Beruflich Dokumente
Kultur Dokumente
aw
= 0.60 x
100
+ 0.10 x
80
+ 0.30 x
60
where
aw
= Weighted average efficiency
100
= Efficiency at 100 percent rated MVA and 0.90 p.f
80
= Efficiency at 80 percent rated MVA and 0.90 p.f
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 47 of 106
60
= Efficiency at 60 percent rated MVA and 0.90 p.f
To formulate uniform basis of losses to arrive at generator efficiency;
following losses shall also be considered and included:
Bearing friction losses (total bearing losses of generator + thrust
bearing losses apportioned to generator rotor weight).
Windage / ventilation losses.
Iron losses.
Stator copper losses.
Stray load losses.
Field winding copper losses
Excitation system losses.
XIII Performance Criteria & Guarantee
The equipment covered under this contract shall be capable of
performing all intended duties and it is the responsibility of the Contractor
to supply the equipment as per guaranteed technical particulars.
XIV Design and Construction
a. General
The generators shall be of suspension type with combined thrust and
guide bearing located above the rotor and another guide bearing below
the rotor. The generators shall be capable of safely withstanding
maximum stresses during normal operation, runaway-speed conditions,
two phase and three phase short-circuit conditions or single phase earth
fault at the maximum output for which generators are capable of, 180 deg
and 120 deg out-of-phase synchronization, magnetic unbalance at
runaway speed with 50% of the poles short circuited and brake
ODISHA HYDRO POWER CORPORATION LIMITED
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R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 48 of 106
application etc. Seismic forces shall also be taken into consideration for
design of the generators.
The construction of the generator shall be such that the rotor poles, stator
bar and generator air coolers can be easily maintained/repaired without
disturbing the upper bracket.
The thrust bearing housing shall be so designed as to provide easy
access to the bearing pads. Openings with removable covers shall be
provided for this purpose. The thrust bearing pads and the thrust faces
shall be capable of being reached and inspected through the oil cooler
windows (after emptying the bearing oil, removal of coolers and with rotor
jacked up).
The guide bearings also shall be of such construction that these can be
removed/ dismantled without disturbing the thrust bearings , rotor, stator,
etc.
The core stacking to the extent shall be carried out at manufacturers
work. In case for sufficient reasons such as transport limits, the work of
core stacking for stator shall be carried out at site, it shall be so
mentioned by the contractors in their tenders, giving reasons. The stator
frame design shall be suitable for lifting the built stator from service bay
for installation in pit.
Similarly, the rotor construction shall be such that rotor poles are easily
removable and replaceable. The poles shall be interchangeable.
The rotor shall also be supplied in the maximum possible assembled
condition within the transport limits given. If to meet the transport limits
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
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R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 49 of 106
rotor rim of lamination sheets is required to be built up at site the rotor
construction shall be designed accordingly to suit the assembly at site
(stacking, pressing, curing of lamination insulation, installation and mount
ing of rotor poles).
All parts of the generating unit shall be designed mechanically to
withstand all electrical, mechanical, and other stresses which may be
experienced during the operation of the unit, including short circuit, faulty
synchronization, over speed and runaway conditions.
All equipment shall be designed and manufactured under due
consideration of the prevailing transport limitations.
The design of the unit, including the relative locations of the rotor,
generator thrust and guide bearings shall be such as to cause no
abnormal vibration or resonant conditions. The unit shall be physically
stable under worst short circuit conditions.
The supporting brackets will be steel fabricated and shall be rigid enough
to support and transmit the load to the concrete structure /foundation
under worst conditions . The bearing bracket supporting the brake
assemblies shall, however, be designed to withstand the braking of the
rotor even at 50% speed (though normal braking speed shall be lower).
Upper and lower guide bearing brackets shall house the upper and lower
guide bearings in their hubs.
Rotor field poles shall be arranged in a manner to permit easy removal
with the unit rotor left in place. Field pole electrical connections shall be
ODISHA HYDRO POWER CORPORATION LIMITED
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TS VOL III Sec .A Ch-06 Page 50 of 106
located in a position to facilitate ease of inspection, separation and
reconnection. The field poles shall be provided with adequate damper
windings to reduce voltage distortion etc.
b. Main Shaft and Coupling
The generator shaft shall be made of the best quality forged carbon or
alloy steel, properly heat-treated.
The design and construction of turbine and generator shafts shall be
adequately coordinated by the generator and turbine manufacturers.
The critical speed and vibration strength of all rotating parts shall be
checked with the turbine manufacturer and shall be verified by
calculations.
The first critical speed of the combined rotating parts of the turbine and
the generator shall be at least 25% above the maximum runaway speed.
The main shaft shall have an integrally forged flange for connection to
turbine shaft flange. All coupling dimensions shall be agreed upon by the
turbine and generator manufacturers and shall essentially conform to
IEEE 810 IEEE standard for hydraulic turbine and generator integrally
forged shaft coupling and shaft run out tolerances or an equivalent
approved standard.
The generator manufacturer shall be responsible for the alignment and
balancing of the rotor with the turbine shaft and runner after installation in
accordance with the stipulations
ODISHA HYDRO POWER CORPORATION LIMITED
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TS VOL III Sec .A Ch-06 Page 51 of 106
c. Bearings
The generator shall be provided with thrust bearing arranged in upper
bracket, upper guide bearing arranged central part of the upper bracket,
and lower guide bearing arranged on the lower bracket. The thrust
bearings shall be with PTFE lined pads of ample sized to be capable of
safely coping with all operational conditions including runaway speed and
start-up /shut-down without lift-pumps, hydrostatic lubrication or applying
the brakes. All guide bearing pads shall be white metal lined.
The arrangement, design and construction of the bearings shall be duly
coordinated with the turbine manufacturer and should take into account
weights of the rotating parts of turbine, with unbalanced hydraulic thrust
under all conditions of operation. Type and quality of the oil shall be the
same for turbine and generator bearings.
The bearings shall be capable of operating at the following, guaranteed
conditions:
Continuously at 50 to 110%rated speed.
30 minutes at any speed between 110% rated and runaway speed
with cooling water supply.
15 minutes at rated speed and full load without cooling water
supply.
2 minutes at runaway speed without cooling water supply.
The thrust bearing shall be of the manufacturers standard design, with
flexible self-adjusting pad, support (spring mattress type, tilting pad type or
of other proven and reliable design), providing sufficient reference for
long-term satisfactory operation.
While designing the withstand capacity of the thrust bearing, weight of all
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
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TS VOL III Sec .A Ch-06 Page 52 of 106
rotating parts including shaft and runner, hydraulic tonnage at over load or
more for which turbine is capable of under worst hydraulic conditions and
severest faults or run away speed shall be taken in to account.
The size of the thrust bearing may further be designed by restricting the
specific pressure on thrust bearing segments as per IEC.
A high pressure lubrication system shall be provided for lubrication of
thrust bearing during start-up and shut-down. The system shall operate
automatically at set speeds between 0 and 100%. Nevertheless, safe
start-up and shut-down shall also be possible in case of failure of this
system.
The guide bearings shall be of the multi-segment type with spherical
segment rests.
The thrust, lower guide bearing and the upper guide bearing shall be of
the self-pumping lubricated type with plug-in type oil-to-water coolers
inserted in the bearing compartment .
The tubes of the oil coolers shall be of germanium silver and shall have
adequate extra capacity to allow for 10%plugging of cooler tubes. The
coolers shall be submerged in oil bath of bearing and oil circulation shall
be natural type due to centrifugal action.
Supply and return line flanges with shut-off valves shall be provided at
generator floor level to allow connecting the oil circuits to the oil transfer
and treatment system. An overflow with connection to the return line shall
be included.
ODISHA HYDRO POWER CORPORATION LIMITED
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R & M WITH NEW TG SET
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TS VOL III Sec .A Ch-06 Page 53 of 106
Special care shall be taken in the design of the bearing seals. No oil
vapour shall enter the generator compartments. The system shall
preferably be based on quenching air and vent-pipes with filters.
The bearings shall be adequately insulated to prevent harmful flow of
shaft currents induced by the generator field. Test points shall be
arranged at an easily accessible location to allow regular checks on the
existence of shaft voltage. Above arrangement can be combined with the
auxiliary brush-holder provided for the rotor earth fault protection.
All provisions shall be included to permit loss measurement using the
calorimetric method.
The thrust bearings shall be equipped with all the necessary indicating
and control devices. Some of them are indicated as under:
One oil level indicator in the bearing oil reservoir with high and low
level alarm contacts and tripping contacts for very low oil level.
Two dial type thermometers to indicate the temperature of the hottest
part of the bearing pads and one for that of the oil.
Resistance temperature detectors located in all the pads and in the oil
reservoir.
One direct-reading water flow gauge along with low-flow alarm
contacts.
One oil-water contamination detector.
Each guide bearing (upper and lower) shall be equipped with the
following:
- One oil level indicator in the bearing reservoir with high and low
level alarm contacts and tripping contacts for very low oil level.
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TS VOL III Sec .A Ch-06 Page 54 of 106
- Four dial type thermometers to indicate the temperature of the
hottest part of the bearing and one for that of the oil. Provision
for DTT and RTDs shall be provided in all pads.
- Resistance temperature detectors located in all the pads and in
the oil.
- One direct-reading water flow gauge, low-flow alarm.
- One oil-water contamination detector.
d. Brakes and Jacks
a. Brakes
The generator brakes shall consist of asbestos free brake liners
mounted on a vertical piston moving in a cylinder and shall operate
against a polished circular steel brake track. The brakes shall be
pneumatically operated type, compressed air at suitable pressure shall
be supplied from the L.P. compressed air system. Limit switches shall
be provided for each brake to prevent the unit from starting if the brake
is applied. The brakes shall be mounted on the bottom bracket of the
generator.
A combined hand operated and solenoid operated air valve to
control the operation of the generator brakes shall be supplied and
mounted in the actuator cabinet brake control panel. The operation of
the solenoid of the air valve shall be selected by means of a control
switch with manual, off and automatic positions. The control switch
shall be provided with spring return to off from the manual position
and shall maintain the automatic position when so placed. A manual
locking device shall be provided to permit locking of the brake valve in
the on position. When in the on position, the control switch shall
operate the solenoid of the air brake valve directly. With the switch in
automatic position, the solenoid of the air brake valve shall be
controlled by means of a suitable electric circuit, the requirements of
ODISHA HYDRO POWER CORPORATION LIMITED
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TS VOL III Sec .A Ch-06 Page 55 of 106
which are given below.
Gate position switches and speed switches as specified herein shall
prevent the application of the brakes until the guide vanes are fully
closed and the unit speed has decreased to the required level. It shall
be possible to apply the brakes continuously after an adjustable period
of time by means of the automatic control. The brakes shall be
automatically released after the adjustable period of time sufficient to
ensure that the unit has been brought to a complete stop.
When the control switch is in the automatic position a separate
contact shall be closed for interlock in the auto-start circuit. A pressure
switch shall be provided in the air line to the brake cylinders with
contacts to open as an, interlock to prevent start up whenever the
brakes are on. A second pressure switch shall be provided in air supply
line to brake valve to energize an alarm circuit of low air pressure.
ii. Jacks
The brake cylinders shall also be designed to serve as hydraulic jack to
lift the generator rotor to a sufficient height to facilitate removal &
adjustment of bearing pads. A limit switch for operation of an indicating
lamp shall be provided to indicate when maximum permissible raised
position of the rotor is reached.
iii. Brakes and Jack Control Panel
Each unit shall be provided with an independent brake and jack control
panel. The panel shall house items such as solenoid valves, manual
isolation valves, associated piping. The unit shall also house air filters
to filter air entering the braking system to prevent rusting etc.
Jacking of the generator rotor shall be done when the rotor is standstill.
A separate inlet and outlet connections shall be provided in the panel
for connecting the pressure and drain line of the pressure oil system.
ODISHA HYDRO POWER CORPORATION LIMITED
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R & M WITH NEW TG SET
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Independent piping of braking and jacking shall be provided which shall
become common at the outlet of this panel and shall connect to brake /
jack assembly. Necessary provision shall be provided for draining of oil
after jacking operation. All required instrumentation and interlocks shall
be provided for safe and reliable operation of the system.
e. Generator Air coolers
RTDs shall be provided at the inlet and outlet of the air cooler cooling
water header. Tenderer shall confirm that the opening of the generator
barrel is sufficient to draw the quantity of air. Any modification on the
barrel required shall be done by the Tenderer.
Complete details of the offered cooling system shall be furnished by the
tenderer. Cooling water inlet temperature shall be taken as 31.5 deg C.
Cooling water inlet/outlet and air inlet/outlet temperature shall be
monitored in Control Room.
All coolers shall be pressure tested at site before erection.
The coolers should be designed to operate at water pressure available
corresponding to minimum water level in reservoir. Coolers tube
material shall be germanium-silver as they have good cooling
properties and less prone to erosion due to impurities in water.
The generator should be able to operate at rated load with clogging of
10% of cooler tubes of all 8 Air coolers.
f. Stator and Stator Winding
The stator shall consist of a frame, a core and a winding. The stator
frame shall be in two or more sections as per transport limits. The stator
frame shall be fabricated of steel plate, suitably ribbed for rigidity and
shall be of robust design to withstand maximum forces acting on it
ODISHA HYDRO POWER CORPORATION LIMITED
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TS VOL III Sec .A Ch-06 Page 57 of 106
under the worst condition of operation, with bolted and doweled joints
between the sections. The stator frame shall have robust foundation
plates rigidly attached to the frame with provision for levelling, centring
and bolting on to foundations. The fastening of the stator frame to the
sole plates will have provision for radial movement of the stator due to
thermal expansion. The stator frame shall be designed for lifting the
completely built stator and provided with suitable lifting lugs and
devices for handling.
The core laminations shall be punched from high grade non-ageing
cold rolled silicon steel coated with suitable insulating enamel to
minimize eddy current losses and piled on dovetail key ribs which are
accurately and securely fastened to the stator frame. The core shall be
ventilated by means of radial air ducts throughout the stack length. The
ducts, formed by non-magnetic space blocks will direct the air uniformly
with minimum obstruction.
The stator core shall be clamped by means of flange and finger
assemblies at both ends of the core. The assemblies are constructed by
welding the non-magnetic fingers to the flanges and together they
bridge the core and stator frame. The required pressure is provided and
maintained with through studs.
All the necessary tests shall be conducted after piling and before
winding at manufacturers work for detection of hot spots. In the event
stator winding is carried out at site, all the necessary tests shall be
conducted at site by the Contractor and all the required items for test
shall be arranged by the Contractor only. The stator winding shall be
bar type, Y-connected with line and neutral leads brought out to the
ODISHA HYDRO POWER CORPORATION LIMITED
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TS VOL III Sec .A Ch-06 Page 58 of 106
stator terminals. Each phase winding shall be distributed around the
stator such as to minimize unbalanced magnetic pull. The stator
winding and connections as well as connecting leads, main and neutral
leads shall be of epoxy cast resin type, corresponding to class 'F'
insulation. The maximum accepted temperature rise at maximum output
will be limited to the temperature rise corresponding to class B
insulation.
The insulation shall be made of the best quality material and suitably
impregnated insulation method employed shall give a homogeneous
insulation without any voids, high thermal stability and insensibility
against humidity, oil and other pollutions. All the strands shall be
insulated suitably so that no short circuit between adjacent strands may
occur. The stator winding shall be adequately supported and braced to
withstand the full stresses due to electrical short-circuiting. End
connections of stator bar shall be made at the top of the winding.
The winding to the extent possible shall be manufactured and
assemled at manufacturers work before shipping to site. In the event
that part of the stator winding is required to be done at site, supply of all
insulation materials and other items and performance of all work for
completing the winding at site shall be done by the Contractor.
Adequate number of temperature detectors per parallel circuit per
phase, shall be embedded in various parts of the stator winding.
Resistance temperature detectors or thermocouples shall be provided
for temperature measurement of the core. All the temperature detectors
in and around generator shall be wired by shielded cables.
The neutral leads shall be brought out in a suitable manner and shall
ODISHA HYDRO POWER CORPORATION LIMITED
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TS VOL III Sec .A Ch-06 Page 59 of 106
terminate at the neutral grounding cubicle. Type and arrangement of
the line terminals shall be suitable for termination of fully insulated,
three single-phase isolated phase bus ducts.
g. Rotor
The design and construction of rotor shall be in accordance with most
modern practices details of which shall be furnished by the Contractor.
The rotor shall be designed for assembly on the rotor assembly bay in
the erection area of the powerhouse. The Contractor shall provide all
suitable rotor erection pedestals and sole plate adapters for the
permanent use by the Purchaser.
The brake track of the rotor shall be designed to withstand all
loads/vibrations/ stresses etc. for the braking at 50% of the rated
speed.
Damper windings shall be provided as necessary. Equipment to monitor
residual voltage of the rotor shall be provided. The rotor winding and
the rotor leads shall be epoxy cast resin type with Class F insulation but
temperature rise shall be limited to class B. For each assembly new
brush gear and slip ring shall be provided. The design should be such
that Rotor pole disassembly as when required is easy. The design of
the rotor shall be such as to permit the removal and replacement of field
poles without the removal of the rotor from the stator. The field coils
shall be adequately braced to withstand the stresses due to worst
condition of short circuit and also due to centrifugal forces. The
connections from the field coils to the collector ring shall be braced
against mechanical forces. If tapered keys are used to secure the field
poles to the rotor rim, the drive key shall project above the rotor rim at a
sufficient distance to facilitate removal of this key by means of a key
ODISHA HYDRO POWER CORPORATION LIMITED
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TS VOL III Sec .A Ch-06 Page 60 of 106
puller and to permit checking for tightness. Suitable keepers keys shall
also be provided to ensure that the keys do not get loose in service.
The brake ring on the rotor shall be supplied in segments, which may
readily be replaced. Provisions shall also be made for rotor fans and air
baffles at the top and bottom.
h. Collector Rings
The collector rings shall be in an accessible location above the rotor
and provision shall be made for reversing the polarity of the collector
rings. The brushes and collector rings shall also be so positioned as to
avoid contamination by oil vapours or oil leakage from the bearing.
i. Rotor Temperature Measurement
One shunt, to be mounted in the generator field leads, shall be
furnished complete with calibrated shunt leads for connection to a field
temperature recorder for measurement of rotor temperature.
j. Rotor Ground Fault Detection
A collector ring and brush assembly shall be mounted on the generator
shaft for field winding ground detector relays.
k. Brake Dust Collector
Suitable exhausting arrangements for sucking and collection of brake
dust, shall be provided during braking operation of the machine,
consisting of extraction unit, hoppers around brake assembly for
trapping dust and flexible hoses for connecting hoppers to the
extraction unit. The extraction unit shall have a motor driven exhaust
fan to be fitted with an easily removable sheet steel bin for collecting
heavy dust. The lighter particles of the dust shall be collected by
suitable fabric based filter.
l. Carbon dust collector
Suitable exhausting arrangement for sucking and collection of carbon
produced/emitted by the brushes shall be provided so as to avoid the
ODISHA HYDRO POWER CORPORATION LIMITED
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TS VOL III Sec .A Ch-06 Page 61 of 106
conduction through carbon deposition resulting in earth faults.
m. Speed measurement
For measurement of speed of the unit for governor operation etc. a
toothed wheel & necessary probes shall be provided and mounted on
the generator shaft.
n. Rotor lifting device
The contractor shall design the device in an optimum manner and
submit the lifting arrangement drawing.
o. Cooling System
The unit shall be self-ventilating, its own circulation action being utilized
by the fans installed on the rotor to force air through the windings, ducts
etc. The generator shall be totally enclosed. Pit seals shall be provided
for separation of the generator air-cooling system from the turbine pit.
The air-water heat exchangers (stator air coolers) shall be mounted on
the stator frame, each provided with shut -off valves at inlet and outlet.
Coolers shall be readily removable without disturbing the operation of
the remaining.
The surface air coolers shall have sufficient capacity to maintain stator
winding temperature rise within class B temperature limit when one
cooler is out of service and the unit is operating at overload output,
under worst system parameters i.e. at the maximum stator current. Each
air cooler shall be provided with 10% additional cooling coils to
maintain adequate cooling even when some cooler tubes are plugged.
The air coolers with tubes shall be made of germanium silver.
The cooling system shall be complete with air coolers, oil coolers,
cooling water pipes, fittings, flow indicating devices, flow relays and all
other accessories. All internal piping shall be terminated in a flange on
the generator barrel for connection with the plant cooling water system
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as specified in Cooling Water System.
The number of coolers provided, the normal working pressure and
pressure drop through the coolers shall be indicated and supported by
calculations. Connections shall be provided at the bottom of the air
coolers to facilitate complete drainage. The coolers shall be designed
for at least 10-kg/cm2 nominal pressure (Though working pressure shall
be 2 to 5 kg/cm2 ). Automatic air vents with drain pipes shall be
provided at the top to prevent air locks in the coolers. Lifting lugs shall
be provided to facilitate the removal of any cooler through the top of the
generator cover. Each cooler shall be provided with a pocket for
inserting thermometer on discharge end. The cooling water pipes inside
the barrel shall be suitably coated with fine quality paint to prevent
damage due to condensation on pipes. Various sensors and
instrumentation shall be provided.
The cooling system of generator shall be provided with the following
supervisory equipment :
RTDs in each water supply line, to measure the temperature of
incoming water.
RTDs to measure the temperature of the outgoing water from each
cooler.
Four RTDs and two TSDs to measure the temperature of the
heated air leaving the stator core and entering the air coolers.
Four RTDs and two TSDs to measure the temperature of the
cooled air entering the generator rotor.
Water flow gauges at inlet and outlet with low-flow alarm contacts
and indicating dial mounted on the gauge panel.
Pressure gauges at inlet and outlet of all the heat exchangers.
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p. Fire Protection
Water based fire protection (HVWS) shall be provided. For details
refer clause no. 06.04.03.08 of this volume.
q. Safety / Monitoring Devices
i Vibration Monitoring System
A continuous vibration monitoring system complete with proximity
probes, input/output module, control/processor unit, relays, junction
boxes, cabling and associated accessories shall be supplied for on-line
monitoring of vibration in the generating units. It shall comprise:
2 nos. non-contact type proximity probes each for all the guide bearings
i.e. upper, lower and turbine guide bearing to measure radial vibration
in both axes.
3 nos. contact type proximity probes at each location at upper bracket,
lower bracket and turbine bracket area to measure axial vibrations.
1 no. contact type proximity probe at thrust bearing to measure axial
vibrations.
Synchronization probe
Set of input/output model, control /processing /communication unit,
relays, junction boxes, cabling and associated accessories. The monitor
with its control accessories shall be located at the respective unit
control panel.
The system shall have the provision to monitor, record, analyze, diagnose,
indicate and trip etc. as provided in chapter Control and Instrumentation
System and Protection System. The system shall be integrated with plant
SCADA system.
The system shall be of a make of international repute having proven
performance and acceptability in the field of Hydropower. The details and
ODISHA HYDRO POWER CORPORATION LIMITED
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scope of the system shall be approved during detailed engineering.
ii. Anti-Condensation Heating
In order to avoid water condensation during long non-operative period of
the machine, heating elements shall be installed inside the generator
barrel. These elements shall be rated for three-phase 415 V A.C., 50 Hz;
and their terminals shall be connected to an easily accessible terminal
box. The heating shall be controlled automatically by adjustable hygrostat,
setting range about 50-100% relative humidity. The anti-condensing
heating shall also be provided with manual ON/OFF switch and
corresponding indication lamps in the local control panel. Provision shall
also be made for adjustable thermostat for automatic control of the
heaters.
r. Miscellaneous Provisions
Instrumentation for Field Assembly and Tests
The Contractor shall make arrangements for bringing all types of electrical
and mechanical instruments required for field assembly of the rotor, stator
and all testing equipment for testing and commissioning including field
acceptance tests. These shall remain the contractors property after
fulfillment of all field tests.
s. Terminal Boxes
The generator manufacturer shall supply terminal boxes to be located
inside the generator pit, for connection of control and secondary leads
from the generator equipment and auxiliaries located in the generator
enclosure. All leads including control and indications shall be wired to this
terminal box.
t. Control Wiring and Conduits
All internal wiring and conduits for control, relaying, fire protection, internal
illumination and other systems shall be brought out to terminal boxes, and
shall be suitably labeled.
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u. Instrumentation, Control and Safety Devices
Necessary sensors/sensing elements, signal generators for sequential
control and interlocks, measurement (indication, recording of quantities),
monitoring of abnormal conditions of operation (for safety, alarm annunciat
ion and shutdown) and related instrumentation which are embedded in
and/or mounted on the generator or its adjacent (local) gauge panel
should be included in the scope of supply of the generator as an integral
part.
These items shall generally pertain to the following:
Temperatures Stator, rotor, bearings.
Liquid Level Oil in bearing oil baths
Pressure Brake air, High pressure lubrication
oil, cooling water
Flow Cooling water for generator air
coolers, bearing oil coolers
Shaft current/Over
speed/Creep/Vibration/Fire
Generator
The contractor shall cover these items in the generator supply. They shall
also include any additional item not indicated but which are necessary for
smooth operation and safety of the equipment. A list of these additional
items shall be decided during detailed engineering.
v. Miscellaneous Piping, Tubing, Valves
All internal piping and valves for the following functions shall be included
in the scope of the Tenderer:
Cooling water inlet, outlet and drain for generator air and oil
coolers.
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H.S. Lubrication oil supply to thrust bearing meant for lubrication
during start-up and shut down of the unit.
Oil filling and drain connections at the bearings.
Piping for brakes and jacks.
Tubing for connections between temperature sensing elements
(vapour bulbs) to dial type thermometers, pressure gauge tubing.
Any other essential piping, tubing, etc.
w. Cabling
The following control and auxiliary power cables and wiring shall form part
of the generator supply:
All wiring within the generator housing for the speed signal
generator connections, thermometers, flow meters, RTDs /DTTs, all
alarms and control and metering circuits associated with the
generator.
Capillary tubes/Cables between the generator and the gauge
board.
All 240 volts A.C. wiring, lighting fixtures and convenience outlets
within the generator housing.
All conduit and/or cable trays required for conductors and cables
within the generator housing.
A cable-marshalling box with approved disconnecting links to
terminate all cables leading to the exterior of the generator.
06.04.03.04 Excitation system
Static high initial response rectifier excitation system shall be provided. Static
rectifier excitation system shall obtain the necessary electrical power directly
from from the terminals of the generator. The system shall consist of a power
transformer, thyristor control element, electronic regulator and de-excitation
unit.
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The capacity of the excitation system shall be adequate to supply continuously
1.1 times the excitation current and voltage required by the generator at its
maximum continuous output and 100% rated voltage and also for supplying
twice the excitation current required by the machine at its maximum continuous
output and 110% rated voltage for a duration of one minute.
The excitation system while operating at its maximum output, terminal voltage,
power factor and speed shall be capable of changing from rated field voltage to
90% of ceiling voltage within 25 milliseconds for a sustained drop in generator
terminal voltage of 5%.
Automatic voltage regulation (AVR), power system stabilizer (PSS) shall be in
accordance with Central Electricity Authority (Technical Standards for
Connectivity to the Grid) Regulations, 2007 and Central Electricity Authority
(Grid Standards) Regulations.
The number of bridges shall be such that one bridge is always available as
redundant. With the failure of two bridges it shall be possible to continue
operation at reduced load. The rectifier PIV (peak inverse voltage) rating shall
not be less than four times the maximum RMS voltage of the input.
The rectifier bridge shall be natural air cooled and shall consist of fully
controlled 3-phase full wave bridge SCR circuits comprising two (2) x100%
sets with associated bus work. Forced cooling of thyristor convertor shall be
provided with 100% reserve capacity, cubicle mounted fans. Number of
bridges shall be provided in such a way that one bridge can be taken for main-
tanence without any restrictions on loading of the unit. Indication of thyristor
fuse failure shall be provided. Arrangement shall be provided to change
thyristor during machine running.
Slip rings made of alloy steel forging shrunk fitted on the rotor shaft and
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insulated from it shall be provided to deliver current to the field windings.
Adequately rated field-flashing system suitable for working on both DC system
and 415 V AC system shall be provided for initial buildup of voltage.
Rotor angle limiters shall be provided to control both over and under excitation
conditions. The thyristor bridge shall be rated to act for 3 phase fault adjacent
to HV terminals of generator transformer cleared in 5 cycles & one auto reclose
on to above fault after 20 cycles followed by clearance in 5 cycles. The bridge
ceiling voltage shall be 1.8 times the normal field voltage.
A D.C. field circuit breaker shall be provided to ensure positive disconnection of
the field from the D.C. source and subsequent discharge of the field energy into
a discharge resistor.
The automatic voltage regulator (DAVR) shall be microprocessor based.
DAVR shall maintain the average 3-phase generator voltage within 0.5%
without hunting for all operating conditions.
The DAVR shall have necessary devices and control circuitry to achieve equal
reactive power sharing of generators.
The DAVR shall operate in both Auto and Manual modes.
DAVR shall have reactive current compounding circuit to provide reactive load
sharing during parallel operation. The compounding characteristic shall be
adjustable. Low excitation or a MVAR limiter shall be included to prevent the
regulator reducing the generator excitation below approved safe limits under
leading power factor conditions. AVR shall operate to keep following conditions.
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- Maintain generator voltage +/- 0.5%
- Maintain generator voltage under load rejection
or 150 % over speed = +/- 5%
- To supply field forcing up to 10 seconds.
All necessary field suppression equipment shall be provided to ensure safe
operation of the plant under all modes of operation.
Neutral point of each generator shall be earthed via a distribution transformer.
Secondary of transformer shall be connected with a suitable resistor.
I. EXCITATION SYSTEM AND DIGITAL VOLTAGE REGULATOR
a. Detailed Scope of Supply
The excitation system and DVR shall consist of: -
One (1) set of dry type excitation Transformer
One (1) set of full wave fully controlled rectifier system with (n+n)
layout thyristor bridge arrangement for 100% redundancy, complete
with firing circuit, control system etc.
One (1) sets of digital voltage regulators with all limiters & power
system stabilizer.
One (1) set of power supply units
One (1) set of field flashing equipment, including transformers.
One (1) set of DC field circuit breakers
One (1) set of discharge resistors
One (1) set of digital control and metering equipment
One (1) set of excitation cable connecting the rotor to DC field breaker
Any other items not specified above but are necessary to complete the
system for satisfactory operation.
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Set of Spares
(Note: One set is defined as the total number required for one unit.)
b. Special Design and Layout Conditions
The excitation system shall be of the static, digital, constant-voltage type with
controlled thyristors. It shall feature a very sensitive, quick acting control of the
generator voltage and reactive power respectively. The system shall be of
reliable design with an adequate record of satisfactorily working reference
plants.
The excitation power shall be supplied via a 3-phase dry type excitation
transformer directly connected to the 11 kV bus system between generator
terminals and transformer terminals. The excitation system continuous rating
shall correspond to 110% of the rated output of the generator at 0.9 p.f., rated
frequency and 110% rated voltage. The nominal excitation system response
shall be not less than 2. The positive and negative ceiling voltage shall be min.
200% and 160% respectively of rated excitation voltage at rated output.
c. Basic Dimensions and Ratings
Unless otherwise stated, rating, characteristics, test and test procedures, etc. of
the equipments of excitation system and DVR shall comply with the provisions
and requirements of the latest applicable International / Indian Standards.
d. Performance Criteria & Guarantee
The equipment covered under this contract shall be capable of performing all
intended duties and it is the responsibility of contractor to supply the
equipments as per guaranteed technical particulars.
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e. Design and Construction
General
The equipment offered shall be capable of withstanding lightning and switching
surges and dynamic over voltages to which they may be subjected to and shall
meet all the performance requirements and tests as described in the
specification. The equipment shall conform to the latest issue of IEEE 421 or
equivalent standard.
f. Excitation Transformer
The excitation transformer shall be of the 3-phase, cast-resin dry type, class H
insulated. The winding material of transformer shall be copper .The L.V. and
H.V. windings shall be impregnated and vacuum cast into moulds of glass fibre
reinforced epoxy resin. The windings shall be provided with temperature
sensors (PT 100) and static alarm and tripping device. The transformer shall be
naturally air cooled, installed in a cage, designed and constructed to match
perfectly with the common switchgear assembly. The L.V. connections to the
rectifier cubicle shall be of copper buses and/or cables respectively and shall
be in the scope of the contractor.
f.1 Characteristics of Excitation transformer
Ratings of the excitation transformers shall be sufficient to meet the duties
specified herein.
Primary rated voltage 11 kV
Secondary rated voltage To be decided by generator and Excitation
equipment manufacturer
Class of insulation H
Type of cooling AN
BIL (High tension) 75 kV
Power frequency withstand voltage 28 kV
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The manufacturer shall supply a metal box, which will enclose the transformer
high voltage bushings and terminate the isolated phase bus feeding the
transformer. The flexible connectors from the isolated phase bus to the
transformer bushing shall be arranged by bus-duct manufacturer. The
manufacturer shall provide a flange for bolting the phase bus enclosure to the
metal box. To maintain the generator isolated phase bus arrangement, metallic
barriers of suitable design to prevent short circuit between phases shall be
installed between phases inside the transformer.
g. Thyristor Equipment
This equipment shall essentially consist of silicon power thyristor bridges
installed in adequate cubicles. Each thyristor with relevant fast acting semi-
conducting fuses shall be mounted on draw-out modules facilitating inspection
and replacement. The fuses shall be monitored individually or in groups
providing alarms and trips as required.
The design shall provide 100% redundancy in (n+n) layout arrangement of
bridges where n is no. of bridges in one circuit. The rectifier shall be rated for
the following duty cycles:
Continuous operation at its maximum rating.
Three phase fault adjacent to HV terminals of the generator
Short circuit on the high voltage side of the transformer with
duration of 2 sec.
The static excitation equipment shall be of modular design in such a way that it
can be readily removed for inspection or replacements of parts.
Two independent circuits shall be provided for the manual and automatic
control respectively.
The following monitoring and protection features shall be included:
Temperature monitoring of thyristors
thyristor failure
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D.C. short circuits
Thyristor and field circuit over voltage protection
Transient over voltage originating from the A.C. system, lightning or
switching surges.
The system shall operate correctly with supply voltages up to 120%
rated voltage or unbalanced supply voltages.
If forced cooling of the thyristor cubicle will be required, the ventilation system
shall be automatically controlled and supervised with 100 % stand-by capacity
of ventilation fans. Design shall be such, that failure of the cooling system does
not require a unit shut-down. The cubicles shall be closed, so that no dust can
enter into the inner part of it.
Calculation for the capacity of rectifier shall be submitted. While determining
the capacity, effect of ageing shall also be considered .The rectifier PIV (Peak
Inverse Voltage) rating shall not be less than 4 times the maximum RMS
voltage of the inputs.
The kVA rating and voltage ratio of the field flashing transformer (forming part
of supply) and requirement of DC for field flashing shall be indicated in the
tender along with other details.
h. Digital Voltage Regulator (DVR)
The DVR shall be a digital (numerical) type regulator. The digital voltage
regulator shall respond continuously and practically instantaneously to correct
any change in generator voltage. It shall maintain the generator voltage for
steady- state load conditions, without hunting, with 0.5% accuracy for any
excitation within the operating range of the generator. For steady-state
conditions with the generator circuit breaker open, the regulator shall maintain
the generator terminal voltage at or below 105% of its rated for speeds ranging
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from rated speed up to an over speed of 120% rated speed. An exciter limiting
control shall be provided to limit the generator voltage to max. 125% of rated
voltage in the event that the digital voltage regulator is tripped coincidentally
with 110%load rejection and the generator speed rising to runaway speed. The
voltage regulator shall be provided with over- and under- excitation limiters.
The intervention of the limiters shall not cause perceptible
deviations or oscillations of the generated active and reactive power. The
characteristics of the under-excitation-limiting curve shall match the static and
dynamic stability curves of the generator. Such devices shall allow the regulator
to reduce the exciter voltage to zero or to negative values in order to prevent
over- voltages in case of operation under line reactive load conditions and over
speeding of the unit.
The following features shall be included:
stator current limiter
field current limiter
load angle limiter
The field current limiter shall act on DVR with a time delay so as not to disturb
transient response of the system during voltage dips/faults. A slip stabilizer unit
shall be provided to suppress the low frequency power oscillation during the
operative conditions. All corresponding protective devices shall be provided,
including a generator field earth-fault detector. The voltage regulator shall be
equipped with a sensitivity-adjusting device and with an adjustable voltage
droop compensation (compounding).
After the generator voltage attaining initial maximum value neglecting the
instantaneous rises following any load rejection up to 110% of the rated load,
DVR shall restore the generator terminal voltage to a value not more than 5%
above or below the voltage being held before load rejection and shall maintain
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the voltage within these limits throughout the period of the generator over
speed.
The excitation system shall be capable of operation on joint control maintaining
even distribution of the reactive load between machines. Reactive power joint
control function devices to ensure satisfactory load sharing during parallel
operation of the generators shall be integrated in the station control computer.
Paralleling of generators shall be achieved on 220 kV side of Generator
transformers. The voltage regulating system shall include device for improving
the damping of active electromechanical oscillations. These devices shall
operate to supplement the voltage regulating action by addition of an additional
control signal into the excitation system input. This supplemental input signal
shall influence the excitation system as to cause a change in field current of the
machine for stabilized operation. As an option, adaptive control function feature
to the slip stabilizer shall be offered. The function of the control is to optimize
the setting of the slip stabilizer to suit the different configuration system. The
setting of device shall be determined by the contractor.
The excitation system shall be designed for manual and automatic operation.
The change-over from automatic to manual control shall be performed
automatically following a failure of the regulator when operating on automatic
control. The generator voltage shall be controlled within a range of +10% and
15% of rated voltage. A static follower shall be provided so that, in the case of
change-over from automatic to manual control, it prevents the excitation current
from deviating more than 5% of no-load excitation current under steady
conditions. An alarm and visual indication shall be provided to indicate change
from AUTO to MANUAL. The automatic and manual control circuits shall be
fully independent. Local and remote control shall be possible.
The voltage setting device shall be of the solid-state digital type providing a
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range of +10% and 15% for local and remote control and indication. For
testing purposes, settings of 0 to 115% shall be adjustable at the DVR cubicle.
Initial Excitation System
In order to overcome the deficiency of remnant magnetism when starting the
machine, initial excitation shall be applied to the field winding. The respective
power shall be derived from the A.C. supply system via transformer and
rectifier. All equipment for automatic field flashing, i.e. circuit-breakers, blocking
diodes, control devices, protection, etc. shall be included. Provision shall also
be made for field flashing through station batteries as stand-by arrangement.
The field flashing circuits shall get disconnected when 70 % of the rated voltage
is achieved at the generator terminals and normal excitation circuit takes over.
This system shall also cope with the requirements of the excitation necessary
for test runs.
i. De-Excitation System
To achieve a quick suppression of the generator field and thus the voltage, the
field winding shall be shunted by a discharge resistor (voltage dependent type).
After tripping the generator circuit breaker the DC field breaker shall connect
the discharge resistor and simultaneously the polarity of the excitation shall be
reversed.
j. Control Cubicle
The control cubicles shall comprise all control and supervisory devices required
for the operation of the entire excitation system and DVR. The minimum
requirements for instrumentation are the following:
A.C. supply voltage
D.C. supply current
D.C. field current
Set-point indicator for DVR control
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k. Interface with Unit and Station Control Equipment
A bus oriented control system will be provided. The digital voltage regulating
and excitation control equipment shall be capable to communicate via serial
interface and the field bus with the unit control boards. All signal interchange
shall be realized through the bus.
l. Cubicles
All the equipment of static excitation and DVR shall be suitably housed in sheet
metal, dust proof cubicles. All these cubicles shall be located at one place in a
row without any gap in between. The dimensions of the cubicles shall be
identical to present a neat and functional line up.
m. Protection of Static Excitation Equipment
The excitation equipment shall be protected against internal faults, failure of
thyristor bridges, cooling fans etc. for which contacts shall be provided for alarm
and shut down of the unit .The items of protection covered shall be the
following but not limited to:
Excitation equipment internal faults
Current asymmetry protection more than two stacks faulty
Over voltage protection for detection of sustained field over voltage
Over current protection for overload and short circuit protection of the
excitation transformer and rectifiers
Cooling fan failure (main and reserve)
Loss of regulator DC power
Failure of thyristor firing circuit
Failure of DVRs
Individual cooling fan failure
Rectifier cubicle exit air high temperature
Current asymmetry, one thyristor stack faulty
Operation at minimum excitation limit
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Operation at maximum excitation limit
Excitation transformer winding temperature
Failure of field flashing circuit equipment
Prevent over fluxing of the transformer
n. Excitation Connections
Excitation power cable connections between the generator slip rings and the
DC field breaker cubicles shall be provided. The power cables shall be of
adequate copper cross-section to continuously carry the rated current of the
excitation system and the maximum current for 10 seconds. They shall be made
of highly flexible conductors and the cable insulation shall be of the heat-
resistant type, taking into account the maximum temperature rise of 65C at
40C ambient temperature in the slip-ring compartment. The cables shall be
adequately spaced and supported with consideration to the electro-mechanical
forces involved and designed to prevent undue heating during continuous
operation.
o. Other items
Bus duct - Generator CT, PT, LA & surge panel shall be provided as described
in respective chapters (refer vol. IV)
06.04.03.05 Cooling Water System
Six new sets of cooling water system(one set for each unit) shall be envisaged
(except embedded pipelines). One cooling water pump for each unit and one
standby common for all six units. The source of the cooling water is tail race .
The existing embedded cooling water pipelines shall be chemically cleaned.
Isolation valve, strainer/ filter in suction line of each set of pump set shall be
provided. Non return valve, strainers, differential pressure gauge across the
strainer, pressure gauge, motorized valves etc. shall be provided in discharge
line of individual pump sets.
The discharge of all pumps shall be connected through a common header and
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an isolation valve shall be provided between two consecutive units. Through
the common header cooling water is fed to individual unit such as generator air
cooler, generator thrust bearing cooler, upper guide bearing, lower guide
bearing, turbine guide bearing, provision for shaft seal cooling, transformer oil
coolers, Air conditioning system etc.
Suitable capacity of pump, size of valves, pipeline, instruments etc. shall be
designed to meet the above water requirement. After cooling, return cooling
water shall be directly discharged through a common header into tail race.
Control panel for cooling water system shall be provided for each unit.
Automatic as well as manual control of cooling water main pump and common
standby pump, vacuum pump and motorized valve shall be provided.
06.04.03.06.a Dewatering System
Water from draft tube (during maintenance), scroll case (during maintenance) are
collected in to the dewatering pit located at an elevation of 155.90m. Dewatering
pit is common for all six units. From the dewatering pit water is dewatered and
transferred to tail race by dewatering pump.
Two nos.(1W+1S) new submersible pumps sets of suitable capacity with pipes,
valves, instruments, electric motor drive with accessories etc. for dewatering the
water from dewatering pit shall be provided. The capacity of pump is such that it
is capable to dewater the dewatering pit within 6 hours operation without raising
the level in the sump as per standard norms for maintenance. Sump water level
controllers with float/level switches shall be provided for start up of both the
pumps and for stopping them at appropriate preset levels.
Draft tube dewatering valve of suitable size and associated piping for each unit
shall also be provided. Valve hand wheel shall be located at turbine floor for ease
of operation.
All existing embedded pipelines for above system shall be chemically cleaned. .
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06.04.03.06.b Drainage System
Seepage through concrete into the underwater premises of the powerhouse
and due to leakage of water from the equipment assemblies, SRV etc is
discharged through gravity into the existing drainage gallery at elevation of
158.40m and accumulated in the sump well located at gallery end in the vicinity
of unit no.1
Two nos.(1W+1S) submersible pumps sets of suitable capacity with pipeline
valves, instruments, electric motor drive with accessories etc. for dewatering
the water from drainage pit will be installed/provided. The capacity of pump is
such that it is capable to dewater the drainage pit in shortest possible time.
Dewatered water is transferred to the tail race through these pumps. Sump
water level controllers with float/level switches shall be provided for operational
control of the pumps at appropriate preset levels and alarms for high water
level.
All existing embedded pipelines if any for above system shall be chemically
cleaned.
06.04.03.07 Compressed Air system
Two numbers new High pressure (HP) compressors of Indian make having
capacity & discharge pressure similar to existing HP compressor with control
panels shall be provided for OPU of governor and SRV of all six units.
Complete pipes, valves shall be replaced by new one.
Automatic as well as manual operation control of HP compressors shall be
provided. All necessary instrumentation like pressure gauge and temperature
gauge etc shall be provided. Temperature sensor, pressure switch and auxiliary
relays etc as per requirement shall be provided.
Cooling water, if required, for the proposed HP compressors shall be taken
from the nearest cooling water header.
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Existing LP compressor system for braking system of each unit, station services
such as in transformer deck, mechanical shop, service bay, turbine premises,
apparatus room, machine hall etc shall be reused however complete pipes,
valves, fittings, , instruments etc. shall be replaced by new one. .
Cleaning and painting of HP and LP air receivers shall be done.
For detail of the piping layout/scheme refer dwg. No MEC/10FX/11/S3/M/27
given in volume-V of this tender document.
06.04.03.08 FIRE PROTECTION SYSTEM
Technical Specification for complete fire protection system to be provided for the
6X60MW Balimela Power House complex is given below.
01 INTRODUCTION
In order to combat any occurrence of fire in various areas/units of the
proposed 6X60 MW Balimela power house complex, an elaborate system of
fire protection shall be provided. The system shall be planned in conformity
with Tariff Advisory Committees (TAC) guidelines, BIS and other relevant
standard/codes.
Major facilities envisaged are as following:
i/ Microprocessor based intelligent Fire detection and alarm system
(FDA)
ii/ Fire Hydrant System
iii/ Water spray system comprising of MVWS and HVWS.
iv/ Portable fire extinguishers
02 SCOPE OF WORK AND SERVICES
02.01 The scope of work covers on turnkey basis design & engineering, supply,
erection, painting, testing, commissioning and handing over of complete Fire
Protection System envisaged for the 6X60MW Balimela Power House complex.
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The Tailrace will be the source of water for fire fighting system. Major work
comprises of following :-
a/ Supply and Erection of motor operated main pumps, and Motor
operated jockey pumps including all associated electrics & Control
b/ Fire Hydrant system consisting of internal as well as external hydrants for
the entire area.
c/ High velocity water spray system(HVWS) for generator transformers and
Medium velocity water spray system (MVWS) for cable rooms/
tunnels/galleries in turbine /generator complex. HVWS system shall be
provided for Generator also.
d Portable fire Extinguishers shall be provided in all control rooms and
other services rooms.
e/ Microprocessor based intelligent Fire detection and Alarm system for
various plant premises.
f/ Piping, valves, sluice gates etc.
g/ All civil & structural works
h/ All electrics.
i/ Controls and instrumentation.
j/ Shop and site painting for all equipment, pipes etc.
k/ Erection, testing, commissioning, PG test and Warranty for the
complete fire protection system
l/ All the requirements of TAC for complete Fire Protection System shall
be incorporated by the tenderer in their scope irrespective of whether
the details are described in specification and/or shown in the drawings
or not.
03 TECHNICAL SPECIFICATION
03.01 Fire Detection & Alarm system :
Fire Detection and Alarm System (FDA) will be intelligent addressable
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microprocessor based automatic system. The Intelligent Addressable
Microprocessor based Automatic Fire Detection and Alarm system will be
software controlled automatic system and will provide necessary programmed
activities and various controls. The system shall consist of central processing
units, man machine interface, communication system, microprocessor based fire
alarm control panels, TFT monitor, printer Addressable Intelligent Automatic
sensors and Interface unit as applicable.
Fire alarm control panel shall function as communication interface between
Central Processing Unit and sensors and controlled devices. Addressable
Intelligent type microprocessor based Detectors / Manual Pull Stations and
required field devices in the various areas shall be connected to fire alarm control
panels by class A wiring to the loop module.
In all the electrical premises Intelligent addressable type microprocessor
based photo- electric detector in double configuration / rate of rise-cum-
fixed type heat detectors shall be provided as applicable. Siren/hooter shall be
mounted on suitable support.
There will be interlocks to shut off the exhaust fans and simultaneous tripping of
A/C and ventilation system.
03.01.01 Scope of work
The scope of work includes design, engineering, supply, erection, testing,
commissioning, performance tests and handing over of intelligent addressable type
Fire Detection and Alarm system for various premises of the project as mentioned
in Table-1.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 84 of 106
TABLE-I
LIST OF ELECTRICAL ROOMS
Sl.
No.
Description False ceiling Type of System
1. 11kV and LT aux
room, Reactor/
LAVT room, Cable
Gallery, m/c hall
No Addressable Automatic Fire
Detection and Alarm ( FDA)
system and Passive Fire
Protection including fire
extinguisher
2. Control Rooms,
Protection Room
Yes FDA system and Automatic
Clean Agent Total Flooding
System.
Inergen/Argonite
3. UAT No Fire Extinguisher
4. Battery & Battery
charger room
No FDA system including Fire
Extinguisher
5. office room yes FDA system with Fire
Extinguisher
6. AC & Ventilation
room
No FDA system with Fire
Extinguisher
7. All other areas
including above
areas
No Fire Extinguishers
03.02 Fire hydrant system
Existing pump house which shall house pumps to meet fire hydrant as well as
for water spray system requirement. There will be common headers for both
systems.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
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TS VOL III Sec .A Ch-06 Page 85 of 106
The capacity & discharge pressure of the hydrant pumps shall be adequate
to meet the total system requirement. No. of pumps for hydrant system shall
be in line with the existing system.
For water spray system, the same hydrant pump will serve the purpose and
the same stand by pump along with 2 nos. of Jockey pumps of 10 m
3
/ hr shall
be considered.
03.03 Water spray system comprising of HVWS and MVWS
For protection of Cable rooms/ tunnels/galleries etc. from fire, Medium
Velocity Water Spray (MVWS) sysytem shall be provided. For protection of
generator transformers, station transformer (20MVA, 220/11KV) located in
switchyard High Velocity Water Spray (HVWS) system shall be provided. The
system shall be designed as per TAC, BIS and NFPA guidelines. For
protection of Generators from fire High Velocity Water Spray (HVWS) system
shall be provided.
Description of the System
HVWS & MVWS envisaged is a special fixed pipe system connected to a reliable
supply of adequate quantity of water and equipped with spray nozzles
(projectors) for specific water discharge and impingement over the surface or
area to be protected. The piping system is to be connected to the water supply
through an automatically actuated valve (deluge valve) which can initiate flow of
water. Deluge valves for the spray system are to be actuated by an automatic
detection system which in the case of transformers consists of quartzoid bulb
detectors mounted around the protected area and for cable galleries these are
part of fire detection & alarm system.
Operation of the System
Initially, delivery line should be pressurised upto deluge valve with the help of
electrically driven Main Pump/Jockey pump and the water line pressure upto
deluge valve should be maintained at around 7 kg/cm
2
. The Q.B. detector line
should be pressurised to a pressure of 4 kg/cm
2
with help of water which should
be tapped from the header itself. Deluge valve clack is kept in horizontal position
in normal condition due to balanced hydraulic pressure on two sides of the clack.
In case of transformer fire, temperature will rise all around the transformer. On
reaching a predetermined temperature (generally 30
o
C above ambient
temperature) quartozoid bulb detectors, which are installed on pressurised water
line (water for which is tapped from the main header itself), will shatter. As the
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 86 of 106
bulb shatters, water in the detector line gets released through the detector
openings and water pressure in detection line drops rapidly. This results in
creation of pressure differential in the deluge valve and leads to latters actuation.
During this operation pressure in the water delivery line falls rapidly resulting in
start up of main electrical driven pump. In case of power failure, pressure in the
header shall go on decreasing causing start up of diesel engine driven pump.
In case of cable galleries the actuation of deluge valves are effected by signal
from fire detection and alarm system provided in the premises. Cable galleries
shall be provided with smoke detectors, photoelectric and ionization type
alternately. These have been described in detail in FDA specification. In the
event of fire in the premises, the detection system shall give signal to Main Fire
Alarm Panel (MFAP) which in turn shall actuate the solenoid of the deluge valve
concerned. There shall be provision for manual operation of the system also by
operating quick opening valves of each deluge valve.
Main components of the system
The HVWS/MVWS System shall be provided with the following major
components:
a/ Water Supply at high Pressure
b/ Arrangement of Spray Nozzles
c/ Arrangement of Quartzoid Bulb Detectors (for HVWS)
d/ Deluge Valve
e/ Y-type Strainers just before deluge valve
f/ Pipes, fittings and fixtures
g/ Basket strainers in HVWS system header
i/ Pressure gauges, pressure switches and solenoid valves
j/ Fire detectors
Design Criteria
Following salient parameters shall be followed for the design of the system.
i/ Water application rate for HVWS - 10.2 lpm/m
2
of the surface area of the
entire transformer including bottom surface, radiators etc. For MVWS in
cable galleries , 6.1 lpm/m
2
on each tray. The working pump capacity shall
be decided based on the water requirement (whichever is higher) and
selection of pump shall be from TAC approved pump capacities. The
capacity of water reservoir shall be equal to at least one hour pumping.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 87 of 106
ii/ The system shall be so hydraulically designed that the pressure at the
hydraulically most remote projector in the network shall not be less than
3.5 bars for outdoor transformer and 2.8 bar for indoor installations. For
cable galleries also Pressure at remotest sprayer - not less than 2.8
bars.
iii/ Velocity in the feed pipe shall not be more than 10 m/s.
iv/ The header shall be laid under ground and tappings for the individual
deluge valve shall be taken there from.
v/ Q.B. detectors shall be installed in two rings one at top and another at
bottom around the protected area. Maximum spacing between detectors
shall be 2.5 m.
vi/ Projectors (for transformers) shall be installed in rings encircling the
protected area. One ring shall be provided at the top and subsequently
rings for every 3 m from top to bottom shall be provided.
vii/ There shall be common header for HVWS and MVWS systems which
shall be fed water from the pump dedicated for the spray system. The
hydrant header and spray system (HVWS & MVWS) headers shall be
inter-connected with a non-return valve in between so that hydrant
system can be a back-up for the spray system.
viii/ In cable galleries, the protected area shall be divided into several zones,
each of which shall be fed by individual deluge valve. In event of fire
water shall be sprayed on the zone concerned (i.e. zone under fire)
along with preceding and succeeding zones. Zone lengths for cable
galleries shall be 30 m .
ix/ Distribution of sprayers in cable galleries : The sprayers shall be installed
in rows at the central aisle between the cable trays and spaced at not
more than 3 m from each other.
03.04 Portable fire extinguishers
Different types of portable fire extinguishers will be deployed in various area
of the complex as a measure of first-aid fire fighting.
Major units of Balimela power complex where extinguishers are to be deployed
are enumerated below:
Turbine/generator complex
ODISHA HYDRO POWER CORPORATION LIMITED
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UNITS 1 TO 6 ( 6 X 60MW)
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TS VOL III Sec .A Ch-06 Page 88 of 106
Fire water Pump house
Unit control roomMain control room
Protection room
All other services rooms /units not listed above
Portable extinguishers will be conforming to IS 15683-2006 code.
06.04.03.09 Oil Handling facilities
Power plant oil handling facilities comprise of four storage tanks of 20KL
capacity each for turbine oil and four storage tanks of 20KL capacity each for
transformer oil, oil purification units, gear type pumps and pipelines. Oil storage
tanks are located at elevation of 160.055m in a special premise on the
upstream side in the SRV floor.
Existing gear type pump motor sets shall be replaced with new of same rating.
In addition, one new gear type pump motor set shall be provided as standby for
turbine oil handling and one transformer oil handling oil facility separately. All
storage tanks shall be cleaned and painted. Pipes, valves, instruments shall be
replaced. Local control panels, cables etc shall be replaced.
06.04.03.10 Vacuum Pumps
Existing 04 nos. vacuum pump motor set located at EL 162.875m floor for
priming of cooling water pumps of unit 1 to 6 and drinking water pumps shall be
replaced with new. All existing pipes, valves, instruments, etc. shall be
replaced.
Control of vacuum pump shall be provided in local control panels of cooling
water system.
06.04.03.11 Drinking water system
Existing drinking water system consist of following
Sl. No. System Location
1 1
st
stage drinking water pumps at EL 158.425 towards
ODISHA HYDRO POWER CORPORATION LIMITED
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UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
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TS VOL III Sec .A Ch-06 Page 89 of 106
(1working + 1 standby) service bay side
2 water treatment plant (consists of 4
vessels with filtering elements,
pipelines and stop valves)
At EL 162.875 towards
Service bay Side
3 2
nd
stage drinking water pumps
(1working + 1 standby), bactrocidal
plant ,
At EL 162.875 towards
Service bay Side
4 Air-water vessel at EL.167.85 towards service
bay side
First stage pump takes suction from fire fighting suction header and feeding
water into pressure filters. After filtration, clean water is tapped for turbine shaft
seal, and second stage pump suction through bactrocidal plant. After second
stage pumping water is fed into air water vessel and drinking purpose. For
back flushing of pressure filter clean water is drawn from air water vessel. If
required priming of the first stage pumps shall be done by vacuum pump for
initial start-up.
Existing pump motor sets of 1
st
stage and 2
nd
stage shall be replaced with new
pump motor sets of adequate capacity. All valves, pipes, instrumentation,
pressure filters, etc shall be replaced with new. Pressure filters shall be
designed in such a way that after filtration water quality shall meet the shaft
seal water quality. For designing of pressure filters suitable IS code
(Specification for filters for drinking water purposes) shall be followed. New
bactrocidal plant shall be provided. For designing of bactrocidal plant BIS
10500 or equivalent national /international standard shall be followed. Air water
vessel shall be overhauled including painting. Embedded pipelines if any shall
be chemically cleaned.
The capacity of the drinking water system shall be adequate to meet all the
requirement of the plant.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 90 of 106
06.04.03.12 Air-conditioning & Ventilation
01. Applicable Codes & Standards
The execution of the work covered under this specification should conform to
the latest Indian Standards specification where the same are available, or the
reputed standards acceptable to the Purchaser. In case such specifications
are not available, the work shall be according to good engineering Practice &
norms acceptable to Purchaser.
The following reputed/ accepted publications, norms/ guidelines, standards,
acts & rules etc. shall be followed for execution of the works:-
a) B.I.S Publications
b) Indian Electricity Rules & statutory requirements of Central Govt. and
State Govt. and Inter Plant Steel Standard, IPSS.
c) ISHRAE handbook
d) ARI publication
e) I.S.O Publications
f) ASME codes for unfired pressure vessels
g) VDI stipulation for vibration level
h) AMCA standard for fan balancing
i) Occupational safety and health act (USA)
In the cases where norms/ standards/ guidelines other than those listed
above are followed, the Tenderer shall furnish a copy of such document (s) in
support for the Purchaser's perusal and acceptance. Wherever a
contradiction is found between different documents being followed, the
decision of the Purchaser shall be final and binding
02. Design Criteria
02.01 General Criteria
The selection/ design and manufacture of plant and equipment shall be
suitable for the intended service and the atmospheric/environmental
conditions prevailing at the plant site.
Design and selection of equipment shall be made with the following also in
view:
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 91 of 106
a) Safety of personnel
b) Uninterrupted operation
c) Long life of equipment
d) Easy maintenance at low cost
e) Lowest operating cost
f) Spares availability
Every endeavor shall be made to achieve standardisation and unification in
designing components and sub assemblies.
All working parts shall be arranged / located for convenience of operation,
inspection, lubrication, ease of repair, replacement and maintenance of parts
and sub-assemblies with minimum downtime, without dismantling other
equipment/ components/structures. Components shall be designed to meet
the specified mechanical properties like hardness, strength, rigidity, wear
resistance, heat resistance, resistance to vibration, etc. Equipment shall be
provided with lifting attachments (wherever applicable) like lugs, bolts etc. to
facilitate handling and lifting during erection and maintenance.
The equipment shall be suitable to operate satisfactorily under variations of
load, pressure and climatic conditions as may occur during working. All
equipment shall be of acceptable modern design and free from all inherent
defects. All the rotating parts shall be statically and dynamically balanced. All
materials used shall be free from surface defects, rusts, cracks and
deformations. The finish of the equipment and its components shall be of first
class quality. To the extent possible, models and sizes of equipment shall be
identical to ensure minimum inventory and interchange ability of parts,
equipment and systems.
While designing the layout of the equipment and system, the following points
shall be covered / considered:
- Co-ordinates and location of the building.
- Equipment, piping and ducting layout with description.
- Maintenance access and neatness of layout.
- Interferences.
- Equipment handling and removal facility
- Floor drain, cable trenches and conduits.
- Battery limit with elevation of utility services.
- MCC, IPBS, DB etc. location.
While designing the equipment and systems, the following maintenance
aspects shall be taken into consideration: -
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 92 of 106
- Sufficient space for maintenance in the layout.
- Access to the equipment.
- Inspection and maintenance doors for equipment.
Air Conditioning & Ventilation systems shall be designed to operate
continuously round the clock, twenty four (24) hours a day for all seasons of
the year while maintaining the guaranteed indoor conditions. All air
conditioning and ventilation systems shall be designed in a such a way that
the noise level of equipment shall not exceed 85 dB(A) at 1m distance. The
noise level shall be limited to 65dBA in the air conditioned premises.
Air Conditioning (General)
The following air velocities shall be considered for the air conditioning
systems. However, standard sizes of equipment, ducts and accessories shall
be adopted satisfying the following limiting conditions:-
i) Fresh/Make up Air filter : 1.5 2.0 m/s
ii) Fine filter : 1.0 1.5 m/s
iv) Main ducts : 6 m/s
v) Branch ducts : 4 - 5 m/s
vi) Supply air diffuser : 1.5 2.5 m/s
vii) Return air grill : 1.5 2.5 m/s
Outside exposed supply/return air duct and indoor tail air end duct above
false ceiling shall be thermally insulated to avoid heating up of cold air duct
and condensation. Supply air diffusers shall be provided at the supply air duct
inside the served premises not exceeding 3 ~ 4m centre to centre distance.
Ventilation system (General)
The following air velocities shall be considered for the ventilation systems.
However, standard sizes of equipment, ducts and accessories shall be
adopted satisfying the following limiting conditions:
i) Dry panel filter : 1.5-2 m/s
iii) Centrifugal fan
a) Inlet : 7-10 m/s
b) Discharge : 10-12 m/s
iv) Main ducts : 8-10 m/s
v) Branch ducts : 6 - 8 m/s
vi) Supply air grills : 2 - 4 m/s
vii) Self acting damper : 2 - 3 m/s
ODISHA HYDRO POWER CORPORATION LIMITED
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UNITS 1 TO 6 ( 6 X 60MW)
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 93 of 106
vii) Air intake louver : 2.0 m/s (max)
Supply air grills shall be provided at the supply air duct inside the served
premises @ 3 - 5m centre to centre distance.
02.02 Outside design ambient conditions
The equipment shall be designed on the basis of climatological data
prevailing at Balimela. The following ambient air parameters shall be
assumed for designing the air conditioning & ventilation systems:
Summer
(min/max)
Monsoon
(min/max)
Winter
(min/max)
Air conditioning
Dry Bulb Temperature (
0
C) : 26.8/30.3 22.2/22.8 16.9/20.9
Relative Humidity, % : 48/60 84/87 56/71
02.03 Inside design conditions to be maintained in the premises
The control rooms shall be maintained at inside conditions of 23 2
0
C and
55 5% RH throughout the year using Water cooled package air
conditioners. The systems shall be designed considering the 24 hour
continuous operation in an industrial environment. Accordingly the Packaged
A/C units shall be suitable for 24hrs continuous duty condition.
02.04 Other design data
02.04.1 List of premises & type of air conditioning system envisaged
The following areas of the Power House units 1 to 6 shall be air conditioned.
Sl.
No.
Name of
Premise/Location
Heat
Load
data
Type of Air conditioning
System
Control Room 12 m X
7.4 m X 5.5 m
5.5KW Water cooled package AC
with 100% standby shall be
provided in the adjacent
A/C Plant room
Protection Room 12 m X
7.4 m X 5.5 m
Water cooled Package A/C with 100% standby capacity shall be provided for
the cooling requirements of the control room and protection room. The
proposed air conditioned equipment shall comprise water cooled packaged
air conditioned units. 100% stand by packaged Unit, Condenser water pump
shall be provided.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 94 of 106
02.04.2 List of premises & type of ventilation system envisaged
The following areas of the Power House units 1 to 6 shall be ventilated.
Sl.
No.
Name of
Premise /
Location
Type of
Ventilation
System
Remarks
i. Cable Cellar
Room
Dry pressurized
ventilation system
1) Ventilation system shall
be overhauled including
total servicing of
ventilation fans,
replacement of dry
filters along with filter
frame.
2) All the ventilation ducts/
grills, damper etc. to be
newly provided.
3) Interlock of ventilation
system with fire
protection system
including fire damper to
be considered
ii. MCC Room, 11
KV switchgear
room
Dry pressurized
ventilation system
iii. Generator &
Turbine Floor etc.
Dry pressurized
ventilation system
03 Description of Air Conditioning & Ventilation System (ACVS)
03.01 Description of Air Conditioning System
Air-conditioning system for main control room shall consist of self contained
water cooled package type air conditioners with 100% standby, , ducting,
cabling, piping, MCC, PDB, etc to cater to the cooling load requirement of the
premises being served.
Cooling water for package AC shall be taken from the nearest cooling water
header.
Cold and treated air from package A/C unit shall be collected at the common
plenum chamber and shall be circulated into the control room through
insulated GI duct, grills, diffuser, etc. Pan type humidifier and electric strip
heaters shall be installed in the Package AC room for temperature and
humidity control throughout the year. One dedicated MCC shall be installed to
control and regulate the PAC unit fan, humidifier, strip heater and other
instruments.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 95 of 106
Spring loaded fusible link fire damper shall be in the main supply air duct at
the outlet of package A/C unit. The fusible link shall snap automatically as
soon as air temperature exceeds 70
0
C. Interlock with fire damper thorough
limit switch shall be provided for PAC units. Fire alarm panel contact provided
in the control room shall be brought up to the MCC of the AC system to cut off
the air supply in case fire signal is activated. All necessary cabling &
hardware shall be incorporated into the Electrics of the AC system.
The A/C room shall have fixed type fresh air intake louver to allow one fresh
air change per hour in the A/C premises. The louver shall be fabricated from
1.6 mm thick CRCA sheet steel and shall be painted with two coats of red
oxide primer and two coats of finished paint matching to the interior dcor.
Manually operated adjustable dampers shall be provided at each branching
point and at each supply air grill. Supply air duct shall be connected to the
PAC through flexible canvas duct via isolation damper.
The AC machine shall be interlocked with fire protection system i.e. if fire
takes place in air conditioned room then fire sensor should give signal for
tripping the AC machine.
03.01.01 Specification of Packaged Air Conditioner
The equipment shall be designed, manufactured and tested as per IS 8148:
2003. The packaged unit shall comprise scroll compressor, cooling coil,
refrigerant circuit, condenser, blower, air filters, electric drives and controls,
instruments and other necessary standard accessories assembled in
packaged form in a steel cabinet. All electrical connections shall be built in.
The compressor shall be hermetically sealed, mounted on anti-vibration pads &
dynamically balanced. Compressor shall be suitable for round the clock duty
condition.
The condenser shall be water cooled, shell and tube type with effective surface
area for heat transfer taking into consideration the scale factor for water side and
optimum number of passes to achieve desired duty conditions in water cooled
package AC unit. Provision shall be made in the steel cabinet for tube side
cleaning during maintenance. The condenser shall also serve as refrigerant
receiver of refrigerant circuit with fusible relief plug.
Cooling coil shall be direct expansion type with integrally finned copper tubes and
fitted with equalizing distributors to ensure equal amount of refrigerant in each
circuit. Condensate drip pan shall be provided below the cooling coil for collecting
ODISHA HYDRO POWER CORPORATION LIMITED
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UNITS 1 TO 6 ( 6 X 60MW)
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TS VOL III Sec .A Ch-06 Page 96 of 106
the condensate.
The refrigerant circuit shall be completely piped at factory and charged with
required amount of refrigerant. The circuit shall comprise of thermostatic
expansion valve, distributor, liquid strainer, liquid line shut off valve, pump down
valves, dehydrator etc. The circuit shall be protected with safety devices such as
high and low pressure cutouts, fusible plug, water flow / differential pressure
switch, oil safety switch, time delay relay etc. to protect the unit from damage due
to sudden and serious fluctuations in operating conditions. The refrigerant shall
be R22 / any other environmental friendly refrigerant.
For control of temperature and dehumidification of the conditioned premises,
thermostat and humidistat shall be provided in the package A/C plant room.
The centrifugal blower shall be designed for distribution of the conditioned air
through the network of duct and supply air diffusers. The impeller shall be of
forward curved, dynamically balanced for low noise and vibration free operation.
The fan shall be coupled with motor by V-belt and mounted on anti vibration
mounting. Fan shall be of low speed and capable of providing an external static
pressure of 25mmWC.
Control & Instruments:
The necessary control and instruments include thermostatic expansion valve,
sight glass, strainer, cooling thermostat, heating thermostat, humidistat, strip
heater, shut off purge valve and drain valve, DP switches at suction & delivery
sides of compressor, dial type pressure and temperature gauges etc. Cooling
thermostat and humidistat shall be provided in the return air circuit (in A/C plant
room).
The dial type 150 mm dia pressure gauge shall be provided with isolating cocks/
valves. Flow switch shall be installed in condenser water inlet line to stop the
compressor while water supply stops. Strip heater shall be installed in the supply
air duct at the discharge end of packaged unit and the strip heater shall be
interlocked with the blower of the packaged unit to prevent independent control /
switching of heaters as required.
The blower and the evaporative coil sections of the packaged unit shall be
thermally insulated to minimize thermal leakage.
The unit shall be supplied with vibration isolating pads for installation on PCC
pedestals.
Circulating condenser water cooling pipeline shall be provided with strainer and
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TS VOL III Sec .A Ch-06 Page 97 of 106
by pass line. Minimum efficiency of pre filter unit in package AC shall be 80%
down to 10 micron.
The air conditioning system shall be fitted with the following control equipment
/ instruments:
a) HP & LP cut out together with HP & LP indicators in the refrigerant
circuit.
b) Ammeter & Voltmeter at the incoming feeder of MCC and Ammeter
with indication lamps in each out going feeder for PAC (compressor
& fan), strip heater, humidifier, pump, etc.
c) Flow switch for condenser water line.
d) Temperature gauge at the inlet & outlet of condenser
e) Pressure gauge at the discharge of pump.
f) Single phasing protection for PAC blower.
03.02 Specification of Equipments and Accessories for AC & Ventilation System
03.02.01 Insulation (AC System)
Insulation - Duct acoustic
Acoustic lining of Duct shall be carried out with 12mm thick Fibre glass rigid
board of density not less than 30 Kg/m3. All ducts up to a distance of 5m from
Packaged unit (including plenum, if applicable) or as required to reduce
noise levels to below 58 dB(A) into the conditioned space, shall be
acoustically lined from inside.
Application
Clean the inner surface of duct that is to be lined, with wire brush to
remove the dirt.
Apply Black Japan paint in the frame of duct.
The adhesive shall be non flammable and having vapour barrier property.
Fix insulation material of 12mm thickness and cover with RP tissue paper
and then cover the material with 26G perforated aluminium sheet having
2mm dia perforation at 3mm centre to centre distance with the help of nuts
and bolts. It shall be neatly finished to give true surface finish.
Insulation - Duct thermal
Thermal insulation of duct shall be carried out with 50mm thk. Aluminium foil
faced fibre glass of density not less than 24 Kg/m3 / 12mm thk. closed cell
ODISHA HYDRO POWER CORPORATION LIMITED
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UNITS 1 TO 6 ( 6 X 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 98 of 106
polyethylene insulation, pre laminated . The thermal conductivity shall not
exceed 0.03 Kcal/hr Sq. m deg C. 75mm wide aluminium tape shall be used
for covering the joints of the foil face of insulation. 24G GI Wire netting
followed by 26G GI cladding shall be used for outside/weather exposed
ductwork.
Application
Clean the surface of duct and apply one coat of Black Japan Paint of
approved make @7Sq.m/Kg.
Apply a thick layer of CPRX compound @1Kg/Sq.m of area.
Fix the insulation material of required thickness before the adhesive dried
up. All longitudinal joints/traverse joints shall have the foil overlap of 50mm
with Aluminium tape of minimum 75mm width.
GI wire netting shall be tied with GI wire.
GI cladding shall be done with boxing around the flanges with 50mm
overlapping & screwed @150mm C/C by self tapping screw with felt gasket
in the joints for stopping moisture ingress into the insulation.
Application
Clean the roof surface, which is to be insulated.
Apply 2 coats of Black Japan Paint on ceiling.
Fix GI frame C section of size 25 x 50 x 25mm, or of equal insulation
thickness as specified, to the ceiling including the soffit of the beam with
screws/bolts.
Apply a coat of adhesive to the underside of the roof.
Insulating material of 50mm thickness shall be fixed in GI frame of 1000
mm x 500mm dimension.
The insulation shall also be carried out to the exposed beams within the
air-conditioned space.
03.02.02 Supply air diffusers (AC system)
Supply air diffusers will be square in shape for air-conditioning application.
The throat of a diffuser will be connected with collar piece provided at the
duct bottom for holding the diffuser as well as for supply of air. No part of
diffuser will project into the main duct. Each diffuser will be provided with
volume control damper. Each diffuser will comprise of fixed plate, damper
blade, damper blade operating knob, spindle, connecting rod, etc and shall be
of removable core type duly powder coated. The diffuser bottom should flush /
match with the false ceiling. False ceiling will not bear the load of any diffuser.
The load of any diffuser will be borne by the duct and collar. Each diffuser will
be painted with appropriate colour to match with the colour of the false ceiling.
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 99 of 106
The diffusers will be true to shape and will be checked with level gauge
before being secured in position. No distortion or warping is permitted.
03.02.03 Return air duct (AC system)
The air supplied in the served premises will return above false ceiling through
the return air slit of 50mm / 75mm (as required) all around false ceiling along
the walls of the served premises. From there it will pass into the PAC room
through a return air duct and damper. Insulated return air duct of suitable size
calculated for the specified range of velocity will be provided for smooth flow
of return air. Return air duct shall be duly insulated & GI cladded, whenever
crossing through unconditioned area.
03.02.04 Strip heater box (AC system)
Strip heater box will comprise of finned heater, mounting plate, heater box/
casing made of 20 SWG G.I. sheet, cable terminal, terminal box with handle,
40x40x3 MS angle flange/ frame. Strip heater box will be placed/ inserted in
supply air duct. Safety thermostat will be mounted on strip heater package to
prevent overheating.
03.02.05 Humidification kit (Pan Humidifier)
The humidification kit will comprise of a pan, immersion heaters (3 Nos.),
immersion heater cover box with handle, 20 NB pipe connection with float
valve for make up water, 20 NB pipe connection for over flow, 25 NB pipe
connection with valve for drain, thermostat, earth stud, etc. Over flow pipe and
drain pipe will be connected together after/ below the valve of drain pipe. The
humidifier will be insulated with 50mm thick mineral wool (T.F. quality). The
humidifier will be kept in the Package AC room and connected to the supply
air path through GI ducting. Safety thermostat will be provided in the pan
humidifier to prevent it from dry heating.
03.02.06 Make up air filter with damper (AC system)
Make up air for packaged air conditioner will be drawn from ambient through
filter and volume control damper, cowl and bird screen.
03.02.07 Flexible connection
Suitable flexible connection of rubberized tarpaulin will be provided at
evaporator / blower discharge line above multi louver damper.
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 100 of 106
03.02.08 Multi louver damper (M.L. Damper)
Multi louver damper (M.L. Damper) will be provided on the package A.C. unit
and below flexible connection in the supply air ducting. The damper blades/
louvers will be provided with external operating links for manual operation of
the damper to control air flow. The fully close/ open/ partial closing position of
the damper will be marked on the damper casing. Frame of the dampers shall
be from 16G and louvers as 18G. Damper blades shall have nylon pivot on
the casing for smooth movement
03.02.09 Fire damper
Fusible relief type fire dampers having 90 mins fire rating as per Ul-555 shall
be provided for all the supply air duct / return air path. The casing thickness
shall be 2mm (min.) and blades of 1.6mm (min.) of MS construction. Limit
switch shall be connected to the fire damper for transmission of damper
closure signal to the fire panel for subsequent switching off the air circulation
device.
03.02.10 Dry Panel Filters (Ventilation system)
Dry panel type air filter shall be of high efficiency cleanable type, constructed
out of HDPE (6 ply) supported by layers of GI wire gauge. It shall be
corrugated to the depth of filter casing in order to increase the ratio of
filtration area to frontal area. It shall be covered by strong GI/MS frame and
have space to ensure uniform distribution of air. Filtering panel shall be of
standard size which can be mounted on angle frame in multiple number as
per capacity of the fan. Face velocity of air shall not exceed 2.0 m/sec. The
resistance of air filter shall not exceed 10 mm WC when dirty. Efficiency of the
filter shall not be less than 90% down to 10 microns. The whole filter and
frame assembly shall be fitted at the inlet side of wall mounted tube axial flow
fan. Fresh air inlet shall also have filters for efficiency 80% down to 20
microns.
03.02.11 Flexible Connection
Suitable flexible connections of tarpaulin shall be provided between adaptor
section and fan inlet as well as between fan outlet damper and ducting.
03.02.12 Supply Air Grills (Ventilation system)
1 mm MS sheet shall be used for manufacturing grills. All grills shall be true to
shape and shall be checked with a level gauge before being secured in
ODISHA HYDRO POWER CORPORATION LIMITED
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R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 101 of 106
position. No distortion or warping is permitted.
All duct mounted grills shall be complete with rubber gaskets and flanged
holding frames of suitable design for the intended installation. They shall be
mounted on collar extending from the duct. No part of grill shall project into
the main duct. The adjustable louver grills shall be provided with volume
control damper as well as double deflection flap/ grill for direction control.
03.02.13 Hand operated damper
The hand operated damper shall be multi leaf opposite acting aerofoil blade
type damper with external operating links provided at the outlet of the fan for
controlling air flow. The damper shall be made of GI sheet with MS frame. The
fully close/ open/ partial closing position shall be marked on the damper
casing. The dampers for centrifugal fans for ventilation system shall be
fabricated from 2.5 mm MS sheet.
03.02.14 Ducting work
All ducting work for air flow from/ to fan shall be fabricated from GI sheet as
per IS 655: 2006. The supply air duct shall be of suitable size, selected for the
specified range of velocity.
All ducting work shall be properly reinforced to prevent sagging, buckling or
vibration. All joints shall be flanged. Flanges made of angle shall be provided
at 2.2m interval.
The interior of all ducts shall be smooth for free flow of air. The radius to bend
shall be preferably 1.5 D. Guide vane shall be provided in all large duct bends
and bends with radius less than 1.5 D for proper air flow.
Access eye for measurement shall be provided in ducting at convenient
locations. Nut, bolts, washers & gaskets required for duct-work and duct fitting
shall be supplied.
All Exposed ducts shall be thermally insulated.
03.02.15 Hangers & Supports for Ducting
All duct work shall be provided with adequate supports as required to ensure
rigid support and to prevent vibration.
The fixing and supports interval shall not exceed 2.5 meters. Hanger rods
ODISHA HYDRO POWER CORPORATION LIMITED
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R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec .A Ch-06 Page 102 of 106
having U-bend at top end and threading at bottom end shall be hanged/
attached to the ceiling by anchor fasteners/ expansion bolts. Hangers shall be
trapeze type constructed from angle iron (as per size of duct) and hung from
steel rods of adequate size. Ducts supported on wall and building structures
shall be suitably fixed with angle, rod and flat etc. Anchor fastener of minimum
10mm size to be used for fixing duct supports.
03.02.16 Water piping network
Heavy class MS ERW piping is to be used as per IS 1239: part-1, 2004 & IS
3589: 2001 (RA 2006) depending on the sizes for interconnecting water
piping network.
Thermometer and Pressure Gauge
Dial type (150 mm) mercury in steel thermometer shall be provided for
measuring the water temperature at inlet & outlet of condenser. The range of
thermometer shall be 0-100
deg. C. Dial type (150 mm) pressure gauges shall
be provided at inlet as well at outlet of condenser water lines.
Valves
Suitable no. of valves shall be provided in the condenser piping network of
AC system as per specification given below.
Gate Valve
1. Type : Gate valve with non-rising spindle & bolted
Bonnet
2. Body: Below 50 mm Bronze. 50mm & above Cast iron
as per IS: 210-1993,GR.200
3. Bonnet : Bolted
4. Spindle : SS as per AISI 410
5. Disc : Cast iron as per IS:210-93 GR 200
6. Body seat ring & : SS as per AISI 410
Disc facing ring
7. End connections : Below 50 mm - Screwed. 50 mm &
above - flanged end, to be drilled as per
IS 6392-1971(RA1998), Table 17/11
8. Pressure rating : PN = 1.0 N/mm2
9. Flange facing : R.F. smooth
10. Manufacturing std. : IS 14846: 2000 (RA 2005)
11. Bolts & nuts : Black hexagonal bolt with nut as per
IS 1363 Part 1 (2002) & Part 3 1992 (RA
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TS VOL III Sec .A Ch-06 Page 103 of 106
1998)
12. Gaskets : Compressed Asbestos Fibers to
IS-2712-1979 1.5 mm thick
13. Hand wheel : Malleable CI
14. Packing : Asbestos
15. Hydrostatic testing : As per relevant IS & Pressure rating of
PN 1.0
16. Test certificates : For Physical/chemical analysis &
metallurgical tests for body parts , Hydro
testing
17. Service : Re-circulation water/Make up water/chilled
water
Globe Valve
1. Type : Globe valve for water supply pipelines
2. Body/Bonnet : Bronze As per IS : 318 Gr 2, CI above 65 dia
3. Disc : -- do --
4. Stem : Brass as per FHTB 1 of IS 6912
5. Hand wheel : CI FG 200 as per IS 210 RA - 93
6. Gland, Gland nut, : As per IS 318 Gr 2
spindle nut
7. Gland Packing : Asbestos
8. Pressure rating : PN 1.0 N/mm2
9. Manufacturing std. : IS : 778 : 1984 (RA 2005)
10. Max. Operating temp : 50
0
C
11. Operation : Manually operated hand wheel with
open and close direction indication.
12. End connection : Screwed as per IS-554 upto 40 mm
except otherwise mentioned. Flanged end
for 50 mm and above.
13. Special features need : 1) Arrow indicating flow direction
2) Embossed nameplate-giving details of
type and size.
14. Service : Water
15. Hydrostatic Testing : As per relevant IS and pressure rating of
PN 1.0
Non-Return Valve
1. Type : Double Swing check type
2. Body : Cast iron as per IS: 210-1993 GR. 200.
3. Cover : - do -
4. Hinge : Cast iron as per IS:210-1993GR.220.
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TS VOL III Sec .A Ch-06 Page 104 of 106
5. Hinge pin : HT brass IS : 320 HT-2
6. Body Seat Ring & : IS : 318 Gr 2
Disc ring
7. Disc : C.I as per IS : 210 1993 Gr.200
8. Gasket : CAF gasket as per IS:2712-1979 of
thickness 1.5 mm
9. End connections : Flanged end, to be drilled as per IS
6392-1971(RA1998), Table 17/11
10. Pressure rating : PN = 1.0 N/mm2
11. Manufacturing Std : IS:5312(Part-1)-2004/BS-5153 1991
12. Bolts & Nuts : Hexagonal type as per IS:1367-
1967 Cl.-4.614.4
13. Companion Flanges : ANSI B 16.5 class 150
14. Hydro static testing : As per IS : 5312(Part-1)-2004/
BS5153 (1991) and pressure rating of
PN 1.0
15. Test certificates : For Physical/chemical analysis &
metallurgical tests for body parts, Hydro
testing
16. Service : Water
Butterfly Valve
1. Type : Wafer type CI Butterfly valve
2. Body & Cover : Cast iron as per IS:210-1993 (RA -
1999) GR.220
3. Disc : - do -
4. Seat, Body/disc : EPDM
5. Pin : Stainless Steel, AISI-410
6. Bolting, internal : - Do -
7. Bolting, external : Carbon Steel
8. Pressure rating : PN= 1.0 N/mm2
9. Manufacturing Std. : IS:13095-1991(RA98)/AWWA:C-
504/BS:5155/
IPSS-1-06-012
10. Hydro static testing : For PN 1.0: Body - 15 kg/cm2g
Seat/Back seat - 10 kg/cm2g
11. Test certificates : Required for material/hydro testing
12. Service : Water
13. Maximum operating : 50
o
C
temperature
14. Type of operation : Lever operated upto DN 250
Gear operated, manual type >DN 300
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TS VOL III Sec .A Ch-06 Page 105 of 106
Duplex Filter
Duplex basket filters of nominal shall be installed on Condenser water
line to arrest suspended particles of 1000 microns or bigger size in
supply water/chilled water.
- Strainers/Duplex basket filters shall be of cylindrical MS construction.
- Strainers/Duplex arrangement with built-in valves shall be such that
one element will always remain in operation ensuring continuous
uninterrupted supply of filtered water from each strainer. It should not
be possible to isolate both the strainers simultaneously due to even
inadvertent rotation of hand wheels for movement of valve disc during
changeover from one basket to another. The changeover valves shall
have manual drive.
- Basket Filter bodies and internals shall be designed to withstand
design pressure with normal surges.
- Pressure equalizing connections for both the chambers shall be
provided for smooth changeover.
- Two nos. dial type pressure gauges of size 150 mm dia shall be
provided suitably mounted at the inlet and outlet mains of each
strainer.
- Flush drain valve and vent shall be provided for each unit of the main
strainer. The design of the strainer shall be suitable for easy
maintenance and replacement of the parts and inspection.
- Each strainer shall be provided with basket opening area (six times of
pipe cross section area or bigger) to ensure high flow volumes at low
pressure and a long service life.
- Provision shall be made for collection of drainage water from the
strainers.
- Valves to be supplied shall conform to the following standards.
Pressure rating of all valves shall be 16kg/cm2.
Gate valves : IS : 780-1984 (RA 1995) .
Globe valves : IS : 778-1984 (RA 2005)
- Strainer element from 3 mm thick sheet with 5mm dia holes enclosed
with 20 mesh 37 SWG wire mesh with suitable stiffeners on circular
and longitudinal direction.
Following material of construction shall be considered :
1. Body : Carbon Steel as per IS 2062 : 2006 Grade
2. Cover : - do -
3. Filter element : SS 304
4. Spindles : EN-8
5. Valve disc : IS 210: 1993 (RA 1999) FG 300/or MS
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TS VOL III Sec .A Ch-06 Page 106 of 106
6. Valve seating : IS 318: 1981 (RA 2001) LTB-2 Gr.2
7. Companion flanges : IS 6392 :1971, Table-17 (RA 1998)
8. Gasket sealing rings : CAF gasket as per IS 2712:1998
(RA 1999) 1.5mm thk.
04.0 Schedule of Equipment
Sr.
No.
System
envisaged
Description of equipment Quantity
Air conditioning System
1 Water cooled
package AC
system
Package AC Unit consisting of scroll compressor,
cooling coil, refrigerant circuit, condenser, thermostatic
expansion valve, blower external static pressure
25mmWc, air-filter, MCC, electric drives, instruments &
control and other standard accessories assembled in a
steel cabinet.
1 Lot
Natural draft cooling Tower & accessories of suitable
matching capacity
1 Set
Condenser cooling pumps 2 nos. (1W+1S)
GI Ducting with supports, grill, diffuser, fittings, etc. Lot
MS heavy class condenser, make up water & drain
Piping, pipe fittings, valves & duplex filter etc.
Lot
Make-up air filter, damper, cowl & bird mesh Lot
Return air grill Lot
Strip heater , pan humidifier with piping & controls Lot
Instruments & controls, pressure gauge, Thermometer,
thermostat, humidistat , geyser stat, water flow DP
Switch, etc.
Lot
Acoustic and Thermal duct line Insulation / GI cladding Lot
MCC, Power & control cabling, Earthing Lot
Cable tray, GI conduit, Clamp, Saddle etc. Lot
Interlocking system of air conditioning system with fire
protection system
Lot
Ventilation System
2 Dry
pressurised
Plenum
ventilation
Systems 3
Nos. ( As
existing)
Dry filter with Filter frame 1 Lot
GI ducting with grills, damper, exhaust damper & fire
damper
Complete overhauling of the ventilation
blowers/connected electrical motors
Interlocking system of ventilation fans with fire
protection system
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
Vol. III Sec-A Ch-07 Page 1 of 4
07. PERFORMANCE REQUIREMENT AND GUARANTEE
07.01 The Tenderer shall study the specification and satisfy himself thoroughly
regarding the work ability of the plant, equipment and systems offered and also
take full responsibility for the guaranteed operation and performance of the
same as well as for their smooth, safe and reliable functioning.
The tenderer shall state and guarantee the following turbine, generator and
generator transformer parameters. The tenderer shall demonstrate the same
during P.G. test, failing which L.D. and reduction clause will be applicable as
per clause no. 4.9.2 Vol-II of tender document.
Sl. No. Description Guaranteed value
1 Rated turbine output, MW
(a) At rated/ design net head of 257m
(b) At maximum net head of 300.1m
(c) At minimum net head of 252.33m
2 Rated generator output, MVA at 0.90 pf
and rated head
3 Rated Generator Transformer output
kVA
4 Turbine efficiency at rated net head for
(a) 100% rated output
(b) 80% rated output
(c) 60% rated output
5 Generator efficiency at
(a) 100% rated output
(b) 80% rated output
(c) 60% rated output
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6 Transformer efficiency at
(a) 100% rated output
(b) 80% rated output
(c) 60% rated output
07.02 Values of critical plant sigma as determined as per IEC code 193A should be
given in the form of curves of different guide vane positions for different heads.
Plant sigma curves as recommended by the manufacturer shall also be plotted
on it clearly to show the safety margin available.
07.03 The Tenderer shall study the temperature & quality of water given in chapter 6
for the submerged components of the turbine to be designed and material to be
selected so that considerable erosion or corrosion due to cavitation will not
occur.
07.04 The Tenderer shall incorporate necessary provisions at the time of executing
civil work and manufacturing of electro-mechanical equipment, so that the
performance testing of the unit can be done.
07.05 The tenderer shall clearly indicate the method he proposes to carry out the
Performance guarantee test, with facilities he proposes to provide during
construction of civil works, manufacturing and erection of equipment.
07.06 The Tenderer shall carry out the performance test to prove the guaranteed
efficiency and performance of turbine in accordance with the IS / IEC publication
no.60041 latest edition, (field acceptance tests to determine the hydraulic
performance of hydraulic turbines). The total system performance shall also be
guaranteed and demonstrated.
07.07 The Tenderer shall state and guarantee the rated output of the unit at generator
terminal at rated head and discharge, which will be duly verified and established
at site. The tenderer shall also furnish output at max. head & discharge within
vibration limits & class B temp limits. Similarly, the max. & min. output at rated
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head shall be furnished along with corresponding discharges with smooth
operation within permissible vibration & class B temp. rise limits.
07.08 The minimum guaranteed weighted average efficiency for turbine cannot be
below 93% and the peak efficiency shall be higher than 94%. The Tenderer shall
state and guarantee the weighted average efficiency of the unit (combining
turbine and generator) at rated head output. The tenderer has to conduct the
performance guarantee test immediately after successful
commissioning & trial operation. Price for these performance tests shall be
quoted separately in the price format.
07.09 The Tenderer shall guarantee the vibration of the machine components in
accordance with IEC 34 - 14 (Mechanical vibration of certain machines with shaft
height 56 mm and higher measurement, evaluation and limits of the vibration
severity).
07.10 The Tenderer shall guarantee the noise limits in accordance with IEC 34 - 9
(noise limits) and as per the General Technical Rules.
07.11 In case the rated output and minimum weighted average efficiency of 93% is not
achieved even after repeated performance test, the machine is liable for
rejection.
07.12 All equipment shall be guaranteed for workmanship, materials design and
satisfactory performance to the parameters in accordance with the tender
specification document and relevant clauses of the general conditions of
contract. The guarantee for performance shall cover individual items and
systems for their ratings/outputs. All machines / equipments shall be guaranteed
for 12 (Twelve) months from the date of commissioning.
07.13 The Tenderer shall also guarantee the integrated operation of all the systems
and equipment covered in his scope as a whole including interfaces required to
be established with other related systems and equipment. The Tenderer shall
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study the specification and satisfy himself thoroughly regarding the workability of
the plant, equipment and systems offered and also take full responsibility for the
guaranteed operation and performance of the same as well as for their smooth,
safe and reliable functioning.
07.14 The Tenderer shall conduct performance acceptance tests on each of the major
items of equipment supplied to demonstrate that the equipment and system
supplied are capable of achieving the performance parameters specified and
contracted for, in accordance with the general conditions of contract. The total
system performance shall also be guaranteed and demonstrated.
07.15 The tenderer shall guarantee the guide vanes, runner, discharge ring and other
hydraulic passages against excessive pitting caused by cavitation for 8000
hours of operation.
07.16 Excessive pitting shall be defined as the removal of metal from runner and other
hydraulic passages of a weight W=0.15 D
2
per 1000 hrs. of operation, where D
is the diameter of the runner in meter and W is the weight of the runner blades in
kg.
In case of cavitation pitting exceeding the guarantee, the turbine supplier shall at
his cost, take corrective measures, such as modification of design, finish,
replacement, repair, etc. and the turbine after modification shall be subject to
cavitation guarantee as per the original equipment. Cavitation and pitting
evaluation shall be in accordance with IEC 609 (Cavitation, pitting evaluation in
hydraulic turbines, storage pumps and pump turbines)
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Vol. III Sec-A
Page 1 of 25
08. GUARANTEED TECHNICAL PARAMETERS
08.01 General
Tenderer shall furnish the complete technical guaranteed parameters of all the
plant & equipment offered for the project as per the format given in this section.
Tenderer shall provide detailed information of the offered equipments. In case
data sheet of any component is not included in this chapter, same shall be
furnished by the tenderer.
08.02 Turbine
08.02.01 Guaranteed and other technical particulars
Sl. No. Item Description Value Remarks
A) TURBINE
1. Name & address of manufacturer
2. Type (i.e. Francis) of turbine and
shaft orientation
3. Critical sigma
4. Plant sigma
5. Guaranteed rated output at rated
net head and rated discharge
kW
6. Guaranteed max. output max.
head
kW
7. Guaranteed max. output at
minimum head
kW
8. Min. output at min. head and min.
discharge
kW
9. Min. output at max. head kW
10. Guaranteed efficiencies at rated
net head and following outputs
i) 100% of full load %
ii) 80% of full load %
iii) 60% of full load %
iv) Best efficiency at an output %
v) Performance curves including
model hill curves (Mention No. of
drawings enclosed)
11 Cavitation guarantee in Kg/1000
hours of operation
a) Parts subjected to max. erosion Kg/1000
hours of
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Page 2 of 25
Sl. No. Item Description Value Remarks
operatio
n
b) Operational restriction for turbine if
any for above guarantee
12. Efficiency at max. head and max.
discharge
%
13. Efficiency at minimum head and
minimum discharge
%
14. Efficiency at minimum output and
max. head
%
15. Efficiency at max. output and
minimum head
%
16. Rated Speed
RPM
i) Specific speed in M.K.S.
17. Max. runaway speed
RPM
18. a) Guaranteed minimum factor of
safety under worst conditions
based on the yield point of the
material
b) Name and location of the part
having the factor of safety in (a)
above
c) Direction of rotation when viewed
from generator end
19. Momentary rise in speed on
suddenly reducing load to zero
at rated speed from
a) 100% of full load not exceeding %
b) full load not exceeding %
c) full load not exceeding %
20. Time of GV gate closing for
regulation
a) Full load rejection
Seconds
b) full load rejection
Seconds
c) full load rejection
Seconds
21. Momentary drop in speed on
increasing load from zero at
rated speed to
a) Full load %
b) full load %
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Sl. No. Item Description Value Remarks
c) full load %
22. Time of GV gate opening in item
(21) above
a) Full load
Seconds
b) full load
Seconds
c) full load
Seconds
23. Fly wheel effect of :
a) The generating unit for regulation
stated above
Kg-m2
b) Generator
c) Turbine runner and shaft
d) Flywheel (if any)
24. Max. water hammer pressure % of
rated head
25. RUNNER
a) Material and composition
b) No. of runner blades
c) Runner discharge diameter mm
d) Weight of complete runner Kg
e) Source of runner casting
f) Velocity of water at runner exit
g) Applicable standard for material
26. Shaft
a) Material and composition
b) Construction
c) Diameter mm
d) Length mm
e) Diameter of bore mm
f) Weight Kg
g) No. of pieces
27. Shaft Gland
a) Type
b) Lubrication arrangement
c) Medium of lubrication
d) Cooling arrangement
i) Medium of cooling
ii) Quantity m3/hr
iii) Pressure
Kg/cm2
e) Flow monitoring device
f) Pressure monitoring device
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Sl. No. Item Description Value Remarks
28. Top Cover
a) Material and Construction
b) Thickness mm
c) Diameter mm
d) No. of sections
e) Weight of each section Kg
f) Applicable standard for material
g) Total weight Kg
29. Facing plate
a) Material and Construction
b) Thickness mm
c) Total weight Kg
30. Hydraulic Thrust
i) Maximum thrust N
ii) Minimum thrust N
31. Thrust Bearing
a) Location
b) Type of bearing
c) Diameter and length mm, mm
d) Working temperature of bearing
surface
Deg.C
e) Medium of lubrication
f) Recommended grade and make of
lube oil
g) Quantity of lubricating oil
h) Material of bearing
i) Weight Kg
j) Max runaway speed the bearing
can withstand
RPM
k) Max. duration of above runaway
speed
Seconds
l) Whether the bearing can
withstand the runaway speed with
or without cooling water
32. Turbine guide bearing
a) Location
b) Type of bearing
c) Diameter and length mm,
mm
d) Working temperature of bearing
surface
Deg C
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Sl. No. Item Description Value Remarks
e) Medium of lubrication
f) Recommended grade and make of
lube oil/water
g) Quantity of lube oil/water
h) Material of bearing
i) Weight Kg
j) Max. runaway speed the bearing
can withstand
RPM
k) Max. duration of above runaway
speed
Seconds
l) Whether the bearing can
withstand the runaway speed with
or without cooling water
33. Discharge ring/ Runner
Chamber
a) Material & composition
b) Thickness mm
c) No. of parts/segments
d) Weight of each part/segment Kg
e) Total weight of the assy. Kg
34. Noise at a distance of 1m from the
turbine
db
35. Vibration (Location also to be
mentioned)
i) Horizontal
ii) Vertical
iii) Axial
B. GOVERNING SYSTEM
1. General
a) Make
b) Type of governor Electronic
digital
c) Rating
d) Whether suitable for automatic
frequency control
e) Whether suitable for head water
level control
f) Whether suitable for normal
operation
2. Electronic governor
a) Guaranteed sensitivity of governor
(Minimum speed change to which
RPM
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Sl. No. Item Description Value Remarks
governor will respond)
b) Dead band
c) Governor output current range A
d) Speed setting range
e) Gate output setting range
f) Permanent speed droop setting
range
g) Temporary off line speed setting
range
h) Temporary off line speed droop
time constant range
i) Derivative time constant
j) Frequency dead band
k) No load gate limit setting range
l) Speed trim
m) Opening damping limit
n) Closing damping limit
o) Description of protection against
failure of governor drive
p) Governor opening & closing time s
q) Description and method of
operation
r) Adjustment range in governor
opening and closing time
s
s) Minimum and maximum
temperature ( tolerable)
degC,
t) Relative humidity( tolerable) %
u) Whether built in test instruments
are provided for testing purpose
3. Hydraulic Actuator
a) Range of adjustment of guide vane
/needle opening time
s
b) Range of adjustment of guide vane
/needle closing time
s
c) Range of pressure for satisfactory
operation
Kg/cm2
d) Size of runner vane distributing
valve
mm
e) Size of runner distributing valve mm
4. Oil Pressure System
a) No. of pumps provided
b) Type of pumps
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Sl. No. Item Description Value Remarks
c) Make of pumps
d) Working pressure
Kg/cm2
e) Nominal discharge lps
f) Type of grade of oil used
g) Volume of oil in the entire system L
h) Volume of oil in sump tank
i) Pressure oil receivers (oil pressure
vessels)
j) Capacity of oil receiver L
k) Volume of oil in oil receiver L
l) No. of complete operations of
servo-motors possible with stored
oil without pumps running
m) Oil pipeline material
n) Design pressure
Kg/cm2
o) Test pressure
Kg/cm2
p) Oil Lubricants
i) Specification of governor oil
ii) Specification of other lubricants
iii) Minimum pour point temp of
governor oil
iv) Minimum temp, for solidification of
lubricants
v) Minimum temp no. of complete
turbine control operations which
can be performed by the oil in
pressure oil tank when pumps are
not working ( may be due to AC
failure)
08.03 GENERATOR, EXCITATION SYSTEM AND AVR
08.03.01 Generator
Sl. NO. DESIGNATION VALUE REMARKS
C GENERATOR
1. Normal voltage and voltage range.
2. Power factor
3. Frequency and frequency range
4. Guaranteed rated output for
temperature rise mentioned in
specifications under conditions of
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i) 0.90 power factor at any voltage in the
operating range.
ii) Rated voltage, zero leading power factor
during line charging with 5% full load
positive excitation margin.
iii) 0.90 power factor lagging continuous
overload capacity at any voltage
iv) 95% rated kV, zero leading power factor
during line charging with 5% full load
excitation margin.
5. Flywheel effect of the rotating parts of the
generator, CD
2
6. Inertia constant of the generator based
on the generator rated KVA.
7. Short circuit ratio.
8. Runaway speed at which all parts are
guaranteed to withstand safety.
9. Minimum factor of safety based on yield
point of materials
10. Maximum temperature rise for the output
guaranteed under item 4 (i)
11. At any voltage and frequency in the
operating range
i) Stator winding by embedded
temperature detector.
ii) Rotor winding by resistance
measurement.
iii) Bearing by embedded temperature
detector
iv) Other parts by thermometer.
12. Guaranteed under item 4 (iii) at any
voltage and frequency in the operating
range
i) Stator winding by embedded
temperature detector.
ii) Rotor winding by resistance
measurement
iii) Bearing by embedded temperature
detector
iv) Other parts by thermometer
13. Overall efficiency of generator while
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operating at rated voltage, 0.90 power
factor lagging and 75
0
C winding
temperature at
i) 110% full load
ii) 100% full load
iii) 80% full load
iv) 60% full load
14. Weighted average efficiency.
Inherent regulation i.e. increase in
voltage at constant speed and
excitation on taking off.
i) 110% full load
ii) 100% full load
iii) 60% full load
15. Reactance (referred to rated generator
KVA base)
i) Synchronous reactance
a) Direct axis (X
d
) sat/unsat.
b) Quadrature axis (X
q
)
ii) Sub transient reactance
a) Direct axis (Xd) sat/unsat.
b) Quadrature axis (X
q
)
iii) Sub transient reactance
a) Direct axis (X
d
) sat/unsat.
b) Quadrature (X
q
) sat/unsat.
iv) Negative phase sequence
reactance
(X
2
) sat/unsat.
v) Zero phase sequence reactance (X
6
)
vi) Armature leakage reactance
vii) Ratio of quadrature axis sub-transient
reactance to direct axis sub-transient
reactance (X
q
/X
d
)
16. Thrust bearing.
i) Temperature rise by RTDs while delivering
rated output with cooling water supply at
30
0
C.
a) Pads.
b) Oils.
ii) Temperature rise by RTDs while delivering
the maximum output with cooling
water supply at 30
0
C.
a) Pads.
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b) Oils.
17. Guide Bearing.
i) Temperature rise by RTDs rated output
with cooling water supply at 30
0
C.
a) Pads.
b) Oils.
ii) Temperature rise by RTDs of the bearing
while delivering the maximum output with
cooling water supply at 30
0
C.
a) Pads.
b) Oils.
18. Operating capability of thrust bearing
(in minutes) for the following conditions
of operation.
i) At rated speed without cooling water
supply.
ii) At runaway speed with cooling water
supply
iii) At runaway speed without cooling water
supply
iv) At low speed of 4% of rated speed with
lubrication system ON
19. Operating capability of guide bearing (in
minutes) for the following conditions of
operation.
i) At rated speed without cooling water
supply.
ii) At runaway speed with cooling water
supply
iii) At runaway speed without cooling water
supply
iv) At low speed of 4% of rated speed with
lubrication system ON
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08.03.02 Schedule of Other Technical Particulars
Sl. NO. DESIGNATION VALUE REMARKS
1. Make of generator
2. Type and reference
3. Rated synchronous speed for
synchronous frequency of 50 Hz
4. Direction of rotation
5. Name and location of part of party
stressed to maximum under runaway
condition
6. Maximum permissible continuous
negative phase sequence current.
7. Generator resistance at 75
0
C.
i) Armature winding per phase.
ii) Field winding
iii) Damper winding
8. Generator time constants
i) Direct axis transient open circuit time
constant
ii) Direct axis transient short circuit time
constant
iii) Quadrature axis transient short-circuit
time constant
iv) Direct axis sub-transient time constant
v) Short-circuit time constant of armature
winding.
vi) Short-circuit time constant of damper
winding with excitation winding shorted.
9. Maximum (I
2
/I
n
)
2
t value.
10. Synchronizing power at rated voltage
50Hz, 0.90 power factor lagging.
11. Allowable continuous single phase
loading at rated voltage and power
factor
12. Calculated generator capacitance per
phase to ground of stator winding.
13. Voltage waveform
i) Waveform deviation factor
ii) No load harmonies in the voltage wave
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Sl. NO. DESIGNATION VALUE REMARKS
14. Telephonic harmonic factor
i) Balance
ii) Residual
15. Schedule of losses
(At Rated voltage, power factor and
frequency)
Sl. No. Losses 110
%
F.L
100%
F.L
60%
F.L
i Friction windings losses
ii Core losses
iii Armature I
2
R losses at 75
0
C
iv Stray load losses
v Field I
2
R losses at 75
0
C
vi Static Excitation system losses
Total losses.
16. Generator stator
i) Material of stator core
ii) Number of sections in which stator is
divided for transportation.
iii) Grade thickness and insulation of stator
Laminations.
iv) Insulation thickness of winding.
a) Slot portion
b) Over-bang portion
v) Stator core dimensions
a) Inside diameter.
b) Outside diameter.
c) Length without/with air ducts.
d) Ratio of stator core diameter and
length
e) Total number of slots
f) Finished slot size.
g) Net weight of active iron
vi) Outside diameter of stator frame.
vii) Diameter of stator foundation
viii) Width of air gap at centre of pole top
ix) Flux density at rated voltage on no load
in
a) Air gap.
b) Stator core.
c) Teeth
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Sl. NO. DESIGNATION VALUE REMARKS
d) Pole body.
x) Current density in stator winding
xi) Cross sectional area of copper winding
stator, cach bar.
xii) Weight of copper in stator winding.
xiii) Resistance of stator winding per phase
at I
2
R losses at 25
0
C
xiv) Calculated capacitance of stator winding
per phase.
xv) Detail of transposition of stator
xvi) Total weight of stator
17. GENERATOR ROTOR
i) Materials
a) Pole Punching.
b) Rim punching.
c) Spider arms
d) Spider hub.
e) Pole and plates.
ii) Type of rotor rim construction
iii) Construction of field poles
iv) Method of attaching field poles to the
rotor rim
v) Class of insulation o field winding
vi) Material and thickness of insulation.
vii) Width and height of pole body
viii) Weight of active iron in each field pole
ix) Maximum current density in rotor
winding.
x) Cross-sectional area of copper in field
winding.
xi) Weight of copper in filed winding per
pole
xii) Damper winding.
a) Number and diameter of damper
bars per pole
b) Whether connected between
poles.
xiii) Resistance of filed winding at 25
0
C
xiv) Factor of safety at maximum speed
based on yield strength of material.
xv) Type of collector rings.
xvi) Number of brushes/collector rings
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Sl. NO. DESIGNATION VALUE REMARKS
xvii) Diameter of assembled rotor
xviii) Total weight of rotor
18. SHAFT
i) Material and construction
ii) Diameter (nominal)
iii) Length
iv) Diameter of axial bore
v) Diameter of coupling flanges.
vi) Weight of assembled shaft.
vii) Computed critical speed of
a) Without considering unbalanced
magnetic force (pull)
b) Considering unbalanced
magnetic force (pull)
viii) Tolerance for shaft alignment
ix) Factor of safety (based on the yield
strength of the material)
19. THRUST BEARING.
i) Type.
ii) Location.
iii) Diameter of bearing
a) Inside.
b) Outside
iv) No. of pads and size
v) Effective bearing area.
vi) Composition of pad material
vii) Thickness of material
viii) Type, number and location of
a) Temperature detectors
b) Dial type thermometers
c) Cooling water requirement
d) Quantity
e) Pressure range
ix) Normal working temperature of bearing
(pad)
x) Maximum permissible temperature of
bearing for
a) Alarm
b) Trip
xi) Total load on thrust bearing including
hydraulic thrust
a) Design load.
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Sl. NO. DESIGNATION VALUE REMARKS
b) Actual during working conditions.
xii) Distance through which rotor is to be
raised for removal of thrust bearing pads
xiii) Pump motor rating for lubrication system
20. GUIDE BEARINGS
i) Type
ii) Location and number
iii) Number pads and size
iv) Effective bearing area
v) Material of bearing pads
vi) Normal working temperature of bearing
vii) Maximum permissible temperature of
bearing for
a) Alarm
b) Trip
21. OIL
i) Type and grade of specification
ii) Standard to which it shall conform
iii) Quantity of oil for first filling of thrust and
guide bearing oil.
22. BEARING BRACKETS
i) Material and composition
ii) Type and construction
iii) No. of arms
iv) Weight
23. GENERATOR BRAKES
i) No. of brake units
ii) Size of brake shoe
iii) Size of piston
iv) Material of brake ring.
v) Material of brake liner.
vi) Air pressure required for operation.
vii) Speed at which the air brakes are
applied.
viii) Time required for bringing the machine
to rest by applying mechanical brakes.
a) In normal shut down.
b) In emergency shut down.
24 GENERATOR COOLING
i) Type and method of cooling
ii) Number and location of fans.
iii) Number of surface air coolers.
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Sl. NO. DESIGNATION VALUE REMARKS
iv) Temperature of air entering generator
from coolers.
v) Maximum number of surface air cooler
required for maximum output of
generator.
vi) Details of other method cooling (if
required)
25 Weight of generator rotating parts
26 Weight of complete generator
27 Heaviest package for transportation
i) Name
ii) Weight
iii) Dimensions (L x B x H)
28 Largest package for transportation.
i) Name
ii) Weight
iii) Dimensions (L x B x H)
29 Heaviest assembly to be lifted by power
house crane.
i) Name
ii) Weight
iii) Dimensions (L x B x H)
30 Largest assembly to be filled by power
house crane.
i) Name
ii) Weight
iii) Dimensions (L x B x H)
31 a.Maximum clearance required for the
EOT crane hook above service bay for
lifting of assembled generator.
b. Whether the available EOT crane
clearance is good enough for the
assembled generator
32 Largest assembly to be taken out
through the stator bore.
i) Name
ii) Weight
iii) Dimensions (L x B x H)
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08.03.03 Excitation and AVR system
08.03.03.01 Guaranteed Technical Particulars
ITEM DESIGNATION VALUE REMARKS
EXCITATION SYSTEM AND AVR
1. Manufacture
2. Place of manufacture
3. Type designation
4. Applicable standards
5. Rating of excitation system at rated
generator output and rated power
factor (hot rotor winding)
i) Field voltage
ii) Field current
iii) Field power
iv) No load excitation voltage
v) No load field current
vi) Field flashing current and duration
6. Ceiling voltage in per units of rated
field voltage
i) Ceiling voltage at no load
ii) Ceiling voltage at rated load.
7. Field current at rated ceiling voltage.
8. Excitation system voltage response ratio
9. Response time to reach 95% of the
difference between rated ceiling voltage
and full load field voltage.
10. Time to rach+0.5% of ceiling voltage
from rated voltage.
11. Maximum time period for operation at
ceiling voltage power factor 0.9 and
maximum generator power.
12. Data of excitation system at 110% rated
generator terminal voltage, power factor
0.9 and maximum generator power.
i) Field voltage
ii) Field current
13 Maximum continuous output capability of
excitation system.
i) Maximum field current
ii) Maximum field voltage
14 Maximum duration of over excitation
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ITEM DESIGNATION VALUE REMARKS
EXCITATION SYSTEM AND AVR
15 Time to reach 5% limit of generator
terminal voltage in case of load rejection
16 Maximum overshoot of generator
terminal voltage in case of load rejection.
17 Setting time to reach 0.5% limit of
generator terminal voltage after over
speed conditions.
18 Range of voltage level setting
19 i) Range for manual control of
excitation.
ii) Frequency range of operation
iii) % transformer drop compensation
20 Excitation transformer
i) Type
ii) Transformer continuous three Phase
power rating.
iii) Transformer voltage ratio
iv) Transformer no-load losses (three-
phase) at rated voltage, and rated
frequency.
v) Vector group / connection.
vi) Transformer total losses (75
0
C three-
phase) at full load at rated voltage and
rated frequency.
vii) No-load current at rated voltage
frequency.
viii) Impedance voltage (75
0
C) at rated
frequency on 100% rated kVA.
ix) Transformer temperature rise after
continuous operation with rated kVA,
under rated conditions.
- Winding (by resistance)
- core
x) Transformer rated voltage at rated
frequency and no-load.
a) High-voltage
b) Low voltage
xi) Standard applicable
xii) Material
a) Core
b) Conductor
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ITEM DESIGNATION VALUE REMARKS
EXCITATION SYSTEM AND AVR
xiii) Class of insulation
xiv) BIL
xv) Temperature rise
21 Voltage Regulation system.
i) Make
ii) Type
iii) Accuracy of voltage regulation
iv) Range of voltage setting.
a) Auto mode
b) Manual mode
v) Voltage regulation from no load to full
load.
22 Rectifiers
i. Type of rectifiers
ii. Type of thyristors
iii. Number of thyristor per Interchangeable
module.
iv. Number of modules per bridges or stacks
v. Number of bridges or stacks
vi. Number of parallel paths.
vii. Number of thyristors
a) In series
b) In parallel per path
viii. Rated current of rectifiers
ix. Rated voltage of rectifier
x. Average forward current rating per
thyristor.
xi. Forward voltage drop per thyristor
xii. Maximum safe operating temperature.
xiii. Maximum surge current rating.
xiv. Max. permissible duration of surge
current.
xv. Cooling fans for rectifiers (if necessary)
number of fans.
xvi. Fan ratings
xvii. Electrical fan motor ratings
a) Rated voltage
b) Rated power consumption
xviii. Auxiliary transformer(s) for cooling
fans and other
a) Ratings
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ITEM DESIGNATION VALUE REMARKS
EXCITATION SYSTEM AND AVR
b) Rated primary voltage
c) Rated secondary voltage
23 Field circuit breaker
i) Rated current
ii) Rated voltage
iii) Rated breaking current
iv) Total opening current
v) Total opening time
vi) Total closing time
vii) Operating sequence
24 AC-field flashing equipment
i) Duration of flashing
ii) Power rating of field flashing transformer.
iii) Rated voltages of transformer
a) Primary
b) Secondary side
25 DC-field flashing equipment
i) Power requirements
ii) Supply voltage
08.04
COOLING WATER SYSTEM
a) Source Tail race
b) Total cooling water required m3/hr
c) Required head mWC
d) Cooling water pipeline material and
standard
e) Design pressure Kg/cm2
f) Working pressure Kg/cm2
g) Test pressure Kg/cm2
h) NDT test of cooling water pipeline
i) Type
ii) Percentage of test (joint %) %
i) Cooling water filter
i) Type Automatic
self
cleaning
duplex type
ii) Make
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iii) Material of construction details
iv) No. of filters required
v) Filtered water quality microns
I Cooling water pump
i) Type
ii) Make
iii) Discharge flow M3/hr
iv) Total dynamic head mWC
v) NPSHR mWC
vi) Pumps rated speed RPM
vii) Pumps shaft power KW
II) Isolation Valves
i) Type
ii) Make
iii) Material of construction
iv) Operation ( manual/motorized)
v) No. of valves of each type
vi) Design pressure Kg/cm2
vii) Working pressure Kg/cm2
viii) Test pressure Kg/cm2
DEWATERING SYSTEM
i) No. of pumps required
ii) Type
iii) Make
iv) Discharge flow m3/hr
v) Total dynamic head mWC
vi) NPSHR mWC
vii) Pumps rated speed RPM
viii) Pumps shaft power KW
ix) Complete pipeline , valves ( type &
make ) material and standard
x) Design pressure Kg/cm2
xi) Working pressure Kg/cm2
xii) Test pressure Kg/cm2
DRAINAGE SYSTEM
i) No. of pumps required
ii) Type
iii) Make
iv) Discharge flow m3/hr
v) Total dynamic head mWC
vi) NPSHR mWC
vii) Pumps rated speed RPM
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viii) Pumps shaft power KW
ix) Complete pipeline , valves ( type &
make ) material and standard
x) Design pressure Kg/cm2
xi) Working pressure Kg/cm2
xii) Test pressure Kg/cm2
3. COMPRESSED AIR SYSTEM
a) HP Compressors
i) Type
ii) Make
iii) Flow cfm
iv) Discharge pressure Kg/cm2
b) Pipeline
i ) Material
ii) Standard & make
iii) Design pressure Kg/cm2
iv) Working pressure Kg/cm2
v) Test pressure Kg/cm2
vi) NDT test of pipeline
i) Type
ii) Percentage of test (joint %) %
c) Valves
i) Type
ii) Make
iii) Material of construction
iv) No. of valves of each type
v) Design pressure Kg/cm2
vi) Working pressure Kg/cm2
vii) Test pressure Kg/cm2
FIRE FIGHTING SYSTEM
a) Pump
i) Numbers
ii) Type
iii) Make
iv) Discharge flow m3/hr
v) Total dynamic head mWC
vi) NPSHR mWC
vii) Pumps rated speed RPM
viii) Pumps shaft power KW
b) Pipeline
i ) Material
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ii) Standard & make
iii) Design pressure Kg/cm2
iv) Working pressure Kg/cm2
v) Test pressure Kg/cm2
vi) NDT test of pipeline
i) Type
ii) Percentage of test (joint %) %
c) Valves
i) Type
ii) Make
iii) Material of construction
iv) No. of valves of each type
v) Design pressure Kg/cm2
vi) Working pressure Kg/cm2
vii) Test pressure Kg/cm2
DRINKING WATER SYSTEM
a) Pump
i) Numbers
ii) Type
iii) Make
iv) Discharge flow m3/hr
v) Total dynamic head mWC
vi) NPSHR mWC
vii) Pumps rated speed RPM
viii) Pumps shaft power KW
b) Pipeline
i ) Material
ii) Standard & make
iii) Design pressure Kg/cm2
iv) Working pressure Kg/cm2
v) Test pressure Kg/cm2
vi) NDT test of pipeline
i) Type
ii) Percentage of test (joint %) %
c) Valves
i) Type
ii) Make
iii) Material of construction
iv) No. of valves of each type
v) Design pressure Kg/cm2
vi) Working pressure Kg/cm2
vii) Test pressure Kg/cm2
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d) Filters
i) Type
ii) Make
iii) Material of construction details
iv) No. of filters required
v) Filtered water quality
e) Water treatment plant
i) Type
ii) Make
iii) Treated water quality
Oil Handling Facility
a) Oil transfer pump
i) Type
ii) Make
iii) Discharge flow m3/hr
iv) Total dynamic head mWC
v) NPSHR mWC
vi) Pumps rated speed RPM
vii) Pumps shaft power KW
b) Pipeline
i ) Material
ii) Standard & make
iii) Design pressure Kg/cm2
iv) Working pressure Kg/cm2
v) Test pressure Kg/cm2
vi) NDT test of pipeline
i) Type
ii) Percentage of test (joint %) %
c) Valves
i) Type
ii) Make
iii) Material of construction
iv) No. of valves of each type
v) Design pressure Kg/cm2
vi) Working pressure Kg/cm2
vii) Test pressure Kg/cm2
VACUUM PUMP SYSTEM
a) Pump
i) Type
ii) Make
iii) Pumps rated speed RPM
iv) Pumps shaft power KW
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v) Vacuum pressure Kg/cm2
b) Pipeline
i ) Material
ii) Standard & make
iii) Design pressure Kg/cm2
iv) Working pressure Kg/cm2
v) Test pressure Kg/cm2
vi) NDT test of pipeline
i) Type
ii) Percentage of test (joint %) %
c) Valves
i) Type
ii) Make
iii) Material of construction
iv) No. of valves of each type
v) Design pressure Kg/cm2
vi) Working pressure Kg/cm2
vii) Test pressure Kg/cm2
AIR CONDITIONING UNIT
a) AC machine
Type
Make
Capacity TOR
Temperature to be mentained
Medium of cooling
Cooling water required If cooling
medium is
water
b) Air Ducts
Type
Make
Material of construction
Thickness of material and standard
VENTILATION SYSTEM
a) Ventilation Ducts
Type
Make
Material of construction
Thickness of material and standard
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9. QUALITY CONTROL, INSPECTION & TESTING
9.1 Quality Control and Inspection
General
Inspection & testing of plant & equipment shall be carried out by
Purchaser/consultant at the works of successful tenderer
(Contractor/Sub-contractor) during manufacturing and on final product
to ensure conformity of the same with the acceptable criteria of
technical specifications, approved drawings, authenticated
manufacturing drawings and reference national/international standards.
This specification is in addition to provisions laid-down in Purchasers
General Condition of Contract (GCC) and special instructions to
tenderers, if any.
Quality Assurance Plan (QAP)
Contractor shall furnish Quality Assurance Plan (QAP) for respective
equipment after completion of detailed engineering and finalisation of
billing schedule / equipment identification number for Consultants
approval prior to start of manufacturing.
QAP shall be prepared and furnished by the successful tenderer in
FORM No. 11.20(DQM)F-09 and 10 Rev 0 (enclosed) for structural &
mechanical and electrical items respectively in four sets.
Indicative Surveillance By OHPC
Surveillance level by OHPC shall vary from equipment to equipment as
per product below for guidance of contractors in developing QAP.
SN Categories of
Equipment
Extent of Inspection (as applicable from
equipment to equipment)
i. Forged, cast, lined
products and piping
Material test certificates to be submitted by
the contractor at the time of giving
inspection call for the main equipment in
the final stage. Following checks/tests will
be carried out in final stage.
Visual inspection
Alignment and fitment checking
Dimensional checking
Witnessing of NDT as per design
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requirement.
ii. Manufactured items
(Mechanical,
fabricated and
welded)
Material and manufacturers test certificates
to be submitted by the contractor at the
time of giving inspection call for the main
equipment in the final stage.
Visual inspection
Alignment and fitment checking
Dimensional checking
Weld inspection visual and NDT as per
design requirement. Radiographs are to be
shown and reports to be submitted to
OHPC/Consultant for review during
inspection, if applicable.
Witnessing of other tests like pneumatic,
hydraulic no-load running, functional,
balancing, performance etc. depending
upon criticality of the part item / equipment.
iii. Bought-out items Following standard bought-out items shall
be accepted on the basis of manufacturers
test certificates.
ERW Pipes,
if supplied by approved manufacturers
Flowmeters
Pneumatic & hydraulic cylinders
Insulation materials
Bolts, nuts & washers (Grade 4.6).
iv. Electrical equipment Final inspection & Testing
Verification of test certificates
Visual & workmanship
Dimensional
Witnessing of routine tests as per relevant
standards. Manufacturers to be submitted
for verification.
Witnessing of type/acceptance tests, as
applicable
v. Instrumentation Final inspection & testing.
Verification of test certificates
Workmanship and visual
Dimensional checking
Calibration of the instrument for specified
parameters shall be checked.
Calibration of Measuring Equipment
All the measuring equipment used for inspection & testing shall be
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calibrated and appropriate accuracy class of measuring equipment
shall be used. Calibration standards used for calibration of measuring
equipment shall be traceable to national standards of National Physical
Laboratory (NPL), New Delhi with unbroken chains of comparison.
Calibration Certificate of All Measuring Equipment
Valid calibration certificate for all measuring equipment used during
inspection and testing with traceability to national standards of
NPL/NPL-accredited laboratories shall be furnished along with
inspection call prior to undertaking inspection by Purchaser/
Consultant.
Calibration certificate shall also indicate reference no. of calibration
standards calibrated by NPL/NPL- accredited laboratories and copies
of such calibration certificates of calibration standards shall also be
furnished when asked for.
Test Certificates And Documents
For each of the items being manufactured, following test certificates
and documents, as applicable for each of the equipment, in requisite
copies including original shall be submitted to Inspection Agency. All
test certificates must be endorsed by the manufacturer and Contractor
with linkage to project, purchase order and acceptance criteria.
Raw materials identification & physical and chemical test certificates for
all materials used in manufacture of the equipment (except IS 2062-
1992 Gr. A & IS 210-1993, FG-150).
WPS, PQR & WPQ Documents as per applicable code.
Details of stage wise inspection & rectification records for fabricated
items, castings, forgings and machined articles.
Control dimension chart with records of alignment, square ness etc.
Manufacturers material and performance/relevant test certificates for
all bought-out items.
Details of heat-treatment and stress relieving charts as per
specification.
Non-destructive Test report as per respective code.
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Static/dynamic balancing certificate for rotating components/ machines.
Hardness test certificate
Pressure Test Certificates
Performance Test Certificates for all characteristics.
Geometric accuracy and repeatability test reports of machine tools
Routine / type / calibration / acceptance /special test certificates for
electrical items.
Surface preparation and painting certificates.
Certificates from components authority for the item coming under
statutory regulations.
Where physical and chemical test certificates of material are not
available, the contractor/Sub-contractor shall arrange to have
specimens and test samples of the materials. Tested in his own
laboratory at his cost and submit the copies of test results in requisite
numbers to Inspection Agency for scrutiny and approval. Number of
test samples against each heat / cast / lot or batch of materials shall be
as per relevant Indian or International Standards.
Where facilities for testing do not exist in the contractor/Sub-
contractors laboratories or in case of any dispute, samples and test
pieces shall be drawn by the Contractor/Sub-contractor in presence of
Inspection Agency and sealed sample shall be sent to any approved
laboratory for necessary tests at Contractor/Sub-contractors cost.
The Inspection Agency shall have the right to be present and witness
all tests being carried out by the Contractor-Sub-contractors at their
own laboratory or approved laboratories. Also the Inspection Agency
shall reserve the right to call for confirmatory test on samples, at his
discretion.
Manufacturing and Inspection Schedule
The Contractor shall submit to the Purchaser quarterly programme of
inspection and tests one month in advance of the commencement of the
quarter. The Contractor shall give the Purchaser/consultant a minimum of
30 days clear notice of any work being ready for inspection and tests
specifying the period likely to be required for such inspection and tests.
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Thereafter, the Purchaser or his inspector shall, unless inspection or test
is voluntarily waived, attend at the Contractor's or his Sub-Contractor's
premises, such inspection and tests within 7 days of the date on which
the equipment is notified as being ready for inspection and test.
Should the Purchaser fail to attend such inspection and test, the
Contractor may proceed with the inspection and test at his option which
shall be deemed to have been made in the Purchaser's presence and
shall forthwith forward to the Purchaser copies of inspection/test
certificates for acceptance by the Purchaser. The proforma and number
of copies for inspection/test certificates shall be mutually agreed.
However, if the Purchaser request the Contractor for a revised date of
inspection but within 15 days of the date of inspection as communicated
by the Contractor, the Contractor shall arrange the inspection on the
revised date as requested by the Purchaser.
Contractor/manufacturer shall not dispatch any equipment till receipt of
MDCC from purchaser/consultant.
Internal Inspection By Contractor / Manufacturer
Inspection and tests shall be carried out by Contractor / Manufacturer
in accordance with approved drawings, TS P. O., and approved QAP.
Contractor / Manufacturer shall maintain record of each inspection and
test carried out and signed documents shall be submitted to OHPC for
verification.
Contractor shall carry out their internal inspection & obtain clearance
from statutory bodies e.g. IBR, CCE, TAC, Weights & measures,
safety. IE rules etc. prior to offering any equipment for OHPC/
Consultant inspection in accordance with approved QAP.
Contractor / manufacturer shall ensure use of appropriate calibrated
measuring equipment during their internal inspection, as well as make
available the same during OHPC / Consultant inspection and tests.
Also they shall make necessary arrangement for access and use of
OHPC owned measuring equipment during inspection.
Contractor / Manufacturers shall identify all the inspected
equipment/component/raw materials & shall maintain the record of
status of inspection viz. Inspected & found acceptable, require
rectification/rework, rejected etc.
The contractor shall establish and maintain procedures to ensure that
product that does not conform to specified requirements, is prevented
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from inadvertent use or installation. The description of non-conformity
that has been accepted subsequently by Designer / CLIENT/Consultant
by concession and/or or repairs, shall be recorded.
Repaired and reworked product shall be offered for re-inspection to
OHPC/ Consultant along with records of corrective action taken.
Contractor / Manufacturer shall not dispatch any equipment till receipt of
dispatch clearance from OHPC/Consultant.
Method of Issuing Inspection call to Purchaser/ Consultant
Inspection call shall be floated to respective offices in the enclosed
Form No. 11.20 (DQM)F-05/2, REV-0 duly filled in, with ten days clear
margin, enclosing all documents like test Certificates, Internal
Inspection Reports, P.O., Sub-P.O., T.S., Approved QAP, approved GA
drawings/data sheets and manufacturing drawings with a copy of call
letter to Inspection Co-ordinating Office, Inspection calls without above
documents shall be ignored.
Obligations of Contractor
The Contractor shall provide all facilities and ensure full and free access
of the Inspection Engineer of Purchaser/ Consultant to the Contractors
or their Sub-contractors premises at any time during contract period, to
facilitate him to carry out inspection & testing of the product during or
after manufacture of the same.
The Contractor shall delegate a Representative/Co-ordinator to deal
with Purchaser/Consultant on all inspection matters. Also, Contractors
Representative shall be present during all inspection at Sub-
Contractors works.
The Contractor / Sub-Contractor shall provide all instruments, tools,
necessary testing & other inspection facilities to Inspection Engineer
free of cost for carrying out inspection.
The cost of testing welds by ultrasonic, radiographic and dye
penetration tests etc. in the fabrication workshop shall be borne by the
Contractor.
The Contractor shall ensure that the equipment/assembly/component of
the plant and equipment required to be inspected, are not dismantled or
dispatched before inspection.
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Inspection Certificate
On satisfactory completion of final inspection & testing, all accepted
plant & equipment shall be stamped suitably and Inspection Certificate
in standard form shall be issued by the Inspection Engineer for the
accepted items. If a final certificate can not be issued, a provisional
certificate shall be issued.
If the tests were not witnessed by the Purchaser/Consultant or his
representative the certificate shall be issued on receipt of the inspection
and tests report from the Contractor but not later than 30 days after the
receipt of the said report by the Purchaser.
In the event a certificate is not issued by the Purchaser/Consultant during
30 days, the Contractor, if considered necessary, can arrange dispatch
along with the certificate with the clear understanding that if the
Purchaser/Consultant reject such equipment at a later date, the
Contractor shall rectify the same at his own cost to the Purchaser's
satisfaction. No Plant shall be shipped or left or otherwise dispatched
before such certificate has been issued.
The satisfactory completion of these inspection and tests or the issue of
the certificate shall not bind the Purchaser/ Consultant to accept the work,
should it on further tests during or after erection be found not to comply
with the Contract.
Inspection Waiver Certificate
For the waiver category of items indentified in the approved QAP,
Consultant shall issue Inspection Waiver Certificate after scrutiny of
Contractors internal Inspection Report, Test Certificates and other
Documents as identified in QAP.
General Clauses
The Contractor shall bear all costs of any and all inspections and tests.
Where special tests in addition to agreed tests are required by the
Purchaser/Consultant, the Contractor shall bear the cost of the testing
provided the Contractor is convinced that within this/these special
test(s) the quality of the equipment in accordance with the specification
can not be proved. If such special tests are necessary based on the
results of the agreed test, then cost of all such special tests shall be to
the account of the Contractor in all cases.
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The Purchaser/Consultant upon giving 7 days notice in writing and stating
any grounds of objection, shall have the right to reject any or all
equipment or demand rectification or replacement thereof.
In the case of commissioning spares, operating & maintenance spares
and mandatory spares, the same shall be offered for inspection along with
the main equipment or after the main equipment has been satisfactorily
inspected and tested.
Purchaser/Consultant reserve the right to inspect any product at any
stage of manufacturing without prior notice to Contractor/Manufacturer
beyond pre-identified stages & hold points of approved QAP.
Inspection / tests including mechanical running test, material test,
performance test shall be carried out and relevant test certificates shall
be furnished.
All pressure parts shall be hydraulically tested at not less than 150% of
design pressure prior to painting and lining. The pressure parts shall be
kept pressurised for at least 15-20 minutes at this pressure.
All other parts including interconnecting piping shall be hydraulically
tested wherever possible as per relevant standards.
9.2 Testing
9.2.1 Shop Test
The equipments / components of turbine and generator such as runner,
turbine shaft, head cover, discharge ring, guide vane, guide apparatus,
servomotor, turbine guide bearing, shaft seal, generator shaft etc. shall
be shop tested as per relevant National/ International
Standards/approved shop assembly drawing .
Following shop tests shall be carried out by the manufacturer at their
works.
1. Tower assembly comprising head cover, discharge ring, guide vane,
guide apparatus, servomotor, etc. as per relevant drawing
- Visual inspection of machined surfaces i.e. chamfered edges, head
cover & bottom ring labyrinths, wearing plates, shutter faces of guide
vane.
- Match marking of X-Y axis
- Level & co-centricity check
- Dimension check
- Radial position of head cover & bottom ring upper & lower labyrinths
with reference to plumb line
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- Diametrical clearance between operating ring & bearing pads
- Gap between two consecutive guide vanes with servomotor at 25 %,
50 %, 75% & 100 % (Opening & closing)
- Guide vane pitch diameter
- Clearance between two consecutive guide vanes in closed position.
- Clearance between head cover wearing plates and guide vane top
edge & clearance between bottom ring wearing plate & guide vane
lower edge
- Free movement of guide vanes
- Stroke length of servomotor
- Normal and emergency closing time of guide vanes.
2. Shop test on Runner & turbine shaft
- Dimension check and surface finish check
- Inlet & outlet pitch of runner
- Blade profile
- Static balancing of runner
- Machine tolerance check of turbine shaft & runner assembly.
- Concavity & convexity of flanges
- Proof assembly of turbine shaft with runner.
9.2.2 Field Acceptance Tests
The turbine shall be tested at site for establishing fulfillment of
guarantees in respect of turbine output & efficiencies including weighted
average efficiency. The test shall be carried out as per IEC 60041 for
field acceptance tests of hydraulic turbine. The arrangement for this test
including the testing devices shall be supplied and erected by the
successful tenderer.
The purchaser at his discretion may call third party for witnessing the
tests before acceptance.
The field acceptance test shall include testing during erection,
certification of the completion of erection of the equipments by the
purchaser/consultant and tenderer. Equipment wise field quality plan
shall be submitted by the tenderer. After completion of erection pre-
commissioning checklist points shall be attended by the tenderer.
Equipment wise pre-commissioning checklist schedule shall be submitted
by the tenderer.
After attending the pre-commissioning checklist points the tenderer shall
go for commissioning of the equipment as per commissioning procedure
and the same shall be submitted by the tenderer before commissioning.
After successful commissioning of the complete system the tenderer
shall go for PG test as per the TGP approved by purchaser/consultant.
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The successful tenderer shall submit formats of protocol for each of
erection, testing and commissioning for approval by
purchaser/consultant.
If the performance at field is found not to meet the requirement, then the
equipment shall be rectified by the Tenderer without any extra cost within
the overall time schedule.
9.2.3 Performance Guarantee Test
The PG tests for the turbine and generator shall be done for satisfactory
performance in accordance with the following standard and TGP
approved by purchaser/consultant:
IEC 60545 - Guide for commissioning, operation and maintenance of
hydraulic turbines
IEC 60034 - Rotating electrical machinery and
IEEE Guide Std 115 - Test procedure for synchronous machine.
Report & Test certificates shall be submitted to Purchaser / Consultant.
Purchaser / Consultant or his authorised representative shall be given
full access to witness all tests. Prior to performance tests, the
Manufacturer shall intimate purchaser / consultant allowing adequate
time so that if purchaser / consultant so desires his representative can
witness the test. All equipment, measuring instruments including tools
and tackles necessary for conducting the performance test to be brought
by the contractor.
9.2.4 Tests on Generator & electrics
The tests listed below are to be carried on each set
A. Test Prior to initial run
1. Insulation resistance of bearings
2. Measurement of the insulation resistance and polarization index of
the stator winding
3. Measurement of the insulation resistance of the field winding
including slip rings
4. High potential DC test on stator winding
5. High potential DC test on field winding
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6. Evaluation of the stator winding capacitance & tan delta
measurements
7. Measurement of rotor impedance / interturn test
8. DC resistance measurement of the stator winding
9. DC resistance measurement of the field winding
10. Preliminary test of all systems
B. Tests after initial run, machine non-excited
1. Bearing temperature test up to rated speed
2. Determination of the braking time
3. Balancing of the rotor
4. Over speed test
5. Measurement of shaft / bearing vibration
6. Check for mechanical vibration on parts of the system
C. Electrical test after initial run and prior to synchronization
1. Primary tests of generator protection
2. Short circuit saturation curve, checking of voltage in all relays &
meters
3. Open-circuit saturation curve, checking of voltage in all relays &
meters.
4. Determination of the synchronous reactance & short circuit ratio.
5. Phase sequence test
6. Measurement of the voltage balance
7. Wave from analysis
8. Optimization of excitation system
9. Measurement of the shaft voltage
10. Shaft / bearing vibration measurement; generator excited
11. Synchronization tests
D. Check of the Excitation system
1. AVR-operation including automatic follow up of manual regulator
and auto change over
2. Response tests of excitation system
3. De excitation circuit
4. Insulation test
5. High voltage test
6. Performance test at reduced voltage (to extent possible)
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E. AVR-
- Accuracy test
- Sensitivity test
- High voltage test
- Performance test at reduced voltage
- Manual channel followed by auto channel
- Range of voltage adjustment test for both auto & manual channel
- Performance test of all limiters
- IR test
All the tests listed above shall also be repeated at site.
- Check OPN of all devices & function of all units / sub units.
- IR Test
F. Synchronization Test
To be indicated by the tenderer.
G. Other tests :
- pressure tests on all water pipe lines of cooling water (For generator
circuit)
- operation check of cooling water circuit with measurement of inlet / outlet
- Measurement of water quantity in air cooling ckt during rated operation
- Braking time from half speed to zero speed with torque reduced to 10%
of rated and with excitation removed.
- Bearing temperatures (all bearings) during rated operation.
- Functional tests of fire fighting equipment.
- Start / Stop sequence test; integrated operation of the plant
- Checking of each equipment, relay, meter, LT motor etc shall be carried
out as per the details given in the respective chapters.
Inspection & Testing
For excitation transformer, field control equipment & items not mentioned
in the write up, routine test as per relevant codes shall be conducted at
works and at site tests shall be conducted as per the manufacturers
erection / commissioning manuals.
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9.2.5 Cooling water System
The contractor shall conduct hydrostatic test on the complete system.
For hydrostatic test, the contractor shall furnish the pumps, barrels, tanks,
blanks, connections, calibrated test gauges along with and all other
necessary apparatus for the test. The contractor shall furnish, install and
dismantle all temporary lines from the purchasers water supply to the
system under test, after obtaining due permission from the purchaser
regarding finalization of the tapping point.
All testing and commissioning shall conform to IS: 5822-1970 for
activities, which have not been specified in this specification but found
necessary for proper execution of the work.
Before commissioning, all the pipelines shall be blown with compressed
air to remove any dirt from inside. The portion of pipe to be blown at a
time shall be selected in consultation with the purchaser, for maximum
effectiveness of the operation. The contractor shall arrange, all the
temporary connection, blanking, compressors, etc. required for the job.
After air blowing, the pipelines shall be furnished with clear water until the
discharge from the pipe is found clean. Flushing velocity shall not be less
than the working velocity. contractor shall provide all the temporary
connections required for inlet and outlet of flushing water as well as the
facilities for drainage of the flushed out water.
9.2.6 Other Auxiliaries
Testing & commissioning of the other auxiliary systems such as
Compressed Air system, Dewatering system, Drinking water system,oil
handling facilities etc shall be carried out as per relevant standard
9.2.7 Fire Protection and HVWS System
Testing & commissioning of Fire Protection System shall be carried out
as per TAC, NFPA & BIS norms
9.2.8 Air Conditioning Unit
Testing & commissioning of complete air conditioning system shall be
carried out as per BIS norms.
9.2.9 Ventilation System : Air leak test of the air ducts shall be carried out as per
BIS norms.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
Vol. III Sec-A Ch-10 Page 1 of 3
10. DATA, DRAWINGS AND INFORMATION TO BE SUBMITTED
10.01 ALONG WITH OFFER
10.01.01 Scope of work with general description of the system and equipment offered
specifying the important features. Tenderer shall indicate clearly the work to be
carried out in turbine, generator and all other auxiliaries with regard to
modifications, additional accessories if required for completion of the job shall
be supplied by the contractor without any extra charge, etc. to achieve the rated
design capacity.
The description to be accompanied by single line diagrams, and equipment
layout to enable the Purchaser to have a proper appreciation of the equipment
offered and its operation.
10.01.02 Filled in Technical Particulars as given in Ch. 08
10.01.03 List of Deviations if any
10.01.04 Detailed scope of work
10.01.05 Specific Exclusion, if any
10.01.06 Work schedule with bar chart indicating all activities
10.01.07 Main cross section drawing of proposed turbine and generator showing the
various components/ parts/ assemblies of the turbine to the extent possible.
10.01.08 Equipment Layout drawing of power house generator floor, turbine floor, control
room, and transformer yards for all six units.
10.01.09 The general arrangement and overall dimensions of the generators, exciters and
bearings
10.01.10 Charts, Curves and Hill Curves showing performance and cavitation
characteristics of the turbine.
10.01.11 Generator Characteristic Curve showing performance of generator
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
Vol. III Sec-A Ch-10 Page 2 of 3
10.01.12 Curves showing areas and velocities at different section of the draft tube.
10.01.13 Schematic Diagram and Block Diagram of bearing oil lubrication system,
Cooling water System, Drainage /Dewatering system, Compressed Air System,
Brake Air System, Fire Protection System, Drinking water system, air
conditioning system, Ventilation system, oil handling facility,
10.01.14 Detailed write up of Microprocessor based digital governor
10.01.15 Physical & Schematic drawings and descriptive literature on the governor and
governing mechanism.
10.01.16 Block diagram of excitation and governor control system with start/stop
sequence of the plant with control levels.
10.01.17 List of commissioning spares and consumables included with the main offer.
10.01.18 List of 5 years operation spares, recommended by the tenderer equipment wise,
in addition to the Mandatory spares asked by the purchaser.
10.01.19 List of special tools and tackles, test jigs and special instruments required for
operation and maintenance of turbine, generator, auxiliaries, generator static
excitation, AVR, protection relays. For all other electro-mechanical equipment,
individual list of special tools and accessories required is to be furnished
for each item.
10.01.20 Proposal for training of purchaser's personnel (equipment wise/mandays basis).
10.01.21 Phase-wise requirements of power for construction, erection/testing and
commissioning activities.
10.01.22 List of performance tests proposed by the tenderer to demonstrate the
guaranteed parameters for turbine, generator, electrical equipment and other
auxiliaries in addition to tests/checks given in the specifications.
10.01.23 Technical catalogues of equipment offered.
10.01.24 List of total aux. drives for unit and common system including Air condition etc.
for main plant with kW rating, enclosure class, class of insulation, cable size,
frame size, duty cycle, places of control, rpm, type of drive (cage, slip ring etc.)
starting method, technological interlocking etc. in a format.
10.01.25 List of annunciation considered in turbine panel, generator desk and in common
aux. panels.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
Vol. III Sec-A Ch-10 Page 3 of 3
10.01.26 P&I diagram for turbine, generator and auxiliary systems like cooling system, fire
fighting system, governor control system, compressed air system, dewatering
and drainage system, oil lubrication system, etc. indicating type of local and
remote instruments recorders, gauges provided at local and remote places.
10.02 AFTER PLACEMENT OF ORDER
The list of Data/Drawing/Documents to be submitted by Successful tenderer for
approval, information will be intimated to the successful tenderer.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS Vol III Sec-A Ch-11 Page 1 of 6
11. LIST OF MANDATORY SPARES
11.01 Turbine and Associated Equipment
1. Guide vane self lubricating bushes 4sets
2. Guide vane stem seals 4sets
3. Guide vanes 18 nos.
4. Shaft sleeves 6 sets
5. Shaft seal packings 12 nos
6. Linkages/Levers self lubricating bushes 4 sets
7. Regulating ring bushes 4 sets
8. Facing plate for head cover and bottom ring 4 sets
9. Servo pin bushes 4 sets
10. Shear pin/breaking pin 4 sets
11. Piston rings for GV servo motor cylinders 4 sets
12. Servo motor seals and packings of each type 8 sets
13. Packing and sealings for spiral casing 8 sets
and draft tube man hole
14. All types of packing and sealings 4 sets
including gaskets for machine and piping.
15. Turbine Guide Bearing Shell 4 sets
16. Regulating pins 4 sets
17. Connecting pins of guide apparatus 3 sets
18. Necessary nuts, bolts, washers etc.: 4 sets(Tenderer to furnish
ODISHA HYDRO POWER CORPORATION LIMITED
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UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS Vol III Sec-A Ch-11 Page 2 of 6
the size and quantity)
19. RTDs 4 sets
20. Dial thermometer 4 set
11.01.01 Digital Governor
1. CPU card - 4 nos.
2. Transducer card - 4 nos.
3. Proportional valve - 4 nos.
4. Power Supply card - 4 nos.
5. PID module - 4 nos.
6. DC input module - 4 nos.
7. AC input module - 4 nos.
11.01.02 Governing System
1. Oil pressure pump with coupling - 4 nos.
2. Hydraulic amplifier valve - 4 sets
3. Oil filter complete - 4 sets
4. Limit switches/ micro switches - 4 sets (2 no. of each type)
5. Seals O rings internal circlips used - 4 sets
in governing equipment
6. Solenoid coils - 4 sets (2 no. of each type)
for each system
7. Pressure Switches - 4 sets (1 no. of each type)
for each system
8. Oil control check valve - 8 nos.
9. Pressure gauges - 4 nos. of each type for
each system
10. Level relay for sump tank - 4 nos.
12. Safety relief valve - 4 nos.
13. Flexible hose pipes - 4 sets
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS Vol III Sec-A Ch-11 Page 3 of 6
14. Non return valve for OPU - 4 sets
15. Bearing for motor - 4nos.
11.02 Generator and Associated Equipment
1. Stator Air Coolers - 2 sets
2. Stator coil with insulation - 1 set of coil
3. Stator bars of each type - 10%
4. Field coil with insulation - 12 coils
5. Thrust pad - 3 sets.
6. Guide pad - 3 sets
7. Bearing shell - 3 sets of each type
8. Bearing oil cooler - 3 sets of each type.
9. Collector ring - 3 sets
10. Brush holder - 4 sets
11. Carbon brush - 4 sets.
12. Brake shoe - 4 sets.
13. RTDs for bearings - 12 nos.
14. Dial type thermometer - 12 nos.
15. Speed sensor probes - 1 no.
16. Brake liner - 3 sets
17. Filter element of oil - 3 sets
18. Solenoid coils - 3 sets
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS Vol III Sec-A Ch-11 Page 4 of 6
19. Level gauge - 6nos.
20. Pressure switch - 12 nos
21. Pressure gauge - 12 nos
22. Contact springs & coils for each - Three complete sets
type of relay contactor
23. Seal packing (all type) - 4 sets
11.02.01 Excitation system & AVR
1. Thyristor with fuse - 9 sets
2. Fuses - 30 nos. of each type
3. Digital/Electronic cards used in (AVR etc.) - Three of each tube
4. Bushings of Excitation transformer - 2 nos. of each type
5. Field breaker coils - 4 sets
6. Field breaker aux. contacts - 4 sets
7. Power supply DC/DC converter - 4 sets
8. Gate pulse transformer unit - 4 sets
9. Fuses of all types - 4 sets (5 of each type)
11.03 Cooling water system
1. Pump motor with coupling - 4 sets
2. Bearing of motor - 4 sets
3. Pump seal - 4 sets
4. Filter element - 4 sets
5. Pressure gauge - 4 sets
6. Valves - 4 sets
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS Vol III Sec-A Ch-11 Page 5 of 6
7. NRV - 4 sets
8. Flow meter - 4 sets
11.04 Dewatering
1. Pump motor with coupling - 2 sets
2. Bearing of motor - 2 sets
3. Pressure gauge - 2 sets
4. Pump seal - 2 sets
5. Head cover dewatering pump motor set - 2 sets
11.05 Drainage system
1. Pump motor with coupling - 2 sets
2. Bearing of motor - 2 sets
3. Pressure gauge - 2 sets
4. Pump seal - 2 sets
11.06 Compressed Air System
1. Pressure gauge - 2 sets
2. Safety relief valve - 2 sets
11.07 Drinking water system
1. Pump motor with coupling - 2 sets
2. Bearing of motor - 2 sets
3. Pressure gauge - 2 sets
4. Pump seal - 2 sets
11.08 Oil Handling Facility
1. Pump motor with coupling - 2 sets
2. Bearing of motor - 2 sets
3. Pressure gauge - 2 sets
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS Vol III Sec-A Ch-11 Page 6 of 6
4. Pump seal - 2 sets
11.09 Draft tube Gates
1. Gate seal - 3 sets of each type
2. Rollers - 2 sets
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS 1 TO 6(6x60 MW)
R&M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
Vol. III Sec-A Ch-12 Page 1 of 1
12. LIST OF PREFERED MAKES
The Tenderer shall have to select any of the sub-vendors from the list of
preferred makes only and no deviation to this effect will be entertained during
the execution of the contract unless a specific approval has been obtained for by
the Tenderer from the OHPC/Consultant.
Sl. No. EQUIPMENT Preferred Makes
1. PUMPS KI RLOSKAR/KSB/MATHER & PLATT/WPIL
2. MOTORS NGEF/BBUGEC/BHEUKEC/ JOYTI/ABB
3.
SOLENOID VALVE ASCO(INDIA), SEITZ-ROTEX, SCADER
DUNCAN
4.
INSTRUMENT
CABLES
CABLE CORP., FINLOEX CABLES,
TOSHNIWAL CABLES
5.
GATE, GLOBE, BALL
VALVE
AUDCO, DEZURIC, TIFLIN, SAKHI
INTERNATIONAL, BDK
6.
DUPLEX FILTER OTOKLIN, SUPERFLO, FILTERATION
ENGINEERS
7.
PRESSURE
CONTROLLERS
SAIL, TISCO, AJANTA TUBE, MAN
INDUSTRIES, MUKAND
8. PLUG VALVES AUDCO, DEZURIC, TUFLIN
9.
AIR
CONDITIONING
MACHINE
VOLTAS/ THERMAX
10. COMPRESSOR ATLAS COPCO/ IR/ ELGI/ KPC
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMEL POWER HOUSE, BALIMELA
UNITS 1 TO 6 (6 x 60MW)
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
VOLUME III
TECHNICAL SPECIFICATION
SECTION- B
CIVIL
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 1 of 33
B. CIVIL WORKS
1.1 General
1.1.1 Civil works include Civil works detailed in Section-I for units 1 to 6 and Section-II for
Architectural finishing works of Power House .
1.1.2 The project comprises of renovation & modernization of Unit No. 1 to 6 out of total 8
units in Balimela Power house. Work shall be executed such that the new
constructions match with the existing structure. Utmost care shall be taken while
carrying out dismantling work so that no damage is done to the existing structures.
Also safety of the existing structure shall be looked into while making new
construction.
1.1.3 The tenderer shall visit and carefully examine the site and surroundings to satisfy
himself about the nature of all existing structure, existing underground services,
general site condition, extent of dismantling work, the site for disposal of surplus
materials, debris etc. and all other matter affecting the works. Claim and objection
due to ignorance of site condition shall not be considered after submission of tender.
1.1.4 The architectural finish shall be carried out through an Interior decorator of repute
with relevant experience in the field. The credential of the interior decorator engaged,
shall be submitted for approval by Client/ Consultant.
SECTION-I : Civil Works of Units 1 to 6
I.1 Scope of work
I.1.1 The successful Tenderer's scope shall include complete engineering and construction
on a turnkey basis inclusive of detail design, basic engineering, detailed engineering,
supply of all materials, construction and testing in respect of all facilities required for
completion and handing over of the work as per technical specification.
I.1.2 All civil works for the buildings, equipment foundations, facilities and miscellaneous
civil works to be provided for the project shall include but not be limited to the
following:
a) Draft tube - The lining of draft tube should be inspected by hammer taping. The
loose area where de-lamination has taken place should be repaired by pressure
grouting. The area where the lining plate are missing and the base concrete is
exposed, the same should be given a layer of concrete with fibre reinforcement
and finished with hardener at top. The delaminated lining of the draft tube shall
be re-fixed.
b) Embedment of Draft tube gate - The loose concrete around the embedment of
gates should be removed and the concrete around the area should be made
dense and water tight by putting fresh concrete with applying epoxy based
bonding agent between old and new concrete or by injecting cement-slurry with
water proofing compound. The damaged embedment shall be refurbished /
replaced wherever required. Re-anchoring of guides including making the
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 2 of 33
concrete near guide water proof and facing plates of gates (if required).
c) Civil foundations for equipment - The repair, refurbishment and modification /
strengthening of existing TG & Auxiliary equipment foundations should be done
as per the requirement of the equipment base profile and static/dynamic loading.
Strengthening should be done by injecting cement slurry with admixture. The
existing concrete surface should be given treatment to develop adequate bond
between old and new concrete. Anchor bolts should be provided by drilling holes
in the existing concrete and fixing it by epoxy based mortar. The grouting under
the base plate should be done with non-shrink free flow grout.
d) Unit Control Room - Unit control room of each of six units is to be modified into
glass cabinet with wood-work below windows.
e) Main Control Room - It contains all the eight units. The whole main control room
including Unit No. 7 & 8 is under the scope of work. The control room floor, false
ceiling, doors & windows shall be replaced to suit the requirement of the
modification of power house.
f) Extension of 220 kV bay it will consist of following works;
Clearing, filling and leveling of area 142 m X 23 m (approx.) for extension of
220 kV bay to match the terrace level with the existing switchyard
Removal of existing boundary wall of length 142 m, height 1.5 m and
thickness 0.30 m in the portion 220 kV bay to be extended. Dismantling of
existing 02 nos. gates.
Construction of new boundary wall of the size and design same as that of
existing boundary wall. New boundary wall shall match with the existing wall
and shall be of length 142 m, height 1.5 m and thickness 0.30 m to cover the
extension portion of 220 kV bay. Fixing of existing gates.
Re-routing of approach road of length 100m (approx.) shall be made of PCC
of thickness 30 cm and width 4 m on the properly graded layer.
Foundation for 220 kV structure, 220/11 kV transformer, 220 kV equipment
(PT, LT, LA)
Construction of earth-pit as per IS3043 .
Extension of cable trench for portion of 220 KV bay.
g) Refilling redundant recesses in floor
h) Drilling panel cable access holes through floors/RCC wall
i) Modification of turbine foundation and the pit to accommodate new runner.
j) Strengthening of existing concrete structure
k) Rehabilitation of distressed concrete structure and inserted parts/steel linings.
l) Stoppage of leakage of water from surface of concrete.
m) Cleaning of dewatering pit
n) Repair of expansion joints and providing MS plate all along external and internal
surfaces for the protection of the joint
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 3 of 33
o) Replacement of Main entrance rolling shutter of Powerhouse building with new
one.
p) Supply and installation of 2 Nos. of lifts (Capacity of 12 persons of each lift).
q) Repair and refurbishment of Tail-pool and Side walls of Tailrace channel
r) Removal of debris after completion of construction.
I.1.3 The successful tenderer shall undertake within the battery limits any change in the
location of units/items and/or structures/parameters, sizes etc. of civil structures
which may be necessary during engineering/execution from those indicated by the
successful tenderer in their contract drawings at no additional cost to the Purchaser.
I.1.4 The checking and correctness of all main centerlines is the responsibility of the
successful tenderer irrespective of any checking by Purchaser/Consultant
I.1.5 All other civil works that will be necessary to complete the work in all respects.
I.2 Civil works General details
I.2.1 Concrete and reinforced concrete structure
a) All concrete and reinforced concrete structures shall be constructed.
b) The mix design adopted shall be suitable for proper strength, workability and service
condition of the structure. Minimum cement content and maximum water cement
ratio shall be normally as per stipulations of BIS codes. However, in case of
exposure to aggressive environments, the mix design adopted shall be suitable to
ensure durability of the concrete under the condition.
c) Unless specifically approved by the Engineer the maximum nominal size of coarse
aggregates for concrete shall be 20mm and down.
d) Steel reinforcement to be used shall be Fe415 grade or equivalent shall be used
unless otherwise specified.
e) Wherever there is a joint of old and new concrete, suitable chemical treatment shall
be given to the surface of old concrete to develop adequate bond between them.
I.2.2 Turbine & Generator and auxiliary equipment foundations
Modification of existing foundations of turbine, generator and other equipment is to
be done as per the base profile of the equipment. The successful tenderer shall
check the adequacy of the strength / serviceability of the existing foundation
considering the static and dynamic loads of the equipment. The preparation of
strengthening scheme/plan, if required and implementation of the same shall be
under the scope of successful tenderer. The successful tenderer has to furnish the
calculations justifying adequacy of the proposed scheme strengthening.
Strengthening of existing concrete structure shall be carried out where it is expected
to carry more superimposed loads than the original design due to new/ upgraded
technological requirement. All necessary modification in the existing structure shall
ODISHA HYDRO POWER CORPORATION LIMITED
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UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 4 of 33
be simultaneously considered to accommodate the new set up.
The Successful Tenderer shall submit the following with regard to strengthening
work.
a) As built drawing of the existing portion as per availability with the Purchaser/
Consultant.
b) Load data of the new structure.
c) Scheme and design calculation for all new structures. The design calculation shall
include static design calculation for all structures and dynamic analysis for all
important structures subjected to impact, vibrations etc. induced by equipment.
d) After getting approval of the Purchaser / Consultant for the scheme and design
calculations, the Successful Tenderer shall prepare construction drgs. for the same
and submit for Purchaser/ Consultant's approval.
The successful Tenderer shall stand fully responsible for design/safety of all
structures irrespective of approval of the same by the Purchaser/ Consultant.
I.2.3 Design Loads
Loads due to normal operating condition as well as due to extra ordinary conditions
shall be taken into account. For normal operating condition, following loads shall be
considered.
Dead loads
Live loads (not less than 2T/m2)
Load throw loads
Piping loads
Thermal loads
Unbalanced dynamic loads from turbine and generator
Torque load
Temperature load (as specified by manufacturer) for extra ordinary conditions,
following loads shall be considered.
Seismic load (as per IS: 1893)
Wind load (as per IS: 875)
Short Circuit load
Any other abnormal load due to machine breakdown, as specified by
manufacturer.
The load combinations shall be as per IS: 2974(part-3)
I.2.4 Material of construction
All reinforced concrete work will be of grade M30. Corrosion inhibitors of approved
make will be used in Concrete for all RCC work excepting for storm water drains as
per manufacturers specification and details.
The following standards shall be taken as guidelines unless otherwise specified
above
.1) IS: 2974(Part-3)
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TS VOL III Sec. B Page 5 of 33
2) IS: 1893-2002
3) IS: 456-2000
4) IS: 4247-1993
I.3 Submission of Design Calculations, Drawings and documents by successful
tenderer
I.3.1 The design calculations shall be submitted prior to submission of construction
drawings.
I.3.2 Structure and foundation design
a) The design calculations for all the structures and foundations shall be furnished. The
design calculations shall include static design calculations for all structures and
foundations, dynamic analysis for all important structures and foundation subjected
to impact, vibrations etc. induced by equipment and other external forces.
b) The data sheet showing specifications of materials, design standards followed, load
data assumed including the seismic loading, vibration considerations, deflection, etc.
shall be furnished. The loading combinations and other design assumptions made in
design are to be furnished.
c) Measures required for the safety of the buildings and foundations.
d) Design and construction/reconditioning of structures, facilities etc. shall take into
account requirement for operation and maintenance of all equipment and its users.
e) This being a renovation/modernisation project, while designing and preparing new
facilities the successful tenderer shall take into account the structures, foundations,
drains, sewers etc of the existing units and modify them, if found necessary, to
match the new ones.
I.3.3 Design Calculations, Drawings and documents
The design calculations/scheme drawing shall be submitted by the successful
tenderer for approval of the Purchaser/Consultant prior to submission of construction
drawings. The following aspects shall be considered with regard to design
calculations.
a) The successful Tenderer shall undertake investigation of field problems by critical
visual examination and additional field test non-destructive as required to be
ascertained:
Defects associated with concrete like erosion, cracks, cavities, pitting, corrosion,
spelling and peeling of and deterioration of reinforcement etc.
Leakage of water through the structures
Condition of components
Condition of external surfaces
Condition of internal surfaces
The successful Tenderer shall submit graphic records of observation of field
ODISHA HYDRO POWER CORPORATION LIMITED
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R & M WITH NEW TG SET
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TS VOL III Sec. B Page 6 of 33
problems. Along with this the successful Tenderer shall submit report/drawing
showing scheme for rehabilitation/reconstruction of distressed concrete struc-
ture/inserted parts.
b) The successful Tenderer shall prepare detailed working drawings considering overall
foundation layout for the equipments, buildings services etc., space requirement and
clearances as necessary. The successful Tenderer shall submit a comprehensive
and complete unit wise classified list of drawings.
c) The successful Tenderer shall submit for approval/information, general arrangement
and detailed working drawings for all concrete, reinforced concrete and other civil
works.
d) The successful Tenderer shall submit As-built drawings incorporating all site
modifications after completion of construction work.
e) If the successful Tenderer intends to carry out any part of the work through
subcontractor then prior approval of the subcontracting agencies shall be taken from
the Purchaser/Consultant
I.4 Quality Control The successful Tenderer shall carryout all checks and tests as
directed by the Purchaser / Consultant and submit the results thereof. Acceptance of
works shall be subjected to achieving required quality as laid down in code of Bureau
of Indian Standards.
I.5 Technical Rule - This Technical Rule is meant for civil engineering works included
in the scope of work in the package. It includes loading standards, permissible
stresses, functional requirement, quality standard, architectural guidelines, norms etc
to be adopted as a basis for preparation of design and drawings by the successful
Tenderer.
The design prepared by the successful Tenderer shall not only provide for the
requirement indicated in this technical rule but also consider the overall process
requirement, service conditions and provisions to be made for future expansion. The
design shall be compatible with the operating conditions in the plant and the
atmospheric conditions prevalent at location of project site.
Standardisation and unification shall be carried out to the maximum extent possible.
Purchaser reserves the right of selecting a particular make of materials and
components. The successful Tenderer shall supply materials / components of the
particular make, if so required.
I.6 Standards
a) The design criteria for civil engineering work shall be in accordance with this
Technical Rule. Detailed instructions on such aspects as are not indicated herein
shall be as per the latest standards, codes and recommendations of the Bureau of
Indian Standards (BIS) specifications/Indian road Congress and specifications
published by Ministry of Surface and Transport (MOST). In the absence of suitable
BIS specification and codes of practices, other recognised international standards
and codes such as of International Standards Organisation (ISO), British Standards
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
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TS VOL III Sec. B Page 7 of 33
and codes, Deutsche Industries Norm (DIN), American concrete Institute (ACI) may
be used, with prior approval of the Purchaser.
b) In case of anything mentioned in this Technical Rule is at variance with BIS or other
standards mentioned herein, the provisions of this Technical Rule will prevail.
I.7 Design Parameter
A) General
In addition to the minimum requirements outlined herein, the successful Tenderer
shall design and construct the buildings, structure, foundations and other civil items
as required for all equipments and systems considering all aspects of operational
requirements and maintenance of these equipments and facilities.
General provision, materials, workmanship, dimensional tolerances, safety
requirements for construction works etc. shall be in accordance
B) Load Condition
01 All foundations and concrete structures shall be designed to resist full operating
dead and live loads, with appropriate combination of wind and seismic forces and
with due allowance for impact, vibration etc as secondary effects of live loads,
temperature variation etc. While designing structures and foundations either the
effect of seismic forces or wind loads, whichever produces the worst effect, shall be
considered along with usual load conditions.
02 Apart from the operating loads indicated by the equipment manufacturers, the
design of buildings and structures shall be based on dead and imposed loads
calculated according to IS: 875, subject to minimum imposed loads indicated below.
03 The live loads listed hereunder are minimum loads for the areas involved. Special
use areas shall be investigated and loading revised upward as necessary. Additional
loading due to electrical cables, ventilation and air conditioning, piping etc. shall be
considered as per technological requirements.
All buildings (except as noted separately):
Roofs 150 kg/m2
Platform and stair 500 kg/m2
On ladders 120 kg at centre of rung
Removable covers 1500 kg/m2
Generator lay down area 2000 kg/m2
Control Room 1000 kg/m2
04 Design wind pressure and forces shall be as per the provisions of IS: 875. Stresses
induced due to dynamic effect of wind shall be considered in design as per relevant
IS codes.
05 Seismic forces shall be considered according to the provisions of IS: 1893.
06 Members subjected to temperature variations shall be designed to withstand the
stresses arising out of such temperature variations.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 8 of 33
07 Design of structures shall provide for temporary loads, which may be lifted during
erection and maintenance of plant and equipment. Consideration shall be given in
the design of structures to the contributing loads from piping and cabling including
provisions for piping anchors and dead endings of electrical conductors.
08 In case of moving loads, full load under worst operating condition together with
minimum 25% vertical impact factor shall be considered for vehicles and machinery
travelling on tracks (rails). Horizontal forces along and transverse to the rails as per
equipment manufacturers data and recommendations shall be considered in design
of the track supporting structures and foundations.
09 The design of buildings and structures shall take into account the loadings due to
future extension of units as well as due to and installation of additional equipment, in
future in the units.
C) Permissible Stresses
Allowable stresses for all reinforced concrete structures shall be as per IS: 456 and
for prestressed concrete structure as per IS:1343
D) Foundations
01 Foundations for structures and equipment shall be proportioned to resist the worst
condition of loadings and shall be generally designed as per the provisions of
IS:1904.
02 Generally foundation for buildings & equipments shall not be structurally connected
to ground floor slab. The top level of the stem for building column foundations shall
be so provided that no part of the steel column base assembly protrudes over
finished floor level. The column base assemblies shall be encased with concrete up
to floor level.
03 Foundation of equipments subjected to dynamic loading shall be isolated from
adjoining floors/foundations to prevent propagation of vibration to adjoining
structures.
04 Supporting structures and foundation for equipments which may cause vibration
shall be designed for the dynamic effect of equipment together with the direct loads.
The dynamic loads and other relevant data required for analysing the dynamic effect
shall be taken as per manufacturers' data and recommendations.
05 Structures and foundations supporting vibrating equipments shall be proportioned to
avoid resonant frequencies. The dynamic analysis shall be done as per the
stipulations as recommended by respective IS codes as well as the stipulations
recommended by equipment manufacturer.
E) Concrete and Reinforced Concrete for Structures and Foundations
01 General
i) Concrete work shall secure a dense, homogeneous, smooth mass including required
finishes, possessing required strength and resistance to weathering and abrasion for
the structures and foundations.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 9 of 33
ii) Design of all reinforced concrete structures shall be as per the IS: 456 and of
prestressed concrete structures as per IS: 1343. The structural safety of all
foundations on soil shall, in general, be based on IS: 1904. The design of water
retaining structures shall be according to IS: 3370.
iii) For calculation purpose "Working Stress Design" or "Limit State Design" methods
may be adopted, but design shall be consistent throughout.
iv) Unless otherwise specified, minimum grades of concrete to be used shall be as
follows:
Blinding concrete M 7.5
Plain cement concrete M10 & M15
All reinforced concrete M30
01 Grouting below machine/equipment bases and pockets shall be of non-shrinking
grout of adequate thickness and strength. Grouting below bases of building structural
members shall be with concrete of minimum grade M35.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 10 of 33
List of Relevant I.S. Codes
IS: 269-1989: Specification for 33 grade ordinary Portland cement.
IS: 383-1970: Specification for coarse and fine aggregates from natural
sources for concrete.
IS: 432 (PART-1)-1982: Specification for mild steel and medium tensile steel bars
and hard drawn steel wire for concrete reinforcement-
hard drawn steel wire.
IS: 432 (PART-2)-1982: Specification for mild steel and medium tensile steel bars
and hard drawn steel wire for concrete reinforcement-
hard drawn steel wire.
IS: 455-1989: Specification for Portland slag cement.
IS: 456-2000: Code of practice for plain and reinforced concrete.
IS: 458-1988: Specification for precast concrete pipes (with or without
reinforcement).
IS: 651-1992: Specification for salt glazed stone ware pipes and fittings.
IS: 771-1963: Specification for glazed earth ware sanitary appliance
(line water closets, urinals wash basins, sink etc.)
IS: 782-1978: Specification for caulking lead.
IS: 783-1985: Code of practice for laying of concrete pipes.
IS: 814-1991: Covered electrodes for manual metal are welding of
carbon and carbon manganese steel.
IS: 816-1969: Code of practice for use of metal arc welding for general
construction in mild steel.
IS: 875(PART-1)-1987: Code of practice for design loads (other than
earthquake) for buildings and structures - dead loads.
IS: 875(PART-2)-1987: Code of practice for design loads (other than earthquake)
for buildings and structures - imposed loads.
IS: 875(PART-3) 1987: Code of practice for design loads (other than earthquake)
for buildings and structures - wind loads.
IS: 875(PART-5)-1987 Code of practice for design loads (other than earthquake)
for buildings and structures - special loads and load
combinations
IS: 1038 -1983: Specification for steel doors, windows and ventilators.
IS: 1080 -1986: Code of practice for design and construction of shallow
foundations on soil (other than raft, ring and shell).
IS: 1609 -1991: Code of practice for laying damp proofing treatment using
bitumen felts
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 11 of 33
IS: 1742 -1983: Code of practice for building drainage
IS: 1786 -1985: Specification for high strength deformed steel bars and
wires for concrete reinforcement.
IS: 1893 -2002: Criteria for earthquake resistant design of structures.
IS: 1904 -1986: Code of practice for design and construction of
foundations in soil: General requirement
IS: 1905 -1987: Code of practice for structural use of unreinforced
masonry
IS: 2062 -1992: Structural steel (fusion welding quality)
IS: 2751-1979: Welding of mild steel plain and deformed bars for
reinforced concrete construction
IS: 2950(PART-1)1981: Code of practice for design and construction of raft
foundations -design
IS: 2974(PART-1) 1982: Code of practice for design and construction of machine
foundation - foundation for reciprocating type machines.
IS: 2974(PART-2) 1980: Code of practice for design and construction of machine
foundations - foundations for impact type machine
(Hammer foundations).
IS: 2974(PART-3) 1982: Code of practice for design and construction of machine
foundations - foundations for rotary type machines
(medium and high frequency).
IS: 2974(PART-4) 1979: Code of practice for design and construction of machine
foundations - foundations for rotary type machine of low
frequency.
IS: 2974(PART-5) 1987: Code of practice for design and construction of machine
foundations - foundations for impact type machines other
than hammers (forging and stamping press, pig breakers,
drop crusher and jolter).
IS: 3006-1979: Specification for chemically resistant glazed stone ware
pipes and fittings.
IS: 3067-1988: Code of practice for general design details and
preparatory work for damp proofing and water proofing of
buildings.
IS: 3114-1985: Code of practice for laying of cast iron pipes.
IS: 33'70(PART-1) 1965: Code of practice for concrete structures for the storage of
liquids -general requirements.
IS: 3370(PART-2) 1965: Code of practice for concrete structures for the storage of
liquids - reinforced concrete structures.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
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TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 12 of 33
IS: 3370(PART-4) 1967: Code of practice for concrete structures for the storage of
liquids - design tables.
IS: 3614(PART-1) 1966: Specification for fire check doors - plate, metal covered
and rolling type.
IS: 3764-1992: Excavation work - code of safety.
IS: 3414-1968: Code of practice for design and installation of joints in
buildings.
IS: 4127-1983: Code of practice for laying of glazed stone ware pipes
IS: 4326-1976: Code of practice for earthquake resistant design and
construction of buildings.
IS: 6494-1988: Code of practice for water proofing of underground water
reservoirs & swimming pools.
IS: 7452-1990: Hot rolled steel sections for doors, window sand
ventilators
IS: 1239-1968: Specification for mild steel tubes, tubular and other
wrought steel fitting (Part -I Mild Steel Tubes).
IS: 1580-1991: Bituminous compounds for water proofing and caulking
purposes.
IS: 13311(Part-I)-1992: Non-destructive testing of concrete
II. SECTION-II : Architectural Finishing Works of Power House
II.1 SCOPE OF WORK
Interior decoration of the existing power plant at Balimela of OHPC which includes
application of appropriate fixtures and finishing items in floor, wall, ceiling, doors and
windows and submission of drawings and BOQ for following use areas.
1. Machine Hall & Service bay
2. Control room,
3. Conference Room
4. Acid/Battery Room
5. Battery charger Room
6. Office ,Corridor ,Lobby
7. Staircase including adjoining areas
8. The Entrance of Power house building
9. Exterior wall of power house building
10. Toilet( Male and Female)
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 13 of 33
The work shall be done as per actual and the payment shall be governed by the
relevant clauses of Vol-I & II. Details of BoQ are given in Vol-I, Price fomat Table-3a.
Note : The bidders are requested to visit the respective units/sections of power plant
before quoting.
SCHEDULE OF FINISHES:
A. MACHINE HALL & SERVICE BAY
i) Flooring
The flooring for this area shall be 20mm thick gang saw cut mirror polished,
premoulded Granite tiles/slabs of required size(>0.5 sq.m) shade, colour and
texture laid over 20mm thick base of cement mortar( 1 Cement: 4 Coarse
sand) with joints treated with white cement, mixed with pigments, epoxy
touch-ups including rubbing, curing, moulding and polishing or complete as
per direction of Engg. in charge.
Chequered plate to be raised to matching with new floor level for which P.C.C
should be laid below the support of all chequered plates to maintain an
uniform level throughout the floor.
Fixing of tile flooring with cement based high polymer modified quick
set adhesive (water based)
When tile flooring is to be laid over the existing flooring without dismantling old
flooring it can be laid with adhesive. The old flooring shall be thoroughly
cleaned and checked for undulations , if any shall be rectified with cement
mortar 1:3 (1 cement: 3 coarse sand). Old cement concrete surface shall be
hacked and cleaned off to have proper bond with the old surface. High
polymer modified quick set tile adhesive (conforming to IS 15477) shall be
thoroughly mixed with water and a paste of zero slump shall be prepared so
that it can be used with in 1.5 to 2 hours. It shall be spread over an area not
more than one sqm at one time. Average thickness of adhesive shall be 3 mm
ii) Skirting / dado
Minimum 150mm skirting matching with floor finish will be provided in all
areas unless specified other wise elsewhere.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 14 of 33
iii) Paneling of wall
4mm thick aluminium composite panel AL-45 of Aludecor or equivalent
make(model-AD 09 & AD 75 with foil thickness of minimum 0.50 mm for wall
cladding in sizes as prescribed in the drawings, the base frame shall be made
up of 2550 mm aluminium section of approved make in required grid so as to
provide proper support to the maximum size of ACP sheet, all the horizontal
and vertical joints of the sheets to be sealed with weather silicon(dow corning)
to make the entire system air and water tight as per direction of EIC.
iii) Paneling of Column
All interior column , beam and few portion of wall as per drawing/sketch
(attached herewith) shall be cladded with PVdF surface coating of 4mm thick
(ACP) aluminium composite panel metallic colour (aluminium thickness shall
be 0.5mm) of approved brand and shade around the columns / dead walls at
all hights.
iv) Painting on wall panel
All interior wall panels shall be coated with approved shade of water based
low VOC led free Acrylic emulsion paint over plaster of paris / wall putty of 1st
quality. A minimum of two finishing coats of paint over a primer will be
provided.
v) Painting of Chequered plate, railing.
All structural beams at ceiling of machine hall shall be painted with two coats
of polyurethane of approved shade and brand ( Recommended DFT: 30-40
per coat Corresponding WFT: 67-90 per coat) over a coat of approved
primer all complete as per drawing, before applying the new coat of paint
scraping of old paint, removing grease, dust suspended particle etc. shall be
ensured.
vi) Louvers
Replacing the existing louvers and Providing and fixing aluminum louvers of
approved brand including fixing 50x5mm glass in slits complete in all respect
as per manufacturer specification and direction of engineer
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 15 of 33
vii) False ceiling
Providing and fixing in position false ceiling with LUXALON 84 R/C ceiling
system comprising of 84 mm wide x 16mm deep perforated panels roll of
approved colour formed of 0.5mm thick Aluminium alloy stove enamelled on
both sides fixed on panel carriers 62 mm wide x 29mm deep out of 0.95mm
thick enamelled Aluminium satin black with cutouts to hold panels in a module
of 100mm (16 mm gap between panels) at maximum 1.3 M c/c carriers to be
suspended from roof by 4mm dia galvanised steel wire hangers with special
height adjustment clips made of spring steel at maximum 1.3 M c/c hangers
fixed to roof by "J" hook and Nylon inserts with provision of openings for fixing
light fittings, air conditioning grills etc. complete with all bye works as per
drawing and manufac-turer's specification.
B. CONTROL ROOM
i) Flooring
2mm thick antistatic PVC Roll of approved shed and brand as per IS 3462
and laid as per IS-5318 over existing concrete floor after removing the existing
PVC mat.
ii) Wall paneling
59.5mm Thick Dry Wall Partitions with 9.5mm USG Fiberock boards fixing
one side with 50mm floor Channel & 48mm Stud, joint finishing with USG All
Purpose jointing Compound & laminate 1.8mm minimum) finish upto 2.1 mtr.
From floor.
iii) Painting on wall panel
All interior wall panels shall be coated with approved shade of water based
low VOC led free Acrylic emulsion paint over plaster of paris / wall putty of 1st
quality. A minimum of two finishing coats of paint over a primer will be
provided.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 16 of 33
iv) False ceiling
Providing and fixing in position false ceiling with LUXALON 84 R/C ceiling
system comprising of 84 mm wide x 16mm deep perforated panels roll of
approved colour formed of 0.5mm thick Aluminium alloy stove enamelled on
both sides fixed on panel carriers 62 mm wide x 29mm deep out of 0.95mm
thick enamelled Aluminium satin black with cutouts to hold panels in a module
of 100mm (16 mm gap between panels) at maximum 1.3 M c/c carriers to be
suspended from roof by 4mm dia galvanised steel wire hangers with special
height adjustment clips made of spring steel at maximum 1.3 M c/c hangers
fixed to roof by "J" hook and Nylon inserts with provision of openings for fixing
light fittings, air conditioning grills etc. complete with all bye works as per
drawing and manufac-turer's specification.
C. CONFERENCE HALL
i) Flooring
Providing and laying 600x600x9.5mm first quality full body/double charged
Vitrified tiles with water absorptions less than .08% and conforming to IS :
15622 of approved shade and brand shall be used
Fixing of tile flooring with cement based high polymer modified quick
set adhesive (water based)
When tile flooring is to be laid over the existing flooring without dismantling old
flooring it can be laid with adhesive. The old flooring shall be thoroughly
cleaned and checked for undulations , if any shall be rectified with cement
mortar 1:3 (1 cement: 3 coarse sand). Old cement concrete surface shall be
hacked and cleaned off to have proper bond with the old surface. High
polymer modified quick set tile adhesive (conforming to IS 15477) shall be
thoroughly mixed with water and a paste of zero slump shall be prepared so
that it can be used with in 1.5 to 2 hours. It shall be spread over an area not
more than one sqm at one time. Average thickness of adhesive shall be 3
mm.
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 17 of 33
ii) Skirting / dado
Minimum 150mm skirting matching with floor finish will be provided in all
areas unless specified other wise elsewhere.
ii) Wall paneling
4mm thick aluminium composite panel AL-45 of Aludecor or equivalent
make(model-AD 09 & AD 75 with foil thickness of minimum 0.50 mm for wall
cladding in sizes as prescribed in the drawings, the base frame shall be made
up of 2550 mm aluminium section of approved make in required grid so as to
provide proper support to the maximum size of ACP sheet, all the horizontal
and vertical joints of the sheets to be sealed with weather silicon(dow corning)
to make the entire system air and water tight as per direction of EIC.
iv) Painting on wall panel
All interior wall panels shall be coated with approved shade of water based
low VOC led free Acrylic emulsion paint over plaster of paris / wall putty of 1st
quality. A minimum of two finishing coats of paint over a primer will be
provided.
v) False ceiling
Supplying and Fixing of USG Suspended ceiling systems components. This
includes Sheetrock Brand ST 55 Perimeter Channel (0.55mm thick having
one flange of 21mm and another flange of 28mm and a web of 25mm) screw
fixed to brickwall / partition with the help of approved screws at 600mm
centers. Then suspending Sheetrock Brand ST 55 Main Channel (38mm x
14mm x 0.9mm thick with two flanges of 14mm each) from the soffit at
1220mm centers with Sheetrock Brand ST 55 Angle Profile (25x10mm x
0.55mm thick) fixed to RCC Slab with Sheetrock Brand ST 55 Soffit Cleat and
M6 Fasteners @ 600mm Centers respectively.
Sheetrock Brand ST 55 Furring Channel (having knurled web of 48mm and
two flanges of 24mm each with lips of 8.9mm) are then fixed to the Main
channel with the help of connecting clip (2.5mm Dia) and in perpendicular
direction to the intermediate channel at 457mm centers.
6.6mm thick USG Fiberock Panel is screw fixed with 25mm long Drywall
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 18 of 33
screws at 230mm centers. The screw fixing of Gypsum Panels to the metal
framing at the periphery, openings and cut edges should be at 150mm
centers. All the Gypsum Panels must be staggered.
All joints to be taped & finished with 50mm wide Sheetrock Brand Paper Tape
& Sheetrock Brand All Purpose Joint Compound Confirming to ASTM C475.
D. ACID/BATTERY ROOM
i) Flooring
Acid / alkali resistant tiles 300x300x14 mm thick, jointed with acid / alkali
resistant cement mortar. Bedding will comprise of potassium silicate mortar
conforming to IS:4832 (Part-1) and resin based mortar like epoxy for jointing.
ii) Dado
10 mm thick acid and/or alkali resistant tiles of approved make and colour
using 12mm thick acid and/or alkali resistant mortar bedding (1:4) and joints
filled with acid/or and alkali resistant cement as per IS:4457.Complete as per
direction of engineer-in-charge.
iii) Painting
All interior walls & Ceiling shall be coated with approved shade of Acid
resistant paint
E. BATTERY CHARGER ROOM
i) Flooring
Acid / alkali resistant tiles 300x300x14 mm thick, jointed with acid / alkali
resistant cement mortar. Bedding will comprise of potassium silicate mortar
conforming to IS:4832 (Part-1) and resin based mortar like epoxy for jointing.
ii) Dado
10 mm thick acid and/or alkali resistant tiles of approved make and colour
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 19 of 33
using 12mm thick acid and/or alkali resistant mortar bedding (1:4) and joints
filled with acid/or and alkali resistant cement as per IS:4457.Complete as per
direction of engineer-in-charge.
iii) Painting
All interior walls & Ceiling shall be coated with approved shade of Acid
resistant paint
F. STAIR CASES
i) Tread
18mm (minimum) thick white marble flooring with 75mm wide black granite
strip with groove & bull nosing in steps & all landings.
Riser - 18mm (minimum) thick black granite in skirting & riser1.6
ii) Hand rail &Railing
Providing and fixing stainless steel ( SS Grade 304) 1000 mm height of knock
down fixing system railing made of 38 mm dia stainless steel Handrail (Wall
Thickness 1.5mm), 40mm x 40mm SS Square Baluster @ 900mm
(maximum) c/c with complete fixtures, 16mm dia x 3 Nos. SS Horizontal
Member.( Existing Brick Wall Railing to be demolished before fixing SS
Railing).
G. OFFICE, CORRIDOR, LOBBY
i) Flooring
Providing and laying 600x600x9.5mm first quality full body/double charged
Vitrified tiles with water absorptions less than .08% and conforming to IS :
15622 of approved shade and brand shall be used
Fixing of tile flooring with cement based high polymer modified quick
set adhesive (water based)
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 20 of 33
When tile flooring is to be laid over the existing flooring without dismantling old
flooring it can be laid with adhesive. The old flooring shall be thoroughly
cleaned and checked for undulations , if any shall be rectified with cement
mortar 1:3 (1 cement: 3 coarse sand). Old cement concrete surface shall be
hacked and cleaned off to have proper bond with the old surface. High
polymer modified quick set tile adhesive (conforming to IS 15477) shall be
thoroughly mixed with water and a paste of zero slump shall be prepared so
that it can be used with in 1.5 to 2 hours. It shall be spread over an area not
more than one sqm at one time. Average thickness of adhesive shall be 3 mm
ii) Skirting / dado
Minimum 150mm skirting matching with floor finish will be provided in all
areas unless specified other wise elsewhere.
iii) Painting
All interior walls shall be coated with approved shade of water based low VOC
led free Acrylic emulsion paint over plaster of paris / wall putty of 1st quality. A
minimum of two finishing coats of paint over a primer will be provided.
iv) False ceiling
Armstrong Aluminium plank system with plain-finish consisting of 300 mm
wide planks of lengths upto 3000mm.Planks made out of pre-coated
aluminium of 0.7mm thickness with bevelled edge in white colour(Global
white) with Light Reflectance>86% .The panel ends will be raised up to 29mm
to create a smart hairline end joint .The panels about each other with a narrow
V groove to facilitate the removal of the individual panel without damaging
the edge of the panel.
Installation : To comprise of 3000 mm long carrier bars manufactured and
supplied by Armstrong to be spaced at 1200mm maximum centres securely
anchored to the soffit by 6mm/8mm rods.The last hanger at the end of each
carrier bar should not be greater than 600mm from the adjacent wall.tiles
should be clipped on to the special locking arrangement provided in the
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 21 of 33
carrier bar from below.Perimeter trims to be Armstrong wall angles of white
colour secured to the walls at 450mm maximum centres
H. DOOR, WINDOWS & PARTITION
Glazed anodized aluminum (minimum 15 micron thickness) door, widow, partition
shall be used (as per schedule of enclosed section no.)
Aluminium sections used for fixed/openable windows, ventilators, partitions, frame
work & doors etc. shall be suitable for use to meet Architectural designs to relevant
works and shall be subject to approval of the Engineer-in-Charge for technical,
structural, functional and visual considerations.
I. ENTRANCE AND EXTERIOR WALL OF POWER HOUSE BUILDING
i. Exterior surface will be provided with combination of heritage finish (
Granular) and Exterior acrylic emulsion paint /texure paint of approved brand
and shade. 20% of the external faade of the power house building shall be
cladded with ACP (Aluminium Composite Pannel) for decoration. Approval of
overall composition of faade treatment of all sides of the building shall be
taken before execution.
ii. Rolling shutter and Grill door at entrance of the power house shall be painted
with synthetic enamel having low VOC content of approved brand and shade.
J. STRUCTURAL GLAZING BY REPLACING GLASS BRICKS
Providing and fixing fully unitized system structural glazing in fixed panels specially
designed based on rain screen and pressure equalized drainage system and
drawings approved by the architects using powder coated 50 micron thickness using
pure polyester powder of NERO COAT / BERGER make extruded aluminium
sections. The split mullions & transom shall be fixed to RCC Beams / columns with
adequately designed M.S. brackets/insert plates etc. Providing and fixing 6 mm thick
toughened classic Dark Blue heat reflective glass manufactured by Saint Gobain
France and fixing glass with structural silicon of DOW Coning / GE / WACKER make.
Sealing the glazing system with specially designed extruded rubber gaskets EPDM
ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNIT #1 TO 6
R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 22 of 33
make to prevent water penetration as per BIS or BS Standards, all complete as per
manufacturers specification.
Glass shall be fixed on sub frame of section No. 14454 (19.05 x 19.05 x 1.63) using
structural sealent at horizontal position & giving sufficient time to gain proper
strength of structural sealent before fixing to the main frame. Gasket between main
frame (22713 101.6x57x2.00) & sub frame will be filled up by weather sealent to
take care of seismic effect, SS clip (mechanical system) will be provided to hold the
glass in addition to structural sealent.
1. Main frame 22713 (101.6x57x2.00)
2. Sub frame 14454 (19.05x19.05x1.67
3. Equal leg angles (12.7 x 12.7 x 3.18)
4. All section no. is of Jindal make or approved equivalent make
K. TOILET AND DRINKING WATER AREA
i) Flooring
1) The Toilet and Drinking water area shall have size of 600x600x9.5mm first
quality full body/double charged Vitrified tiles with water absorptions less
than .08% and conforming to IS : 15622 of approved shade and brand
shall be used
2) Entrance Steps shall be of 20 mm thick granite flooring with bull nosing of
ruby red shade and riser shall be 18 mm thick black granite.
ii) Dadoing:
Toilet and drinking water area shall have dadoing upto 2100 mm with ceramic
tiles of approved shade and size 200 mm x 300 mm.
iii) Water Supply and Sanitary Fixtures:
All Sanitary fixtures shall be of approved make from Hindware / Parryware /
jaquar / Neyser. Two number of each 1000 litre PVC water tank shall be
ODISHA HYDRO POWER CORPORATION LIMITED
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R & M WITH NEW TG SET
TECHNICAL SPECIFICATION- MECHANICAL & CIVIL
TS VOL III Sec. B Page 23 of 33
provided at the terrace for supply of water .
iv) Doors, Windows and Ventilators:
PVC panel door (laminated) with PVC door frame of approved shade and
brand). For window Glazed anodized aluminum (minimum 15 micron
thickness) door, widow, shall be used (as per schedule of enclosed
section no.)
v) Painting on wall and ceiling
All interior wall and ceiling shall be coated with approved shade of water
based low VOC led free Acrylic emulsion paint over plaster of paris / wall putty
of 1st quality. A minimum of two finishing coats of paint over a primer will be
provided.
L. TECHNICAL SPECIFICATIONS OF FURNITURE IN OFFICE, CONFERENCE
HALL & CONTROL ROOM
1. Workstation
a. L-Shaped workstation 1500x1500 overall worktop size. (Four person module with
1200 high cross partition in between)
1.1 Partitions (Tile based) attached with work station
The double skin partition system shall consist of powder coated metallic frames,
interchangeable panels of marker / writing white panels, / powder coated metallic
tiles, plain /frosted glass minimum 5mm thick, powder coated aluminum capping and
curvilinear trimmings, heavy duty connectors etc. complete. The entire system shall
be modular based, free standing but rigid, without any toxic material, and flexible
to accommodate changes. Partition system shall be hollow type with concealed wire
way ducts for cable management of power, communication and LAN. Metal Tile
Sheets shall be of minimum 0.8mm thickness with stiffener as per IS: 513-1994
or other approved IS.
Main frame work of a partitions shall be double walled, 1200, unless otherwise
specified, with facility to extend in all direction. These should be firmly secured to
work station /ground, with no crippling or chasing of Floors.
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TS VOL III Sec. B Page 24 of 33
The frame work and partition system including tiles shall be of sound structural
design to support mounted storages, work surfaces and supplementary components.
Such hanging slots shall be concealed and provided with safety catches to prevent
unintended pull fall out. The partitions shall be designed to support work surfaces on
either or both faces of the modules. Partition shall be assembled with proper fittings
to form basic skeleton structure on to which panels are slide in /snap tiles finished in
50 micron (minimum) powder coating. Overall thickness of partition system shall
be minimum 50 mm.
i) All partition main frameworks shall have following minimum
components & dimension:
a) Vertical members/mainframe
CRCA mild steel sections with 50 micron powder coated / Extruded
anodized / powder coated aluminium sections & thickness varying from
1.2mm to 2.1mm.
b) Bottom Horizontal members
CRCA mild steel (Graded)
C channel
c) Top Horizontal members
1.2mm thick M.S. tube / composite section made out of 0.8mm thick
CRCA in parts welded together having enough stability.
d) Intermediate members.
Minimum two numbers horizontal members shall be provided at
intermediate excepting top and bottom with additional member
above/below worktop shall be provided for raceways. All partition shall
have continuous raceway at the bottom of all partition.
e) Leveler bracket and leveler
Leveler bracket shall be 2mm thick CRCA with M4 nut to be weld for
connecting vertical channel with M8 nut to be weld for better stability
along with M8 leveler and shall have minimum 20mm adjustment.
f) Cover section assembly
Cover sections (0.8mm thick CRCA) should be fixed with 2mm bracket
/ sliding arrangement for the panels.
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TS VOL III Sec. B Page 25 of 33
g) End post
End post shall be of minimum 1.5mm thick CRCA of minimum 50
micron powder coated with cap provided at the end or in between to
provide strength to the free standing partition of height 1200/1500 mm.
h) Vertical & Horizontal Trim with cap
Vertical & Horizontal Trim shall be of 1.2mm thick (minimum)
aluminium curvilinear sections.
Staggered height junction shall be of same profile of vertical &
horizontal trim and the profile at junction shall match with the top profile
of the trim. Universal cap / end cap and junctions shall be of die cast
i) Raceway
Raceway-
There shall be raceway (and not mounting plates) at 2 different levels
(one continous raceway at skirting level & 2nd part raceway of 750 mm
long below worktop), for each modular workstation. Each raceway shall
be 750mm long and 100 to 150mm high. Total length of raceway per
workstation shall be minimum 4500 mm.(for L- shaped)
j) Tile size
100mm to 150mm high skirting & There will be 2 module tiles above
skirting (externally). No. of internal tiles to match with the technical
requirements.
1.2 Worktops: (Post form)
i) The worktop shall be of post form finished at the front.
ii) All the work surfaces shall be of minimum 25mm thick pre-laminated
exterior grade (PF) particle board finished with 0.6mm (minimum) post
formed laminate (approved make) on top & 0.6mm balancing laminate
(approved brand) on bottom as per IS:12823:1990 or other approved IS of
approved colour & shade. All the edges of the board shall be sealed. All the
work surfaces shall be with capability of having panel hung system, shall be
sturdy and rigid against vibration and capable of supporting heavy electronic
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TS VOL III Sec. B Page 26 of 33
equipment. Where ever required vertical/horizontal supports shall be
provided. The clear depth & length of the table shall be 750/600 & 1500/750
respectively. Worktop shall be fixed at 700-750 mm (approx.) above floor
finish level.
iii) Big size cantilever brackets of approximate size 430mm for 600mm
(depth) worktop end brackets/angle brackets / cantilever bracket assembly
shall be of minimum 2mm thick CRCA and support the work surfaces. They
should be capable of being assembled on either side of partition. Small
bracket will be as per manufacturer detail.
Work surfaces shall be provided with two openings of 80mm (cable outlet
two pieces, round with swiveling section in cover) for cables as per
requirements.
1.3 Gable Ends. (Pre laminated particle board)
Both side 25mm thick (minimum) pre laminated partition board (both side laminate of
approved makes, colour & shade) with PVC edge strip (all sides) upto bottom of
table top with proper leveler. The bottom lipping in the board should be of metal for
fixing leveler. It shall have rectangular shape.
1.4 Mobile Drawer Unit with Castors (minimum size 435x450 mm depth)
All metal (including bottim & back parts) Mobile Drawer Unit of min. size 435 (W) x
450 (D) x 700mm (H) with castors comprises of 2 (two) nos. small drawers and 1
(one) no. big drawer unit made of powder coated minimum 0.8mm thick CRCA with
antirust treatment with heavy duty telescopic channel (ball bearing slides) & the
carrying capacity of the channels shall be 40 kg/pair and upper drawer shall have
two compartments. Wheel should have minimum 35mm diameter with a load
bearing capacity of 25 kg/per castor. Pedestal should have central locking system.
All drawer should have separate recess handle / flush type handle / built in pulling
system.
1.5 Keyboard Tray
Keyboard tray including sliding mouse tray shall be minimum 550mm wide made of
minimum 1.2mm thick CRCA mild steel body with anti-rust treatment. This shall be
finished with powder coating (minimum 40-50 micron). The key board tray shall be
fixed below table top with drawer runner (25 kg/pair ) for easy sliding.
1.6 CPU Trolley
CPU Trolley shall be made of powder coated (minimum 40-50 micron) CRCA mild
steel (minimum 1.2mm thickness) with anti-rust treatment supported on castor.
Adjustment should be such that the trolley width can be adjusted to hold the CPU
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R & M WITH NEW TG SET
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TS VOL III Sec. B Page 27 of 33
width varying from 90mm to 180mm (approx).
2. Storage units
2.1 Lateral filing cabinet
i) Lateral filing cabinet, two drawer unit of approx size { (750 (W) x
450(D)x750(H)} with ball bearing slides full extensions of capacities 40
Kg per pair with recess handle / flush type handle / built in pulling
system with central locking system (made out of zinc die-cast/alu. Bar,
nickel plated).
It shall be made of CRCA sheet (minimum 0.8mm thick) with powder
coating (minimum 40-50 micron) with top covered with approved board
matching with worktop with edges sealed with PVC lipping. Shutters
made of CRCA (minimum 0.8mm thick)/ both side pre-laminated
particle board 25mm thick.
ii) Lateral filing cabinet three drawer unit approx size 750(W) x
450(D)x1050(H) with ball bearing slides full extension of capacities 40
kg/pair with handle/pull out arrangement with central locking systems
(Made out of zinc die cast / Alu. bar, nickel plated).
It shall be made of CRCA sheet (minimum 0.8mm thick) with powder
coating (minimum 40-50 micron) with top covered with approved board
matching with worktop with edges sealed with PVC lipping. Shutters
made out of CRCA (minimum 0.8mm thick )/both side pre-laminated
particle board 25mm thick.
2.2 Hinge door unit
Hinge door unit (Full height) approx size 900(W) x450(D)x1980(H)}with two leaves
shutters & 5 (five), shelves inside. Shutters, made of CRCA/ both sides 25mm thick
prelaminated particle board with espagnolette lock ( Finish- zinc alloy, nickel plated).
It shall be made of CRCA sheet (minimum 0.8mm thickness) with powder coating
(minimum 40-50 micron) with all front facia covered with CRCA (0.8mm minimum
thick)/ Pre-Lam particle board matching with worktop and top covered with approved
board matching with worktop with edges sealed with PVC lipping it shall have
minimum 60 Kg per shelf load bearing capacity.
1. All locks shall be of Hafele / hettich make.
2. Leveling bolt & matching nut shall be welded with the bottom horizontal
members for proper gripping (dia of bolt shall be minimum 8mm).
3. Magnetic buttons
Magnetic button shall be of approved quality shade & 40mm approx. diameter.
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TS VOL III Sec. B Page 28 of 33
Minimum 4 nos. per work station/executive table shall be provided.
4. Conference Table
Supplying conference table of size minimum 6750mm (L) app. 1350 mm (W) app.
made of both side pre-laminated particle board (minimum 25mm thick) laminated
with 0.8mm laminate of formica / merino / century make and supported on modesty
panel made from pre lam board (minimum 18mm thick) / Steel Leg (minimum
60mm dia meter). Table shall have wire management system and facility to extend in
future.
A. Executive Tables :
Self supported executive desk (1650x750x750) with worktop made out of pre-lam
particle board(minimum 25 mm thk.) with post formed edge on both sides, side
return (1350x400x750 mm) made out of pre-lam particle board with post form edge
on front side matching with the workstation top. & Mobile pedestal (400x550x585)
with 3 drawer unit, it comprises of two nos. small drawers and one big drawer made
of powder coated minimum 0.8mm thick CRCA with antirust treatment with heavy
duty (40 kg) telescopic channel for two small drawers & bottom big drawer. Keyboard
tray as per specification shall be provided in the side return. Castor shall have
minimum 25 kg load bearing capacity. Metal perforated Leg Guard (CRCA sheet)
should be provided. Modesty shall be of minimum 18mm thk. prelaminated particle
board. All exposed edges shall be covered with lipping.
5. General
5.1 Castors
a) Load bearing capacity 50 kg/caster for chairs
b) Load bearing capacity 25 kg/caster all other units
5.2 Office organization (Cable Outlet)
1. Cable outlet - two piece, round with swiveling section in cover &
drilling 80 mm dia of plastic (catalogue No. 428.96 304)
5.3 Hinges.
1. Metal concealed Hinges for silent fold system (Opening angle 105
degree min.)
2. Nos. of hinges per shutter shall be 2 nos. for 900 height, 3 nos for
1050 height, 4 nos. for 1980 height.
5.4 Drawer Runners
Ball bearing slides full extension, side mounted features of load bearing
capacity of 40 kg/pair.
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TS VOL III Sec. B Page 29 of 33
5.5 Locks
1. Espagnolattee locks with accessories should be provided in all shutters
of the storage unit.
2. Syms 3000 central locking system for all pedestal.
5.6 CRCA Finish
All CRCA Sections shall have powder coating (minimum 50 micron) as per IS
13871:1993.
5.7 Cut Out on Tiles for electrical & LAN points
Cut-out sizes for Electrical, LAN and Telephone Point will be provided by
Mecon after placement of order.
Note: All accessories / hardware fittings mentioned above are of M/s Hafele /
Hettich make as mention in list of approved make.
6. List of approved make(furniture):
Sl. No. Items Name of Manufacturer
a) Aluminium extrusions INDAL/HINDALCO/JINDAL
b) Locks//hardwares/castors/ M/s Hafele / M/s Hettich
Drawer runners/cable outlet
c) Screw M/S Nettle / G.K.W
d) Glazing M/S Modi / M/S Saint Gobain /M/s
Pilkington
e) Prelaminated Board / Prelaminated M/S Mangalam Timber product / M/S
particle board Merino / M/s Century
f) Laminate M/S Formica / M/s.Merino / M/s Century /
g) Furnishing Fabric Praveen kumar / Royal Handloom
h) CRCA Tata / Jindal/ SAIL
Note: All dimensions shown above are approximate.
7. Chairs
Chairs shall be of:
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7.1 (Workstation/Discussion/visitor) : Medium back revolving type with
approximate minimum size of seat 47cm (W) x 48cm (D) and back
47.5cm(W)x48cm(H) Armrest shall be of hard PP & directly to be fixed with
the bottom face of the seat (without any joint). Chair shall have synchro
mechanism with upright position locking and tilt tension adjustment & height
adjustment by hydraulic gas lift mechanism. Foam shall have minimum
density of 45 Kg/m3 and hardness 20. Each castor shall have minimum 50
Kg load bearing capacity. Minimum Nos. of castor shall be 5 (five).
7.2 Senior Executives : High back Revolving type approximate minimum size of
seat 50.0 cm (W) X 49.5 cm (D) and back size 48 cm(W) x 51cm (H). Chair
shall have synchro mechanism with upright position locking and tilt tension
adjustment & height adjustment by hydraulic gas lift mechanism. Back rest
shall be in mesh fabric. Foam shall have minimum density of 45 Kg/m3 and
hardness 20. Each castor shall have minimum 50 Kg load bearing capacity.
Armrest shall be provided made out of hard PP. Minimum Nos. of castor shall
be 5 (five).
7.3 GENERAL
a) Fabric shall be as per IS: 12467 (Part-1) & (Part-2) 2006 in black color.
b) Seat and backrest cover - made out of ABS
c) Armrest shall be of hard PP.
d) For seat of all chair base material shall be 9 mm thick ply, for back of C2, C3 &
C4 base material shall be SS and back for C1 shall be 9 mm thick ply.
e) Base of chair- Nylon material.
7.4. Lounge chair (for waiting area)
Lounge chair shall have back (separate back for 2 seater & 3 seater) system
standing on beam with side frame assemblies. Frame work shall be of powder
coated MS Pipe of dia 38.1mm x 2mm thick. Foam shall have minimum density of 45
Kg/m3 and hardness 20. All member shall be powder coated (minimum 50 micron) /
SS with adjustable levelers below. It shall have approximate size given below:
(i) S2: Double seater - 113 cm (W) x 70 cm (D) x 78.5
cm (H)
Seat height (43.5 cm)
(ii) S3 Triple seater - 164 cm (W) x 70 cm (D) x 78.5 cm (H)
Seat height (43.5 cm.
Fabric shall be as per IS: 12467 (Part-1) & (Part-2) 2006 in black color.
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TS VOL III Sec. B Page 31 of 33
i) Centre table
Rectangular center table of size 1000 (W) x 650 (D) x 450 (H) with 12mm thick
toughened glass top & 8mm thick toughened glass shelf below table top & 50 x 50
square polished teak wood leg / SS leg system. The supporting system for both the
glass shall be either polished teak wood framework / SS framework.
Note:
1. All dimensions shown above are approximate.
2. Minimum two sets of tools and tackles for maintaining chairs to be supplied.
7.4.1. List of approved make:
Sl. No. Items Name of Manufacturer
a) Aluminium extrusions INDAL/HINDALCO/JINDAL
b) Hardwares/castors/ M/s Hafele / M/s Hettich
c) Screw M/S Nettle / G.K.W
d) Glazing M/S Modi / M/S Saint Gobain
e) Furnishing Fabric Praveen kumar / Royal Handloom
f) Powder Coating Epoxy Finish
g) CRCA Tata / Jindal/ SAIL
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STANDARD ALUMINIUM SECTION NO.
Sl. No. Description Aluminium
Section No.
(Hindalco
Alupuram)
Size Weight
Kg/mtr.
I. DOORS
A. Normal Door
1. Door Vertical Plain 9239 85x44.5
x2
1.365
2. Door Vertical 9241 -do- 1.412
3. Door Bottom (for upto 1 mtr.
Shutter Width)
9208 101.1x4
4.5x3.1
2.379
4. Door Bottom (for more than 1
mtr. Shutter Width)
9212 180x44.
5x3.18
3.438
5. Door Top 9208 101.1x4
4.5x3.1
2.379
6. Lock Rail 9232 150x44.
45x3.2
3.290
7. Glazing Clip 4660 19.7x17
.8x1.3
0.167
B. Twin Style Door
1. Top/Bottom Rail (for 12mm
glass thickness)
9211 90x45x
3
3.727
2. Top/Bottom Rail (more than
12mm glass thickness)
9206 90x45x
3.0
3.506
C. Frame 8422 120x80
x3
3.143
II WINDOWS
A. Casement Window 40mm
Series
1. Z Shutter 4132 40x28x
2.5
0.585
2. Hollow Z Shutter 9148 41.50x2
9x1.5
0.636
3. Mullion 9149 63x40x
1.5
0.933
4. H Shutter/alternative of Sl. No.
2
4133 40x41x
2.5
0.638
5. Crimping Angle 2081 50x50x
4.9
1.177
6. Double glazing clip 4134 25x8x1. 0.132
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2
7. Single glazing clip 4135 24x25x
1.2
0.166
Sl. No. Description Aluminium
Section No.
(Hindalco
Alupuram)
Size Weight
Kg/mtr.
B. Sliding Window
1. 2 Track Bottom 4095 61.98x29.7
0
0.875
2. 2 Track Side & Top 4096 61.98x29.7
0
0.778
3. 3 Track Bottom 4097 92.36x29.7
0
1.233
4. 3 Track Side & Top 4098 92.36x29.7
0
1.067
5. 4 Track Bottom 4121 123.02x29.
70
1.500
6. 4 Track Side & Top 4120 123.02x29.
70
1.293
7. Shutter Vertical 9777 39x20x1.5 0.493
8. Shutter Interlock 9778 39x20x1.5 0.612
9. Shutter Top & Bottom 4148 41x20x1.5 0.472
III. PARTITIONS
A. Partition (Height
more than 1.5 mtr.)
1. Single Partition
(Single Glazing)
9205 101.5x44.4
5x3
2.34
2. Double Partition
(Single Glazing)
9204 101.5x44.4
5x3
2.420
3. Single Partition
(Double Glazing)
9229 101.5x44.4
5x2.5
2.03
4. Double Partition
(Double Glazing)
9228 101.5x44.4
5x2.5
2.00
B. Partition (Height
upto 1.5 mtr.)
1. Single Partition
(Single Glzaing)
9210 63.5x38.1x
2.5
1.376
2. Double Partition
(Double Glzaing)
9207 63.5x38.1x
2.5
1.443
3. Glazing Clip 4660 19.7x17.8x
1.3
0.167