.1 9.2 9.3 9.4 9.5 9.6 SINGLE PHASING PREVENTERS Is it in built-in bimetal thermal overload relay CURRENT TRANSFORMERS Make Applicable standards All other parameters of CT as per enclosed SLD/list and Section-D VOLTAGE TRANSFORMERS Make Applicable standards Ratio Output per phase Accuracy class Over voltage factor
YES/NO
YES/NO
V/V VA
ISSUE NO.R6
9.7 10.0 10.1 10.2 10.3 10.4 10.5 10.6 11.0 11.1 11.2 11.3 11.4 12.0 12.1 12.2 12.3 12.4 12.5 13.0 13.1 13.2 13.3 13.4 14.0 14.1 14.2 14.3 15.0 15.1 15.2 16.0 16.1 16.2 16.3 16.4 17.0
Class of insulation CONTROL TRANSFORMERS Make Type Applicable standards Ratio Class of insulation Rated output INSTANTANEOUS OVERCURRENT RELAY Application (phase fault or earth fault) Make Type designation Setting range INVERSE TIME AND THERMAL OVERCURRENT RELAY Application Make Type Current setting range Time setting range at 10 times the current setting UNDERVOLTAGE RELAY Make Type Voltage rating Setting range AUXILIARY RELAYS AND TIMERS Make Type Coil voltage CONTROL/SELECTOR SWITCH Make Type designation VOLTMETER Make Type Applicable standards Accuracy class AMMETER
VA
Sec.
V V
ISSUE NO.R6
17.1 17.2 17.3 17.4 18.0 18.1 18.2 18.3 18.4 19.0 19.1 19.2 19.3 19.4 19.5 20.0 20.1 20.2 20.3
Make Type Applicable standards Accuracy class WATTMETER Make Type Applicable standard Accuracy class INDICATING LAMPS Make Type Voltage Series resistor Wattage of lamp PUSH BUTTONS Make Type designation No of contacts: i) Normally open
V Ohms W
20.4 21.0 21.1 21.2 21.3 21.4 21.5 22.0 22.1 22.2 22.3
ii) Normally closed Contact rating SPACE HEATER Make Type Rated voltage Heater output for each vertical panel Thermostat at setting C WIRING AND TERMINAL BLOCKS Voltage grade Insulation Minimum size of conductor for : i) Power wiring
V W
Sq.mm Sq.mm
22.4
ii) Control wiring Type of terminal blocks :
ISSUE NO.R6
i) For withdrawable Type 22.5 22.6 23.0 23.1 ii) For Fixed type Minimum current rating of terminal blocks Whether terminals for CTs have been provided with short circuiting facilities PUSH BUTTON STATION Metal Enclosure : i) ii) Die-cast aluminium/sheet metal of 2mm thickness Degree of protection YES/NO YES/NO YES/NO A YES/NO
23.2 22.3 23.4
iii) Painting, inscription earthing terminals as specified Gland plate and cable glands provided Facility for fixing on wall/structure provided No. of Contacts : i) Normally open
23.5
ii) Normally closed Contact rating : I) At 415 V AC ii) At 110 V AC A A A YES/NO
23.6
iii) At 220 V DC Terminal blocks with identification nos. provided for external connections.
ISSUE NO.R6
TCE FORM 329 R3
ISSUE NO.: R4
SPECIFICATION NO.
VOLUME IIIA
DATA SHEET B24
TCE-M4-203-06
MOTOR OPERATED VALVES ACTUATORS ENQUIRY /SPECIFICATION NO. BIDDER
SHEET 1 OF 2
SR.NO. 1.0 2.0 3.0 4.0 5.0 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 6.0 6.1 6.2 6.3 6.4 6.5 7.0
ITEM Manufacturers Name & Address Type / Model No. Motor Rating Operating time of actuator Integral Motor Starter provided (please furnish detailed wiring diagram) Contactor Make and type Rated Duty Rated utilisation category Rated voltage and current Rated voltage of coil Thermal overload relay range Interposing relay Make of relay Type of relay Coil voltage rating Relay Burden Contact rating Space heating supply derived from control transformer (Applicable for 3 phase, 3 wire system) Space heater rating Actuator catalog furnished Typical test certificates furnished V
KW Secs. Yes / No.
V,A V % of motor current rating
VA V, A Yes / No.
8.0 9.0 10.0
V, Watts Yes / No Yes / No SIGNATURE OF BIDDER DATE TCE FORM 294 R1
ISSUE NO.: R4
SPECIFICATION NO.
VOLUME IIIA
DATA SHEET B24
TCE-M4-203-06
MOTOR OPERATED VALVES ACTUATORS ENQUIRY /SPECIFICATION NO. BIDDER
SHEET 2 OF 2
SR.NO.
ITEM
11.0
Technical requirements
11.1
Whether technical requirements as per section D (write up), data sheet A1 and the standards as per data sheet A3 are met fully. If No to Cl. 11.1 whether all deviations are brought out in schedule of deviations in section F
Yes / No
11.2
Yes / No
ISSUE R4
TCE FORM 329 R3
ISSUE NO R7
SPECIFICATION NO.
VOLUME IIIA
DATA SHEET B 25 TCE-M4-203-11
D.C. MOTORS ENQUIRY /SPECIFICATION NO. BIDDER
SHEET 1 OF 2
SR.NO.
ITEM
1.0 2.0 3.0 4.0 5.0
Application / Designation Manufacturer Applicable Standards Type of Motor Rating a) Output b) Speed kW RPM
6.0 6.1 6.2 7.0
Duty Type of Duty Duty Designation Current a) Full Load (FL) i) Armature ii) Field b) Starting i) Max. starting ii) Min. starting % FL % FL % Amps Amps
8.0 9.0 10.0
Full Load Efficiency Method of Starting D.O.L./ Reduced Voltage Starting Torque a) Full Load (FLT) b) Starting c) Maximum
Kg-m % FLT % FLT
11. 11.1. 11.2
Resistance Armature Wdg. Field Wdg. Ohms Ohms SIGNATURE OF BIDDER DATE TCE FORM 294 R1
ISSUE NO R7
SPECIFICATION NO.
VOLUME IIIA
DATA SHEET B 25 TCE-M4-203-11
D.C. MOTORS ENQUIRY /SPECIFICATION NO. BIDDER
SHEET 2 OF 2
SR.NO.
ITEM
12.0 12.1 12.2 13.0 14.0 15.0 15.1 15.2
Inductance Armature Wdg. Field Wdg. Dimensional Dwg. Enclosed Starter in Vendors Scope of Supply Technical Requirements Technical requirements, as per Section-D, Data Sheet-A1 and the standards as per Data Sheet-A2 If NO to CL. 15.1, deviations are brought out in Schedule of Deviations in Section-F Yes/No Yes/No mH mH Yes/No Yes/No
ISSUE NO. R1
VOLUME IIIA
DATA SHEET B26
SHEET 1 OF 4
ENQUIRY / SPECIFICATION NO. SR.NO. ITEM BIDDER
1.0 2.0 2.1 2.2 3.0 4.0 4.1 5.0 6.0 6.1 6.2 6.3 6.3.1
Converter Designation Overload capacity & duration Minimum duration required for two successive overloads as specified above Switching frequency (specify if derating required for any switching frequency) Transient change in the nominal output voltage for 100% charge in motor load Size of largest motor which can be started direct on line Maximum length of power supply cable without output filter Max distortion factor of input current at I/P of drive CONTROL SYSTEM Nature of system Detailed technical information enclosed Auxiliary Voltage Supply Analog Inputs No. of Inputs Input Range Digital Inputs No. of Inputs Analog Output No. of Output Range
% , Mins Min/Hrs kHz --- % with recovery to steady state within ------ sec. kW
Analog/Digital Yes/No
6.3.2 6.3.3
ISSUE NO. R1
VOLUME IIIA
DATA SHEET B26
SHEET 2 OF 4
ENQUIRY / SPECIFICATION NO.
SR.NO.
ITEM
BIDDER
6.3.4 6.3.5 6.3.6 7.0 7.1 7.1.1 7.1.2 7.2 7.2.1 8.0 9.0 10.0
Digital Outputs Serial Communication for panel (specify port and protocol) Serial Communication for external control (specify port and protocol) MONITORING AIDS Power Semi-conductors Are temperature sensing elements provided? Technical write up enclosed Cooling system Nature of cooling of converters Tentative Dimensions & weight Type of Mounting GA drawing of Drive Panel enclosed Yes/No Natural/Forced Yes/No Yes/No
ISSUE NO. R1
VOLUME IIIA
DATA SHEET B26
SHEET 3 OF 4
SR.NO.
ITEM
DC DRIVE
BIDDER
1.0 2.0 2.1 2.2 3.0 4.0 4.1 5.0 5.1 5.2 5.3
Pulse Number No. of parallel six pulse bridge arms Current rating per bridge arm Total current rating of converter No. of power semi-conductors in series per bridge arm Whether Converter connected to source directly If no rating of the converter transformer If Armature Control used the field is connected Directly to the sources Through converter transformer of the armature voltage control Through separate converter transformer of rating
6/12
Yes/No kVA
Yes/No Yes/No kVA
ISSUE NO. R1
VOLUME IIIA
DATA SHEET B26
SHEET 4 OF 4
SR.NO.
ITEM
AC DRIVE
BIDDER
1.0 1.1 2.0 2.1 2.2 3.0 4.0 5.0
Rated Output Voltage Accuracy of output voltage to maintain constant V/f Output Frequency Setting range Accuracy Output rating kVA at power factor specified in data sheet A Output transformer rating & details, if provided Maximum Distortion factor of output Voltage
Hz Hz %
kVA, V, %Z
TCE FORM 329 R3
ISSUE NO. R7
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED 2X800 MW TPP NEAR KRISHNAPATNAM CONTROL CABINETS
ENQUIRY /SPECIFICATION NO. SR.NO. ITEM 1.0 2.0 3.0 4.0 5.0 6.0 Manufacturer's name Indoor/Outdoor application Thickness of sheet steel Degree of protection provided (as per IS:2147 or equivalent) Bill of Material for the various equipment giving make, type, ratings etc. enclosed Colour of finish paint a) Outside b) Inside 7.0 Busbars for power devices (when applicable) a) Material b) Continuous current rating 8.0 Control Wiring/Power Wiring a) Material of conductor and size b) Conductor solid/Stranded Cu/Al mm2 A (PVC Insulated/Bare) Yes/No mm BIDDER
R7
TCE FORM NO.329R3
MAIN PLANT & AUXILIARIES SPECIFICATION
STEAM GENERATORS & AUXILIARIES VOLUME IIIB
SPEC.NO. TCE-5103A-C-510-01
VOLUME IIIB CONTENTS SHEET 1 OF 3
STEAM GENERATORS AND AUXILIARIES VOL IIIB - CONTENTS ISSUE NO. R8 R8 D2 TCE-M4-219-01 R7 R7 D3 TCE-M4-219-11 R7 R7 D4 TCE-M4-203-71 R1 R1 D5 TCE-M4-203-02 R8 NO OF SHEETS 5 3 6 1 18 4 19 1 4
SECTION D1
CONTRACT NO TCE-M4-203-01
TITLE INDUCTION MOTORS DATA SHEET-C CONTROL CABINETS DATA SHEET-C LOW VOLTAGE SWITCHGEAR DATA SHEET-C VARIABLE SPEED DC/AC DRIVES DATA SHEET-C INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS DATA SHEET-C MOTOR OPERATED VALVE ACTUATORS DATA SHEET-C D.C. MOTORS DATA SHEET-C SHELL AND TUBE HEAT EXCHANGER DATA SHEET-C WELDED UNFIRED PRESSURE VESSEL DATA SHEET-C GUSSETS FOR NOZZLE 40 NB AND BELOW EARTHING CLEAT FABRICATION TOLERANCE FOR PRESSURE VESSELS
R8 D6 TCE-M4-203-06 R4
4 4
R4 D7 TCE-M4-203-11 R8 R8 D8 TCE M4-101-01-01 R3 R3 D9 TCE.M4-102-01-01 R3
1 4 1 10 1 9
R3 D10 TCE.M4.102-34 R1
1 1
D11 D12
TCE.M4-102-43 TCE.M4-102-51
R1 R3
1 2
ISSUE R0
TCE FORM NO. 329 R4
STEAM GENERATORS AND AUXILIARIES VOL IIIB - CONTENTS ISSUE NO. R3 NO OF SHEETS 1
SECTION D13
CONTRACT NO TCE.M4.102-30-01
TITLE SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 219.1 TO 508 SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 600 TO 900 SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 1000 TO 1200 SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 1300 TO 1900 SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 1901 TO 2500 SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 2501 TO 4000 SUPPORTING SADDLE GENERAL NOTES VALVES AND SPECIALITIES DATA SHEET-C CAST STEEL VALVES DATA SHEET-C FORGED STEEL VALVES DATA SHEET-C WEATHERHOODS FOR PIPES THROUGH ROOF SLAB AND EXTERNAL TYPICAL INSULATION DETAILS FOR FLANGED VALVES AND FLANGES TYPICAL INSULATION FOR BENDS TYPICAL INSULATIONS FOR HANGERS
D14
TCE M4 102-30-02
R3
D15
TCE.M4 102-30-03
R3
D16
TCE.M4-102-30-04
R3
D17
TCE M4 102-30-05
R3
D18
TCE M4 102-30-06
R3
D19
TCE M4 102-30-07
R3
D20
TCE M4 103-99
R3 R3
4 1 6 1 4 1 1
D21
TCE M4-103-54
R3 R3
D22
TCE M4-103-55
R3 R3
D23
TCE. M4- 104-50
R3
D24
TCE. M4- 104-51
R3
D25 D26
TCE. M4- 104-52 TCE. M4- 104-53
R3 R4
1 1
STEAM GENERATORS AND AUXILIARIES VOL IIIB - CONTENTS ISSUE NO. R7 R5 D28 TCE. M4- 134-02 R2 NO OF SHEETS 14 2 13
SECTION D27
CONTRACT NO TCE. M4- 134-103
TITLE DESIGN OF POWER PLANT PIPING DATA SHEET-C SUPPLY, SHOP FABRICATION AND TESTING OF POWER PLANT PIPING HORIZONTAL CENTRIFUGAL PUMPS DATA SHEET C ELECTRICAL OPERATED HOISTS AND TROLLEYS DATA SHEET-C CHAIN PULLEY BLOCKS DATA SHEET-C SUPPLY, DESIGN, FABRICA-TION ,TESTING AND ERECTION OF STRUCTURAL STEEL FOR STEAM GENERATOR THERMAL INSULATION FOR HOT SURFACES DATA SHEET-C ERECTION AND TESTING OF POWER PLANT PIPING DATA SHEET-C WELDING SPECIFICATION FOR PIPING SYSTEM
D29
TCE. M4-105-01
R10 R10
3 1 4
D30
TCE.M4-113-54
R5
R5 D31 TCE. M4- 113-50 R3 R3 D32 TCE.M4-405-03 R3
1 2 1 6
D33
TCE.M4-104-02
R9
12
R9 D34 TCE.M4-134-03 R4
2 11
R4 D35 TCE.M4-134-04 R5
1 15
SPEC.NO. TCE-M4-203-01

TITLE
VOLUME IIIB SHEET 1 OF 5
2X 800 MW TPP NEAR KRISHNAPATNAM
INDUCTION MOTORS
1.0 1.1
SCOPE The specification covers the design, material, constructional features, manufacture, inspection and testing at the VENDOR'S/his SUB-VENDOR'S works, delivery to site and performance testing of induction motors. For motors of rated above 500 V, a separate specification (TCE.M4-203-02 Additional requirements for HV motors) covers the additional requirements, any or all of which shall be complied with for motors rated 415V if specified in Data Sheet-A. CODES AND STANDARDS The design, material, construction, manufacture, inspection, testing and performance of induction motors shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the applicable standards specified in data sheet A1 latest revision as on the date of offer Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. In case of conflict between the standards and this specification, this specification shall govern. DRIVEN EQUIPMENT When this specification forms part of the driven equipment specification, information not given in the Data Sheet-A will be governed by the driven equipment specification. Motors shall be capable of satisfactory operation for the application and duty as specified in the motor Data Sheet-A and as specified for the driven equipment. PERFORMANCE AND CHARACTERISTICS Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under either of the following supply conditions as
1.2
2.0 2.1
3.0 3.1
3.2
4.0 4.1
ISSUE R8 CONSULTANTS: TCE Consulting Engineers

Limited
TCE FORM NO. 329 R4

TITLE
INDUCTION MOTORS
specified in Data Sheet-A. I (a) (b) (c) 4.2 4.3 4.3.1 Variation in supply voltage from rated voltage Variation in supply frequency from rated frequency Combined voltage and frequency variation +6% +3% 9%
Supply Condition
II +10% +5% 10%
Motors shall be suitable for the method of starting specified in the Data Sheet-A. The minimum permissible voltage shall be 85% of the rated voltage during motor starting Motors shall be capable of starting and accelerating the load with the applicable method of starting, without winding temperatures reaching injurious levels, when the supply voltage is in the range of 85% of the rated motor voltage to maximum permissible voltage specified in Data Sheet-A. The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerances as per the applicable standard) unless otherwise specified. Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage. If such operation is envisaged for a period of one second, the pull out torque of the motor shall be atleast 205% of full load torque. Motors when started with the driven equipment coupled shall be capable of withstanding atleast two successive starts from cold conditions & one start from hot condition without injurious heating of windings. The motors shall also be suitable for three equally spread starts per hour under the above referred supply conditions. INSULATION The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate.
4.4 4.5
4.6
5.0 5.1
6.0
TEMPERATURE RISE
ISSUE R8 TCE FORM NO. 329 R4
CONSULTANTS: TCE Consulting Engineers

Limited

TITLE
INDUCTION MOTORS
6.1
The temperature rises shall not exceed the values given in IS 12802. Under extremes of supply condition (clause 4.1 above), the temperature rise shall not exceed the value indicated in IS by 10oC. For motors specified for outdoor installation heating due to direct exposure to solar radiation shall be considered. CONSTRUCTIONAL FEATURES Motors weighing more than 25 kg. shall be provided with eyebolts, lugs or other means to facilitate safe lifting. BEARINGS Unless otherwise specified in data sheet-A, motor bearings shall not be subjected to any external thrust load. Unless otherwise specified, motor bearings shall have an estimated life of atleast 40,000 hrs. The bearings shall permit running of the motor in either direction of rotation. When forced oil lubrication or water cooling the purchaser shall be obtained. is required, prior approval from
6.2 7.0 7.1 8.0 8.1 8.2 8.3 8.4 8.5
When forced oil lubrication or water cooling is required, the machine shall be suitable for starting & continuous operation for atleast 10 minutes, without the availability of lubrication or cooling system If the bearings are oil lubricated, a drain plug shall be provided for draining residual oil & an oil level sight gauge shall be provided to show the precise oil level required for stand still and running conditions. It shall be possible to lubricate the bearings without dismantling any part of the motor. TERMINAL BOX Terminal boxes shall have a degree of protection of atleast IP 55 for out door applicable Unless otherwise approved, the terminal box shall be capable of being turned through 360o in steps of 90o. Terminals shall be of stud type & the terminal box shall be complete with necessary ISSUE lugs, nuts, washers. R8 TCE FORM NO. 329 R4
8.6
8.7
9.0 9.1 9.2 9.3

Limited

TITLE
INDUCTION MOTORS
9.4 9.5
When single core cables are to be used the gland plates shall be of non magnetic material. Sizes of terminal boxes and lugs shall be as given in Table-I, unless specified otherwise in data sheet A or Section C. TABLE-I
415 V MOTORS - SIZES OF CABLES, STUDS, TERMINAL LUGS & TERMINAL BOXES (TO BE PROVIDED ON MOTORS BY VENDOR) ------------------------------------------------------------------------------------------------------------------------SL. MOTOR RATING 1100V Al Conductor Stud Terminal lug size Minimum Terminal NO. kW armoured PVC Cable Size of DOWELL MAKE Box Size Cores x mm2 equivalent to HxWx D DOWELL'S CAT NO. mm x mm x mm ------------------------------------------------------------------------------------------------------------------------1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Upto 3 3.1 - 7.5 7.6 - 15 16 - 25 26 - 40 41 - 55 56 - 70 71 - 85 86 - 110 111 - 175 3x4 3x6 3x16 3x35 3x70 3x120 3x185 3x240 3x400 3x1Cx500 M6 M6 M6 M8 M10 M12 M16 M20 M20 M20 CUS/06 CUS/07 CUS/09 CUS/12 CUS/17 CUS/22 CUS/28 CUS/30 CUS/33 CUS/34 100 x 100 x 60 100 x 100 x 60 100 x 100 x 60 150 x 150 x 75 200 x 200 x 100 400 x 400 x 125 450 x 450 x 150 500 x 500 x 200 600 x 600 x 200 600 x 200 x 200 (3 separate cable boxes for the 3 single core cables)
----------------------------------------------------------------------------------------------------------------------

Limited
TCE FORM NO. 329 R4

TITLE
INDUCTION MOTORS
10.0 10.1
PAINT AND FINISH All motor parts exposed directly to atmosphere shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with one coat of primer and finished with two coats of grey enamel paint. HEATING DURING IDLE PERIODS For motors rated 30 kW and below, during idle periods, the stator winding will be connected to a 24 V single phase, 50 Hz, AC supply for heating and elimination of moisture. The supply will be connected between any two terminals.
11.0 11.1
11.2
Motors rated above 30 kW shall have space heaters suitable for 240V, single phase, 50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal temperature above dew point to prevent moisture condensation during idle period. The space heaters shall be placed in easily accessible positions in the lowest part of the motor frame. ACCESSORIES Two independent earthing points shall be provided on opposite sides of the motor, for bolted connection of the PURCHASER'S earthing conductors as specified in data sheet-A. These earthing points shall be in addition to earthing stud provided in the terminal box. Except when otherwise specified, the motors shall be provided with a bare shaft extension having a key slot and a key at the driving end. TESTS Motor shall be subjected to all the routine tests as per applicable standard in the presence of the PURCHASER'S representative. Copies of test certificates of type and routine tests, shall be furnished as specified in the distribution schedule, for the PURCHASER'S approval. The VENDOR shall ensure to use calibrated test equipment/instruments having valid calibration test certificates from standard laboratories traceable to national/international standards.
12.0 12.1
12.2 13.0 13.1

Limited
TCE FORM NO. 329 R4

TITLE
2 X 800MW TPP NEAR KRISHNAPATNAM
DATA SHEET-C INDUCTION MOTORS
INFORMATION TO BE SUBMITTED BY THE VENDOR AFTER AWARD OF CONTRACT
1.0 2.0 3.0 3.1 3.2 3.3 4.0 5.0 6.0 7.0 7.1 7.2 8.0 9.0 9.1 9.2 9.3 9.4
Technical particulars as per data sheet B of tender specification. (Based on motor manufacturer) Type and frame size : Starting time (Secs) With 100% voltage at terminals With minimum voltage at terminals (at ____ % Rated voltage) With 110% voltage at terminals Safe stall time at 100/110% rated voltage under hot/cold condition. Type and size of cable for which gland is provided in the terminal box : Type of bearings and expected life. Total weight of motor (kg) Weight of Stator (kg) Weight of Rotor (kg) Motor GD2 : Efficiency (%) Full Load Efficiency 75% Load Efficiency 50% Load Efficiency 25% Load Efficiency ISSUE R8

TITLE
DATA SHEET-C INDUCTION MOTORS 10.0 10.1 10.2 10.3 10.4 11.0 11.1 11.2 11.3 12.0 13.0 14.0 14.1 14.2 14.3 15.0 15.1 15.2 15.3 16.0 16.1 16.2 16.3 Power Factor Full Load Power Factor 75% Load Power Factor 50% Load Power Factor 25% Load Power Factor Torque (% FLT) Starting Maximum (Pullout torque) Pull up torque Type of Enclosure Cooling designation Space heaters Rated voltage/number Rating total Separate terminal box provided Motor reactances (Pu) Subtransient reactance Transient reactance Steady state reactance Guaranteed losses (kW) Iron loss Copper loss Friction, Windage & Stray losses.
ISSUE R8

TITLE
DATA SHEET-C INDUCTION MOTORS
17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0
Motor outline dimension drawing (Number of copies as per distribution schedule) Type test certificates (Number of copies as per distribution schedule) Speed torque curve at rated & minimum starting voltage. Current - speed curve. Current - time curve. Efficiency, power factor, slip, current against output curve. Thermal withstand characteristic for motors of 100 kW & above - Hot & Cold. Negative sequence current Vs time curve for motor of 100 kW & above. Rotor voltage/Rotor current (for wound motors).
ISSUE R8
VOLUME IIB SHEET 1 OF 6
CONTROL CABINETS
1.0 1.1
SCOPE This specification covers the design, material, construction features, manufacture, inspection and testing at the VENDOR'S / his SUBVENDOR'S works, delivery to site and performance testing of Control cabinets upto 415V. CODES AND STANDARDS This design, material, construction, manufacture, inspection, testing and performance of control cabinets shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the latest applicable standards mentioned in Data Sheet A2. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. Supply items which are bought out by the VENDOR shall be procured from approved manufacturers acceptable to the PURCHASER/ENGINEER. CONSTRUCTIONAL FEATURES Control cabinets shall be sheet steel enclosed and shall be dust, weather and vermin proof providing a degree of protection of IP 52 for indoor use and IP 54 for outdoor use. Sheet Steel used shall be cold rolled and at least 2.0mm thick and properly braced to prevent wobbling. Control cabinets shall be provided with hinged door(s) with padlocking arrangement and suitable brackets/channels shall be provided for the type of mounting specified in Data Sheet A1. All doors, removable covers and plates shall be gasketed all around with neoprene gaskets. All accessible live connections shall be shrouded and it shall be possible to change individual fuses, switches, MCBs without danger of contact with live metal. All live parts shall be provided with atleast phase to phase and phase to earth clearances in air of 25 mm and 20mm respectively. Adequate interior cabling space and suitable removable cable glands shall be provided if specified in Data Sheet 1 Sr No.1.5 (C). Necessary number of cable glands shall be supplied and fitted screwed-on type and made of brass.
2.0 2.1
2.2
3.0 3.1
3.2
3.3
3.4 3.5
ISSUE R7
TCE FORM NO. 329 R4
CONTROL CABINETS
3.6 3.7
Two earthing terminals shall be provided to suit the PURCHASER'S earthing conductor. All sheet steel work shall be degreased, pickled, phosphated and then applied two coats of zinc chromate primer and two coats of finishing synthetic enamel paint, both inside and outside, of colour as specified in Data Sheet A1. For chemical/corrosive areas epoxy paint shall be used whenever specified in Data Sheet A1. MAIN BUSBARS Busbars shall be insulated and of aluminium alloy of E91E grade and shall have adequate cross-section to carry the required continuous currents such that the operating temperature of the busbars does not exceed 850C. MOTOR FEEDERS Each motor to be controlled from the cabinet shall be provided with 3 pole/2 pole isolating switch, HRC fuses, contractors with thermal overload relays and other equipment required for satisfactory control of motors. When schematic drawings/bill of material is enclosed, all equipment shown shall be supplied by the VENDOR. The isolating switch and contactor shall be rated at least 20% more than the connected motor full load current. Unless otherwise specified motors rated 0.5KW and above being controlled from the control cabinet will be rated for 415V, 3 phase, 50 Hz and motors rated below 0.5 KW will be 240V, 1 phase, 50 Hz. SWITCHES/MCBS Switches / MCBs / MPCBs /MCCBs shall be hand operated, air break, heavy duty, quick make, quick break type conforming to applicable standards mentioned in Data Sheet A2. The rating of switch shall be so chosen as to get complete protection by associated O/L relay or fuse under all normal/abnormal conditions such as full load, overload, locked rotor, short circuit etc. MCBs / MPCBs /MCCBs shall be provided with overload/short-circuit protective device. It shall be the responsibility of the VENDOR to fully coordinate the overload and short circuit tripping of the MCBs / MPCBs /MCCBs with
ISSUE R7
4.0 4.1
5.0 5.1
5.2
6.0 6.1
6.2
6.3
TCE FORM NO. 329 R4
CONTROL CABINETS
the downstream MCBs/fuses/motor starters, to provide satisfactory discrimination. 6.4 Switch handle shall have provision for locking in both fully open and fully closed positions. MCBs / MPCBs /MCCBs shall be provided with locking facility when called for in Data Sheet A1. CONTACTORS Contactor type motor starters shall be of the full voltage, direct-on-line, air break, single throw, electro-magnetic type unless otherwise specified. Automatic star-delta type starters shall be provided when specified. Contactors shall be provided with at least 2 'NO' and 2 'NC' auxiliary contacts. Contactor shall be provided with a three element, positive acting, ambient temperature compensated time lagged, hand reset type thermal overload relay with adjustable settings to suit the rated motor current. FUSES Fuses generally shall be of the HRC cartridge link type, mounted on plug-in type of fuse bases having a rupturing capacity of 80 kA. Fuses upto 63A may be of HRC cartridge screw-cap, D-type, having a rupturing capacity of not less than 46 kA at 440V A.C. and 16 kA at 250V D.C. Fuses shall be provided with visible operation indicators to show that they have operated. All accessible live connections shall be adequately shrouded, and it shall be possible to change fuses with the circuit alive, without danger of contact with live metal. INSTRUMENT TRANSFORMERS Current and voltage transformers shall be dry type. Unless otherwise specified it shall be the responsibility of the VENDOR to ensure that the class and VA burdens of the instrument transformers provided are adequate for the relays and meters connected to these. Facilities shall be provided for short circuiting and grounding the CT secondary at the terminal blocks. Test links shall be provided in the CT secondary leads to carryout current and phase angle measurement tests with CTs in
7.0 7.1
7.2 7.3
8.0 8.1
8.2 8.3
9.0 9.1
ISSUE R7
TCE FORM NO. 329 R4
CONTROL CABINETS
service. Voltage transformers shall be provided with suitably rated primary and secondary rated fuses. The details of the instrument transformer are subject to the PURCHASER's approval. 10.0 10.1 CONTROL AND AUXILIARY POWER SUPPLY All AC control equipment shall be suitable for operation on 240V AC, 1 phase, 50 Hz system. This supply may be obtained from phase and neutral when 4 wire 415V main supply is available. Otherwise, or when control voltage, other than 240V is specified, a suitable transformer shall be provided. The control transformer shall be complete with isolation facilities and primary and secondary HRC fuses. Separate circuits with switches, fuses etc. of adequate rating shall be provided for control of space heater, through thermoster and panel illumination etc. RELAYS Necessary auxiliary release for alarm, time-delay relays, voltage relays as required for control and protection shall be mounted inside the cabinet. Relays shall be equipped with externally reset, positive action operation indicator. Voltage relays shall have sufficient thermal capacity for continuous energization, using external resistors if necessary. Auxiliary relays shall be rated to operate satisfactorily between 80% and 110%of the rated voltage. Each relay shall be provided with at least two potential free contacts (1NO+1NC) for the PURCHASER's use. Make and type of relay shall be subject to the PURCHASER's approval. CONTROL AND SELECTOR SWITCHES Control and selector switches shall be of the rotary type provided with properly designated escutcheon plates clearly marked to show the operating positions. Control switches shall have momentary contacts, spring return to centre, with pistol grip handle. Selector switches shall have stay put contacts with oval handles. The number of contacts and their operation in each switch shall be as indicated in control schematic (when enclosed) or shall be as per the requirements of the connected
10.2
11.0 11.1
11.2 11.3 11.4 12.0 12.1
CONTROL CABINETS
circuit. The switches shall be rated for minimum 10A at 240V A.C. and 1A inductive break at 220V D.C. 13.0 13.1 PUSH BUTTONS All pushbuttons shall be of push to actuate type having 2 'NO' and 2 'NC' self reset contacts. They shall be provided with integral escutcheon plates, engraved with their functions. Pushbuttons contacts shall be rated for 10 Amps at 240V A.C. and 1 Amp inductive breaking at 220V D.C. INDICATING LAMPS Indicating lamps of the Clustered Coloured LED type with coloured Lens engraved ON,OFF,TRIP. SPACE HEATER Strip type space heaters of adequate capacity shall be provided inside each cabinet. Heaters shall be complete with rotary type 'ON-OFF' switch, HRC fuse on phase or a single-pole MCB with overload and short circuit protection, link on the neutral and a thermostat to cut off the heaters at 45 Degree Celsius and shall have continuously settable range from 30 to 90 degree Celsius. INTERIOR LIGHTING AND RECEPTACLE Control cabinet shall be provided with a 240V, 1 phase, 50 Hz, 40W preferably fluorescent lighting fixture for interior illumination controlled by a 'ON-OFF' switch / MCBs and 240V, 1 phase, 5/15 Amp., 3 pin receptacle with Plug and Switch/MCB for Switching ON & OFF. Power source for interior lighting and receptacles shall be completely independent of control power source. CABINET INTERNAL WIRING Control cabinet shall be supplied completely wired, ready for the PURCHASER'S external connections at the terminal blocks. All wiring shall be carried out with 650/1100V grade, PVC insulated, stranded conductors. Power circuits shall be wired with standard aluminium conductors of adequate sizes to suit the rated circuit current; the minimum size shall be 4 sq.mm. Control, alarm and indication circuits shall be wired with stranded copper conductors of sizes not smaller than 1.5 sq.mm. C.T. circuits shall be colored wired for R Y B phases with stranded copper conductor of size, not smaller than 2.5 sq.mm.
14.0 14.1 15.0 15.1
16.0 16.1
16.2 17.0 17.1
ISSUE R7
TCE FORM NO. 329 R4
CONTROL CABINETS
17.2
Engraved identification ferrules, marked to correspond with the wiring diagram shall be fitted at both ends of each wire. All wiring shall be adequately rated for the circuit current, the minimum rating shall be 20A. LABELS AND DIAGRAM PLATE Every equipment mounted in the cabinet shall be provided with individual labels with equipment designation/rating. Also, the cabinet shall be provided on the front & Rear side with a non-rusting label engraved with the designation of the cabinet as furnished by the PURCHASER. Inside the door a circuit diagram engraved on non-rusting metal / PVC shall be fixed for reference. DRAWINGS AND DATA As part of the proposal, the BIDDER shall furnish the following drawings and data for scrutiny. a) b) c) Control cabinet general arrangement drawing showing dimensioned views, cable entry location and mounting details. Schematic wiring diagram of the control cabinet. Bill of material listing equipment designation, make, type, rating etc. of the various equipment mounted on the control cabinet.
18.0 18.1
18.2 19.0 19.1
20.0 20.1
TESTS & TEST REPORTS Acceptance and routine tests for all supply equipments/component parts shall be carried out as per the relevant standards for the respective equipment. These test reports and available type test reports shall be submitted to the PURCHASER before despatch of the equipment. Control cabinet shall be subjected to following tests:
a) High voltage test (2000 volts for 1 minute)
20.2
b) c)
Megger test Electrical control, interlock and sequential operation tests.

ISSUE R7
20.3 Calibration certificates. Instruments used for testing and inspection shall have valid calibration and accuracy traceable to National Standards.
TCE FORM NO. 329 R4
CONTROL CABINETS DATA SHEET -C DATA TO BE FURNISHED BY THE VENDOR AFTER AWARD OF CONTRACT 1.0 1.1 1.2 Following data shall be submitted within 3 months after placing the order. Schematic diagram indicating terminal numbers for external connections and with a Bill of Material for all the equipment. Control cabinet drawing showing outline dimensions, cable entry openings, floor / wall / pedestal fixing arrangements, padlocking arrangement, weights. MANUFACTURER'S technical literature on various equipment mounted on control cabinet. Cabinet internal wiring diagram (This drawing shall be submitted only for information and records and shall be based on a approved schematic drawing. The correctness of this drawing shall be the responsibility of the VENDOR). Test certificates for the control cabinet and the various equipment mounted therein shall be submitted atleast 2 weeks before despatch of equipment.
1.3 2.0
3.0
Note The VENDOR should allow atleast 4 weeks time in his manufacturing schedule for approval of the drawing by the PURCHASER.
R7 CONSULTANTS: TCE Consulting Engineers Limited TCE FORM NO. 329 R4

TITLE
1.0
SCOPE This specification covers the requirements of design, materials, manufacturing, testing and inspection at Vendor's works of Low Voltage switchgear for voltage not exceeding 1000 V A C.
2.0
CODES AND STANDARDS The design, manufacture and performance of equipment shall comply with latest applicable Codes of Standards specified in Data Sheet-A2. In case of conflict between standards and this specification, this specification shall govern.
3.0 3.1
CONSTRUCTIONAL FEATURES The major parameters of the switchgear and other required features are given in data sheet - A1, A2 and A3. The bidder shall in his offer specifically conform compliance of these data in full. Deviation if any should be specifically brought out in the schedule of Technical Deviation. The switchgear shall be indoor, metal enclosed, floor mounted of uniform height not more than 2450 mm, made up of the requisite vertical sections, dust and vermin proof construction with IP - 52 degree of protection, unless otherwise stated. Adjacent switchgear cubicles shall be provided with side sheets on either side to ensure complete isolation. The switchgear shall be easily extendable on both sides by the addition of vertical sections. The bottom of the switchgear shall be fully covered by sheet steel. Removable gland plates shall be provided for power and control cables. The gland plates shall be 3mm thick for panel with breaker cubicles and 2mm thick for other cubicles. The gland plates for single core cables shall be of non-magnetic material. All sheet steel work shall be thoroughly cleaned of rust, scale, oil, grease, dirt and swarf by pickling, emulsion cleaning etc. The sheet steel shall be phosphated and then painted with two coats of zinc rich primer paints. After application of the primer, two coats of finished synthetic enamel ovenbaked/stoved, paint shall be applied or powder coated. Each switchgear cubicle shall be fitted with a label in the front and back of the cubicle. Each switchgear shall also be fitted with label indicating the
ISSUE R7
3.2
3.3
3.4 3.5
3.6
3.7
TCE FORM NO. 329 R4

TITLE
switchgear designation, rating and duty. Each relay, instrument, switch, fuse and other devices shall be provided with separate labels. 3.8 Operating devices shall be incorporated only in the front of the switchgear. No equipment needing manual operation shall be located less than 250 mm above ground level. The switchgear shall be divided into distinct vertical sections comprising of a) Individual feeder module which shall be integral multiples of basic module, containing all associated equipment, enclosed in sheet steel enclosure on all sides and the rear except cable alley side and provided with hinged door on the front. A completely metal enclosed, busbar compartment running horizontally, and a vertical busbar compartment serving all modules in vertical section. A vertical cable alley covering the entire height, except horizontal busbar compartment with minimum 250 mm width for MCC modules at right hand side and minimum 200 mm for circuit breaker controlled modules, with adequate number of slotted cable support arms. A horizontal separate enclosure or enclosures separated by hylum/FRP sheets for power and control buses with tap off connections to each vertical section.
3.9
b)
c)
d)
3.10
The circuit breakers shall be fully draw out type. The circuit breakers shall have distinct service, test, isolated and maintainance positions. In the test position the circuit breakers shall be capable of being tested for operation without energising the power circuits. Four normally open auxiliary contacts shall be provided for each of the services and test limit positions switches. The test position should preferably be obtained without the need to disconnect normal control connections and use extension cords for testing.
3.11 3.12
The current transformers shall be mounted on the fixed portion of the switchgear but not directly on buses or the breaker truck. The withdrawable chassis housing feeder for motor control equipment except circuit breakers/common control transformers of big size, shall be of the fully drawout, semi-drawout, or fixed type as specified in the Data Sheet-A1.

TITLE
3.12.1 Fully Drawout Type Withdrawable Chassis In this type of construction it shall be possible to drawout the withdrawable chassis without having to unscrew or unbolt any connections to the equipment mounted on the withdrawable chassis. The power and control drawout type connections shall be of the stab-in or sliding type. All drawout contacts, including for auxiliary and control wiring shall be of self aligning type. 3.12.2 Semi-Drawout Type Withdrawable Chassis In this type of construction, it shall be possible to drawout the withdrawable chassis after manually unplugging at the terminal blocks the control circuit connections of the equipment mounted on the withdrawable chassis, without having to unbolt any power connections of the equipment. The power connections shall be of the stab-in or sliding type and shall be disconnected when the chassis is withdrawn. 3.12.3 Fixed Type Withdrawable Chassis In this type of construction all power connections to the equipment mounted on the withdrawable chassis shall be of the bolted type. All control circuit connections to equipment mounted on the withdrawable chassis shall be carried out through conventional terminal blocks mounted in the respective chassis. It shall be possible to drawout the chassis after unbolting/ unscrewing all the power and control circuit connections to the equipment mounted on the withdrawable chassis. 3.13 All identical equipment and corresponding parts including chassis of drawout modules of the same size shall be fully interchangeable, without having to carry out modifications. The draw-out contacts shall be made of copper/ copper alloy/aluminium faces, which shall be silver or tinplated. If ventilating louvers are provided they shall be provided with fine-screened brass or GI meshes from inside to prevent entry of vermin and dust. Module Types
3.14 3.15 3.16
3.16.1 The various types of modules indicating the control requirements of each type, together with the list of component equipment required for each type are detailed in the enclosed drawings. These are as follows : A - Incoming circuit - Isolating switch & fuse.

TITLE
B - Incoming circuit - Circuit Breakers. C - Incoming circuit - Isolating switch. D - Voltage transformer circuit. E - Outgoing feeder - Circuit breaker. F - Outgoing feeder - Switch-fuse unit controlled. G - Bus coupler H - Auxiliary services - Common equipment for annunciation scheme. J - Auxiliary services - Common equipment for space heater supply. K - Motor control - Direct-on-line-non essential motors L - Motor control - Direct-on-line essential motors M - Motor control - Automatic Star-Delta motor (open-transition) P - Motor control - Automatic Star-Delta motor (close-transition) R - Motor control - Reversing control 3.16.2 Motor control modules are further differentiated by suffixes as described below, unless otherwise stated in Data Sheets-A3. Suffix in First Digit 1 Denotion (Control location) Controlled from MCC Suffix in Denotion second (Motor kW digit rating range) 1 2 3 4 1 2 3 4 Upto 30 kW 31 - 49 kW 50 -125kW above 125 kW Upto 30 kW 31-49 kW 50-125 kW above 125 kW
2.
Controlled remote from MCC
3.17
Main And Auxiliary Buses
3.17.1 Busbars shall be of uniform cross section throughout the length of the switchgear, and upto the incoming terminals of the incoming feeder circuit breaker/ switch.

TITLE
3.17.2 All busbars, shall be insulated with close fitting sleeve, all bus taps, joints shall be insulated with moulded caps. If insulating sleeve is not coloured busbars shall be colour coded with coloured bands at suitable intervals. 3.17.3 Busbars shall be adequately supported on insulators. These shall withstand dynamic stresses due to short circuit currents specified. 3.17.4 Auxiliary Buses Auxiliary buses for control power supply, space heater power supply or any other specified service shall be provided. These buses shall be insulated, adequately supported and sized to suit specific requirements. The material of control power supply buses shall be electrolytic copper. The material for space heater power supply buses shall be same as that for the main power buses. Supply transformer(s), auxiliary busbars and necessary connections to the supply transformers and associated circuits shall be in the VENDOR'S scope. 3.18 SAFETY INTERLOCKS AND FEATURES
3.18.1 Withdrawal or engagement of circuit breakers or switch (isolator) shall not be possible unless it is in the open position. 3.18.2 Operation of circuit breaker shall not be possible unless it is fully in service positions or in test position or is fully drawn out. 3.18.3 Circuit breaker cubicles shall be provided with safety shutters operated automatically by the movement of the circuit breaker carriage, to cover the exposed live parts when the breaker is withdrawn. 3.18.4 Caution name plate with inscription "Caution - Live Terminals" shall be provided at all points where the terminals are likely to remain live and isolation is possible only at remote end, e.g. incoming terminals. 3.18.5 A breaker of given rating shall be prevented from engaging with a stationery element of higher rating. 4.0 4.1 CIRCUIT BREAKERS Circuit breakers shall be provided with following accessories.
4.1.1 Accessories as asked in Data sheet - A1

TITLE
4.1.2 Mechanically operated targets to show 'Open', 'Closed', 'Service' and 'Test' positions of the circuit breaker. 4.1.3 Mechanically operated, red 'trip' push button, shrouded to prevent accidental operation. 4.1.4 Locking facilities in the 'Service', 'Test', and 'Isolated', positions. In test position the breaker will be tested without energising the power circuits. The breaker shall remain fully housed inside the compartment in the test position. 4.1.5 Minimum 6 NO and 6 NC potential free auxiliary contacts, rated 10 A at 240V A.C. and 1A (inductive breaking at 220 V D.C.) 4.1.6 'Red', 'green' and 'amber' indicating lamps to show 'Closed' 'Open', and 'Autotrip' conditions of the circuit breaker when breaker operation is controlled by a control switch. 4.1.7 Closing and trip coil shall operate satisfactorily under the following conditions of supply voltage variation : Closing coils - 85% to 110% of rated voltage. Trip coils - 70% to 110% of rated voltage. 4.1.8 When series trip circuit breakers are specified the following releases with adjustable settings shall be provided : (Oil dash-pot type release is not acceptable): a) b) c) Overload Short circuit Undervoltage
4.1.9 In addition to the adjustable current setting range specified in the Data SheetA1 short circuit releases shall be provided with at least four adjustable time delay settings, If it is not possible to provide the specified adjustable current setting range for the short circuit releases, shunt trip circuit breakers together with necessary protective relays shall be offered and shall be indicated in Data Sheet-B by the VENDOR. 4.1.10 Facilities shall be provided for blocking the under-voltage release, if so required at Site. 4.1.11 Each of the foregoing releases shall be provided with a single pole, double throw, potential free alarm contact rated for 0.5A, 220V D.C.

TITLE
4.1.12 The breakers controlling motors shall operate satisfactorily under following conditions : a) b) 4.2 Direct-on-line starting of the specified motor. Breaking no load current of the specified motor.
SPRING OPERATED MECHANISM The operating mechanism shall be manually operated spring charging stored energy type or with motor, opening and closing springs, limit switches for automatic charging and all necessary accessories. Facility for manual charging of the closing spring shall be provided. The operating mechanism shall be trip-free and non-pumping electrically. An antipumping relay to achieve electrical anti-pumping feature even if the breaker has provision for anti-pumping by mechanical arrangement. Power operated mechanism shall be : a) Provided with facilities for remote panel closing and opening operations whenever specified in Data Sheet-A3 as per breaker module designation and respective enclosed control scheme drawing. The control scheme will be as follows for remote control : Breaker Position Selector Switch Service Local Remote Yes Yes Yes Yes Yes Test Local Remote Yes Yes Yes Yes
1. 2. 3. 4.
Switchgear Protection Tripping Remote Interlock Tripping Switchgear Manual Closing Remote and Auto Closing through Interlocks Switchgear Manual Tripping
5.
Yes
Yes

TITLE
6. 7.
Remote Manual Tripping Local P.B. Station of Motor (For breaker operated motors): a) b) Closing for trial run Tripping
Yes
Yes
Yes
Yes Yes
Yes
Yes
Yes
Power operating mechanisms shall be provided with the following additional features: b) c) Closing of the circuit breaker shall automatically initiate recharging of the spring ready for the next closing stroke. The motor shall be mechanically decoupled as soon as the emergency manual charging handle is coupled.
5.0
PROTECTION COORDINATION It shall be the responsibility of the Vendor to fully coordinate the overload and short circuit tripping of the circuit breakers with the upstream and downstream circuit breakers/fuses/motor starters, to provide satisfactory discrimination.
6.0 6.1
AIR BREAK SWITCHES Air break switches shall be of the heavy duty, group operated load-break, fault-make type, complying with the requirements of applicable standards mentioned in Data Sheet-A2. Continuous current rating of switches shall be as specified in Data Sheet-A3 or single line diagam enclosed with specification. Whenever solid link are used for the connections between switches and fuses, such links shall be fitted with insulated sleeves. Whenever the links are of less than 100 mm length where sleeves cannot be fitted, taping is acceptable. All live parts of the switch shall be shrouded. Switch operating handle shall be suitable for padlocking in 'OFF' position.
ISSUE R7
6.2 6.3
6.4 6.5
TCE FORM NO. 329 R4

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6.6 6.7
It shall be possible to open the door only when the switch is in the 'off' position. Suitable means shall be provided to intentionally release the interlocks specified in the preceeding clause 6.6 for making trip setting adjustments and operation tests. FUSES Fuses generally shall be of the HRC cartridge fuse-link type having a certified rupturing capacity of not less than 80 kA at 440V. Fuses shall be provided with visible indication to show that they have operated. Fuse ratings chosen by the VENDOR for application in various circuits shall be subject to the PURCHASER'S approval. Fuses shall preferably be mounted in moulded plastic carriers and shall be complete with fuse bases. Wherever it is not possible to mount fuses on carriers, fuses shall be directly mounted on plug-in type of bases. In such cases an insulated fuse pulling handle shall be provided for each size of fuse for each switchboard. Current time characteristics of fuses shall be furnished along with bid. MOTOR STARTERS CONTACTORS
7.0 7.1 7.2 7.3 7.4 7.5
7.6 8.0 8.1
8.1.1 Motor starter contactor shall be of the electromagnetic type rated for uninterrupted duty as defined in applicable standards unless otherwise specified in Data Sheet-A1. 8.1.2 Operating coils of contactors shall be suitable for operation from the control supply system specified in Section-B or as per enclosed control schemes. 8.1.3 Class of coordination for starter module shall be class '2' as per IS-13947. 8.2 DIRECT-ON-LINE STARTERS

TITLE
8.2.1 Direct-on-line starters shall be suitable for Class AC 3 utilisation category as specified in applicable standards, unless otherwise mentioned in Data SheetA1. 8.3 8.3.1 AUTOMATIC STAR-DELTA STARTERS Automatic star-delta starters shall comprise three sets of contactors one for the line, one for the star point and one for the delta, and a timer to automatically change the connections from star to delta.
8.3.2 Star-delta contactors shall be electrically interlocked to permit starting of the motor in the proper sequence, namely star contactor closing, line contactor closing, timer energised after time delay, timer contact de-energising the star contactor, and delta contactor closing. 8.3.3 Star-delta starters shall be suitable for AC 3 utilisation category as specified in applicable standards, unless otherwise mentioned in Data Sheet-A1. 8.4 REVERSING STARTERS
8.4.1 Reversing starters shall comprise forward and reverse contactors, electrically interlocked with each other. 8.4.2 Reversing starters shall be suitable for Class AC 4 duty as specified in applicable standards, unless otherwise mentioned in Data Sheet-A1. 8.5 THERMAL OVERLOAD RELAYS
8.5.1 Starters shall be complete with a three element, positive acting, ambient temperature compensated, time lagged thermal overload relay with adjustable settings and built in single phasing preventer. The setting range shall be properly selected in accordance with the rating of the motor. 8.5.2 Thermal overload relays shall be hand reset type, unless otherwise specified in Data Sheet-A1. 8.5.3 'Stop' push button of the starter and hand reset device shall be separate from each other. 8.5.4 Overload relay hand reset push button shall be brought out on the front of the compartment door. 8.6 SWITCH AND CONTACTOR RATINGS

TITLE
8.6.1 Switch and contactor rating for various motor starter modules shall be selected by the bidder and indicated in the bid. BIDDER shall also select appropriate ratings for HRC fuses and ranges for thermal overload relays and indicate the same in the bid. These details shall be subject to the PURCHASER'S approval. 8.7 Moulded Case Circuit Breakers
8.7.1 Moulded case circuit breakers (MCCBs) shall be provided when called for in Data Sheet-A1, for use in lieu of switchfuse for the motor controls. The MCCBs shall conform to the latest applicable standards. 8.7.2 MCCBs in AC circuits shall be of triple/four pole construction arranged for simultaneous three/four pole manual closing and opening. If indicated in Data Sheet-A1, power closing device for remote operation shall be provided. Operating mechanism shall be quick-make, quick-break and trip-free type. The ON, OFF and TRIP positions of the MCCB shall be clearly indicated and visible to the operator. Operating handle for operating MCCBs from door of board shall be provided. 8.7.3 The instantaneous short circuit release shall be so chosen by the VENDOR as to operate at a current in excess of the peak motor inrush current and a range of settings shall be provided for the PURCHASER'S selection. 8.7.4 MCCB terminals shall be shrouded and designed to receive cable lugs for cable sizes relevant to circuit ratings. 8.8 MINIATURE CIRCUIT BREAKERS
8.8.1 Miniature circuit breakers for use on motor space heater control circuits shall comply with the requirements of applicable standards, unless otherwise mentioned in Data Sheet-A1. 9.0 9.1 EARTHING An earthing bus shall be provided at the bottom and extended throughout the length of the switchgear. It shall be bolted/welded to the frame work of each unit and each breaker earthing bar. All non-current carrying metal work of the switchgear shall be effectively bonded to the earth bus. Hinged doors shall be earthed through flexible earthing braid. Positive earthing of the circuit breaker frame shall be maintained both in service and test position.
9.2
9.3

TITLE
10.0 10.1
INSTRUMENT TRANSFORMERS The ratings of instrument transformers specified in Data Sheet - A1 and A3 are approximate. The BIDDER shall ensure that the specified ratings are adequate for the relays and meters furnished by him. If specified ratings are not adequate the BIDDER shall offer instrument transformers of required rating. The CTs and VTs shall be dry type and withstand momentary and short time current ratings of the associated switchgear. For feeders with fuse, CTs shall have withstand capacity equal to let-through current of associated fuse. Unless otherwise specified minimum performance requirements of CT's & VTs shall be as follows.
10.2
10.3
10.3.1 CURRENT TRANSFORMERS Measuring CTs - 10VA, accuracy Class 1.0 and ISF of 5 Protective CTs - 10 VA, accuracy class of 5P-10. CTs shall be provided with test links in both secondary leads for carrying out current and phase angle measurement. 10.3.2 VOLTAGE TRANSFORMER Measuring VT's - 50 VA per phase with accuracy class of 1.0. Protective VT - 50 VA per phase with accuracy class of 3.0. Dual purpose VT - 100 VA per phase and dual accuracy of 1.0/3.0 for metering and protection respectively. Voltage transformer shall have continuous over voltage factor of 1.2 and short time over voltage factor of 1.5 for 30 seconds for effectively earthed system and 1.9 for 8 hours for non-effectively earthed system. Voltage transformers shall be complete with suitable rated primary, secondary and tertiary fuses. Primary fuses shall have a rupturing capacity equal to the rupturing capacity rating of the associated switchgear. Fuses shall be provided on each sub circuit. It shall be possible to replace voltage transformers without having to deenergise the main bus bars.

TITLE
The terminals of V.T. secondary and tertiary windings which are required to be connected to earth shall be earthed by an isolating link without a fuse. 11.0 11.1 SWITCHGEAR ACCESSORIES AND WIRING Switchgear shall be supplied completely wired internally upto terminal blocks ready for the PURCHASER's external cable connections at the terminal blocks. Inter panel wiring between cubicles of same switchgear shall be routed inside by the VENDOR. All auxiliary wiring shall be carried out with 1100 volts grade, single core, stranded copper conductor with PVC insulation. The sizes of wire shall be not less than 2.5 mm per lead of CT circuits and 1.5 mm per lead of other circuits. Terminal blocks shall be of stud type, 1100 volts grade, 10 amps. rated complete with insulated barriers. Terminal blocks for CTs and VTs shall be provided with test links and isolating facilities and CT terminals shall have short circuiting and earthing facility. All spare contacts and terminals of cubicle mounted equipment and devices shall be wired to terminal blocks. Accuracy class for indicating instruments shall be 2.0 or better. Instruments shall be 96 mm square 90 scale for semi-flush mounting with only flanges projecting. Relays shall be suitable for semi-flush mounting with only flanges projecting. All protective relays shall be in draw-out cases with built-in test facilities. Necessary test plugs shall be supplied loose and shall be included in the VENDOR'S scope of supply. All auxiliary relays and timers shall be supplied in non-draw-out cases. All relays shall be of self reset type except lockout relay unless otherwise specified. Externally operated hand reset flag indicators shall be provided on all relays and timers. Timers shall be of electromagnetic or electronic type only. Control and instrument switches shall be rotary type provided with escutcheon plates clearly marked to show operating position and suitable for semiflush mounting with only switch front plate and operating handle projecting out. Breaker control switches shall be pistol grip black and selector switches shall be oval or knob, black. Breaker control switches shall be 3 position spring return to neutral. Instruments selector switches shall be of the maintained
11.2
11.3
11.4 11.5
11.6 11.7
11.8
11.9

TITLE
stay-put type. Contacts of the switches shall be spring assisted and contact faces shall be with rivets of pure silver. The contact ratings shall be adequate to meet the requirements of circuit capacity in which they are used. If specified in data sheets, control switches with builtin flashing type discrepancy lamp shall be provided to control circuit breaker. 11.10 Push buttons shall be provided wherever specified. They shall be provided with inscription plates engraved with their functions. Push buttons shall be rated for 10A at 240 AC and 1A at 220 VDC, with 2 No and 2NC contacts. Start PB shall be green in colour and stop PB shall be red coloured stay put type. 11.11 Indicating lamps shall be Cluster type LEDS. 11.12 Space heaters of adequate capacity shall be provided inside each panel. They shall be suitable for 240 V, 1 ph, 50 cycles supply. They shall be complete with MCB or HRC fuses, isolating switches and adjustable thermostat. 11.13 Each switchgear panel shall be provided with 240 Volts, 1 phase. 50 cycles, 5 amps. 3 pin receptacle with switch located in a convenient position. 11.14 The single phasing preventer relay shall be provided when called for in data sheet-A1 and shall have following characteristics. Operate for supply voltage unbalance of more than + 5% and when relay internal wiring is open circuited. Not operate for 3 ph supply failure. Instantenous hand reset type Visual indication for operation Suitable for reversible and non-reversible motors
11.15 Transformers For Control, Space Heating And Annunciator Supplies 11.15.1 Adequately rated single phase, two winding, dry type transformers shall be provided for providing supply to the switchgear control and alarm circuits, space heaters provided in plant equipment and space heaters in the switchgear and motor winding heating circuits. 11.15.2 As specified in the enclosed module control wiring drawing/bill of material either duplicate common transformer with one as stand by shall be provided

TITLE
in each switchgear or a separate control transformer shall be provided in each module to cater for that particular module. Common control transformer rating shall be adequate to cater for all the control equipment connected across it. For control transformers in each module, the minimum rating shall be as follows :Motor rating kW ------------------Upto and including 30 Control type ------------K-11 or K-21 or R21 L-11 or L-21 All types Control transformer rating VA -------------------------75
100 300
Above 31 11.15.3
All transformers of 500 VA and above shall be controlled by MCBs/ switches and fuses on the primary and secondary side.
11.15.4 Common control transformer shall have fuses on all line leads of each winding and control transformer in individual module shall have fuse in the line lead of only secondary winding. The fuses shall be of proper rating to protect the control transformers against over loads and short circuits. the neutral or the earth lead shall have earth link instead of fuses. 11.16 Window Type Alarm Annunciator 11.16.1 The alarm annunciator if called for in Data Sheet-A shall consist of flush mounted facia and shall have following features:Fault indication by steady lit window Audiable alarm on fault occurrence Acknowledgement, resetting and test Suitable for NC/NO initiating contacts Facility for separate audio visual alarm on control supply failure
11.16.2 The alarm annunciator scheme operation shall be as follows : Visual Audible alarm alarm ---------------------ISSUE R7 CONSULTANTS: TCE Consulting Engineers Limited TCE FORM NO. 329 R4

TITLE
Normal On occurrence of fault First fault Subsequent faults Accept fault First faults Subsequent faults Reset - Faults cleared Faults not cleared Lamp test 12.0 12.1 CABLE TERMINATION
OFF
OFF
Flashing Flashing
ON ON
Steady Steady OFF Steady Steady
OFF OFF OFF OFF OFF
If asked for in Data Sheet-A1 necessary number of cable glands and lugs shall be supplied for terminating power and control cables. Glands shall be of heavy duty brass castings, machine finished and complete with check nut. washers, neoprene compression ring etc. The lugs shall be tinned copper/aluminium depending on cable conductor and of solderless crimping type. LOCAL PUSH BUTTON STATIONS The local P.B. stations shall be metal enclosed, provided with IP-55 protection, made up of diecast aluminium or 2 mm thick sheet metal. The P.B. station shall be suitable for wall or structure mounting, provided with lables, earthing terminals, suitable lugs glands. Push buttons shall be fitted with 2 No and 2NC contacts (1A at 220V DC and 10A at 240V AC) with stop PB of stay put type and red in colour. Other PB's shall be green in colour. PB station shall be of one of the following types
ISSUE R7
13.0 13.1 13.2 13.3
13.4
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TITLE
Type A Type B Type C 14.0
-Three PB's forward-reverse-Stop for reversible motors -Two PB's start-stop for non-reversible motors -One PB STOP for emergency
SPARE PARTS The BIDDER shall furnish a list of recommended spare parts for five years operation along with unit prices.
15.0 15.1 15.2
TESTS AND REPORTS Type test reports for the switchgear and circuit breakers shall be furnished along with the tender and subsequently. The switchgear, circuit breakers and all associated equipment shall be tested in accordance with relevant standards. All routine tests shall be carried out. Type tests shall also be carried out if not tested previously. Type and routine test report shall be submitted for the PURCHASER's approval before the equipment is despatched. Bound copies of test reports shall be furnished along with the switchgear. All meters and other reference devices used for testing shall have valid calibration from reputed national laboratories/institutes. Inspection by Purchaser/ Engineer will not be carried out unless the vendor confirms that calibrated equipment are ready for proceeding with the tests. Equipment shall not be despatched unless the test certificates are duly approved by the PURCHASER/ ENGINEER. DRAWINGS AND DATA The following shall be furnished as part of the tender: a) b) c) d) General arrangement showing plan, elevation and typical sectional views. Foundation plan showing location of fixing channels, floor openings etc. Schematic wiring drawings for each cubicle. Technical literature on the equipment offered.
ISSUE R7
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e) f)
All drawings and data sheets shall be annotated in English. Quality Assurance Plan.

TITLE
DATA SHEET-C DATA TO BE FURNISHED BY THE VENDOR AFTER AWARD OF THE CONTRACT Time periods indicated below are for project with equipment delivery period of 12 months these will be proportionately revised as per agreed delivery period. 1.0 OVERLOAD RELEASE (a) (b) 2.0 2.1 2.2 2.3 3.0 3.1 3.2 3.3 Characteristics Settings
SINGLE PHASING PREVENTERS Make Type designation Rated voltage AUXILIARY RELAYS AND TIMERS Time delay range (for timers) Resetting features No. of contacts Sec.
3.3.1 Normally open/Normally closed 3.3.2 Contact rating 3.4 4.0 4.1 Whether operation indicator is provided CONTROL/SELECTOR SWITCH Whether contact arrangement as given in control scheme YES/NO A YES/NO

TITLE
5.0
LIST OF DRAWINGS The VENDOR shall furnish the following drawings for each panel and switchgear within the time indicated after placing the order. If a large number of switchgears are involved, the PURCHASER will indicate the priorities.
5.1
Overall outline dimensions and general arrangement including plan, front elevation, rear & side elevations, clearances required in front and back, details of busduct connections, if any. Switchgear layout plan including floor openings, fixing arrangements and loading details. Schematic control diagrams to cover controls, protection, interlocks, instruments, space heaters, etc. for each type of module (a) Detailed internal wiring diagram of each type of module, including terminal block numbers, ferrule numbers and the PURCHASER's external cable connection designations Itemised bill of material for each module, listing all devices mounted and also otherwise furnished like cable glands, indicating the MANUFACTURER's type, rating, quantity & special notes, if any.
2 months
5.2
2 months
5.3
3 months
5.4
4 months
(b)
4 months
5.5
Interpanel interconnection wiring diagram including terminal numbers and ferrule numbers Switch development diagrams
6 months
5.6
6 months

TITLE
5.7 5.8 5.9
Each type of protection relay and circuit breaker release characteristics Fuse characteristic curves for each type and rating of fuse Space heater ratings and numbers provided per cubicle and the internal distribution scheme for the same, for each switchgear
6 months 6 months 6 months
NOTES: (a) (b) The VENDOR shall be entirely responsible for the correctness of the internal wiring diagrams mentioned against Item 5.4. The VENDOR shall ensure that the characteristics of the CTs, fuses, protection relays, VTs and all other devices offered by him are such as to be suitable for the purpose for which they are intended. The VENDOR shall plan his manufacturing schedule so as to allow atleast 4 weeks time for approval of the drawings after their receipt by the PURCHASER. TEST CERTIFICATES Type test certificates of all standard component parts, e.g. contactors, breakers, switches, fuses, relays, CTs, VTs, and for the standard factory built assembly shall be submitted by the VENDOR within 3 months from receipt of order. INSTRUCTION MANUALS The VENDOR shall furnish specified number of copies of the instruction manual which would contain detailed instructions for all operational & maintenance requirement. The manual shall be furnished at the time of despatch of the equipment and shall include the following aspects : a) b) Outline dimension drawings showing relevant cross-sectional views, earthing details and constructional features. Rated voltages, current, duty-cycle and all other technical information which may be necessary for correct operation of the switchgear.
(c)
6.0 6.1
7.0
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TITLE
c) d) e) f) g) h) i) j) k)
Catalogue numbers of all components liable to be replaced during the life of the switchgear. Storage for prolonged duration. Unpacking. Handling at site. Erection. Precommissioning tests. Operating procedures. Maintenance procedures. Precautions to be taken during operation and maintenance work.

TITLE
VOLUME IIIIB SHEET 1 OF 19
1.0 1.1
SCOPE This specification covers requirements for the design, manufacture, testing and supply of semiconductor (Thyristor/ Transistor) controlled variable speed DC/AC drives, both analog & digital type. The motors and Converter Transformer when forming part of Bidders scope, shall meet the requirements given in following standard specifications: a) b) c) d) e) Squirrel Cage Induction Motor (General Purpose) Squirrel Cage Induction Motor (Special Purpose) DC Motor Converter Transformer Induction motors for hazardous area (General purpose) : : : : : TCE-M4-203-01 TCE-M4-203-02 TCE-M4-203-11 TCE-M4-200-21 TCE-M4-203-51
1.2
2.0 2.1
CODES AND STANDARDS The design, material, construction, manufacture, inspection, testing and performance of AC/DC Drives shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. Unless otherwise specified, the equipment / system shall conform to the latest applicable standards as mentioned in enclosed Data Sheet-A.4 DESIGN BASIS FOR POWER SEMICONDUCTORS Power semiconductors of reputed make either in stud mounting form or disc/flat pack type can be offered based on the duty requirements specified in Data Sheet A1 and to meet the technical and functional requirments. The peak reverse voltage rating of each power semiconductor shall be as follows:
2.2 3.0 3.1
3.2

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3.2.1 Power Semiconductors Protected by RC Snubber The following factors of safety shall be observed: a) b) For converters operating in rectifying mode only For converters operating both in rectifying and inverting modes : : 2.0 times peak of the No load source voltage. 2.5 times peak of the no load source voltage
3.2.2 Power Semiconductors Protected by Avalanche Diodes The BIDDER shall choose and recommend the factor of safety which however, shall not be less than 1.5. The current rating of the power semiconductor shall be estimated for the specified duty class in Data Sheet A. In sizing the power semiconductor both the forward voltage drop and the forward resistance shall be considered. 3.3.1 A derating of approximately 20% shall be made to take into account series operation of devices. 3.4 The class of overload shall be one of the following: - - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Duty Class Rated current values for converter (in percent of rated direct current - - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I 100 % Continuous II 100 % Continuous 150 % overload for 1 minute once in period of 24 hours III 100% continuous 150 % overload for 2 minute once in period of 24 hours 200 % overload for 10 seconds once in period of 24 hours - - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.5 For the cases where the power semiconductor chosen is of inadequate current or voltage capacity the BIDDER shall conform to the following guidelines: 3.3
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3.5.1 Inadequate Current Capacity a) If the power semiconductor is of stud mounting type, then current sharing reactors shall be provided to prevent current missharing between the power semiconductors connected in parallel. If the power semiconductors in parallel are of capsule type, then, one of the following options may be exercised: i) Power semiconductors with adequate derating and the layout configured so that current missharing between various power semiconductors in parallel is minimised. Selection of power semiconductors so that their forward voltages are within a tolerance band of 100 mV to 250 mV.
b)
ii)
3.5.2 Inadequate Voltage Capacity In this case the power semiconductors shall be connected in series with adequate protection to prevent irregular voltage grading across each power semiconductor during turn-on. 3.6 The converter shall be provided with adequate surge suppression circuitry at the AC input, DC output and across the devices to limit the main voltage surges, transformer switching surges, reverse recovery transients to less than twice the peak value of line working voltage. QUADRANTS OF OPERATION The drive should be according to the no. of Quadrants specified in Data Sheet A. The Quadrant Operation of the Drive will be according to the following criteria. a) b) One Quadrant Operation -> (I) : One Quadrant of operation means only Motoring is required & the drive should operate in the Ist Quad. Two Quadrant Operation -> (II) :- Two Quadrant Operation means the drive should be able to control the motoring & Braking of the motor. It can be of two types. i) Voltage Positive & Current can charge Polarity i.e. Operating in First & Second Quad.
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ii) c)
Current Positive & Voltage can charge Polarity i.e. operating in first & fourth Quad.
Four Quad Operation -> (IV) :- The drive should be able to operate in all four Quadrant i.e. the motor requires forward motoring, forward braking, Reverse motoring & Reverse braking.
5.0 5.1
CONTROL FOR DC MOTORS Armature Voltage Control Converter
5.1.1 This converter shall consist of, unless otherwise stated in Data Sheet-A, a three phase full wave bridge circuit. 5.1.2 Each arm of the bridge can have a number of power semiconductors both in series and/or in parallel. The design basis for such cases shall be in conformity with Clause 3.0 of this specification. 5.1.3 If the drive operates in the first quadrant only, a free wheeling diode may be provided for the purpose of allowing decay of energy during the condition of braking of the drive. This diode may be housed within the same cubicle as the bridge converter. 5.1.4 Redundancy shall be provided as follows: a) b) For power semiconductors in parallel one additional parallel three phase full wave bridge arm shall be provided as redundant element. For power semiconductors in series, at least 2% of the total thyristors in series for each parallel arm shall be provided.
The factors of safety to be observed in such designs shall be in conformity to Clause 3.0 of this specification. 5.2 Field Excitation Control Converter
5.2.1 Unless otherwise stated in Data Sheet A, this converter shall be powered from a single phase line-to-line source tapped at the three-phase incomer to the armature voltage control converter with adequate isolation. 5.2.2 Unless otherwise stated in Data Sheet-A, this converter shall be a bridge of diodes of adequate capacity.

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5.3
Transducers
5.3.1 Armature Circuit a) For drives where accuracy of speed control is better than 0.5%, the actual speed of the drive shall be measured by a tacho-generator of suitable rating, and type (Digital pulse tacho or analog tacho). For drives where accuracy of speed control required can exceed 2% or more, measuring the current by a current transformer on the AC side of the converter can be accepted. For drives whose accuracy of speed should not exceed 2% it is necessary that a suitable DC shunt of 75 mV and adequate current capacity shall be provided.
b)
c)
5.3.2 Field Circuit For Drives where there is a possibility of field circuit failing, then in such cases transducers should be provided. 6.0 6.1 FREQUENCY CONVERTERS FOR SQUIRREL CAGE INDUCTION MOTORS Configuration Frequency converters shall have one of the two configurations given below: a) b) 6.2 Current source inverter. Voltage source inverter.
DC Link
6.2.1 Current Source Inverter a) The smoothing reactor shall be sized to avoid conditions of discontinuous current operation of the frequency converter at its lowest frequency of operation, which shall not be less than 5 Hz. The smoothing reactor shall be uniformly insulated and shall be protected for voltage surges occurring during sudden load throw-off.
b)

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c)
The smoothing reactor shall be made from electrolytic grade copper/aluminium and shall be epoxy encapsulated with suitable class of resin decided from techno-economic considerations and performance requirements in conformity with IEC-146.
6.2.2 Voltage Source Inverter a) b) The smoothing reactor shall conform to requirements specified in Clause 6.2.1 The DC capacitor shall be shunt connected at the input to the inverter. It shall be sized so that the reactive power requirements of the motor during its total range of operation is met. Further, the following aspects shall be observed: i) As per standards, the nominal value of capacitance referred to the temperature of 250C shall be within tolerance range of 10%. At the design ambient temperature, the value of capacitance and the tolerance range shall be such as to meet the normal operation/performance requirements of the frequency converter. As per standards, the dissipation factor of each unit of the capacitor shall be less than 1% at 250C. However, the design ambient shall be such as to meet the normal operational/performance requirements of the frequency converter. The impregnant used for the capacitor shall be noninflammable, non PCB dielectric liquid. The voltage rating of each capacitor shall be selected based on considerations of life expectancy, overvoltage during regeneration of energy, design ambient temperature, ripple voltage etc.
ii)
iii) iv)
6.3
Inverter
6.3.1 The inverter system suitable for three phase output shall consist of the following subsystems: a) The basic inverter circuit consisting of the switching device say Thyristors/Transistors/IGBT/MOSFET, connected so as to supply three phase power.
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b) c) d)
The logic network to enable rapid transition of the main inverter switching devices from on-state to off-state. Suitable feedback system to allow balance of reactive power flow during load power factor fluctuation as well as regeneration. The filter system of the inverter output to supress 5th, 7th, 11th, 13th harmonics at the output of the inverter to less than 5% of the fundamental amplitude. The ripple control system to limit current ripple to 4% at the input terminals of the inverter caused by distorted current output.
e)
6.3.2 The output frequency of inverter shall be controlled to within the limits specified in Data Sheet-A. 6.4 Inverter for AC drive
6.4.1 Current Source Inverter a) Constant Torque Operation The current output by the DC link shall be accurately monitored so that the ratio of the terminal voltage of the motor and the corresponding frequency remains constant and the duty cycle requirements indicated in Data Sheet A are met. Necessary protective features for tripping the frequency converter, alarm/annunciation and fault diagnostics shall be provided. b) Constant Horsepower Operation In this type of operation, the motors internal voltage shall be maintained within + 1% while the frequency of the inverter is varied to meet the duty cycle requirements indicated in Data Sheet A. Necessary protective features for tripping the frequency converter, alarm/annunciation and fault diagnostics shall be provided. 6.4.2 Voltage source Inverter a) Constant Torque Operation The DC voltage input to the inverter shall be accurately monitored to maintain the ratio the terminal voltage of the motor to frequency at the
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rated/design value so that the duty cycle requirements indicated in Data Sheet A are met. The DC voltage input shall be maintained within + 1% of the required value. Should this fall for any reason, necessary action for tripping the frequency converter, and initiation of annunciation/alarm and fault diagnostic shall be provided. b) Constant Horsepower Operation In this type of operation, the voltage at the terminals of the motor shall be maintained within +1% of the rated value while the frequency of the inverter is varied to meet the duty cycle requirements indicated in Data Sheet A. Necessary protective features for tripping the frequency converter , initiation of alarm/annunciation and fault diagnostic shall be provided. 6.5 Output Overcurrent Limit Unless otherwise stated, the inverter shall be capable of being temporarily overloaded to 150% of its full load ampere capacity for sixty (60) seconds beyond which a current limit action shall be initiated and an alarm contact initiated for annunciation. 6.6 Control Modules
6.6.1 All elements of the control system shall be mounted on epoxy laminate boards and each board shall be a plug in module mounted on a standard nineteen inch rack which shall be accessible from the front. Each card shall have LED indication on its front plate to indicate normal condition of the card. Readily accessible and clearly marked test pins shall be provided at the important points on the cards to enable signal analysis. The BIDDER shall furnish the signal input to the card. 6.6.2 The epoxy laminates shall be free from manufacturing errors and shall be designed to prevent incorrect insertion in the card rack. The copper side of the card shall be suitably lacquered to prevent oxidation. The gap between two cards shall be sufficient to permit adequate ventilation. 6.6.3 Adjustments susceptible to change by accidental contact shall be lockable. 7.0 7.1 CONTROL REQUIREMENTS Short time voltage dips upto 80% of nominal (e.g. in case of large motor startup connected to same bus) shall not cause the control system to stop functioning and shall not trip the drive system.
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7.2
The drive motor shall be speed regulated corresponding to 4-20mA or 0-10V reference input signal. Upon complete loss of users speed reference signal, the drive shall automatically run at constant speed as determined by the last speed reference available prior to loss of the signal. The required provision for interfacing with PLC/DCS, including details of communication module and data transfer facility, I/O details shall be furnished by the Bidder. DRIVES WITH WOBBULATION CONTROL Drives used in application like synthetic fibre projects should have the main feature of Wobbulation control as specified in the data sheet. The Wobbulation control should consist of a generation of a modulated frequency, in converters feeding traversing drives. The drive should produce a triangular voltage of variable frequency and amplitude, which is superimposed on the frequency set-points voltage in the analog frequency generator.
7.3
8.0
9.0 9.1
PROTECTION Protection of Power Semiconductor a) Each power semiconductor shall be protected against short circuit. The fuse shall be sized so that its I2t does not exceed the I2t characteristic of the power semiconductor itself. The voltage and current rating of the fuse shall match the duty on the power semiconductor. The arc voltage, due to melting of the fuse shall not exceed the repetitive peak reverse voltage of the power semiconductor. All fuses shall have a trip indicator to operate a suitable microswitch with at least 1 NO + 1 NC potential free contacts for annunciation and/or tripping. A fast tripping feeder circuit breaker shall be used in case fuses for short circuit protection of thyristors are not used.
b)
c) 9.2
Protection of Converter System for DC Drive
9.2.1 Armature Circuit


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The basic protection to be provided are as follows: a) b) Earth fault relay Thermal overload relay
Other optional protections that are required shall be considered in scope of supply as listed in Data Sheet A. 9.2.2 Field Circuit The basic protection to be provided are as follows: a) b) c) Minimum excitation limit relay Thermal overload relay Earth Fault Relay
Other optional protections that are required shall be considered in scope of supply as listed in Data Sheet A. 9.3 Protective Systems for AC Inverter Drive a) Fuses for all power semiconductors and/or other devices like commutation chokes, capacitors etc. which are not adequately protected against flow of abnormal currents. Under voltage and over voltage protection on the input side. Loss of input voltage to inverter shall entail tripping of the inverter. Protection for all control cards, power supply stabilisers, filter circuits etc. Protection shall be provided such that failure of a part does not cause damage elsewhere in the system. Polarising relay to prevent reversal of polarity on the input side of the inverter. Protection of inverter thyristor, commutating circuits and other inverter elements during regenerative operation of the inverter and also during sudden load throw-off. Besides the above, the following protective systems shall be supplied if called for in Data Sheet A.
b) c)
d) e)
f)

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i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) 9.4 10.0 10.1
Current limit fuses at the output of the inverter. Commutation circuit undervoltage Inverter overfrequency Programmable overcurrent Phase sequence/loss of phase protection Earth fault protection DC link overvoltage protection Specific motor protection Incoming line surge protection Ventilation Loss Over temperature
All controls, indication, Metering, Annunciation on the Drive Panel, will be as specified in Data Sheet-A. COOLING OF POWER CONVERTERS Power semiconductors shall be mounted on heatsink which can be individual or common to a number of devices. Adequate provision for clamping and mounting the power semiconductors shall be available. Cooling of power semiconductors can either be natural air cooled or forced air cooled. The BIDDER shall recommend the type of cooling. However, for power converters which exceed capacities of 2 kA continuous load, alternative cooling methods as oil or water cooling shall be considered. The power semiconductors shall preferably be double side cooled. Auxiliary power supply for the forced cooling system shall be drawn from the alternatives specified in Section-B. All equipment required for safe and correct operation as drive motor, blower/pump, cooling water/oil header, water/oil distribution piping, daioniser system, flow monitors etc. as applicable shall be considered in the BIDDERs scope of supply. SWITCHING DEVICES
10.2
10.3
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11.1
Switching devices as circuit breakers, isolators, contactors; switch-fuse units etc. shall be considered in the scope of supply as specified in Section-C of this specification and Data Sheet A-3. The switching devices shall be enclosed in a separate enclosure forming the set of panels for the power converters. They shall have adequate clearance both with adjacent devices and metalwork at earth potential. Connection between devices shall be by adequate size of electrolytic grade of copper/aluminium strips. These connections shall be adequately braced and insulated. CONSTRUCTIONAL FEATURES The controller should have modular construction to facilitate maintenance.
11.2
12.0
12.1
Busbars
12.1.1 Power connections shall be of the bolted type and mating surfaces shall be tinned. 12.1.2 The bus bars running to various converters shall be suitably designed to ensure equal sharing between the parallel strings and prevent mechanical stress on the fuse. 12.1.3 All bus bars shall be adequately insulated for full circuit voltage by insulating tapes and similar insulating material. 12.1.4 In case aluminium bus bars are specified, care shall be taken to ensure that bimetallic connections are provided wherever necessary. 12.1.5 All cubicles shall have copper earth buses of adequate size running the entire cubicle height along the sides. 12.2 Cubicle
12.2.1 Cubicles housing the power semiconductors and drive level control system shall conform to IP 42 degree of protection to enclosures. 12.2.2 Panels shall be free standing, floor mounting type and shall comprise rigid welded structural frames enclosed completely with cold rolled sheet steel of thickness no less than 2.5 mm for front and rear portions and 2.0 mm for sides, top and bottom portions. There shall be sufficient re-inforcement to provide

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level surfaces, resistance to vibrations and rigidity during transportation and installation. 12.2.3 All doors, removable covers and panels shall be gasketed all round with neoprene gaskets. Ventilating louvers shall have screens and filters. The screens shall be made of either brass or GI wire mesh. 12.2.4 Design, material selection and workmanship shall be such as to result in a neat appearance inside and outside with no welds, rivets or belt heads apparent from outside, with all exterior surfaces true and smooth. 12.3 Painting
12.3.1 All sheet steel work shall be phosphated in accordance with the following procedure and in accordance with IS:6005 Code of Practice for Phosphating Iron and Steel. 12.3.2 Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning. 12.3.3 Rust and scale shall be removed by pickling with dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and drying. 12.3.4 After phosphating, thorough rinsing shall be carried out with clean water followed by final rinsing with dilute dichromate solution and even drying. 12.3.5 The phosphate coating shall be followed by the application of two coats of ready mixed stoving type zinc chromate primer. The first coat may be flash dried while the second coat shall be stoved. 12.3.6 After application of the two coats of primer finishing synthetic enamel paint shall be applied, each coat followed by stoving. The second finishing coat shall be applied after completion of tests. 12.3.7 The final finished thickness of paint film on steel shall not be less than 100 microns and shall not be more than 150 microns. 12.3.8 Finished painted surface of panels shall present an aesthetically pleasing appearance free from dents and uneven surface. 12.3.9 A small quantity of finishing paint shall be supplied for minor touching up required at site after the installation of the panels. 12.4 Bins and Printed Circuit Cards

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12.4.1 Individual bins shall be mounted on a swingable frame so that the connections at the rear are also accessible. 12.4.2 Self retaining thumb head screws shall be needed for holding the bins in position. 12.4.3 Adequate number of card/bin extenders for testing of PCBs shall be provided, each with flexible cables at least two metres long. These extenders shall be of a universal type suitable for use with any card / bin as the case may be. 12.4.4 All adjustments which are to be made while changing a card shall be outside in a separate module preferably plugged into the regulator bin. 12.4.5 Locking of individual cards in a bin shall preferably be through self retaining thumb-head screws. 12.4.6 Control modules shall be in the form of plug in packages, plugged into a module bin. Each plug in unit shall consist of a strong frame on which a printed circuit board would be permanently screwed. The plug connections shall only be of the pin type. 12.4.7 The printed circuit board (P.C.B.) shall be made of glass fibre filled with epoxy laminates. The plug in unit shall be screwed to the basic socket in the module bin with long through bolts and knurled heads. 12.4.8 The front plates of the plug in unit shall have the switches, the potentiometers, miniature monitoring meters, test points etc. Each plug in unit shall have its own identification legend. 12.4.9 All plug in units shall be polarised to prevent incorrect insertions into the module bin. 12.4.10 The gap between two plug in units inside a bin shall be sufficient to permit adequate ventilation. 12.4.11 The copper side of the printed circuit board shall be lacquered to prevent oxidation. 12.4.12 Each side of the printed circuit board shall have a shield cover to prevent inter circuit and external interference. 12.4.13 The P.C.B. shall be mounted on P.C.B. guides fixed on standard racks and the shield properly grounded.
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12.4.14 Control circuit test points shall be easily accessible for monitoring and maintenance. 12.5 Annunciation
12.5.1 The annunciator shall work on DC power supply as specified in Data Sheet-A. 12.5.2 Each annunciator window shall have two lamps connected in parallel which operate at not more than 75% of their rated voltage. 12.5.3 Window shall be arranged in a logical group. 12.5.4 The annunciator shall have a module construction with glass epoxy plug in cards. 12.5.5 Alarm bell/siren shall be continuously rated and shall have a series resistance. 12.5.6 The annunciator shall have the following facilities. a) b) c) First in sequence, memory reset. Fleeting faults shall be memorised. Test Feature.
12.5.7 There shall be a three tier system of protection and annunciation: a) b) c) 12.6 Meters Alarm both audible and visual. Warning with delayed shut down time delay through a timer of range 0-60 sec. Disturbance associated with failures of systems elsewhere.
12.6.1 Individual meters shall be provided for speed reference, speed feed back, current reference, current feedback, pulse output, and regulated power supply voltages. 12.6.2 All meters shall be identical and fed through individual buffer I.C. amplifiers.

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12.6.3 All meters shall be the circular scale type having a full scale deflection of 2700. 12.6.4 All meters shall conform to at least accuracy class 1.0 12.6.5 All meters with their individual buffer amplifier cards shall be housed in separate bin. It is recommended that the buffer amplifiers all be housed on a single/two card/s and this card/s be itself/themselves housed in the regulator bin. Sensitive signal leads in that case will not have to traverse from one bin to another, only noise insensitive buffer amplifier output leads will need to go to the meter bin. 12.6.6 Selector switches if used with any meters shall have pistol grip handles. 12.7 Wiring
12.7.1 Stranded, flexible copper cable of 2.5 sq.mm shall be used for C.T. circuits and 1.5 sq.mm for other control circuits. However for PCB terminals 0.75 sq.mm may be accepted. 12.7.2 Ultra flexible cables shall be used for all connections from a fixed part to a movable member. In addition, a hanging loop of sufficient length shall be provided to avoid any cable stressing. 12.7.3 All terminal boards for outgoing connections shall be at a height of at least 250 mm from the cubicle floor, and preferably tilted at an angle of 450 to the horizontal for ease of connections. Similarly, connection of the incoming power cables to the bus bars shall be done at a height of at least 250 mm from the cubicle floor. 12.7.4 Item designation and location marking shall be in line with IEC recommendations. 12.7.5 Device labeling shall be on its fixed mounting and not on the device itself such that labeling remains even when the device is replaced. Metallic labels/paper labels or sticker shall be accepted. 13.0 TESTING All routine tests shall be carried out on various devices / assemblies in line with codes & standards indicated in data sheet-A4. Type Tests shall be carried out wherever indicated in Data sheet-A1 to A3 and / or in Section C
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13.1
Tests on Power Semiconductors All power semiconductors selected shall be subject to quality assurance tests to check on the characteristics submitted by the successful BIDDER on samples. The BIDDER and/or his sub-vendor shall allow PURCHASERS authorised representative to witness the tests. Details of the test are to be agreed between the PURCHASER and the BIDDER. The broad outlines of the tests to be conducted are as follows: a) b) c) d) e) f) g) h) i) j) Off state voltage and reverse voltage Critical rate of rise of off state voltage On state voltage Thermal resistance Surge on-state current Triggering data Recovery charge and recovery time Critical rate of rise of on-state current Switching losses Environmental Tests
13.2
Tests on Converters Converter with its enclosure and cooling system shall be connected to a dummy load. A variable voltage source on the source side shall be adjusted so that the specified current rating of the converter at no-delay of the firing angle (in case thyristors) shall be passed. At the end of stipulated period of test a timer shall cut-off the source. The load side and source side current shall be measured/recorded during the testing phase. The temperature of the case and the heat sink and wound components like chokes shall be suitably recorded. The temperature decay measurement/recording shall continue for the off-duty cycle at agreed intervals. During the course of test the cooling system shall be operative. The following tests shall be conducted: (IEC 61800-2)
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a) b) c) d) e) f) g) h) i) 13.3
Checking of the setting of the protection devices and their functioning. Checking of the auxiliary devices and their functioning. Speed regulation of the drive shall be observed at different output voltage and frequency settings (for AC drives). Determination of the power losses at Calculation).(Type Test) specified loads (By
Load test or rated current test for large converters (above 1 MW). Insulation test Temperature rise (Type Test). Light load & Functional Test. Observation of various wave forms i.e. current and voltage.
Other Composite Test at No-load a) b) Environmental tests on printed circuit boards, pulse transformers etc. Other tests as may be agreed on various converter subsystems.
13.4
Acceptance Test These shall be conducted at the works of the VENDORS and/or his subvendor to ascertain that performance stipulated in this specification has been honoured (e.g. overcurrent capability, measurement of ripple voltage & current, P.F. measurement, Audible noise, etc). Dummy loads as required for the purpose of simulating the operation conditions at the VENDORs works shall be considered in scope of this specification. However, should this not be possible, testing at site with the actual load shall be conducted to prove the performance of the power converters.
13.5
All the meter, instruments, devices used for the testing purpose shall be properly calibrated by standard authorised agencies which shall be traceable to National Standards. For each such instrument proper validity of calibration shall be documented by Vendor.

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14.0
HARMONICS LIMITATIONS When specified in Data Sheet A, the harmonics generated on source (Input) side (Both AC/DC drive) and output side (For AC drive only) shall be restricted to the following limits: (IEEE-519 for source side and IEC-61800 for load side) a) b) Voltage Harmonics Current Harmonics 5th 7th 11th Source side Maximum 5% Source side Maximum 30% Maximum 20% Maximum 10% Load side Maximum 5%(THD)
Bidder shall indicate clearly the method of achieving above requirement.

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DATA SHEET C DATA TO BE SUBMITTED BY VENDOR 1.0 1.1 1.2 1.3 1.4 2.0 Following data shall be submitted within the period specified in Section C, after placing the order, for the PURCHASERS approval. General arrangement drawings showing outline dimensions, cable entry openings, fixing/foundation details, weights and door openings. Front & cross section views showing arrangement details of equipment and terminals and with a Bill of Material for all equipment. Schematic diagram indicating terminal number for external connections & block diagram of control system. MANUFACTURERS technical literature on various equipments supplied. Wiring diagram of complete inverter. This shall be based on approved schematic drawing. The correctness of this drawing shall be the responsibility of the VENDOR. Test certificates for the cabinet and all individual equipments and performance load tests shall be submitted atleast 2 weeks before dispatch of equipment. Operation and maintenance manuals shall be furnished with the equipment. Detailed drawing of converter showing layout of power semiconductors, fuses, heat sinks, cooling system etc. Details of testing procedures for power semiconductors and power converters as per Standards/Code of Practice for approval. Shipping details of the equipment.
3.0 4.0 5.0 6.0 7.0

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INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS 1.0 1.1 SCOPE This specification covers requirements of HV induction motors. These are in addition to the requirements of specification No.TCE.M4-203-01. Clauses of this specification which are not applicable for any motor are mentioned in Data Sheet-A1 of TCE.M4-203-01. In case of conflict between TCE.M4-203-01 or applicable standard and this specification, this specification shall govern. PERFORMANCE AND CHARACTERISTICS Motors shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is 80% of the rated voltage. Motors shall be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 minutes, commencing from hot condition. Motors shall withstand the voltage and torque stresses developed due to the vector difference between the motor residual voltage and the incoming supply voltage equal to 150% of the rated voltage, during fast change over of buses. The duration of this condition is envisaged for a period of one second. The locked rotor current of the motors shall not exceed the which are inclusive of 20% tolerance. following values
1.2
2.0 2.1
2.2
2.3
2.4
2.4.1 600% of full load current for motors upto and including 1500 kW. 2.4.2 2.5 450% of full load current for motors above 1500 kW. The locked rotor withstand time under hot conditions at 110% rated voltage shall be more than the starting time at minimum permissible voltage (clause 2.1 above) by atleast three seconds or 15% of the accelerating time whichever is greater. Provision of speed switch shall be avoided to the extent possible. In case the speed switch is required, it shall be indicated out by the bidder in his offer. When a speed switch is mounted on the motor shaft , the same shall remain closed for speeds lower than 20% and open for speeds above 20% of the rated speed. The speed switch shall be capable of withstanding 120% over speed in either direction of rotation. If the speed switch requires any auxiliary voltage, it shall be suitable for the auxiliary voltage specified in Section-B - Project Information of the specification
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INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS 3.0 3.1 INSULATION TREATMENT Motors shall be given power house treatment. Additional treatments to withstand heavily salt polluted or similar atmospheric conditions shall be given based on the location indicated in Data Sheet-A ACCESSORIES EMBEDDED TEMPERATURE DETECTORS (ETD'S) Atleast six resistance type temperature detectors for the stator winding each having D.C. resistance of 100 ohms at 0oC, embedded in the stator winding at locations where highest temperatures may be expected, shall be provided. The material of the ETD's shall be platinum. One ETD shall be provided for each of the motor bearing & shall be wired upto the terminal box. The temperature detectors shall be of 3 wire , duplex type. 4.2 4.2.1 BEARING THERMOMETERS Each bearing shall be provided with a dial type thermometer. Each thermometer shall consist of 2 potential free contacts. They shall be designed to close independently at two different temperatures - one for 'Alarm' and another for 'Trip'.
4.0 4.1
4.2.2 The contact rating of the potential free contacts shall be 1A at 240V AC & 0.1A at 220V DC.Any auxiliary supply ,if required shall be indicated by the bidder. 4.2.3 4.2.4 4.3 The thermometers shall be located at a convenient height for easy reading and handling. One bearing shall be insulated to prevent shaft currents. DRAIN PLUGS Motors shall be provided with drain plugs, so located to drain water, resulting from condensation or due to other causes ,from all pockets in the motor casing. 4.4 FLOW SWITCHES Flow switches shall be provided for monitoring motors are specified. 4.5 VIBRATION PADS Vibration pads shall be provided when called for in the specification. CONSULTANTS: TCE Consulting Engineers
Limited ISSUE R8
cooling
water flow if CACW
TCE FORM NO. 329 R4

TITLE
INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS 5.0 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.3 6.0 TERMINAL BOX Separate terminal boxes shall be provided for each of the following : Stator Leads Rotor leads (wound motors) Space Heaters Temperature Detectors The three phases shall be segregated by barriers of metal or fibre glass. The cable box design shall be suitable for available. EARTHING PAD The earthing pads shall be of non-corrodible metal welded or brazed at two locations on opposite sides complete with suitable bolt and washers for connecting the PURCHASER'S earthing flat. 7.0 7.1 7.1.1 RATING PLATE The following details, in addition to those specified in applicable standards shall be included on the rating plate. Temperature rise of windings in degree centigrade at rated load, rated voltage, frequency and ambient conditions and the method of measuring temperature rise. (Thermometer/ Winding resistance). Type of bearings, recommended lubricant, lubricating interval & re-lubricating quantity. TESTS Type test certificates for similar motors shall be furnished with the Bid. Extra price for performing type tests on the motor as per applicable standard shall be quoted. If specified in data sheet-A, for motors rated 3.3 kV and above, the induced shaft voltage shall be measured at the manufacturer's works during shop testing. The maximum value of induced voltage in the motor shaft shall not exceed 250mV.
ISSUE R8
any type of cable termination kits
7.1.2 8.0 8.1 8.2 8.3

Limited
TCE FORM NO. 329 R4

TITLE
INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS 8.4 The polarisation index test shall be carried out on all motors rated at 3.3 kV and above. The minimum value of the polarisation index shall be 2 when determined as per IS-7816. Coils of HV motors shall be tested as per IEC-34-15. Loss tangent measurement of coils for motors rated 6.6 kV & above shall be done as per IS-13508. All other routine tests shall be carried out as per applicable standards.
8.5 8.6 8.7
ISSUE R8

Limited
TCE FORM NO. 329 R4

TITLE
INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS DATA SHEET-C INFORMATION TO BE SUBMITTED BY THE VENDOR AFTER AWARD OF CONTRACT
A .DOCUMENTS TO BE SUBMITTED FOR PURCHASER'S APPROVAL. 1.0 2.0 2.1 2.2 2.3. 2.4 3.0 Technical particulars as per data sheet-B of TCE.M4.203-01 & 02 Bearing temperature indicator Type and make Number Number of contacts in each indicator Contact rating at 220V DC at 240V AC A separate dimensioned outline and general arrangement drawing of motor shall be furnished indicating the following: Name of Manufacturer, Wight of motor (kg.) Centre line of motor Foundation details, Openings ,embedment details in foundation for entry of all cables such as power,space heater,etd etc. Connection details of motor i.e, start/delta , terminal markings, clearance between phase, disconnecting facilities and direction of cable entry and cable glands (if provided). Dimensions of terminal boxes for main power leads, space heater leads and ETD leads. Size, type and overall diameter of cable for which terminal boxes are suitable. Openings and embedments in foundation for cable entry for power leads, space heater leads, ETD leads and earthing conductor, etc. with relative locating dimensions and sizes in all views of motor.
ISSUE R8
3.1
3.2 3.3

Limited
TCE FORM NO. 329 R4

TITLE
INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS DATA SHEET-C
3.4 3.5 3.6 3.7
Location of bearing thermometers and pockets for the same. No. & type (NO/NC) of contacts provided on bearing thermometers. Location and size of earthing terminals/holes in earthing pads. Coupling type, diameter of shaft extension, dimensions of key slot and details of half coupling (if specified). The following additional data/details should be shown on the motor drawing, when applicable. Cooling water requirement for water cooled bearing (Lts/min). Cooling water requirement for water cooled windings (Lts/min).
3.8 3.9 3.10
3.11 3.12 3.13 3.14
Required pressure of cooling water (kg/cm2). Required maximum temperature of cooling water (oC). Weight of cooler if removable (kg). Oil level sight gauges for oil lubricated bearings
B. DOCUMENTS TO BE SUBMITTED FOR INFORMATION. 1.0 1.1 2.0 2.1 Insulation Material and treatment of insulation Winding Stator winding (a) Connection (b) Resistance/phase 2.2
Limited
Rotor winding
ISSUE R8
TCE FORM NO. 329 R4

TITLE
INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS DATA SHEET-C
(a) Connection (b) Resistance/phase 3.0 3.1 3.1.1 3.1.2 3.1.3 Bearing DE Bearing Type, No. & make Lubricant Initial quantity
3.1.4 Relubricating interval 3.1.5 Relubricating quantity 3.1.6 Anticipated life 3.2 NDE Bearing
3.2.1 Type, No. & make 3.2.2 Lubricant 3.2.3 Initial quantity 3.2.4 Relubricating interval 3.2.5 Relubricating quantity 3.2.6 Anticipated life 4.0 4.1 Motor bearing lubrication system Self lubrication/Forced oil lubrication Forced oil lubrication system (if provided) a) Whether this is compatible with forced oil lubrication system of driven equipment. If NO, furnish the following details for motor bearing i) ii)
Limited
Type, make and specification of oil Flow rate (Ltrs/Sec)
ISSUE R8
TCE FORM NO. 329 R4

TITLE
INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS DATA SHEET-C iii) Pressure (Kg/cm2) iv) Quantity of lube oil pump sets provided for each motor v) Local control panel provided for forced oil lubrication system of each motor vi) Make, type and name plate particulars of lube oil pumps & 415V, 3 phase, 50Hz motors. vii) Filters - Make & type
5.0 5.1 5.2 5.3 5.4 6.0 6.1 7.0
Air temperature detector (Internal) (CACA/CACW motor) Type & make Number Number of contacts in each indicator Contact rating at - 220V DC - 240V AC Terminal box Location of main terminal box viewed from non drive end (Right/Left) No load current of motor at rated voltage & frequency (for each type of motor) Limiting rotor temperature for determining safe stall time Instruction Manual (Number of copies as per distribution schedule)
8.0 10.0
ISSUE R8

Limited
TCE FORM NO. 329 R4

TITLE
1.0
SCOPE This specification covers the requirements of motor operated valve actuators with and without integral starters.
2.0 2.1
CODES AND STANDARDS The design, manufacture and performance of the valve actuator and its accessories shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. All codes and standards referred to in the specification shall be understood to be the latest version on the date of offer made by the BIDDER unless otherwise indicated. MOTOR OPERATED VALVE ACTUATOR Each valve actuator motor operating mechanism shall essentially consist of the following components: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) AC electric motor Reduction gear unit (with thrust bearing if required) Torque switch mechanism Limit switch mechanism Hand wheel, for manual operation Valve position indicator Manual-Auto lever with suitable locking arrangement Valve position transmitter (To be provided only if called for in data sheet-A1) Space heater for enclosure Thermostat if called for in data sheet A1
2.2
3.0 3.1
3.2
For valve actuator with integral starter The following components in addition to those indicated in clause 3.1 shall be provided (a) (b) (c) Integral reversing contactor starter complete with overload relays of suitable range and adequately rated control fuses Local / Remote selector switch Local control switch / push buttons

TITLE
(d)
415V / 110 V - 240V AC control & space heating transformer or if space heater is rated for 110V AC, space heating supply shall be derived from 415V / 110V control transformer (Control transformer required for 415V, 3 phase, 3-wire system only). For 3-phase, 4-wire system control supply and space heating supply shall be 240 V AC derived between phase-neutral A white lamp for supervision of main supply. To be provided locally. A potential free contact shall be provided to annunciate over load trip / main supply failure on remote panel. A blinker relay and lamp shall be provided such that the lamp shall blink as long as the actuator is running ; either to close or to open position. Two (2) DC interposing relays for matching the low voltage of remote commands with the control voltage. The command signal voltage and the control voltages will be, as indicated in Data Sheet-A1.
(e) (f) (g)
(h)
4.0 4.1 4.2
CONSTRUCTIONAL AND TECHNICAL REQUIREMENTS The constructional and technical requirements of actuators including motor shall be as per IS 9334, except as noted in this specification. Reversing Contactor Starters For Valve Actuators
4.2.1 Forward and reverse contactors shall be mechanically and electrically interlocked with each other. 4.2.2 The contactors shall have a minimum thermal rating of 9A and shall be suitable for class AC4 duty as specified in applicable standards. The contactor shall have 20% margin over the rated current of the motor. 4.2.3 The thermal overload relays provided with the reversing starters shall be three element, positive acting, hand reset type, ambient temperature compensated, time lagged, thermal overload relay with adjustable settings and built in single phasing preventer. The setting range shall be properly selected in accordance with the rating of the motor.

TITLE
4.2.4 Stop push button of the starter and hand reset push button for the thermal overload relay shall be separate from each other. 4.2.5 Overload relay hand reset push button shall be brought out to the front and made easily accessible. 4.2.6 Overload relay shall be provided with at least one NO and one NC or one change-over contact. 5.0 5.1 TESTS The routine and acceptance tests specified in IS 9334 shall be conducted on each valve actuator. In addition to the above tests the following shall also be conducted as part of routine tests.
5.1.1 Visual checks of workmanship, dimensions, component assembly, number of torque and limit switches, cable entry and valve position transmitter. 5.1.2 Mechanical checks of gear ratio and torque clutch operation. 5.1.3 Wiring check as per approved VENDOR drawing. 5.1.4 Resistance values of potentiometric type position transmitter and 420mA dc signal of transducer type position transmitter shall be measured at various positions of the valves. 5.1.5 Insulation resistance test ( Meggering) using 1000V megger for power terminals and 500V megger for control terminals. 5.1.6 High voltage test at 1.5 kV AC for 1 sec. 5.1.7 Performance test (at no load) to check the operation of the actuator limit switches and torque switches. Measurement of torque and motor currents shall be done and the values at which the torque switch operates, noted.

TITLE
5.1.8 For actuator with integral starters, all the above tests shall be performed in addition to the following :(a) (b) (c) 5.2 The wiring of the starter shall be checked as per the approved VENDOR drawing The operation of the starter shall be checked. Tests as per standards indicated in data sheet - A3.
Type test certificates for type tests carried out as per IS 9334 on similar actuators shall be furnished for PURCHASERS review. If type test has not been carried out on similar actuators, then VENDOR shall carry out the tests. All instruments used for testing shall have valid calibration certificates, which shall be produced at the time of inspection. All test reports shall be submitted for PURCHASERs approval.
5.3 5.4

TITLE
DATA SHEET - C MOTOR OPERATED VALVE ACTUATORS
DATA TO BE FURNISHED BY THE VENDOR AFTER AWARD OF THE CONTRACT

1.0 1.1 The VENDOR shall furnish the following drawings / documents / data for each type of valve actuator in his scope of supply : Drawings for Approval (a) (b) (c) (d) 1.2 Drawing indicating overall dimensions and mounting details of valve actuator on the valve Detailed internal wiring diagram of the actuator and limit switch development diagram Detailed Bill of Materials of all electrical items indicating clearly make, type, ratings, etc. Terminal box details.
Drawings / Data for Information (a) (b) (c) (d) Type test certificates of similar valve actuators and also for all individual electrical components used. Valve Actuator catalogues and operating and maintenance manual Gear ratio, motor shaft speed and output shaft speed. Full load current and starting current of the valve actuator motors
1.3
Final Test Certificates for Approval (a) (b) Routine and acceptance test certificates of the valve actuators Equipment shall not be despatched unless the test certificates are duly approved by the PURCHASER.
ISSUE R4
TCE FORM NO. 329 R4

TITLE
D.C. MOTORS
1.0
SCOPE This specification covers the design, material, construction features, manufacture, inspection and testing at the VENDOR's/his SUBVENDOR's works, delivery to site and performance testing of D C Motors for general purpose.
2.0 2.1
CODES AND STANDARDS The design, material, construction, manufacture, inspection, testing and performance of D C Motors shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the latest applicable standards. Nothing in this specification shall be construed to relieve the VENDOR from this responsibility. All codes and standards referred to in the specification shall be understood to be the latest version on the date of offer made by the BIDDER unless otherwise indicated. DRIVEN EQUIPMENT When this specification forms part of the driven equipment specification, information not given in Data Sheet-A1 will be governed by the driven equipment specification. Motors shall be capable of satisfactory operation for the application and duty as specified in the Data Sheet-A1 and as required by the driven equipment. PERFORMANCE AND CHARACTERISTICS Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously at a supply voltage within +10 to 15 % from the motor rated voltage or as specified in Data SheetA1. Motors shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is in the range 85% of the rated motor voltage to maximum permissible voltage specified in Data SheetA1.
ISSUE R7
2.2
3.0 3.1
3.2
4.0 4.1
4.2
TCE FORM NO. 329 R4

TITLE
D.C. MOTORS
5.0 5.1 5.2 5.3 6.0
TEMPERATURE RISE The temperature rise shall be in accordance with the relevant standards. For motors specified for outdoor installation, account shall be taken of heating due to direct exposure to solar radiation. The field windings for the motors shall be continuously rated without forced ventilation. CONSTRUCTIONAL FEATURES Motors weighing more than 25 Kg shall be provided with eyebolts, lugs or other means to facilitate safe lifting.
7.0 7.1 7.2 7.3
BRUSHES AND BRUSH GEAR Brush materials with large brush contact area for good commutation under high acceleration and overload conditions should be provided. The brushes shall be of electric graphite of high quality. The pressure on the brush shall be adjustable, if necessary. The brush holder to which the brushes are fixed should be so constructed that the brushes touch the commutator face evenly. Individual brush holders shall be with drawable without disturbing any other part of the machine. There shall be provision for holding off each brush from commutator to facilitate maintenance. The brush rocker should be split to facilitate easy erection and dismantling which will enable the brush rocker to be adjusted to its correct position. When specified in Data Sheet-A1, motors located in acid fume area shall be specifically treated against corrosion from acid fumes and shall be provided with sealed bearings.
7.4 7.5
7.6

TITLE
D.C. MOTORS
8.0 8.1
TERMINAL BOX Terminal box shall be weather proof construction designed for outdoor service to eliminate entry of dust and water. Gaskets of neoprene or approved equivalent shall be provided at cover joints and between box and motor frame. All terminals should be brought out to the terminal box. The terminals shall be stud type with necessary plain washers, spring washers and check nuts. The construction of terminal box shall be such that the terminals are easily accessible. The terminals themselves shall be such as to facilitate easy change of connections in the box without disturbing any internal connections in the machine. ACCESSORIES Two independent earthing points shall be provided on opposite sides of the motor for bolted connection of the PURCHASER's earthing conductors, as specified in the Data Sheet-A1. These earthing points shall be in addition to the earthing stud provided in the terminal box. Except when otherwise specified, the motors shall be provided with a bare shaft extension having a key slot and a key at the driving end. When the motor half coupling is supplied by the PURCHASER or driven equipment VENDOR, the motor VENDOR shall strictly adhere to the dimensional requirements and other instructions related to accessory. STARTER PANEL Starter panel when included in motor VENDOR's scope shall meet the following requirements. The constructional features of these panels shall comply with the requirements of specification TCE.M4-219-01, Section-D. The starter for motor feeders shall preferably be housed within the main panel. If starting resistors are provided in the power circuits, the same can be located in a separate box which will be placed near the main panel.
ISSUE R7
8.2
9.0 9.1
9.2 9.3
10.0 10.1 10.2 10.3
TCE FORM NO. 329 R4

TITLE
D.C. MOTORS
10.4
The motor Starter shall be provided with the following. a) b) c) d) e) f) g) h) i) j) Switch, fuses, air break contactors. Thermal overload relays (for alarm only) Starting resistors with associated timers. ON, OFF and fault indicating lamps. Necessary auxiliary contactors for fault alarm circuit. 240V space heating circuit VENDOR). (240V supply to be arranged by
ON, OFF PBs for testing purposes. One shunt, ammeter and one shunt for providing remote ammeter. Suitable circuitry to receive ON, OFF commands from remote panel, interlocks, off command from local Push button station etc. MCB for space heating circuit.
11.0
FIELD RHEOSTAT Field rheostat for adjusting the motor speed at site, to match the requirement of the driven equipment, shall be provided by the motor VENDOR and it shall be mounted in the starter panel. If starter panel is not in motor VENDORs scope, the field rheostat shall be supplied as a loose item.

TITLE
DATA SHEET-C D.C. MOTORS
DATA TO BE FURNISHED BY THE VENDOR For approval: 1. 2. 3. 4. 5. 6. 7. 7.1 7.2 7.3 8. AFTER AWARD OF CONTRACT
Motor GD (Kg.m). Motor outline dimension drawing (Number of copies as per distribution schedule). Type and routine test certificates (Number of copies as per distribution schedule). Electrical time constant in seconds (te). Mechanical time constant in seconds (tm). Field time constant in seconds (tf). Starter data / drawings. Detailed design calculations for starting current and selection of starting resistance values. Schematic drawing. General arrangement / foundation drawings. Field rheostat details
For information: 10. 11. 12. 13. 14. Type and frame size Starting time in seconds. Safe stall time at 100% rated voltage and under hot condition. Make and type of bearings and expected life. Total weight of motor (kg).
SPEC.NO. TCE.M4-101-01

TITLE
SHELL AND TUBE HEAT EXCHANGERS
1.0
SCOPE This specification covers the general design, preparation of detailed fabrication drawings for review and approval, supply of materials, fabrication, stage-wise inspection, final inspection, testing, packing, forwarding, transportation and delivery at site of unfired shell and tube heat exchangers.
2.0 2.1
CODES AND STANDARDS The design, materials, fabrication, inspection, testing and performance of shell and tube heat exchangers shall comply with all currently applicable design codes and standards, statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal, or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. This specification covers shell and tube heat exchangers designed as per the standards of the Tubular Exchanger Manufacturers Association (TEMA). If statutory approvals are specified in data sheet A, the VENDOR shall be responsible for obtaining all approvals on design, materials, stage-wise inspection, final inspection and testing of the heat exchanger. MATERIALS All materials used in the fabrication of heat exchangers shall be as specified in the data sheets. Equivalent materials are acceptable only when approved by the PURCHASER in writing. All plates shall be ultrasonically tested as follows : (a) (b) (c) (d) For nominal thickness 20 mm and higher when used for fabrication of dished ends For nominal thickness 40 mm and higher when used for fabrication of shells For nominal thickness 50 mm and higher when used for blind flanges All thicknesses, when used for body flanges and tube sheets
2.2 2.3
3.0 3.1
3.2
3.3
The VENDOR shall ensure that code mandatory requirements of impact testing are met in accordance with the minimum design temperatures specified in the data sheets. Any non-pressure parts such as cleats, pads at support lugs or legs, wear plates at saddles and pads at pipe supports etc., welded directly on to the pressure parts, shall be of the same material as the pressure parts.
3.4
ISSUE R3
TCE FORM NO. 329 R4

TITLE
3.5 3.6 3.6.1 3.6.2
Reinforcement pads at nozzles and other load bearing locations shall be of the same material and nominal thickness as the pressure part. ALLOY STEEL PROTECTIVE LINING AND CLADDING Lining is defined as loose strip lining and bush lining. Cladding may be by weld deposit overlay or explosion bonding or roll bonding. Clad plate or lining shall conform to the following requirements : (a) Clad plate thickness shall be minimum 3 mm, exclusive of pass-partition groove depth. Wherever pass-partitions are specified cladding or lining shall be minimum 8 mm thick. Clad plate made either by the explosion bonding process or reduction roll bonding process is acceptable. Clad plate shall meet the ASME code requirements of SA 263,SA 264, SA 265 including bond test or AD - Merkblatter W-8.The shear bond test shall be executed as per SA 264, Figure 1.Ultrasonic inspection shall be carried out in accordance with SA 578, acceptance level S-6. For the purpose of ensuring that cladding thickness of reduction roll-bonded clad plates is not less than 3 mm, each plate shall be inspected at the mill using a "coating gauge".Plates shall be scanned on at least three edges and one across the width of the plate. Thickness shall be plotted at points not more than 600 mm apart. The VENDOR shall furnish a mill certificate, showing an outline of the plate and the points at which readings were taken together with the results. Instead of lining, weld deposit overlay may also be considered. At weld deposit overlay or clad-restoring welds, at least the same chemical composition shall be present at 3 mm depth, to be analysed by the welding procedure qualification in advance. Weld deposit overlay and clad-restoring welds shall be dye penetrant tested and crack-free. Weld deposit overlay and clad-restoring welds as a minimum, shall be qualified as per ASME section IX.
(b) (c)
(d)
(e) (f)
(g) (h)
3.6.3
Alloy steel lining shall not be used when cladding is specified. Alloy steel lining, when specified, shall be so designed that the distance between attachments does not exceed 150 mm. The minimum required thickness of pressure parts shall exclude cladding or lining. Cladding or lining requirements discussed in this specification are using low and high alloy steels only. For cladding or lining using non-ferrous and other ISSUE
R3 TCE FORM NO. 329 R4
3.6.4 3.6.5

TITLE
materials, when specified, the VENDOR shall furnish on his drawings all details, including Welding Procedure Specification (WPS), for review and approval. 4.0 4.1 MINIMUM THICKNESS The thicknesses of pressure parts as shown in the data sheets or drawings are the minimum acceptable thicknesses after manufacture, even though the code may permit a lesser thickness. The minimum acceptable thickness includes specified corrosion allowance. The VENDOR shall be responsible for proper selection of plate thickness considering the fabrication and forming allowances, mill under-tolerances etc., to meet the minimum thickness requirements as specified. SHELLS Shell courses shall be of the largest possible dimensions to minimise the number of weld seams. 6.0 6.1 HEADS AND REDUCING SECTIONS Heads shall be of 2:1 ellipsoidal or equivalent ellipsoidal type (crown radius R = 0.9 D, knuckle radius r = 0.17 D), unless specified otherwise, where D is the inside diameter of the shell. Reducing sections or conical bottoms shall have a knuckle radius of r = 0.06D, unless specified otherwise. However, knuckle radius shall not be less than 50 mm. Dished ends shall be seamless or 100 % radiographed when made from more than one piece. NOZZLES AND MANHOLES Nozzles fabricated from plates are acceptable for sizes larger than 250 mm NB in case of carbon and low alloy steels and 150 mm NB in case of high alloy steels. However, this is to be done with prior approval and subject to all welds being 100% radiographed. All nozzle sizes and quantities indicated in the data sheets are tentative and for bid purpose only. Final sizes and quantities are subject to confirmation during review of drawings. The BIDDER shall include and confirm in his BID, that changes, to the extent of one size lower or higher for each nozzle and quantities plus or minus one number for each size, are acceptable at no extra cost to the PURCHASER. All nozzles with butt-welding end connections shall have edge preparation as per ANSI B 16.25 suitable for connected piping inside diameter. Such nozzles shall have 100 mm extra stub length with pipe caps for hydrotest purpose. All nozzles of sizes 40 mm NB and below shall be gusseted as per the ISSUE companion specification TCE.M4-102-34.
R3 TCE FORM NO. 329 R4
4.2
5.0
6.2
6.3 7.0 4.3
7.2
7.3
7.4

TITLE
7.5 7.6 7.7
All openings in pressure parts shall be compensated for the area of opening as per code. Minimum width of pad shall be 50 mm. All load bearing areas in pressure parts shall be verified for buckling and local stresses. Adequate reinforcement shall be provided. Nozzle and manhole necks shall be flush with the inside surface unless specified otherwise. Inside edges of manholes shall be smooth and roundedoff with a radius of 3 mm. FLANGES Unless specified otherwise, all nozzles shall be provided with rated flanges only, from considerations of interchangeability, as per the dimensional standards indicated in the data sheets. Bolt holes shall straddle the main exchanger axes, unless specified otherwise. All flanges on nozzles shall be of forged construction with integral hubs. Plate or plate type forged flanges are not acceptable in place of forged flanges with integral hubs. All slip-on type flanges of sizes larger than 50 mm NB and girth flanges shall be provided with adequate venting arrangement during welding. Girth flanges, if made out of multiple plates, shall be a maximum of three segments. All welds shall be 100 % radiographed. Pre-heating and postweld heat treatment shall be carried out as per code. Companion flanges specified with alloy steel liner shall be supplied with 100 mm long alloy steel stub ends with butt-welding edge preparation to suit connected pipe thickness. When companion flanges are of welding neck type, the same shall be to suit bore of connected pipe. However, this information shall be provided by the PURCHASER, during review of drawings. Blind flanges and covers intended for inspection or access openings shall be provided with adequate arrangement to facilitate opening and closing without undue effort . Unless specified otherwise, seating surfaces for non-metallic gaskets shall have stock or serrated finish. For other types of gaskets, the type of finish shall be furnished by the VENDOR on the drawings for review and approval. When flanges specified are of tongue and groove or male and female type, groove or female face shall be on the nozzle flanges and tongue or male face on the companion flanges.
ISSUE R3
8.0 8.1
8.2 8.3
8.4 8.5
8.6
8.7
8.8
8.9
8.10
TCE FORM NO. 329 R4

TITLE
SHELL AND TUBE HEAT EXCHANGERS TUBES All tubes shall be seamless, unless specified otherwise.
9.0 9.1 9.2 9.3 9.4 10.0 10.1 10.2 10.3
When welded tubes are specified, the same shall be tested with eddy current method besides other test requirements. All tubes shall be formed from a single length without circumferential welds. The VENDOR shall check the adequacy of pressure. TUBE BUNDLES The tube bundle, after taking out the floating head cover and the backing device, shall be removable through the inlet channel end. The tube bundle shall be capable of being rotated, through 180 degrees about the longitudinal axis without bending. When straight tube channel type construction is used, all tubes shall be accessible for inside cleaning, rolling and replacement from both ends of the exchanger. On vertical removable bundle units with channel down, stationary tube sheet shall be provided with at least four collar bolts or other means approved by the PURCHASER, to hold the tube bundle with channel removed. Guide devices to ensure alignment and to facilitate assembly shall be provided for floating head covers, internal bellows, flanges, channel covers and stationary tube sheets having grooved partitions. Sliding bars or rails shall be provided to facilitate pulling the removable tube bundles. Vertical exchangers shall be provided with four sliding bars or rails equally spaced around the circumference of the bundle. When mechanical cleaning is required on shell side (tube layout of square pitch patterns), the sliding bars or rails shall not obstruct the tube lanes. Kettle-type exchangers (TEMA - type K) shall be provided with sliding rails continuously welded to the shell.Bundles shall be provided with suitable means to be secured in place during shipment and erection. tube gauge for external
10.4
10.5
10.6 10.7 10.8 10.9
10.10 Annular clearances between tubes and shell shall be kept to minimise by-passing for efficient heat transfer. If the clearance exceeds 20 mm, suitable longitudinal sealing strips shall be provided. 10.11 U-TUBES 10.11.1 All tubes shall be seamless, unless specified otherwise.

TITLE
10.11.2 Tubes shall be cold bent. 10.11.3 Each U tube shall be formed from a single length. Thinning shall meet the stipulations as per TEMA. 11.0 11.1 11.2 11.3 EXPANSION BELLOWS Expansion bellow shall preferably be made from a single piece. When made from more than one piece, all seams shall be 100% radiographed. When carbon steel is specified as the expansion bellow material, the outer diameter of cylindrical portion of bellow shall be flush with outer diameter of the shell. All exchangers fitted with expansion bellows shall be provided with restraining bars to protect the bellows assembly during handling and transportation. These bars shall be painted yellow. Expansion bellows without internal sleeve shall be installed between two transverse baffles. Only a single ply construction shall be provided for expansion bellows, unless specified otherwise. Expansion bellows shall preferably be located near the supports. GASKETS All gaskets with or without internal web segments shall be made in one piece. All spiral-wound gaskets shall be provided with outer centering ring and inner ring, unless specified otherwise. PASS PARTITION PLATES Pass partition plates shall be tightly welded in place. Adequate weep holes shall be provided in the pass partition plates. BAFFLES AND SUPPORT PLATES Baffles shall be provided with adequate bottom notches for shell draining. All removable tube bundles shall be provided with a full baffle or support plate for support at the free end. Also, a central opening, of area equal to percentage cut in the baffle, shall be provided in the full baffle. However, this opening requirement is not applicable for kettle-type of exchangers.
11.4
11.5 11.6 11.7 12.0 12.1 12.2 13.0 13.1 13.2 14.0 14.1 14.2

TITLE
SHELL AND TUBE HEAT EXCHANGERS WEIR PLATES
15.0
Weir plates for kettle-type exchangers shall have a minimum thickness of 10 mm and 6 mm for carbon steel and stainless steel materials respectively. In no case shall the thickness be less than two times the specified corrosion allowance on shell side. 16.0 16.1 IMPINGEMENT PLATES The impingement plate shall be square or rectangle in shape having double the area of the inlet nozzle. It shall have a minimum thickness of 10 mm and 6 mm for carbon steel and stainless steel materials respectively and shall be located on the tube bundle and not in the nozzle. Perforated impingement plates are not acceptable. VENT AND DRAIN CONNECTIONS All high and low points on shell side and tube side of an exchanger shall be provided with 20 mm NB flanged connections covered with blind flange, unless specified otherwise. 18.0 PRESSURE GAUGE CONNECTIONS All flanged nozzles 50 mm NB or larger shall be provided with 20 mm NB flanged connection covered with blind flange, unless specified otherwise. 19.0 THERMOMETER CONNECTIONS All flanged nozzles 100 mm NB or larger shall be provided with one 25 mm NB flanged connection covered with blind flange, unless specified otherwise. 20.0 20.1 20.2 21.0 JACK SCREWS Jack screws of proper size and number shall be provided for breaking the channel cover joint, shell cover joint and floating head cover joint. The jack screws shall be of the same material as the bolting. HOLDING LUGS AND EYE BOLTS Suitable holding lugs and forged steel eye bolts shall be provided for channel and shell cover, tube sheets and floating head cover for assembly and dismantling the unit. 22.0 DOWEL PINS Dowel pins shall be provided to prevent misassembly of floating head cover, channel, channel cover having grooved partitions and stationary tube sheet to shell flange. 23.0 TEST RIG / TEST FLANGE
16.2 17.0

TITLE
23.1 23.2 24.0 24.1 24.2
At least one set of test rigs and/or test flanges shall be supplied in case of heat exchangers with removable tube bundle for each size and each type. In the case of stacked units, number of sets to be supplied shall be equal to number of shells in a stack. STACKED UNITS For stacked units, the VENDOR shall develop and furnish the required details for accommodating expansion. The VENDOR shall check and ensure that the local stresses at support and intermediate nozzles (assuming exchanger in corroded condition) are within the allowable limits. Intermediate nozzles between units shall have raised face flanges for ease of assembly. Bolting in flanges of mating connections between stacked exchangers shall be removable without moving the exchangers. Intermediate supports shall be installed during fabrication and the entire stack shall be erected at the manufacturer's works and checked for accuracy of nozzle location and alignment. A set of shim plates with a total thickness of 15 mm shall be provided for final adjustments at site. MISCELLANEOUS The BIDDER shall include two (2) numbers stainless steel name plates in his scope. This requirement is exclusive of manufacturer's name plate. The details on name plate shall be furnished during review of drawings. Lifting lugs shall be provided for all heat exchangers. Details are subject to review and approval. Earthing cleats as per companion specification TCE.M4-102-43 shall be provided at the approved locations. All pads at nozzles, supports etc. shall be provided with a tell-tale hole at the bottom-most location, which shall be tested with air at 1.0 kg/cm2 (g) and checked with soap solution for leakage. Such tell-tale holes shall be plugged after satisfactory testing. For insulated or fire proofed heat exchangers, the insulation or fire proofing supports as per enclosed companion specification shall be provided by the VENDOR. Where materials are free issue as indicated in the enquiry specification or data sheet, the BIDDER shall furnish along with the technical BID, a firm Bill
24.3 24.4 24.5
24.6 25.0 25.1
25.2 25.3 25.4
25.5
25.6
ISSUE R3
TCE FORM NO. 329 R4

TITLE
of Materials (BOM) of all free issue items and also indicate cutting and wastage allowances both accountable and unaccountable. 26.0 ANCHOR BOLTS Anchor bolts are not included in the scope of supply of the VENDOR, unless specified otherwise in the data sheets. 27.0 27.1 FABRICATION All welders, WPS and Procedure Qualification Records (PQR) shall meet the requirements of the specified code irrespective of pressure service or non-pressure service. Before welding , edges shall be checked in order to ascertain the absence of flaking, irregularities or serious defects. Stainless steel and high alloy steel fabrication shall have independent set of tools, grinding wheels and wire brushes etc. Welding shall be executed by qualified welders. Butt-welds shall have full penetration. Single sided welds shall be chipped back to sound metal and rewelded from the other side. Wherever chipping is not possible, root run shall be by TIG. Backing strip shall not be used without prior approval. Openings, reinforcing pads and attachments shall clear longitudinal and circumferential weld seams. Circumferential welds shall be situated 100 mm above or below the support rings and packing support rings meant for supporting internals, if specified. Circumferential and longitudinal weld seams shall clear saddles and support lugs. Longitudinal seams, in case of horizontal heat exchangers, shall be at least 150 mm above saddle wear plate. Nozzle and reinforcement pads, where applicable, shall be set-in type and attached to the heat exchanger by full penetration welds. shall be deburred, free from undercuts, overlap ridges and
27.2 27.3 27.4 27.5
27.6 27.7 27.8
27.9
27.10 All welds valleys.
27.11 No welding shall be carried out after stress relieving and/or postweld heat treatment. All flange faces shall be suitably protected against oxidation during heat treatment. 28.0 PAINTING All carbon steel exteriors shall be descaled, edges deburred and wire brushed. Subsquently, all such surfaces shall be painted with two coats of red oxide primer.
ISSUE R3
TCE FORM NO. 329 R4

TITLE
SHELL AND TUBE HEAT EXCHANGERS ESSENTIAL AND RECOMMENDED SPARES
29.0 29.1
The BIDDER shall include following essential spares in his scope of supply : (a) (b) (c) Two (2) gaskets as spares for each nozzle Three (3) gaskets as spares for body flanges 10% spare fasteners of each size and length. However, the minimum quantity shall be four (4) for each size and length.
29.2
In addition to essential spares as indicated in para 29.1, the BIDDER may recommend additional spares considered necessary by him, for three (3) year trouble-free operation. The BIDDER shall include essential spares as indicated in para 29.1 and recommended spares as considered necessary by him, in TCE.M4-993-01 Schedule of Essential and Recommended Spares. Total value of such spares shall not be included in the quoted price for supply of equipment. This value shall be considered for the purpose of BID evaluation.
29.3

TITLE
DATA SHEET C DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE ORDER 1. Schedule of complete design calculations, drawings and documents to be submitted along with submission dates 2. Quality Assurance Plan (QAP) 3. Complete design calculations 4. General arrangement drawing indicating overall dimensions, complete design data, general notes, BOM, specifications of each of the pressure and nonpressure parts, tube bundle assembly, tube sheet details, tube layouts and related details, nozzle schedule with nozzle tag number, service, size, nozzle wall thickness, complete end connection details, nozzle elevations, locations, and orientation, support details, locations and orientation etc. Drawing shall also include removal space for tube bundle, wherever applicable. Tube bundle weight, operating weight, erection weight and weight filled with water shall also be indicated. 5. Detailed fabrication drawing for each part and welding details 6. Welding procedure
ISSUE R1
FILE NAME : M410101R3.DOC TCE FORM NO. 329R3

TITLE
WELDED UNFIRED PRESSURE VESSELS
1.0
SCOPE This specification covers the general design, preparation of detailed fabrication drawings for review and approval, supply of materials, fabrication, stage-wise inspection, final inspection, testing, packing, forwarding, transportation and delivery at site of welded unfired pressure vessels.
2.0 2.1
CODES AND STANDARDS The design, materials, fabrication, inspection, testing and performance of welded unfired pressure vessels shall comply with all currently applicable design codes and standards, statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal, or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. If statutory approvals are specified in data sheet A, the VENDOR shall be responsible for obtaining all approvals on design, materials, stage-wise inspection, final inspection and testing of the vessel. MATERIALS All materials used in the fabrication of pressure vessels shall be as specified in the data sheets. Equivalent materials are acceptable only when approved by the PURCHASER in writing. All plates shall be ultrasonically tested as follows : (a) (b) (c) (d) For nominal thickness 20 mm and higher when used for fabrication of dished ends For nominal thickness 40 mm and higher when used for fabrication of shells For nominal thickness 50 mm and higher when used for blind flanges All thicknesses, when used for body flanges
2.2
3.0 3.1
3.2
3.3
The VENDOR shall ensure that code mandatory requirements of impact testing are met in accordance with the minimum design temperatures specified in the data sheets. Any non-pressure parts such as cleats, pads at support lugs or legs, wear plates at saddles and pads at pipe supports etc., welded directly on to the pressure parts, shall be of the same material as the pressure parts.
ISSUE R3
3.4
TCE FORM NO. 329 R4

TITLE
3.5 3.6
Reinforcement pads at nozzles and other load bearing locations shall be of the same material and nominal thickness as the pressure part. Material for skirt in case of alloy steel vessels and columns shall be the same as that of pressure part at least for a minimum length of 500 mm from bottom tan-line. ALLOY STEEL PROTECTIVE LINING AND CLADDING Lining is defined as loose strip lining and bush lining. Cladding may be by weld deposit overlay or explosion bonding or roll bonding. Clad plate or lining shall conform to the following requirements : (a) (b) (c) Clad plate thickness shall be minimum 3 mm, unless specified otherwise. Clad plate made either by the explosion bonding process or reduction roll bonding process is acceptable. Clad plate shall meet the ASME code requirements of SA263, SA264, SA265 including bond test or AD-Merkblatter W-8.The shear bond test shall be executed as per SA264, Figure 1.Ultrasonic inspection shall be carried out in accordance with SA 578, acceptance level S-6. For the purpose of ensuring that cladding thickness of reduction roll-bonded clad plates is not less than 3 mm, each plate shall be inspected at the mill using a "coating gauge". Plates shall be scanned on at least three edges and one across the width of the plate. Thickness shall be plotted at points not more than 600 mm apart. The VENDOR shall furnish a mill certificate, showing an outline of the plate and the points at which readings were taken together with the results. Instead of lining, weld deposit overlay may also be considered. At weld deposit overlay or clad-restoring welds, at least the same chemical composition shall be present at 3 mm depth, to be analysed by the welding procedure qualification in advance. Weld deposit overlay and clad-restoring welds shall be dye penetrant tested and crack-free. Weld deposit overlay and clad-restoring welds as a minimum, shall be qualified as per ASME Section IX.
3.7 3.7.1 3.7.2
(d)
(e) (f)
(g) (h) 3.7.3
Alloy steel lining shall not be used when cladding is specified. Alloy steel lining, when specified, shall be so designed that the distance between attachments does not exceed 150 mm.
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TCE FORM NO. 329 R4

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3.7.4 3.7.5
The minimum required thickness of pressure parts shall exclude cladding or lining. Cladding or lining requirements discussed in this specification are using low and high alloy steels only. For cladding or lining using non-ferrous and other materials, when specified, the VENDOR shall furnish on his drawings all details, including Welding Procedure Specification (WPS), for review and approval. MINIMUM THICKNESS The thicknesses of the pressure parts as shown in the data sheets or drawings are the minimum acceptable thicknesses after manufacture, even though the code may permit a lesser thickness. The minimum acceptable thickness includes specified corrosion allowance. The VENDOR shall be responsible for proper selection of plate thickness considering the fabrication and forming allowances, mill under-tolerances etc., to meet the minimum thickness requirements as specified. SHELLS Shell courses shall be of the largest possible dimensions to minimise the number of weld seams.
4.0 4.1
4.2
5.0
6.0 6.1
HEADS AND REDUCING SECTIONS Heads shall be of 2:1 ellipsoidal or equivalent ellipsodial type (crown radius R = 0.9D, knuckle radius r = 0.17D), unless specified otherwise, where D is the inside diameter of the shell. Reducing sections or conical bottoms shall have a knuckle radius of r = 0.06D, unless specified otherwise. However, knuckle radius shall not be less than 50 mm. Dished ends shall be seamless or 100% radiographed when made from more than one piece.
6.2
6.3
7.0 7.1
AGITATOR ASSEMBLY Agitator assembly shall be complete with drive motor, mechanical seal with seal housing, bearings, gear box, agitator shaft with impellers, foot-step bearing with support, rigid coupling between agitator shaft and gear box output shaft with spool piece, flexible couplings between gear box and drive motor, suitable base plate and supporting structure for agitator drive
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TCE FORM NO. 329 R4

TITLE
arrangement and necessary fasteners etc. so as to make it complete in all respects. 7.2 7.3 Drive motor and gear box shall be mounted on a common base frame and duly coupled and aligned through flexible couplings. Agitator shaft and gear box output shaft shall be coupled through a rigid coupling with split ring locking arrangement in order to ensure that agitator shaft does not fall into the vessel during operation. Agitator, shaft and impeller assembly shall be statically and dynamically balanced. The VENDOR shall obtain necessary approvals from the seal manufacturer regarding arrangement of assembly and application of API cooling plan etc. for the mechanical seal. The gear box shall be rated for heavy duty agitator service, continuously working for 24 hours a day and shall be suitable to withstand static and dynamic loads and bending moment on the gear box due to agitator shaft. Drive motor and gear box unit shall be provided with a suitable lifting eye hook. There shall be no oil spillage from gear box on to the vessel. Base frame shall be provided with suitable lifting lugs suitably designed for lifting complete agitator assembly. NOZZLES AND MANHOLES Nozzles fabricated from plates are acceptable for sizes larger than 250 mm NB in case of carbon and low alloy steels and 150 mm NB in case of high alloy steels. However, this is to be done with prior approval and subject to all welds being 100% radiographed. 8.2 All nozzle sizes and quantities indicated in the data sheets are tentative and for bid purpose only.Final sizes and quantities are subject to confirmation during review of drawings.The BIDDER shall include and confirm in his BID, that changes, to the extent of one size lower or higher for each nozzle and quantities plus or minus one number for each size, are acceptable at no extra cost to the PURCHASER. All nozzles with butt-welding end connections shall have edge preparation as per ANSI B16.25 suitable for connected piping inside diameter. Such nozzles shall have 100 mm extra stub length with pipe caps for hydrotest purpose.
7.4 7.5
7.6
7.7 7.8 7.9 8.0 8.1
8.3

TITLE
8.4 8.5 8.6 8.7
All nozzles of sizes 40 mm NB and below shall be gusseted as per the companion specification TCE.M4-102-34. All openings in pressure parts shall be compensated for the area of opening as per code. Minimum width of pad shall be 50 mm. All load bearing areas in pressure parts shall be verified for and local stresses.Adequate reinforcement shall be provided. buckling
Nozzle and manhole necks shall be flush with the inside surface of vessel, unless specified otherwise. Inside edges of manholes shall be smooth and rounded-off with a radius of 3 mm. FLANGES Unless specified otherwise, all nozzles shall be provided with rated flanges only, from consideration of interchangeability, as per the dimensional standards indicated in the data sheets. Bolt holes shall straddle the main vessel axes, unless specified otherwise. All flanges on nozzles shall be of forged construction with integral hubs. Plate or plate type forged flanges are not acceptable in place of forged flanges with integral hubs. All slip-on type flanges of sizes larger than 50 mm NB and girth flanges shall be provided with adequate venting arrangement during welding. Girth flanges, if made out of multiple plates, shall be a maximum of three segments. All welds shall be 100% radiographed. Pre-heating and postweld heat treatment shall be carried out as per code. Companion flanges specified with alloy steel liner shall be supplied with 100 mm long alloy steel stub ends with butt-welding edge preparation to suit connected pipe thickness. When companion flanges are of welding neck type, the same shall be to suit bore of connected pipe.However,this information shall be provided by the PURCHASER, during review of drawings. Blind flanges and covers intended for inspection or access openings shall be provided with adequate arrangement to facilitate opening and closing without undue effort. Unless specified otherwise, seating surfaces for non-metallic gaskets shall have stock or serrated finish. For other types of gaskets, the type of finish shall be furnished by the VENDOR on the drawings for review and approval.
9.0 9.1
9.2 9.3
9.4 9.5
9.6
9.7
9.8
9.9

TITLE
9.10
When flanges specified are of tongue and groove or male and female type, groove or female face shall be on the nozzle flanges and tongue or male face on the companion flanges. SUPPORTS All skirt supports shall have at least one access opening and adequate vent holes at the top of skirt. Skirt shall be provided with adequate holding and climbing rungs inside, above and below the skirt opening. Details shall be furnished by the VENDOR on the drawings for review and approval. MISCELLANEOUS The sizing of vessel internals shall be such that all removable parts can be removed through manholes. Wherever applicable and unless specified otherwise in data sheets all support rings, bolting bar for internals such as trays, tower packings, downcomers etc. shall be in the scope of the VENDOR. Internal baffles, tray support beams of other internals spanning a chord or diameter of the vessel shall be provided with a means for allowing differential expansion between the part and the vessel shell. Unless specified otherwise, baffles or weir plates shall not be welded directly to the shell or dished end of the vessel. These shall be bolted to the support attachments which are welded to the shell or dished end. The BIDDER shall include two (2) numbers stainless steel name plates in his scope.This requirement is exclusive of manufacturer's name plate. The details on name plate shall be furnished during review of drawings. Lifting lugs shall be provided for all vessels. Details are subject to review and approval. Earthing cleats as per companion specification TCE.M4-102-43 shall be provided at the approved locations. All pads at nozzles, supports etc. shall be provided with a tell-tale hole at the bottom-most location, which shall be tested with air at 1.0 kg/cm(g) and checked with soap solution for leakage. Such tall-tale holes shall be plugged after satisfactory testing. For insulated or fire proofed vessels, insulation or fire proofing supports as per enclosed companion specification shall be provided by the VENDOR.
10.0 10.1 10.2
11.0 11.1 11.2
11.3
11.4
11.5
11.6 11.7 11.8
11.9

TITLE
11.10 Wherever platforms and ladders are specified in the data sheets, necessary supports shall be provided by the VENDOR as per details which shall be made available during review of drawings. 11.11 Where materials are free issue as indicated in the enquiry specification or data sheet, the BIDDER shall furnish along with the technical BID, a firm Bill of Materials (BOM) of all free issue items and also indicate cutting and wastage allowances both accountable and unaccountable. 12.0 ANCHOR BOLTS Anchor bolts are not included in the scope of supply of the VENDOR, unless specified otherwise in the data sheets. 13.0 13.1 FABRICATION All welders, WPS and Procedure Qualification Records (PQR) shall meet the requirements of the specified code irrespective of pressure service or non-pressure service. 13.2 13.3 13.4 13.5 Before welding, edges shall be checked in order to ascertain the absence of flaking, irregularities or serious defects. Stainless steel and high alloy steel fabrication shall have independent set of tools, grinding wheels and wire brushes etc. Welding shall be executed by qualified welders. Butt-welds shall have full penetration. Single sided welds shall be chipped back to sound metal and rewelded from the other side. Wherever chipping is not possible, root run shall be by TIG. Backing strip shall not be used without prior approval. Openings, reinforcing pads and attachments shall clear longitudinal and circumferential weld seams. Circumferential welds shall be situated 100 mm above or below the support rings and packing support rings meant for supporting internals, if specified. Circumferential and longitudinal weld seams shall clear saddles and support lugs. Longitudinal seams, in case of horizontal vessels, shall be at least 150 mm above saddle wear plate. Nozzle and reinforcement pads, where applicable, shall be set-in type and attached to the vessel by full penetration welds.
13.6 13.7 13.8
13.9

TITLE
13.10 Skirt to vessel heads joints shall have continuous flat-faced weld matching with outer diameter of the vessel. The width of the weld shall be equal to skirt thickness and height of weld shall be twice the width. 13.11 All welds shall be deburred, free from under cuts, overlap ridges and valleys. 13.12 No welding shall be carried out after stress relieving and/or postweld heat treatment. All flange faces shall be suitably protected against oxidation during heat treatment. 14.0 14.1 FIELD ERECTION Where size or shape of vessel makes it impossible to ship it in one piece for erection by others, the VENDOR shall ship largest shop fabricated sections suitable for shipment and ease of handling for field erection and assembly. Fabrication and erection shall be completed at the site by the VENDOR. 14.2 14.3 All pieces shall be shop fit-up into sections and each sections shall be fit to adjacent section and all pieces shall be match marked. The width of permissible gap during fit-up shall be in accordance with approved drawings and welding procedures and shall generally be 3 mm maximum with a tolerance of plus 0.8 mm to minus 0.0 mm. Flame cut edges shall be ground by the VENDOR as required to remove slag, detrimental discoloration and non-uniformity of edges. All radiographic requirements for welds completed in shop shall be made by the VENDOR before the parts of section leave the shop. PAINTING All carbon steel exteriors shall be descaled, edges deburred and wire brushed. Subsequently, all such surfaces shall be painted with two coats of red oxide primer. 16.0 16.1 ESSENTIAL AND RECOMMENDED SPARES The BIDDER shall include following essential spares in his scope of supply : (a) (b) (c) Two (2) gaskets as spares for each nozzle Three (3) gaskets as spares for body flanges 10% spare fasteners of each size and length. However, the minimum quantity shall be four (4) for each size and length.
14.4 14.4 15.0

TITLE
16.2
In addition to essential spares as indicated in para 16.1, the BIDDER may recommend additional spares considered necessary by him, for three (3) year trouble-free operation. The BIDDER shall include essential spares as indicated in para 16.1 and recommended spares as considered necessary by him, in TCE.M4-993-01 Schedule of Essential and Recommended Spares. Total value of such spares shall not be included in the quoted price for supply of equipment. This value shall be considered for the purpose of BID evaluation.
16.3

TITLE
2 X 800MW TPP NEAR KRISHNAPATNAM WELDED UNFIRED PRESSURE VESSELS
DATA SHEET C DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE ORDER 1. Schedule of complete design calculations, drawings and documents to be submitted along with submission dates 2. Quality Assurance Plan (QAP) 3. Complete design calculations 4. General arrangement drawing indicating overall dimensions, complete design data, general notes, BOM, specifications of each of the pressure and nonpressure parts, nozzle schedule with nozzle tag number, service, size, nozzle wall thickness, complete end connection details, nozzle elevations, locations, and orientation, support details, locations and orientation etc. Operating weight, erection weight and weight filled with water shall be indicated. 5. Detailed fabrication drawing for each part and welding details 6. Details of internals 7. Details of external cleats and structurals 8. Welding procedure

TITLE
2 X 800MW TPP NEAR KRISHNAPATNAM VALVES AND SPECIALITIES GENERAL REQUIREMENTS
1.0
SCOPE The following paragraphs describe general requirements for valves and specialities. Only the applicable paragraphs for the type of valve or speciality are to be considered along with data sheet-A. These apply unless specified otherwise in data sheet-A.
2.0
CODES AND STANDARDS Valves and specialities shall be generally as per the following standards:
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 3.0
ANSI B16.1 ASME B16.34 API 594 API 600 API 602 API 609 BS 1414 BS 1868 BS 1873 BS 5156 BS 5351 BS 5352 IS 778 MSS-SP 67
: : : : : : : : : : : : : :
Cast Iron Valve Ratings Ratings of Valves-Flanged, Threaded and Welding Ends Wafer and Wafer - Lug Check Valves Steel Flanged and Butt Welding End Gate Valves Steel Gate Valves, Threaded and Socket Welding Ends Butterfly Valves Steel Gate Valves, Flanged and Butt Welding Ends Steel Check Valves, Flanged and Butt Welding Ends Steel Globe Valves, Flanged and Butt Welding Ends Diaphragm Valves Steel Ball Valves Steel Gate, Globe and Check Valves, 50 mm and Smaller Bronze Valves Butterfly Valves
GEAR OPERATORS Gear operators shall be provided on the following basis:
3.1
GATE AND GLOBE VALVES Up to and including ANSI 300 class 600 class and higher 350 mm and larger 200 mm and larger
3.2
OTHER VALVES Plug and ball 150 mm and larger

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TCE FORM NO. 329 R4

TITLE
Butterfly 3.3 3.4 4.0 4.1
200 mm and larger
Gear operators shall be suitable for a differential pressure corresponding to the maximum valve rating at room temperature. All gear operators shall be of the enclosed type. INTEGRAL BYPASS Gate valves shall be provided with integral bypass valve, as per MSS-SP 45, as follows: Classes 150 and 300 Class 600 and higher 350 mm and larger 200 mm and larger
4.2
Type of bypass valve shall generally be the same as the main valve. Bypass pipe shall be at least schedule 80 and material of construction of bypass valve and pipe shall be compatible with the main valve. VALVE STEMS Valve stems shall be of wrought materials. Castings are not acceptable.
5.0
6.0
BACKSEAT All gate, globe and piston valves shall be provided with back seating arrangement to facilitate replacement of gland packing with the valve in service.
7.0
CHECK VALVES Check valves of sizes 350 mm and larger shall be provided with features to prevent slamming and hammering. These can be in the form of springs or external dash pot.
8.0
HARDNESS 13% chromium steel seat surfaces shall have a minimum hardness of 250 BHN and a differential hardness of 50 BHN.
9.0
NAME PLATES The details on name plates shall be as per MSS-SP 25.
10.0
TAG PLATES Tag plates shall be of stainless steel type 304 or aluminium.

TITLE
11.0
TESTING Strength and leak tests shall be as per any of the standards MSS-SP-61, API 598 or BS EN 12266-1 and 2 at the test pressures indicated in data sheet-A. Stainless steel valves shall be tested using potable water.
12.0 12.1
NDT REQUIREMENTS All cast steel valves shall be subject to radiography in all accessible areas, as defined in ASME B16.34, on the following basis: (a) (b) (c) Class 600 and higher Class 300 Class 150 All sizes Sizes 450 mm and larger Sizes 600 mm and larger
12.2 12.3 12.4 13.0 13.1 13.2 14.0 14.1
All cast steel valves of class 600 and higher shall also be subject to magnetic particle or liquid penetrant examination as per ASME B16.34. All cast steel valves of class 300 shall have radiography quality castings irrespective of size. Acceptable levels of defects shall be as per ASME B16.34. FACE-TO-FACE OR END-TO-END DIMENSIONS Face-to-face dimensions of flanged-end valves and end-to-end dimensions of butt welding-end valves shall be as per ASME B16.10. For valves not covered by ASME B16.10, the dimensions shall be as per applicable valve standards. PREPARATION FOR DESPATCH COATING All carbon steel and cast iron exposed surfaces shall be given one coat of primer and two coats of aluminium finish paint after release has been given for painting and before despatch. Machined surfaces shall be coated with an easily removable rust protective except that this is not applicable for austenitic stainless steel components.
14.2
END PROTECTION After completion of the requirements of para 14.1, body end ports, flange faces and welding ends shall be covered with suitable close fitting protectors to protect the machined ends and prevent ingress of dirt and moisture.

TITLE
14.3
DISC The disc shall be closed before despatch except in the case of soft-seated valves where the disc shall be backed off to relieve the pressure on the seal.
14.4
PACKING Valves and specialities shall be so packed as to minimise the possibility of damage during storage or transit. The packing shall be suitable for tropical conditions.

TITLE
DATA SHEET-C DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE ORDER 1.0 2.0 3.0 List of drawings and documents to be submitted for review, approval or information with scheduled submission dates. Quality Assurance Plan (QAP) Drawings showing outline dimensions, clearance dimensions for disassembly, weight, part numbers, materials of construction, test pressures, statutory and any special requirements, sizes, tag numbers and quantities. All information covered in data sheets A and B shall be incorporated in this drawing. The PURCHASER'S identifying tag numbers shall be shown on each drawing or on a sheet attached to the drawing with proper cross-references. Operation and maintenance manuals
4.0

TITLE
CAST STEEL VALVES
1.0
SCOPE This specification covers the design, material, construction features, manufacture, inspection and testing at the VENDOR's/his SUBVENDOR's Works and delivery to Site of cast steel gate, globe including angle and Y-type and check valves generally for sizes NB65 and larger.
2.0 2.1
CODES AND STANDARDS The design, material, construction, manufacture, inspection, testing and performance of valves shall comply with all currently applicable statutes, regulations and safety codes in the locality where the valves will be installed. Valves shall also conform to the latest editions of applicable codes and standards as specified in various clauses of this specification. Nothing in this specification shall be construed to relieve the VENDOR from this responsibility. Various codes and standards referred in this specification shall form an integral part of this specification. In the event of conflict between this specification and the codes and standards, the same shall be brought to the attention of the CONSULTANT for resolution. DESIGN AND CONSTRUCTION FEATURES The following design and construction features of valves shall be minimum acceptable unless otherwise specified in Data Sheet-A and/or Section-C. All gate and globe valves shall be of rising stem, outside screw and yoke type. The design of valves shall ensure a streamlined passage and gate valves shall have low pressure drop. The seats and discs shall be easily renewable and/or shall be suitable for easy refacing and grinding. Valve discs shall be of such design as to keep the seats tight when the valve body is subjected to pressure, temperature variations and piping stresses. Gate valves shall close in both flow directions. All globe valves shall be capable of being closed against pressure. All valves end details shall be as specified in Data Sheet-A. In the case of all end-welded valves, the stub ends of the valves shall project from the valve body a sufficient amount to ensure that the welding process will not distort the valve body and internal parts. Valves for regulating duties shall be of the globe type with tapered plug type disc. Hardness of seating surfaces shall be a minimum of 350 BHN and a minimum differential hardness of 50 BHN shall be provided between seats to prevent galling. This is not applicable for stellited seats.
ISSUE R3
2.2
3.0 3.1 3.1.1
3.1.2 3.1.3
3.1.4 3.1.5
TCE FORM NO. 329 R4

TITLE
CAST STEEL VALVES
3.1.6 3.1.7 3.1.8
Check valves arrangement.
of sizes 400 mm NB and
larger
shall have dash pot to
All gate and globe valves shall have back-seating arrangement facilitate easy replacement of packing with the valve in service.
All valves shall be so designed that the hand-wheel moves in a clockwise direction to close the valve. The face of the hand-wheel shall be clearly marked with the words 'OPEN' and 'CLOSE' and an arrow to indicate the direction for opening. All hand-wheels shall be fitted with name plate. Piston lift check valves shall have accurately guided pistons so that the pistons are cushioned in their cylinders as they move up. All gate, globe, Y-type and angle valves intended for manual operation and falling under the following categories shall be equipped with a gear operator for ease of operation and to ensure fast and tight closure: ANSI PRESSURE RATING ----------------------------------Class 300 and below Class 600 and above VALVE SIZES FOR WHICH GEAR OPERATOR IS REQUIRED ---------------------------------------------350 mm and larger 200 mm and larger
3.1.9 3.2
3.3
All gate valves falling in the following categories shall be provided with integral bypass valve. Bypass size shall conform to MSS-SP-45 as a minimum standard unless otherwise specified in Data Sheet-A. The bypass valve shall be hand operated unless otherwise specified in Data Sheet-A. Pipe for bypass shall be at least Schedule 80 seamless and of a material of the same nominal chemical composition and physical properties as that used for the main line. Orientation of bypass arrangement shall be subject to the approval of PURCHASER/ENGINEER. ANSI PRESSURE RATING -----------------------------------Class 600 and over Class 300 & 150 VALVE SIZES FOR WHICH BYPASS IS REQUIRED ------------------------------------------------200 mm and larger 350 mm and larger
3.4
All gate valves of ANSI pressure rating class 150 and 300 shall have solid or flexible wedge and ANSI pressure rating class 600 and above shall have flexible or parallel slide type of wedge.

TITLE
CAST STEEL VALVES
3.5 3.6
Valves with flexible wedge shall have provision for relieving the pressure in the neck of the valve when the valve is in the closed position. All valves of ANSI pressure rating upto class 600 shall have bolted bonnet construction and class 900 and above shall have bonnet construction of the pressure seal type. Pressure seal valves shall have stainless steel inlay in the gasket area and silver-plated gaskets or other acceptable proven features. All carbon steel valves of ANSI pressure rating upto class 150 and 300 shall have stainless steel trim (13% Cr) unless otherwise specified in Data Sheet-A and ANSI pressure rating class 600 and above shall have stellited trim. All alloy steel valves shall have stellited seats. All valves of ANSI pressure rating upto class 900 and higher shall have yoke with anti-friction bearing arrangement. Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be provided with a non-detachable locking arrangement. The locking arrangement provided shall be subject to approval by the PURCHASER. As specified in Data Sheet-A, valves operating under vacuum conditions shall have glands with water sealing. The inlet and outlet connections shall be NB 15mm. The VENDOR shall indicate the maximum and minimum sealing water pressure and the required flow rate. Motor operators shall be designed to close the valve within the time shown in Data Sheet-A. For details of motor operator, refer companion specifications TCE.M4-203-01 and TCE.M4-203-06. Y-globe valves shall have flow area designed for minimum turbulence and pressure drop. Stop check valves shall have full floating and accurately guided discs. When chain wheels are specified for valves, they shall be constructed to give good traction for the chain. Roller guides shall be provided to hold the chain to a greater part of the circumference of the wheel, to increase traction and to prevent the chain from jumping off the wheel. Extension stems where specified, shall be of extra strong pipe with suitable coupling, fastened by locknuts and set screws. Floor stands shall be of sturdy construction and shall be at least one metre high from the floor. They shall be provided with chromium-plated scales and valve movement indicators. Where lateral and/ or vertical movements of valve are indicated in Data Sheet-A, the floor stand and extension spindle shall be
ISSUE R3
3.7
3.8 3.9 3.10
3.11
3.12
3.13 3.14 3.15
3.16
TCE FORM NO. 329 R4

TITLE
CAST STEEL VALVES
designed to permit these movements. Adequate greasing facilities shall be provided for all pedestals and extended operating spindle attachments. 3.17 3.18 Flow direction shall be clearly embossed on the valve body for globe and check valves. Wherever special class valves as per ANSI B16.34 "Steel Valves" are specified in Data Sheet-A, all requirements of ANSI B16.34 for this class of valves shall be met in addition to the requirements given in this specification. WELDING REQUIREMENTS All welding procedure qualifications and welder performance qualifications shall be in accordance with Section-IX of the ASME Boiler and Pressure Vessel Code. Hard facing operations require procedure qualification. 5.0 CLEANING Prior to factory inspection, all manufacturing waste, such as metal chips and filings, welding rods and stubs, rags, debris and all other foreign matter shall be removed from the interior of each valve. All mill scale, rust, oil, grease, chalk, crayon, paint marks and other deleterious material shall be removed from the interior and exterior surfaces. At the time of shipment, valves shall be clean inside and outside. 6.0 6.1 6.2 6.2.1 INSPECTION AND TESTS Inspection & tests shall be as per TCE.M4-185-17 and TCE.M4-185-01. Defect Removal and Repair in Castings Defects in excess of acceptance standards shall be removed by suitable means. If removal of surface defects does not result in reduction in wall thickness below 5% of intended thickness of metal at that location, the area shall be blended smoothly into the surrounding surface. Where defect removal results in a wall thickness below the above, resultant cavity may be repaired by welding. The procedure and operator shall be qualified as per applicable standards. Major weld repairs shall be stress relieved or heat treated in accordance with ASME Section VIII Division I-UCS 56. The required area shall be re-examined and the acceptance standards shall be as in the original examination. Weld repairs made as a result of radiographic examination shall be radiographed after welding. Repairing a particular area more than 2 times is not permitted and the component shall be rejected. The acceptance
4.0
6.2.2 6.2.3

TITLE
CAST STEEL VALVES
standards for welds shall be as per ASME Boiler and Pressure Vessel Code, Section VIII, Division I, UW - 51. 6.2.4 Prior approval shall be obtained from the PURCHASER/ ENGINEER before taking up major weld repairs (major weld repair - when depth of repair exceeds 20% of thickness or 1 inch whichever is smaller). Mapping of major weld repairs is also required. All valves shall be tested hydrostatically for strength, tightness of seats and tightness of backseating at the pressures indicated in Data Sheet-A, in accordance with MSS-SP 61, "Hydrostatic Testing of Steel Valves". Water used for hydrostatic testing of valves with stainless steel components shall not have chloride content exceeding 20 ppm. Clean potable water may be used for testing of all other valves. All valves except check valves shall be tested for seat tightness by air at a pressure of 6 bar (g) on both sides of seat. All check valves shall also be hydrotested at 25% of the seat hydro test pressure. All valves shall be checked for correctness in respect of specified end details as per applicable standards. PAINTING AND CORROSION PROTECTION Unless otherwise specified in Data Sheet-A/Section-C, two coats of primer of thickness 35 microns for each coat shall be applied to all steel and cast iron exposed surfaces as required to prevent corrosion, after release has been given for painting and before despatch. The use of grease or oil, other than light grade mineral oil, for corrosion protection is prohibited. Bores of all valves shall be covered, immediately after testing, draining and drying with suitable plastic end covers to avoid ingress of foreign materials. 8.0 DRAWINGS The BIDDER shall furnish, along with his Bid, drawings giving outline dimensions, clearance dimensions for disassembly and weight of valve with actuator. 9.0 NAME PLATES All valves shall have permanent stainless steel name plates indicating details as per MSS SP-25 "Standard Marking Systems for Valves, Fittings, Flanges and Unions". Also for all carbon steel valves of ANSI pressure rating class 600 and above, the pressure containing castings shall be marked with melt identification number. In addition, they shall
6.3
6.4 6.5 6.6 7.0

TITLE
CAST STEEL VALVES
have a permanent stainless steel tag fixed on the valve body indicating the PURCHASER's valve tag number and service. 10.0 DATA SHEETS As specified in Data Sheet-A/Section-C, the BIDDER shall submit details about valves. 11.0 INFORMATION TO BE FURNISHED AFTER THE AWARD OF CONTRACT The VENDOR shall furnish all the information as called for in Data Sheet-C.

TITLE
CAST STEEL VALVES
DATA SHEET - C DATA TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF CONTRACT The VENDOR shall submit, in the manner and within the time set forth in the Purchase Order/Letter of Intent the following : 1.0 Drawings showing Purchase Order number, outline dimensions, clearance dimensions for disassembly and weight (valve and actuator). The VENDOR's drawings identified by character, number and date, when reviewed by the PURCHASER, will be considered a part of this specification. The PURCHASER's identifying tag numbers shall be shown on each drawing or on a sheet attached and referenced to the drawing. Quality plans as per the format enclosed in TCE.M4-185-01, covering also the inspection requirements as indicated in this specification, as minimum. Operation and maintenance instruction manuals. Test Certificates/reports for : a) b) c) 5.0 6.0 Physical and chemical analysis components of valves. Hydrostatic and pneumatic tests. Non-destructive tests. and metallurgical tests for all
2.0 3.0 4.0
Test certificates as required by statutory regulations. If specified in Data Sheet-A/Section-C, the details of all valves and valve list as per enclosed formats.

TITLE
FORGED STEEL VALVES
1.0
SCOPE This specification covers the design, material, construction features, manufacture, inspection and testing at the VENDOR's/his SUBVENDOR's Works and delivery to Site of forged steel valves comprising gate, globe including angle and Y-type, needle and check valves generally for sizes NB 50 and smaller.
2.0 2.1
CODES AND STANDARDS The design, material, construction, manufacture, inspection, testing and performance of valves shall comply with all currently applicable statutes, regulations and safety codes in the locality where the valves will be installed. The Valves shall also conform to the latest editions of applicable codes and standards as specified in various clauses of this specification. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. Various codes & standards referred in this specification shall form an integral part of this specification. In the event of conflict between this specification and the codes and standards, the same shall be brought to the attention of the CONSULTANT for resolution. DESIGN AND CONSTRUCTION FEATURES The following design and construction features of valves shall be minimum acceptable unless otherwise specified in Data Sheet-A and/or Section-C.
2.2
3.0 3.1
3.1.1 All gate and globe valves shall be of rising stem, outside screw and yoke type. The design of valves shall ensure a streamlined passage and low pressure drop. The seats and discs shall be easily renewable and/or shall be suitable for easy refacing and grinding. Valve discs shall be of such design as to keep the seats tight when the valve body is subjected to pressure, temperature variations and piping stresses. Gate valves shall close in both directions. 3.1.2 In the case of all end-welded valves, the stub ends of the valves shall project from the valve body a sufficient amount to ensure that the welding process will not distort the valve body and internal parts. 3.1.3 Valves for regulating duties shall be of the globe type with tapered plug type disc. 3.1.4 Hardness of seating surfaces shall be a minimum of 350 BHN and a minimum differential hardness of 50 BHN shall be provided between seats to prevent galling. This is not applicable for stellited seats.

TITLE
FORGED STEEL VALVES
3.1.5 All gate and globe valves shall have back-seating arrangement facilitate easy replacement of packing with the valve in service.
to
3.1.6 All valves shall be so designed that the hand-wheel moves in a clockwise direction to close the valve. The face of the hand-wheel shall be clearly marked with the words 'OPEN' and 'CLOSE' and an arrow to indicate the direction for opening. All hand-wheels shall be fitted with name plate. 3.1.7 Forged steel needle and Y-type valves shall have extra long thread chambers and a plug type disc which shall be resistant to wear and foreign matter. The stuffing box shall be adequately deep and shall be fitted with a high grade packing. Stems shall have fine pitch threads to permit fine adjustment. The discs and seats shall be cone shaped. 3.2 All valves of ANSI pressure rating upto class 600 shall have bolted bonnet construction and class 900 and above shall have bonnet construction of integral or welded type. All carbon steel valves of ANSI pressure rating class 600 and 800 shall have stainless steel trim (13% Cr.) unless otherwise specified in Data Sheet-A and ANSI pressure rating exceeding class 800 shall have stellited trim. All alloy steel valves shall have stellited seats. Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be provided with a non-detachable locking arrangement. The locking arrangement provided shall be as per standard practice and shall be subject to approval by the PURCHASER/ENGINEER. As specified in Data Sheet-A, valves operating under vacuum conditions shall have special glands designed for such conditions. Motor operators shall be designed to close the valve within the time shown in Data Sheet-A. For details of motor operator, refer companion specifications TCE.M4-203-01 and TCE.M4-203-06. Wherever extension stems are specified , these shall be of extra strong pipe with suitable coupling, fastened by locknuts and set screws. Floor stands shall be of sturdy construction and shall be at least one metre high from the floor. They shall be provided with chromium-plated scales and valve movement indicators. Where lateral and/ or vertical movements of valve are indicated in Data Sheet-A, the floor stand and extension spindle shall be designed to permit these movements. Adequate greasing facilities shall be provided for all pedestals and extended operating spindle attachments.
3.3
3.4 3.5
3.6 3.7
3.8

TITLE
FORGED STEEL VALVES
3.9 4.0
Flow direction shall be clearly embossed on the valve body for globe and check valves. WELDING REQUIREMENTS All welding procedure qualifications and welder performance qualifications shall be in accordance with Section-IX of the ASME Boiler and Pressure Vessel Code. Hard facing operations require procedure qualification.
5.0
CLEANING Prior to factory inspection, all manufacturing waste, such as metal chips and filings, rags, debris, welding rod stubs, and all other foreign matter shall be removed from the interior of each valve. All mill scale, rust, oil, grease, chalk, crayon, paint marks and other deleterious material shall be removed from the interior and exterior surfaces. At the time of shipment, valves shall be clean inside and outside.
6.0 6.1 6.2 6.3
INSPECTION AND TESTS Inspection & tests shall be as per TCE.M4-185-18 and TCE.M4-185-01. All valves shall be checked for correctness in respect of socket dimensions as per standard. All valves shall be tested hydrostatically for strength, tightness of seats and tightness of backseating at the pressures indicated in Data Sheet-A . Water used for hydrostatic testing of valves with stainless steel components shall not have chloride content exceeding 20 ppm. Clean potable water may be used for testing of all other valves. All valves shall be tested for seat tightness by air at a pressure of 6 bar (g) except for check valves. All check valves shall also be hydrotested at 25% of the seat hydro test pressure. PAINTING AND CORROSION PROTECTION Unless otherwise specified in Data Sheet-A/Section-C, two coats of primer of thickness 35 microns for each coat shall be applied to all steel and cast iron exposed surfaces as required to prevent corrosion, after release has been given for painting and before despatch. All parts shall be adequately protected for rust prevention. The use of grease or oil, other than light grade mineral oil, for corrosion protection is prohibited. Bores of
6.4 6.5 7.0

TITLE
FORGED STEEL VALVES
all valves shall be covered, immediately after testing, draining and drying with suitable plastic end covers to avoid ingress of foreign materials. 8.0 DRAWINGS The BIDDER shall furnish, along with his Bid, dimensioned outline and cross sectional drawings. 9.0 NAME PLATES All valves shall have permanent stainless steel name plates indicating details as per MSS SP-25 "Standard Marking Systems for Valves, Fittings, Flanges and Unions". In addition, they shall have a permanent stainless steel tag fixed on the valve body indicating the PURCHASER's valve tag number .

TITLE
FORGED STEEL VALVES
DATA SHEET C DATA TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF CONTRACT The VENDOR shall submit, in the manner and within the time set forth in the Purchase Order/Letter of Intent the following : 1.0 Drawings showing Purchase Order number, outline dimensions, clearance dimensions for disassembly and weight (valve and actuator). The VENDOR's drawings identified by character, number and date, when reviewed by the PURCHASER, will be considered a part of this specification. The PURCHASER's identifying tag numbers shall be shown on each drawing or on a sheet attached and referenced to the drawing. Quality plans as per the format enclosed in TCE.M4-185-01, covering also the inspection requirements as indicated in this specification, as minimum. Operation and maintenance instruction manuals. If specified in Data Sheet-A/Section-C, the details of all valves and valve list as per Purchasers formats.
2.0 3.0 4.0

TITLE
DESIGN OF POWER PLANT PIPING SCOPE
1.0
This specification covers the minimum technical requirements and essential particulars for the design of the piping systems included in the VENDORs scope as identified in the drawings and documents forming a part of this specification. The VENDOR/CONTRACTOR shall demonstrate that the piping meets the specification and the applicable codes. 2.0 2.1 CODES AND STANDARDS The design of pipes, pipe assemblies, pipe fittings, flanges and components, valves and specialities and any other pressure retaining part in a piping system shall be carried out in accordance with the applicable power piping code. The design of the piping systems shall also meet the statutory requirements of the countries of manufacture and installation of the piping systems. In case the piping systems are manufactured and / or installed in India, the design shall meet the requirements of the Indian Boiler Regulations (IBR) for system under the purview of IBR. Notwithstanding the recommendations and stipulations of the codes and standards mentioned above, the requirement of this specification and associated Data sheets shall be deemed minimum and shall be complied with fully. All codes and standards referred shall be the latest version on the date of offer made by the Bidder unless otherwise indicated. Nothing in this specification shall be construed to relieve the Vendor/Contractor of his responsibilities as above. BASIC DESIGN CRITERIA Piping shall be designed adequately to meet the system requirements of flow, pressure drop, etc., under all operating modes of the plant, both normal and abnormal. Planned and forced outages of equipment or systems shall be taken into account and it shall be ensured that realisation of maximum feasible plant performance in terms of output and efficiency is not hampered by inadequacies in piping design. It shall also be ensured that, under no circumstances, including mal-operation or failure of an equipment or system, the safety of the plant, equipment or personnel is endangered by inadequate design of piping. Piping systems shall also be designed and conceived in such a manner as to maximise plant or equipment availability. Provision of ring headers, sectionalising valves, isolating valves, block valves, bypass, etc., are examples illustrating this concept and it is the responsibility of VENDOR/CONTRACTOR to ensure provision of such facilities, at no extra cost to the PURCHASER, as deemed
2.2
2.3
2.4 2.5 3.0 3.1
3.2
3.3

TITLE
DESIGN OF POWER PLANT PIPING
necessary regardless of whether the same have been identified in contract documents and drawings or not. 4.0 4.1 LINE SIZING Sizes of piping shall be selected such that the velocity of fluid in pipes does not exceed the following limits under conditions of maximum possible volumetric flow. STEAM Superheated steam Saturated steam / Exhaust steam Wet steam WATER Pump suction Pump delivery Boiler feed pump discharge City water OIL Heavy oil (Heated) Light oil GASES Compressed air Natural gas 4.2 15 m/s. 30 m/s. 2 m/s. 2 m/s. 1.5 m/s. 3.0 m/s 6.0 m/s. 1.5 m/s. 75 m/s 40 m/s. 30 m/s.
Lower values of velocities than those stated above shall be used to determine line size if dictated by considerations of pressure drop, NPSH, surges, water hammer, etc. The design flows considered in line sizing shall not be less than the rated capacities of equipment to which the piping is connected such as pumps, blowers, compressors turbines, boilers, etc., rated capacity of control valve, flow limiting orifices, etc., or, the system heat and / or mass balance diagrams. The selection of line size shall take into account likely increase in pressure drop with the ageing of the pipe due to increase in pipe roughness, encrustation of pipe
ISSUE R7
4.3
4.4
TCE FORM NO. 329 R4

TITLE
with scale, dirt, foreign matter, etc. A suitable allowance shall be made towards this expected increase in pressure drop and the same shall be subject to the approval of PURCHASER/ENGINEER. 4.5 While sizing pump suction lines, NPSH requirements of pumps shall be fully met under all conditions of operation including trip-out of an operating pump and failure of the standby pump to come on line. Wherever strainer pressure drops are considered, the same shall be for the 50% clogged condition of the strainers. Pressure drops across equipment shall correspond to unclean condition of the equipment. Sizes of boiler feed pump suction piping shall be selected to meet the NPSH requirements of the pumps under transient conditions prevailing on turbine trip out and simultaneous loss of steam supply to feed water tank. Cascade drain piping systems of feed water heaters shall also be designed to handle the additional flows that are likely to occur due to tube rupture in the heaters besides other operating conditions stipulated elsewhere. The minimum additional flow to be considered shall be either 10 percent of tube side flow at Maximum Continuous Rating (MCR) conditions or the flow that can result from the complete rupture of one tube with two open ends, whichever is greater. All overflows shall be designed for a capacity not less than the maximum possible difference between inlet and outlet flows under all operating conditions normal and abnormal, including mal-operation. MATERIALS The material specifications of piping of various systems shall be as specified in Data sheet A. Bidders may offer, if they so desire, alternate materials equal or superior to those specified. However, no credit would be given to offers containing materials superior to those specified. The responsibility for establishing equality or superiority of the alternate materials offered to those specified rests entirely with the Bidder, the PURCHASER/ENGINEER reserves the right to reject such alternate materials and insist upon those specified. Bidders shall note that equality or superiority of the materials offered by them vis-vis those specified would be judged not only based on a comparison of the material standards but also on the ease of fabrication, shop and field welding, heat treatment, service record and any other characteristics considered important by the ENGINEER. Bidders shall indicate, in their offer, reasons for their wishing to deviate from the materials specified.
4.6
4.7
4.8
4.9
5.0 5.1 5.2
5.3
5.4

TITLE
DESIGN OF POWER PLANT PIPING DESIGN PRESSURES
6.0 6.1
The minimum design pressures of piping systems shall be as indicated in Data Sheet A attached to this specification. In the event of this information not being available in the Data sheets, the following shall be construed to be the minimum requirements for design pressures. MAIN STEAM LINE The main steam line beyond the steam stop valve shall be designed for the design pressure of boiler, i.e. not less than the highest pressure at which any safety valve is to be set to lift, except that, for piping which are operating under thermal creep and the total capacity of the safety valve on the superheater is not less than 20% of the evaporative capacity of the boiler, the lowest pressure at which any superheater safety valve is set to lift. When there is no superheater, the design pressure of the piping shall be the design pressure of the boiler. In case of a forced flow steam generator, the design pressure shall be as indicated in data sheet A. REHEAT STEAM LINES In reheat systems which are not operating under thermal creep, the design pressure shall be the highest pressure at which any safety valve on the reheat system is set to lift. When no safety valves are mounted at the reheater inlet, the design pressure of the reheater inlet piping shall be the highest pressure at which any reheater outlet safety valve is set to lift, increased to take account of the pressure drop through the reheater corresponding to the most severe condition of operation. In reheat systems which are operating under creep, the design pressure shall be the lowest pressure to which any safety valve on the reheat system is set to lift. EXHAUST STEAM LINES All uncontrolled extraction steam lines of turbine shall be designed for 1.1 times the maximum possible working pressure on the lines.
6.2 6.2.1
6.2.2 6.2.3 6.3 6.3.1
6.3.2 6.4
6.5 6.5.1
FEED WATER PIPELINE The feed water piping beyond the discharge nozzles of the feed water pumps, shall be designed for the pump discharge pressure under no-flow condition for a fluid temperature of 15 deg. C. In the event of there being a likelihood of the speed of the prime mover exceeding the rated speed by more than 10%, the design pressure shall be increased by the effect of the excess in overspeed over 10%.
ISSUE R7
6.5.2
TCE FORM NO. 329 R4

TITLE
DESIGN OF POWER PLANT PIPING Feed water booster pump suction line.
6.5.3
The design pressure shall be not less than the sum of the highest set pressure of safety valves on the deaerator / feed water tank and the pressure due to static head of the water in the suction line calculated for a fluid temperature of 15oC. 6.5.4 Feed water booster pump discharge line. The design pressure shall not be less than the sum of the design pressure as calculated for the suction line of the booster pump and the differential head of the booster pump for the no-flow condition with a fluid temperature of 15 deg. C. 6.6 6.6.1 PROVISION OF SAFETY AND RELIEF VALVES Piping downstream of pressure reducing devices such as control valves, orifices, etc., shall be designed for the same pressures as applicable for piping upstream of the devices unless the downstream piping systems are adequately protected by safety or relief valves as under : In order to take cognisance of the provision of safety or relief valves, the combined relieving capacity of all safety or relief valves provided to protect a system shall equal or exceed the maximum possible mass flow that the system may be expected to handle under all normal or abnormal conditions of operation. In the case of safety valves located downstream of a control valve for example, the combined relieving capacity of the safety valves shall equal or exceed the estimated flow through the control valve when the valve is wide open with maximum upstream pressure and all downstream valves closed. When safety and / or relief valves have been provided as above, the design pressure of the piping system protected by the safety valves shall not be less than 1.1 times the highest set pressure of any safety valve. The lowest set pressure of any safety valve shall not be less than 1.1 times the maximum expected working pressure of the system. PUMP DISCHARGE LINES The discharge piping of all pumps other than the boiler feed pumps and boiler feed booster pumps shall be designed for a pressure not less than 1.1 times the pump discharge pressure under no-flow conditions for a working fluid temperature of 150C. 6.8 6.9 The design pressure of all branch piping including drain, vent and instrument impulse piping up to the last roof valve shall be the same as that of the main line. In general, piping shall be designed for the maximum possible pressure attainable under the most arduous operating condition including pressure surges. However, the design pressure of any piping system shall not be less than 10 kg/cm2g.
6.6.2
6.6.3
6.7

TITLE
DESIGN OF POWER PLANT PIPING DESIGN TEMPERATURES
7.0 7.1 7.2 8.0 8.1
The design temperatures shall be as indicated in the Data Sheets A. Where no value is indicated in the Data sheets, the same shall be as per the recommendations of applicable codes. WALL THICKNESS The calculation of wall thickness required for piping subject to internal and / or external pressure shall be based on the formulae and recommendations given in the applicable codes. Adequate allowances shall be made towards thinning due to bending, weakening at branch connections, threading, commercial tolerances on pipe wall thickness, corrosion and erosion, etc., and the same shall be subject to approval by the ENGINEER. A minimum corrosion / erosion allowance of 1 mm, shall be considered while selecting wall thickness of pipes for all systems. Additional allowances would be required in the case of piping handling corrosive and / or erosive media and in case of piping located in a corrosive environment. Pipe handling flashing liquids, as in case of feed heater drain lines, shall be selected with extra wall thickness to combat erosion. Much greater wall thickness than called for by strength calculations would be required in order to minimise noise and vibration at certain locations such as downstream sections of high pressure reducing valves. The thickness and lengths of such sections shall be as specified by the ENGINEER. Unless otherwise indicated in Data sheets A, piping shall be designed for a maximum equivalent full temperature cycles of 7000 occurring over the design life of the piping system. In case of carbon steel materials, (primarily for water & air services) the nominal wall thickness of no piping shall be less than the minimum acceptable values given below. For rolled and welded pipes thickness shall be 8 mm from NB 500 to NB 800, 10 mm from NB 850 to NB 1000, 12 mm from NB 1050 to NB 1200. 20 (3/4) 3.25 25 (1) 4.05 32 (1-) 4.05 40 (1-) 4.05 50 (2) 4.5 65 (2-) 4.5 80 (3) 4.85 100 (4) 5.4 125 (5) 5.4
8.2
8.3 8.4
8.5
8.6
NB mm (in)
15 (1/2) Min. Nominal 3.25 Thickness mm Nb mm (in) 150 (6) Min. Nominal 5.4 Thickness mm
200 (8) 6.35
250 (10) 6.35
300 (12) 6.35
350 (14) 7.1
400 (16) 7.1
450 (18) 7.1

TITLE
Minimum thickness for other services (steam, feed water, condensate, fuel oil system etc.,) shall be as per standard schedule of ASME B 36.10. 9.0 9.1 FLEXIBILITY ANALYSIS Formal flexibility analysis calculations shall be carried out in case of piping subject to restrained thermal expansions or contractions. The following piping systems shall be analysed. Pipelines with a maximum operating temperature equal to or greater than 150 deg. C. Regardless of the operating temperatures, all piping connected to sensitive rotating equipment such as turbines, feed pumps etc., for which limiting values of pipe reaction have been specified by the equipment manufacturer. Any other pipeline which in the opinion of the ENGINEER requires a formal analysis even for the lines less than 150 deg.C OBJECTIVES OF FLEXIBILITY ANALYSIS The flexibility analysis calculation carried out shall meet the following basic objectives. 9.2.1 9.2.2 To ensure that the stresses in the piping system are within the permissible values as given in the applicable codes under operating conditions, hot or cold. To ensure that the forces and moments exerted by the piping on connected equipment are within the maximum allowable values stipulated by the supplier of equipment under any operating condition, either hot or cold. To ensure that the forces and moments at the various restraints and anchors in the piping system are within limits acceptable to the ENGINEER under any operating conditions either hot or cold. To calculate the deflections and rotations of the piping at various salient points and to ensure availability of adequate space for the same. To arrive at a rational basis for the selection and design of hanger and support system for the piping. METHOD OF ANALYSIS Wherever formal analysis is called for, comprehensive analytical methods employing the use of modern electronic computers shall be adopted and these methods shall be comparable to the state of the art. The software used for analysis shall be validated with bench mark problems. In particular, the following requirements shall be met.
9.1.1 9.1.2
9.1.3 9.2
9.2.3
9.2.4 9.2.5 9.3

TITLE
DESIGN OF POWER PLANT PIPING Piping systems shall be treated as a whole between anchor points.
9.3.1 9.3.2 9.3.3 9.3.4
Linear and rotational behaviour of connecting equipment and intermediate attachments shall be taken into account. All linear and rotational restraints shall be taken into account. The restraining effect of hangers and supports shall be taken into account. Thus, the CONTRACTOR shall include, in his flexibility analysis calculations, all piping beyond his terminal points upto the next available anchor in each branch in order to treat the system as a whole for purposes of flexibility analysis. Flexibility characteristics and stress intensification factors for bends, and other items branches shall be utilised. Flange correction factor and bend stress intensification shall be used where applicable. All components in a piping system which have heavy wall section and do not contribute to the flexibility of the piping system shall be considered as rigid elements (for example, valves). The effect of the dead weight of the piping system shall be taken into account. Piping systems shall be analysed for all possible temperature distributions arising from various modes of operation, normal and abnormal, including possible maloperation and the objectives of the analysis shall be met for each mode of operation. In the case of equipment to which several pipelines are connected each of which is analysed independently, it would be necessary to ensure that the combined values of the forces and moments exerted by each pipeline on the equipment for all possible modes of operation are also within acceptable limits as specified by the equipment manufacturer. The method of combining the values of forces and moments shall be as specified by the equipment manufacturer. COLD SPRINGING Cold springing of piping may be carried out when the operating temperatures are high and the net thermal expansions are large, provided that the same is acceptable to the equipment manufacturer. Cold springing of piping systems with relatively small thermal expansions as in case of boiler feed pump suction and discharge piping, is not permitted. CONTRACTOR shall obtain specific approval from ENGINEER in the event he proposes to carry out cold springing of any piping system. If the cold springing is carried out, it is recommended that the cold spring factor lies between 0.5 and 0.85.
9.3.5
9.3.6
9.3.7 9.3.8
9.4
9.5 9.5.1
9.5.2

TITLE
DESIGN OF POWER PLANT PIPING SURGE ANALYSIS
10.0 10.1
If it is deemed necessary by the PURCHASER / ENGINEER, a surge analysis shall be carried out by the CONTRACTOR to evaluate the effect of sudden closure of valves that are hydraulically or pneumatically actuated. The pressure rise in the piping, additional thrusts and moments created at the terminal ends and intermediate restraints, additional stresses to which the piping is subjected and the deflection and rotation that the piping is subjected to due to the impact and / or surge shall be computed. The additional stresses, forces and moments created shall be studied in conjunction with the corresponding values computed by the flexibility analysis and the combined values shall be held within permissible limits specified by the equipment manufacturer and / or codes. The deflection and rotations of the pipe at the locations of the power actuated valves causing the impact and surge shall be within the limits specified by the valve manufacturer. In the event of these limits being exceeded, the CONTRACTOR shall introduce shock absorbers at suitable locations to hold the deflection and rotations within permissible limits. These shock absorbers shall not offer any resistance to the movements and rotations of the piping caused by the thermal expansion as computed by flexibility analysis studies. The details of the shock absorbers, mode of their connection to piping and structures and the loads transferred to the structures shall be furnished to PURCHASER/ENGINEER for review and approval. The CONTRACTOR shall also submit to the PURCHASER/ENGINEER, a write-up outlining the procedure adopted by him for carrying out the surge analysis to the PURCHASER / ENGINEER for prior approval. LAYOUT AND DETAILING Contractor shall prepare composite drawings floor/elevation - wise on AUTOCAD which shall cover the following details : (a) (b) (c) (d) (e) (f) Piping layout (NB 65 and above). Hanger location Valve spindle Orientation. Equipment with maintenance details Cable tray and ventilation ducts. All main and internal columns, vertical bracings and other civil details.
10.2
10.3
10.4
10.5
11.0 11.1

TITLE
DESIGN OF POWER PLANT PIPING (g)
Individual drawings shall be prepared only after approval of the composite drawings. Composite drawings shall be drawn to scale 1:50 scale. The CONTRACTOR shall also furnish floppy of the composite drawings.
11.2
All pipes of sizes greater than NB 50 mm are considered as shop fabricated piping and detailed piping layout drawings shall be to scale and shall be prepared as plan and sections and shall contain the following minimum details. Fully dimensional layout with locating dimensions referred to plant axes and coordinates. Details of all stub connections and other welded attachments as required for anchors, restraints, hangers, supports, etc., and all details to meet IBR requirements. Slope, drains and vents. Edge preparation details of weld ends. Mounting and orientation of valves and specialities and maintenance space requirements. Location and tag nos., of hangers, supports, restraints, anchors, etc. Locations and magnitudes of cold cuts, if any. Pipe sizes, materials, design parameters, shop and field test requirements. Insulation details. Tolerances if any. Any specific requirements on shop fabrication and / or field erection. Any other details considered necessary by the ENGINEER. Pipes of sizes of NB 50 mm and smaller are regarded as field -routed. The CONTRACTOR shall however indicate any specific requirements he may have in regard to the routing of these pipes. Detailed bills of material shall be prepared for all piping systems. In case of shop fabricated piping, the bill of materials shall correspond to the layout drawing prepared. In the case of field - run piping, these shall be estimated quantities, with adequate surplus materials for wastage and contingencies. While routing piping, the following requirements shall be taken into account : All piping shall be routed so as to avoid interference with other pipes and their hangers and supports, electrical cable trays, ventilation ducting, structural
ISSUE R7
11.2.1 11.2.2
11.2.3 11.2.4 11.2.5 11.2.6 11.2.7 11.2.8 11.2.9 11.2.10 11.2.11 11.2.12 11.3
11.4
11.5 11.5.1
TCE FORM NO. 329 R4

TITLE
members, equipment, etc. Adequate clearances shall be ensured with respect to the above to accommodate insulation and pipe movements. After the award of the contract, adequate number of prints of the PURCHASERs / ENGINEERs structural, general arrangement and such other drawings as may be required to finalise the piping layout will be furnished to the VENDOR / CONTRACTOR for his reference and use. 11.5.2 11.5.3 All piping shall be grouped where practicable and shall be routed to present a neat appearance. The piping shall be arranged to provide clearance for the removal of equipment requiring maintenance and for easy access to valves and other piping accessories. Piping shall be generally be routed above ground but where specifically indicated / approved by the ENGINEER, the pipes may be arranged in trenches or buried. Pipes at working temperatures above the ambient shall however not be buried. Buried piping shall be coated and wrapped as per TCE.M4-134-102 Overhead piping shall have a minimum vertical clearance of 2.3 metres above walkways and working areas and 6 metres above roadways unless otherwise approved by the ENGINEER. Drains shall be provided at all low points and vents at all high points as per actual layout regardless of whether the same have been shown in the flow diagrams or not. Pipes shall be sloped towards the drain points. Besides at low points, tell-tale drains shall be provided at all other locations as necessary to remove on-line valves & specialities from piping for repair or replacement (e.g on either side of control valves). Where spray water is introduced into steam piping, at a suitable location downstream, drain pots shall be envisaged along with motor - operated drain valves and high and low level switches. The drain valves shall be interlocked with the level switches for automatic operation. All start-up drains on main steam, cold reheat, hot reheat and HP-LP bypass piping shall be furnished with motor-operated regulating valves. All other drains on steam piping systems shall be trapped and all trap stations shall be provided with isolating, bypass and free-blow valves. When drains are headered, each drain shall be provided with a non-return valve. Only drains from lines at identical operating pressures may be headered. Drains from all steam and hot water lines and equipment other than tell-tale drains shall be led into suitable flash tanks which in turn shall be drained and vented to condenser and/or atmosphere as directed by the PURCHASER/ENGINEER. All cold water drains shall be led down to the nearest floor drain. All vents shall be
11.5.4
11.5.5
11.5.6

TITLE
led into conveniently located anti-flash funnels which shall be drained into the nearest floor drain. 11.5.7 Provision shall be made while preparing piping layout to accept control valves, flow measuring elements and any other online speciality or equipment supplied by others. Sufficient upstream and downstream lengths shall be provided for flow measuring devices, control valves, desuperheaters and other specialities as required by the suppliers. At all the screwed valves and screwed connections on equipment, unions or flanges shall be provided to facilitate disassembly. Likewise, unions/flanges shall also be provided at suitable points on straight length of screwed piping. All local instruments shall be so located on piping as to render them observable from the nearest available platforms/floors. At all points where pipes pass through concrete floors or brick or other walls, suitable floor collars or wall boxes shall be provided by OTHERS. The VENDORS / CONTRACTOR shall design and furnish the details of the floor collars to the ENGINEER / PURCHASER. In the case of flanged piping, boxes shall be large enough to permit the passage of the flange. HANGERS AND SUPPORTS All piping supports, guides, anchors, turnbuckles, and hangers, spring hangers, rollers, with incidental structural subframing shall be designed, by the VENDOR/CONTRACTOR. The VENDOR/CONTRACTORs supports, spring hangers, guides, anchors and rollers shall utilise the PURCHASERs existing steel in so far as this can be done. Where additional steel is required for the attachment of hangers, it shall be designed by the VENDOR/CONTRACTOR. The hangers and supports shall be spaced in accordance with standard engineering practice as outlined in applicable codes and standards. Their locations shall also be so chosen as to avoid unduly heavy loads being transferred to the PURCHASERs structures. The location of hangers and supports is be subjected to approval by the PURCHASER/ENGINEER. If severe vibration of piping is encountered in systems over which the VENDOR/CONTRACTOR has control, or if the piping system is to be subjected to shock loading, hangers shall be supplemented by vibration control equipment and/or snubbers of an approved design. At locations where lateral or axial movement is expected, the hangers shall be provided with suitable linkages to permit swing. All hangers shall be designed to be vertical in the cold position unless otherwise stipulated by the ENGINEER.
11.5.8 11.5.9 11.5.10
11.5.11 11.6 11.6.1
11.6.2
11.6.3
11.6.4
11.6.5

TITLE
11.6.6
In order to minimise any horizontal force components of the dead weight or any binding of the pin or rocker joints used on the hangers, hanger rods should be as long as possible. In critical piping systems, the length of the hanger assembly capable of swinging shall not be less than 20 times the maximum expected pipe movement in the horizontal plane at the hanger location. The CONTRACTOR shall furnish embedded part details covering type, size, location, design load, material specification and detailed drawings of the part (If necessary). He shall furnish the embedded part list and details to the PURCHASER when called for. When medium or heavy brackets are bolted to walls, back plates of adequate size and thickness shall be furnished to distribute the load against the wall. Where the use of a back plate is not practical, the brackets shall be fastened to the wall in an approved manner. However, the attachment of support brackets to brick walls shall be avoided as far as possible and where this is not possible, details of the attachment shall be furnished to the ENGINEER for his approval. In case the PURCHASER is carrying out the building structural steel design, the CONTRACTOR shall furnish the following details : (a) (b) Intensity of piping load to be considered in all areas. Location of the hanger with load. (To mark this PURCHASER/ENGINEER would furnish floor framing drawing or floppy. CONTRACTOR shall indicate location of these on floor framing drawings and return the floppy to PURCHASER/ENGINEER).
11.6.7
11.6.8
11.6.9
11.7 11.7.1
FITTINGS AND FLANGES Branch connections in piping shall as far as practicable be made by the use of wrought or forged seamless fittings such as tees, laterals and crosses. Small stubs as may be required for instrument, drain and vent connection may be provided in the form of weldolet fittings or forged couplings. Pipe to pipe branch connections are acceptable only in the event of non-availability of fittings. Such connections shall be reinforced as required. Mitred bends may be adopted for piping systems upto a design pressure of 10 kg/cm2g only. Mitre angle shall not exceed 22.5 degrees. Slip-on type of flanges shall be used only upto a maximum pressure rating of ANSI class 300 in the case of non-steam systems and 150 class in the case of steam systems. In case of higher pressure ratings, welding neck type of flanges shall be employed. DIMENSIONAL STANDARDS Uniform dimensional standards for all piping components shall be employed to ensure compatibility with one another.
ISSUE R7
11.7.2 11.7.3
11.8 11.8.1
TCE FORM NO. 329 R4

TITLE
11.8.2
Nominal pipe sizes and pipe outside diameters shall generally be as per ASME B36.10. In case of deviation, the CONTRACTOR shall bring it to the specific attention of the ENGINEER for prior approval stating reasons for the deviation. INSTRUMENT CONNECTIONS Unless otherwise called for by the PURCHASER, all thermowell stubs shall have an internal threading to M33 x 2. All stubs for pressure or flow measurement for piping with a maximum working pressure equal to or above 62 barg or with a maximum working temperature equal to or above 4250 C shall be NB 25 mm and double root valves shall be used. Stubs for pressure or flow measurement on pipelines with a maximum working pressure less than 62 bar(g) or with a maximum working temperature less than 4250C shall be NB 15 mm size and single root valves shall be used. Pressure measurement stubs on fuel oil lines shall be of NB 25 mm size. DRAIN AND VENT CONNECTIONS Vent and drain connections on pipelines shall be atleast of NB 25 mm size. For pressure as defined in clause 11.9.2, double isolating valves shall be used on drain and vent lines. For pressure and temperature conditions as defined in clause 11.9.3, single isolating valves are considered adequate. For drawings and documents to be submitted by the CONTRACTOR after the award of the CONTRACT, refer Data sheet C attached to this specification.
11.9 11.9.1 11.9.2
11.9.3
11.9.4 11.10 11.10.1 11.10.2
12.0

TITLE
SECTION : D SHEET 1 OF 2
2 X 800MW TPP NEAR KRISHNAPATNAM DESIGN OF POWER PLANT PIPING DATA SHEET-C
INFORMATION TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF CONTRACT The VENDOR shall submit, in the manner and within the time set forth in the purchase order/letter of intent, the following: 1.0 DESIGN CALCULATIONS FOR THE FOLLOWING: (a) (b) (c) (d) (e) (f) (g) 2.0 3.0 Line sizes Pipe wall thickness calculations Branch reinforcement calculations Results of the flexibility analysis. Hanger loads, selection and related details. Results of surge analysis (Where applicable). Code compliance calculations.
Necessary piping layout and/or isometric drawings for submission to statutory authorities/IBR. Composite piping layout drawings. This shall indicate the piping layout engineered by the VENDOR as well as other piping layouts which are used by him to check for interferences. This shall also indicate the hanger locations. Floppy of Purchasers drawing (where applicable) with locations of hangers and supports marked therein. The VENDOR/CONTRACTOR shall be responsible for maintaining arrangement, dimensions etc., in accordance with the ENGINEERs approved drawings. Results of the flexibility analysis: The results shall indicate for each system and each mode of operation on the following: Ranges of hot and cold values of forces and moments exerted by the piping on each nozzle of connected equipment. Summation of above values at all nozzles of a particular equipment as per the procedure to be outlined by the PURCHASER/ENGINEER. Ranges of hot and cold values of forces and / or moments at all other anchors, restraints, etc..
4.0
5.0 5.1 5.2 5.3
FILENAME: M4134103R7.DOC

TITLE
SECTION : D SHEET 2 OF 2
2 X 800MW TPP NEAR KRISHNAPATNAM DESIGN OF POWER PLANT PIPING DATA SHEET-C
5.4 5.5 5.6
Ranges of hot and cold values of stresses as computed at all salient points of the piping system. Permissible values of stress range and hot and cold working stresses as per the governing code. Ranges and if applicable, design to hot and design to cold values of rotations and movements of the piping systems at all junction points and at all hanger locations. An isometric plot of the layout indicating dimensions, temperature distributions considered, pipe materials and properties, locations of anchors, restraints, etc. Magnitudes and locations of cold pulls where applicable. Detailed procedure and write-up for cold springing if adopted. Detailed valve list with tag numbers, service, pressure rating, VENDOR details etc., (as per format agreed between PURCHASER/ENGINEER). Bill of materials for all piping system in the VENDORs scope. Complete hanger details. Line designation schedule PURCHASER/ENGINEER). (as per format agreed between
5.7
5.8 6.0 7.0 8.0 9.0 10.0
FILENAME: M4134103R7.DOC
SPEC. NO. TCE.M4-134-02

TITLE
SUPPLY, SHOP FABRICATION AND TESTING OF POWER PLANT PIPING
1.0
SCOPE This specification covers the technical requirements and essential particulars for the design (as applicable), supply, shop fabrication, inspection, testing, cleaning, commissioning assistance and protection of the piping systems as covered in the tender specification documents and drawings. The CONTRACTOR shall demonstrate that the piping satisfies the requirements of the specification and applicable codes. To the extent design and engineering of piping systems are specified to be in the CONTRACTOR scope in Section C of the tender documents and hereunder, all references to the PURCHASER drawings and documents in the subsequent clauses of this section shall be understood to imply the CONTRACTOR's drawings and documents.
2.0 2.1
CODES AND STANDARDS All piping systems including subcontracted items shall comply with all currently applicable statutes, regulations and safety codes in the locality where the system will be installed. The piping shall also conform to the latest editions of the codes and standards listed under Clause 2.2 below. Nothing in this specification shall be constructed to relieve the CONTRACTOR of this responsibility. The system and work under this contract shall conform to the following standards/codes: (a) (b) (c) (d) (e) (f) Indian Boiler Regulations Indian Regulations of Inspector of Explosives ASME Code Power Piping - ASME B 31.1 and all other associated ANSI/ASME standards. Manufacturer's Standardisation Society (MSS), USA, Standard Practices. American Society for Testing and Materials (ASTM) Specifications. Pipe Fabrication Institute (PFI), USA, Standards
2.2
2.3 3.0 3.1
In case of conflict between the codes and standards referred to herein and the requirements of this specification, the more stringent requirement shall govern. SCOPE OF WORK The scope of supply of the CONTRACTOR under this contract shall be as defined in Section C of this specification. For all the piping systems included in this scope of supply, the CONTRACTOR shall supply all materials except those items specifically excluded from his scope in Section C, and render the piping systems complete as applicable. The CONTRACTOR's scope of supply shall include but not be limited to the following: (a) Pipes, tubes, headers, manifolds, etc.

TITLE
(b)
Bends, elbows, returns, tees, laterals, crosses, reducers, caps and closures, full and half couplings, plugs, sleeves and saddles, stubs and bosses, unions and other similar fittings. Flanges Gaskets and fasteners Complete assemblies of hangers, supports, anchors, guides, restraints, snubbers, shock absorbers, etc., including welded attachments, springs and spring gauges, beam clamps, clips, shoes, rollers, trapezes, trunnions, etc. Auxiliary steel, concrete foundations, pedestals, etc., as required for hangers, supports, guides, restraints, anchors, snubbers, shock absorbers, etc. All materials as required for providing anti-corrosive treatment to buried pipes All paints, varnishes, primers, thinners and other painting materials. Weather hoods for bare pipes crossing ceilings and walls.
(c) (d) (e)
(f)
(g) (h) (i) 3.2
Unless otherwise specified in Section C, the CONTRACTORs scope of supply includes all instrument impulse piping and fittings upto the last root valve. In the case of temperature measurement points, the CONTRACTORs scope includes supply of thermowell stubs. The CONTRACTOR shall supply all necessary drains and vents including anti flash funnels as required for the safe and effective draining/venting of the piping systems. It must be noted that the flow diagrams may not indicate all the drains and vents that would be required. As stated elsewhere, it is the CONTRACTOR's responsibility to identify the requirements of drains and vents whether the same have been shown in the flow diagrams or not and supply the necessary pipe work, fittings, hangers, supports, etc. The drains and vents indicated on the flow diagrams shall however be regarded as minimum requirements. The drains and vents shall be led upto the nearest floor drain in case of cold water systems and upto the flash tank in case of steam and hot water systems, as directed by the PURCHASER. In the case of pipes laid in trenches or on pipe racks, the CONTRACTOR shall supply necessary steel members, cross beams and other supporting accessories such as stools, saddles, base plates, clamps, U-bolts, angles, clips, etc. All concrete pedestals and foundations other then those specifically indicated as excluded from the CONTRACTORs scope in Section C shall be supplied by the CONTRACTOR.
3.3
3.4
3.5
ISSUE R4
TCE FORM NO. 329 R4

TITLE
3.6
Wherever uninsulated pipes cross walls or roofs, the necessary weather hoods shall be designed, fabricated and supplied by the CONTRACTOR as directed by the PURCHASER. The CONTRACTOR shall design, fabricate and supply all hangers and supports, anchors, guides, restraints, etc., including necessary welded attachments and auxiliary steel based on data furnished by the PURCHASER/ENGINEER. The data to be furnished by the PURCHASER / ENGINEER would be from the systems point of view and would typically include the overall configuration of the support system, operating and design loads, cold to hot movements of pipe, desired hanger/support spring constant, type of spring support, viz., constant load type or variable load type, etc. It is the CONTRACTORs responsibility to design, engineer and select the individual components of the hangers, supports, restraints, guides or anchors based on the PURCHASERs data and in accordance with the requirements of this specification. The loads indicated in the PURCHASERs hanger/support sketches do not include the weights of hanger components such as clamps, turnbuckles, trapezes, spring cage assemblies, etc. The weights of these components shall be considered by the CONTRACTOR in the design and settings of hangers and supports under advice to the PURCHASER/ENGINEER. The CONTRACTOR shall perform necessary internal machining of pipes for installing orifices, flow nozzles, straightening vanes, etc. At all intersection joints, it is the CONTRACTORs responsibility to design and provide suitable reinforcements as per the applicable codes and standards taking into account the pressure, temperature and dead weight loads. Welding, nondestructive examination of welded joints and repair of weld defect areas shall conform to TCE specification no. TCE.M4-134-04. The CONTRACTOR shall prepare fabrication isometric drawings and bills of material for piping NB 65 mm and larger based on the PURCHASERs piping drawings except for Low Pressure (LP) piping systems such as water and air. The PURCHASER/ ENGINEER will review, prior to release for fabrication, all piping isometric drawings. The PURCHASER/ENGINEER may request changes, if the PURCHASER/ENGINEERs stress analysis or other considerations require it. As the CONTRACTOR is responsible for the design and adequacy of hanger components, no comments or approval may be given by the PURCHASER/ENGINEER except in those instances where it may appear that the CONTRACTORs work does not meet the standard desired by the PURCHASER/ ENGINEER. In such cases, the CONTRACTOR shall be guided by the PURCHASER / ENGINEER's comments and the CONTRACTOR shall comply to the requirements at no extra cost. The CONTRACTOR's fabrication drawings shall take into account the requirements of this specification as also all applicable codes and standards including statutory regulations such as the Indian Boiler Regulations. The
3.7
3.8
3.9 3.10
3.11 3.12
3.13
ISSUE R4
TCE FORM NO. 329 R4

TITLE
CONTRACTORs fabrication drawings shall carry all details of fabrication, welding, etc., as may be required for obtaining necessary statutory clearances. It is the CONTRACTOR's responsibility to obtain all such clearances, and fabrication shall commence only after the necessary clearances have been obtained from the appropriate authorities. All expenses incurred in obtaining these clearances shall be to the CONTRACTORs account. 4.0 4.1 MATERIALS AND WALL THICKNESS All piping materials to be supplied by the CONTRACTOR shall be in accordance with the PURCHASERs piping material specification and/or piping bill of materials. The BIDDERs may offer if they so desire, alternate materials equal or superior to those specified. However, no credit would be given to offers containing materials superior to those specified. The responsibility for establishing equality or superiority of the alternate materials offered to those specified rests entirely with the BIDDER. The PURCHASER / ENGINEER reserves the right to reject such alternate materials and insist upon only those specified. The BIDDERs shall note that equality or superiority of the materials offered by them vis-a-vis those specified would be judged not only based on a comparison of the material standards but also on the ease of fabrication, shop and field welding, heat treatment, service record and any other characteristic considered important by the ENGINEER. BIDDERs shall indicate in their offer, reasons and justification for their wishing to deviate from the materials specified. Materials inferior to those specified will not be acceptable. Where bending and forming allowances are excluded from the wall thicknesses specified in the specification documents, the specified wall thicknesses shall be increased in accordance with the CONTRACTOR's standards to allow for the manufacturing process for bends and fittings. In no case shall the wall thicknesses of fittings be less than those specified for straight pipes. For steam piping systems, all materials shall be procured directly from the manufacturers. Materials procured from traders and stockists are not acceptable. For LP piping systems, these can be procured from reputed and approved traders or stockists. All materials procured shall be new and specifically for the subject contract. All materials shall be certified by proper material test certificates. All material test certificates shall carry proper identification number or other acceptable references to enable identification of the certificate with the material it purports to certify. The heat number shall also be indicated on the material certified.
4.2
4.3
4.4 4.5 4.6
4.7
4.8 4.9

TITLE
5.0 5.1
FABRICATION Unless otherwise specified in Section C, all steam piping systems of size NB 65 mm and larger shall be supplied fully prefabricated at works as per the piping drawings. All piping, NB 50 mm size and smaller, shall be supplied in straight lengths, with the pipe ends cut square to the axis. Unless otherwise specified in piping drawings or piping materials specification data sheets, all pipeline joints shall have welded construction. Butt-welded joints shall be used for pipes NB 65 mm and larger. Socket welded joints shall be used for pipes NB 50 mm and smaller. The use of companion flanges to connect two pieces of pipe or the use of odd or short pieces of pipes in making up long runs is prohibited, except as noted on the PURCHASER's piping drawings. Where welded pipes or fittings are used, longitudinal welds in adjoining sections shall be staggered by minimum of 90o during fabrication. All piping shall be fabricated true to lines and elevations as indicated in the piping drawings. Neither butt nor branch joints shall be closer than twice the pipe diameter to any other joint in the same pipeline except where 'weldolet' type fittings are used, in which case the branch weld will be made to the 'weldolet'. The number of joints for field welding shall be kept as a minimum as practicable and limited to accessible circumferential butt welds. All pipe bends shall have a bend radius of five nominal pipe diameters unless otherwise specified in the PURCHASERs piping drawings. The pipe bends shall be true to angle and radius and shall maintain a true circular cross section of pipe without deformity or undue stretching. Crimping of pipes to form bends is not acceptable. All pipe flanges and contact surfaces shall be concentric with the axis of the piping. All flanges and fittings shall be accurately machined and drilled true to template. All threads on piping components shall be taper pipe threads as per applicable standards. Threaded connections for insertion type fluid temperature sensing and sampling devices shall be seal welded when the service temperature exceeds 495oC or the service pressure exceeds 103.5 bar (g). The threads shall be entirely covered by the seal weld and only qualified welders shall carry out such seal welding. The CONTRACTOR shall cut the pipe short for cold spring for all hot lines in accordance with the data furnished by the PURCHASER. In addition to the cut for cold spring, a length of pipe must be cut to attain slope when the line is in the cold or hot position. The additional cut must not add to the cold spring in the system. In order not to add to the cold spring, the pipe must be detailed and fabricated so that the affected horizontal runs will be sloped to the proper angle when installed in the field before the final weld is made. At the point of closure,
ISSUE R4
5.2
5.3
5.4
5.5 5.6
5.7
5.8
5.9
TCE FORM NO. 329 R4

TITLE
the two pipe ends should be separated by the required amount of cold spring only. 5.10 All welded attachments such as lugs, shoes, trunnions, etc., as required for supporting, restraining or anchoring a pipe shall be welded to the pipe at works and stress relieved as required. All welded attachments and thermocouple pads shall be of the same material as the parent pipeline and shall be subjected to the same fabrication and welding procedures as the associated piping. All welds between dissimilar materials shall be carried out at works. welding of joints involving dissimilar materials shall be avoided. Field
5.11 5.12
The first circumferential weld joint after a pipe bend shall as far as possible be after a minimum straight length of two times the pipe diameter or 500 mm whichever is less. All pipelines shall be pitched to low point(s) where drainage is indicated on the PURCHASER's drawings. The pitch shall be sufficient to prevent pockets of moisture collecting at low points between supports. The CONTRACTOR shall fabricate the pipe assemblies in such a way as to avoid any difficulty during field erection. All branch connections shall be realised through the use of tees, crosses and laterals to the extent such standards fittings are available as per ANSI standards. Where intersection welds are employed due to non-availability of a standard fitting, they shall be of suitable structural adequacy by virtue of intrinsic weld connection, reinforcing pads or rings or materials inherent in the branch. It is the CONTRACTOR's responsibility to provide reinforcement, wherever necessary for branch connections. The CONTRACTOR shall machine welding ends of all pipes, bends and fittings, to make sound welds. The welding rod shall be compatible with the parent material. The CONTRACTOR shall be responsible for determining the proper bending procedure, including bending temperature, as well as the heat treatment or stress relieving procedures to produce the desired end product. Cold bending may be performed on carbon steel, carbon molybdenum and chromium molybdenum steel pipes with chromium content less than 1 % in a stress relieved, normalised and tempered or fully annealed condition. Bending performed at temperatures below 900oC shall be considered "cold bending". Only hot bending at 900oC to 1200oC shall be performed on chromium molybdenum steel regardless of its heat treatment by full annealing. The pipes shall be filled with free running, sulphur free silica sand or other dry solid inert material, firmly tapped for the hot bending operations. Optical pyrometry or other approved methods shall be used for temperature control of these operations.
ISSUE R4
5.13
5.14 5.15
5.16
5.17
5.18
5.19
TCE FORM NO. 329 R4

TITLE
5.20 5.21 5.22 5.23
Oxyacetylene torches shall not be used for heating purposes during bending operations. Carbon steel, carbon molybdenum and chromium molybdenum piping shall be bent hot if cold bends, free of cracks or buckles, cannot be made. Bends in seam welded pipes shall be oriented so that the seam is positioned along the neutral axis. All materials that have been bent, forged or formed shall be subsequently heat treated in a furnace as described below: (a) (b) (c) Hot bent, forged or formed carbon steel piping require no subsequent heat treatment. Hot bent, forged or formed ferritic alloy steel piping shall receive a stress relieving treatment, a full anneal or a normalise and temper treatment. Cold bent, forged or formed carbon steel and ferritic alloy piping shall be stress relieved after bending when: i. ii. Carbon steel pipe wall thickness equals or exceeds 19 mm. Ferritic alloy steel pipe wall thickness equals or exceeds 13mm or when the nominal pipe size is 100 mm or larger.
5.24
Cold bending of carbon and ferritic alloy steel pipe in sizes and wall thicknesses less than specified in para 5.23(c) may be used without a postheat treatment, if it is demonstrated that the mechanical and metallurgical properties are not impaired by omission of such post heat treatment. Ferritic piping materials upto and including 2.25 Cr - 1 Mo that have been bent, forged, formed or welded may have the final heat treatment delayed until a full furnace charge is available. The preferred method of heat treatment is full annealing for the low chromium molybdenum steels. The full annealing heat treatment shall be carried out in a temperature-controlled furnace capable of accommodating the assembly with adequate supports and contact thermocouples. The PURCHASER/ENGINEER shall reserve the right to select the alternative heat treatment, viz., normalising and tempering. Liquid quenching for heat treatment is not permitted. The preferred method of heat treatment for the chromium molybdenum steel is full annealing. Following are the recommended heat treatments in the order of preference: (a) Full annealing chromium molybdenum steels, 1 Cr 1/2 Mo to 3 Cr 1 Mo inclusive. Full annealing shall be accomplished by heating in a heat treatment furnace to a metal temperature of 900oC+14oC and holding at that temperature for a period equal to one hour per 25 mm of wall
5.25
5.26
5.27
ISSUE R4
TCE FORM NO. 329 R4

TITLE
thickness of the thickest section but in any case not less than one hour. The material shall then be allowed to cool in the furnace at a rate of 30oC per hour to a metal temperature of 600oC. The material shall then be removed from the furnace and cooled in still air in a building having a room temperature of not less than 10oC. (b) Normalising and tempering chromium molybdenum steels, 1 Cr 1/2 Mo to 3 Cr 1 Mo inclusive. Normalising shall be accomplished by heating in a heat treatment furnace to a metal temperature of 900oC to 960oC and holding at that temperature for a period equal to one hour per 25 mm of wall thickness of the thickest section but in any case not less than one hour. The material shall then be allowed to cool in still air to a metal temperature of 315oC or below. The air temperature shall not be lower than 10oC. Tempering shall be accomplished by reheating in a heat treatment furnace to a metal temperature of 630oC to 750oC depending on the alloy range and holding at that temperature for a period equal to one hour per 25 mm of wall thickness of the thickest section but in any case not less than one hour. The material shall then be cooled to 315oC in the furnace at a controlled rate not to exceed 110oC per hour. At 315oC, the material may be removed from the furnace.
5.28
Stress relieving treatment for carbon steel shall be accomplished by heating in a heat-treatment furnace to a metal temperature of 635oC to 675oC and holding at that temperature for a period equal to one hour per 25 mm of wall thickness of the thickest section but in any case not less than one hour. The material shall then be cooled in the furnace until the metal temperature drops to 315oC. or below, and then air cooled in a draft free area where the air temperature is not below 10oC. Stress relieving treatment for C - 1/2 Mo and 1/2 Cr 1/2 Mo steels shall be accomplished by heating in a heat treatment furnace to a metal temperature as follows: Carbon 1/2 Molybdenum steel 650oC 675oC 1/2 Chromium1/2 Molybdenum steel 690oC 729oC The temperature shall be held for a period equal to one hour per 25 mm of wall thickness of the thickest section but in any case not less than one hour. The material shall then be cooled in the furnace until the metal temperature drops to 315oC or below, then air cooled in a draft free area where the air temperature is not below 10oC.
5.29
5.30
When pipe must be threaded before bending, forging or heat treating, all exposed thread surfaces should be protected during heat treatment with high temperature silicone paint.

TITLE
6.0 6.1
CLEANING OF PIPING All hot bent, forge formed, fabricated and straight sections of piping shall be chemically cleaned, pickled or wire brushed and purged with an air blast or shot / grit blast to remove all sand and scale from the inner surface. The inside and outside of all pipes shall be free of sand, loosely adhering scale, dirt and other foreign matter. The method of cleaning shall not leave any material on the inner or outer surfaces that will affect the serviceability of the pipe. During manufacturing and fabrication of carbon and alloy steel piping, surfaces shall be descaled by any one of the following methods: (a) Completely grit blast inner and outer surfaces with angular silicon carbide or steel grit (Sand blasting is prohibited). Grit shall be removed completely by an air blast or other convenient means such as rotary brushing. Pickle in commercial hot inhibited sulphuric acid. Wash in cold water followed by wash in hot water. Clean by power driven wire brushes. The brushes shall be of the same or similar material as the metal being cleaned.
6.2
(b) (c) 6.3 7.0 7.1
Cleaning technique and tests shall follow the guidelines of Structural Steel Painting Council Surface Preparation Specifications. CORROSION PROTECTION The outside of carbon steel and low alloy steel piping, with exception of machined surfaces (e.g., weld ends) shall be coated with enamel or other protective paint. All weld end preparations shall be coated with deoxaluminate paint. Use of grease or oil, other than light grade mineral oil, is prohibited. After cleaning carbon or low alloy steel piping by any method producing continuous white metal on the inside of the pipe and prior to shipment, the surface shall be coated with a readily water soluble corrosion inhibitor such as a solution of 1/2 % sodium nitrite, 1/4 % monosodium phosphate and 1/4 % disodium phosphate. Following the application of corrosion protection systems, all components shall be covered, boxed, capped, plugged or otherwise shielded from further contamination of corrosion. MARKING All pipe and fittings supplied by the CONTRACTOR shall be legibly marked with its identifying pipeline description and piece number, as per the relevant component or spool piece drawing.
ISSUE R4
7.2
7.3
8.0 8.1
TCE FORM NO. 329 R4

TITLE
8.2
Materials may be marked with any method, provided the method does not result in sharp discontinuities and does not loose its identity until the piping system is erected. Materials 6 mm or thicker may be marked by stamping, which when adopted, shall be done with round nose or interrupted hot die stamps having a minimum radius of 0.8 mm. Any item too small to be legibly marked shall have a metal tag containing the necessary information securely attached to each bundle or container of such items, so that it does not lose its identity during shipping and storage. Marking paint, ink and tape shall be certified to be free of chloride, sulphur, lead, tin, or mercury. HANGERS AND SUPPORTS The design loads indicated on the PURCHASERs hanger sketches include the weight of pipe, the weight of insulation and the weight of medium transported or the medium used for testing, whichever is heavier. All components of hanger or support assembly shall be designed for the above design load and the selfweight of hanger/support assembly. Each rod of a double rod hanger shall be designed for the full design load specified for the hanger. All hanger components including springs shall generally conform to MSS SP58 'Pipe Hangers and Supports-Material and Design'. The design shall take full advantage of commercially available, load rated and tested hanger components to the maximum extent possible. Uniformity and simplicity in design shall be maintained. All hangers shall be functional and shall be easily installable using conventional field erection techniques. The materials used in the construction of hangers, supports and accessories shall be the most suitable for the service intended. Lugs or other means of welded attachments to pipes shall be welded on in the shop and shall be of the same materials as the parent pipe. Wherever possible, pipe attachments for horizontal piping shall be a pipe clamp. The hangers shall be designed, fabricated and assembled in such a manner that any movement of the supported pipe does not disengage them. The hangers shall be provided with suitable linkages to permit swing. The diameter of hanger rods for piping, NB 50 mm and smaller, shall be minimum of 9.5 mm. The diameter of hanger rods for piping, NB 65 mm and larger, shall be minimum of 12.5 mm. Bolted pipe clamps, used with rod hangers, shall have a minimum thickness of 5 mm for weather-protected locations and 6 mm for places exposed to weather.
ISSUE R4
8.3 9.0 9.1
9.2 9.3
9.4 9.5
9.6 9.7 9.8 9.9 9.10
TCE FORM NO. 329 R4

TITLE
9.11
Springs, for spring hangers, shall be of helical compression type and shall be provided with means to prevent misalignment, buckling and eccentric loading and with stops to prevent excessive travel. The construction shall also be such that complete release of piping load will be impossible in case of spring failure or misalignment. Suitable stops shall be provided for field hydrostatic test of piping. Springs shall be enclosed in spring cages. Load/travel indicators shall be provided on the spring cages. Constant support hangers shall have a field load adjustment range of 20% of the operating load specified and shall be provided with stops for field hydrostatic test of piping and also with suitable distant visible travel scales and indicators clearly showing cold and hot settings. The total travel of the unit selected shall be the calculated travel plus 20% (minimum 25 mm) to take care of possible discrepancy between calculated and actual thermal movements. Constant support hangers shall have support variation of not more than 2.5% throughout the total travel range. Where variable spring hangers are specified, the units selected shall have support variation of not more than 25% through its total travel range. All rigid hangers shall have a means for vertical adjustment after erection. Pipe springs shall be fitted with an adequate malleable iron adjusting nut of the locking type, threaded to a rod that will allow adjustment after erection while supporting the load. All spring hangers shall be furnished with forged steel turnbuckles to permit adjustment and setting of pipe elevation at site. All rigid hangers for loads 250 kg and above shall have forged steel turnbuckles. All rigid hangers, for loads less than 250 kg, shall have the hanger rods threaded to permit adjustment and setting of pipe elevation at site. Beam clamps shall be of forged steel, each equipped with a rod to fix a nut. All supports for carbon steel piping shall be provided with carbon steel machine bolts and nuts in accordance with applicable codes. Bolt heads shall be regular square and unfinished. Nuts shall be cold punched, semi finished, heavy hexagonal type. For supporting alloy steel piping, bolts and nuts, as per applicable codes shall be provided. All threaded members shall have a true and complete depth of thread. The turnbuckles or adjusting nut shall have its full length of thread in service while in use and the amount of adjustment plainly visible. All similar adjustable arrangements shall have provision for locking. The threads on threaded parts such as hanger rods, nuts and turnbuckles shall conform to applicable codes for the coarse thread series with a 'medium' class fit or equivalent.
ISSUE R4
9.12
9.13 9.14 9.15
9.16
9.17 9.18
9.19
9.20
TCE FORM NO. 329 R4

TITLE
9.21 9.22
All hangers shall be furnished with beam clamps, rods, pipe stubs and all other materials required to make the hanger complete. All hangers shall be designed for rigid fastening to the structure either directly or through a bracket. Anchors and guides shall be capable of withstanding the moments and forces imposed by thermal expansion. The parts of hangers which move relative to the pipe during expansion shall be connected to the pipe clamps or lugs in such a way that these parts lie entirely outside the insulation. All components of hangers and supports and anchors shall be given one shop primer coat of red oxide paint. INSPECTION AND TESTING All items covered by this specification shall be subject to inspection by the PURCHASER/ENGINEER at no additional cost to the PURCHASER and the CONTRACTOR shall advise the PURCHASER / ENGINEER promptly when items are ready for inspection. All materials shall be subjected to source inspection by the CONTRACTOR to ensure compliance with material specifications mentioned herein or any other approved material specifications. The CONTRACTOR shall permit the PURCHASER to maintain one or more of his representatives in the CONTRACTORSs shops and the shops of his SUBCONTRACTORSs, for the purpose of inspecting various steps in the shop fabrication of the materials specified herein. The PURCHASERs representative shall at all reasonable times have free access to the VENDOR's shops and be able to witness the CONTRACTORs heat treatment records and magnetic particle, fluroscent particle or dye penetrant or ultrasonic or radiographic inspection records, reports of repairs, etc. The works shall also be subject to inspection in the CONTRACTORs / his SUBCONTRACTORs shop by an inspector of a selected inspection or insurance company, where required, depending upon local manufacturing, construction and safety codes. The inspection shall be as frequent as required to ensure progress of work and quality of workmanship. Any workmanship or material inspected in the field and found not to comply with this specification, the same shall be replaced or repaired at the VENDORs expense, if the noncompliance is the fault of the VENDOR. All inspection shall meet the requirements of TCE standard nos. TCE.M4-185-28 and TCE.M4-185-38. For radiography procedure, ASTM E94 and ASTM E142 shall be followed.
ISSUE R4
9.23
9.24 10.0 10.1
10.2
10.3
10.4
10.5
10.6 10.7
TCE FORM NO. 329 R4

TITLE
10.8
Radiographic Acceptance Criteria for weld ends, the examination techniques, requirements and repairs for weld ends shall meet the mandatory requirement of ASME Section VIII Division 1 Appendix 7 in all respects. Defect Removal and Repair in Castings (a) Defects in excess of acceptance standards shall be removed by suitable means. If removal of surface defect does not result in reduction in wall thickness below acceptable minimum, the area shall be blended smoothly into the surrounding surface. Where defect removal results in a wall thickness below the acceptable minimum, resultant cavity may be repaired by welding. The procedure and the operation shall be qualified as per applicable standards. Major weld repairs shall be stress relieved or heat treated in accordance with the material specification. The repaired area shall be reexamined and the acceptance standards shall be as followed in the original examination. Major weld repairs made as a result of radiographic examination shall be re-radiographed after welding. The acceptance standards for porosity and slag inclusions in welds shall be as per ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.
10.9
(b) (c)
10.10 On completion of forging and subsequent heat treatment operations on chromium molybdenum fittings, the forged material shall be machined / ground and blasted to clean metal on the interior and exterior surfaces. 10.11 Unacceptable defects disclosed by visual, magnetic particle, radiographic or ultrasonic inspection, shall be repaired by removing the defects completely and re-welding. The repaired spots shall be re-examined in a way similar to the one followed for the main weld. Only qualified welders shall be employed for repair welding and shall be carried out as per approved welding procedure. 10.12 All pipes, fittings, etc., shall be tested hydrostatically at the shops, where manufactured, at test pressures which are given in the applicable codes, material specification sheets and/or Section C. After completion of test, the piping shall be completely drained prior to shipment to insure against damage from freezing. When such drainage requires removal of plugs, valves, drain cover, caps, etc., the CONTRACTOR shall ensure that these parts are reinserted or reassembled prior to shipment. 10.13 Where the pipe work is composed of pipe and standards fittings, the test pressure to be applied shall be the standard test pressure for the lowest rated standard component in the assembly.

TITLE
HORIZONTAL CENTRIFUGAL PUMPS SCOPE
1.0
This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at manufacturers works and delivery at site of Horizontal Centrifugal Pumps. 2.0 CODES AND STANDARDS The design, materials, construction, manufacture, inspection, testing and performance of horizontal centrifugal pumps shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. 3.0 3.1 DESIGN REQUIREMENTS Pumps of a particular category shall be identical and shall be suitable for parallel operation with equal load division. Components of identical pumps shall be inter-changeable. Flow rate versus head curve shall have a stable and continuously rising characteristics towards the shut-off head. In case of unstable (drooping) characteristics the duty point shall be well away from the unstable region. Besides the actual flow rate versus head curve, curves for minimum and maximum impeller diameters shall also be shown. The shut-off head shall be at least 110% of the differential head. The required NPSH at duty point shall be at least one (1) metre less than the available NPSH. The rating of the pump driver shall be the larger of the following : (a) (b) 3.6 3.7 The maximum power required by the pump from zero discharge to runout discharge at site climatic conditions. 110% of the power required at the duty point at site climatic conditions.
3.2
3.3 3.4 3.5
The corrosion allowance for pressure parts shall be 3 mm. Pumps shall run smooth without undue noise and vibration. Noise level produced individually or collectively shall not exceed 85 dB(A) measured at a distance of 1.86 metres from the source in any direction. The overall vibration level shall be as per zones A and B of ISO 10816-1. In case of fire water pumps, pumps and drivers with all the accessories shall meet the requirements of Tariff Advisory Committee (TAC) or any other standard as called for in data sheet A. Pump type shall be as approved by TAC.
ISSUE R10
3.8
TCE FORM NO. 329 R4

TITLE
HORIZONTAL CENTRIFUGAL PUMPS CONSTRUCTION FEATURES
4.0 4.1 4.2
In addition to static balancing, impeller and balancing drum shall be balanced dynamically at or near the operating speed. Pump shall be provided with renewable type casing ring. Pump having capacity 1,000 M3/Hr and above shall be provided with impeller ring in addition to casing ring. The hardness of impeller ring shall be 50 BHN higher than that of casing ring. Pump casing shall be provided with drain and vent connection with plugged or valve connection. Bearing shall be oil-lubricated or grease-lubricated and shall have a life of 40,000 hours of working. In case of oil-lubricated bearing, constant oil leveller with magnetic drain plug shall be provided. Replaceable shaft sleeves shall be provided to protect the shaft where it passes through stuffing box. Stuffing box shall be of such design that it can be repacked without removing any part other than the gland and lantern ring. Mechanical seals shall be provided if called for in data sheet - A. If required, a flushing line shall be furnished, complete with strainer and orifice, from the pump discharge to the sealing face. When pumping liquid is not suitable for this purpose, a flushing connection shall be provided so that it can be connected to an external source. Auxiliary piping and plan shall be in accordance with appendix - D of API 610. The allowable loads on the pump nozzles shall be at least twice the values listed in the relevant tables of API 610 without reference to any other criterion. The base plate shall be designed to cater to the above increased loads. All pumps, except for back-pull out type, shall be provided with flexible coupling. Back-pull out type pumps shall be provided with spacer type coupling. Coupling guard made of expanded metal and bolted to the base plate shall be furnished for all coupled pumps. In addition to accessories listed in data sheet A, any other accessories required for safe and efficient operation of pump shall be provided. All incidental piping and valves required for sealing, lubrication and cooling for stuffing box packing and/or bearing of pump shall be furnished by the VENDOR. Leakage from the pump shall be led to the nearest surface drain by OTHERS. Pump VENDOR shall provide necessary arrangement like drip tray, base plate drain connection etc.
ISSUE R10
4.3 4.4
4.5 4.6 4.7
4.8
4.9 4.10 4.11 4.12 4.13
TCE FORM NO. 329 R4

TITLE
HORIZONTAL CENTRIFUGAL PUMPS TESTS AND INSPECTION
5.0 5.1
Hydrotest pressure on casing shall be 1.5 times maximum discharge head or twice differential head whichever is higher. ( Maximum discharge head = shut-off head + maximum suction head). Unless otherwise stated in data sheet A, the hydrostatic tests on the casing shall be conducted for a minimum duration of 30 minutes. The pumps shall be tested as per IS 5120, at rated speed at MANUFACTURER' s works to measure capacity, total head, efficiency and power. The negative tolerance on efficiency shall be limited to 2.5% and not 5% as indicated in IS 5120. These tests shall form the basis for acceptance of pumps except for vibration and noise. The pumps shall be tested over the range covering from shut-off head to the maximum flow. The duration of the test shall be minimum one (1) hour. Minimum five (5) readings approximately equidistant shall be taken for plotting the performance curves. After installation, the pumps shall be subjected to testing at site also. If the site performance is found not to meet the requirements regarding vibration and noise as specified, the equipment shall be rectified or replaced by the VENDOR, at no extra cost to the PURCHASER. PERFORMANCE GUARANTEE Performance parameters to be guaranteed by the VENDOR and tolerances permitted shall be as indicated in section C and/or data sheet A. BIDDER shall confirm acceptance of these by indicating values in data sheet B. Pump or any portion thereof is liable for rejection, if it fails to give any of the guaranteed performance parameters.
5.2
5.3
6.0

TITLE

HORIZONTAL CENTRIFUGAL PUMPS
DATA SHEET C DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE ORDER 1. 2. 3. List of drawings and documents to be submitted for review, approval and information with scheduled submission dates Quality Assurance Plan (QAP) Detailed dimensioned general arrangement drawing of pump and driver. This drawing shall indicate all the design data and information furnished in data sheets A and B. Foundation drawing of pump and driver with static and dynamic loads, details of fixing, grouting and all relevant data required for design of foundation Cross-section drawing of the pump with complete part list, materials of construction and relevant standards for each part Pump performance curves flow rate Vs head, BKW, efficiency, NPSHR from zero flow to maximum flow and torque-speed curve Scheme for pump sealing, lubrication and cooling Driver dimensional drawing Surface preparation and painting procedures Catalogues, data sheets and drawings for instruments Installation, operation and maintenance manual along with lubrication schedule
4. 5. 6. 7. 8. 9. 10. 11.

TITLE
1.0
SCOPE This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at the manufacturers works, delivery at site and performance testing at site of Electrically Operated Hoists.
2.0
CODES AND STANDARDS The design, materials, construction, manufacture, inspection, testing and performance of electrically operated hoist shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.
3.0
CONSTRUCTION FEATURES Electrically operated hoist shall be a complete unit with travelling trolley, hoisting motor, travel motor (if travelling trolley is motor operated), rope drum, wire rope, necessary gearing, sheaves, brakes, hook, pendent push button station, contactor panel, all wiring, conductor for travel motion (if travelling trolley is motor operated), limit switches, end stops, buffers, earthing terminals and other accessories to make the equipment complete in all respects. Electrically operated hoist shall have minimum factor of safety as five (5).
3.1
TRAVELLING TROLLEY The travelling trolley shall be motor driven or push pull or manual geared type as specified in data sheet A. Trolley frames shall be fabricated from rolled structural steel sections. The side plates of the trolley shall extend beyond wheel flanges, thus providing bumper protection for the wheels. The two side plates shall be connected by means of an equalising pin. The wheels shall be machined on their treads to match the profile of the monorail.
3.2
ROPE DRUM Rope drum shall be as per IS 3938. Rope drum shall be either cast or welded to sustain concentrated loads resulting from rope pull. Drum shall be machine grooved right and left with grooves of a proper shape for the rope used. Grooving shall be of proper length to handle entire rope required to make the specified lift plus the two dead laps at each anchor point, without overlapping.

TITLE
3.3
WIRE ROPES Wire ropes shall be extra flexible with well lubricated hemp core having six (6) strands of thirty-seven (37) or thirty-six (36) wires per strand with ultimate tensile strength of 1.6 106 KN/M. Wire ropes shall be of Right Hand Ordinary (RHO) lay construction. The rope shall be fastened to the drum with an attachment having strength equal to that of the rope. The rope fastening at the swinging end shall be aligned so as to prevent rope coming off its reeving. Rope shall be of sufficient length so that two (2) full laps shall remain on the drum at extreme low position of the hook. Reverse bends or cross bends and bird caging shall be avoided. The breaking loads for the hoist ropes shall not be less than the factor specified in IS 3938. The load shall include rated load on hooks, weight of the bottom block and the weight of rope.
3.4
LOAD CHAIN AND LOAD CHAIN WHEEL In case chain is employed for lifting the load instead of wire rope, it shall be heat treated to give required ductility and toughness so that it stretches before breaking. The total length of the load chain shall exceed the minimum length required to give the specified range of lift by not less than three (3) links per fall to ensure that the slack end anchorage is not loaded. The load chain wheel shall be of adequate strength and shall be suitably designed to ensure effective operation of the chain and shall be properly secured with shaft, preferably with splines
3.5
SHEAVES Sheaves shall be as per IS 3938. These shall be equipped with anti-friction bearings and shall be fully guarded to prevent the rope coming off. Equalising sheaves, if provided, shall also be as per IS 3938. Grooves shall be machined to proper shape for the rope used.
3.6
GEARS Gears shall be cut from solid cast or forged steel blanks or shall be of stressrelieved welded steel construction or built-up from steel billets and welded together to form a one piece gear section. Pinions shall be of forged carbon or heat treated alloy steel. All gears and pinions shall be totally enclosed type upto last stage of reduction in all motions and shall be carried in fabricated steel gear boxes which shall be dust proof and firmly sealed to prevent oil leakages. For travel motion, creep speed if specified shall be achieved by one of the following methods : (a) (b) (c) Planetary gear box integral with main gear box Planetary gear box independent with motor Worm reducer with clutch
However, for hoisting motion, creep speed shall be achieved only by methods (a) or (b) indicated above. Creep speed shall be generally 10 % of main speed.

TITLE
3.7
BEARINGS Bearings may be ball or roller type. All anti-friction bearings shall be of approved make, which are interchangeable with corresponding size bearings of other make. Bearing housings shall be of split type or so designed to permit easy removal of the shaft. The design shall be such that there is no ingress of dust and oil or grease does not leak out. Bearings shall have a minimum life expectancy of 20 years based on equivalent running time as per specified class.
3.8
SHAFTS AND AXLES Shafts and axles shall be of forged steel and shall have ample strength, rigidity and adequate bearing surface for intended duties. Shafts and axles shall be accurately machined and properly supported. Shafts shall, as far as possible, be furnished straight. If shouldered, these shall be provided with fillets of ample radius or shall be tapered to avoid loss of strength and stress concentration. These shall be designed considering allowances for keys and splines.
3.9
BRAKES All brakes shall be of fail-safe design and shall operate automatically in case of power failure. Each of the trolley and hoisting motors shall be equipped with electrically released, spring set, friction shoe type brakes. Hoisting brake shall be designed to hold 1.5 times full load torque while trolley travel brake shall be designed to hold 1.25 times full load torque. Separate brakes shall be provided for creep motions. All brakes shall have weather-proof enclosures. Coupling halves shall not be used as brake drums.
3.10
LIFTING HOOK The lifting hook shall be single hook type, solid, forged, heat treated, of rugged construction and provided with a standard depress type safety latch. Lifting hook shall have swivels and operate on ball or roller thrust bearings with hardened races. Lock to prevent hook from swivelling shall be provided.
3.11
BUFFERS, STOPS AND SWEEPS
3.11.1 Spring or rubber buffers shall be provided on the trolley. Suitable end stops shall be provided which shall be welded on the ends of monorail to contact the buffers mounted on the trolley. 3.11.2 Trolley wheel stops shall be provided before the end stops. These shall match to wheel radius. Stops to prevent trolley from running off the monorail shall be abutted against ends of monorail. Stops shall be welded to the monorail. 3.11.3 Sweeps shall be attached to the trolley to remove foreign material from the rails. 3.12 GUARDS

TITLE
3.12.1 All exposed couplings, shafts, gear wheels, pinions, drives etc. shall be safely encased and guarded. 3.12.2 The sheaves of hook blocks shall be guarded to prevent trapping of hand between a sheave and the in-running rope. 4.0 4.1 ELECTRICAL EQUIPMENT MOTORS Drive motors shall be as per IS 325 and companion specification TCE.M4-20301. Motor shall be suitable for frequent reversal, braking and acceleration. Pullout torque shall be 2.15 times the rated torque. 4.2 PENDENT PUSH BUTTON STATION The pendent push button station shall be supported independently, earthed separately independent of suspension and shall comprise the following push buttons and indicating lamps : (a) (b) (c) Start and Stop Trolley travel - To and Fro Hook - Hoist and Lower
Red lamp shall indicate supply ON 4.3 MISCELLANEOUS Controllers and resistors, controls, electrical protective devices, cables and conductors, earthing guards etc. shall be as per IS 3938. Limit switches shall be provided for overhoisting and overlowering and for two extreme ends of trolley travel.

TITLE
SECTION: IIIB SHEET 1 OF 1
2X 800 MW TPP NEAR KRISHNAPATNAM ELECTRICALLY OPERATED HOISTS
DATA SHEET C DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE ORDER 1. 2. 3. 4. 5. List of drawings and documents to be submitted for review, approval and information with scheduled submission dates Quality Assurance Plan (QAP) Motor power calculations Brake selection calculations Detailed to-scale dimensioned general arrangement drawing showing all the components. Drawing shall also indicate all design data and information furnished in data sheets A and B Part list of all the components with materials and codes of construction Flexible trailing cable arrangement drawing Detailed explanatory functional write-up of control scheme, wiring diagrams and control cabinet drawings Dimensional drawing for the hook Installation, operation and maintenance manual with lubrication schedule
6. 7. 8. 9. 10.
CHAIN PULLEY BLOCKS SCOPE
1.0
This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at the manufacturers works, delivery at site and performance testing at site of Chain Pulley Blocks. 2.0 CODES AND STANDARDS The design, materials, construction, manufacture, inspection, testing and performance of the chain pulley blocks shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. 3.0 CONSTRUCTION FEATURES The chain pulley block shall be a complete unit with travelling trolley, load chain, load chain wheel, hand chain, hand chain wheel, necessary gearing, brakes for hoisting, hook and other accessories to make the equipment complete in all respects. Chain pulley block shall be of worm or spur gear type and shall have minimum factor of safety as five (5). 3.1 TRAVELLING TROLLEY The travelling trolley shall be of push pull or manual geared type as specified in data sheet A. Trolley frames shall be fabricated from rolled structural steel sections. The side plates of the trolley shall extend beyond wheel flanges, thus providing bumper protection for the wheels. The two side plates shall be connected by means of an equalising pin. The wheels shall be machined on their treads to match the profile of the monorail. 3.2 LOAD CHAIN AND LOAD CHAIN WHEEL The load chain shall be heat treated to give required ductility and toughness so that it stretches before breaking. The total length of the load chain shall exceed the minimum length required to give the specified range of lift by not less than three (3) links per fall to ensure that the slack end anchorage is not loaded. The load chain wheel shall be of adequate strength and shall be suitably designed to ensure effective operation of the chain and shall be properly secured with shaft, preferably with splines. 3.3 HAND CHAIN AND HAND CHAIN WHEEL The hand chain for the hoisting and traverse mechanism shall hang well clear of the hook and both the chains shall be on the same side. The length of the hand chain shall be such that the lowest point of the suspended loop shall hang 400 mm above the operating floor level. The hand chain wheels shall be provided with flanges and designed to ensure effective operation. The hand chain wheels
CHAIN PULLEY BLOCKS
shall be provided with roller type guarding to prevent snagging and fouling of the chain. 3.4 GEARS Gears shall be cut from solid cast or forged steel blanks or shall be of stressrelieved welded steel construction or built-up from steel billets and welded together to form a one-piece gear section. Gears shall have proper lubrication arrangement and shall preferably be of totally enclosed type. 3.5 SHAFTS AND AXLES Shafts and axles shall be of forged steel and shall have ample strength, rigidity and adequate bearing surface for intended duties. Shafts and axles shall be accurately machined and properly supported. Shafts shall, as far as possible, be furnished straight. If shouldered, these shall be provided with fillets of ample radius or shall be tapered to avoid loss of strength and stress concentration. These shall be designed considering allowances for keys and splines. 3.6 BRAKES Brakes shall be of automatic type that shall stop and hold the load when handchain pull is released and shall permit controlled lowering of the load when hand-chain pull is applied for lowering the load. 3.7 RATCHET AND PAWL Ratchet and Pawl mechanism shall be provided to arrest the full load from lowering due to gravity. The ratchet and pawl shall be of steel, hardened and tempered so as to attain required wear resistance and toughness. 3.8 LIFTING HOOK The lifting hook shall be single hook type, solid, forged, heat treated, of rugged construction and provided with a standard depress type safety latch. Lifting hook shall have swivels and operate on ball or roller thrust bearings with hardened races. Lock to prevent the hook from swivelling shall be provided.
SECTION: IIIB SHEET 1 OF 1
CHAIN PULLEY BLOCKS DATA SHEET C
DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE ORDER 1. 2. 3. 4. List of drawings and documents to be submitted for review, approval and information with scheduled submission dates Quality Assurance Plan (QAP) Calculations for manual effort required to lift the load and for cross travel Detailed to-scale dimensioned general arrangement drawing showing all the components. Drawing shall also indicate all design data and information furnished in data sheets A and B. Part list of all the components with materials and codes of construction Dimensional drawing for the hook Installation, operation and maintenance manual with lubrication schedule
5. 6. 7.
SPEC NO.

TITLE
VOLUME IIIB

SHEET 1 of 6
TCE. M4-405-03
SUPPLY,DESIGN, FABRICATION,TESTING & ERECTION OF STRUCTURAL STEEL FOR STEAM GENERATOR SUPPORTING STRUCTURES
1.0 1.1 1.2
SCOPE This specification covers the general requirements for the supply, design, fabrication, testing and erection of structural steel for steam generator supporting structures. Structural framing shall be provided as required, including but not limited to the following : Buckstays for pressure parts, top supporting girders, main and auxiliary columns, bracings, base plates, anchor bolts, ladders, platforms, stairways and hand railing, gratings, pipe and other supports, curb plates and angles, chequered floor plates, hangers and hanger supports, miscellaneous steel such as frames, sill plates, struts, ties, lifting hooks, eye bolts, etc. and steel for enclosures and other items as may be required for satisfactory completion of the work.
2.0
APPLICABLE CODES AND SPECIFICATIONS The following standard specifications and codes of practice are made a part of this specification. All standards and codes referred to herein shall be the latest editions including all applicable official amendments and revisions. i) ii) iii) iv) v) IS:456 IS:800 IS:875 IS:1893 AWSD 1.1 Code of practice for plain and reinforced concrete. Code of practice for General construction in steel. Code of practice for design loads (other than earthquake) for buildings and structures. Criteria for earthquake resistant design of structures. Structural welding code - steel.
3.0 3.1
SUPPLY, DESIGN, FABRICATION & TESTING OF STRUCTURAL STEEL Design and fabrication of structural steel shall be in accordance with TCE specification no. TCE.M4-405-01 and as further specified herein below. In case of any conflict, requirements of this specification shall govern. Steam generator supporting structure and necessary auxiliary steel shall be adequate to support loads of the steam generator and all piping and accessory equipment furnished by the VENDOR/CONTRACTOR. In addition such loads, both vertical and horizontal, as may be imposed by the PURCHASER's piping, connecting steel, maintenance monorails, miscellaneous platforms, stairs and elevator connections with the boiler shall also be considered. Hangers as are required for piping furnished by the VENDOR/CONTRACTOR shall also be provided.
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TCE FORM NO. 329 R4
SPEC NO.

TITLE
VOLUME IIIB

SHEET 2 of 6
TCE. M4-405-03
3.3 3.3.1
Design Parameters All structures and equipment, including ducts shall be designed for wind loads as specified in Indian Standard "Code of Practice for Design loads ( other than earthquake) for buildings and structures - IS:875 - Part III." All structures and equipment, including ducts shall be designed for seismic loads as applicable as per "Criteria for Earthquake Resistant Design of Structures" IS:1893. For seismic design, platform live load shall not be considered for calculation of lumped mass. Wind and earthquake shall not be considered as acting simultaneously. The VENDOR/CONTRACTOR shall submit the foundation design loading accordingly. Insulation of steam generating unit shall be so arranged that the temperature of the steel is kept below 93 C. Base plates shall be designed according to IS:800 for an allowable bearing pressure on the PURCHASER'S concrete foundation as per IS:456 for M20 grade concrete, with 33-1/3% increase for wind/seismic loading. All horizontal shears shall be transferred from column base plates to the foundation through adequate shear plates welded to underside of base plates. Anchor bolts shall not be designed to transfer any shear load. Level of the bottom of base plate of all columns shall be fixed such that only the column shaft projects above the boiler area grade slab and the entire base plate assembly is embedded below the grade slab. The VENDOR/CONTRACTOR shall design anchor bolts for uplift using a basic allowable unit tensile stress as per IS:800 on nominal area at root of thread with 25% increase allowed for wind/seismic loading. Anchor bolts shall be provided with pipe sleeves of adequate size and length. The anchorage length of foundation bolts beyond the pipe sleeves shall be designed in accordance with IS:456 or alternatively sufficient mechanical anchorage shall be provided. Platforms shall be designed for a live load of 500 kg/m2 except areas where dismantled equipment has to be placed or conveyed, which shall be designed for appropriate loading. Deflection of grating shall be limited to 1/325 of span. Design Requirements Vertical bracings shall be so arranged that the entire wind/seismic horizontal loading is distributed over as many number of foundations as possible.
3.3.2
3.3.3 3.3.4 3.3.5
3.3.6
3.3.7
3.3.8
3.4 3.4.1
SPEC NO.

TITLE
VOLUME IIIB

SHEET 3 of 6
TCE. M4-405-03
3.4.2 3.4.3 3.4.4 3.5 3.5.1
Vertical bracings shall be so arranged that the entire width of all walkway areas shall have a minimum clear head room of 2.2 metres. Column ends and contact area of base plates shall be milled to transmit full vertical load by direct bearing at base plates and splices. Projecting lengths of all foundation anchor bolts, nuts, locknuts and washers shall be galvanised. Platforms & Stairs Platforms and stairways needed for access to all parts of steam generator and for operation, inspection and maintenance shall include but not be limited to the following : a) b) c) d) e) f) g) h) i) j) k) l) Air heater access platform Superheater platform, each side Main steam drum platform, each side Intermediate platforms, each side, as required and particularly at access doors, soot blowing equipment and damper control units. Safety valve platforms Elevator access platforms Burner access platforms Access platforms vertical around the ends of retractable soot blowers when the soot blowers are in the retracted or withdrawn position. Dust and soot hopper access platforms. Electrostatic precipitator access platform. Access platform for access to fan bearings, coupling motor etc. All major access platforms shall completely circumscribe the unit and a stairway shall be furnished on each side. Ladders shall not be used unless unavoidable and approved by the PURCHASER.
3.5.2 3.5.3
Arrangement of platforms shall be subjected to PURCHASER'S approval. Platform walkways shall not have clear width less than 1000 mm. Those areas requiring maintenance shall have adequate platform or work space and shall also be
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SPEC NO.

TITLE
VOLUME IIIB

SHEET 4 of 6
TCE. M4-405-03
designed for maximum anticipated loads that could be encountered during maintenance. 3.5.4 Stairs shall be not less than 900 mm clear width except where interference of equipment makes this impracticable. The PURCHASER'S approval for all exceptions shall be taken. Stairs shall have a slope of not more than 42 degrees to the horizontal and, preferably be limited to 38 degrees. Stairway head room shall not be less than 2.2 M. Stairway risers shall be limited to 200 mm maximum. Stair treads shall be galvanised rectangular welded grating with minimum 25 mm x 6 mm bearing bars at 25mm centres. All treads and landings shall have cast aluminium (or other approved material) abrasive nosings. Treads shall be fastened to steel stringers with galvanised bolts. Ladders shall be provided only where access is seldom required or where congestion makes it impossible to provide stairs and the location in each case shall be subject to the PURCHASER'S approval. Ladder side rails shall be spaced 400 mm apart and rungs shall be 20 mm dia. spaced 300 mm apart. Where the height of ladder exceeds 3 M, safety cage shall be provided. Unless otherwise specified, all gratings shall be rectangular, welded, hot dip galvanised with bearing bars of 6 mm minimum thickness suitably fastened at all supporting members. The span of gratings shall not generally exceed 1.5 metres. The maximum width of openings in gratings shall not exceed 40 mm. Grating and chequered plate shall be neatly shop cut to fit around columns, major equipment and pipes requiring openings 200 mm or more in diameter. Pipe openings shall clear insulations by 25 mm beyond extreme movement. The PURCHASER will indicate locations and sizes of openings required for his piping. Grating cut to within 25 mm of columns and equipment shall be banded with a flush top bar. Pipe openings 300 mm or larger shall be provided with curb plates. All platforms and stair landings shall have two rows of galvanised pipe hand railing, the top rail 1.0 M above platform/landing level and pipe posts spaced not more than 2.0 M apart. They shall have screwed ends with necessary accessories of bends, tees, junctions, sockets etc. Pipes used for hand rail shall be 32 NB type 'medium' as per IS 1239. Where the platforms and stair landings are located 30m above grade level, height of the handrail shall be 1.35m above platform/landing level with 3 rows of pipes. Toe guards shall be provided at the edges of all platforms and stair landings, they shall be of 8 mm minimum thickness and shall extend 75 mm above platform/ landing level. Curb plates and curb angles shall be neatly finished at corners and shall be shop assembled and attached to supporting steel members wherever practicable. All
3.5.5 3.5.6
3.5.7
3.5.8
3.5.9
3.5.10
3.5.11
SPEC NO.

TITLE
VOLUME IIIB

SHEET 5 of 6
TCE. M4-405-03
curb plates and curb angles for chequered plate platforms shall be seal welded to supporting steel. 3.5.12 Staircases shall have hand railing as specified for platforms and stair landings, the top rail being at 1.0M above nosing line for stairs upto 30M elevation and 1.35m for higher elevations. Hand rail posts shall be placed opposite each other on stringers.
3.6 3.6.1
Fabrication All steel shall be fabricated for field bolting with high strength friction grip bolts or welding. M.S. bolts shall be permitted for field connections of girts, stairs and hand railing only. The fabrication of structural members shall be planned to keep the field fabrication work to minimum. All welding of structural steel shall conform to the specific requirements as per the standard AWSD 1.1. Before commencement of shop welding, the VENDOR/ CONTRACTOR shall furnish complete details of welding procedures he proposes to adopt, for the PURCHASER'S approval. The VENDOR/CONTRACTOR shall furnish anchor bolt assemblies in time to enable the PURCHASER to place them in position for taking up the execution of the boiler foundations. STRUCTURAL ERECTION Erection of structural steel shall be in accordance with TCE specification No. TCE.M4-405-02 and as further specified herein below. In case of any conflict, requirements of this specification shall govern. Columns which support main boiler supporting girders shall be extended, as required, above top of roof steel to facilitate erection of girders. These column extensions shall be removed by the VENDOR/CONTRACTOR after erection of girders. All structural components shall have erection marks to permit identification. The final elevation of the component shall be designated by a letter (A, B and C etc.); area location by a number (1,2,3 etc); shipping sequence by a circled number (1), (2), (3), etc. The VENDOR/CONTRACTOR shall supply all high strength friction grip bolts for all field connections including that of the PURCHASER'S steel to the VENDOR/CONTRACTOR'S steel.
3.6.2 3.6.3
3.6.4
4.0 4.1
4.2
4.3
4.4
SPEC NO.

TITLE
VOLUME IIIB

SHEET 6 of 6
TCE. M4-405-03
4.5 5.0 5.1
The VENDOR/CONTRACTOR shall furnish temporary or fitting up bolts, shims, wedges, guys, etc. for erection of the structural steel. PAINTING Surface preparation and painting of steel surfaces shall be in accordance with TCE specification M4-405-04.

TITLE
1.0
SCOPE This specification covers the technical requirements and essential particulars for the supply, application and finishing of the complete thermal insulation for hot equipment, piping systems, flues, ducts, steam generator casing, fixture casing, steam turbine etc. up to an operating temperature of 5650C. This specification is not applicable where the insulation is to be used for dual temperature (both hot and cold) service. Unless specified otherwise in section C and/or data sheet A, the scope of supply of the CONTRACTOR shall include, but not be limited to, the following items : (a) (b) (c) (d) (e) (f) Insulation materials of all types as specified and required Finishing materials of all types as specified and required Auxiliary materials such as binding and lacing wires, wire netting, bands, screws etc., as specified and required Angles, clamps, lugs etc. for supporting insulation Weather hoods Any other material as may be required for making the insulation complete
2.0 2.1
CODES AND STANDARDS The supply and application of thermal insulation and finishing covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where it is to be applied. The materials and application shall also conform to the latest editions of the codes and standards listed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. The following are some of the codes and standards relevant to this specification : IS 277 IS 737 IS 3144 IS 3677 IS 3690 IS 8154 Galvanised Steel Sheets (Plain and Corrugated) Wrought Aluminium and Aluminium Alloy Sheet and Strip for General Engineering Purposes Mineral Wool Thermal Insulation Materials - Method of Test Unbonded Rock and Slag Wool for Thermal Insulation Unbonded Glass Wool for Thermal Insulation Preformed Calcium Silicate Insulation for Temperatures up to 650C.
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TCE FORM NO. 329 R4

TITLE
IS 8183 IS 9842 IS 14164 BS 5970 3.0 3.1
Bonded Mineral Wool Preformed Fibrous Pipe Insulation Industrial Application and Finishing of Thermal Insulation Materials at Temperatures above (-) 800C and up to (+) 7500C Thermal Insulation of Pipework and Equipment Temperature Range (-) 1000C to (+) 8700C) (in the
GENERAL DESIGN REQUIREMENTS All exposed portions of the plant which operate at temperatures of 650C and above during normal operation shall be thermally insulated so that the temperature on the outer surface of the finish does not exceed 600C based on an ambient temperature of 300C in still air conditions, unless specified otherwise in data sheet A. Insulation thickness for rock wool and glass wool materials have been indicated in data sheet A. These insulation thickness do not include thickness of finishing materials such as cement sand plaster, aluminium or Galvanised Steel (GS) sheet, binding and lacing wires, wire netting and bands etc. Insulation thickness indicated in data sheet A shall be regarded as the minimum requirement. BIDDER may provide higher thickness in order to meet the design criteria indicated at para 3.1. Equipment and piping which are not insulated from heat conservation considerations but have a surface temperature exceeding 650C shall be insulated for personnel protection when : (a) (b) The bottom of the equipment or pipe is less than 2 metres from the ground or working floor or platform or walkway, or The equipment or pipe, or parts thereof, are within 600 mm from a working floor or platform or walkway
3.2
3.3
3.4
Equipment and piping to be insulated for personnel protection, shall be insulated to the extent that the temperature on the outer surface of the finish does not exceed 600C. 3.5 Equipment in horizontal position, which are to be insulated for personnel protection, shall be fully insulated when the equipment outside diameter is less than 1250 mm and to a height of 2 metres from the working floor or platform for larger sizes.

TITLE
4.0 4.1 4.1.1
MATERIALS GENERAL All materials shall be new and fresh, incombustible, fire retardant, rot-proof, non-hygroscopic, vermin proof, fungus proof, non-injurious to health, chemically inert, non-corrosive to steel and aluminium (even if soaked in water for extended periods) and shall be guaranteed to withstand continuously and without deterioration the maximum temperature to which these shall be subjected to under the specified applications. The insulation materials and any component of the finished insulation job shall not react chemically, singly or in combination, with water or moisture to form substances that are more actively corrosive to applied surface than water or moisture alone. In order to protect the workers from the hazards of insulation materials, suitable protective gadgets shall be provided. Required safety precautions shall be taken during handling and application of insulation. The insulation material shall be kept dry at all times during transport, storage and installation. Decking and covering tarpaulins alone are not adequate for any length of time and shall not be allowed except in extreme emergencies and only for short period. Stacking of insulation materials directly on ground shall not be done. No wet insulation shall be installed. If wet insulation is present, it shall be removed and replaced with new dry insulation. The insulation may be protected with plastic film but shall be vented to prevent sweating. INSULATION MATERIALS The insulation material shall be one or more of the following types as specified in data sheet A. Material Description Material Code U150
4.1.2
4.1.3
4.1.4
4.2
4.2.1
Unbonded rock wool mattress as per IS 3677 Type 2 at an application density of 150 Kg/M3 for temperatures 65 to 3990C Unbonded rock wool mattress as per IS 3677 Type 2 at an application density of 200 Kg/M3 for temperatures 400 to 5650C Unbonded glass wool mattress as per IS 3690 Type 2 at an application density of 80 Kg/M3 for temperatures 65 to 5500C Lightly resin-bonded rock wool mattress as per IS 8183 at an application density of 100 Kg/M3 for temperatures 65 to 3990C
4.2.2
U200
4.2.3
U80
4.2.4
L100

TITLE
Material Description 4.2.5 Lightly resin-bonded rock wool mattress as per IS 8183 at an application density of 150 Kg/M3 for temperatures 400 to 5650C Bonded rock wool pipe sections as per IS 9842 at an application density of 144 Kg/M3 for temperatures 65 to 5650C Calcium silicate preformed blocks, slabs and pipe sections as per IS 8154 at an application density of 200 Kg/M3 for temperatures 65 to 5650C FINISHING MATERIALS
Material Code L150
4.2.6
PS1
4.2.7
CS1
4.3
The finishing material shall be one or more of the following types as specified in data sheet A. Material Description 4.3.1 4.3.2 Portland cement and inorganic fibre with water proofing compound at an application density of 1050 to 1100 Kg/M3 Aluminium sheet as per IS 737, designation 31000, condition H3 for insulation material codes U150, U 200 and U 80 (a) (b) (c) (d) (e) 4.3.3 Insulation outside diameter above 450 mm - sheet thickness 18 SWG Insulation outside diameter 150 to 450 mm - sheet thickness 20 SWG Insulation outside diameter below 150 mm - sheet thickness 22 SWG Flues and ducts - sheet thickness 1.0 mm Steam generator casing and rear wall enclosure sheet thickness 1.6 mm AL2 Material Code FC AL1
Aluminium sheet as per IS 737, designation 31000, condition H3 for insulation material codes L100, L150, PS1 and CS1 (a) Insulation outside diameter above 450 mm - sheet thickness 20 SWG

TITLE
Material Description (b) (c) (d) (e) 4.3.4 Insulation outside diameter 150 sheet thickness 22 SWG to 450 mm -
Material Code
Insulation outside diameter below 150 mm - sheet thickness 24 SWG Flues and ducts - sheet thickness 1.0 mm Steam generator casing and rear wall enclosure sheet thickness 1.6 mm GS1
GS sheet as per IS 277, designation GP, for insulation material codes U150, U200 and U80 (a) (b) (c) (d) (e) Insulation outside diameter above 450 mm -sheet thickness 20 SWG Insulation outside diameter 150 sheet thickness 22 SWG to 450 mm -
Insulation outside diameter below 150 mm - sheet thickness 24 SWG Flues and ducts - sheet thickness 1.0 mm Steam generator casing and rear wall enclosure sheet thickness 1.2 mm GS2
4.3.5
GS sheet as per IS 277, designation GP, for insulation material codes L100, L150, PS1 and CS1 (a) (b) (c) (d) (e) Insulation outside diameter above 450 mm - sheet thickness 22 SWG Insulation outside diameter 150 sheet thickness 24 SWG to 450 mm -
Insulation outside diameter below 150 mm - sheet thickness 26 SWG Flues and ducts - sheet thickness 1.0 mm Steam generator casing and rear wall enclosuresheet thickness 1.2 mm
4.4 4.4.1
AUXILIARY MATERIALS Binding and Lacing Wires

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TITLE
(a) (b) 4.4.2
For temperatures up to 3990C For temperatures from 400 to 5650C
: :
Annealed GS 20 SWG Annealed SS 304 20 SWG
Wire Netting (a) (b) For temperatures up to 3990C For temperatures from 400 to 5650C : : 20 SWG GS wire with 20 mm hexagonal opening 20 SWG SS 304 wire with 20 mm hexagonal opening
4.4.3
Bands (a) (b) For securing insulation material For securing aluminium and GS sheets For securing aluminium foil on SS surface : : 20 SWG GS, 20 mm wide 24 SWG anodised aluminium or SS 304, 20 mm wide 24 SWG aluminium, 20 mm wide
(c)
4.4.4
Screws Screws shall be of self-tapping type and shall be of aluminium or stainless steel for aluminium sheets and GS for GS sheets.
5.0 5.1 5.1.1
INSULATION OF EQUIPMENT AND PIPING (EXCEPT STEAM TURBINE) GENERAL The application of insulation shall be made in a professional manner. The insulation shall be applied to all surfaces when these are at ambient temperature. Ample provision shall be made for the maximum possible thermal movement and the insulation shall be applied in a manner which shall avoid breaking or telescoping due to alternate periods of expansion and contraction. A single layer of insulation shall not be more than 75 mm thick. Insulation shall be applied after all leak tests on equipment and piping are over and the section of the plant has been specifically released by the PURCHASER for such work. If insulation has to be applied before the leak test, all welded and flanged joints shall be left exposed and insulated after satisfactory completion of the leak test. All surfaces to be insulated shall be clean and dry before the insulation is applied. The surfaces shall be cleaned of all foreign material such as scale,
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5.1.2
5.1.3
TCE FORM NO. 329 R4

TITLE
dirt, rust and paint, by the use of steel wire brushes and steel scrapers, where necessary. Where a surface is not free of paint the CONTRACTOR shall notify the PURCHASER of the condition for remedial action. The insulation shall be applied after remedial action, suggested by the PURCHASER, has been taken by the CONTRACTOR. 5.1.4 Carbon steel and low alloy steel surfaces to be insulated shall be thoroughly cleaned by wire brushing. For operating temperatures below 125 C, the surface shall be given one coat of heat-resistant aluminium paint of coating thickness not less than 20 microns. All stainless steel surfaces to be insulated shall be protected against chloride attack as follows : (a) For operating temperatures up to 500 C, the stainless steel surfaces shall be mechanically separated from insulation surface by wrapping with 0.1 mm (42 SWG) thick aluminium foil. Application and other details shall be same as those described for steam traced piping in para 5.2.6. Above 500 C, the metal surface shall be given one coat of heat-resistant aluminium paint of coating thickness not less than 20 microns.
5.1.5
(b) 5.1.6
All sheet metal joints shall be sealed with bitumastic paint and made effectively weather and water-proof. All flat surfaces shall be adequately sloped to prevent pools of water collecting. The sheet shall be protected internally with 2 coats of bitumastic paint. All actions shall be taken to complete the application of finishing on exposed surfaces covered with insulation before closing the days work. If this is not practicable, adequate precautions shall be taken to protect the insulation from weather, for example by wrapping it with polythene sheet, roofing felt or other approved material. INSULATION ON PIPING All vertical pipes shall be provided with suitable insulation supports to prevent the insulation from collapsing due to its own weight. Suggested method is indicated in TCE.M4-104-54. Any welding required, shall be carried out by the CONTRACTOR with the prior permission of the PURCHASER and only under his direct supervision. Where welding is not permitted, suitable clamped supports shall be used. The insulation shall be applied starting from bottom up. Mattress type insulation materials shall be clamped from top. If rock wool preformed pipe section insulation material is used, the sections shall be fitted closely to the pipe. Where there is more than one layer of insulation material, all joints shall be staggered. Each section shall be held in place by circumferential bands or wires at spacing not greater than 450 mm. If mattress is used, the insulation shall be formed to fit the pipe and applied with edges pulled together tightly at the longitudinal joint and secured by lacing wire. The insulation shall be turned to bring this joint to the lower side. Adjacent
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5.2 5.2.1
5.2.2
TCE FORM NO. 329 R4

TITLE
length shall be butted closely and laced together with lacing wire. Mattress insulation shall be backed-up by wire-netting on one side. For insulation thickness of more than 75 mm, where application shall be in two or more layers, each layer of mattress shall be backed up with wire netting. 5.2.3 When calcium silicate is the insulation material, all pipes up to and including 300 mm nominal diameter shall be covered with preformed rigid sections to form a robust pipe covering. Larger sizes shall be covered with segmental blocks moulded to a diameter to fit the curved surfaces. All sectional and segmental insulation shall be carefully fitted to the pipes with side and end joints butted tightly and securely wired in place at spacing not greater than 400 mm. The ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully pressed into the surface of the insulation. All calcium silicate insulation joints shall be fully staggered and any cavities between joints and cracks if any in both inner and outer layers shall be filled with insulating cement. When preformed insulation material is used, the number of segments shall be minimum and all joints shall be filled with the same basic insulation material in loose form. The thickness of insulation for steam traced lines shall be the higher value as determined by the size and temperature of the steam tracer and the service line. The tracer shall be tightly wired to the main pipe at intervals of 500 mm. Aluminium foil not less than 0.1 mm thick (42 SWG) shall then be wrapped around both the pipe and tracer with an overlap of at least 25 mm and wired or banded in place. This is to prevent insulation from separating the pipe and tracer and to provide a hot air enclosure and also to provide a barrier to radiant energy leaving the pipe. The insulation proper shall then be fitted and finished in the normal way. Cross-section of preformed insulation shall be suitable for accommodating tracers. All insulation shall be protected by a finishing material as specified in data sheet A. The sheets shall be installed with the longitudinal lap joints at 45 below the horizontal for horizontal pipes and the joints sealed with bitumastic paint. On vertical pipes the sheets shall be applied working from bottom up. Each section of sheets shall have a minimum overlap of 50 mm longitudinally and circumferentially. Each circumferential joint shall be made weather-proof by securing with a band of sheet material and sealing with bitumastic paint. Longitudinal lap joints shall be fixed with screws at approximately 150 mm centres. Weather hoods shall be provided for insulated piping passing through roof, and external walls as per TCE.M4-104-50. INSULATION ON PIPE FITTINGS, VALVES AND SPECIALITIES All pipe fittings, valves and specialities shall be covered with the same type and thickness of insulation as specified for the adjoining pipe, with the special
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8 5.3 5.3.1

TITLE
provisions and/or exceptions as listed below. On pipe fittings, insulation outside diameter shall be same as the outside diameter of adjacent pipe insulation. 5.3.2 5.3.3 Unless specified otherwise in section C or data sheet A, all valves and specialities, shall also be insulated to the same extent as the adjacent piping. Unless specified otherwise in section C, valves and specialities of sizes 100 mm NB and larger shall be provided with removable box type insulation. Box shall be fabricated from sheet material specified for adjoining pipes. Pipe insulation on adjoining flanges shall be stopped at one bolt length plus 25 mm before flange to permit removal of the bolts and nuts. The insulation shall be applied after the finish has been applied over insulation on the adjacent piping. A typical arrangement is shown in TCE.M4-104-51. Flanged joints shall be insulated. Arrangement shall be similar to that for valves shown in TCE.M4-104-51. Unions shall not be insulated. Non-metallic expansion joints shall not be insulated. Metallic expansion joints identified in bill of materials shall be insulated. Traps shall not be insulated. However, trap discharge lines and safety valve discharge lines shall be insulated for personnel protection only. Pipe hanger clamps shall be covered with insulation along with the pipe. Upper bolts of three-bolt hanger clamps shall not be insulated. A typical arrangement is shown in TCE.M4-104-53. On piping outdoors, a weather hood packed with waterproof sealing material shall be supplied and installed. INSULATION ON EQUIPMENT Where the insulation material is in the mattress form, cleats in the form of wire nails or nuts or angles and flats for supporting the insulation material, shall be welded to the equipment by others. If wire nails are to be used as insulation cleats, these shall be bent and secured with the metal fabric of the mattress, after the insulation has been applied. Where insulation cleats are in the form of M6 and M10 nuts, the CONTRACTOR shall supply and install bolts of suitable length for fixing the insulation. The insulation applied to equipment shall be reinforced with wire netting. One course of wire netting shall be applied to the surface of the equipment and each layer of insulation shall be backed up with wire netting. All irregularities of the surface shall be filled and levelled over with insulating cement. All mattress joints shall be butted tightly and the mattresses shall be secured with 20 mm wide 24 SWG GS bands at 450 mm centres. After banding, all mattress edges shall be laced tightly. When calcium silicate is the insulation material, segmental blocks moulded to fit the curved surfaces shall be used for cylindrical portions of the equipment. Flat blocks shall be used for equipment of diameter greater than 2500 mm and for flat surfaces.
5.3.4 5.3.5 5.3.6 5.3.7
5.4 5.4.1
5.4.2

TITLE
5.4.3
For equipment up to 2500 mm in diameter and temperatures up to 200 C, the blocks shall be cut and fitted so that the inner diameter of insulation is 13 mm greater than the equipment outside diameter to take care of equipment circumferential expansion. The blocks shall be applied tightly butted and sealed with insulating cement. The insulation shall be secured by circumferential bands in such a way that tension of the bands produces compression on the butt edges rather than on the surface towards the equipment. For equipment either above 2500 mm in diameter or at temperatures above 200 C, a 25 mm thick rock wool fibre mattress insulation shall be applied around the equipment prior to the application of calcium silicate. Calcium silicate blocks must be cut and fitted to the outside radius of the equipment plus the thickness of the rock wool spacer insulation. The insulation, when installed, shall not compress the fibrous mattress. All equipment, unless specified otherwise, shall have a smooth aluminium or GS sheet finish as specified in data sheet A, applied in a manner similar to that specified for piping. For fixing of aluminium or GS sheets, spacer rings at 1000 mm centres shall be welded to the equipment by the CONTRACTOR. If welding is not permitted, spacer rings shall be suitably clamped. Spacer ring material shall be the same as that of the surface to be insulated. All vertical and horizontal sheets shall be overlapped a minimum of 75 mm. The lapped joints of adjoining sections of sheets shall be secured with screws. On all equipment above 2500 mm diameter and flat surfaces the sheet shall be further secured by circumferential bands at approximately 1000 mm centres. Each sheet joint shall be sealed with bitumastic paint. The roof sections shall overlap the side walls to prevent water seepage between insulation and the equipment wall. Side wall sheets shall be securely banded at intersections of the side wall and roof sections. All equipment manholes, hatches, bolted or screwed cover plates, flanged ends etc. shall have removable box type insulation, with same thickness of insulation as for adjacent surfaces. Insulation adjoining such equipment openings shall be tapered towards these openings to permit removal of bolts, screws, heads, covers or plates with no damage to adjacent surface insulation or cover. A typical detail of manhole insulation is shown in TCE. M4-104-56. Nozzles and other connections on tanks, heaters and other equipment shall be insulated in the same manner as the pipes. Pump casing shall be completely insulated with removable type of boxes fabricated from the specified sheet material. Name plates on equipment shall not be insulated. CEMENT SAND PLASTER FINISH On piping and equipment, where cement sand plaster finishing is specified in data sheet A, a barrier of polythene bonded hessian with the hessian layer outwards or bituminised Kraft paper shall be provided over the insulation. A
ISSUE R9
5.4.4
5.4.5
5.4.6
5.4.7 5.4.8 5.4.9 5.5 5.5.1
TCE FORM NO. 329 R4

TITLE
total of 15 mm thick cement sand (1:4) plaster shall be applied in two layers after a GS wire netting is stretched over the entire surface of the barrier and securely fastened down. The plaster shall be hand-trowelled over the wire netting to a smooth finish. Curing shall be carried out by wrapping damp hessian cloth around the plaster. The application of finishing plaster shall be terminated, at the end of day' s work, at an expansion joint. 5.5.2 The cement sand plaster finish shall have the following properties : (a) (b) A light shower of rain, falling immediately after application shall not wash off the plaster. At any time, one week or more after application, it shall not shatter if struck a sharp blow with a 0.7 Kg hammer. Such a blow may damage the finishing locally but shall not cause large pieces to break away. When set, it shall withstand prolonged exposure to the weather without additional protection.
(c) 5.5.3
Outdoors, the finishing plaster shall be applied immediately after application of insulation. If this is not practicable, the CONTRACTOR shall take adequate precautions to protect the insulation from weather, e.g. by wrapping it with polythene sheet, roofing felt or other approved material. INSULATION EXPANSION JOINTS Necessary insulation expansion joints shall be provided to prevent cracking of rigid insulation and hardsetting finishing cement layer. Insulation expansion joints shall be provided at intervals as shown in TCE.M4-104-54. These shall also be fitted on both sides and within 1000 mm of each bend and branch connections. At the insulation expansion joint, there shall be complete cut through the insulation and the sheet metal covering shall be provided with sliding joints.
6.0
7.0 7.1 7.2
STEAM TURBINE INSULATION Steam turbine and its integral piping shall be lagged with calcium silicate plastic composition in multiple layers. Before applying the insulation, the surface to be insulated shall be thoroughly cleaned with wire brush to remove all dirt, rust and scale. After cleaning, the insulation shall be applied in successive layers to the required thickness. Each individual layer shall be properly dried before the next layer is applied. The heating of the steam turbine cylinder before the application and drying of the individual layers shall be by infra-red lamps. The CONTRACTOR shall provide all equipment and make all necessary arrangements.
ISSUE R9
7.3
TCE FORM NO. 329 R4

TITLE
7.4
The insulation shall be reinforced with GS wire netting and lacing. Where layer interface temperature is 4000C and above, SS 304 wire netting and lacing shall be used. Reinforcing wire netting shall be provided over each successive layer of insulation. The insulation shall be secured to the steam turbine cylinder and steam chests. For securing the insulation properly, nuts shall be provided on the outer steam turbine casing and steam chest. Studs of suitable length shall be screwed on to the nuts and the insulation shall be held rigidly by the studs. The studs shall be wrapped with asbestos mill board paper or rope to avoid direct contact of the wire-mesh with the studs. The studs shall be of stainless steel material. The insulation shall be finished with a layer of hard setting insulating cement, trowelled to a smooth finish, to prevent damage. The steam turbine shall then be covered with 1.2 mm thick aluminium appearance cladding. MEASUREMENT Measurement of insulation over equipment and piping shall be as per IS 14164.
7.5
7.6
7.7 7.8 8.0
9.0 9.1
GUARANTEES The CONTRACTOR shall demonstrate to the PURCHASER that the temperature of the outer surface of the finish has not exceeded 60C. Temperature shall be measured at the middle of a segment of piping run to be mutually agreed. Two measurements, one at the top and other at the bottom, shall be taken at the measuring points. These temperatures shall be taken as the representative temperature for that length of piping. The CONTRACTOR shall guarantee that, if the temperature on the outer surface of the finish exceeds 60C, the CONTRACTOR shall either replace the insulation with a superior material or provide additional insulation thickness at the PURCHASER' S discretion at no extra cost to the PURCHASER. MISCELLANEOUS Approval of the PURCHASER shall be obtained of samples of all materials and necessary test certificates of approved national laboratories, before despatching these to site. Insulation shall not be applied until specific release is given by the PURCHASER.
9.2
10.0

TITLE
DATA SHEET C DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE CONTRACT 1. 2. 3. 4. 5. 6. 7. 8. AWARD OF
List of drawings and documents to be submitted for review, approval and information with scheduled submission dates Quality Assurance Plan (QAP) List of insulation materials with specifications and properties like density, thermal conductivity etc. Values for thermal conductivity at various mean temperatures for all insulation materials List of finishing materials with specifications List of auxiliary materials with specifications Test certificates for insulation and other materials Detailed insulation application and finishing procedure

TITLE
ERECTION AND TESTING OF POWER PLANT PIPING
1.0
SCOPE This specification covers the minimum technical requirements and essential particulars for erection, inspection, testing and cleaning of power plant piping systems included in the CONTRACTOR's scope of work. The CONTRACTOR shall demonstrate that the piping meets the requirements of the specification and applicable codes. In the event supply and shop fabrication of piping systems are also included in the CONTRACTOR's scope of work in Section C, all references to the PURCHASER's drawings in the subsequent clauses of this section shall be understood to imply the CONTRACTOR's drawings.
2.0
CODES AND STANDARDS The CONTRACTOR shall comply with the latest editions of applicable Codes and Standards. The CONTRACTOR shall also comply with all applicable statutes, regulations and safety codes in the locality where the piping will be erected. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility.
3.0 3.1
GENERAL REQUIREMENTS The CONTRACTOR shall erect all piping, online instruments, control valves, block valves, specialities, etc., as per the PURCHASER's piping drawings for piping systems of NB 65 mm size and larger. Unless otherwise specified in Section C, piping systems of size NB 65 mm and larger are deemed shop-fabricated and would be delivered to site in prefabricated condition. The extent of fabrication to be carried out on these pipelines at site by the CONTRACTOR is indicated in the piping layout drawings and also specified in Clauses 3.3, 3.4, 3.5, and 3.6 of this specification. If adequate dimensional data is not available sufficiently in advance from the suppliers of control valves, flow nozzles, orifice plate assemblies, desuperheaters and such other specialities, pipe spools on either side of these specialities may be sent to site in unfabricated or semi-fabricated condition. The CONTRACTOR shall cut these spools to the required lengths, prepare their ends for purposes of welding, weld bosses for drains, vents, instruments, etc., as required, weld support lugs or shoes, if required and carry out any other fabrication work on these spools as might be required to render these system complete in all respects and compatible with the final piping drawings. Flow nozzles, flow orifices and control valves on pipelines which are steam blown shall be installed after steam blowing. These pipelines would therefore be sent to site without being cut short for the flow nozzles/orifices/control valves. After completion of blow out operation, CONTRACTOR shall cut spool pieces of appropriate lengths, prepare the weld ends and install the flow nozzle / orifice assemblies / control valves.
ISSUE R4
3.2
3.3
3.4
TCE FORM NO. 329 R4

TITLE
3.5
All other fabrication work as required on prefabricated pipe work for connecting temporary piping for purposes of mass flush, chemical cleaning, steam blow out, hydraulic testing, vacuum testing, etc., dismantling the temporary pipe work and restoring the permanent pipe work to their design condition shall be carried out by the CONTRACTOR. Where required for hydrotesting, chemical cleaning or steam blowing of piping, the CONTRACTOR shall provide necessary vents and drains, whether these are shown on piping drawings or not. The CONTRACTOR shall install all hangers and supports, guides, restraints, anchors, vibration dampeners, shock absorbers, etc., as per the approved hanger sketches. Any field fabrication such as cutting and threading of hanger rod, etc., required for the installation of such hangers and supports shall be carried out by the CONTRACTOR. Pipelines of size NB 50 and below are regarded as field-run piping. It is the CONTRACTOR's responsibility to plan suitable layouts for these systems at site as per the requirements of this specification and in consultation with the PURCHASER and/or the ENGINEER. The CONTRACTOR shall prepare isometric drawings indicating the layout of field-run pipe work based on the PURCHASER's flow diagrams and general arrangement drawings. The isometric drawings shall be approved by the PURCHASER/ENGINEER prior to the installation of the field run pipe work. Any layout for field-run pipe work that may be indicated on PURCHASER's layout drawings may be used for guidance. While routing field run piping, the following requirements shall be taken into account by the CONTRACTOR. All piping shall be routed so as to avoid interference with other pipes and their hangers and supports, electrical cable trays, ventilation ducting, structural members, equipment, etc. Adequate clearances shall be ensured with respect to the above to accommodate insulation and pipe movements. All piping shall be grouped where practicable and shall be routed to present a neat appearance. The piping shall be arranged to provide clearance for the removal of equipment requiring maintenance and for easy access to valves, instruments and other piping accessories required for operation and maintenance. Piping shall generally be routed above ground but where specifically indicated / approved by the ENGINEER, the pipes may be arranged in pipe trenches or laid buried. Insulated pipes shall not be buried. Overhead piping shall have a minimum vertical clearance of 2.3 meters above walkways and working areas and 6.0 meters above roadways unless otherwise specified by the ENGINEER.
ISSUE R4
3.6
3.7
3.8
3.9 3.9.1
3.9.2 3.9.3
3.9.4
3.9.5
TCE FORM NO. 329 R4

TITLE
3.9.6
Drains shall be provided at all low points and vents at all high points as per actual layout regardless of whether the same have been shown in the flow diagrams or not. Pipelines shall preferably be sloped towards the drain points. Provision shall be made while preparing piping layout to install control valves, flow measuring elements and any other on line speciality or equipment supplied by OTHERS. Sufficient upstream and downstream lengths shall be provided for flow measuring devices, control valves, desuperheaters and other specialities as required, in consultation with the ENGINEER. At all screwed valves and screwed connections on equipment, unions shall be provided to facilitate disassembly. Likewise, unions shall also be provided at suitable locations on straight lengths of screwed pipelines. All local instruments shall be located on pipelines so as to render them easily observable from the nearest available platforms Piping with operating temperatures above or below the ambient shall be routed so as to provide adequate flexibility for the pipeline. The CONTRACTOR shall be responsible for the design and provision of suitable expansion loops, guides, restraints and anchors so as to keep the pipe stresses within the limits imposed by the governing codes. Tap offs on main lines for field routed pipe work, if not indicated on PURCHASER's layout drawings, shall be suitably located by the CONTRACTOR to suit the layout evolved by him. For field run piping, the CONTRACTOR shall plan, locate, design, fabricate and install all hangers and supports as required with due regard to general arrangement, layout of other pipeline, hangers, cable trays, ducting, structural members, etc., and in consultation with and to the approval of the PURCHASER/ENGINEER. The CONTRACTOR shall utilise the PURCHASER's existing structural members for supporting field run piping after ascertaining that the existing member can safely bear this extra load. Any auxiliary structural steel, if necessary to be provided, shall be designed, fabricated and erected by the CONTRACTOR. Welding to structural members for hangers and supports shall be made only under the supervision of the PURCHASER/ENGINEER and in no case, shall welding be permitted across flanges of main structural members. Unless otherwise specified in Section-C, the supply of the necessary auxiliary steel is also included in the CONTRACTOR's scope. Erection of field-run piping shall be started only after completion of erection of other piping, structures, equipment, etc., in the vicinity, unless otherwise directed by the PURCHASER / ENGINEER. The CONTRACTOR shall install all thermowell stubs and all instrument trim piping and fittings upto the last root valve(s) and reducer(s) including the root valves and reducers as shown on the relevant flow diagrams.
3.9.7
3.9.8
3.9.9 3.9.10
3.9.11
3.10
3.11
3.12
3.13
ISSUE R4
TCE FORM NO. 329 R4

TITLE
3.14
When stubs required for vents, drains and instrumentation or welded attachments required for hangers and supports are not provided on prefabricated piping, the CONTRACTOR shall install these stubs or attachments as per the PURCHASER's piping drawings, flow diagrams or hanger sketches. Where the CONTRACTOR's scope ends adjacent to equipment or piping installed by OTHERS, the final joint shall be the made by the CONTRACTOR. If at his terminal connections or at connections to online specialities, the supply of counter flanges is by OTHERS, the same shall be erected by the CONTRACTOR. Necessary gaskets and fasteners are included in the CONTRACTOR's scope of supply. The CONTRACTOR shall also install small accessory piping and any specialities furnished with equipment such as relief valves, built-in bypasses, etc. The CONTRACTOR shall install thermowells supplied by the PURCHASER prior to hydrotesting of the piping systems. In the event of non-availability of thermowell in time, the CONTRACTOR shall provide necessary plugs to carry out the hydro testing of the piping systems. The CONTRACTOR shall cold pull pipes wherever cold cuts are indicated on the PURCHASER's drawings / documents. The CONTRACTOR shall submit his cold pulling procedure for review and approval by the PURCHASER/ENGINEER, prior to starting of the operation. Setting and logging of all spring hangers, supports, restraints, etc., is the responsibility of the CONTRACTOR. Initial setting of all such supporting systems shall correspond to the cold values indicated on the PURCHASER's drawings. The CONTRACTOR shall check all hangers / support loads after completion of all weld joints in the piping systems and after cold pulling of pipes wherever required. In case of any significant differences between the load readings and the cold loads indicated on the PURCHASER's drawings, the CONTRACTOR shall take necessary steps to adjust the settings in such a manner as to eliminate these differences. He shall however consult the PURCHASER/ENGINEER before adjusting the hanger settings. After satisfactory completion of the settings, all load values shall be properly logged by the CONTRACTOR as per the format to be furnished by the PURCHASER. The CONTRACTOR shall monitor the behavior of the hangers, supports, restraints, snubbers, etc., during initial stages of the plant startup. Upon the unit reaching its rated load and the individual piping systems obtaining their rated temperatures, the CONTRACTOR shall log all the load readings of the hangers, supports, etc., in their hot condition and compare the same with the desired hot settings indicated in the PURCHASER's drawings. In case of any significant differences, the CONTRACTOR shall take necessary steps to minimise/eliminate the differences as directed by the PURCHASER. Final hot load values of the hangers, supports, etc., shall be recorded by the CONTRACTOR as per the
ISSUE R4
3.15
3.16
3.17
3.18
3.19
TCE FORM NO. 329 R4

TITLE
PURCHASER's format. All logs of hot and cold loads shall be submitted by the CONTRACTOR to the PURCHASER. 3.20 In case of critical piping, in addition to the procedure outlined in clause 3.19, additional adjustments to settings might be required for certain hangers in order to render the final weld joints at the turbine valve nozzles stress free. CONTRACTOR shall carry out all such adjustments as directed by the PURCHASER as part of his scope of work. The CONTRACTOR shall carry out hydrostatic/pneumatic testing of all piping erected by him. All necessary equipment including temporary pipes, fittings and supporting arrangement for carrying out such tests shall be provided by the CONTRACTOR. The CONTRACTOR shall ensure that the arrangement made by him for hydrostatic/ pneumatic testing will not transfer forces and moments to permanent piping in an unacceptable manner. After the successful completion of hydro tests, the piping shall be drained and thoroughly dried. The CONTRACTOR shall restore the permanent piping to its original condition after the testing is completed. The CONTRACTOR shall erect all temporary pipes, fittings, valves and hangers and supports required for steam blowing of main steam, cold reheat and hot reheat piping in accordance with the PURCHASER's drawings. The PURCHASER / ENGINEER will carry out the steam blowing operations. If severe vibrations are encountered during steam blowing, the CONTRACTOR shall modify the supporting arrangement and provide additional supports, if necessary, to eliminate/minimise vibrations, as directed by the PURCHASER/ENGINEER. In addition to the above, as part of the erection scope of contract, the CONTRACTOR shall supply and install all required temporary pipes, fittings, valves and specialities and hangers and supports for cleaning operations to be carried out by him as described in Clause 5.0. The CONTRACTOR shall ensure that the arrangement made by him will withstand the conditions during cleaning operations and that it will not transfer forces and moments to permanent piping in an unacceptable manner. After completion of cleaning operations, the CONTRACTOR shall dismantle temporary piping and hangers and supports and restore permanent piping to its final position. Welding, nondestructive examination of welded joints and repair of weld defect areas shall conform to TCE specification no. TCE.M4-134-04, `welding specification for power plant piping systems'. FABRICATION Unless otherwise specified on piping drawings or piping material specification Data Sheets, all pipeline joints shall be of welded construction. Butt-welded joints shall be used for pipe sizes NB 65 mm and larger and socket welded joints for pipe sizes NB 50 and smaller. The use of companion flanges to connect two pieces of pipe and the use of odd or short pieces of pipe in making up long runs is prohibited except as noted in the PURCHASER's piping drawings.
3.21
3.22
3.23
4.0 4.1

TITLE
4.2 4.3
Where welded pipes or pipe fittings are used, longitudinal welds in adjoining sections shall be staggered by a minimum of 90 during erection. Neither butt nor branch joints shall be closer than twice the pipe diameter to any other joint in the same pipe except where `Weldolet' type fittings are used, in which case the branch weld will be made to the `Weldolet'. All pipe flanges and contact surfaces shall be concentric with the axis of the piping. All threads on piping components shall be taper pipe threads as per applicable standards. Threaded connections for insertion type fluid temperature determination and sampling devices shall be seal welded when the service pressure exceeds 103.5 bar (g) or when the temperature exceeds 495o C. The threads shall be entirely covered by the seal weld and such seal welding shall be done by qualified welders only. The CONTRACTOR shall machine all welding ends to make sound welds including those to valves, fittings or equipment. The welding rod used shall be compatible with the parent material. When pipe must be threaded before hot bending or heat treatment, all exposed thread surfaces shall be protected with high temperature silicone paint Before commencement of fabrication or erection, the CONTRACTOR shall ensure that the drawings available with him are the latest issues on date. Welding of joints shall be undertaken only after ensuring that the pipeline alignment is correct and conforms to the construction drawings and after obtaining the PURCHASER's clearance for the same. At equipment terminal points, welding shall be carried out after taking into account specific requirements and/or recommendations of equipment suppliers. CLEANING OF PIPING All piping including valves and specialities shall be cleaned by the CONTRACTOR before and during erection to remove grease, dirt, scale and welding slag. The CONTRACTOR should carry out the following cleaning operations after hydrostatic tests: (a) (b) All piping will be mass flushed, in addition to the specific cleaning operations as described below, as required Main steam, cold and hot reheat piping and HP & LP bypass piping shall be steam blown. Necessary target plates, for steam blowing, shall be supplied by the CONTRACTOR.
4.4 4.5
4.6
4.7
4.8 4.9
4.10
5.0 5.1
5.2
ISSUE R4
TCE FORM NO. 329 R4

TITLE
(c) (d) (e) (f) (g) 6.0 6.1
Extraction steam, condensate, boiler feed suction and discharge and heater drains and vents piping shall be alkaline flushed Auxiliary steam piping, steam piping to turbine drives; pressure reducing stations and other users shall be steam blown. Fuel oil, fuel gas and light oil piping shall be mass flushed. Compressed air piping shall be blown by air at compressor discharge pressure. Turbine lubricating oil piping shall be pickled and passivated and flushed with DM water.
HANGERS AND SUPPORTS For field run piping, the CONTRACTOR shall space hangers and supports in accordance with standard engineering practice as outlined in applicable codes. In selecting the position and type of pipe hangers, the CONTRACTOR shall endeavor to layout the work in such a manner that: (a) (b) (c) Pipe load stresses imposed on the supporting steel are kept to a minimum The forces and moments on connecting equipment are kept within allowable values, and Field work is made simple and inexpensive
6.2
Unless design loads are specified by the PURCHASER / ENGINEER, the strength of all supporting components shall be based on the weight of the pipe, the weight of medium transported or the medium used for testing, whichever is higher, and the weight of insulation covering. If vibration is encountered after a piping system is in operation, appropriate vibration control equipment shall be installed by the CONTRACTOR at the direction of the PURCHASER /ENGINEER. FLOOR COLLARS AND WEATHERHOODS At locations where pipes pass through concrete floors or brick or other walls, suitable carbon steel floor collars or wall boxes will be supplied and installed by the PURCHASER. The CONTRACTOR should indicate requirements. For all bare pipes, which pass through roofs and external walls, a suitable sheet metal hood shall be designed, fabricated, supplied and installed by the CONTRACTOR as a protection against the weather.
6.3
7.0 7.1

TITLE
8.0 8.1
ERECTION TOOLS AND PERSONNEL The CONTRACTOR shall deploy qualified and experienced personnel and provide all necessary erection tools and tests equipment needed for the complete erection and testing of all piping. Shipment of such tools and equipment shall be made at the CONTRACTOR's expense and liability. The PURCHASER assumes neither responsibility nor liability for tools and equipment care and their storage. All site fabrication machinery, erection tools, rigging, scaffolding, bending, flaring, cutting, welding and stress relieving and all other equipment, thermocouples, asbestos blanket, cables, temperature recorders, X-ray and Gamma ray equipment isotopes radiographic films, penetrameters, magnetic particle test equipment and consumables for checking the M.P testing dyes for D.P. tests, etc., required for complete erection and field testing of all the piping specified, shall be furnished by the CONTRACTOR. All transport and material handling equipment shall be provided by the CONTRACTOR. The CONTRACTOR shall furnish all welding electrodes required for the complete erection of all piping systems including those required for welder and procedure qualification tests. As a part of scope of erection contract, the CONTRACTOR shall furnish gaskets and fasteners (bolts, studs, nuts, washers, etc.) required for all flanged joints. These shall be as per the job specification. The CONTRACTOR shall furnish all erection consumables such as oxygen, acetylene, argon, carbon dioxide and any other gases that may be required, filler rods temperature sensing crayons, chalks, charts for temperature recorders, etc. The CONTRACTOR shall furnish all equipment and materials as required for cleaning, flushing, blowing out and testing of the piping systems. These shall include but not be limited to pumps, blowers and compressors with prime movers, instruments, pipe work with supports, valves, strainers and other specialities, blanks, plugs, spool pieces, dummy plates, electrical accessories, etc. (All to be taken back by the CONTRACTOR after completion of work). Where systems for which alkaline flushing is required, necessary tanks, pumps and chemicals shall be provided by the CONTRACTOR. The CONTRACTOR shall provide services of erection superintendent, managers, engineers, supervisors, foreman, fitters and riggers, welders, transport and crane operators, clerical and administrative staff, skilled and unskilled labour.
8.2
8.3 8.4
8.5
8.6
8.7
8.8

TITLE
9.0 9.1
INSPECTION AND TESTING All fabrication/erection work covered by this specification shall be subject to inspection by the PURCHASER / ENGINEER at no additional cost to the PURCHASER and the CONTRACTOR shall advise the PURCHASER/ ENGINEER promptly at various stages of erection for inspection. The PURCHASER/ENGINEER shall have free access to the CONTRACTOR's /his SUB-CONTRACTOR's works at the site or elsewhere at all times when any fabrication testing work is being carried out and the CONTRACTOR shall provide all necessary facilities/cooperation to the PURCHASER/ ENGINEER in this regard. The PURCHASER's representatives shall, at all times, have facility to witness the CONTRACTOR's operator's qualification tests conducted by the CONTRACTOR. They shall also have access to the CONTRACTOR's heat treatment records and magnetic particle, fluorescent particle or dye penetrant, ultrasonic and radiographic records, reports and repairs, etc. Any workmanship by the CONTRACTOR/his SUB-CONTRACTOR inspected in the field and found not to comply with this specification the same shall be repaired at the CONTRACTOR's expense, if the noncompliance is the fault of the CONTRACTOR. Only approved welders shall be permitted to correct any defect with the prior approval of the CONTRACTOR's welding supervisor. On completion of erection, the inside of all pipes, valves, fittings, etc., shall be clean and free from loose scale and foreign matter before subjecting the line to any test/inspection. Prior to erection, the CONTRACTOR shall examine and ensure that all prefabricated spools and components received by him either from his works or from the PURCHASER conform in respect of overall dimensions to the certified drawings available with him. Necessary steps shall be taken by the CONTRACTOR to rectify any inaccuracies exceeding the limits of manufacturing tolerances on materials supplied by him. No dislocation in the pipe work or cold pull of pipe work arising from improper fitup would be acceptable to the PURCHASER. All piping systems shall be tested hydrostatically / pneumatically by the CONTRACTOR, after erection, at pressures given in the applicable codes listed in Data Sheet A or Section C or as given in the Line Designation Schedule. The test pressures shall be maintained until all welded/flanged joints are inspected for leakage or at least for thirty minutes. Wherever possible, underground lines should be tested before backfilling. Where it is essential to backfill any section of a line before testing, such a section should be subjected to test pressure for a period of at least two hours and checked for pressure drop.
ISSUE R4
9.2
9.3
9.4
9.5 9.6
9.7
9.8
9.9
TCE FORM NO. 329 R4

TITLE
9.10
Mechanical equipment and pressure relieving devices should be blanked off or removed from the line during pressure testing and control valves should be set in open position for the duration of the test. Orifice plates should not be erected untill hydrostatic testing and cleaning operations are completed. Lines having check valves should have the source of test pressure located on the upstream side. Expansion joints, instruments, filters and similar equipment for which the maximum permissible cold test pressure is lower than the hydrostatic test pressure applied to the system, shall be removed or blanked off from the line before testing. The CONTRACTOR shall consult the PURCHASER/ENGINEER for specific guidance Test pressure readings may be taken at the lowest point of the system being tested provided the effect of static head is taken into account. When conditions require a test pressure to be maintained for a period of time during which the testing medium in the system might be subjected to thermal expansion, provision may be made for the relief of excess pressure. After hydrostatic test, leaky joints, if any, shall be cut and repaired or completely replaced, and test repeated until the test has satisfactorily passed. After completion of hydrostatic test, safety valves, orifice plates, etc., withheld for the hydrostatic tests, shall be installed in an approved manner. Orifice plates shall however be installed after completion of cleaning operations. Clean water at a temperature not less than dew point or 10oC which ever is higher, nor exceeding 50oC shall be used for hydrostatic test. The rate of pressure increase must not exceed 7 bars per minute. No personnel shall be allowed near piping/equipment under test when the hoop stress induced by the test pressure is near the yield strength or when test pressures over 35 bar being applied. The pressure should be lowered by 10% before inspecting for the leaks. When draining the test liquid, the pipeline vent shall be opened to avoid vacuum. A block valve shall be installed on the pipeline from the test pump to the pipe line/equipment under test. All bolted joints for pipes, valves and fittings which are subject to high pressure or high temperature conditions are to be tightened up after the initial heating and before any thermal insulation is applied. The CONTRACTOR shall notify the PURCHASER before this operation is carried out.
9.11 9.12 9.13
9.14 9.15
9.16
9.17
9.18 9.19 9.20
9.21 9.22 9.23
ISSUE R4
TCE FORM NO. 329 R4

TITLE
10.0
UNDERGROUND PROTECTION Underground protection for buried pipes shall be as per TCE specification No.TCE.M4-134-102, `underground protection for piping'. The CONTRACTOR shall supply and apply all the necessary materials in this regard. All equipment necessary for application and testing of protection such as kettles, thermometers, recorders, holiday detectors, etc., shall be supplied by the CONTRACTOR.
11.0
INFORMATION TO BE FURNISHED AFTER THE AWARD OF CONTRACT The CONTRACTOR shall furnish all the information as called for in Data Sheet C.

TITLE
ERECTION AND TESTING OF POWER PLANT PIPING DATA SHEET C INFORMATION TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF CONTRACT 1.0 Prior to erection, the CONTRACTOR shall submit the following: (a) Erection sequence sufficiently detailed to describe and identify the type of operations, inspection and/or test at each point in the stage of erection to enable the PURCHASER to keep in readiness the corresponding equipment or facilities to perform his duties and to select inspection points for witnessing. Cold pulling procedures. Welding procedure and performance qualification reports. NDT procedures. Weld repair procedures. Heat treatment and/or stress relieving procedures. Hydrostatic / pneumatic test procedures.
(b) (c) (d) (e) (f) (g) 2.0
Site Weld Data: (a) Identification of the weld procedure specification, procedure qualification record & performance of the welder, preheating, postweld heat treatment data, results of nondestructive examinations along with the name of the INSPECTOR and the date of inspection. Certification of ASNT-TC-1A qualification. Weld procedure specification & performance qualification records and its test reports. Weld filler material test reports.
(b) (c) (d) 3.0 4.0
Hydrostatic or Pneumatic test records hold time and the results of the tests (after the testing of the piping system is completed). Test certificates and reports as required by statutory regulations.
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
WELDING SPECIFICATION FOR POWER PLANT PIPING SYSTEMS SCOPE
SHEET 1 OF 15
1.0 1.1
This specification shall apply to all welded pipe joints of carbon and alloy steels including stainless steels for power plant piping systems. This specification is applicable to shop fabrication, site fabrication and field erection. The welded joints are hereby defined as including: All the line joints of the longitudinal and circumferential butt welded and socket welded type. The attachment of castings, forgings and flanges to pipe. Welded manifold headers and all other sub-assemblies. Welded branch connections with or without saddles and reinforcement rings. Fabrication of built-up fittings. The attachment of smaller connections for drips, drains instruments, branch lines, weldolets, sockolets, thermowells, couplings, etc. Any other similar joints not specified above but encountered during fabrication and/or erection stage. It is imperative that the CONTRACTOR makes every effort to secure the same high degree of competent supervision and workmanship during field erection as is intended for shop fabrication in view of the adverse field conditions of weather, piping location etc. Material specifications generally covered are as follows : Alloy Steel Piping Ferritic alloy steel pipes to SA 335 grades P11, P12, P22, P-91 or equivalent: austentic alloy steel pipes to SA 312 Grade TP 304, 316, etc. or equivalent and corresponding materials for fittings, flanges valves etc.
1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7
1.2 1.2.1
1.2.2
Carbon Steel Piping Carbon steel pipes to SA106 grade A,B,C or SA 53 Grade A,B; SA 672 Gr B60 C1.12, IS-1239, IS-1978, API-5L grade B, etc. or equivalent and corresponding materials for fittings, flanges, valves, etc.
2.0
CODES AND STANDARDS The welding of fusion welded system shall comply with all currently applicable statutes, regulations and safety codes in the locality where it will be installed.It shall also conform to the latest applicable standards. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. In particular, the welding and fabrication shall conform to the latest editions of the following codes and standards.
2.1
ASME code for power piping (ASME B31.1)

ISSUE R5
TCE FORM NO. 329 R4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
WELDING SPECIFICATION FOR POWER PLANT PIPING SYSTEMS Indian Boiler Regulations (IBR) ASME Boiler and Pressure Vessel Codes: Section II, Part A Section II, Part C Section V Section VIII Section IX Ferrous Material Specifications
SHEET 2 OF 15
2.2 2.3
Specifications for Welding Rods, Electrodes and Fillter Metals Non Destructive Examination Rules for Construction of Pressure Vessels Welding and Brazing Qualifications.
2.4 2.5 2.6 2.7
Standards of Pipe Fabrication Institute, USA. BS 2633 Specification for Class 1 Arc Welding of Ferritic Steel Pipe Work for Carrying Fluids. Any other codes/ standards specified in Section C The above mentioned codes and standards form an integral part of this specification. In the event of conflict between this specification and the codes and standards listed above, the stricter requirement of the two shall govern. WELDING PROCESSES The welding processes that are used in the fabrication and welding are restricted to shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW) or a combination of the two. GTAW root pass shall be employed for all alloy steel piping and carbon steel piping. Subsequent welding after root pass can be carried out by SMAW with coated electrodes. Exceptions are as follows : (a) For pipes of thickness less than 6mm, the entire welding shall be carried out by GTAW only. When using GTAW welding process, welding without the addition of filler metal shall not be done. For LP piping systems such as water and air piping systems entire welding including root pass may be carried out by SMAW.
3.0 3.1
3.2
(b) 3.3
Where special welding techniques are recommended by equipment manufacturer for piping connecting to equipment, appropriate qualification tests and welding techniques shall be followed. The specific and detailed instructions of equipment manufacturer regarding welding, preheating, stress relieving etc. shall be strictly adhered to by the CONTRACTOR at no extra cost to the Purchaser.
ISSUE R5
TCE FORM NO. 329 R4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
WELDING SPECIFICATION FOR POWER PLANT PIPING SYSTEMS PROCEDURE AND PERFORMANCE QUALIFICATIONS
SHEET 3 OF 15
4.0 4.1
No production welding shall be undertaken until the procedure qualification tests which are to be used have been established as per ASME Boiler and Pressure Vessel Code- Section IX and/or IBR. Test results and specimens from qualification tests of the welding process and welding operators-shall be made available to the PURCHASER/ ENGINEER, for approval, where results of existing procedure qualifications and of welders, performance tests are acceptable to the PURCHASER/ ENGINEER, such results shall be kept on file and be subject to review regularly. Where doubt exists regarding the acceptability of any qualification test, a retest shall be made. All such qualifications tests and specimen testing shall be conducted in the presence of the PURCHASER/ENGINEER. The costs of all procedure qualification and tests shall be borne by the CONTRACTOR. The CONTRACTOR shall prepare a written specification containing the information detailed in section IX of ASME Boiler and Pressure Vessel Code. Form QW-482, - Welding Procedure Specification (WPS) and the qualification test data and other information detailed in Form QW-483.- Procedure Qualification Record (PQR). These documents shall be provided to the PURCHASER/ENGINEER for review and approval. The CONTRACTOR shall prepare certificate of Welder/Welding operator Performance Qualification Test (WPQ) containing the information detailed in Form QW-484 : Manufacturers Record of Welding or Welding Operator Qualification Test of ASME Section IX . These shall be kept on field and made available to the PURCHASER/ ENGINEER upon request. WELDERS AND SUPERVISORS Unless otherwise agreed, the CONTRACTOR shall advise the PURCHASER/ENGINEER, in writing at least three (3) weeks before any welder is employed on the work, the names and qualifications of the proposed welders and welding supervisors. It shall be the CONTRACTORs responsibility to ensure that all welders employed by him or his SUBCONTRACTORS on any part of the Contract either in the CONTRACTORS /his SUB-CONTRACTORs works or at site are fully qualified as required by the code. Each welder shall qualify for all types of welds and materials he may be called upon to weld. Should the PURCHASER/ENGINEER require test or retest of any welder, the CONTRACTOR shall arrange for the same at no extra cost to The PURCHASER/ENGINEER. Welding supervisors shall have qualifications such as Engineering Degree/Diploma in welding technology with adequate knowledge of nondestructive testing and a minimum of 5 years experience in supervising welding of pipe joints.
4.2 4.3
5.0 5.1
5.2
5.3
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
WELDING SPECIFICATION FOR POWER PLANT PIPING SYSTEMS
SHEET 4 OF 15
5.4
All welding including tack welding shall be carried out by approved welders only. Any weld made by other than an approved welder shall be cut out and rewelded. For purposes of identification and to enable tracing full history of each joint, each welder employed on the work shall be given a designation. The welders designation and the date on which the joint was made shall be stamped on the relevant piping and marked on the relevant drawings also. Copies of the drawings so marked shall be furnished to the PURCHASER/ENGINEER for record purposes. Alternatively, record charts may be used. For each welder, a record shall be maintained showing the procedures for which he is qualified. The details of production welds, the date of welding the type of defects occurred and their frequency. The record shall be available for review by the PURCHASER/ENGINEER and those welders whose work required a disproportionate amount of repair shall be disqualified from welding. Requalification of welders disqualified shall be entirely at the discretion of the PURCHASER/ENGINEER. PREPARATION OF WELD ENDS Surfaces to be welded shall be smooth, uniform and free from fins, tears and other defects which would adversely affect the quality of the weld. All welding faces and adjoining surfaces, for a distance of atleast 150 mm from the edge of the welding groove or 12mm from the toe of the fillet in the case of socket welded or fillet welded joints shall be thoroughly cleaned of rust, scale, paint, oil or grease both inside and outside prior to welding. Unless otherwise specified, joints for pipes 50mm NB and smaller, shall be socket welding type and for pipes 65mm NB and larger, shall be of the butt-welding type. All butt welds shall be full penetration welds. BUTT JOINTS Butt joints shall be prepared as per ASME B 16.25 and/or IBR unless otherwise specified. While meeting the alignment requirements of piping joints as per Cl. 127.3.1 C of ASME B31.1, care shall be exercised that the trimming depth in case of excess mis-alignment does not interfere with Radiography/Ultrasonic Test (RT/UT) interpretations. In such cases the trimming width from the tip of the edge preparation along the pipe shall be large enough that it is well away from the weld face. Unless noted otherwise, all butt welds shall be made without using backing rings. T, CORNER AND LAP JOINTS These shall be prepared as follows :
ISSUE R5
5.5
5.6
6.0 6.1
6.2
6.3 6.3.1 6.3.2
6.3.3 6.4
TCE FORM NO. 329 R4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
WELDING SPECIFICATION FOR POWER PLANT PIPING SYSTEMS a) b)
SHEET 5 OF 15
Fillet welds shall have a throat dimension equal to the nominal thickness of either of the joint members. Weld edges of full penetration groove welds for T joints shall be prepared with a minimum included angle of 45 deg.
6.5
The ends shall be prepared by machining , grinding or flame cutting. Where flame cutting is used, the effect on the mechanical and metallurgical properties of the base metal shall be taken into consideration. Flame cutting of alloy steel pipes is not allowed. However, flame cutting of carbon steel pipes is permitted. Wherever practicable, flame cutting shall be carried out by machine. Machine flame cut edges shall be substantially as smooth and regular as those produced by edge planing and shall be cleaned free of slag. Manual flame cutting shall be permitted only where machine flame cutting is not practicable and with the approval of the PURCHASER/ENGINEER, and such surfaces shall be ground or dressed to a smooth finish as required by the specification and to the satisfaction of the PURCHASER/ENGINEER. Slag, scale or oxides shall be removed by grinding to bright metal atleast 2mm beyond the burnt area. Thermal cutting of carbon steel piping shall be performed under the same conditions of preheat and post heat as for the welding of carbon steel material. However, post weld heat treatment is not required when : a) The heat affected zone produced by thermal cutting is removed by mechanical means immediately after cutting However, in any case, all remaining slag scale or oxides shall be removed by grinding to bright metal at least 2mm beyond the burnt area, or Thermal cutting is part of fabrication, manufacturing or erection sequence leading to a weld end preparation where welding immediately follows.
6.6
b)
6.7
For the piping systems that are supplied by the PURCHASER/ ENGINEER but being erected by the CONTRACTOR, bevelling of pipes for butt welds shall be carried out as indicated on the respective piping fabrication drawings, where required. For systems which the CONTRACTOR supplies and erects, the pipe ends shall be bevelled to conform to applicable codes/standards. At connections to equipment, the bevelling of piping shall conform to the requirements of the equipment connections. Any change in the joint configuration shall be done after the approval from the PURCHASER/ENGINEER. All weld joint fit-up shall comply with the tolerances specified on the design drawings or applicable codes and standards. If the CONTRACTOR uses a header arrangement with central location of oxygen and acetylene for cutting and edge preparation operations, the arrangement shall be in accordance with best safety practices and standards and shall be approved by the PURCHASER/ENGINEER.
ISSUE R5
6.8 6.9 6.10
TCE FORM NO. 329 R4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
SHEET 6 OF 15
6.11
Before fitting up the weld joint, the profile and dimensions of the weld end preparation shall be checked by the PURCHASER/ENGI-NEER. If the specified tolerances are exceeded, this shall be corrected (with prior approval) by grinding, machining or any other method acceptable to the PURCHASER/ ENGINEER. All fit-ups shall be examined by the PURCHASER/ENGINEER prior to welding the root pass. WELDING OF PIPES All vertical welding shall be carried out in the uphill direction unless otherwise approved by the PURCHASER/ ENGINEER. No single run in SMAW shall exceed 8 mm in size. Each leg of the fillet weld shall have a length of atleast 1.25 times the nominal wall thickness of the pipe. Socket and fillet welds shall have a minimum of two weld layers. All tack welds shall be made using a qualified procedure and qualified welders. Any preheat requirements specified on the welding procedure shall also apply to tack welds. All tack welds shall be examined visually for defects, defective shall be completely removed. and if found
6.12 7.0 7.1 7.2 7.3
7.4
7.5 7.6
As the welding proceeds, tack welds shall be either removed completely or shall be properly prepared by grinding or filling their stopping and starting ends so that they may be satisfactorily incorporated in the final weld. The maximum weaving of any SMAW or GTAW run shall be of 3 times the electrode dia. Welded-on branches for all piping systems shall be full penetration type connection. Preheating prior to tack welding and welding as called for in clause 8.0 shall be employed as a means of crack prevention and improving general weld reliability. At no time during welding shall the temperature of the joint be allowed to fall below the minimum preheat temperature. Excessive preheating shall be avoided. Irrespective of the class of steel, root runs shall be made without interruption except for changing the electrodes or to allow the welder to reposition himself. Root runs made in the shop may afterwards be allowed to cool by taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry asbestos blanket. Welds made at site shall not be allowed to cool until the thickness of weld metal deposited exceeds one third of the final weld thickness or 10 mm, whichever is greater.
ISSUE R5
7.7 7.8 7.9
7.10
TCE FORM NO. 329 R4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
SHEET 7 OF 15
7.11
When welding alloy steels, it is strongly recommended that interruption of welding shall be avoided. Where such interruption is unavoidable, either the preheat shall be maintained during interruption or the joint shall be wrapped in dry asbestos blankets to ensure slow cooling . Before recommencing welding preheat shall be applied again. No welding shall be done if there is impingement of rain, snow, sleet or high wind on the weld area. Welded-on bridge pieces and temporary attachments should prefer-ably be avoided. Where approved by the PURCHASER/ ENGINEER. they may be used .Material of these shall be compatible with parent material. All these pieces shall be removed carefully without damaging the parent material after welding of pipe joints and the weld area ground flush and subjected to magnetic particle examination before applying any postweld heat treatment, which shall embrace the area occupied by the bridge pieces also. These pieces shall be welded by qualified welders and with electrodes compatible with the parent material. The preheating requirements shall be applied and maintained during the welding of pieces. The arc shall be struck only on those parts of parent metal where weld metal is to be deposited. In the event of any inadvertent arc strikes the defects shall be removed by grinding and the area examined by liquid penetration or magnetic particle testing method. (a) Oxides shall not be permitted to form during welding or heat treatment or both, on the internal surfaces of pipes which will not be subsequently cleaned. Inert gas purging will be an acceptable method to prevent such oxidation. All joints in materials which contain greater or equal to 5% chromium shall be purged to assure that less than 1% of oxygen is present on the joint underside before initiation of the welding. The purging operation shall be maintained for two passes. Refer Cl. 7.15 (b) for flow rate during purging .The CONTRACTOR may submit examples of any other procedures for consideration of the PURCHASER/ENGINEER. Argon gas used in GTAW process for shielding and purging shall be of minimum 99.95%. purity. Purging shall be carried out at a flow rate depending on diameter of pipe until 6 times the volume between dams is displaced. In no case shall the initial purging period be less than 10 minutes. After initial purging, the flow of the backing gas shall be reduced to a point where only a slight positive pressure prevails. Any dams used in purging shall be fully identified and removed after welding and accounted for in order to avoid leaving them in the system.
7.12 7.13
7.14
7.15
(b)
7.16 7.17
Thorough check shall be exercised to ensure that the required inter pass temperature is maintained. All equipment necessary to carry out the welding for supporting of the work, for the preheating and post weld heating including thermal insulation for
ISSUE R5
TCE FORM NO. 329 R4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
SHEET 8 OF 15
retaining the heat and for the protection of the welder shall be provided by the CONTRACTOR. 7.18 After deposition, each layer of weld metal shall be cleaned with a wire brush to remove all slag, scale and defects, to prepare for the proper deposition of the next layer. The material of the wire brush shall be compatible with pipe material. Special care shall be taken to secure complete and thorough penetration of the fusion zone into the bottom of the weld. It is recommended that the root run be checked by liquid penetrant or magnetic particle procedures. The cleaning of the root from the second side of butt welds is to be carried out wherever feasible by gouging, grinding, chipping, machining or other approved methods. The gouged surface must be cleaned to remove any carbon or oxidised metal before commencing the welding. The welding grove shall be examined by dye penetrant or magnetic particle method to ensure that the root is free from defects. Repair of weld metal defects shall meet CL 127 .4.11 of ASME B31.1. Upon completion of welding , the joints shall be wrapped in dry asbestos blankets to ensure slow cooling, unless post-weld heat treatment is applied immediately. No welding or welded parts shall be painted, plated, galvanised or heat treated until inspected and approved by the PURCHASER/ ENGINEER. Welds shall be prepared/ground in such a way that weld surfaces merge smoothly into the base metal surface. Except where necessary to grind flush for non-destructive examination purpose, the centre of reinforcement for butt welds shall be as indicated below: Component Thickness (mm) Upto 12 Over 12 to 25 Over 25 to 50 Over 50 Max Reinforcement 1.6 2.4 3.2 4.0 (mm)
7.19
7.20 7.21
7.22
7.23
The reinforcement shall be crowned at the centre and tapered on each side of the joined members. The exposed surface of the weld shall be ground where required to present a workman like appearance and shall be free from depressions below the surface of the joined members. The exposed surface of the butt welds shall be free from undercuts greater than 0.8 mm in depth, overlaps or abrupt ridges or valleys and shall merge smoothly into the pipe surface at the weld toe. However, undercuts shall not encroach on the minimum section thickness. 7.24 Any weld repair shall PURCHASER/ENGINEER. be subject to the approval of the
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
SHEET 9 OF 15
7.25 7.26 7.27
The same area on the weld shall not be repaired more than twice. The joint shall be remade in case of more than 2 repairs. Postweld heat treatment shall be carried out as per Cl. 132 of ASME B31.1. IDENTIFICATION OF WELDS Wherever code symbol stamps are required on carbon steel and ferritic alloy steel piping they shall be applied directly to the pipe with low stress dotted design metal die stamps or to a small stainless steel plate especially provided for such marks. These plates shall be lightly tack welded to the pipe using electrodes (of diameter 3 mm or less ) of the type specified for the material. Before making the required tack weld, the pipe material in the immediate surrounding area shall be preheated, as required, by electric means or propane or natural gas burners. Cooling shall take place under asbestos insulation in a draft free area. Stress relieving of these welds is not required. Steel stamping directly on the surface of alloy steel piping with other than low stress die stamps shall not be permitted. Use of oxy acetylene gas for pre-heating is not allowed.
7.28 7.28.1 7.28.2 8.0
SEAL WELDS Seal welding shall be done by qualified welders and in accordance with approved drawings Threaded joints that are to be seal welded shall be made without the use of thread lubricating compound. PREHEATING Preheating prior to cutting, tack welding and welding shall be employed as a means of crack prevention and improving general weld reliability. The general requirements listed in para 9.0 ' Stress Relieving shall be applied for preheating. Preheating when performed shall be in accordance with Cl. 131 of ASME B31.1 Preheating requirement for thermal cutting shall be the same as applicable to welding.
8.1 8.1.1
CARBON STEEL /ALLOY STEEL At no time during the welding operation shall the temperature of the weld area be allowed to fall below the specified temperatures. Before performing any tack welding which may be required in preparing alloy/carbon steel pipe for welding or other fabrication, or before attaching thermocouples, the pipe area to which the tack weld is to be made shall be evenly heated to these temperatures preferably by resistance heating or induction coils. Propane or natural gas torches or preferably burner rings shall be employed where it is impossible to use electric heating. The use of oxy-acetylene is prohibited. The metal temperatures in this procedure shall be determined by the use of thermocouples and potentiometers except that temperature sensitive crayons may be used as temperature indicators in tack welding thermocouples.
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TITLE
VOLUME IIIB
TCE.M4-134-04
SHEET 10 OF 15
8.1.2
Welded joints for piping NB 100mm and larger shall be heated by means of induction coil or resistance heating . Welded joints in smaller pipe shall be heated by means of electrical resistance coils or suitable propane or natural gas torches. AUSTENITIC STAINLESS STEEL Welded joints in austenitic stainless steel piping need not be preheated except where the ambient temperature is below 0oC. For this condition , the joint shall be heated to 40oC by propane, natural gas or electrical means before any welding is performed.
8.2
9.0
POSTWELD HEAT TREATMENT Postweld heat treatment of piping welds is required when so specified in code clause 132 of ASME B31.1 and shall be performed as described below. However for carbon limitation on carbon steel material of all piping refer Cl. 9.2.1.
9.1 9.1.1
GENERAL REQUIREMENTS A complete automatic temperature recording shall be used during preheating and stress relieving operations. Where propane gas burners or electrical resistance coils are employed, a complete temperature record of the preheating and stress relieving operation shall be made by means of a box type potentiometer. Other means of recording temperatures are permissible subject to the PURCHASER/ENGINEERS approval. Stress relief may be local or full furnace. Local stress relief shall be performed with electric induction or electric resistance coils. Suitable gas burning equipment using natural gas or propane may be employed. During stress relieving / preheating cycle, no water or liquid cooling medium shall be employed. Where members being joined are unequal in thickness, the dimension of the heavier section shall govern the selection of width of the heated band and the duration of the holding period. When local stress relief is performed, the area of the welded joint and the adjacent material to be postweld heat treated, shall be as called for in para 132.7 of ASME B31.1 For local stress relief using electrical methods, a minimum of two thermocouples tack-welded to the surface and potentiometers, shall be used on the pipe under at least 4 layers of asbestos paper. The hot junctions of the thermocouples shall be located on either side of the joint atleast 12mm from the edge of the joint, but no farther away than 100mm. When employing induction heating , at least six turns of induction cable shall be wrapped on top of the asbestos paper protecting the
ISSUE R5
9.1.2
9.1.3 9.1.4
9.1.5
9.1.6
TCE FORM NO. 329 R4
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VOLUME IIIB
TCE.M4-134-04
SHEET 11 OF 15
thermocouples with the first turn approximately 150mm from the centre of the weld. 9.1.7 Local stress relief using natural gas torches or ring burners may be employed. However, the procedure shall be limited to pipes below 100mm NB and must be approved by the PURCHASER/ENGINEER. The stress relieving temperature shall be maintained for a period of time proportioned on the basis of one hour per 25 mm of wall thickness of the thickest section at the joint, but in no case less than one hour. For tubing joints and socket welded joints, pads, bosses and couplings, one thermocouple shall be positioned at a minimum distance of two pipe wall thickness from the weld. For welds used for attachment of base brackets, two thermocouples shall be used for determinations of preheating and stress relieving temperatures. They shall be tack welded directly to the header and located 180 deg apart on the circumference of the header and midway between adjacent legs. Piping on both sides of any joint shall be adequately supported throughout the preheating, welding and stress relieving operations to prevent distortion. When a butt welded joint is to be post-weld heat treated and the piping is cold sprung, the forces required to position the pipes shall be maintained by external means until the completion of the heat treatment procedure. All heating and cooling must be performed in still air CARBON STEEL Welded joints of carbon steel piping where the nominal pipe wall thickness of the heaviest material being joined is greater than 19mm or the carbon content more than 0.25% for piping system under IBR and 0.3% for non-IBR piping systems shall be stress relieved upon completion of welding operation. When the height of a boss above the OD of the pipe is 19 mm or greater the weld shall be stress relieved When the wall thickness of a coupling or a pad is greater than 19 mm the weld shall be stress relieved When local stress relief is employed, the welded joint shall be heated to a temperature of not less than 600oC. This temperature level shall be maintained within the limits of 600 oC to 650 oC for one hour per 25mm of wall thickness, but in no case less than 1 hour. The weld area shall then be allowed to cool undisturbed in still air to a temperature not exceeding 315 o C.
9.1.8
9.1.9
9.1.10
9.1.11
9.1.12 9.2 9.2.1
9.2.2 9.2.3 9.2.4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
SHEET 12 OF 15
All welded joints which are locally stress relieved in pipes 100mm NB and larger shall be heated by means of electric induction coils or resistance heating. Welded joints in pipes smaller than 100mm NB shall be stress relieved by means electric resistance coils or suitable propane or natural gas torches only. 9.2.5 Heating and Cooling Carbon steels after having reached their specific stress relief temperatures, may be cooled in the furnace or under wraps i.e leaving the induction coils or resistance heaters and insulation in place. This means that at the stress relief temperatures, the power to the furnace or heating coils may be shut off and cooling is allowed to take place in the furnace or with all insulation and coils remaining on the pipe. For furnace stress relief, the doors of the furnace may be opened after the power is shut off, at 315 deg C The thermocouples controlling the temperatures shall remain during the cooling cycle so that excessive cooling, if it occurs, can be observed and immediately corrected. The rate of heating and cooling shall conform to Cl.132.5 of ASME/B31.1. The stress relieving coils and insulation shall be removed only after the piping has cooled to below 315 deg C, or if stress relieved in a furnace, the pipe may be removed from the furnace and permitted to cool in still air, when this pipe has cooled below 315 oC. 9.3 9.3.1 ALLOY STEEL All welds in alloy steel piping shall be stress relieved after the welding operation in accordance with C1.132 of ASME B31.1. Immediately after welding the material shall be wrapped in asbestos and allowed to cool. Local Stress Relief All welded joints in pipes 100 mm NB size and larger shall be locally stress relieved by means of electric induction coils or resistance heating. Welded joints in smaller pipe sizes shall be stress relieved by means of electric resistance coils or propane or natural gas torches only. 9.3.3 For full furnace stress relief of a welded assembly the entire fabricated section shall be heated uniformly to the temperature specified. The temperature shall be maintained for a period of time proportioned on the basis of one hour per 25 mm wall thickness of the piece having the greatest wall thickness in the furnace charge, but in no case less than one hour. Heating and Cooling The rate of heating and cooling shall conform to CI. 132.5 ASME of B31.1 9.4 AUSTENITIC STAINLESS STEEL Joints in austenitic stainless steel piping need not be stress relieved after welding.
9.3.2
9.3.4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
SHEET 13 OF 15
10.0 10.1
ELECTRODES (a) The specification and size of the electrodes, voltages and amperages, thickness of beads and number of passes shall be as specified in the approved welding procedure or otherwise agreed in writing Only basic coated electrodes shall be used, which will deposit weld metal having the same or higher physical properties and similar chemical composition to the members being joined. For each batch of approved brand, certificate showing compliance with the specification shall be secured and shall be submitted to PURCHASER/ENGINEER for review before being released for use on project piping. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. All low hydrogen electrodes shall be baked at 350 deg. C for 1 hour and stored in ovens kept at 80-100 deg C before being used. Recommendations of the electrode manufacturer shall be followed. For welding of all grades of steel and alloys by the GTAW process, a 2% thoriated tungsten electrode conforming to SFA-5 .12 EWTH-2 (AWS-A5.12, EWTH-2 ) classification shall be used. CARBON & ALLOY STEEL All electrodes to be used on alloy and carbon steel shall conform to ASME Boiler and Pressure Vessel Code Sec 2 Part C or any other equivalent code.
(b)
10.2
10.3
As welding electrodes deteriorate under adverse conditions of storage leading to dampness in the electrode coating, they should normally be stored in air conditioned rooms or in hot boxes or ovens in their original sealed containers whose temperatures shall be maintained within specific limits. The condition of electrodes shall be frequently inspected. Electrodes with damage to coating shall not be used. Electrodes shall remain identified until consumed. The type of electrodes used should be only those recommended by the manufacturer for the use in the position in which the welds are to be made. Electrodes which have the areas of flux covering broken away or damaged shall not be used. INSPECTION AND TESTING The PURCHASER/ENGINEER shall have accessibility to inspect the welding or any other related operations at any time and at any stage of fabrication. The PURCHASER/ENGINEER may require non-destructive testing of any weld for reasons other than those given in the specification. The responsibility for the cost of such testing shall be mutually decided between the PURCHASER/ENGINEER and the CONTRACTOR.
ISSUE R5
10.4
11.0 11.1
11.2
TCE FORM NO. 329 R4
SPEC.NO.

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VOLUME IIIB
TCE.M4-134-04
SHEET 14 OF 15
11.3
The CONTRACTOR shall inform the PURCHASER/ENGINEER when the weld preparation and setting up for welding of various members selected by the PURCHASER/ENGINEER is in progress so that the PURCHASER/ENGINEER can inspect the assembly before welding starts. The responsibilities of the PURCHASER/ENGINEERs representative shall in no way reduce the CONTRACTORs responsibilities to ensure that the work is carried out in accordance with the specification. Non-Destructive Test (NDT) shall be carried out at appropriate time as below. Radiographic Testing (RT) on welds shall be carried out after final heat treatment except for welds on PI Group material for which (Refer ASME Sec. IX ) RT can be performed either before or after final heat treatment. All requirements specified in TCE.M4-185-28 and TCE.M4-185-38 shall be strictly followed. EXAMINATION METHODS OF WELDS Non destructive examinations of welds shall be carried out in accordance with TCE. M4-185-28 and TCE.M4-185-38. Penalty Clause Where radiography specified is less than 100%, the penalty shall follows: be as
11.4
11.5
11.6 11.7 11.7.1 11.7.2
(a) For every weld found defective two additional penalty joints on either side of the joint shall be marked for RT. (b) If any of the penalty joints is found defective, entire weld joints represented by the defective joint shall be radiographed. (c) If the penalty joints referred under point (a) above are found acceptable, the original defective weld shall be repaired to the required standard and re-radiographed. 11.7.3 In addition, at the discretion of the PURCHASER/ENGINEER and the INSPECTORS, and where requested by them, the CONTRACTOR shall perform radiography and other tests of the joints of any other piping. Refer 11.2 on cost of such testing. (a) Where access holes for radiography have been provided in the piping, the CONTRACTOR shall employ single wall thickness radiography. The access holes shall be plugged and seal welded only after the radiograph is found acceptable
11.7.4
SPEC.NO.

TITLE
VOLUME IIIB
TCE.M4-134-04
SHEET 15 OF 15
(b) Where no access holes for radiography are provided in the piping, the CONTRACTOR shall employ double wall radiography, with elliptical projection technique. (c) The CONTRACTOR shall ensure that isotopes of sufficient strength and quality are used in order that the radiographs taken are of proper density, contrast and visibility. (d) Access hole plug welding shall be examined by magnetic particle or liquid penetrant methods. 12.0 QUALIFICATIONS AND CERTIFICATION OF NON- DESTRUCTIVE EXAMINATION PERSONNEL Organisations performing code required, non-destructive examinations shall use personnel competent and knowledgeable to the degree specified by ASME. 13.0 ACCEPTANCE STANDARDS The acceptance standards for radiographic, ultrasonic, magnetic particle, liquid penetrant and visual examinations etc. shall conform to ASME B31.1. 14.0 14.1 REPAIR WELDING All defects in welds requiring repair shall be removed by flame or arc gouging, grinding, chipping or machining. The major repairs may involve. (a) Cutting through the weld (b) Cutting out a length of pipe containing the weld, or Removing the weld metal down to the root depending upon the magnitude of the defects. After removing the defect, the welds shall be examined by the same nondestructive testing methods as specified for the original weld and the same acceptance criteria shall hold good. All the repair welds shall be made using same or other specified welding procedures as those used in making the original welds including preheating and stress relieving as originally required. (c)
14.2
14.3

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MAIN PLANT & AUXILIARIES SPECIFICATION

STEAM GENERATORS & AUXILIARIES

VOLUME IIIA CONTENTS

STEAM GENERATORS AND AUXILIARIES

VOLUME III A CONTENTS

TCE.5103A-C-510-01 TCE.5103A-C-510-01 TCE.5103A-C-510-01 TCE.5103A-C-500-01 TCE.5103A-C-500-01 DATA SHEETS A

5 1 1 1 1 1 1 1 1 1 1 2 1 2 2 9 2 2 2 1 5 ISSUE R0 TCE FORM 329 R3

VOLUME IIIA CONTENTS

STEAM GENERATORS AND AUXILIARIES

A22 A23 A24 A25 A26 A27

T CE.M4-203-02 TCE.M4-203-11 TCE.M4-203-06 TCE.M4-219-01 TCE.M4-219-11 TCE-M4-203-71 DATA SHEETS B

INDUCTION MOTORS -ADDITIONAL REQUIREMENT FOR HT MOTOR D.C. MOTORS

11 3 5 3 2 2 2 3 2 2 3 2 2 2 7 2 1 1 1 3 3 ISSUE R0 TCE FORM 329 R3

VOLUME IIIA CONTENTS

STEAM GENERATORS AND AUXILIARIES

B22 B23 B24 B25 B26 B27 B28

TCE.5103A-C-500-01 TCE-M4-219-11 TCE-M4-203-06 TCE-M4-203-11 TCE-M4-203-71 TCE-M4-219-01 TCE-M4-203-01

ISSUE R0 TCE FORM 329 R3

SECTION D1.1 SHEET 1 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4

STEAM GENERATORS & AUXILIARIES

SECTION D1.1 SHEET 2 OF 17

STEAM GENERATORS & AUXILIARIES 1.17

SECTION D1.1 SHEET 3 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4

STEAM GENERATORS & AUXILIARIES Atmospheric Flash Tank 1.26

SECTION D1.1 SHEET 4 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4

STEAM GENERATORS & AUXILIARIES 1.33

SECTION D1.1 SHEET 5 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4

STEAM GENERATORS & AUXILIARIES 1.41

SECTION D1.1 SHEET 6 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4

STEAM GENERATORS & AUXILIARIES

SECTION D1.1 SHEET 7 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4

STEAM GENERATORS & AUXILIARIES 1. 50.4 1. 50.5

SECTION D1.1 SHEET 8 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4

STEAM GENERATORS & AUXILIARIES

SECTION D1.1 SHEET 9 OF 17

STEAM GENERATORS & AUXILIARIES 1. 67.2

SECTION D1.1 SHEET 10 OF 17

1. 67.5 1. 67.6 1. 67.7

STEAM GENERATORS & AUXILIARIES a) b)

SECTION D1.1 SHEET 11 OF 17

STEAM GENERATORS & AUXILIARIES 1.71

SECTION D1.1 SHEET 12 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4

STEAM GENERATORS & AUXILIARIES

SECTION D1.1 SHEET 13 OF 17

CONSULTANTS: TCE Consulting Engineers Limited

TCE FORM NO. 329 R4