30 MWSri Gomathi Energy Technical Tenderspecifications

SRI GOMATHI ENERGY Pvt Ltd
Regd. # 10-2-46, plot No: 118, Road No.3, Street No.7, West Marredpally, Secunderabad-500026 A.P
BID DOCUMENT Technical Specification for 1X30MW Thermal Power Plant, SGEPL.
Reference No: SGEPL/IICT/OE/EPC/2013-14/002-Vol-2
Dated 22nd April 2013
IIC Technologies Limited

8-2-350/5/B-22, Road No 3, Banjara Hills, Hyderabad 500034, Andhra Pradesh, India Tel: +91 40 3914 4459;Fax: +91 40 3914 4455 E-mail suribabu.chunduri@iictechnologies.com Website http://engineering.iictechnologies.com/
SGEPL
REVISION HISTORY
Proposal Title Title: Technical Specification for 1X30MWThermal Power Plant, SGEPL.
Reference No: SGEPL/IICT/OE SGEPL/IICT/OE/EPC/2013-14/002-Vol-2 Dated 22nd April 2013
22.04.2013 Date
00 Version
Technical Specification Description
IICT Author
IICT
SGEPL
Reviewed Authorized
1|Page
SRI GOMATHI ENERGY PRIVATE LIMITED 1X30MW THERMAL POWER PLANT TENDER SPECIFICATION. No: SGEPL/ IICT/OE /EPC/2013-14/002Vol: :2
SGEPL
Table of Contents
1. 2. 3. INTRODUCTION ................................ ................................................................................................ .............................................. 14 PROJECT INFORMATION .............................................................................................. .............................. 15 CODES AND STANDARDS ............................................................................................ ............................ 17 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 GENERAL CODES ................................ ................................................................................................ .................................... 17 STEAM TURBINE, INE, GENERATOR, CONDENSER AND AUXILIARIES ............. 17 PUMPS ................................ ........................................................................................................................ ........................ 18 PIPES, FITTINGS & VALVES ................................................................ .................................................. 19 AIR CONDITIONING AND VENTILATION SYSTEM ......................................... ................................ 21 FUEL & BED MATERIAL HANDLING SYSTEM ................................................. ................................ 24 Ash Handling System ................................ ................................................................................................ .................................. 24 Compressor and Root blower ...................................................................................... ...................... 25 Air Receivers ................................ ................................................................................................ ............................................... 25 MS Pipes ................................ ..................................................................................................................... ..................... 25 Inter cooler / after cooler ............................................................................................. ............................. 25 COMPRESSED AIR AND INSTRUMENT AIR SYSTEM...................................... ................................ 25 E.O.T. CRANE AND HOIST TROLLEYS ................................................................ ................................ 26 FIRE PROTECTION AND DETECTION SYSTEM ................................................ ................................ 27 WATER TREATMENT PLANT PLANT................................................................ ................................................ 30 ELECTRICAL ................................ ................................................................................................ ............................................ 32 CIVIL ................................ .......................................................................................................................... .......................... 33 CONTROL & INSTRUMENTATION ................................................................ ....................................... 33 Temperature Measurement .......................................................................................... .......................... 33 Pressure Measurement................................ ................................................................................................ ................................. 33 Flow Measurement ................................ ................................................................................................ ...................................... 33 Instrument Switches and Contacts ................................................................ .............................................. 33 Enclosures ................................ ................................................................................................ ................................................... 33 2|Page
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3.24 3.25 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 4. Apparatus, Enclosure and Installation Practice in Hazardous Area ............................ 34 Sampling System ................................ ................................................................................................ ......................................... 34 Annunciators ................................ ................................................................................................ ............................................... 34 Control Valves................................ ................................................................................................ ............................................. 34 Instrument Tubing ................................ ................................................................................................ ....................................... 35 Cables ................................ .......................................................................................................................... .......................... 35 Cable Trays and Conduits ........................................................................................... ........................... 35 Surge protection ................................ ................................................................................................ .......................................... 36 Instrument end connections ......................................................................................... ......................... 36 SURFACE PREPARATION AND PAINTING ......................................................... ......................... 36
FUEL ANALYSIS ................................ ................................................................................................ ............................................. 38 4.1 4.2 4.3 FUEL ANALYSIS ................................ ................................................................................................ ...................................... 38 ASH ANALYSIS ................................ ................................................................................................ ........................................ 39 Design Criteria ................................ ................................................................................................ ............................................ 39
5.
SPECIFIED DATA SHEET FOR BOILER AND AUXILIARIES ................................... ................................ 40 5.1 5.2 GUARANTEE PARAMETERS (AT MCR OPERATION) ...................................... ................................ 45 MATERIAL SPECIFICATION ................................................................ .................................................. 46
6. SPECIFIED DATA SHEET FORSTEAM TURBINE GENERATOR AND AUXILIARIES ................................ .......................................................................................................................... .......................... 48 6.1 6.2 6.3 6.4 SHOP TESTS ................................ ................................................................................................ .............................................. 49 SITE TETS ................................ ................................................................................................ .................................................. 50 MAINTENANCE TOOLS .......................................................................................... .......................... 50 CONDENSER & AIR EVACUATION SYSTEM FOR EACH TURBINE .............. 51
Condenser ................................ ........................................................................................................................... ........................... 51 6.5 6.6 Performance (100% MCR) and Construction Requirements ...................................... ................................ 52 AIR EVACUATION SYSTEM ................................................................ .................................................. 54
Hogging ejector ................................ ................................................................................................ .................................................. 54 3|Page

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Vacuum pumps for air ejection .......................................................................................... .......................... 54 6.7 6.8 TESTING & INSPECTION: ....................................................................................... ....................... 55 FEED WATER HEATERS ......................................................................................... ......................... 56
L.P Heaters ................................ ............................................................................................................................. ............................. 56 Material of Construction: ................................ ................................................................................................ ....................................... 56 H.P Heaters................................ ............................................................................................................................. ............................. 57 Material of Construction ................................ ................................................................................................ ........................................ 57 6.9 DEAERATOR & FEED WATER TANK ................................................................ .................................. 58
MATERIAL OF CONSTRUCTION ..................................................................................... ..................... 58 6.10 7. FEED WATER STORAGE TANK ................................................................ ............................................ 58
FEED WATER SYSTEM ................................ ................................................................................................ .................................. 59 7.1 L.P HEATER ................................ ................................................................................................ .............................................. 59
General ................................................................ ................................................................................................ ................................... 59 Material of Construction: ................................ ................................................................................................ ....................................... 59 7.2 DEAERATOR DESIGN CRITERIA CRITERIA................................................................ .......................................... 59
Deaerator ................................................................ ................................................................................................ ................................ 59 7.3 7.4 Feed tank ................................ ..................................................................................................................... ..................... 59 BOILER FEED WATER PUMP ................................................................ ................................................ 60
MATERIALS OF CONSTRUCTION ................................................................ ................................................... 62 TESTING G AND INSPECTION ............................................................................................. ............................. 62 STRAINERS ................................ .......................................................................................................................... .......................... 62 MATERIALS OF CONSTRUCTION ................................................................ ................................................... 63 DATA FOR SYSTEM RESISTANCE CURVE ................................................................ ................................... 63 7.5 H.P HEATER ................................ ................................................................................................ .............................................. 63
General ................................................................ ................................................................................................ ................................... 63 Material of Construction ................................ ................................................................................................ ........................................ 64 8. SPECIFIED DATA SHEET FOR WATER TREATMENT PLANT ................................ 65 4|Page
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8.1 8.2 8.3 8.4 SOFTENING PLANT ................................ ................................................................................................ ................................. 65 DM Plant ................................ ..................................................................................................................... ..................... 65 Design raw water er analysis ........................................................................................... ........................... 65 FILTRATION PLANT ............................................................................................... ............................... 66
Alum dosing tank................................ ................................................................................................ ................................................ 66 Agitator ................................ ............................................................................................................................... ............................... 66 Alum dosing pump ................................ ................................................................................................ ............................................. 66 Multi grade / Pressure Sand / Activated Carbon Filters ..................................................... ..................... 67 Air Scouring Blowers (common for filters and MB units) ................................................. ................................ 67 Filter Back Wash Pump (if applicable) ................................................................ .............................................. 68 8.5 SOFTENING AND DM PLANT ................................................................ ................................................ 68
Softener (Na cycle based exchanger) / SAC ................................................................ ...................................... 68 Degasser................................ .............................................................................................................................. .............................. 69 Degasser Blower ................................ ................................................................................................ ................................................. 70 Degassed Water Tank ................................ ................................................................................................ ......................................... 70 Degassed water pump / Soft water transfer pump .............................................................. .............................. 70 Strong Base Anion Exchanger ............................................................................................ ............................ 71 Mixed Bed Exchanger ................................ ................................................................................................ ........................................ 72 DM water ater regeneration Pump Pump............................................................................................. ............................. 73 Bulk Acid Storage Tank ................................ ................................................................................................ ..................................... 73 Acid unloading pump ................................ ................................................................................................ ......................................... 73 Acid Measuring Tank ................................ ................................................................................................ ......................................... 74 Bulk Caustic Storage Tank ................................ ................................................................................................ ................................. 74 Caustic unloading pump ................................ ................................................................................................ ..................................... 74 Caustic Dilution Tank ................................ ................................................................................................ ......................................... 75 Agitators for Caustic Dilution Tanks Tanks................................................................ .................................................. 75 Ejectors ................................ ............................................................................................................................... ............................... 75 5|Page
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Neutralized Waste Disposal Pump ..................................................................................... ..................... 75 DM water transfer pumps ................................ ................................................................................................ ................................... 76 Morpholine dosing system................................ ................................................................................................ .................................. 76 Morpholine dosing tank ................................ ................................................................................................ ...................................... 76 Morpholine dosing pump................................ ................................................................................................ .................................... 76 FABRICATED TANKS ................................ ................................................................................................ ..................................... 77 DM & Soft Water Storage Tank ......................................................................................... ......................... 77 9. WATER SYSTEM ................................ ................................................................................................ ............................................. 78 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 COOLING TOWER ................................ ................................................................................................ .................................... 78 COOLING WATER TER PUMPS PUMPS...................................................................................... ...................... 79 AUXILIARY COOLING WATER PUMPS .............................................................. .............................. 79 Material of Construction ............................................................................................. ............................. 79 COOLING TOWER FANS ........................................................................................ ........................ 80 RAW WATER PUMPS .............................................................................................. .............................. 80 Raw Water Pumps Material of Construction .............................................................. .............................. 80 BOILER BLOW DOWN TRANSFER PUMPS......................................................... ......................... 81 Material of Construction ............................................................................................. ............................. 81 Chemical Addition Tank ............................................................................................. ............................. 82 COOLING WATER ACID DOSING SYSTEM ........................................................ ........................ 82
Sulphuric acid (storage tank bulk) ...................................................................................... ...................... 82 Acid unloading pump ................................ ................................................................................................ ......................................... 82 Acid dosing pump ................................ ................................................................................................ ............................................... 82 CHLORINATION SYSTEM ............................................................................................. ............................. 83 SIDE STREAM FILTRATION SYSTEM ................................................................ ......................................... 83 10. 10.1 11. SPECIFIED DATA SHEET FOR FUEL HANDLING SYSTEM SYSTEM................................ ................................. 84 FUEL HANDLING SYSTEM .................................................................................... .................... 84 SPECIFIED DATA SHEET FOR ASH HANDLING SYSTEM SYSTEM................................ ................................... 85 6|Page
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11.1 11.2 ASH HANDLING SYSTEM ...................................................................................... ...................... 85 SCREW AIR COMPRESSOR .................................................................................... .................... 89
General Information ................................ ................................................................................................ ........................................... 89 11.3 11.4 11.5 11.6 11.7 Supply of Accessories & Services ................................................................ .............................................. 89 Special Features................................ ................................................................................................ ........................................... 90 Material of Construction ............................................................................................. ............................. 90 Testing & Inspection ................................ ................................................................................................ ................................... 91 Inter cooler (if required), after cooler & Moisture Separator ...................................... ................................ 92
General................................................................ ................................................................................................ ................................ 92 Equipment Parameter for Inter cooler (if required) & After Cooler .................................. ................................ 92 11.8 11.9 11.10 Supply of Accessories and Services ................................................................ ............................................ 93 Intake Air Filter ................................ ................................................................................................ ........................................... 94 Air Receiver ................................ ................................................................................................ ............................................. 94
General................................................................ ................................................................................................ ................................ 94 Material of Construction (Air receiver) ................................................................ .............................................. 95 Test Requirement ................................ ................................................................................................ ................................................ 96 11.11 Piping Components & Valves ................................................................ ................................................. 96
Pipes................................................................ ................................................................................................ .................................... 96 Fittings ................................................................ ................................................................................................ ................................ 96 Gate / Globe Valves ................................ ................................................................................................ ............................................ 97 Check Valves ................................ ...................................................................................................................... ...................... 99 12. SPECIFIED DATA SHEET FOR COMPRESSED AIR AND INSTRUMENT AIR SYSTEM ................................................................ ................................................................................................ .................................. 101 12.1 AIR COMPRESSOR ................................ ................................................................................................ ................................ 101
General Information ................................ ................................................................................................ ......................................... 101 Supply of Accessories cessories & Services .................................................................................... .................... 101 Special Features ................................ ................................................................................................ ................................................ 102 7|Page
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Material of Construction ................................ ................................................................................................ ................................... 102 Testing & Inspection ................................ ................................................................................................ ........................................ 103 12.2 INTERCOOLER, COOLER, AFTERCOOLER & MOISTURE SEPARATOR SEPARATOR....................... ....................... 104
General................................................................ .............................................................................................. .............................. 104 Equipment Parameter for Inter Cooler and After Cooler ................................................. ................................ 104 Supply of Accessories and Services ................................................................ ................................................. 104 After Cooler ................................ ...................................................................................................................... ...................... 104 Inter Cooler ................................ ....................................................................................................................... ....................... 105 Moisture / Oil separator ................................ ................................................................................................ .................................... 105 Material of Construction ................................ ................................................................................................ ................................... 105 Tests Requirement ................................ ................................................................................................ ............................................ 106 Intake Air Filter ................................ ................................................................................................ ................................................ 106 12.3 AIR RECEIVER ................................ ................................................................................................ ....................................... 107
General................................................................ .............................................................................................. .............................. 107 12.4 AIR DRYING PLANT................................ .............................................................................................. .............................. 108
General Information ................................ ................................................................................................ ......................................... 108 Operating Data ................................ .................................................................................................................. .................. 109 Special Factors ................................ .................................................................................................................. .................. 109 Supply of Accessories ories and Services ................................................................ ................................................. 109 Material of Construction ................................ ................................................................................................ ................................... 110 Testing & Inspection ................................ ................................................................................................ ........................................ 111 12.5 PIPING COMPONENTS & VALVES ................................................................ ..................................... 111
Pipes................................................................ ................................................................................................ .................................. 111 Fittings ................................................................ .............................................................................................. .............................. 111 Gate / Globe Valves ................................ ................................................................................................ .......................................... 112 Check Valves ................................ .................................................................................................................... .................... 113 13. SPECIFIED DATA SHEET FOR E.O.T. CRANE AND HOIST TROLLEYS .......... 115 8|Page
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13.1 13.2 14. 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 14.10 14.11 14.12 14.13 14.14 14.15 14.16 14.17 14.18 E.O.T. CRANE................................ ................................................................................................ .......................................... 115 MANUAL ANUAL / ELECTRIC HOIST AND TROLLEY ................................................. ................................ 118 FIRE PROTECTION AND DETECTION SYSTEM .................................................. .................. 120 Pump Accessories required (For all pumps) ............................................................. ............................. 121 DIESEL ENGINE ................................ ................................................................................................ ..................................... 121 Engine Parameters ................................ ................................................................................................ ..................................... 121 Special features ................................ ................................................................................................ ......................................... 121 PIPING ................................ ...................................................................................................................... ...................... 122 FITTINGS ................................ ................................................................................................ ................................................. 122 GASKET ................................ ................................................................................................................... ................... 122 BOLTS, NUTS ................................ ................................................................................................ .......................................... 123 SLUICE VALVES ................................ ................................................................................................ .................................... 123 GLOBE VALVES ................................ ................................................................................................ ................................. 123 CHECK VALVES ................................ ................................................................................................ ................................. 123 HYDRANT VALVE ............................................................................................. ............................. 123 WATER MONITOR ............................................................................................. ............................. 124 BRANCH PIPE & NOZZLE ................................................................ ................................................. 124 HOSE COUPLING................................ ................................................................................................ ................................ 124 FIRE HOSE ................................ ................................................................................................ ........................................... 125 HOSE CABINET ................................ ................................................................................................ .................................. 125 FIRE DETECTION SYSTEM ................................................................ .............................................. 125
15. SPECIFIED DATA SHEETS FOR AIR CONDITIONING AND VENTILATION SYSTEM ................................................................ ................................................................................................ .................................. 126 16. 17. 18. 19. CONTROL & INSTRUMENTATION ................................................................ ........................................ 130 CIVIL, ARCHITECTURAL AND DESIGN PARAMETERS .................................... ................................ 155 STEEL STRUCTURAL WORKS ................................................................ ................................................ 173 SPECIFIED DATA SHEETS FOR ELECTRICAL ..................................................... ..................... 176 9|Page
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19.1 SPECIFIED DESIGN DATA GENERATOR ....................................................... ....................... 176
GENERATOR ................................ .................................................................................................................. .................. 176 19.2 SPECIFIED DESIGN DATA TRANSFORMER .................................................. .................. 177
TRANSFORMER ................................ ................................................................................................ ............................................. 177 19.3 132 kV SWITCHYARD EQUIPMENT ................................................................ ................................... 179
Technical Requirements of 132 kV IsolatorRating .......................................................... .......................... 179 Design Requirements ................................ ................................................................................................ ........................................ 179 Insulation Level ................................ ................................................................................................ ................................................ 180 Miscellaneous ................................ ................................................................................................................... ................... 180 The 132 kV Nominal rated circuit breakers shall comply with following requirements: 182 Applicable Standards ................................ ................................................................................................ ........................................ 184 Technical Requirements for Current Transformers .......................................................... .......................... 184 Technical Requirements Capacitor Voltage Transformer: ............................................... ................................ 185 Technical Requirements for Surge Arrestor ................................................................ ..................................... 187 Technical Requirements for Insulators and Hardware ..................................................... ..................... 188 20. 21. 21.1 21.2 21.3 21.4 21.5 21.6 21.7 21.8 21.9 21.10 LIST OF APPROVED VENDORS ................................................................ .............................................. 190 MANDATORY SPARES ............................................................................................. ............................. 206 Spare Management ................................ ................................................................................................ .................................... 206 STEAM GENERATOR AND AUXILIARIES ........................................................ ........................ 206 Centrifugal fans (for each type) ................................................................ ................................................ 207 Coal Burners ................................ ................................................................................................ .............................................. 207 Regenerative Air Preheater ....................................................................................... ....................... 208 Steam Coil Air Preheater Preheater........................................................................................... ........................... 208 Oil Burners ................................ ................................................................................................ ................................................ 208 Dampers (for each type) ............................................................................................ ............................ 208 Pressure parts................................ ................................................................................................ ............................................. 209 Safety valves (Each type) ...................................................................................... ...................... 209 10 | P a g e
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21.11 21.12 21.13 21.14 21.15 21.16 Valves ................................ .................................................................................................................... .................... 209 Safety Valve ................................ ................................................................................................ .......................................... 210 ELECTROSTATIC PRECIPITATOR (ESP) ....................................................... ....................... 210 For filter chamber ................................ ................................................................................................ .................................. 210 For control panel & rectifier of ESP ................................................................ ...................................... 211 STEAM TURBINE GENERATOR AND AUXILIARIES .................................. ................................ 211
Turbine................................................................ .............................................................................................. .............................. 211 Generator ................................ .......................................................................................................................... .......................... 212 Control Systems (Atrs) ................................ ................................................................................................ ..................................... 212 TSI System ................................ ....................................................................................................................... ....................... 212 Condenser ................................ ......................................................................................................................... ......................... 213 CEP ................................................................ ................................................................................................ ................................... 213 Other spares for STG ................................ ................................................................................................ ........................................ 213 FEED WATER PUMPS ................................ ................................................................................................ ................................... 214 DEAERATOR ................................ .................................................................................................................. .................. 215 21.17 WATER SYSTEM / WATER TREATMENT PLANT ........................................ ................................ 215
CENTRIFUGAL PUMPS ................................ ................................................................................................ ................................ 215 PLUNGER/RECIPROCATING/METE PLUNGER/RECIPROCATING/METERING PUMPS ................................................... ................... 217 LOBE TYPE / ROOTS BLOWERS ................................................................ ................................................ 217 CENTRIFUGAL BLOWERS .......................................................................................... .......................... 218 Degasser Blower ................................ ................................................................................................ ............................................ 218 AGITATORS................................ .................................................................................................................... .................... 218 PRESSURE FILTERS................................ ................................................................................................ ................................... 218 MIXED BED ................................ .................................................................................................................... .................... 219 21.18 FIRE PROTECTION AND DETECTION SYSTEM ........................................... ................................ 219
Diesel Engine ................................ .................................................................................................................... .................... 219 Pumps ................................................................ ............................................................................................... ............................... 220 11 | P a g e
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Strainers ................................ ............................................................................................................................ ............................ 220 21.19 21.20 21.21 AIR CONDITIONING AND VENTILATION SYSTEM .................................... ................................ 220 E.O.T. CRANE AND HOIST TROLLEYS .......................................................... .......................... 221 FUEL, BED MATERIAL HANDLING SYSTEM ............................................... ................................ 222
Spares for Belt Conveyors (For each size and type belt conveyor).................................. ................................ 222 Spares for Crushers ................................ ................................................................................................ ........................................... 223 Spares for Vibrating Screens ............................................................................................ ............................ 223 Spares for Electronic metal detector ................................................................ ................................................. 223 Spares for Magnetic separator .......................................................................................... .......................... 223 Spares for online belt weigher .......................................................................................... .......................... 224 Spares for Dust extraction system .................................................................................... .................... 224 Spares for Gear reducers and coupling ................................................................ ............................................. 224 Vent Filter ................................ ......................................................................................................................... ......................... 225 Blower (for each blower) ................................ ................................................................................................ .................................. 225 Rotary Feeder (for each valve) ......................................................................................... ......................... 225 Ash Conditioner (for each conditioner) ................................................................ ............................................ 225 COMPRESSED AIR AND INSTRUMENT AIR SYSTEM ........................................... ................................ 226 21.22 21.23 21.24 21.25 ELECTRICAL ................................ ................................................................................................ ....................................... 227 TRANSFORMER ................................ ................................................................................................ .................................. 228 KV SWITCHGEAR ................................ .............................................................................................. .............................. 229 L.T. SWITCHGEAR ............................................................................................. ............................. 231
Push buttons................................ ...................................................................................................................... ...................... 231 Selector switches ................................ ................................................................................................ .............................................. 231 Main switches ................................ ................................................................................................................... ................... 231 Contactors ................................ ......................................................................................................................... ......................... 232 Meters ................................................................ ............................................................................................... ............................... 232 Protection relays ................................ ................................................................................................ ............................................... 233 12 | P a g e
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BATTERY CHARGER ................................ ................................................................................................ .................................... 234 BATTERY ................................ ........................................................................................................................ ........................ 234
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1. INTRODUCTION
Sri Gomathi Energy Private Limited (SGEPL) was formed in 2010 with a vision to be one of the leading players in Thermal Power. The Company, backed by strong financial background of its promoters, its experience and knowledgeable Technical Team has laid ambitious goals to acquire projects d diverse iverse in geographic location, fuel type, fuel source and off-take, take, and each project is planned to be strategically located near an available fuel supply or load center. SGEPL is a Private Limited enterprise established with an objective to generate and supply upply power developed from conventional sources of energy. The Company is well positioned with long-term term fuel access to its power plants and its power projects which are under planning. With a Vision to be an active player in India's emerging Power sector by exploiting the rich treasure of alternate energy and conventional sources prevalent in the country, it is committed to take a prominent role in fuelling the industrial and economical growth in the country simultaneously by creating a cleaner and safer e environment nvironment for the economy to thrive and flourish. The SGEPL Group has proposed to set up a coal based power plant near Madavelli Village, Dahegaon Mandal, and Adilabad District in Andhra Pradesh. SGEPL has availed the services of M/s IIC Technologies Limited a leading engineering Services company and a leading Consultancy firm in the areas of Power Sector for Owner Engineering, Services for the proposed 1x30 MW coal based power project project.
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2. PROJECT INFORMATION
SRI GOMATHI ENERGYPVT. LTD West Maredpally,Secunderabad: 500026 Andhra Pradesh, INDIA. IIC Technologies, Road No: 3, Banjara Hills, Hyderabad: 500034 Andhra Pradesh, India. 1X30 MW STG Power Plant. Latitude: 19 11 28.32 North. Longitude: 79 40 25.15 East. 172.00 M Hyderabad Vishakapatnam
1 2 3 4 5 6 7 8 9
Purchaser
Owners ENGINEER Project Site Location
10
11
12
13
14 15
16
Elevation above mean sea Level Nearest Airport Nearest Harbour Nearest road NH-16 Bellampally-35Km (National/StateHighway) Ambient Temperature (Deg.) summer winter monsoon Max. Dry bulb temp. 46 31 35 Min. dry bulb temp. 21 5.2 22 Design temp. for electrical 50 Equipment / device Relative Humidity (%) Maximum 90 Minimum 20 Wet Bulb Temperature (C) Maximum 11.8 Minimum 26 Rain Fall Max. Intensity of rain falls per hour 35mm Total rainfall/year 663 mm/year Period of Monsoon showers June-August Wind Data Basic wind speed 2-3 Km/Hr Most predominant wind direction West to East Seismic data Zone (As per IS: 1893) Zone III Soil Data (For guidance only. Actual data needs to be obtained for construction area) General nature Black on top/sandy Soil bearing capacity & depth 15-20 MT/M Ground water table from ground level Minimum 80 ft Maximum 120 ft
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17 Electrical system Variation in voltage Variation in frequency
10% 5%
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3. CODES AND STANDARDS
The design, manufacture and testing of the equipment covered by this specification shall comply with the requirements of all applicable and latest specifications of Indian/ British/ American/ DIN Standards and codes (along with all agenda and amendments). In case of conflict between various codes, the more stringent requirement as per Owners decision shall be applicable.
3.1
GENERAL CODES
In particular the following mentioned codes shall be used for all equipment covered by this specification. Standards of Hydraulic Institute, USA. ASTM standard for all tests and materials. Indian Boiler Regulations (IBR) (Latest version) API 610 -VIII edition - Centrifugal pumps for general refinery services. ASME Section-VIII - Div.I - Unfired pressure vessels. ASME Sec V - Non-destructive destructive Examination.
3.2
STEAM TURBINE, AUXILIARIES
GENERATOR,
CONDENSER
AND
API-612 IEC-44 API-613 DIN-2056 DIN-2059 IEC-34(all parts) ASME PTC-6 ANSI-C50.13 TEMA-SM-23 AGMA 421.06 DIN-40719 ASME TDP - 1-1998
Lubrication oil supply and drain system
Rotating Electrical Machines
Procedure for routine performance test of steam turbines
Reduction gear box
Turbine drains
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3.3 PUMPS
These codes shall be used for all equipment covered by this specification unless otherwise specifically mentioned and general codes
API 971 AGMA 515.02 IS 1520 IS 1710 1989 ISO 1940 IS: 2595 IS: 3038 IS: 3664 IS: 3703 IS: 4260 IS: 5120 IS: 9137 IS: 10981
Coupling & coupling mountings. Coupling dynamic balancing. Horizontal centrifugal pumps for clear cold fresh water Specification for pumps vertical turbine mixed and (2nd Amendments) axial flow for clean cold water. Dynamic balancing of impeller. Code of Practice for Radiography Testing. Specification for alloy steel casting for pressure Containing parts suitable for high temperature service. Code of Practice for Ultrasonic Testing by Pulse Echo Method (Direct Contact). Code of Practice for Magnetic Particle Flaw Detection. Recommended practice ractice for ultrasonic testing of welds in ferritic steels. Technical requirements for rotodynamic special purpose pumps. Code of acceptance test for centrifugal, mixed flow and axial flow class "C" (Amendment 4) Code of acceptance test for centrifugal, mixed flow and axial flow class "B"
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3.4 PIPES, FITTINGS & VALVES
Design, fabrication, assembly and testing of pipes, fittings shall generally conform to the requirements of ANSI B 31.1. But the portions, which come under the purview of Indian Boiler Regulation (IBR), shall completely meet the requirements of IBR as a minimum. Any other internationally accepted codes and standards are also acceptable. However, the requirements of ANSI codes and IBR will be considered as min minimum imum for acceptance of the piping and all appurtenances. The design, manufacture, inspection and testing of the equipment pipes valves &\ & fittings covered under this specification shall conform, in general, to the standard and codes mentioned below or approved roved equal. These codes shall be used for all equipment covered by this specification unless otherwise specifically mentioned and general codes
ANSI B 1.20.1 ANSI B16.11 ANSI B16.20 ANSI B16.21 ANSI B 16.25 ANSI B 16.34 ANSI B 16.5 ANSI B 16.9 ANSI B18.2 ANSI B 31.1 ANSI B 36.10 ANSI B 36.19 API 601 API 605 ASTM A 530 IS 1239 (Part-1 & 2) IS 3589 Pipe Threads general purpose Forged steel fittings, Socket weld and threaded ends Ring joint gaskets and grooves for steel pipe flanges Non-metallic metallic flat gaskets for pipe flanges. Butt-welding welding ends Steel valves flanges and butt-welding ends Steel pipe flanges and flanged fittings Wrought steel butt butt-welding fittings Square and Hexagonal bolts & screws Code for pressure piping power piping. Welded and seamless wrought steel pipes Stainless Steel Pipes Metallic Gasket for piping Large diameter carbon steel flanges Standard specification for general requirements for specialized carbon and alloy steel pipes. Mild steel tubes and pipes, Pipe fittings Seamless or ERW pipes for water, gas and sewage.
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ANSI B 16.10 API 594 API 598 - 1996 edition API 599 API 600 - 1996 edition MSS -SP-45, 1992 MSS-SP-53, 1995 MSS-SP-54, 1995 MSS-SP-55, 1995 MSS-SP-61, 1992 ASTM-E 165 AWWA C 207 IS: 638 EJMA IS: 780/IS: 2406 IS: 5290 IS 4682 Part-I BS: 5146 Face to face and end to end dimensions of ferrous valves Wafer type check valves Inspection and testing of Valves Steel plug valves, flanged or butt welding ends Steel valves, flanged and butt welding ends Bypass and drain connection standard Quality standard for steel castings and forging for valves, flanges etc.etc. Magnetic particle examination method. Quality standard for steel castings and forging for valves flanges etc. Radiographic examination method. Quality standard for steel castings and forging for valves flanges etc. - visual method. Hydrostatic testing of valves. Liquid Penetration examination Steel water flanges for water works service Sheet rubber jointing & rubber insertion jointing. Expansion joint manufacturer association Sluice valves for water works purposes Specification for landing valves Code of practice for lining of vessels & equipment for chemical process Rubber lining Inspection and test for steel valves
Indian Boiler regulations (IBR)
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3.5 AIR CONDITIONING AND VENTILATION SYSTEM
Design, manufacture, inspection and testing of the equipment covered by the specification shall, unless otherwise specified, conform to the latest edition of the codes and standards including all addenda mentioned below:
IS:3103 IS:4894 IS:3588 AMCA 210 BS 848 IS 3963 IS 2312 IS 277 IS 617 IS 1570 IS 210 ISO 1940 BS 2831 IS-655 IS-8183 IS 5120 IS -2062 IS-702 ASHRAE-23-67 ARI-450-6 ASME Section-VIII IS: 4503 ASHRAE-22-72 ANSI B.91 ARI-210 Code of practice for industrial ventilation Centrifugal fans. Electrical Axial flow fans Standard code for testing centrifugal & axial flow fans method of performance test for centrifugal fan Roof extractor units Propeller type ventilating fan Galvanized sheet steel Aluminum for general engineering purposes Schedules for wrought steel for general engineering purposes Grey iron castings Dynamic balancing Method of Test for air filters in air conditioning and general Ventilation. Specification for metal Air ducts Bonded mineral wool / fiber glass for thermal and acoustic insulation. Technical requirements for rotodynamic special purpose pumps Steel for general structural purpose specification Industrial Bitumen Standard method of testing and rating air r conditioner Standard for water cooled refrigerant condenser. Unfired pressure vessels Shell & tube type heat exchangers. Method of testing for rating water cooled refrigerant condensers Safety code for mechanical refrigeration Standard for unitary air conditioning equipment.
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IS: 8188 IS:210 IS:2676 IS-5111 ASHRAE 23 IS-5493 ARI-710 ARI-750 ARI-760 ARI-495 IS-4671 IS-5688 ARI-430 Code of practice for treatment of water for industrial cooling system. Specification grey iron casting. Dimensions for wrought aluminium and aluminium alloy sheets and strips. Code of practice and Measurement Procedure for Testing Refrigerant Compressor Methods of Testing for Rating Positive dis-placement placement compressors. Dimensions for wrought copper and copper alloy tubes Standard for liquid line driers Standard for Thermostatic refrigerant expansion valves Standard for solenoid valves for liquid flow Standard for liquid receivers Expanded polystyrene foam for thermal insulation purpose. Method of test for preformed block type and pipe covering type thermal insulation. Standard for central station air handling units
National Bureau Test methods for Air filter at standard (NBS)ASHRAE guide and data book. ARI-410 ASHRAE-33 BS-2831 ARI 520 ARI 441 ANSI B 31.5 AMCA 210 IS-659 SMACNA ARI-280 UL standard 1096 & NEC Article 424 IS:655 Standard for forced circulation air cooling and air heating coil. Standard methods of testing for rating forced circulation air cooling and air heating coils. Methods of test for air ir filters in air conditioning and general ventilation. Standard for positive displacement refrigerant compressor and condensing unit. Standard for room fan coil Air conditioner. Code for refrigeration piping Test Code for Air movement device Safety codes for air conditioning HVAC duct construction standards Standard for control forced air electric heating equipment Safety code for electric heaters Metal Air ducts
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IS-277 IS-8183 IS-2825 IS-702 IS-5120 HIS IS- 660 BS 4485 ATC 105 IS-3588 IS-3963 ISO 1940 Specification for GI Sheets Bonded mineral wool / fibre glass for thermal and acoustic insulation. Code for unfired pressure vessels. Industrial bitumen Technical requirements for roto-dynamic dynamic special purpose pumps Hydraulic Institute standards, USA Safety code for mechanical refrigeration Specification for water cooling tower Acceptance test code for water cooling towers Electric axial flow fan Roof extractor units Dynamic balancing
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3.6 FUEL & BED MATERIAL HANDLING SYSTEM
The fuel & bed material handling and associated systems shall be designed, manufactured, inspected, tested, erected, commissioned and performance tested to highest engineering practices and safety codes. The system shall be built to satisfy all applicable reputed national codes / standards.
IS : 1891 IS : 3612 IS : 4776 IS : 7155 IS : 8531 IS : 8598 IS : 8723 IS : 11592 IS : 12213 IS : 13148 Part 1
Conveyor and elevator textile belting Crushing and grinding equipment classification and methods for measuring capacity. Specification for Troughed belt conveyors Part I Troughed belt conveyors for surface installation. Code of recommended practice for conveyor safety. Specification for Pulleys for Belt Conveyors Specification for Idlers and Idler sets for belt conveyors Dimensions for vibrating conveyors and feeders with rectangular or trapezoidal trough Code of practice for selection and design of Belt conveyors Code for Mechanical vibrating screen Bulk handling equipment mobile continuous type rules for the design of structures
Also other relevant Indian international standards shall be referred. Good engineeringpractices shall be followed at all other places where specific standards are not available available.
3.7
Ash Handling System
The Ash handling system shall be designed, manufactured, inspected, tested, erected, commissioned and performance tested to the highest engineering practices and safety codes. The e system shall be built to satisfy all applicable national codes / standards standards.
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3.8
IS 6206 IS 5456 IS 5727
Compressor and Root blower

Guide for selection installation and maintenance of air compressor upto 10 bars. Code practice for testing of positive displacement type air compressors and exhausters. Glossary of terms relating to compressor and exhausters
3.9
IS 2825
Air Receivers
Code for unfired pressure vessels Design Code for Pressure Vessels Specification for Air receivers for compressed air installation
ASME sec VIII IS 7938
3.10 MS Pipes
IS 1239 IS 3589 IS 4771 MS tubes, tubular and other wrought steel fittings. Steel pipes for water and sewage (168.3 to 2540 mm outside diameter). Abrasion resistant iron castings
3.11 Inter cooler / after cooler

TEMA Code for design of heat Exchangers
3.12 COMPRESSED AIR AND INSTRUMENT AIR SYSTEM

The compressed air system, all associated piping and systems shall be designed, manufactured, inspected, tested, to well established engineering practices and safety codes of the latest applicable Indian / British / American / DIN / ISO standards. The latest edition of the following standards shall be followed in particular.
IS: 2825 Code for unfired pressure vessels
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Code of practice for testing of positive displacement type air compressors and exhausters Glossary of items relating to compressors and exhausters Guide for selection, installation and maintenance of air compressor plants with operating pressures up to 10 bars Specification for Air receiver for compressed air installation Specification for Shell tube type Heat Exchanger Power test codes for Displacement Compressors, Vacuum Pumps & Blowers Fusion Welded Steel Air Receiver Standards of Tubular Exchanger Manufacturer's Boiler & Pressure Vessel code Code for pressure piping power piping.
IS: 5456 IS: 5727 IS: 6206 IS: 7938 IS: 4503 PTC: 9 BS: 487 TEMA ASME ASME/ANSI B 31.1
3.13 E.O.T. CRANE AND HOIST TROLLEYS

The design, manufacture and testing of the crane shall conform to the latest editions of the following codes and standards along with their amendments:
IS: 807 IS: 3177 IS: 1835 IS: 2266 IS: 3443 IS: 3815 IS: 816 Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists. Code of Practice for Electric Overhead Travelling Cr Cranes anes and Gantry Cranes other than Steel Works Cranes. Specification for Round Steel Wire for Ropes. Steel Wire Ropes for General Engineering Purposes specification. Crane Rail Sections. Specification for Point Hook with Shanks for General Engineering Purpose. Code of practice for use of metal arc welding for general construction in mild steel.
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IS: 9595 IS: 7318 IS: 1323 IS: 325 IS: 4029 ANSI B 30.2.0 IS : 6547
Recommendations for metal arc welding of carbon manganese steels. Approval test for welder when welding procedure approval is not required. (Part-I) I) Fusion welding of steel. Code of practice for oxy oxy-acetylene acetylene welding for structural work in mild steel. Three Phase Induction Motors. Guide for Testing Three Phase Induction Motors. Safety Codes for overhead and Gantry Cranes. Electric chain hoist
3.14 FIRE PROTECTION AND DETECTION SYSTEM

The entire Fire Protection System shall be designed in line with the regulations and rules of Tariff Advisory Committee (TAC) of India. In the absence of TAC regulations, for a specific aspect of design the codes of National Fire Protection Association, (NFPA) U.S.A. shall be followed. The entire design and installation shall be approved by the Reg Regional ional Committee of TAC The design, manufacture and testing of the equipment covered by this specification shall comply with the requirements of all applicable and latest Indian/ International Standards / codes / regulations in force and also in particular the following:HIS ASME / ANSI B16.5 ASTM Hydraulic Institute Standards. Code of steel flanges and pipe fittings. Standards for all tests and materials.
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ASME Sec V ASTM-E -165 IS: 9137,(Reaffirmed 1993) IS: 325 API 971 AGMA 515.02 IS: 5 IS: 101 IS: 161 IS: 2074
Non destructive examination. Liquid Penetration examination. Code of acceptance test for centrifugal, mixed flow and axial pumps - Class C (Amendment 4) Three phase induction motors Coupling & coupling mountings. Coupling dynamic balancing. Colours for ready mixed paints and enamels. Methods of test for ready mixed paints and enamels. Heat resistant paints. Specification for ready mixed paint, air drying, red oxide zinc chrome priming. Specification for enamel, synthetic, exterior
IS: 2932
(a) Undercoating (b) Finishing
MSS - SP 55 ISO 1940 API 605 AWWA C 207
Visual inspection. Dynamic balancing of impeller. Large diameter carbon steel flanges. Steel water flanges for water works service.
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IS: 638 EJMA IS: 1239, Part-I & Part-II IS: 3589 Gr.410 IS: 780 / IS: 2406 IS: 5290 IS: 8442 IS: 903 IS: 3042 IS 3764 IS 4081 IS 5153 IS 9759 IS: 1642 IS: 1646 IS: 1648 IS: 1600
Sheet rubber jointing & rubber insertion jointing. Expansion joint manufacturer association. Heavy class ERW MS black pipes for sizes 150 NB and below. (Pipes and pipe fittings) ERW MS black pipes for sizes above 150 NB. (Water, gas and sewages). Sluice valves for water works purposes. Specification for landing valves. Functional requirements for stand post type, water monitor for the fighting. Fire hose delivery couplings, branch pipe, nozzles and nozzle spanner. Specification for single faced sluice gates (200 to 1200 mm size). Safety code for excavation works Safety codes for blasting and related drilling operations. Cast iron check valves for general purpose. Guidelines for de de-watering during construction Code of practice for fire safety of building (general). Code of practice for fire safety of buildings (general) electrical Installations Installa Code of practice for fire safety of buildings (general) firefighting equipment and its maintenance Code for testing of constant speed internal combustion Engines for general purpose
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Performance of constant speed internal combustion engines for general purpose
IS: 1601
3.15 WATER TREATMENT PLANT

ASME Sec. VIII, Div.I IS: 9222(Part I): 1990 ASME/ANSI B31.1 IS: 2825 IS: 10500 1983 IS: 3025 IS: 1239/IS: 3589 MSS-SP-58 MSS-SP-69 BS: 5156 BS: 5352 BS: 4994 IS 803 ANSI B 16.5 ASTM ASME Sec V ASME Sec II Boiler and pressure vessel code Recommendations for handling and dosing devices for chemicals for water treatment Codes for power piping Code for unfired pressure vessels Drinking water specifications Methods of sampling and test for water and waste water Piping material Pipe hangers & supports - Material & Design Pipe hangers & supports Selection & Application Diaphragm valves Forged steel gate, globe, check valves Specification for design and construction of vessels and tanks in reinforced plastics Code for design fabrication and erection of cylindrical welded storage tanks Code of steel flanges and pipe fittings Standards for all tests and materials Non destructive examination Material specification.
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API-2000 IS : 875 ANSI B16.5 ANSI B16.9 ANSI B16.20 ANSI B16.21 ANSI B16.25 ANSI B18.2 ANSI B 2.1 ANSI B 36.19 API 601 API 605 IS 4682 Part-I ANSI B 16.10 ANSI B 16.34 API 594 API 598 API 599 API 600 BS: 5146
Venting of storage tanks. Code of practice for design loads for buildings and structures Steel pipe flanges and flanged fittings Factory made wrought steel butt welding fittings Ring joint gaskets and gr grooves for steel pipe flanges Non-metallic flat gaskets for pipe flanges. Butt welding ends Square and Hexagonal bolts & screw Pipe Threads Stainless Steel Pipe Metallic Gasket for piping Large diameter carbon steel flanges Code of practice for lining of vessels & equipment for chemical processprocess Rubber lining Face to Face and End to End dimensions of ferrous valves Steel valves, flanged and Butt welding ends Wafer type check valves Valve Inspection and test Steel plug valves, flanged or butt welding ends Steel Gate Valves, flanged or butt welding ends. Inspection and test for steel valves
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AWWA C 207
Steel pipe flanges for water works service
3.16 ELECTRICAL
The various items of equipment in general, shall conform to the following Indian / IEC standards:
Generator- IEC Power Transformers HT Switchgear Circuit Breaker HT Cables Low Voltage Switchgear LT Cables Generator Busduct LT Busduct Current Transformer Potential Transformer Protection Relays DC Battery Illumination system Earthing Lightning Protection UPS Control / Relay Panels Motors 34 / IS 5422 IS 2026 / IEC-76 IEC - 298 / IS 3427 IEC - 56 / IS 13118 IS -7098 IS 4237 / IS 4047 IS 1554 IS 8084 IS 8623 IS 2705 IS 3156 IS-3231 / IEC-55 IS 1651 / IS 1652 IS 3646 IS 3043 / IEEE - 80 IS 2309 IEC 146 IS 4237 / IS 8623 IS 3842 / IS 4483 IS 325 / IS 4029
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3.17 CIVIL
Refer detail civil specification for all codes and standards.
3.18 CONTROL & INSTRUMENTATION

The design, manufacture, inspection, testing and installation of all equipment and systems covered herein shall conform to the latest editions of codes and standards mentioned below
3.19 Temperature Measurement

i) Instrument and apparatus for temperature measurement - ASME PTC 19.3(1974). ii) Temperature measurement - Thermocouples ANSI - MC 96.1 - 1982. iii) Temperature measurement - Guide to electrical resistance thermometry IS-2806. 2806. (1992) iv)Industrial Platinum resistance thermometer - IS: 2848 (1986). v) RTD Design code - DIN 43760, BS 1904 class II
3.20 Pressure Measurement

i) Instrument and apparatus for pressure measurement - ASME PTC 19.2 (1987). ). ii) Bourdon tube pressure and vacuum gauges IS: 3624 (1987).
3.21 Flow Measurement

i) Instrument and apparatus for flow measurement - ASME PTC 19.5 (1972). Interim Supplement, Part-II ii) Measurement of fluid flow by means of pressure differential devices BS EN ISO 5167-1: 1992.
3.22 Instrument Switches and Contacts

i) Contact rating - AC services NEMA ICS ICS-2 2 1978 (with revision through May 1983) Part - 2 125, A 6000 ii)Contact rating - DC services NEMA ICS ICS-2 1978 Part-2-125, A600.
3.23 Enclosures
i) Types of Enclosures - NEMA Std. ICS ICS-6-1978 (with rev.1-4/80) 4/80) through 110.22 (Type 4 to 13) 33 | P a g e
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ii) Racks, , panels and associated equipment - EIA: RS-310-C C (R1983), (ANSI C83.9 - 1972). iii) Protection class for enclosures, nclosures, cabinets control panel & desks IS: 2147 - 1962 / 13947 Part - I (1993). IS:
3.24 Apparatus, Enclosure and Installation Practice in Hazardous Area

i) Classification of hazardous area - NFPA 70-1984 Article 300. ii) Electrical instruments in hazardous dust location - ISA-512.11 (1973) iii) Intrinsically safe apparatus - NFPA 493-1978. iv) Purged and pressurized enclosure for electrical equipment in hazardous location NFPA 496-1982. v) Enclosure for instruments - IS: 2148 (1981) reaffirmed 1993.
3.25 Sampling System

i) Stainless steel material of tubing for sampling system - ASTM A 269-82 82 Grade 7P 316. ii) Submerged helical coil heat exchanger for sample coolers ASTM D D-1192-1964. 64. iii) Water and steam in power cycle - ASME PTC 19.11. iv) Standard methods of sampling system - ASTM D 1066-69 v) Solvent tolerance of Amine Resins - ASTM D 1192-70-1984
3.26 Annunciators
i) Specifications and guides for the use of general purpose annunciat annunciators -ISA ISA S19.1, 1979 ii) Surge withstand capability tests - ANSI C 37.90 a-1974 and IEEE Std. 472-1974. 1974. iii) Annunciation sequence: ISA S 18.1 (1985)
3.27 Control Valves

Flow equations for sizing control valves Valves - flanged, threaded and welding end ISA S 75.01 (1985) ANSI B 16.34
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Casting Welded end connection Forging Defect removal Cleaning CV test
ASTM A 216 / A 351 As per ASME boiler and pressure vessel code / ANSI B16.34, B16.25, B 16.11. ASTM A 105 / A 182 ANSI B 16.34 ASTM A 380 As per ISA procedure S 75.02 (1982).
3.28 Instrument Tubing

i) Dimensions offittings - ANSI B B-16.11 ii) Code for pressure piping, welding hydrostatic testing - ANSI B 31
3.29 Cables
Cable Insulation Sheathing Armouring Fire retardant test Oxygen index test Colour coding Thermocouple extension cables Elastomer insulated cables IS 1554 Part - 1 (1988) IS 5831 (1984) IS 5831 (1984) IS 3975 Part-1 1 (1988) Reaffirmed 1992. IEC 332 Part - 3 category A ASTM D 2863 - 1974. IS 1554 (1988) As per ISA standard. IS 9968 Part - 1 (1988)
3.30 Cable Trays and Conduits

i) Repeat Test Standards. TEMA EMAVE-1-1979. ii) Zinc coating hot dip on assembled products (for Gal Galvanizing vanizing of Carbon Steel cable trays) 35 | P a g e
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ASTMA-386-78.
3.31 Surge protection

i) IEEE - 472 (1974) ii) ANSI - C37.90 A (1982)
3.32 Instrument end connections

Threaded Flanged Cable entry in Jbs and instruments NPT ANSI B 1.20.1 ANSI B 16.5 NPT ANSI B 1.20.1
WHERE
IEEE ISA NEMA ANSI NFPA ASME IS IEC ASTM EIA DIN Institute of Electrical and Electronics Engineers. Instrument Society of America National Electrical Manufacturers Association American National Standards Institute National Fire Protection Association American Society of Mechanical Engineers Indian Standards International Electrotechnical Commission American Society for Testing Materials Electronic Industries Association Deutsche Institute Normal
3.33 SURFACE PREPARATION AND PAINTING

In addition to the detailed specifications of the contract, the following code codes s and standards shall be followed for the work covered by this contract. 36 | P a g e
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IS:5 IS:101 IS: 161 IS: 1477 IS: 2074 IS: 2339 IS: 2379 IS: 2932 IS: 9404 IS: 9954 SIS-05 5900-1967 SSPC-SP BS-4232. NACE Colours for ready mixed paints and enamels. Methods of test for ready mixed paints and enamels. Heat resistant paints Code of practice for painting of Ferrous metals in Buildings Specification for ready mixed paint, Air drying, red oxide zinc chrome priming. Aluminium paint for general purposes, in dual container. Colour code for identification of pipelines. Specification for enamel, synthetic, exterior (a) undercoating, (b) Finishing. Colour code for identification of pipe lines used in the Thermal Power Plants. Pictorial surface preparation standards for painting steel surfaces Swedish standard institution - (Surface preparation standards for painting steel surfaces), Steel structures painting council, U.S.A. (Surface Preparation Specification) British Standards Institution (Surface Finish of Blast steel for painting) National Association of Corrosion Engineers, U.S.A.
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4. FUEL ANALYSIS
Fuel means all type of Indonesian& Indian coal, Grade from C to F.Analysis .Analysis of different type proposed to be used is given below
4.1
Sl No A 1 2 3 4 B 1 2 3 4 5 6 7 C
FUEL ANALYSIS
Details Proximate Analysis Ash Volatile matter Fixed Carbon Moisture (Total) UltimateAnalysis Ash Carbon Hydrogen Sulphur Nitrogen Oxygen (by diff.) Moisture (As received) Gross CalorificValue Maximum Minimum Grindability index Ash Deformation temperature % % % % % % % Kcal / kg 8-12 55.6 2.75 0.5 > 1 1.4 4.25 32-36 5300 42 36 3.5 0.5 1 9 8 3700 % % % % 8-12 36-40 46.5 32-36 42 23 27 8 Unit Grade C Grade F
D E
45 C 1200
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Start up Fuel for Boiler - HSD/LDO Fuels for flame stabilization when required HFO
4.2
Sl.no 1 2 3 4 5 6 7 8 9 SiO2 Al2O3 Fe2O3 TiO2 CaO MgO SO3 P2O5
ASH ANALYSIS
Average (%) 70.40 28.60 10.76 1.80 1.30 2.00 0.29 1.10 2.30
Component
Alkalies by differences
4.3
Design Criteria
Boiler shall be designed for guaranteed performance with C-grade grade coal of GCV 5300 kcals/Kg and ash content of 12%and with F grade coal also. . Bidder shall give correction curves or deviation in coal quality. The boiler shall be capable of generating steam at MCR parameters in the following conditions. a. Using coal of grade C, the GCV range of 5300kcals/kg. b. A coal of grade C and one of the washery rejects and shale shale. c. Wherever required grinding inding of coal shale and blending of different types of fuels is envisaged to bring the fuel within the range of 5300 Kcals/kg. Bidder shall demonstrate the performance of the boiler at MCR while firing coal grade C as well as combination of I. Coal/ washery rejects (up to max. of 20% heat value) II. Coal/shales(up up to a max. of 20% of heat value). The boiler shall be capable of generating steam up to 40% MCR capacity without oil support. 39 | P a g e
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5. SPECIFIED DATA SHEET FOR BOILER AND AUXILIARIES
The following data sheet is for one boiler auxiliaries of TMCR+5% unit unless otherwise specified
SL.NO 1 1.1 2 2.1 2.2 2.3 2.4 3 4 4.1 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.2 MECHINICAL UNITS DATA
Ambient conditions as defined in section PROJECT INFORMATION AND GENERAL TECHNICAL SPECIFICATION Ambient conditions to be used as base for calculations of any data and efficiencies which are to be required in the following Design Data Sheets Air temperature C 45.29 % Relative humidity 60 Height above sea-level m 172 Wind velocity The fuels shall be adopted for the design of the boilers and associated equipment as defined in Feed water temperature at inlet of economizer(HP heater out condition) HP heater in condition Boiler water & steam quality Boiler water Quality Conductivity at 25oC pH-value Phosphates Total dissolved solids Oil & organics Steam purity The steam sample taken under steady State conditions at the primary superheater inlet shall not exceed the following values of the various components uS/cm ppm ppm ppm < 20 10.8 -11.8 <1 50 NIL KMPH C C C 5.2 140 165 250
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5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 6 6.1.1 6.1.2 6.1.3 7 7.1 7.2 7.3 8 Specific conductivity measured at 250C Silica (SiO2) Total iron (Fe) Total copper (Cu) Total sodium and potassium (Na, K) Total dissolved solids (Max.) Economizer Maximum height of heating surface banks Minimum space between two Banks Space for future installation of heating surfaces of the total heating surfaces Superheater Maximum height of heating surface banks Minimum space between two Banks Space for future installation of heating surfaces of the of the primary total superheating surfaces provided Drum The elliptical manholes at each end of the drum shall not be less than Maximum saturated steam velocity in connecting tubes to superheater no. 1 9 Furnace a) 120% of max.shut off pressure of The strength of the furnace chamber against pressure transient shall be designed against following whichever is governing without permanent deformation based on normal allowable stresses mmWC PA fan b) +889mm to -889mm c)various fans trip and transient condition mm 410 x 300 m m % 1.5 1 15 (minimum 2 loops) m m % 1.5 1 15 (minimum 2 loops) uS/cm ppm ppm ppm ppm ppm 0.2 0.02 0.02 0.003 0.01 0.1
m/s
10
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10 10.1 Oil Burners The number & capacity of burners per boiler start start-up shall be The burners shall have a turn down ratio of not less than 10.2 when burning fuel oil 11 11.1 Bunker Bulk density for design shall be Capacity of fuel bunker 11.2 -Coal (Effective) Bed Material Bunker 11.3 12 12.1 12.2 13 13.1 a. b. c. 13.2 13.3 14 - Bed material (Effective) Ash hopper Density to be considered for volume sizing Density to be considered for weight calculation Air Ducts and Flue gas The maximum velocity shall be Cold and hot air Flue gas Flue gas velocity at the heating surfaces within the boiler The thickness of all plates of air ducts shall be not less than The thickness of all steel plates of flue gas shall be not less than Cladding and Roofing mm mm m/s 13 12 8 5 6 kg/m kg/m 750 1000 kg/m 800 for volume cal.1000 for structure/weight design for 16 Hrs storage Capacity considering the m requirement for 2 cold start ups of boiler To be indicated by bidder
To be indicated by bidder 1:3
kg/m
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14.1
The thickness of corrugated Al sheets for cladding of boiler body shall not be less than Plain Al. sheets for ducts & Piping equipment Start-up vent valve For a start-up flow off
mm
1.2
14.2 15
mm
% of MCR
30
16
Piping System Allowable velocity range Main steam lines > 40 kg/cm(g) M.P. steam line > 40 kg/cm(g) Saturated steam line Boiler feed discharge line Maximum flow velocity 40 - 50 M/sec. 20 - 30 M/sec 10 M/sec 2 to 3 M/sec
17
Fuel oil pump Unloading cum forwarding pump
Type
Screw with mechanical seal As Reqd. to feed all HSD burners of boiler at their maximum fuel firing capacity 2 x 100 % (1W + 1S) Feed water quality (EPC Vendor to meet the requirement through the DM plant)
Head
Capacity Nos. 18
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SL.No. 18.1 18.2 18.3 18.4 18.5 18.6 18.7 18.8 18.9 18.10 18.11 19 19.1 Conductivity pH Total silica Total iron Total copper Oxygen Hydrazine residual General Appearance Total Hardness as CaCO3 Oil & organics Total Dissolved Solids Safety valves No. & operation margin between Max. operating pressure and Set point As per IBR ppm ppm ppm ppm ppm ppm Characteristics Unit Data < 0.5 8.8 - 9.2 0.02 0.01 0.005 0.007 0.02 Clear & colorless Commercial Zero NIL 0.1
NOTE:The proposed CFBC steam generators and auxiliaries shall be designed for 100% BMCR steam generation at rated parameters with the fuel, Washery rejects; ; however performance fuel shall be C grade coal with a calorific value of 5300kcals/kg and also with F grade calorific value of 3000Kcal/Kg. The system design, equipment, auxiliaries and their layout arrangement shall specifically consider the following critical aspects: - Severe erosion potential otential of fuel ash on circulating system materials (on all gas touched sections) and very high dust loading level of the entire circulating system. - All design and operating parameters for boiler and boiler auxiliaries shall be normal range 44 | P a g e
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while firing fuels and at 100% BMCR. * Supplier should submit proposed equipment detailed engineering specifications and required preliminary engineering drawings and load data.
5.1
GUARANTEE PARAMETERS (AT MCR OPERATION)
Note: The performance parameters listed below are based on the specified fuels.
SL.No. 1.1 i) ii) Description Feed water temperature at inlet to Economizer Normal operation at 100% Boiler MCR (BMCR) Operation at 100% BMCR during HP heater outage C C Unit Data
iii)
Normal operation at 60% Boiler MCR (BMCR)
1.2 1.3 -
Boiler turn down ratio for auto control
1:04
The steam sample taken under steady State conditions at the primary superheater inlet shall not exceed the following values of the various components Specific conductivity measured at 250C Silica (SiO2) Total iron (Fe) Total copper (Cu) Sodium and potassium (Na, K) S/cm Ppm Ppm Ppm Ppm 0.2 0.02 0.02 0.003 0.01
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1.4
Total dissolved solids (Max.) The maximum value of excess air at MCR being measured at economizer outlet. Minimum boiler availability/year The heat loss of any insulated surface referred to max. surface temperature of 60C, ambient temperature of 35C and a wind velocity of 5 m/s shall not exceed Fuel requirement Auxiliary Power Requirement % of UBC in fly ash Steam Parameters at boiler outlet Flow Rate Temperature Pressure
Ppm %
0.1 20
1.5
Hours
8000
1.6
W/m2
210
1.7 1.8 1.9 2.0
kg/hr KW %
TPH C Bar C 145
2.1
Flue gas temperature at APH outlet
5.2
SL.No. 1 2 3 4
MATERIAL SPECIFICATION
Description MATERIAL SA 516 Gr 70 SA 210 Gr A1 SA 213 GR A1, T11, T22, T91 SA 335 P 11 / P 22 /P91
Drum Plate Furnace Tubes Super heater Superheater outlet header
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5 6 7 8 9 10 11
Economizer Economizer Headers Steam Coil Air Pre heater IBD & CBD Tanks Chemical dosing pump Ducts Final superheater outlet header
SA 210 Gr A1 SA 106 Gr B SA 106 Gr B SA 516 Gr 70 SS 304 IS 2062 SA 335 P91
Notes: Equivalent materials to other international standards are also acceptable subject to approval from Owner/Owners consultant. The above material specification is the minimum requirement. In case of any requirement of superior material owing to design requirement of the componen component, the same shall hall be provided by the tender without any extra cost to the Owner. * Supplier should submit proposed equipment detailed engineering specifications and required preliminary engineering drawings and load data.
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6. SPECIFIED DATA SHEET FORSTEAM TURBINE GENERATOR AND AUXILIARIES
The following data sheet is for one steam turbine, generator & water cooled condenser and Auxiliaries of 1 x 30 MW units unless otherwise specified
SL.NO
STEAM TURBINE
Unit
Data
1.1.0
Application
Power generation
1.1.1
Operating mode
Continuous, Base load
1.1.2
Number of turbines in operation
Nos. MW Bar
One(1) 30 88.3
1.1.3 1.1.4 1.1.5
Generation Main steam inlet pressure
Main steam inlet temperature
535 Number of bleeds and bleed pressure to be optimized by the bidder to Attain maximum heat rate.
1.1.6
Bleed off pressure
1.1.7
Condenser pressure
Ata
0.1 Less than 85 at a distance of 1 mfrom the surface of the equipment/ enclosure.
1.1.8
Noise level
1.1.9
Turbine speed
rpm
3000
1.1.10
Material of Construction
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Turbine Casing
Bidder to indicate
Rotor
Bidder to indicate
Valve internal
Bidder to indicate
HP Blades
Bidder to indicate
LP Blades
Bidder to indicate
Steam Nozzles
Bidder to indicate
Bearing Liners
Bidder to indicate
Design life of Turbine & Auxiliaries
25 years
6.1
SHOP TESTS
Cylinder, rotor & blade test on forge master:

Microscopic examination Magnetic particle and dye penetrant test Ultrasonic and radiographic tests Rotor forging heat stability test Static and dynamic balancing of rotors Residual stress measurement Dimensional check Yes Yes Yes Yes Yes Yes Yes
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Check for concentricity, straightness and Surface finishing of shafts. Hydrostatic test for cylinders Rig tests for governor performance/trip Setting Full speed NO LOAD test Over speed test Shop assembly and dimensional clearances Check Other tests, as required Steam test Yes Yes Yes Yes Yes Yes Yes Yes Yes
6.2
SITE TETS
Yes Yes
Performance tests as specified Start-Up Spares For STG Unit
6.3
MAINTENANCE TOOLS
Yes
Lifting tackles, including lifting beams, slings and eye bolts for turbine casing and rotor
Turbine flange bolt heating and tightening Equipment (if applicable) Lifting gear for ESV and governing valves (if necessary)
Yes Yes
Assembly rig for turbine casing (if required) Any special tools required for maintenance
Yes Yes
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Two sets of spanners of appropriate sizes to fit all nuts and bolts.
Yes
Two sets of special dies and taps for all bolts and nuts.
Yes
6.4
CONDENSER & AIR EVACUATION SYSTEM FOR EACH TURBINE
Condenser
1 2 3 4 5 6 7 Number of condensers Installation Type of condenser Orientation of condenser tube axis Number of passes Design Standard Quality of cooling water One (1) Indoor Downward exhaust flow surface type Perpendicular to the Turbine axis Two Pass on tube side, single pass on shell side HEI As per ANNEX
Shell design temperature
Turbine exhaust hood temperature high trip setting
Tube thickness in condensing zone BWG
18
10
Tube thickness in air cooling zone BWG
20
11
Minimum tube sheet thickness mm
40
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12
Minimum tube support plate Thickness mm
15
13
Minimum steam impingement baffle thickness mm
10
6.5
1 2 3 4
Performance (100% MCR) and Construction Requirements

0.1 33.0C 9C 5%
Operating back pressure with steam turbine operating at its 100% MCR load. Ata Cooling water inlet operating temperature Maximum permissible temperature rise in cooling water Design margin on heat load(Over and above VWO condition
Fluid circulated
Shell side Exhaust steam
Tube side Cooling water
6 7 8 9 10 11 12 13 14
Fluid quantity (TPH) Cooling water pressure at water box inlet [ata] Maximum allowable pressure drop on tube side (ata) Hot well storage capacity from normal level to low low-low level (150 mm above bottom of hot well).(Based on VWO demand) Tube cleanliness factor Oxygen in condensate at hot well outlet No. of additional tubes to be provided in the Condenser Minimum steam impingement baffle thickness Cooling water velocity In tubes
-- (Max.) }Bidder to --(Normal) (Normal) }indicate 2.5 0.5 2 Mins 85% Not to exceed 42 ppm 5% 10mm Max. 1.8 m/s
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15 16 17 a) b) 18 19 20 21 22 23 24 a b c d e Water box lining Tube sheet lining Type of protection for tubes against impingement of steam from Main turbine exhaust/Dump steam area Drains Type of tube sheet to shell joint Vertical movement of condenser Material of expansion joint (if applicable) Corrosion allowance on ferrous parts Radiography Joint efficiency Material of construction Condenser shell, hot well Water box Structural parts Tube sheets Condenser tubes Carbon steel (SA 516 Gr. 70) Carbon steel (SA 516 Gr. 70) Carbon steel or equivalent (IS2062) Carbon steel (SA 516 Gr. 70) Seamless Admiralty Brass (SB-111 (SB Gr 44300) 2 rows of Stainless steel, Balance seamless Admiralty Brass (SB-111 (SB Gr C 44300) Carbon steel (IS 2062) Neoprene ASTM B.164-99T 99T or equivalent on CW side. ASTM B.193-B7 B7 or equivalent Higher thickness tubes Baffles Bolted Stainless steel expansion joint /at turbine exhaust Alternatively Condenser can be spring mounted Stainless steel 3.20 mm Spot 0.85 Epoxy paint Epoxy paint (on CW side)
f g h i j
Tubes in air suction section and steam pigment section Tube support plates Gaskets on water side Bolts, studs, nuts, washers etc. Shell flange bolts
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25 26 Water box design pressure Shell design pressure Cooling water connection: Inlet Outlet 4 Kg/cm2 (g) 1.1 kg/cm2 (g) and full vacuum.
27
}Bidder to indicate
6.6
AIR EVACUATION SYSTEM Hogging ejector
A B C D E F G H
Type Capacity Op. steam press Op. steam temp Max. steam press Max. steam temp Start-up up time down to 225 mm Hg Hogging steam Temperature & pressure
Single-stage, stage, steam jet with Silencer As per latest edition of HEI
Lowest possible parameters to achieve vacuum as quickly as possible during boilerstart up
20 minutes (Maximum) Bidder to indicate (minimum possible from start upstream).
Vacuum pumps for air ejection

A Nos required Capacity 1 working + 1 standby Shall not be less than 120 % the capacity obtained from HEI standards. Multi-stage, multi element
Type
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D E F
Steam strainer Size and capacity System vacuum
Yes As per HEI To be indicated by bidder
6.7
1 a b c d e 2 a b c 3 4 a b 5
TESTING & INSPECTION:

Yes Yes(as per HEI standard) Yes Yes Yes
Shop Tests during Manufacture Physical and chemical test Ultrasonic tests and radiography Hydro test Tube leak test Other tests as required Site Tests Hydro test Performance test Other tests as required Start-up Spares Essential Spares Condenser tubes % Condenser plugs % Maintenance tools and tackles 5% of total number of tubes of each type 5% of total number of tubes of each type All special maintenance tools and tackles as required Yes Yes Yes To be included as required
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6.8
FEED WATER HEATERS L.P Heaters
Disposition Design margin on heat load Shell design pressure
Horizontal Preferably 5% 20% above max shell operating pressure or 3.5 bar (g), whichever is higher and full vacuum 10 C above sat: temp. Corresponding to design
o
Shell design temperature pressure Shell side corrosion allowance Tube design pressure extraction pump Tube design temp Max. Allowable pressure drop on tube side 170 C 0.5 bar
o
3.2 mm 5% above shut off pressure of condensate
Material of Construction:
Tube Shell Thermal Design Standard Mechanical design standard SA 249 TP 304 SA 516 Gr. 70 HEI TEMA `C
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H.P Heaters
Disposition Design margin on heat load Shell design pressure operating pressure 10C C above sat: temp corresponding to shell Shell design temp design pressure. Cold water shut off pressure of boiler feed Tube design pressure pumps Tube design temp Shell design temp. in desuperheating zone Tube design temperature in desuperheating zone Corrosion allowance on shell side Maximum allowable pressure drop 0.5 bar on tube side 20C C margin over Max operating temp 10C C above max.operating temp 20C C above shell design temp 3.2 mm Vertical Preferably 5% 20% margin on max:
Tube Shell Thermal Design Standard Mechanical design standard SA 213 TP 304 SA 516 Gr. 70 HEI TEMA `C
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6.9
Location Design standard Arrangement tank Type Design pressure Operation Flow arrangement
DEAERATOR & FEED WATER TANK

Outdoor HEI Deaerator mounted on feed Spray cum tray type Full vacuum and 20% margin on maximum operating pressure Variable pressure Steam flow upwards water flow downwards
MATERIAL OF CONSTRUCTION
Shell (Deaerator) Trays Tank Shell (Feed Storage) Nozzles & Pipes Internal fasteners SA 516 Gr. 70 SA 240 TP 304 SA 516 Gr. 70 A 106 GR. B Stainless steel
6.10 FEED WATER STORAGE TANK

Feed tank orientation Feed tank storage capacity between normal and low low-low level Maximum dissolved oxygen in feed water at feed tank outlet at all loads Dissolved CO2 content in feed water at feed tank outlet at all loads Horizontal 10 min. of feed water flow rate 0.007 ppm Nil
Note:* Supplier should submit proposed equipment detailed engineering specifications and required preliminary engineering drawings and load data.
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7. FEED WATER SYSTEM
7.1 L.P HEATER General
Horizontal 5% 20% above max shell operating pressureor 3.5 bar (g), whichever is higher. 10oC above sat: temp. Correspondingto design pressure. 3.2 mm 5% above shut off pressure ofcondensate extraction pump. bidder to design accordingly 0.5 bar
Disposition Design margin on heat load Shell design pressure Shell design temperature Shell side corrosion allowance Tube design pressure Tube design temp. Max. Allowable pressure drop on tube side
Material of Construction:
Tube Shell Thermal Design Standard Mechanical design standard SA 249 TP 304 SA 516 Gr. 70 HEI TEMA C
7.2
Location Arrangement Type Operation
DEAERATOR DESIGN CRITERIA Deaerator

Outdoor Deaerator mounted on feed tank Spray cum tray type or stroke type Constant pressure Steam flow upwards water flow downwards (for spray cum tray type).
Flow arrangement
7.3
Feed tank
Horizontal 10 min. of feed water flow rate
Feed tank orientation Feed tank storage capacity between normal and low low-low
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level Operating parameters Pressure Temperature of feed water Design Pressure Design temperature Hydro test pressure The total deaerator feed water flow required at 145.40Cand 4.2 Kg/cm2 (a) Maximum dissolved oxygen in feed water at feed tank outlet at all loads. Dissolved CO2 content in feed water at feed tank outlet at all loads Heating steam parameter Pressure Temperature Flow Condensate Parameter Pressure Temperature Flow Make up DM water parameter Pressure Temperature Flow
Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize 0.007 ppm Nil
Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize
7.4
BOILER FEED WATER PUMP

Boiler Feed Water Two (2) nos. (2 x 100%),Boiler feed Pumps, motors and foundations shall be suitable for variable speed drive (VSD). 1W+1S Continuous Indoor Yes Yes Yes
Service No. of pumps required No. of pumps working Duty Location Online Oxygen (O2) Analysers required deaerator outlet Online PH Analysers required deaerator outlet Online conductivity Analysers required deaerator outlet PUMP PARAMETERS Design capacity of the pump TPH Rated capacity of the pump
Bidder to indicate 15% margin over design capacity,calculated based on 3 % make up.
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Discharge pressure developed by the pump at design point kgf/cm2(a) Drum safety valve set pressure kgf/cm2(a) Pressure drop across economiser, kgf/cm2 Pressure drop across flow control valve kgf/cm2 Pressure drop across pipingand valves kgf/cm2 Pressure drop across flow nozzle kgf/cm2 Static head Discharge pressure at rated
Maximum speed RPM Reverse flow through pump will be considered for drive selection Deaerator pressure during normal operating condition kgf/cm2(a) Deaerator operating temp during normal operating condition. C NPSH available at normal operating condition MWC Shutoff head Feed water analysis pH Oxygen ppm Total iron content ppm Copper content ppm Total silica content ppm Hydrazine residual ppm Conductivity S/cm CONSTRUCTION DETAILS Type of casing Type of impeller Shaft sealing Type of bearing lubrication Flange drilling standard Axial thrust balancing device to be designed for pump shut-off Type of pump drive connection Type of bearing lubrication for thrust bearing Type of oil seal required
5% margin over the pressure condition developed at design point. (Based on 2nd drum safety valve set pressure: further margins like frequency corrections shall also be applied) 3000 Yes 6.5 ** 162 ** Bidder to optimize Shall not exceed more than 125% of rated head. 8.8 - 9.2 0.007 0.01 0.01 0.02 0.02 0.2 Ring section Closed Mechanical seal arrangement Ring oil ANSI B 16.5 Yes Direct Ring oil Labyrinth type
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MATERIALS OF CONSTRUCTION
Material of the pumps for the following parts shall preferably be as indicated below
Ring section Impeller and diffuser Wear rings Shaft sleeves Shaft Case gasket 12% chromium steel 12% chromium steel 12% chromium hardened.(Minimum 50 BHN difference between mating rings shall be provided). 18 - 8 stainless steel Forged 12% chromium steel SS spiral wound with CAF/Teflon
TESTING AND INSPECTION

Radiography Parts to be examined Testing standard Acceptance standard Dye penetrant testing Parts to be examined Testing standard Acceptance standard Ultrasonic examination Parts to be examined Testing standard Acceptance standard Magnetic particle testing Parts to be examined Testing standard Acceptance standard Material Testing Hydrostatic testing of pump Dynamic balancing of rotor Performance test at shop (as per API 610, 8th edition) NPSH test Field testing for pump required as given All full penetration welds ASME Sec V ASME sec VIII Div 1 All welded joints ASME Sec V ASME sec VIII Div 1 Shafts and forgings ASME Sec V As per material standard of shaft and forgings Steel forgings and castings ASME Sec V ASTM E 125 Required (Material test certificates to be submitted) Yes; to be witnessed Yes; to be witnessed Yes; to be witnessed Yes; to be witnessed Only mechanical reliability run test
STRAINERS
Type Size NB Quantity Nos. Location Conical Bidder to optimize Bidder to optimize Suction side of BFP
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Normal flow rate TPH Maximum flow rate TPH Normal operating pressure kgf./cm2(a) Design pressure kgf./cm2(a) Normal operating temperature C Permissible pressure drop during Clean condition mWC 50 % clogged condition mWC Effective strainer area m2 Type of the ends Flange standard Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize Bidder to optimize 1.0 2.0 Not less than three times that of the cross sectional area of the pipe. Mesh shall be of 0.2 mm size. Flanged ANSI B16.5
MATERIALS OF CONSTRUCTION
Body (shell) Screen (Conical type) Stiffner End plate Ring Body flange Companion flange Stud & Nuts Gasket Degree of filtration mm A 106 Gr. B SS 304 SS 304 SS 304 SS 304 IS 2062 Gr.A IS 2062 Gr.B A 307 Gr.A/B. M-24 IS 2712 Gr.W/2 As per pump manufacturers requirement.
DATA FOR SYSTEM RESISTANCE CURVE

Pressure at economiser inlet kg/cm2(g) Static head kg/cm2(g) Drop across FCV kg/cm2(g) Piping loss kg/cm2(g) Suction pressure kg/cm2(g) Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate
Note: Fine mesh strainer screens of size 2 mm dia shall be provided for commissioning
purpose.
7.5
Disposition
H.P HEATER General

Vertical
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5% 20% margin on max operating pressure. 10oC above sat: temp corresponding to shell design pressure. Cold water shut off pressure of boiler feed pumps. 20oC margin over Max operating temp. 10oC above max. operating temp. 20oC above shell design temp. 3.2 mm 0.5 bar
Shell design pressure Shell design temp. Tube design pressure Tube design temp. Shell design temp. in desuperheating zone Tube design temperature in desuperheating zone Corrosion allowance on shell side Maximum allowable pressure drop on tube side
Tube Shell Thermal design standard Mech. Design standard SA 213 TP 304 SA 516 Gr. 70 HEI TEMA `C
Note: * Supplier should submit proposed equipment detailed engineering specifications and required preliminary engineering drawings and load data.
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8. SPECIFIED DATA SHEET FOR WATER TREATMENT PLANT
8.1
1 2 3
SOFTENING PLANT
214 m/hr(Net) Net) (2 x 50%) Manual / Indoor 22 hrs. In service & 2 hrs. Regeneration for each stream.
Softening water plant Net continuous capacity Operation / Location of the plant Operation
8.2
1 2 3
DM Plant
1 x 12 m/hr (Net) Manual / Indoor 20 hrs in service and 4 hrs. in Regeneration 140 hrs. In service and 4 hrsin hrs regeneration.
Demineralization water Plant Net continuous capacity Operation / Location of the plants Stream operation cycle for each cation and anion unit
Stream operation cycle of each In MB unit.
8.3
1 2 3 4 5 6 7 8 9 10
Design raw water analysis

26 195 Apprx. 7.4 72 104 69 35 34 9 0.64
Turbidity (NTU) Dissolved solids (mg/l) pH M - Alkalinity (as CaCO3) mg/l Total hardness (as CaCO3) mg/l Calcium (as CaCO3) mg/l Magnesium (as CaCO3) mg/l Chlorides (as Cl) mg/l Sulphates (as SO4) mg/l Nitrates (as NO3) mg/l
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11 12 13 Fluorides (as F) mg/l Iron (as Fe) mg/l Silica (as SiO2) 0.04 0.14 15 (Assumed)
8.4
FILTRATION PLANT Alum dosing tank
1 2 3
Capacity Quantity Material of construction
For holding 10% of solution for dosing upto 30 mg/l 1 No. MSRL
Agitator
1 2 3 4 Quantity Type Material of construction Impeller / shaft SS 316 1 no. per tank Turbine type
Alum dosing pump

1 2 3 Type Quantity Material of construction Positive displacement pump 1W+1S MSRL
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Multi grade / Pressure Sand / Activated Carbon Filters
1 2 3 4 Vessel design standard Type No. of units Capacity IS 2825 Vertical with internal epoxy painting 2 x 50% 100% gross capacity of each stream (DM & Softening) + filter backwash requirement. Suitable considering the shut-off off head of raw water supply pump. 1.5 times design pressure 15 m/hr/m (max. for PSF/ MGF/ ACF) 36 m/hr/m (max. for PSF/ MGF) & 9 m/hr/m (max. for ACF) Sand / Gravel / Anthracite/ Activated carbon 1000 mm 6 mm 50 % of bed depth 2 mm corrosion allowance, 0.2 mm mill tolerance & 2 mm thinning allowance for dished end. As per manufacturers' standard
5 6 7 8 9 10 11 12 13
Design pressure Hydrostatic test pressure Specific normal flow rate Back wash flow rate Filtering medium Minimum bed depth Minimum shell thickness Minimum free board Thickness tolerance / allowance
14
Type of under drain and distributor system
Air Scouring Blowers (common for filters and MB units)

1 2 3 4 5 Type No. of Units Capacity & Head Material of construction Filtered water quality Rotary, twin lobe 2 x 100% (1W+1S) As per requirement of filters and MB units. CI Gr25-with with EN8 shaft with SS sleeving, damper and filters in CS, Base plate in M.S. TSS not to exceed 2.0 mg/l. Turbidity less than 0.5 NTU
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Filter Back Wash Pump (if applicable)
1 2 3 4 5 i) ii) Type Design Standard No. of units Capacity & head of each pump Material of construction Casing Shaft IS 210 Gr FG260 A 276 Gr 410 Horizontal, Centrifugal IS 1520 / IS : 5120 2 x 100% (1W + 1S) As per backwash requirements
8.5
1 2
SOFTENING AND DM PLANT Softener (Na cycle based exchanger) / SAC
Design standard Type
IS 2825 Vertical, dished ended, rubber lined, mild steel, welded vessel IS:2062; Rubber lining - 4.5 mm (min.) as per IS:4682, Part - I 2 x 50% - Softener 1 X 100 % - SAC 100% capacity of each stream + internal requirement between regeneration High capacity strongly acidic polystyrene based cation exchanger resin of Indion /Tulsion / Rohm & Hass / Dow / equivalent approved grade
3 Material of construction 4 5 Gross output of exchanger No. of units
Resin type
7 8 9
Guaranteed outlet water quality Max./ Min. specific flow rate Free board
Hardness: Nil, sodium leakage less than 1 mg/l as CaCO3. 40 /10 m/hr/m 75 % of bed depth
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10 11 12 13 14 15 16 17 18 19 20 21 22 23 Minimum resin bed depth Minimum shell thickness Tolerance Regeneration chemical Method of Regeneration Under drain system Salt Saturator Capacity Material of construction Brine Measuring tank Capacity Quantity Material of construction Construction Bidder to consider for 30 days regeneration requirement with 20% margin. RCC One regeneration requirement with 20% margin. 1 No MSRL Vertical 1000 mm 6 mm 0.2 mm mill tolerance and 2 mm thinning allowance for dished end. Hydrochloric acid / NaCl Counter current Strainer on plate
Degasser
1 2 3 4 5 6 7 Type No. of units Capacity of tower Material of construction Guaranteed outlet water quality Minimum air flow rate Packing Forced draft 1 x 100% - For DM section One stream maximum flow + 10% margin. IS:2062, Rubber lined, 4.5 mm (min.) as per IS:4682, Part - I CO2 content not more than 5 mg/l as CaCO3 1100 m/hr/m Polypropylene raschig rings or pall rings
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Degasser Blower
1 2 3 4 Type No. of blowers Air flow rate & head of each blower Material of construction of blower Horizontal, centrifugal 2 x 100% (1W + 1S) As per degasser requirements. Carbon steel with FRP lining
Degassed Water Tank

1 2 3 4 5 Design standard Type Material of construction No. of units Capacity of tank IS:803 Atmospheric IS:2062; Rubber lining - 4.5 mm (min.) as per IS:4682, Part - I 1 no. along with each degasser. Capacity equivalent to 150% of degassed water required for regeneration.
Degassed water pump / Soft water transfer pump

1 2 3 4 5 6 7 Design standard Type No. of pumps Capacity of each pump Head Material of construction Shaft sealing arrangement IS :1520 / IS: 5120 Centrifugal, horizontal. 2 x 100% (1 W + 1 S) Maximum capacity of each stream +10% margin. Pressure drop upto DM water storage e tank+ 10% margin DM section. Pressure drop upto Cooling tower forebay +10% margin Softening system (If Required) SS : 316 Gland packing
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Strong Base Anion Exchanger
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Design standard Type Material of construction No. of units Resin type Design pressure Hydrostatic test pressure Max. /Min. specific flow rate Free board Minimum resin bed depth Regeneration chemical Method of regeneration Under drain system Tolerance Guaranteed outlet water quality IS:2825 Vertical, dished ended, rubber lined, Mild Steel, welded vessel IS:2062; Rubber lining - 4.5 mm (min.) as per IS:4682, Part I 1 x 100% Strongly basic, poly-styrene base. Shut-off head of upstream pumps 1.5 times design pressure 40/ 10 m/hr/m 100 % of bed depth 1000 mm Sodium hydroxide Counter current Strainer on plate. 0.2 mm mill tolerance and 2 mm thinning allowance for dished end. Silica leakage<0.2 mg/l as SiO2 Conductivity<5 micro ho/cm
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Mixed Bed Exchanger

1 2 3 4 5 6 7 8 9 10 11 12 13 Design standard Type No. of units Net output of each exchanger per cycle Material of construction Resin type Maximum flow rate Free board Minimum resin bed depth Tolerance Method of regeneration Under drain system Guaranteed outlet water quality IS:2825 Vertical, dished ended, rubber lined, MildSteel, welded vessel 1 x 100% As per requirement indicated in Section-1 1 of this specification. IS:2062; Rubber lining - 4.5 mm (min.) as per IS:4682, Part I Same type of cation and anion resins as specified for SAC (strong acid resin) & SBA exchangers 45 m/hr/m 100 % of bed depth 1000 mm 0.2 mm mill tolerance for dished end, 2 mm thinning allowance. Cocurrent Strainer on plate. Total Silica < 0.02 mg/l as SiO2 Conductivity - <0.5 micro mho/cm. pH - 7 0.2
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Air scouring blower (Commonfor filter & MB unit):
Refer details on filtration plant.
DM water regeneration Pump

1 2 3 4 Type Design standard No. of pumps Capacity & head of each pump Material of construction Casing / impeller / shaft Shaft sealing arrangement Centrifugal, horizontal. IS :1520 / IS: 5120 2 Nos. (1 W + 1 S) Sufficient to regenerate One SBA and MB Exchanger plus 10% allowance SS : 316 Mechanical Seal
5 6
Bulk Acid Storage Tank

1 2 3 Fluid handled Total capacity of tanks MOC 33% HCl (wt/wt) One no. acid storage tank of 30 days capacity or 15 m whichever is higher (As per BS 4994 design standard) FRP
Acid unloading pump

1 2 3 4 5 6 Type Design standard No. of pumps Capacity & head of each pump Material of construction Casing / impeller / shaft Shaft sealing arrangement Centrifugal, horizontal. IS :1520 / IS: 5120 2 Nos. (1 W + 1 S) Bidder to decide PP Mechanical Seal
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Acid Measuring Tank
1 2 Design standard Material of construction BS 4994 FRP i) 1 no. each 100% capacity for cation exchanger. ii) 1 no. 100% capacity for mixed bed exchanger 33% HCl diluted to required concentration One regeneration requirement with 20% margin
No. of tanks
4 5
Fluid handled Capacity
Bulk Caustic Storage Tank

1 2 3 Fluid handled Capacity MOC 48% NaOH (wt/wt) One no. caustic storage tank of 30 days capacity or 15 m3 whichever is higher. (As per IS 803 design standard) MSRL
Caustic unloading pump

1 2 3 4 Type Design standard No. of pumps Capacity & head of each pump Material of construction Casing / impeller / shaft Shaft sealing arrangement Centrifugal, horizontal. IS :1520 / IS: 5120 2 Nos. (1W + 1S) Bidder to decide
5 6
PP Mechanical Seal
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Caustic Dilution Tank
1 2 3 4 5 Design standard Material of construction Nos. off Fluid handled Capacity IS 803 MSRL i) 1 x 100% capacity for anion exchanger. ii) 1 x 100% capacity for mixed bed exchanger 48% NaOH diluted to 10% solution One regeneration requirement with 20% margin
Agitators for Caustic Dilution Tanks

1 2 3 Quantity Type Material of construction Impeller / shaft 1 no. per tank Turbine type
SS - 316
Ejectors
1 2 3 4 Nature of fluid No. of ejectors Injection fluid Material of construction Degassed water / DM water / Filtered water 6 Nos. HCl / NaOH / Effluent / NaCl Ebonite lined CI
Neutralized Waste Disposal Pump

1 2 3 Type Design standard Capacity of each pump Material of construction i) Casing / impeller / shaft Vertical, sump pumpset. IS 1710 / Manufacturers standard To dewater one no. Neutralization pit in 4 hrs. SS 316 / MSRL
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5 6 7 8 9 10 No. of pumps Liquid handled Head Shaft sealing arrangement Priming of pumps Liquid handled 2 x 100% capacity Effluent water Suitable for transfer up to nearest storm water drain Gland packing By ejector using filtered water as power water Effluent water
DM water transfer pumps

1 2 3 4 5 6 Type Design standard No. of pumps Capacity & head of each pump Material of construction Casing / impeller / shaft Shaft sealing arrangement Centrifugal, horizontal. IS :1520 / IS: 5120 2 Nos. (1W + 1S) Bidder to decide SS 316 Mechanical Seal
Morpholine dosing system

Morpholine dosing tank
1 2 3 4 Quantity Material of construction Capacity Construction 1 No. MSRL 300 litres Vertical
Morpholine dosing pump

1 2 Capacity & head Quantity & Type 0 10 lph and 8 kg/cm2 2 (1W + 1S); Plunger/ Diaphragm type
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FABRICATED TANKS
DM & Soft Water Storage Tank
1 2 3 4 Design standard No. of tanks Material of construction Type IS:803 2 Nos. DM water (2 x 200 m3) 2 Nos. Soft water tank (2 x 500 m3RCC) IS : 2062 epoxy lined Conical roof type, Vertical atmospheric steel tank.
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9. WATER SYSTEM
9.1
Sl.no 1 2 Type Cooling water flow M/hr
COOLING TOWER
Description Unit Data Induced draft, counter flow Bidder to indicate(5% margin in flow) Cooling tower design shall be based on the required temperature difference T between cooling water inlet and outlet plus 50% margin of T as design margin.
Cooling range
4 5 6 7 8 9 10 11 12 13
Maximum average dry bulb temperature Minimum average dry bulb Air temperature Maximum Relative Humidity Minimum Relative Humidity Average Relative Humidity Design wet bulb temperature (including recirculation) Approach to wet bulb temperature Cycle of concentration of circulating water TDS in Cooling water for heat exchangers design Seismic Design Data
C C % % % C C 31 5 5 2000 ppm minimum As per IS: 1893 (Latest Edition) Refer Project Information
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9.2
Type No of pumps
COOLING WATER PUMPS

Horizontal, centrifugal 3 Nos. (2W+1S)
Delivery Rate (10% margin in flow)
Bidder to indicate Delivery Head Suitable to supply cooling water considering pressure drop across Condenser and auxiliaries, frictional drop across pipes, pipe fittings, valves etc. static height and sufficient margin.
9.3
Type
AUXILIARY COOLING WATER PUMPS

Horizontal, centrifugal 2 Nos. (1W+1S) Bidder to indicate indicate.(10% (10% margin in flow) Delivery Head Suitable to supply cooling water considering pressure drop across all auxiliaries, frictional drop across pipes, pipe fittings, valves etc. static height and sufficient margin.
No of pumps
Delivery Rate
9.4
Casing Impeller Shaft Shaft Sleeve Gland
IS - 210 Gr. FG 260 ASTM A 743 Gr. CF8M ASTM A276 Gr. 410 ASTM A276 Gr.316 SS 410 Gland Packing SKF / FAG
Type of Sealing Bearing Make
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9.5
Type Features Blade Material Speed reducer service factor
COOLING TOWER FANS

Induced draft, axial flow type Adjustable pitch type FRP 1.75 times the fan power at design condition or the installed motor power, whichever is higher
9.6
Type
RAW WATER PUMPS

Horizontal, centrifugal 2 Nos. (1W+1S). Suitable for capacity mentioned.
No of pumps Delivery Rate (10% margin in flow)
Delivery Head
Suitable to supply Raw water considering pressure drop across all auxiliaries, frictional drop across pipes, pipe fittings, valves etc. static height and sufficient margin.
9.7
Casing Impeller Shaft
Raw Water Pumps Material of Construction

IS - 210 Gr. FG 260 ASTM A 743 Gr. CF8M ASTM A276 Gr. 410 ASTM A276 Gr.316 SS 410
Shaft Sleeve Gland
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Type of Sealing Bearing Make Gland Packing SKF / FAG
9.8
BOILER BLOW DOWN TRANSFER PUMPS

2 Nos. (1W + 1S) Vertical sump pump. Vendor to indicate Delivery Head Suitable to deliver boiler blow down water from blow down sump to raw water reservoir considering pressure drop across all auxiliaries, frictional drop across pipes, pipe fittings, valves etc. static height and sufficient margin.
No of pumps Type of pump
Delivery Rate (10% margin in flow)
9.9
Casing Impeller Shaft
IS - 210 Gr. FG 260 ASTM A 743 Gr. CF8M ASTM A276 Gr. 410 ASTM A276 Gr.316 SS 410 Gland Packing SKF / FAG
Shaft Sleeve Gland Type of Sealing Bearing Make
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9.10 Chemical Addition Tank
No. of Tanks No 1 or 2 depending on recommended chemical and its preparation method Sufficient to hold 30 days Chemical requirement or 25 m3, whichever is higher To hold corrosion inhibition Chemical in solution form which shall be dosed at CWP pump suction
Capacity of Tank
Functional requirement
9.11 COOLING WATER ACID DOSING SYSTEM Sulphuric acid (storage tank bulk)
Nos. Capacity One (1) no. 30 days requirement or 25 m whichever is higher
Acid day tank capacity: One (1) day acid requirement
Acid unloading pump

Nos. Capacity (m3/hr.) Head Two (2) nos. (1W + 1S) As per requirement Suitable
Acid dosing pump

Nos. Two (2) nos. (1W + 1S) Suitable considering C.O.C. of cooling water system and Alkalinity to be reduced.
Capacity (m3/hr.)
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CHLORINATION SYSTEM
Raw water chlorination (Vacuum type) Cooling water chlorination (Vacuum type) 2 x 100 % system capacity each 2 x 100 % system capacity each
SIDE STREAM FILTRATION SYSTEM

Filters Capacity 2 Nos. (1W + 1S ) bidder to finalize
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10. SPECIFIED DATA SHEET FOR FUEL HANDLING SYSTEM
10.1 FUEL HANDLING SYSTEM
1 Fuel to be handled System Capacity ( net throughput average) TPH No of streams of conveyors Type of conveyors Pollution control requirement Fuel as per fuel analysis The Fuel Handling system shall have a net throughput (average) of 186 TPH while handling all type of as fuel analysis/ Vol-II in this tender... Single Troughed belt conveyor with closed gallery and 16 SWG GI sheeting / cladding. Dust extraction for belt transfer points and bunkers.
3 4 5 6
Location of MCC for fuel handling As per plot plan.
Note:* Supplier should submit proposed equipment detailed engineering specifications and required preliminary engineering drawings and load data. The conveyor shall be designed to carry all grades of coal specified as per fuel analysis.
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11. SPECIFIED DATA SHEET FOR ASH HANDLING SYSTEM
11.1 ASH HANDLING SYSTEM
Ash Collection Data No of bed ash discharge points No of fly ash discharge points Maximum generation of bed ash Maximum generation of Fly ash Ash temperature at collection point Ash distribution Headroom available Ash discharge point flange details Bed Ash Conveying Details No of conveying pipes for bed ash Type of ash vessel Type of inlet valve Type of isolation valve Surge hopper Lump separator Bypass valve Expansion joints Density stabilization air line Fly Ash Conveying Details No of conveying pipes for fly ash Type of Ash vessel Type of inlet valve Type of isolation valve Surge hopper One for ECO, One for APH, one for ESP 1st field One for ESP 2nd field, one for other r ESP fields Denseveyorsystem operated vessels Dome valve Manual knife gate valve. To be provided if required Separate pipe up to silo from each outlet. Blow tank , Master ash vessel Dome valve Manual knife gate valve. Water cooled Required Required SS Bellow type Required Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate
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Fluidization of ESP Hopper Vent valve Expansion joints Fluidization Blower Type of Blower Quantity Capacity Pressure Installation Type of drive Type of coupling Provision for belt tensioning Suction filter Discharge silencer Discharge isolation valve Discharge check valve Discharge air heating chamber Bed Ash Silo No of bed ash silo Effective capacity Construction Liner on inclined surfaces Access stair / platforms Discharge outlets Accessories for dry unloading Accessories for wet unloading Vent filter Man hole One 2 days storage (for the fuel having max. ash content-as content per attached fuel analysis) RCC with conical bottom & dish end SS 304 , 3.15 thick Required One for dry unloading, one for wet unloading and one for emergency discharge Rotary feeder & telescopic spout Single shaft ash conditioner. Required. Required Positive displacement, twin lobe type 2 Nos. (1 W + 1 S) Sufficient for simultaneous fluidization of all silos. (Bidder to indicate) Bidder to indicate Outdoor TEFC motor V Belt and Pulleys Required Low resistant, dry type with replaceable cartridge. Required Required Required Required Required Required SS Bellow type
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Fly Ash Silo No of fly ash silo Effective capacity of each silo Construction Liner on inclined surfaces Access stair / platforms Discharge outlets on each silo Accessories for dry unloading Accessories for wet unloading Vent filter with exhaust fan Man hole Ash Conditioner Type Single shaft with built in screw feeder for bed ash / double shaft for fly ash ,paddle type 1 No for bed ash, two nos for fly ash 20 TPH Hardened (400 BHN), replaceable Wear / abrasion resistant steel Helical geared motor Bidder to indicate. Required Two each one days storage RCC with conical bottom & dish end SS 304 , 3.15 thick Required One for dry unloading, one for wet unloading and one for emergency discharge Rotary feeder & telescopic spout Rotary feeder & double shaft ash conditioner. Separate for each silo. Required.
Quantity Capacity Type of paddles MOC of trough Drive No of spray nozzles Inspection cover
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Telescopic Spout Type Quantity Capacity Extended length Retracted length Dustless loading spout. 1 No for Bed ash, 2 nos. for Fly ash 20 TPH Bidder to specify Bidder to specify
MOC of inner cone
Hardened ( 400 BHN) , wear resistant steel
Vent filter with fan Limit switches / level probes
Required Required
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11.2 SCREW AIR COMPRESSOR General Information
Designation Nos. required Type Duty and Control Location Discharge pressure Capacity (Nm3/hr& FAD) Position Loading-unloading regulation Auto-start-stop regulation Low air receiver pressure alarm Air compressor for ash conveying air 2 Nos. (1W + 1S) Each compressor Non-lubricated, single/multi-stage stage reciprocating Continuous and dual type. Indoor Bidder to indicate Bidder to indicate Horizontal/Vertical Bidder to indicate Bidder to indicate Bidder to indicate
11.3 Supply of Accessories & Services

Suction filter/Silencer Inter cooler (if required) & After cooler with moisture separator and trap station Temperature indicator pressure gauges and instruments as shown in enclosed P&ID. Interconnecting piping valves. Companion flanges with nuts, bolts, gaskets Unions for cooling water terminals Compressor control Base plates Yes Yes
Yes Yes Yes Yes Yes Yes
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Foundation bolts, nuts sleeves Eyebolts, lifting tackle etc. Tools & tackle Spare parts for 2 years Painting Supervision of erection, testing & commissioning required Yes Yes Yes Yes Yes Yes
11.4 Special Features

Type of Lubrication Type of cooling Type of drive Type of drive-compressor Anti vibration arrangement required Galvanization of interconnecting piping Pulsating dampers Self lubricated for cylinder & forced oil lubrication for others Water Motor V-Belt driven connection Yes Yes As applicable
11.5 Material of Construction

Cylinder / cylinder heads Piston ring Piston Piston rod Cross head C.I. FG 260 of IS 210 Teflon graphite AS12 UNY 20 (Aluminium Alloy) EN8 / Forged steel IS:1875 SGI Gr 600 of IS: 1885
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Cross head pin Cross head busing Cross head guide Wearing shoes Connecting rod Crank shaft Stuffing box packing Crank case Interconnecting pipes Fly wheel Main bearings Cylinder lining, if applicable Valve Spring/Seat Oil / impulse tubing
Steel A108 Gr. 1018 / A S En 24 or equivalent Phosphor Bronze CI IS : 210 FG 260 Teflon graphite Forged steel ASTM A108 - Gr.1035 Forged steel ASTM A108 - Gr.1035 /SGI Gr 700 /2 , IS: 1865 Teflon CI FG 260 of IS:210 ASTM-A-53/IS: IS: 1239 Heavy Class. CI FG 260 of IS:210 White metal with steel back CI - Ni Resist Hardened stainless Steel plates / Channel / Guide Copper
11.6 Testing & Inspection

Radiography Magnetic particle Ultrasonic Cylinder hydro test Required for all welded parts Required for crank shaft, connecting rod and piston rod. Required for crank shaft. Required
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Valve leak test
Required, to be witnessed by Owner/Owners Consultant Required to be witnessed by Owner/Owners Consultant
Performance test
11.7 Inter cooler (if required), after cooler & Moisture Separator General
Designation Installation Nos. required Location Accessories for compressed air system Horizontal/Vertical One set each for each compressor Indoor
Equipment Parameter for Inter cooler (if required) & After Cooler
Outlet air temperature C Inlet water temperature C Maximum average ambient temperature C Design pressure kg/cm2 (g) Hydrostatic test pressure kg/cm2 (g) Safety valve set pressure Safety valve capacity Cooling water inlet pressure kg/cm2 (g) Cooling water quality 42 36 Refer Project Information. 1.5 times max. operating pressure 1.5 times design pressure As required As required 2.5 Refer water analysis.
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11.8 Supply of Accessories and Services

Inter cooler (if required) and After Cooler Relief Valve Moisture separators Trap. Station Pressure gauge Temperature indicator Moisture / Oil separator Required Trap station Moisture Level indicator Supporting stand with bolts, nuts, gaskets etc Eye bolts, lifting tackle Painting Material of Construction Inter cooler (if required) and After Cooler Tube Shell Tube sheet Fin. if applicable Safety valve body Safety valve spring Moisture sep. body Tests Requirement Hydro test Dye penetrant test Magnetic particle test Radiography For shell & tube Required Required Spot radiography for welds. Admiralty Brass Carbon steel Carbon steel -Cast steel Carbon steel Carbon steel Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
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11.9 Intake Air Filter
Designation Nos. required Location Type Air pressure Max. Dry Bulb temperature Min. Dry bulb temperature Performance Required Air flow rate, Nm3/hr, dry Filtering efficiency Max. pressure drop across filter Special Feature Silencer required Operating sound level Filtering element Test Requirement Capacity test required Pressure drop test at rated flow required Efficiency test required Capacity test to be witnessed Pressure drop test at rated flow to be witnessed Efficiency test to be witnessed Yes 85 dB at 1.00M distance (max) Compressed felt equivalent Bidder to mention 99.00% Shall be negligible Intake Air Filter for compressors One for each compressor Suction pipe of compressor Dry type with weather hood, suitable for outdoor conditions. Refer Project Information Refer Project Information Refer Project Information
Yes Yes Yes Yes Yes Yes
11.10 Air Receiver General

Designation Type Air receiver Vertical
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Capacity Nos. required Location Supply of Accessories and Services Companion flanges with nuts, bolts, gaskets Pressure gauge Temperature indicators Relief Valve Trap station Supporting stand with necessary bolts, nuts, sleeves Pressure switches Receiver design code Eyebolt lifting tackle etc, for the receiver Tools & Tackle Spare parts (for 2 years operation) Painting Internal External Equipment Parameter Capacity Working pressure Design pressure Hydraulic test pressure Relief valve set Relieving valve capacity minimum Type & sizes of Inlet nozzle Type & size of outlet nozzle Bidder to indicate (minimum 15 m3each) Bidder to indicate Bidder to indicate 1.5 times design pressure 10% higher than normal pressure operations As per IS: 7983 As per IS: 7938 As per requirement Yes Yes Yes Yes Yes Yes Yes Yes Yes IS: 2825 Yes Yes Yes Bidder to indicate (minimum 15 m each) Two (2 nos.) Outdoor
Material of Construction (Air receiver)

Shell IS: 2041
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End plates Relief valve body Relief valve spring IS: 2041 Cast steel Carbon steel
Test Requirement
Hydrostatic test to be witnessed Mechanical run test to be witnessed Dye penetrant Magnetic particle Radiography Yes Yes Required Required 100% for T joints, 10% for other welds
11.11 Piping Components & Valves Pipes

Service Material Dimension Length End finish Test Certificates Product marking Cooling Water/Service Air Conveying air/ ash conveying. SA 53 Gr B, ERW galvanized or IS:1239 / IS: 3589 ERW ANSI B 36.10 In 5 to 6 m lengths Square end upto& including 40 NB Bevelled end for sizes above 40 NB Hydro test required Chemical, tensile and hydro test certificates required Manufacturer's name, specification no. and Grade
Fittings
Bends, Elbows & Tees Service Cooling Water/Service Air/ conveying air
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Material / Std. Ends Tests Flanges Service Material/Std. Type Design / Dimension Gasket Service Material Design Bolts & Nuts Service Material Test Certificates
IS: 1239 Part-II SW for sizes up to 40 NB and bevelled ends as per B 16.25 for sizes > 40 NB Product analysis, hydro test
Cooling Water/Service Air IS 6392 SORF for sizes 50 NB/SWRF(for < 50 NB), serrated finish IS6392/B 16.5
Cooling water/Service Air NBR ANSI B16.21
Cooling Water/Service Air IS: 1367 Tensile test Chemical & tensile test certificates
Gate / Globe Valves

Design / Construction Service Cooling Water
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Ends Design/Dimensions Type Bonnet connection Actuator Seat Hand wheel Sealing element Material Body Bonnet Seat Wedge/plug Stem Gasket (Bonnet) Gland Packing Studs Nuts Inspection/Testing Testing Code Hydro Test Magnetic particle API Required. Required. SA 105/SA 216 WCB. SA 105/SA 216 WCB. Carbon steel, 13% Cr faced. 13% Cr steel 13% Cr steel CAF/NBR CS Teflon/Lubricated Asbestos A 193-B7 A 194-2H Flanged to B 16.5/AWWA- C207 ANSI B 16.34/API 600/B 16.10 OS & Y Flanged for 50NB and above, Flanged or screwed for sizes < 50 NB Gear operated for size 400 NB and above Renewable Cast/Fabricated Flexible wedge
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Dye penetrant Test Certificates Marking Size, Rating, Flow direction & Material spec. no. Required Required. Tensile and chemical Test Certificates, Hydrostatic, Magnetic particle, dye penetrant certificates.
Check Valves
Design/Construction Service Ends Design/Dimensions Service Air / conveying air Flanged to B 16.5 ANSI B 16.34/B 16.10 Swing check for 50 NB and above. Swing or Piston type for sizes below 50 mm. Screwed Flanged
Type
Seat Body Seal Material Body Disc Lever arm Arm nut Arm pin Seat ring Stud & nut Cover plate
SA 216 WCB SA 216 WCB MS MS MS 13 % Cr. SA 193-B7/SA 194-2H CS
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Inspection/Testing Test Code Hydrotest Magnetic particle test Dye penetrant test Marking Material spec. no., Size, Rating & Flow Direction Required API 598 Required Required Required
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12. SPECIFIED DATA SHEET FOR COMPRESSED AIR AND INSTRUMENT AIR SYSTEM
12.1 AIR COMPRESSOR General Information
Designation Nos. required Air compressor 2 Nos. (1W + 1S).
Type
Non-lubricated, lubricated, oil free, screw compressor
Duty and Control
Continuous and dual type.
Location Discharge pressure Capacity (Nm3/hr& FAD) Position Loading-unloading regulation Auto-start-stop regulation Low air receiver pressure alarm
Indoor 8.1 kgf/cm2(g) Bidder to indicate Horizontal/Vertical 7.5 - 8.1 kg/cm2(g) 7.1 - 8.1 kg/cm2(g) 6.6 - 7.1 kg/cm2(g)
Supply of Accessories & Services

Suction filter/Silencer Yes
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Inter cooler with moisture separator and trap station After cooler with moisture separator and trap station Temperature indicator Pressure gauges and instruments as shown in enclosed P&ID. Companion flanges with nuts, bolts, gaskets Unions for cooling water terminals Compressor control Base plates Foundation bolts, nuts sleeves Eyebolts, lifting tackle etc. Tools & tackle Spare parts for 2 years Painting Supervision of erection, testing & commissioning required Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Special Features
Type of Lubrication Type of cooling Type of drive Antivibration arrangement required Galvanization of interconnecting piping Self lubricated Water Motor Yes Yes
Cylinder / cylinder heads Piston ring Piston Piston rod Cross head Cross head pin C.I. FG 260 of IS 210 Teflon graphite AS12 UNY 20 (Aluminium Alloy) EN8 / Forged steel IS:1875 SGI Gr 600 of IS: 1885 Steel A108 Gr. 1018 / A S En 24or
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Cross head busing Cross head guide Wearing shoes Connecting rod Crank shaft Stuffbox packing Crank case Interconnecting pipes Fly wheel Main bearings Cylinder lining, if appl. Valve Spring/Seat plates / Channel / Guide Oil / impulse tubing Phosphor Bronze CI IS : 210 FG 260 Teflon graphite Forged steel ASTM A108 - Gr.1035 Forged steel ASTM A108 - Gr.1035 /SGI Gr 700 /2 , IS: 1865 Teflon CI FG 260 of IS:210 ASTM-A-53/IS: 53/IS: 1239 Heavy Class. CI FG 260 of IS:210 White metal with steel back CI - Ni Resist Hardened stainless Steel Copper
Testing & Inspection

Radiography Magnetic particle Ultrasonic Cylinder hydro test Valve leak test Required for all welded parts Required for crank shaft, connecting rod and piston rod. Required for crank shaft. Required Required, to be witnessed by Owner/Owners Consultant Required to be witnessed by Owner/Owners Consultant
Performance test
Mechanical run test
Required to be witnessed by Owner/Owners Consultant
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12.2 INTERCOOLER, AFTERCOOLER & MOISTURE SEPARATOR General
Designation Installation Nos. required Location Accessories for compressed air system Horizontal/Vertical One set each for each compressor Indoor
Equipment Parameter for Inter Cooler and After Cooler

Outlet air temperature C Inlet water temperature C Maximum average ambient temperature C Design pressure kg/cm2(g) Hydrostatic test pressure kg/cm2(g) Safety valve set pressure Safety valve capacity Cooling water inlet pressure kg/cm2(g) Cooling water quality 42 36 Refer Project Information. 1.5 times max. operation Pressure 1.5 times design pressure As required As required 2.5 Refer water analysis.
Supply of Accessories and Services After Cooler

Relief Valve Moisture separators Trap. Station Pressure gauge Temperature indicator Yes Yes Yes Yes Yes
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Inter Cooler
Relief Valve Moisture separator Trap Station Pressure gauge Temp. indicator Yes Yes Yes Yes Yes
Moisture / Oil separator

Required Trap station Moisture Level indicator Supporting stand with bolts, nuts, gaskets etc Eye bolts, lifting tackle Painting Yes Yes Yes Yes Yes Yes
After Cooler Tube Shell Tube sheet Fin. if applicable Safety valve body Safety valve spring Moisture sep. body Inter Cooler Tube Shell Tube sheet Admiralty Brass Carbon steel Carbon steel Admiralty Brass Carbon steel Carbon steel -Cast steel Carbon steel Carbon steel
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Fin. if applicable Safety valve body Safety valve spring Moisture Sep. body Carbon steel Cast steel Spring steel Carbon steel
Tests Requirement
Hydro test Dye penetrant test Magnetic particle test Radiography For shell & tube Required Required Spot radiography for welds.
Intake Air Filter

Designation Nos. required Location Type Air pressure Max. Dry Bulb temperature Min. Dry bulb temperature Performance Required Air flow rate, Nm3/hr, dry Filtering efficiency Max. pressure drop across filter Special Feature Silencer required Operating sound level Filtering element Test Requirement Capacity test required Pressure drop test at rated flow required Intake Air Filter for compressors One for each compressor Suction pipe of compressor Dry type with weather hood, suitable for out door conditions. Refer Project Information Refer Project Information Refer Project Information Bidder to mention 99.00% Shall be negligible Yes 85 dB at 1.00M distance (max) Compressed felt Yes Yes
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Efficiency test required Capacity test to be witnessed Pressure drop test at rated flow to be witnessed Efficiency test to be witnessed Yes Yes Yes Yes
12.3 AIR RECEIVER General

Designation Type Capacity Nos. required Location Supply of Accessories and Services Companion flanges with nuts, bolts, gaskets Pressure gauge Temperature indicators Relief Valve Trap station Supporting stand with necessary bolts, nuts, sleeves Pressure switches Receiver design code Eyebolt lifting tackle etc, for the receiver Tools & Tackle Spare parts (for 2 years operation) Painting Internal External Equipment Parameter Capacity Working pressure Design pressure Hydraulic test pressure Relief valve set Air receiver Vertical Bidder to indicate (Minimum 10 meach) Two (2) Outdoor Yes Yes Yes Yes Yes Yes Yes IS:2825 Yes Yes Yes Yes Yes 10 m each 8.1 kg/cm2(g) Min 10.125 kg/cm(g) 1.5 times design pressure 10% higher than normal pressure operations
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Relieving valve capacity minimum Type & sizes of Inlet nozzle Type & size of outlet nozzle Material of Construction (Air receiver) Shell End plates Relief valve body Relief valve spring Test Requirement Hydrostatic test to be witnessed Mechanical run test to be witnessed Dye penetrant Magnetic particle Radiography
As per IS:7983 As per IS:7938 As per requirement
IS : 2041 IS : 2041 Cast steel Carbon steel
Yes Yes Required Required 100% for T joints, 10% for other welds
12.4 AIR DRYING PLANT General Information

Designation Type Duty Nos. required Location Site Altitude Air Drying Plant for Instrument Air Heatless, purge type Continuous 2 x 100% (1W + 1S). Indoor Refer Project Information
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Ambient temperature C Relative humidity -do-do-
Operating Data
Air flow rate Nm3/hr Dew point Drying cycle period (min) Ambient air temp. (max.) Bidder to indicate (-)40C 5 Minutes Refer Project Information
Special Factors
Type of drying Type of changeover of towers from duty to regeneration Class of tower vessel as per IS-2825 Type of regeneration Purge air piping Heatless Purge type Automatic Class - 2 Purging with dry air Through muffler to outside the building.
Supply of Accessories and Services

Laboratory type humidity measuring instrument Yes
Instrumentation as shown in enclosed drawing/stated elsewhere. Safety valve with each tower Chamber sight glass Dew Point Indicator All interlock, safety and sequential control
Yes Yes Yes Yes Yes
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Local control panel All wiring inside the air drying plant All interconnecting pipings complete with valves etc. Companion flanges/union at all pipe terminals Galvanization of piping Insulation as necessary Base frame, Foundation bolts, nuts etc. Painting (Anti-corrosive) Spare parts Pre-filter After filter First fill of adsorbent material Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Adsorbed vessel Desiccant Interconnecting piping Orifice plate, if applicable Filter vessels Isolation valve body Isolation valve trim Relief valve body Relief valve spring IS 2062 Activated Alumina/Silica gel ASTM A-53/IS: 1239. ----IS 2062 Cast /Forged Steel Gun Metal Cast steel Carbon steel
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Testing & Inspection
Material testing and identification Hydrostatic Test required Hydrostatic Test to be witnessed Performance test required Performance test to witnessed Field test to be performed Required Yes Yes Yes Yes by Owner/Owners Consultant Yes
12.5 PIPING COMPONENTS & VALVES Pipes

Service Material Dimension Length End finish Test Certificates Product marking Cooling Water/Service Air SA 53 Gr B, ERW galvanized or IS:1239 / IS:3589 ERW ANSI B 36.10 In 5 to 6 m lengths Square end up to & including 40 NB Beveled end for sizes above 40 NB Hydro test required Chemical, tensile and hydro test certificates required Manufacturer's name, specification no. and Grade
Fittings
Bends, Elbows & Tees Service Material / Std. Ends Tests Cooling Water/Service Air IS:1239 Part-II SW for sizes upto 40 NB and bevelled ends as per B 16.25 for sizes > 40 NB Product analysis, hydro test
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Certificates Flanges Service Material/Std. Type Design / Dimension Gasket Service Material Design Bolts & Nuts Service Material Test Certificates
Chemical, mechanical and hydrostatic test certificates
Cooling Water/Service Air IS 6392 SORF for sizes 50 NB/SWRF (for < 50 NB), serrated finish IS6392/B 16.5 Cooling water/Service Air NBR ANSI B16.21 Cooling Water/Service Air IS:1367 Tensile test Chemical & tensile test certificates
Gate / Globe Valves

Design / Construction Service Ends Design/Dimensions Type Bonnet connection Actuator Seat Hand wheel Sealing element Material Body Bonnet Seat Wedge/plug Cooling Water Flanged to B 16.5/AWWA- C207 ANSI B 16.34/API 600/B 16.10 OS & Y Flanged for 50NB and above, Flanged or screwed for sizes < 50 NB Gear operated for size 400 NB and above Renewable Cast/Fabricated Flexible wedge SA 105/SA 216 WCB. SA 105/SA 216 WCB. Carbon steel, 13% Cr faced. 13% Cr steel
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Stem Gasket (Bonnet) Gland Packing Studs Nuts Inspection/Testing Testing Code Hydro Test Magnetic particle Dye penetrant Test Certificates Marking Size, Rating, Flow direction & Material spec. no. Required 13% Cr steel CAF/NBR CS Teflon/Lubricated Asbestos A 193-B7 A 194-2H API Required. Required. Required. Tensile and chemical Test Certificates, Hydrostatic, Magnetic particle, dye penetrate certificates.
Check Valves
Design/Construction Service Ends Design/Dimensions Type Seat Body Seal Material Body Disc Lever arm Arm nut Arm pin Seat ring Stud & nut Cover plate Service Air Flanged to B 16.5 ANSI B 16.34/B 16.10 Swing check for 50 NB and above. Swing or Piston type for sizes below 50 mm. Screwed Flanged SA 216 WCB SA 216 WCB MS MS MS 13 % Cr. SA 193-B7/SA 194-2H CS
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Inspection/Testing Test Code Hydro test Magnetic particle test Dye penetrant test Marking Material spec. no., Size, Rating& & Flow Direction
API 598 Required Required Required
Required
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13. SPECIFIED DATA SHEET FOR E.O.T. CRANE AND HOIST TROLLEYS
13.1 E.O.T. CRANE
UNIT Location Quantity No. Crane capacity (SWC) Main hoist Tonnes Auxiliary hoist Tonnes * - Bidder to optimize Span i) Building column CL to column CL ii) Rail CL to Rail CL Height of lift - Main Aux. Length of travel Type Duty class No. of falls of hoist rope Main Auxiliary Operating speeds Hoist (Full load) Main speed For main hoist. For Aux. hoist. Creep speed (For both Main & Auxiliary Hoist). Cross travel (Full load) Main speed. Creep speed Long travel (Full load) M M M M M Bidder to indicate. Bidder to indicate. Up to ground level Up to ground level Bidder to indicate Double girder box type M-5 5 for mechanical and structural equipment and M-7 7 for electrical equipment. 8 4 DATA Inside Steam Turbine generator hall One 45* 10 *
mtr./min mtr./min mtrs/min mtrs/min mtrs/min
2 to 3 3 to 5 10% of Main speed through planetary gear box/thruster control. 10 10% of Main speed through planetary gear box / thruster control.
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Main speed Creep speed Type of control Type of brakes For hoist Main Primary Secondary Torque rating to be considered for sizing of brake both primary & secondary Auxiliary Primary Secondary Torque rating to be considered for sizing of brake both primary & secondary For long travel/cross travel Primary Secondary Torque rating to be considered for sizing of brake both primary & secondary Emergency braking action required for cranes Test load requirements Hazard area classification safe Electrical Runway conductor Cross travel conductor Min. rating time for short-time time rated motors Control Min. No. of speed step Hoist Bridge travel Trolley travel : 4 steps Auxiliaries mtrs/min mtrs/min 15 10% of Main speed through planetary gear box / thruster control. Pendant with counter weight.
Electro hydraulic thruster Electro Magnetic 150% of design requirement Electro hydraulic thruster Electro Magnetic 150% of design requirement. Electro hydraulic thruster Electro Magnetic 125% of design requirement. Yes 1.25 times the safe working load Safe Insul. bar type of DSL PVC insulated flexible festooned cable 30 Min. or more
4 steps 4 steps 4 steps
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Illumination for working area No. of fixtures & wattage No. of socket outlets Crane bridge Protective panel Separate lighting cabinet complete with all accessories Transformer & accessories for aux. power Tolerances Difference in levels of Crane rails Difference in levels of Crane rails columns Difference in levels of crane rails across the building Over supports At mid span of girders Deviation in crane rail level from type level Difference in Crane rail actual levels between any two points 2 M apart along rail length Deviation of crane rail from centerline of web Relative shift of crane rail surfaces at a joint in plan & elevation (surface grinded) Relative shift in location of crane stops (buffers) along crane tracks Deviation in crane rail alignment in plan measured at any two points 2 M apart Deviation in crane rail gauge Power supply Voltage Phase Frequency Fault level Short time rating Scope of Supply Yes 4 Nos. 250 W each (High pressure Mercury vapour) Two (2) One (1) Yes Yes
Mm
mm mm mm mm mm mm Mm
10 10 5 2 3.5 2 2
Mm
1 3.5
V Hz KA KA
415 10% Three (3) 50 5% 50 50 for 1 sec.
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Crane structures complete with all driving gears Drive Motors Runway rails including all clamps, anchors anchors, bolts, nuts, screws, end stop and other fixtures Power/Earth conductor complete with all supports, insulators, brackets, fixtures, , etc. Lifting lugs, eye bolts, etc. for handling of crane parts Complete electrical work including all controls and interlocks complete with internal wiring protective panel, grounding terminals, etc. Illumination of crane and working area Final painting Shop tests as per IS. Site tests as per IS. First charge of oil, lubricants, , grease etc. Set of special tools & tackles Spare parts
Yes Yes
Yes
Yes
Yes
Yes
Yes Yes Yes Yes Yes Yes Yes
13.2 MANUAL / ELECTRIC HOIST AND TROLLEY

Locations Hoist capacity (SWL), Tones Quantity Type Height of lift (m) Duty class Refer enclosed table Refer enclosed table Refer enclosed table Manually operated chain hoist & trolley Refer enclosed table II
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Effort Test load Material of construction of major components Chain pulley block Load chain Gears(trolley) Lifting hook Additional features Lifting lugs, eye bolt section for handling of parts Final painting Shop test First change of oil, lubricants etc. Set of special tools and tackles Spare parts Yes Yes Yes Yes Yes Yes cast steel / mild steel Alloy steel Cast steel / CI Forged steel Maximum torque 20 M-Kg 1.25 Times of SWL
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14. FIRE PROTECTION AND DETECTION SYSTEM
1.0.0 PUMPS Pump No. of Pumps required Type 1.1.0 Pump Parameters Rated capacity as per TAC Minimum 273 Minimum 273 Minimum 20 equirement,m3/hr. Head at discharge flange as per TAC requirement, Minimum 88 Minimum 88 Minimum 88 mwc Max. operating speed 1500 1500 1500 RPM Capacity and head mentioned above are minimum requirement, if Capacity and head requirement as per TAC/LPA is more than this requirement then pumpsshall be supplied accordingly without any extra cost to the Owner. 1.2.0 Constructional features Type of impeller Drive Mechanical seal / Gland Coupling 1.3.0 Materials of construction Casing Column pipe Impeller Wear rings Shaft Shaft sleeve Base plate C.I. CS Bronze Bronze Forged Steel ASTM A 276 Gr.316 MS C.I. CS Bronze Bronze Forged Steel ASTM A 276 Gr.317 MS C.I. CS Bronze Bronze Forged Steel ASTM A 276 Gr.318 MS Closed Diesel engine Gland Packing Flexible Closed A.C. Motor Gland Packing Flexible Closed A.C. Motor Gland Packing Flexible Main Pump 1 Horizontal Centrifugal Diesel engine driven Standby Pump 1 Horizontal Centrifugal Motor driven Jockey Pump 2 Horizontal Centrifugal Motor driven
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14.1 Pump Accessories required (For all pumps)

Base plate Sole plate (if separate) Foundation bolts, nuts, sleeves etc. Counter flanges with bolts, nuts & gaskets Coupling & Coupling guard Eye bolts, lifting tools etc. Inspection & Testing Hydrostatic Test DP Test for casing, machined surfaces of all castings. Ultrasonic test for pump shaft Radiography for casing Performance test Balancing test YES YES YES YES YES YES YES YES YES NO YES YES
Note: All tests shall be carried out as per TAC requirement.
14.2 DIESEL ENGINE

Service Nos. required For driving main fire water pumps. One
14.3 Engine Parameters

Rating, kW Ambient conditions As per TAC requirement Refer Project information section. Turbo charged & after cooled High Speed Diesel Direct injection, multi cylinder, water cooled, 4-stroke 4 cycle Water 1 m/s Direct/geared
14.4 Special features

Aspiration Fuel used Type of Engine Cooling medium Velocity of cooling water to be considered Type of connection
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Starting mode Type of lubrication Intake air fitter Exhaust gas outlet Accessories required Fuel oil tank Fuel oil piping Anti-vibration arrangement Battery - Auto/Manual mode Forced Required Outside Fire Pump House
Yes Yes Yes
Notes: 1. Necessary battery and battery charger are to be included in scope of supply. 2. Vendor to provide fuel oil tank as required.
14.5 PIPING
Material / IS Code Length End finish Test Certificates Product marking IS 1239 medium/IS 3589 6 MM THK ERW In 5 to 6 m lengths Square end up to & including 40 NB Beveled end as per ANSI 16.25 for sizes above 40 NB Hydro test required Chemical, tensile and hydro test certificates required Manufacturer's name, specification no.and Grade
14.6 FITTINGS
Material / IS Code Ends Tests Certificates IS 1239 medium/Fabricated fittings from IS 3589 6 mm TAC pipes SW for sizes 40 NB and bevelled ends as per B 16.25 for sizes > 40 NB Product analysis, hydro test Chemical, mechanical and hydrostatic test certificates
Notes: tes: 1) For water spray system, galvanized pipes & fittings shall be used downstream ofthe isolation valve.
14.7 GASKET
Material Nitrite Butyl Rubber (NBR)
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Thickness Design Facing 3 mm ANSI B16.21 Full Face
14.8 BOLTS, NUTS

Service Material / IS Code Test Certificates Fire Water IS 1367 Cl 4.6/4 Tensile test Chemical & tensile test
14.9 SLUICE VALVES

Material/ IS Code Manuf. /Testing Std. Rating IS 210 Gr FG 220 For Body & bonnet 13% Cr Steel faced Carbon Steel Seat IS 780 / IS 2906 PN 1.6
14.10 GLOBE VALVES

(Sizes 40 NB and below)
Material Manuf./Testing Std. End Connection Rating A 105 BS 5352/BS 6755 Socket welded - Sch 40 800 #
14.11 CHECK VALVES

Material/ IS Code Manuf. /Testing Std. Rating IS 210 Gr FG 220 IS 5312 Compatible with 10 kgs/cm2 (g) working pressure
14.12 HYDRANT VALVE

Type Code / Standard End connection Single headed, female oblique type IS : 5290, Type A Flanged and drilled to ANSI B 16.5, 150#
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Material of construction Testing Test pressure Gun Metal to IS : 318 Gr.2 As per IS : 5290 Body - 21 kg/cm Seat - 14 kg/cm
14.13 WATER MONITOR

Type Size Code / Standard End connection Material construction Water barrel Nozzle Handle Brass flange Reducer & 90 Elbow Swivel joints (horizontal & vertical) Rotation lock (Horizontal / vertical) Grease ripple Drain cock Testing Test pressure Painting Approval Horizontal and vertical swivel type As per TAC. IS : 8442 Flanged and drilled to ANSI B 16.5,150# Seamless to ASTM A106 Sch. 40 GM IS 318 LTB-2 MS to IS 2062 MS IS 2062. Drilled to ANSI B 16.5, 150# Seamless ANSI B 16.9 Bronze IS 318 LTB-2 Brass IS 319 Brass Bronze IS 318 LTB - 2. As per IS : 8442 25 kg/cm2 Fire red as per IS-5 Total DFT - 100 microns ISI marked / TAC approved
14.14 BRANCH PIPE & NOZZLE

Size Code / standard Material of construction Branch pipe / nozzle As per TAC IS : 903-1995 Gun metal grade LTB-2 , Instantaneous male and female 63 NB IS : 903 Gun Metal to IS : 318 LTB-2 As per IS : 903
14.15 HOSE COUPLING

Type Size Code / standard Material of construction Testing
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14.16 FIRE HOSE

Type Size Code / standard Length Approval Controlled Percolation 63 mm IS : 8423 15 m for external hydrant and T.G building common platform 7.5 m for internal hydrant ISI marked / TAC approved
14.17 HOSE CABINET

Type Size Mounting Special requirement (i) (ii) (iii) (iv) Painting Fabricated out of 16 Gr. MS sheet 800 x 600 x 250 Wall / column mounted Cabinet to have double door having toughened glass panel marked `Fire' on it in 150 mm letters. Approved lock with duplicate keys kept wired in a break glass key cabinet in the hose box itself. A spanner and a set of spare rubber rings packed in fresh chalk to be kept inside the hose box. Clamp for holding branch pipe to be provided. Two coats of zinc phosphate primer and two coats of finish paint to shade fire red of IS : 5 total tot DFT - 100 microns
14.18 FIRE DETECTION SYSTEM

For specific requirements of fire detection system, refer section 15, 17 and 20 of volume - II for details.
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15. SPECIFIED DATA SHEETS FOR AIR CONDITIONING AND VENTILATION SYSTEM
Sr.No Building / Area Type of System Design Amb. Temp. Inside design condition (DBT oC /RH %) Minimum design ventilation Equipment capacity Redundancy
(A) (i)
VENTILATION SYSTEM Cable Cellar Room
Wet ventilation system
50 oC
45 (Max.)/65 (Max.)
10 AC / hr./ or air flow corresponding to heat load whichever is higher, 2-3 mmWC over pressurisation
(ii) (iii)
Switchgear room TG bay
- do - do -
- do - do -
- do 50 (Max.)/60 (Max.)
(iv)
WTP, Aux cooling water, Raw water, Fire water
Wet ventilation system
43oC
38 (Max.)/65 (Max.)
- do - do (TG bay shallreceive air fromcable cellar andSwitchgear room and exhaustthrough roofextractor) 10 AC / hr./ or air flow corresponding to heat load
2 x 50% capacity centrifugal fan & 2 x 100% centrifugal water pump and all auxiliaries as per technical specifications with design heat load or 10 AC/hr whichever is higher plus 10% margin in flow rate. Cable spreader room, switchgear room & TG Hall in STG building bu shall have common wet ventilation system - do - do -
No.
- do - do -
2 x 50% capacitycentrifugal fan &2 x 100% centrifugal water pump and allauxiliaries as
No.
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MCC whichever is higher, 2-3 mmWC over pertechnical specifications With design heat load or10 AC/hr whichever ishigher plus 10% marginin flow rate. - do -
(v)
ESP, Compressor, Fuelhandling, Ash handlingsystem MCC
- do -
- do -
- do -
- do -
- do -
(vi)
ACW pump house
Exhaust Ventilation
- do -
Max. 3 deg. Caboveambien t - do - do - do - do - do -
15 AC / hr.
As per designventilation requirement+10% margin
No.
(vii) (viii) (ix) (x) (xi)
RW & FW pump house RW chlorination building CW chlorination building Chemical storage area WTP WTP Exchanger area
- do Exhaust Ventilation - do - do Dry pressurized and filters, exhaust through gravity damper
- do - do - do - do - do -
- do 20 AC / hr. 20 AC / hr. 15 AC / hr. 20 AC / hr.
- do - do - do - do - do -
No. No. No. No. No.
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(xii) Battery room Dry pressurized and filters, exhaust through gravity damper A/C plant room Dry pressurized &filtered Toilet & store house Exhaust Ventilation Air Conditioning System CCR control building Ductable , Air cooled package A/Cunit - do - do Non ductable, Air cooled multi split A/Cunit - do - do 20 AC / hr. - do No.
(xiii)
(xiv) B (i)
- do -
Max. 3 deg. Cabove ambient General air exchange
1.5 AC / hr.
- do -
No.
15 AC / hr.
- do -
No.
50oC
22+1 / 505
1. 5 AC / hr.
7.5 TR Unit rating ; in multiples thereof
1 unit of 7.5 TR to be kept as standby
(ii) (iii) (iv)
Electronic cubicle room UPS room Office area
- do - do - do -
22+1 / 505 22+1 / 505 24+1 / 505
- do - do 20 cfm / person
- do - do 5 TR Unit rating ; in multiples thereof 1 unit of 5 TR to be kept as standby
(v)
Conference room
24+1 /505
(vi)
Shift incharge room
Non ductable,
- do -
24+1 /505
- do -
1.5 / 2 TR
1 unit of 5 TR to be kept as standby No.
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(vii) (viii) (ix) (x) Air cooled split A/C unit SWAS room boiler area - do SWAS room TG area - do Physical and chemical lab - do WTP area WTP plant local control - do room - do - do - do - do 24+1 /505 24+1 /505 24+1 /505 24+1 /505 - do - do - do - do - do - do - do 1.5 / 3 TR No. No. No. One (1) unit of1.5/3 TR to bekept as standby One (1) unit of1.5/3 TR to bekept as standby No
(xi)
ESP, Ash handling, fuel handling control room
- do -
- do -
24+1 /505
- do -
1.5 / 3 TR
(xii)
Instrument lab
- do -
- do -
24+1 /505
- do -
1.5 / 3 TR
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16. CONTROL & INSTRUMENTATION

1.0 GENERAL This chapter is intended to define the basic requirement for Control & Instrumentation of Steam Turbo Generator (STG), Boilers along with its auxiliary units, other units of Thermal power plant and communication system as specified in the tender document. The basic philosophy of Control & Instrumentation system shall be based on microprocessor based programmable logic controller with 4 4-20 20 mA unified current signal system. The Control & Instrumentation tation system shall ensure safe, efficient and smooth operation of the plant and equipment with minimum intervention of the operating personnel during normal working of the plant, load fluctuation /shut down and manual start start-up of the unit. INTRODUCTION he basic philosophy of C&I system shall be based on microprocessor based Distributed The Digital Control Monitoring & Information system (DDCMIS) for the entire plant with 4-20 4 mA unified current signal system. The C&I system shall ensure safe, efficient and smooth s operation of the plant and equipment with minimum intervention of the operating personnel during normal working of the plant, load fluctuation / shut down of the unit. DDCMIS with a no. of HMI Stations (OS &ES) has been envisaged for the Power & Blowing Bl Station (Boilers & STG).. Separate PLC based Control System shall be provided for the DM Plant and WTP facilities. These PLCs shall have necessary interfacing facilities with the DDCMIS of Power & Blowing Station. Scope of Work The scope of supply & work shall include design, engineering, procurement, manufacture, assembly, inspection, supply, packing, transportation to site, storage, calibration, erection, testing and commissioning of the complete control & instrumentation (C&I) system with all types es of cables, pipes and erection hardware necessary for completion of C&I work for the Boilers, Steam Turbine Generators and their auxiliary units on a turnkey basis. The scope of work shall also include all civil work like chipping, digging, concreting, i including ncluding filling material etc., and associated erection of instrumentation equipment. Measurement and control equipment offered shall be complete in all respect and any equipment / accessories not explicitly indicated in this specification, but considered essential 130 | P a g e
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for proper functioning of equipment and process shall beincluded in the Tenderers scope of supply and work. The scope of supply and work shall include but not limited to the following: The instrumentation equipment for boilers, steam turbine generators, the auxiliary units like fuel oil system, lube oil system, circulating water and cooling water system, DM plant as covered in this specification and also as felt necessary by the successful tenderer for the completeness of the job. Distributed Digital Control, Monitoring and Information System (DDCMIS) along with the computing device for performance efficiency calculation. Fully wired panels, cabinets, desks, consoles, racks, transmitter cabinets and junction boxes. All types of power, control, signal, instrument and system cables required for instrumentation work. All the cables shall be FRLS type. All regulating control valves shall be furnished with pneumatic actuators except Turbine Governing Control Valve, which shall be electro electro-hydraulic. draulic. For pneumatic actuators, nitrogen shall be used and for this, necessary provision of Pressure Reducing Station (PRS) shall be considered. All impulse pipes shall be of SS. Erection material as required including all necessary materials required for earthing of entire C&I system including DDCMIS. All the instrumentation items for Coal handling shall be selected as per hazardous area classification. Erection, calibration, testing and commissioning of the total equipment included in this specification. tion. All tools and tackles, special testing equipment and consumables required for erection and commissioning activities shall be arranged by the successful Tenderer. Two years mandatory spares for trouble free operation maintaining at least 20% of each equipment. Maintenance platforms and access ladders for instrumentation equipment installed at inaccessible heights. 131 | P a g e
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Supply, erection, testing, commissioning of Instrumentation and control system for DM plant on turnkey basis. DM plant shall have indepen independent dent PLC with HMI station for operation and control. PLCs shall be linked to the DDCMIS on communication link. Any C&I equipment required during any stages for the efficient / safe / reliable operation of the plant either during detail engineering / commi commissioning ssioning shall be supplied, installed and commissioned by the successful Tenderer without any additional cost. DESIGN PHILOSOPHY Control & Instrumentation (C&I), system shall be provided to enable the power plant operation to be carried out in a safe, effective ective and reliable manner, without invoking plant of system operational limits and to provide the quality of control to support the overall performance guarantees detailed in other sections. One control room is envisaged for coal fired boiler turbo turbo-generator ator and gas fired boiler turbogenerator. The control room shall house all Operator workstations, Engineering Workstations, Emergency control desk. Separate equipment rooms to house the controllers and other panels shall be provided adjacent to the contro control rooms. Similarly equipment rooms RIO panels shall be provided at field locations. The main objective of centralized control room operation for the plant is for the following actions All routine unit operations (including all normal, emergency, start start-up, p, shut down operations on load). The design of control system and related equipment shall adhere to the principle of fail-safe operation at all system levels (i.e.) the loss of signal, loss of power or failure of any component should not cause a hazardous ous conditions and at the same time prevent occurrence of false trips and provide reliable and efficient operation of the plant under dynamic conditions and attainment of maximum availability. The entire unit operation and monitoring under all regimes of operation i.e. start-up, start normal operation, shut down, etc shall be possible through colour TFTs / Keyboards / Mouse or equivalent cursor control devices mounted on table top top inthe Control Room. A minimum quantity of back-up up push button station may be provided on back-up up Control Desk. For all electrical systems within the plant, all electrical breakers control shall be performed from Operators Work Station with back up from miniaturized hard hard-wired switches and push buttons mounted on electrical control panel provided with mimics. Alarm displays, sequence of event monitoring etc. shall be provided for rapid diagnosis and logging of events following a unit trip. 132 | P a g e
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Vibration monitoring devices, bearing temperature temperature-monitoring monitoring devices etc for major auxiliaries shall be provided to give alarms for proper healthiness of the equipment. Extensive self-monitoring monitoring and diagnostic features shall be employed to enable location of faulty components / system in the minimum possible time. DESIGN CRITERIA The equipment and nd system shall be designed and constructed to meet all specification requirements, and perform accurately and safely under the environmental and operating conditions without undue heating, vibration, wear, corrosion or other operating troubles. It shall be e the responsibility of the Bidder to fully acquaint himself with the functional requirements and operating conditions, for equipment, system and accessories offered for the project Control Room (CR) shall house the Human Machine Interface system necessary necessa for the operation and monitoring of the Boilers, STGs & auxiliaries. The Control Equipment Room (CER) adjacent to CR shall house all control cabinets and the necessary marshalling racks. DM Plant shall have separate Control Room for operation of the r respective facilities. Local control rooms or local control panels shall be provided for the normal operation of auxiliary plants, at locations where local operations shall be performed. The Control Room, Control Equipment Room, Engineers room shall be provided with air conditioned, false flooring and false ceiling. UPS / battery charger and battery room shall be preferably located in A/C room. The clear gap between false floor and false ceiling shall be three (03) mtrs. Redundancy of components and sys system tem shall be governed by availability criteria to ensure the system availability target as well as safety considerations in critical applications. Separate sensors shall be provided for Control and protection Measurement and alarm If a transmitters signal is used for control, there shall be another transmitter furnished for measurement with facility for transfer of signal to use the measurement transmitter for control, in the event of loss of control transmitter. The operations shall be notified of the t transfer by alarm. Any single failure of instruments or control equipment shall not affect the performance of the unit in anyway. 133 | P a g e
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For very critical application like protection of Boiler, Turbo Turbo-Generator Generator and critical closed loop control system, 2 out of 3 redundant sensor / transmitter shall be used. For balance protection rest of the closed loop controls, sequential logic and related measurement dual redundant hardware shall be used. For balance measurement non-redundant redundant hardware may be used. The e DDCMIS shall have redundancy in following levels Main processor, I/O modules (for critical I/Os), Network interface module, communication cable and power supply. For all measurements, independent transmitters shall be connected to separate tapping points. points The design of the system and related equipment shall adhere to the principal of fail Safe operation wherever safety of personnel / plant equipment is involved involved. Fail Safe operation wherever signifies that the loss of signal, loss of excitation or failure ilure of any component shall not cause a hazardous condition. However, it shall also be ensured that occurrence of false trips are avoided / minimized. The types of failure which shall be taken into account for ensuring operability of the plant shall include but not limited to Failure of sensor or transmitters. Failure of controller / other modules during automatic operation Loss of motive power to final control element Loss of control power Loss of instrument air. Selection and design criteria for inst instruments ruments used shall be as per standards used for Power plant application. Electronic Remote drum level monitoring system - In Boiler Drum, to measure and monitor drum level, the Tenderer shall provide electronic remote drum level monitoring system working or principle of difference in electric conductivity between steam and water. Vibration Monitoring System (VMS) - Microprocessor based VMS shall be provided for turbine, generator, ID, FD, BFPs and all other major pumps / motors. The system shall be from Bentley entley Nevada (3500 or latest series) only. The number of bearing locations to be monitored on each turbine, generator, fan / pump shall be as per requirement finalized during detail engineering.
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Turbine Supervisory System - The turbine supervisory equipment shall be complete and shall include sensors, transmitters, converters, limit value monitors, measuring and amplifier modules, power supplies etc with the required accessories including twisted and shielded instrumentation cables, compensating cables, junction unction boxes etc. for safe start-up, start operation and shut-down of the turbine generator. The system shall be from Bentley Nevada (3500 or latest series) only. The system shall be integrated with the DCS using Modbus protocol. The necessary trip signals shall l be hardwired to the DCS in addition to the communication link. Turbine supervisory system offered for each unit shall consist of probes, pickups, indicators, etc., for the following as minimum : Vibrations Total expansion Speed Steam & Water Analysis System (SWAS) - Continuous analysis shall be done on steam and water media to establish their purity and suitability for long life of equipment. The measurements shall be carried out in different plant cycle at strategic points to establish conductivity, pH, H, dissolved Oxygen and Silica content. The exact sample points, their location, and type of chemical analysis to be carried out for each sample, measurement ranges etc. shall be subject to the approval of the Owner/Consultant. The steam and water analysis system (SWAS) shall include all requisite microprocessor based analyzers, sampling system, complete with sample table and analyzers, panels and integrated to the DCS. The system shall be generally designed in accordance to the recommendation of ASME PTC P Part art-II, water & Steam in Power Cycle. SPECIFICATION FOR CABLES All cables shall be FRLS type. Signal cables between individual field instruments / sensors and field junction boxes: Single twisted pair, 1.0 sq. mm annealed tinned electrolytic stranded co copper conductor, outer sheath extruded FRLS PVC, inner sheath extruded FRLS PVC, aluminum tape, screened with tinned copper drain wire, armoured with galvanized round steel wire and overall FRLS PVC sheathed of 1100V grade insulation. Signal cables between field junction boxes and DCS marshalling cabinets - Multiple twisted pair, 0.75 sq. mm annealed tinned electrolytic stranded copper conductor with individually screened and overall screened, outer sheath extruded FRLS PVC, inner sheath extruded FRLS PVC, aluminum tape, screened with tinned copper drain wire, armoured with galvanized round steel wire and overall FRLS PVC sheathed of 1100V grade insulation. Control Cables between individual field switches and field junction boxes Three core cable, heavy duty, 1.5 sq.mm flexible annealed tinned electrolytic stranded copper conductor, outer sheath extruded FRLS PVC, inner sheath extruded FRLS PVC, armoured with galvanized 135 | P a g e
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round steel wire and overall FRLS PVC sheathed of 1100V grade insulation. Core number marking shall be provided for each core at every 500 mm interval for easy identification. Control Cables between field junction boxes - and Marshalling Cabinets Multi core cable, heavy duty, 1.5 sq.mm flexible annealed tinned electrolytic stranded copper conductor, onductor, outer sheath extruded FRLS PVC, inner sheath extruded FRLS PVC, armoured with galvanized round steel wire and overall FRLS PVC sheathed of 1100V grade Insulation. Core number marking shall be provided for each core at every 500 mm interval for easy sy identification. In addition to above all thermocouple extension cable, fibre optic cable, communication cables shall be supplied as per Indian/ International standards. CO Analyzer The carbon Monoxide (CO) analyser system shall be microprocessor base based. d. The system shall be complete with sensor probe, electronic unit, calibration equipment with reference gas & accessories, purge air blower (if required, interconnecting cable and other accessories as per requirement. Auto calibration facility shall be pr provided. The carbon monoxide (CO) analyser system shall have following features: - Dual microprocessor based/ease of operation - Diagnostic capacity - NEMA 4X enclosure if required - Automatic zero/span analysis - In-situ situ analysis/ Extraction type - HART compatibility The Carbon Monoxide (CO) analyser system shall be provided as per following specification as a minimum Principle of Measurement Measurement Range 0-200,0-999 ppm Accuracy Linearity Repeatability Response Time final value Drift Sensor Type Filter Compensation for temperature IR absorption 0-999 selectable in 0-100 +/- 2% of F.S. +/- 1% of F.S. +/- 1% of T.S. Less than 3 seconds to 90% of +/- 1% of 100C IR Sintered Bronze. 5 micron 136 | P a g e
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Including cables up to JB To be provided Output signal analog/binary 4-20mA dc 2 NO + 2NC for high / low alarm Zero & span adjustment To be provided. Indication digital Enclosure Type NEMA 4 X / IP65 Digital signal Transmission RS 232 or RS 485 or as per Protocol requirement Calibration Auto & manual (from Remote) Diagnostic To be provided Minimum requirement: * IR light transmittance Intensity Indicator * Detector Level Indicator * Microprocessor Status Indicator * Calibration check Path Length 1.5 to 40 ft as per requirement Other HART compatible Dust Density Analyser (Opacity Meter) The Dust Density analyser shall be provided as per following specification as a minimum : Type of Instrument : Principle of measurement : Measurement Range : Accuracy : Resolution : Linearity : Response Time : Drift : Sensor Type : Operating Range of Temperature : Filter : Measurement Units : In situ dry-type visible light (through LED) Transmission & Absorption 0 to 999 mg/Nm3 +/- 0.2% of F.S =/- 0.1% Opacity +/- 1% of F.S 5 seconds < 2% IN 3 Months Luminescence 0 to 3000C Sintered Bronze, 5 micron Opacity, transmittance, optical density, Extinction, dust concentration Measurement Unit, Signal
Selectable Parameters : Averaging, Optical Path length Ration (OPLR), Analog Output Signal Selection, Alarm Setting, Manual Calibration utomatic Calibration Verification : User Selectable Automatic Analog Output : Two/Four isolated 4-20 mA Contact output : Eight SPDT relays Including four selectable Alarms 137 | P a g e
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Digital communication : Communication link between Transceiver and Control Room Processor Compensation for Temperature : Yes to be provided Accessories Purging System : Yes Digital Signal Transmission Protocol: RS 232 / RS 485 or as per Requirement The Dust Density Analyser shall have the following features : The Control Room unit shall consist of a graphical User Interface (GUI) and a display panel with following display Continuous Continuous opacity, optical density, extinction, and dust concentration readings, instantaneous and average. verage. Automatic zero/span calibration checking Adjustable ranges and alarm set points Oxygen Analyzer (In-Situ Situ Type) Oxygen in flue gas shall be non non-sampling type using zirconia probe. Zirconia probe analyser should have facility of in situ calib calibration should be done using standard test gases. Analyser shall have built-in-auto-calibration calibration facility. The Oxygen Analyser System shall have following features : - Totally field repairable probe - Electronic cell protection - HART Communication Protocol compatibility - Easy calibration facility - High speed of response - System diagnostics The oxygen Analyser shall have be provided as per following specification as a minimum Type : Principle of measurement : Measurement Range : Accuracy : Linearity : Response Time : Drift : Sensor Type : Temperature Operating Range : In-situ dry type, nonheated Partial-pressure using Zirconium Oxide cell 0.01 to 10% oxygen +/- 0.2 of span +/- 1.0% of full scale 3 seconds or less +/- 0.005% High temperature Zirconium oxide cell 0-16000C 138 | P a g e
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Compensation for temperature : with thermocouple as/ moisture including cables required Up to JB Output signals analog/binary : 4-20mA dc/2No + 2 NC for high & low Alarm Zero & span adjustment : To be provided Ambient Temperature : 600C Indication : digital Enclosure Type : IP65/NEMA 4x Type of Electronics : Microprocessor based Digital signal transmission Protocol: RS 232 / RS 485 or as per requirement Calibration : Auto & Manual (from remote) Error Diagnostic : to be provided Other : HART communication protocol NOx Analyzer The NOx Analyser system shall be provided as per following specification as a minimum. Type of Instrument : Principle of Measurement : Sensor type : Measurement Range : Accuracy : Linearity : Response Time : Drift : Filter : Sample points : Sampling System : Sampling / In In-situ Type Radiation Luminescence / IR/UV 0-200 200 / 0 0-1000 / 0-2000 selectable in Mg/Nm3 +/- 1% of F.S. +/- 1% of F.S. 60 secs or less +/- 1% /100C Sintered Bronze. 5 micron Multiple With dual sampling through heavy duty pumps, solenoids, filters etc. along with coolers and flow meter & level switch in gas coolers for auto draining purpose.
Output signals analog/binary: 4-20mA 20mA dc / 2No + 2 NC for high alarm Zero & span Adjustment: To be provided Error Diagnostic: To be provided Indication: Digital Type of Electronics: Microprocessor based Digital Signal Transmission: RS 232 or RS 485 or as per Requirement Protocol Calibration : Auto & manual (Remote) Enclosure type: Weather & Dust Proof IP 65 Accessories/Purging System: Yes 139 | P a g e
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Compensation for temperature/: Yes to be provided Moisture including cables up to JB Other : HART compatible The NOx Analyser system shall be provided as per following feature as a minimum. - Complete system for monitoring NO & NO2 from emission sources - No catalyst requirement - No wet chemistry requirement - Proven high reliability - Minimum maintenance requirement - Zero standardization: automatic every 10 or 15 minutes
SOx Analyzer
The Sox Analyzer system shall be provided as per following specification as a minimum. Principal of Measurement : Sensor Type : Measurement Range : Accuracy : Linearity : Response Time : Drift : Filter : Sampling System : Radiation absorption Luminescence / IR 0-200 200 / 0 0-1000 / 0-2000 selectable in mg/Nm3 +/- 1% of F.S. +/- 1% of F.S. 60 secs or less +/- 1% / 100C Sintered Bronze, 5 micron With dual sampling Through heavy duty pumps, solenoids, filters etc. along with coolers and flow meter & level switch in gas coolers for auto draining purpose.
Output signals analog/binary : 4-20mA dc 2 No + 2NC for high alarm Error Diagnostic : To be provided Zero & span Adjustment : To be provided Indication : Digital Ambient Temperature : 600C Enclosure type : Weather & Dust Proof IP 65 Type of Electronics : Microprocessor based Calibration : Auto & manual (Remote) Digital Signal Transmission Protocol: RS 232 or RS 485 or as per requirement Accessories / Purging System : Yes Compensation for temperature/ : Yes to be provided Moisture including cables up to JB 140 | P a g e
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Other : HART compatible The SOx Analyser system shall be provided as per following feature as minimum. - It should have fast response: less than 60 seconds, full scale - Zero standardization : Automatic every 10 or 15 minutes - Remote span verification - Multi point sampling & extractive sampling
JUNCTION BOXES
Junction boxes of size 500x500mm or below shall be of Die Cast Aluminium Alloy. For higher size JBs CRCA sheet of minimum 2mm thickness shall be used. All JBs shall confirm to weather proof IP65. 5. Terminal connecting screws and shall be suitable to connect signal, control and power cables. Junction boxes shall be sized to accommodate the terminations with 20% spare terminals in each box. All wires in junction boxes shall be neatly dressed and ferruled. Junction boxes shall be provided with double compression type cable glands and these shall be firmly grounded. Each junction box shall have spare entries, minimum of 10% or 3 nos. whichever is higher. Spare entries shall be provided with plugs. Voltage ltage levels within the junction box shall be isolated from lower voltages and shall be labeled.
CABINETS / PANELS
The panels shall be upright, floor mounted and dead front type and shall have ventilation with steel mesh. The outside colour of the panels shall be powder coated with colour RAL 7032 or equivalent international code. The inside colour of all these panels shall be brilliant white. Panels shall be provided with antivibration mounting pads. The panel shall be made from CRCA steel sheet with a minimum thickness of 2mm. The gland plate shall be of thickness 3mm. The width of panel shall be as per approved panel G.A. drawings. Panels shall have lifting hooks or eyebolts on the top at the four corners, for ease of transportation. Cabinets shall be equipped with front and rear access doors. Doors shall be equipped with lockable handles. All the cabinets shall be free standing, enclosed type and shall be designed for bottom entry of cables. The inside of panel shall be illuminated, preferably using C CFL lamp. The illumination lamp shall be switched on/off using a door switch. Fans shall be used for effective cooling of controller and subsystem panel. 141 | P a g e
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UPS
UPS for the automation shall be parallel redundant. UPS shall be of provided with SMF (Sealed Maintenance tenance Free) battery with backup time of 30 min. The UPS shall be as per IEC standards. The UPS shall include power input device, rectifier unit, battery unit, inverter unit, automatic by-pass pass unit with SCVS. Facility shall be provided for manual transfer of load from inverter to bypass. The output voltage of the UPS shall be 110V AC, 50Hz, single phase. The UPS shall provide potential free contacts for annunciation at the DCS/ PLC. The operating temperature range shall be 0-50 50 deg.C with 95% RH Non Non-condensing. nsing. The maximum noise shall be 60db @ 1mtr distance. The UPS paint shade shall be RAL RAL-7032 7032 or suitable to match with adjacent panels. The battery shall be installed in floor mounted racks. UPS offered for each area shall be of sufficient capacity; requ required ired for smooth, efficient and trouble free operation of the unit/area. The UPS shall be capable to provide power to DCS / PLC, HMI network and field instrument. Each UPS shall be designed to have 25% of spare capacity of rated power. UPS shall have on-line ne monitoring and diagnostic system with LCD screen on the control panel which shall have comprehensive information on the equipment status and assist in fault diagnosis. The UPS shall have the following salient features: * Bumpless switchover of load on either UPS, on failure of the other UPS. * Bumpless switchover of load on battery, on failure of incoming mains * Bumpless switchover of load on SCVS, on failure of both UPS, battery. Power from the UPS shall be distributed through Power Distribution Boar Board d (PDB). Spare feeders of 20% shall be provided for future expansion in the PDB. Instrument power supply shall be through circuit breakers. Electric motor actuators shall have independent circuit breakers. The bidder shall supply all necessary furniture including ergonomically designed chairs & desks for use at the control room and various programming stations. All the equipment like PCs, Programmers stations, various peripherals & similar devices shall be complete with desks, stands and other mounting a accessories.
Process Connection Size
The following connection sizes shall be adopted for the instrumentation tapping points for measurement, control and test: 142 | P a g e
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i. Pressure measurement (above 40.0 bar pressure and / or 450C temperature and fuel oil): 25 NB socket Weld (SW) ii. Pressure measurement) low pressure / temperature): 15 NB SW iii. Temperature measurement (high pressure / temperature): M33 * 2 (screwed) full coupling with seal welding. iv Temperature measurement (low pressure / temperature): M33 * 2 (screwed) full coupling. v. Flow, level and differential pressure measurement: Same as (i) & (ii) vi. Level switches: 25NB (SW) vii. Gauge glasses: 1 NPT (Screwed) viii. Sampling connections (water/steam): 25 NB (SW) ix. Flue gas sampling: As per analyze analyzer manufacturers recommendations
DISTRIBUTED DIGITAL CONTROL, MONITORING & INFORMATION SYSTEM (DDCMIS)
Bidder shall be responsible for engineering, selection and connection of all components and sub-system system to form a complete system whose performance is in accordance with functional, hardware, software and other requirements of the specification. The successful bidders activities in compliance with the present specification shall include design, analysis, issue of drawings / documents, manufacturing, insp inspection ection and testing, packing, shipping, storage and commissioning as well as furnishing of instruction and maintenance manuals. The main purpose of the DDCMIS shall allow the plant to be automatically managed in all the foreseen operative conditions, while guaranteeing the reliability, availability, maintainability requirements relative to the entire plant. Omission in the present specification do not make supplier exempt from supplying a complete and operative system, in compliance with the highest quality standards. The DCS system offered shall be proven for power plant application and shall be working in similar plants elsewhere. Tender shall give reference of such plant along with contact details of the plant officials to assess the performance of the system by client / consultant. System Requirement The DDCMIS based control system must unify all the processes from steam generation to electric power generation on one platform. This shall include but not limited to FSSS/BMS, Boiler Analog Controls, Turbine bine EHTC, AVR control, Plant Electrics, Data acquisition and Historian, Sequence of event recording, Performance calculation, Man machine interface and data transfer to the office LAN for MIS integration. 143 | P a g e
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The proposed DDCMIS shall be able to control and monitor all electrical system / equipment with auto plant start-up, up, auto synchronization and shut shut-down. The control system along with its measurement system shall perform functions of closed loop control, sequence control, interlock & protection of SG, ST STG and auxiliaries in all regimes of unit operation. The control system shall consist of the following basic system: Boiler Protection System (BPS) Turbine Protection System (TPS) )
Open Loop Control System (OLCS) Closed Loop Control System (CLCS)
Turbine Control System (TCS)
The measurement and control system shall perform the functions of signal acquisition, conditioning and signal distribution of various types of inputs / outputs like analog (4-20 (4 ma dc, thermocouple, RTD), binary, pulse etc. Separate & dedicated measurement system shall be provided for each of the system indicated above. Human Machine Interface System (HMI) The HMI System shall perform control, monitoring and operation of SG, TG and auxiliaries in all regimes of unit operation, interac interacting ting with the control system. For this, HMI system shall primarily perform following functions. i. Operator interface for control system. ii. Plant supervisory functions like displays, alarm monitoring & reporting (reports & logs, calculations, trend reco recording, historical and long term data storage & retrieval, etc.). Communication System The data communication system shall be provided for communication between control system and HMI system as well as communication & signal exchange with each system / sub-system sub like FPS, TPS, OLCS, CLCS, TCS, and HMI etc. of DDCMIS. The main data bus shall be redundant network with minimum 10/100mbps Ethernet TCP/IP. Controller to RIO communication shall be industry standard redundant control bus like profibus, devicenet, control net etc. using Fiber optic cable. Third party PLCs used for DM water and other units if any shall communicate directly with the dual redundant main data bus using terminal servers.
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In case of main bus failure or any communication device failure, the transfer to the backup device or bus shall be automatic without interrupting the system operation and without any operators intervention. Information about the failed device / bus shall be displayed on the operator console.
Sequence of Event Recording
The sequence of event monitoring device shall be provided to guarantee the chronological recording of the events relative to the plant. The time resolution for this function must be 1 milli second or better. The Sequence of Event Recording Syste System m shall provide the operators with a time-tagged tagged log of all conditions which can directly trip Steam Turbine, Generator, Electrical system or Boiler as well as other conditions which require better time resolution than the standard alarm printer offers. ER system shall accept sequence of events (SOE) inputs in the form of potential free contacts. SER The member of SOE inputs shall be on as required basis but not less than 512 points. System Diagnostic Station A dedicated central diagnostic display station s shall hall be provided for automatic display and recording of any system disturbances and enhancing the system availability. All types of faults and disturbances in all modules used in the system shall be automatically displayed and printed. reign Devices / PLC Interfacing with Foreign Foreign device interface shall be capable to transfer information from the Control Systems of Boilers & TG and for BOP facilities namely DM Plant, Analyzer system, Stack Emission Monitoring System, Vibration Monitoring System (VMS), HART Management System and any other dedicated control system to the DDCMIS in an efficient manner. Each device interface shall be redundant. Synchronization System (Master Clock) The DDCMIS shall be equipped with a master clock system for the synchronization synchroniz of modules through a satellite signal (GPS). The system shall also foresee an adequate number of interfaces for the connection and synchronization of the other plant control system and subsub system.
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System Hardware The control function of the syste system m shall be executed by the latest, industrially proven controllers (minimum 32 bit microprocessor based controller) consisting of power supply modules, processor modules, communication modules and I/O modules and a set of algorithms which are easily field configurable using userfriendly software. CPU loading of the Controller shall be limited to 60 %. Likewise, I/O loading of the processor shall not be greater than 70 % . Controller shall be provided with redundant power supply, processor and communication modules. Controller processor memory shall be non non-volatile. volatile. However in case volatile memory is provided, battery back-up up shall be provided with a minimum of 48 hours to keep program storage intact. A battery drain indication shall be provided when the charge in the battery dips below 50%. The hardware capability of the controller shall be exploited for regulatory control, sequencing and interlocking functions. Controllers shall be capable of accepting process signals from various process sensors, switches ches and electrical transducers preferably without requiring external or auxiliary signal conditioning devices. The system inputs shall include 4 4-20 20 mA dc, thermocouple, resistance temperature detector and discrete inputs as minimum. The controller shall be b capable of processing linear and non-linear linear analog inputs, providing square root extraction for flow signals, linearisation and compensation for thermocouple. The controller shall be able to generate 4-20 20 mA dc current signals for analog outputs and pote potential ntial free contacts for the discrete outputs as minimum. Controller operating system shall be Real Time Operating System. Loop integrity shall be maintained in controller sub sub-system system architecture by providing one-toone one controller back up. In case failure is detected in the active controller, all the loops of the failed controller shall be transferred to the back back-up up controller. The controller sub-system sub shall have automatic control transfer switching, which shall transfer the entire configuration and data base ase of failed controller to the back back-up up controller. The transfer should be bump less. Design must ensure that data integrity is maintained during switch over and no portion of data to be transferred is corrupted before and during switch over to the back up controller. The same shall be done during normal operation. The indication of the failed controller shall be displayed at local level as well as on the central level. Loop integrity shall also be applicable to I/O modules, power supply modulus and any other device associated with the controller sub sub-system. 146 | P a g e
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The controller shall be able to operate either in manual or auto and cascade mode. In cascade loops, the primary controller shall be able track the steeping of the secondary controller when not operating ting in cascade mode. All controllers shall have facility for slow and fast ramping of steeping output.
I/O Module Subsystem
Each analog input / output channel shall be isolated from external control circuit by optical / galvanic isolation. Each digital input / output shall be galvanically / optically isolated from external control circuit. The minimum isolation level between I/O and logic circuit shall be1000 be1000-volt dc. Each I/O shall be protected from short circuit and reverse polarity of power voltage. Each I/O channel shall have an indication to indicate the status. Each input shall be provided with filters to filter out any noise in the input line and contact bouncing noise. All digital inputs shall be provided with dry contacts. All the digital inpu inputs ts shall be double ended i.e. two wires per input and not with common return for all inputs. The interrogation voltage to the digital input contacts shall be powered from separate power supply. Interrogation voltage shall be 24V dc. The digital output from the system shall be potential free dry contact with rating 240V AC & 5.0 A. Each output shall be short circuit proof and protected by fuse. Visual indication of fuse blow must be provided for each module. All digital input / digital output channel shall have ave a facility to force the input or output. All DI / Dos shall be wired to the I/O cards with external interfacing relays. 20 % I/O channels of actual used shall be provided as spare. The spare channels shall be distributed equally through out all the I/ I/O O modules and shall be wired up to the terminal blocks. Also 20 % spare module space shall be provided in all the panels.
Redundancies
The following shall be completely redundant: All the process controllers. All the power packs All the communication devices including switches, buses. Critical I/O modules for closed loop controls & protection. The redundant communication buses between the process stations and the operator stations shall follow different parts. 147 | P a g e
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The redundant processor shall all be connected to the same I/O of the processor that it is associated to and shall be able to carry out all the operations assigned to this processor. In case of a processor failure the redundant processor shall become operative within the cycle time, without thout causing any loss of data or the interruption of the process control. The switch between the processor being utilised and the reserve processor shall be bump less and shall not cause any interruptions / stopping of the station functions. Further more, this switching shall be signaled by a high priority alarm. CONTROLLER DISTIBUTION Dedicated controllers with redundancy as described earlier shall be considered for following functional areas Each Boiler 3 nos. of controllers Each Boiler BOP 3 nos. s. of controllers Each Turbine 1 no. of controller Each Generator 1 no. of controller Turbine and generator controllers shall be common for one generation stream, hence in effect each generation stream is to have 8 nos. of controllers the associated R RIO IO panels. The grouping of functions for each controller may be decided by the Tenderer for which the basis will be discussed during further tender discussions. The tenderer is free to increase the number of controllers to realize the overall functionality functionality.
Control System
The control system shall have on on-line line simulation & testing facility. Further, it shall be possible to on-line line configure & tune controllers through configuration & tuning station for control system. The system shall have the flexibility to easily reconfigure any controller at any time without requiring additional hardware or system wiring changes and without disabling other devices from their normal operation mode. Modification shall not require switching off power to any part of the system. The remote manual operation from Push Buttons (PB) stations (wherever provided) shall be independent of availability of controllers & power supply to controllers. up controllers shall be identical in hardware and software All the 100% hot back-up implementation mentation to their corresponding main controllers and shall be able to perform all its tasks. The back-up up controller shall track its corresponding main controller. There shall be an automatic and bump-less less switchover from the main controller to its corresp corresponding onding back-up back controller in case of main controller failure and vice versa without resulting in any change in 148 | P a g e
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control status. In case of switchover from main controller the backup controller, the backup controller shall be working as the main controller. Facility shall be provided for manual switchover from main to hot back back-up up controller and vice versa from the programmers console. The controller system hardware design shall be such that it is able to withstand power line disturbance. The FPS shall meet all applicable relevant safety requirements including those stipulated in VDE 0116, Section 8.7, VDE 0160, Section 8.83; DIN 57116; NFPA etc.
Human Machine Interface System
All the Operating Stations (HMI) and Engineering Stations shall be of desktop mounted workstations. All the Operating Stations & Engineering Stations shall of open architecture with universal hardware for continuous operation in industrial environment. The Operating Workstation and Engineering Workstation envisaged for the DCS system syst shall be complete with processor, memory, power supply, bulk memory units, high resolution color monitor, key-board, board, mouse, communication interface modules, printer etc. along with necessary software modules. Dual screen (sideby (sideby- side) shall be provided with operation by single mouse and keyboard having full screen mode and multi window mode. Selection of screens shall not be required. Multi Multi-window window environment shall also be provided. The Operating Workstation and Engineering Workstation shall be on Wind Windows ows XP platform. Softwares offered for programming, controlling and monitoring shall be fully compatible with Windows 2000/XP platform. Dedicated individual licenses shall be provided for use of the softwares in these workstation. The Operating Station shall ll present the necessary plant information in a manner, which can be easily understood and absorbed by the Operator. The Engineering Station shall also provide the facilities to engineer and program the plant so as to control the plant process and shall be loaded with engineering software. It shall also be possible to use the Engineering Station as Operator Station. These displays shall be in the form of plant overviews, area overviews, group and sub group overviews, drive level displays, alarm list, seque sequences of event list with time stamping, mimic diagrams, hardware status displays, logs, bar charts, trends curves, etc. The workstation shall have the following minimum design features and shall be identical and interchangeable: Processor of latest configuration guration (preferred above 3GHz). Minimum 1 GB RAM and shall be expandable. Minimum 160 GB Hard Disc. 149 | P a g e
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Drive controllers RAID-5, 5, SCSI controller (Hot swappable and expandable), IDE, SATA. High resolution 21-inch inch TFT colour monitor with pixel resolution of 1280x1024, 32 bit color support as minimum. Serial, Parallel, USB, Network interface ports for connecting the data highway, printers etc., Latest DVD-RW for data back-up up and installation. 3 Floppy Disc Drive. Optical scroll mouse and QWERTY keyboard. Dynamic amic graphic capability with control through dynamic graphics. Furniture for mounting the monitors, key key-board, mouse and the electronic unit of the workstation along with strain relieving type of chair for each station. Redundant sets of communication controllers shall be provided to handle all the communication between HMI and redundant system bus. For operation and control of the turbo turbo-generator, generator, following shall be provided in each control room: Six number of operator workstation Two number of engineering eering workstation One Dot matrix Printer One A3 colour laser printer One A4 B/W laser printer Necessary consumables for printing shall be provided with the printer. All OWS of the HMI shall be fully interchangeable i.e. all operator functions including (for ( quick access to displays & other operator functions) control, monitoring and operation any plant area or drive shall be possible from any of the OWS at any point of time without the necessity of any action like downloading of additional files. Each OWS shall be able to access all control / information related data under all operating conditions including a single processor / computer failure in the HMI. Further, simultaneous operation from a single display without calling additional displays for multipl multiple drive operation shall be possible.
System Software
The Tenderer shall provide all software required by the system for meeting the intent and functional / parametric requirements of the specification. Software to be supplied shall include but not limited to the following to perform all the functions specified under this specifications. All software shall be in English. Software for microprocessor based distributed control system shall include the following. Real time operating system Input scanning, processing ssing and alarm monitoring. Open and closed loop control software. Graphic utility 150 | P a g e
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Communication between process modules through data bus On line diagnostic Human machine communication Input data base generation and maintenance Log generator. Utility for the he software development Background executive for software development in time time-sharing mode. Visual C or equivalent compiler. Screen editor for software engineering. File handling utility Library facility for object modules On line debugging facility for the purpose of software development. Utility of data transformer from magnetic tape to disk and vice versa Software for communication with system supplied by others. Full scale steam / water property routines conforming to ASME 1967steam tables. Any other software as required meeting all the specification requirements. The tenderer shall have the total responsibility for the design, development and implementation of software for the control & instrumentation system. The tenderer shall include in his scope of work the following. All computation for alarm cutouts, variable alarm limits. Class - I and Class II performance calculation. The formulae etc. shall be developed by the Tenderer subject to the approval of the owner / consultant. The application software for implementing control algorithms, interlocks, generation of mimics shall be using a graphics editor and graphic tool kit and shall not use a programming language approach. Graphic blocks, engineering blocks etc. shall be used to configure the software. s The requisite licenses for the system software and application software shall be included. Software Licenses as far as possible shall be taken on group basis rather than individual PC based. Alternatively, the software license shall be taken as p project roject specific instead of hardware / machine specific. All licenses shall be valid for the continuous service life of the plant. Source code for all application software shall be handed over to the Purchaser. The Tenderer shall include and indicate any ot other software e.g. Anti-virus, virus, communication, MS office etc required for realization of functions and completeness of system. All software upgrades / new releases, which take place after commissioning of the system, should be reported to the Purchaser for subsequent ubsequent procurement and installation at site, if desired. The Operating System (OS), Standard Software (like MS Office, Antivirus etc.), Application Software etc shall be supplied in suitable media (CD) and as preloaded with the system. 151 | P a g e
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SYSTEM GROUNDING
Generally the earthing for the system shall confirm to IS: 3043 Protective Earthing PE (Frame Earthing): All enclosures of the DCS / PLC equipment shall be connected to separate earth conductor, which shall be connected with plant critical earthing s system. Technical Earthing TE (Signal Earthing): Technical earthing (with one or more separate earth pits) shall be provided, having minimum earth resistance as specified by DCS / PLC manufacturer. Common signal ground points of DCS / PLC, Instruments and screens of signal cables shall be earthed to this technical earthing system. Control rooms shall be provided with TE bars and shall be different from PE system connected to the electronic earthing system. Shields of 24 VDC signal cables shall be connected conne to TE system only at one end. i.e. at control rooms. Earthing of DCS / PLC system shall be done as per manufacturer recommendations.
Drawing and Documents
Following drawings and documents shall be submitted. All communications/descriptions in the drgs., rgs., documents, technical literatures and manuals shall be in English language Along with the offer Process and instrumentation (P&I) diagrams for the package with all auxiliary equipment / system / facilities indicating all mounted instruments and DDCM DDCMIS IS displayed measurement using ISA symbols and using suitable tag numbers against each instrumentation equipment. Alarm and interlock functions shall also be indicated in the P & I diagrams. i. ii. Schedule of instruments for the entire plant within the scope of supply shall be submitted along with the offer. Analogues control schemes along with write write-up up for boiler, turbo generator and its auxiliaries and protection interlock schemes for boiler, turbine generator and its auxiliaries. Approximate instrument panel and desk dimensions. Approximate dimension of control rooms and analyser rooms. 152 | P a g e
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v. vi. vii. Quality and quantity of electric power requirement for instrumentation and also instrument air requirement. System configuration diagram along with write write-up on the system Technical ical specifications with literatures of all the units of DDCMIS system viz. processing units, process I/O unit, sequence event recorder, data bus, system cables, communication unit etc. I/O listing Instrument power requirement Tentative integral layout ske sketch tch of cubicles, consoles, peripherals etc. inside control room including total area requirement. List of technical deviations. List of installations in India where similar capacity with similar system is working in similar application for more than one (1) year.
viii. ix. x. xi. xii.
Drawings/documents to be submitted by the successful Tenderer For approval
i.
ii.
iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv.
Process and instrumentation (P&I) diagrams for the package with all auxiliary equipment / system / facilities indicating all field and panel mounted instruments using ISA symbols and using suitable tag numbers against each instrumentation equipment. Alarm and interlock functions shall also be indicated in the P & I diagram. Specifications of each instrumentation equipment indicating make, model no., application, scale range, ange, quantity, tag no. (as per P&I diagram), accuracy, power consumption etc. Data sheets for each instrument as per standard format shall be submitted with all the required details filled in along with detailed technical literature. Schedule of instruments ts / BOM shall be submitted by the Contractor. Instrument list System configuration diagram along with write write-up on the system. Technical specification of DCS / PLC and its sub sub-system system along with technical literatures / catalogues. ting description, cabinet no., module no., channel no., etc. Input/output list indicating Overall G.A. and general arrangement of various cabinets, panels, consoles etc. showing internal disposition of all components / units etc. with dimensional details. Bill of Material for DDCMIS / PLC Hardware design manual Software design manual Control philosophy Quality assurance plan. Earthing arrangement drawing, earthing layout drawings and earthing calculation drawings Factory acceptance test procedure & format 153 | P a g e
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For procedural Checking and Records
Hook-up diagrams. Flow sensor & control valve sizing calculation sheets. Instrumentation layout drawing showing location of sensors, control valves, transmitters etc. and route of cables from these up to the instrument panel in the control room. Instrument interconnection diagram indicating tag no of instruments, cable nos. with the specification between instrument and the junction boxes, junction box no. & terminal no., multipair cable no. with the specification considered between junction box and d marshalling panel, marshalling cabinet no & terminal no., prefab cable number considered between marshalling panel and system panel and I/O card location & channel no. Cable / Cable tray routing / Layout diagram Cable schedules. Single line power supply diagram. Control room layout and RIO room layout List of various scan time / cycle time, etc. set in multifunction controllers (CPUs) and for different control functions. Disposition of sampling instruments, cabinets, racks etc. inside analyser rooms (both (bot dry and wet). The protection and interlock schemes for all equipment, general interlocking schemes for boiler, turbo-generator generator scheme. Control schemes for boiler and turbo turbo-generator generator and measurement diagram. List of alarm points with set points. System grounding ounding scheme with bill of materials. Graphic display sheets, plant mimic sheets. Formats and work sheets for generation and display of overview groups, loops, graphics, alarms, operators guide messages, real time and historical trends, log and shift formats. Bus loading calculations Manufactures test, calibration and guarantee certificates for all the instruments. Operation and maintenance manual for each instrument. Quality assurance plan for each instrument. 2 years O & M spares lists for each instrum instrumentation item as per Manufacturers recommendation. Final As Built Drawings and electronic media.
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17. CIVIL CIVIL, ARCHITECTURAL AND DESIGN PARAMETERS
1.0 GENERAL 1.1 This part of the specification defines the Architectural requirements and design parameters for analysis and design of the civil buildings, civil Structures and facilities. 2.0 ARCHITECTURAL DESIGN REQUIREMENTS 2.1 Architectural design shall be in accordance with the following referenced publications: a) National Building code of India, b) State Government Factories Act. c) Local Municipality or any other authoritys Byelaws as applicable. 2.2 Spatial requirements: 2.2.1 Spatial requirements inside a building shall be based on the activities to be performed in the building, equipment ment layout, etc. 2.2.2 The objective of spatial arrangement is to satisfy functional requirements and physical comfort and safety regulations as well as aesthetics which has significant role in creating a favorable working and living conditions. 2.2.3 However owever the following are the limiting sizes, dimensions for various purposes, which are to be adhered to: A. Minimum size of any habitable room 9sqm with minimum dimension not less than 2.5m B. Minimum height of any habitable room 3m, which may be reduced to 2.75 m for air-conditioned areas. C. Maximum height of any habitable room 3.6 m D. Scale of accommodation for Industrial work spaces 14 cum. per occupant. Minimum clear height of such workspaces shall be 3.6m. 2.3 Day lighting and Natural ventilation: 2.3.1 Established level of illumination shall be maintained for all parts of the buildings by means of windows, skylights, etc. Established level of ventilation in terms of air 155 | P a g e
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changes per hour shall be maintained for all spaces. References s shall hall be made to National Building Code & Factories Act in this regard. Natural ventilation shall be supplemented by mechanical or electrical means of ventilation in all human occupied areas. 2.4 Safety requirements: 2.4.1 Safety from fire and like emerge emergencies ncies shall be taken into account in building/shed design. Every building/ shed meant for human occupancy shall be provided with exits sufficient to permit safe escape of occupants in case of emergency. 2.4.2 The exits shall be in terms of doorway, corrid corridors, ors, passageways to internal/ external staircase or to areas having access to outside. 2.5 Building services: 2.5.1 Water supply, distribution drainage and sanitary services shall be provided for all Buildings / sheds as essential services. 2.5.2 Areas of control room, spaces for housing equipments, machinery, panels, offices, etc., which require special conditioned environment, shall be provided with forced ventilation/ air conditioning. 2.6 Aesthetics: 2.6.1 Apart from the fulfillment of functional & safety requirement, aesthetic requirement of the building shall be given due importance in the design. Elements like canopies, Overhangs, Shades, Gutters, Door/window/ ventilator composition, external wall location with respect to columns, colour scheme, grooves in plaster, etc. shall be considered as contributory elements to aesthetics and these shall be designed judiciously. 2.7 Structural and construction elements: 2.7.1 Type of structure and construction shall be as per technical requirements. However the following may be followed as guidelines: Building Building Trestle foundations for Tg set Cooling tower water plant Type of structure and construction Structural steel above operating platform level In situ RCC framed construction RCC construction RCc framed structure 156 | P a g e
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Electrical rooms, control rooms, pump houses, office, etc 2.8 Terrace Levels: 2.8.1 The terrace levels shall be fixed based on the topography of the area and the filling/cutting requirements as well as road gradients. In general terrace levels shall be 150mm below the road top level. 2.8.2 In areas of rock outcrops/ cutting the surface shall be so chiseled so as to be aesthetically pleasing. 2.9 Finished floor levels: 2.9.1 In general finished floor levels of the building, sheds shall be determined with respect to top of approach road or pavement. Generally FFL shall be 60mm above terrace levels near the building or as indicated in the drawings. 2.10 Steps/ Ramps: 2.10.1 Steps/ ramps shall be provided for access to the building/ sheds for pedestrian/ vehicular, equipment entry. Minimum 100 mm wide platform shall be provided in between entrance door and steps/ ramps. Following dimensions of steps/ ramps shall be adhered to; A C D head slope of ramp Maximum number of steps in one flight. 50 mm minimum Not steeper than 1:6 2 Nos. RCC structures and brick/ CC block infill walls
2.11 Walls: 2.11.1 Following shall be adhered to for wall material and thickness: 2.11.2 A External & Load bearing walls 200 mm solid block masonry B Fire wall (around transformers as 300 mm solid block masonry specified) C Internal partition wall 200/150 mm solid block masonry Note: 1. 150 mm thick partition walls shall be provided with 75 mm thick horizontal RCC bands at every 5th course. 157 | P a g e
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2. Wherever conduits or pipes are required to be concealed within partition wall, or boxes are to be provided, the wall thickness shall be increas increased suitably. 2.12 Doors: Doors shall be provided for access, security and safety at all entry & exit of rooms, functional areas and buildings. Sizes of the doors shall be determined on the basis of the following schedule: A B C D E Equipment, Panel area Other areas Minimum entrance door size WC, Bath cubicle door(min) Minimum size of other doors Size of maximum equipment including packing. Volume of movement through the door. 1500mm x 2100mm (wall opening size) 750 mm x 2100mm (wall opening size) 1000mm x 2100mm (wall opening size)
Note: 1. Normally entrance doors shall be provided covering full width of the entrance lobby. In that case the door shall be of composite type consisting of openable shutters & fixed portions. 2. Rolling shutters shall be provided wherever area requirement of openable shutters exceed 2500 x 2500 mm. 3. Mechanically operated rolling shutters shall be provided for all opening sizes. 2.13 Windows/ Ventilators: 2.13.1 Windows/ Ventilators shall be provided in all areas for natural lighting, ventilation and visibility at working level. 2.13.2 For the purposes of ventilation, total openable areas of the windows/ ventilators shall be as per Factory act, subject to a minimum of 15% of the floor area to be ventilated. However, for non-process process Control Room, security block, Gate Houses and in Office areas, etc. where visibility from inside is of prime importance, increased window areas shall be provided. Areas accommodating panels/equipments shall be normally provided wit with h ventilators at high level for unobstructed distribution of lighting. 2.13.3 Issue counters wherever required shall be provided with separate sliding/ hinged shutters and peep holes in the glass at appropriate height. 2.13.4 For height more than 4000 mm additional window/ ventilators shall also be provided 158 | P a g e
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to ensure minimum illumination & ventilation at every level of the building/ shed. In case of walkway/ gangway, etc. windows/ ventilators at working levels shall be provided in the same manner as at working area. 2.13.5 Wherever due to limitation of external wall area or any other reasons, stipulated area of Windows/ Ventilators cannot be provided, suitable mechanical/ electrical devices shall be provided. 2.13.6 Fly mesh shutters shall be provided fo for r Pantry & Dining hall Windows/ Ventilators. 2.14 Canopy/ Overhang: 2.14.1 Canopy/ overhangs shall be provided at all entries and exist for rain & sun protection, accentuation of entry/ exit and movement from or to parked vehicle. Size of the overhang shall sh be decided based on the aesthetics of the building/ shed subjected to minimum 1200 mm. 2.15 Shading devices shall be provided over all windows, openable ventilators for rain & sun protection. These devices shall be in form of horizontal projections, v vertical projected fins or combination of both as per building faade treatment. Minimum projection shall be 750 mm. The top surface of the shading devices shall be finished with cement plaster mixed with water proofing compound (laid to slope) and shall be provided with GI/PVC spouts. Roof projection shall be provided wherever feasible for at least 750 mm. 2.16 Parapets shall be minimum 300 mm high for non non-approachable approachable roof. In case of future expansion, GI/ MS railing may be provided. 2.17 PVC Rain water pipes, spouts shall be provided for roof water drainage. Number of rain water pipes shall be decided on the basis of roof area., slope and rainfall intensity. Rain water pipes shall be provided with bottom shoes and drain channels leading to surface drains. drains 2.18 Entrance lobby & corridors: 2.18.1 Entrance lobby shall be provided as a common entrance for such buildings/ sheds accommodating separate or similar functional spaces integrated together. Individual entries to such functional spaces shall be from this lobby by means of passages/ corridors. Apart from common entry lobby, separate independent entries to these functional spaces shall be provided if required. 2.18.2 Passages/ corridors shall be provided to integrate various spaces. Width of the passages/ ges/ corridors shall be as per following schedule: 159 | P a g e
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A B C D Singly loaded passage/ corridor Doubly loaded passage/ corridor Stores etc Minimum 1200 mm Minimum 1800 mm As per movement requirements
2.19 Air lock lobby: Air lock lobby shall be provided for all entry and exit of Air-conditioned Air space. However air lock lobby may be avoided in case of small Air Air-conditioned conditioned habitable spaces. 2.20 Emergency exits: Emergency exits shall be provided for all the building/ sheds as per Factory acts. Emergency exits for individual functional spaces such as console area, cable cellar, and switchgear rooms shall also be provided. Emergency exits shall be located in such a manner that the escape route is direct, unobstructed and without passing through any an other function areas to safe area. Corridor/ staircases shall be provided as escape route to the emergency exits. 2.21 False ceiling: false ceiling shall be provided for the following purposes wherever required. A B C D 2.22 False Flooring/ cavity floor: False floor/ cavity floor shall be provided to accommodate under floor cabling in instrumentation console, rack, UPS room, etc. 2.23 Plinth protection: Plinth protection shall be provided to all buildings/ sheds with minimum 1000 mm width and sloped towards drain arou around the building. 3.0 ARCHITECTURAL FINISHES 3.1 All architectural finishes shall be as per specifications, standards and approved list of vendors. 3.2 Colour scheme for all architectural items shall be as approved by Consultant/ Owner. To reduce the volume and hide ducting etc. for Air-conditioned space. To maintain acoustic level inside any space To reduce habitable room, corridor, lobby, toilet heights located in high ceiling building/ shed to minimum 3000 mm
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3.3 All building elements i.e., floor wall, ceiling, roof, doors, & windows, etc.shall be provided with architectural finishes as shown in the building drawings. Wherever the finishes are not mentioned, the following finishes shall be followed: 3.3.1 Floor finish Sl. No A B C D E F G Building/ room/ area Control rooms, UPS room etc. Entrance, Conference rooms, Office rooms, Corridors, etc. Change rooms, Documentation rooms, etc. Equipment rooms, service rooms, pump houses, etc. Stores Toilets Battery rooms Finish False flooring Marble stone/ Vitrified ceramic tile (mirror polish) Terrazzo tiles. Heavy duty cement concrete flooring Granolithic floors. Antiskid ceramic tiles and matching ceramic tile dado (2.1m ht.) Alkali/ acid resistant flooring & walls as per Requirements
Note: 1. Skirting shall be provided in all areas. Cement plaster skirting shall be provided in areas having cement concrete granolithic/ heavy duty cement concrete flooring. For other areas, skirting shall be of same material as that of the floor. Skirting shall be of 125mm ht. minimum for cement skirting and terrazzo tiles and 100 mm for ceramic tiles. 2. Panel dividers shall be provided in cement concrete flooring. 3.3.2 Wall finishes & roof treatment. Sl. Surface No. A Internal finishes of all buildings A Control room, Office room, Conference room, Labs, entrance foyer, etc. B Change rooms, documentation rooms, stores, Panel rooms, etc.. B Exterior finishes A Admin building B All other buildings C Roof treatment
Finish
Plastic emulsions paint over 12 mm thick cement plaster. Acrylic washable distemper r over cement plaster
Exterior emulsion paint. Water proof cement paint. 161 | P a g e
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A B Flat roofs Slopped roofs Polymeric water proofing membrane over screed (average 75mm thk.) Mangalore pattern tiles over water proof cement plastering.
4.0 ANALYSIS & DESIGN 4.1 Analysis and design of buildings/facilities shall be done as per good engineering practices by experienced personnel. All data required for checking of analysis and design shall be properly documented and readily available. Cross Cross-references references to relevant data and clauses of codes shall be explicitly mentioned at every stage. 4.2 Design and construction of buildings, structures shall take into account requirements of o operation and maintenance of all equipment and its users. All the design work shall be carried out as per latest IS codal requirements. The buildings shall have good architectural features. 4.3 The tenderer is free to use Staad Pro software for the purp purpose ose of analysis. However detailed working of design shall be submitted based on the results of analysis. The tenderer shall be solely responsible for the analysis results and the design notwithstanding the approval accorded by the Consultant. If in the opinion nion of the consultant the results are not satisfactory, alternate method of analysis and design shall be used with the approval of Consultant. 4.4 Preliminary soil investigation of site indicate that ordinary spread footing/raft will suffice for various structures. However, the tenderer shall carryout his own soil investigation and satisfy himself on the characteristics of soil and type of foundation system to be provided. No claim shall be entertained on account of ignorance of soil characteristics. 5.0 LOADS AND LOAD COMBINATIONS 5.1 General 5.1.1 All structures shall be designed for the most critical combinations of different loads. The loads shall include, dead loads, imposed loads, equipment loads, crane loads, slurry piping (static & dynamic) and other piping loads, wind loads, seismic loads, temperature loads, Blast loads, forces developed due to differential settlement and any other loading conditions which can occur during the design life of the facility. All codes and standards referred are the latest editions/ revisions along with amendments if any. 5.2 Dead loads 162 | P a g e
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5.2.1 Dead loads consist of the weights of the complete structure with finishes, fixtures, partitions, wall panels and all equipment of semi semi-permanent permanent nature including tanks, bins, partitions, artitions, roofing, piping, cable trays, bus ducts etc. The content of tanks, silo, bins and hoppers etc. shall be measured at full capacity for this purpose. 5.2.2 The piping loads, cable tray loads and the contents of the tanks, bins and hoppers shall be b listed separately so that they can be excluded from dead load when dead loads are acting as stabilising load for uplift. 5.2.3 The following unit weights of materials shall be considered for computing loads. Loads given in IS: 875 (part-I) I) shall be made use of for the material not listed below. Materials Unit weight Plain cement concrete : 2.40 t/cum Reinforced cement concrete: 2.50 t/cum Structural steel : 7.85 t/cum Cement plaster : 2.10 t/cum Floor Finish : 2.40 t/cum 5.3 Imposed loads : 5.3.1 Imposed loads in different areas shall include live loads, dust loads loads, , minor equipment loads, cable trays, small pipe racks / hangers, erection loads, operation/ maintenance loads, etc. The loads considered shall not be less than that specified in IS: 875 (Part II). The loads listed hereunder are the minimum loads for the areas involved. Special use areas shall be investigated and loads revised upward as necessary. Floors and supporting members which may be subjected to heavy equipment live loads shall be d designed esigned on the basis of the weight of equipment or specifically defined live loads, whichever is greater. 5.3.2 The specific minimum floor live loads are listed below Roofs: a) Flat Roof : 1.50 kN / sqm Main control room/ electrical buildings a) Control room floor : 10 kN / sqm b) MCC room : 15 kN / sqm c) Plant floors : 10 kN / sqm d) Switch gear room : 15 KN / sqm Other areas: a) RCC floors : 5 KN/sqm for amenities 163 | P a g e
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Building and general floors b) Toilet : 2 KN / sqm 5.3.3 Culverts and allied structures including RCC pipes shall be designed for Class AA loading and checked for Class A loading as per IRC standards. 5.3.4 Covers for trenches & channels, which are not exposed to vehicular traffic, shall be designed for live load of adjoining area or 2 t / sqm whichever is higher. Where covers for trenches and channels are likely to be exposed to vehicular traffic, the requirements of code of practice for road bridges shall be adhered to. 5.3.5 In addition to the live loads, a minimum of 0.50 kN / sqm s shall hall be considered as Hung loads for electrical, ventilation & air conditioning. Load of 1.0 kN / sqm shall be considered as Hung loads for piping unless otherwise mentioned. 5.3.6 Live load reduction shall be in accordance with the provisions of IS:875 and a IS:1893 in case of seismic analysis. 5.4 Earth pressure loads 5.4.1 Earth pressure for all underground structures shall be calculated using coefficients of earth pressure at rest, coefficient of active or passive earth pressure (whichever is applicable). applicabl However, for design of cold-water water basin of cooling towers and under ground liquid storage tanks earth pressure at rest shall be considered. Temperature stresses shall also be considered for tanks subjected to the same like hot water storage tank. 5.4.2 In addition to earth pressure and ground water pressure, etc. a minimum surcharge load of 2.00 t/sqm shall also be considered for the design of all underground structures including channels, sumps, cable and pipe trenches, etc. to take into account t the he vehicular traffic in the vicinity of the structure. 5.5 Wind load 5.5.1 Wind load on structures shall be calculated as per provisions of IS: 875 (part 3). The wind shall be assumed to blow in any direction and most unfavourable condition shall be considered for design. 5.5.2 In design of structures, wind force on equipment supported on frame including all fixtures, piping, staircases, ladders, handrails, etc. shall also be considered. 5.6 Seismic loads 164 | P a g e
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5.6.1 Seismic analysis using response spectrum m method as per IS:1893-2000 shall be done. 5.7 Equipment loads 5.7.1 Static and dynamic loads of major equipment shall be based on the manufacturers data of the specified equipment and shall be considered in design in addition to the live load. 5.7.2 All equipment, tanks and piping design loading shall include hydraulic test loading. Weight of equipment, ducts, tanks, pipes, conduits, etc. supported by structure shall include maximum possible loading conditions i.e. flooded conditions and associated impacts, impac test loading, anchorage and constraint effects. 5.8 Other loads 5.8.1 Stresses imparted to structures due to differential settlements, variation of water table, erection and maintenance loads, creep and shrinkage shall also be considered in design of all structures. 5.9 Basic load cases 5.9.1 The following basic load cases shall be considered for the analysis as a minimum: i) Dead load : D ii) Self weight of permanent equipment EL iii) Live load on floor/walkway :L iv) Live load on roof :LR v) Crane load with lift :CR1 vi) Crane load without lift :CR2 vii) Wind load : WL viii) Seismic load : SL ix) Load due to soil pressure :SP x) Load due to surcharge SCL xi) Load due to hydrostatic pressure:HP xii) Load due to temperature :TL xiii) Special loads : SPL xiv) Blast loads BL 5.10 Load combinations 5.10.1 The individual members of the frame shall be designed for worst combination of forces such as bending moment, axial force, shear force and torsion. Permissible stresses for different 165 | P a g e
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load combinations tions shall be taken as per IS:875 (Part (Part-V) V) and other relevant IS code. Wind and seismic forces shall not be considered to act simultaneously. 5.10.2 Criticality of erection / maintenance loads shall also be checked separately in combination with other simultaneously multaneously occurring loads for possible design loading. 5.10.3 Load combinations for underground structures 5.10.3.1 Following loading conditions shall be considered in addition to the loading from super structure for the design of sub structure of cha channels, nnels, sumps, tanks, trenches and other under ground structures. 5.10.3.2 Only liquid pressure from inside and no earth pressure and ground water pressure and surcharge pressure from outside (applicable only to the structures which are liable to be filled with water or any other liquid). 5.10.3.3 Earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside. 5.10.3.4 Design shall also be checked for buoyancy due to ground water during construction and operation on stage. Minimum factor of safety as per IS:3370 against buoyancy shall be ensured considering empty condition ignoring superimposed loads. 6.0 DESIGN & DETAILING OF STRUCTURES AND FOUNDATIONS 6.1 General 6.1.1 All structures, building foundations, machines / equipment foundation, water retaining structures, trenches, pits, etc. shall be designed as per latest relevant IS codes in general. Construction in general shall follow provisions of IS:456 2000 and IS: 3370 for normal and liquid retaining structures ructures respectively. 6.1.2 All designs of RCC structures shall be carried out by limit state method as per IS: 456 2000 unless use of working stress method is specifically mentioned. Design strength of materials and design loads shall be calculated us using ing appropriate partial safety factors over characteristic strength and characteristic loads as per IS: 456 2000. 6.1.3 For reinforcement detailing IS: 5525, SP: 34 and IS: 13920 shall be followed. 6.1.4 The walls shall be provided with reinforcement o on n both faces for sections 150 mm or more, even if not required from design consideration. 166 | P a g e
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6.2 Foundations and Underground Structures 6.2.1 Type of foundation system, i.e. isolated, strip, or raft shall be decided based on the loading arrangement, load intensity tensity and soil strata. Design of foundations at various levels shall be dependent upon the soil bearing capacity at that level. 6.2.2 Foundation system adopted shall ensure that settlement / relative settlement is as per provision of IS: 1904 and other Indian Standards. However, the settlement shall be restricted to a lower value, if necessary as per the system requirement. 6.2.3 All foundations including machine / equipment foundations shall be of RCC Construction. All foundations shall be designed in accordance with relevant parts of the latest revisions of Indian standards IS: 2974 and IS: 456. Raft foundations shall be designed as per IS: 2950. 6.3 Liquid Retaining Structures 6.3.1 RCC liquid retaining structures like storage tanks, over head water tank etc. shall be leak proof and designed as untracked section in accordance with IS:3370 (Part 1 to IV) by working stress method. 6.3.2 All liquid retaining / storage structures shall be designed assuming liquid up to the height of wall irrespective of provision of any over flow arrangement. No pressure relieving devices shall be permitted in underground structures. 6.3.3 In all liquid retaining structures, PVC water bar shall be provided at each construction / expansion joint. The sequence of construc construction tion shall also be specified on drawings showing construction joints. 6.4 Machine Foundations 6.4.1 The design of machine / equipment foundation shall be as per IS: 456 and IS: 2974. 6.4.2 All machine / equipment foundations and structures subject to vibrations shall be suitably proportioned so that amplitude and frequency of the foundation / structures are within permissible limits. 6.4.3 In all block foundations resting on soil, the mass of the RCC block shall not be less than three times mass of the e machine. Dynamic analysis shall be carried out to calculate natural frequencies in all modes including coupled modes and to calculate vibration amplitudes. 167 | P a g e
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Frequency and amplitude criteria as laid down by the relevant codes or machine manufacturers shall be satisfied. Minimum reinforcement shall be governed by IS: 2974 and IS:456. 6.4.4 For the foundations supporting minor equipment weighing less than one ton or if the mass of the rotating parts is less than one hundredth of the mass of the foundation, no n dynamic analysis is necessary. However, if such minor equipment is to be supported on building structures, floors, etc. suitable vibration isolation shall be provided by means of springs, neoprene pads, etc. and such vibration isolation system shall be d designed esigned suitably. 6.4.5 Pumps, ID fans shall be supported on conventional framed / block type RCC foundations. 6.4.6 All such foundations shall be separated from adjoining parts of building and other foundations. Joints at floor / slab shall be suitably sealed. All appendages to such foundations shall be reinforced suitably to ensure integral action. 6.5 Increase in Stresses 6.5.1 Where stresses due to wind (or seismic) and temperature are combined with those due to other loads, the allowable stresses i in n concrete and reinforcement steel shall be as per relevant Indian Standards in case of working stress design. However, where the wind load is the predominant load on the structure, no increase in permissible stresses is allowed in case of working stress design. 6.5.2 Bearing capacity of the soil shall be allowed to increase by 25% under wind load condition. Increase of bearing capacity under seismic conditions shall be as per IS:1893. 6.6 Stability of Structures 6.6.1 Design shall be checked against buo buoyancy yancy due to the ground water during construction and maintenance stages for structures like underground storage tanks, pits, trenches, etc. Minimum factor of safety of 1.2 against buoyancy shall be ensured considering empty condition inside and ignoring the he superimposed loading. For purpose of calculating downward load due to any overburden, only the mass located vertically above the projected area of the base slab shall be taken in to consideration. 6.6.2 All building sub-structures structures including pump houses / retaining wall shall be checked for sliding and overturning stability during both construction and operating conditions for various combination of loads. Factor of safety for these cases shall be taken as mentioned in IS: 456 and other latest relevant IS S codes. However, following minimum factor of safety shall be followed: 168 | P a g e
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a) Factor of safety against overturning due to wind, seismic or other lateral load shall be 1.5 minimum b) Factor of safety against sliding shall be 1.5 minimum c) Factor of safety against uplift due to hydrostatic forces shall be 1.2 and due to any other loads shall be 1.5. 6.6.3 In cases where dead load provides the restoring force, only 0.90 times characteristic dead load shall be considered. Imposed loads shall not be considered as restoring force. 6.7 Minimum. Thickness of concrete structural elements 6.7.1 The following minimum thickness shall be followed: a) Suspended floor / slab / walkways /canopy slabs, etc.: b) Ground floor slab (non-suspended) suspended) c) Water retaining slabs / walls, buildings walls d) Cable/pipe trenches/underground pits/ launder walls and base slab e) All footings (including raft foundations) f) Parapets g) Sunshades at edge h) Precast louvers / fins i) Precast trench cover slabs / floor slabs / louvers 200mm : 150mm : 200 mm : 125mm :400mm : 125mm : 75mm : 50mm : 75mm
6.7.2 From fire resistance point of view minimum thickness of reinforced concrete members shall be as per IS: 456 - 2000. Minimum fire rating of 2 hours shall b be e considered where fire hazard is expected. 6.8 Minimum heights for pedestals of steel columns: 6.8.1 Top of RCC foundations (pedestals) shall normally be kept at a lower level so that the column base plates together with gussets and stiffeners remain be below low finished floor level (FFL) unless otherwise specified. Encasing of pedestals for steel columns shall be done, wherever required, as per Clause No. 6.9. Foundation levels for columns shall be decided to accommodate underground services, pits, trenches, etc. 6.8.2 Stair and ladder pedestal shall be kept 200 mm above the finished floor level. 6.8.3 Pedestals of steel columns for equipment structures: 169 | P a g e
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a) Equipment in open area as required (300mm min) b) Equipment in covered area as required (150mm min) c) Structures and equipment Supplied by vendor as per vendors data subject to minimum as specified above 6.9 Minimum heights for encasement of steel columns 6.9.1 In case the top of pedestal is kept at a lower level so that the column base plate together tog with gussets and stiffeners remain below finished floor level (FFL) the column bases as well as the column sections shall be encased in concrete, above FFL as per following: a) Open area: 300mm above paved level b) Covered area: 150mm above FFL The size of encasement shall be equal to the size of RCC pedestal. 6.10 Concrete mix 6.10.1 Cement used shall conform to the following standards: standards:- 43 Grade Ordinary Portland Cement IS: 8112-1989 6.10.2 In case the chemical nature of the soil warrants specia special l cement the same shall be used for structures below ground level 6.10.3 The proportions for nominal mix of concrete shall be as per Table 9 of IS: 456. nominal mix in concrete shall be allowed for grades up to M 10 only and all other grades of concrete shall be with Design Mix concrete in accordance to IS:456 and SP:23. 6.10.4 The concrete grade used for different structures shall be as follows. M5 Fill concrete M7.5 leveling course of foundations, trenches and underground structures. M10 Foundation below concrete block wall, RR masonry walls. M15 Pavement around buildings including plinth protection work, damp proof course below concrete block work, Base plate encasement, encasement of structural steel work, block area paving, screed concrete, etc. M20 20 Reinforced concrete work non plant buildings M25 Reinforced concrete work for plant buildings foundations, framed structure, underground structure, Equipment foundations, water retaining structure etc. as per design requirement. M30 Pre cast elements 170 | P a g e
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6.10.5 Minimum cement content, maximum water cement ratio, and minimum grade of concrete shall be considered as per IS : 456 for moderate exposure condition. Weigh batching plant shall be mobilized for all types of RCC works. 6.11 Reinforcement steel 6.11.1 1.1 Reinforcing bars for concrete shall be TMT bars with strength requirements conforming to IS: 1786-1985 1985 of Grade Fe - 415 from SAIL / TISCO / RINL 6.12 Grouting 6.12.1 Non-shrink shrink flowable grout shall be used for under pinning work below base plate of columns. Non-shrink shrink cum plasticizer admixture shall be added in the grout. For grouting the base of machine foundation, high strength ready mixed non non-shrink shrink flowable grout shall be used. 6.12.2 Crushing strength of the grout shall generally be one grad grade e higher than the base concrete. Minimum grade of grout shall be M 30. 6.12.3 Nominal thickness of grouting shall be at least 50mm for building columns and pedestals of major equipment. For secondary posts, stair and ladder base etc,. grouting shall not be less than 25mm thick. 6.13 Foundation bolts and insert plates 6.13.1 Minimum distance from the anchor bolt to the edge of pedestal shall be the maximum of the following: 6.13.2 Clear distance from the edge of base plate / base frames to the outer edge of the pedestal shall be minimum 50mm. 6.13.3 Clear distance from the face of pocket to the outer edge of pedestal shall be 75mm. 6.13.4 Clear distance from the edge of sleeve or anchor plate to the edge of pedestal shall be 75mm. 6.13.5 Steel templates s shall be used for placement of bolts in position in all types of foundations. Foundation bolts and pockets shall be pre pre-fabricated, fabricated, before placing them in position.
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6.13.6 Anchor bolts shall be designed for working stress, in tension, shear and for required requ embedded length in concrete. Shear and crushing strength of concrete shall also be checked. Increase in allowable stress for loading including seismic and wind loads shall not be permitted in design of anchor bolts. 6.13.7 Insert plates shall be designed/checked for shear and bending moment. All lugs shall be checked for tension. Bond strength of concrete shall also be checked. Lugs using steel bars shall preferably be fillet welded to the plate to transfer full strength of the lug.
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18. STEEL STRUC STRUCTURAL WORKS
1 SCOPE OF WORK The scope of structural steelworks includes (but is not necessarily limited to) the following: Steel Structural building works pertaining to the following units of Thermal Power Plant & Steam Generation: i) Steam turbo generator or sets 1 x 30 MW Nb: Upto the height of 8.5 metre level R.C.C. Structures 8.5 metres & above Steel Structures Roofs of the building shall be of precast R.C.C.slabs/Cast R.C.C.slabs/Cast-in-situ situ R.C.C.slabs supported on Steel Structural beams, i) Preparation and supply of f general arrangement drawings with basic design loads, all necessary design calculations, design drawings, shop detail drawings, erection drawings, material lists and dispatch documents for the steel structures. ii) Supply, fabrication, shop painting, tr transportation, ansportation, delivery, storage of all steel structures and sheeting/glazing including site bolts, electrodes, sheeting fixtures and all consumables etc., complete in all respects. iii) Erection of structures including transportation handling at site incl including uding alignment, bolting, welding, etc., and sheeting / glazing including arrangement of tools, tackles etc., necessary for erection, complete in all respects. iv) Supply and painting of structures after erection. 2 DESIGN PARAMETERS 2.1 LOADING The superimposed erimposed loads to be considered in the design of steel structures shall be as per IS: 875 1987 Part-II, II, in conjunction with technological loads wherever applicable. Wind loads, wherever applicable shall be as per IS: 875 1987 Part-III. Earthquake loads shall be as per IS: 1893 (Latest) 2.2 DESIGN The steel structures shall be designed conforming to relevant safety regulations and as per National standards and codes of practice in addition to the technological loads. Structures shall be designed to harmonize in external appearance with adjacent stru structures.
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All crane girders and supporting structures shall be designed for loads from the EOT cranes in the most unfavorable loading position. All staircases shall have a minimum clear width of 800 mm with treads formed from chequered plates for indoor staircases taircases or gratings for staircases exposed to rain. The slope of the staircases shall be 38 degrees with respect to the horizontal. Minimum headroom of 2. 2.2 metres shall be ensured while planning the staircases. No staircase shall rise more than 3.0 metres metre vertically in any one flight. In addition to the staircases, suitable cat ladders with safety cages shall be provided wherever necessary. Clear width of ladder shall be 550 mm. Landing Platform shall be provided at every 3 m rise. nsist of top, mid rail and posts of M.S tubes and flat toe plates of 150 mm Hand railing shall consist width. Top rail shall be 1100 mm above floor level. 3 METHOD OF CONSTRUCTION Unless specified otherwise, steel structures shall generally be of welded Construction. Welding may by means of manual metal arc welding or submerged arc welding. The welding electrodes shall be of approved and reputed manufacturers. Black bolts may be used for holding in position prior to welding. The erection bolts shall be retained in position after welding. wel Where welding is specifically ruled out, connections shall be by means of turned and fitted (Grade 4.6) or high strength bolts (Grade 8.8 or 10.9) spring washers / antivibration nuts / washers shall be used for supporting vibrating equipment. 4 MATERIAL RIAL OF CONSTRUCTION The material of construction shall be Mild steel conforming to Fe 410 WA (IS: 2062 - Grade A ) for all rolled sections and plate thickness less than 20 MM and Fe 410 WB (IS : 2062 Grade B) for thickness equal to or exceeding 20 MM. Ele Electrodes ctrodes , bolts nuts and washers shall conform to relevant IS codes. Only tested material shall be used and all test certificates submitted by the contractor unless written authority by the Owner/Engineer is granted for use of untested material for specifically specif mentioned structures. In case of non - availability of sections substitution shall be made with prior approval of the owner / engineer at no extra cost for such substitution. 5 FABRICATIONS, ERECTION AND INSPECTION Fabrication and erection shall co conform nform to IS: 800 and other relevant standards referred to herein. Standard tolerances for fabrication and erection as set out in relevant IS codes shall apply. Where no IS Standards exist, American, British or German Standards shall apply. 174 | P a g e
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All steel structural tural work shall be subject to inspection by the owner/ engineer before erection. All butt welds shall be tested ultrasonically. Additionally 2 % of the butt welds shall be tested radio graphically. The welds to be tested by Means of radiography shall be i identified dentified by the Owner or the Consultant. The inspection personnel shall be at liberty to reject whole or part of any work or material that does not conform to the specification and may order such work /works to be removed, replaced or altered at the expense nse of the contractor. Tanks should be tested for leakage at the ground before erection as per relevant Indian Standard or equivalent. 6 ROOF AND SIDE CLADDING WITH CGI SHEETS Procurement and supply of sheets of all gauges and sizes, flashings and fittings like corner pieces, apron pieces, ridges, cutting and bending of sheets wherever required; J hooks , bolts ,nuts, washers, bitumen washers , drilling of holes all as per specification and drawings. 7 PAINTING SYSTEM All the fabricated structures will be subjected to the cleaning and preparation of all steel surfaces to Swedish Standard ST ST-3 3 for painting, supply and application of 2 coats Zinc Phosphate in phenolic alkyd medium of 40microns DFT each. Intermediate painting one coat of synthetic MIO of 75 microns DFT Each. Finishing painting of two coat of synthetic enamel of 25 microns DFT each shall be applied one before erection and one coat after Erection. Total thickness of paint shall be 205 microns DFT.
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19. SPECIFIED DATA SHEETS FOR ELECTRICAL
19.1 SPECIFIED PECIFIED DESIGN DATA GENERATOR GENERATOR
DESCRIPTION Rated Output No. of Generators Max. system Voltage UNITS MW Nos. KV 30 1 11 11/13.8 kV 5%, 50 Hz, 3% (when running in independent mode) While running in parallel mode with grid, the generator shall be able to with stand voltage variation of 10% and frequency variation of 5%. 2 120% of rated speed Cos % % 0.8 Bidder to furnish. (shall be minimum 22) Bidder to furnish. Closed air circuit ventilation with intermediate cooling water system/ or Hydrogen cooled C Bidder to furnish Air cooled closed circuit (CACW) /Hydrogen Class `F' with temperature rise limited to `B'. Not less than 0.5 Brushless with static rotating Rectifier DATA
Rated Terminal Voltage & Frequency
Volt & Hz Nos.
No. of poles Over speeding capability Rated Power Factor Direct axis saturated sub-transient reactance (x"d) Negative sequence and zero sequence reactance Cooling Maximum auxiliary cooling water temperature Stator core and rotor Insulation Class of Generator & exciter Short circuit ratio Type of excitation
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Applicable standard Excitation system response ratio Protection class of Generator and Exciter Automatic Voltage Regulator( 1 x 100% ( independent Auto and manual) Voltage range of electronic voltage regulator Type Accuracy Response time Quantity % % m sec Nos. IEC 34/IS-5422 1.0/ Sec. IP 54
Automatic channels with manual tracking.
12% Digital microprocessor based 0.50% 20 1
19.2 SPECIFIED DESIGN DATA TRANSFORMER TRANSFORMER

DESCRIPTION Type Number of transformers Rated output No-load voltage ratio Frequency Impedance (nominal pos.) at Max. rating Vector group Type of cooling Connections H.V. ( 132kV) L.V. ( 11kV) HV neutral OCTC range Temperature rise of oil over 50C Temperature rise of windings over 50C UNITS 3 Phase MVA kV/kV Hz % DATA Oil transformer with atmoseal type conservator 1 100/110 11 / 132 50 15.625 ( With no negative tolerance) YNd11 ONAN /ONFA/FA FO YNd11 O/H WIRE Bus duct SOLID grounding 10%, in step of 2.5% 50 55
C C
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II) Unit Aux. Transformer/Station transformer Type Number of transformers Rated output No-load voltage ratio Impedance at max. rating (Nominal Position) Vector group Type of cooling On load tap changer range Frequency L.V. Neutral grounding Connections HV LV Temperature rise of oil over 50C Temperature rise of winding over 50C I) Station service Transformer Type Number of transformers Rated output No-load voltage ratio Frequency Impedance (nominal pos.) at Max. rating Vector group Type of cooling Connections H.V. ( 6.9kV) L.V. (415V) LV neutral OCTC range Temperature rise of oil over 50C Temperature rise of windings 3-Phase Phase Nos. MVA kV/kV %
Unit Aux. Transformer Oil transformer with atmoseal type conservator 1 10 11 / 6.9 10% Dyn1 ONAN / ONFA 10 % in steps of 1.25% 50 5% Resistance earthed Bus duct Cable C C 50 55
Station transformer Oil transformer with atmoseal type conservator 1 10 132 / 6.9 12.50% YNyn0d11 ONAN /ONFA 10 % in steps of 1.25% Resistance earthed O/H WIRE Cable 50 55
Hz
3 Phase MVA kV/kV Hz % -
Oil transformer with atom seal type conservator 2 1 6.9/0.433 50 Bidder to specify YNd11 ONAN YNd11 Cable Bus duct SOLID grounding 5%, in step of 2.5% 50 55
C C
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over 50C
19.3 132 kV SWITCHYARD EQUIPMENT Technical Requirements of 132 kV IsolatorRating

DESCRIPTION Application Type DATA outdoor type Centre rotating, single/double breaks/type. 132 kV nominal/ 145 kV rated 50Hz 3 ph 2000 A / 2000 A
Nominal / Rated Voltage Frequency No. of phases Rated current for site conditions Short time current Rating and duration Rated peak short circuit current (peak)
40 kA for 3 sec. 100 kA peak
Design Requirements
DESCRIPTION Ambient temp. Phase spacing Mounting Main blade material Operating device For isolator & emergency For earth switch 415V, 3ph Motor driven manual manually /motor operated DATA 50 C 4000mm Horizontal upright. Electrolyte grade copper or high Conductivity AL
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Insulation Level
DESCRIPTION Rated voltage 1.2/50 sec lightening impulse voltage withstand : :Phase to earth Across Isolating Contact 1 minute power frequency with stand voltage: voltage:Phase to earth Across Isolating Contact 275 kV rms 370 kV rms Minimum 31mm per rated Kv rms L-L For very Total Cree page distance for insulator heavy polluted atmosphere. 650 kV peak 750 kV peak DATA 132 kV
not less than 50 % of total Cree page Protected Cree page
Miscellaneous
DESCRIPTION Aux. supply 220V DC for control and interlock;415V AC 3ph Electrical for motor drive DATA
Interlock with circuit breaker Number of N.O. & N.C aux.contacts Rating of Aux. contacts
Necessary to be provided 10NO+10NC for main switch 10NO+10NC for earth switch 10 A at 220 V DC
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Operating mechanism box with all accessories such as local - remote selector switch, open close push button, open/close indicators, reversible starter with O/L relay, single phasing Mechanism box preventer, motor, fuses, aux. contactors etc. shall be housed in a weather- proof box conforming to IP 55 protection made of sheet steel (thickness not less than 2.5 mm), thermostat controlled space heater with ON / OFF switch hall be provided. Painting shall all be shade 631 of IS: 5. Supporting Hot dip galvanized structures lattice type shall be provided. Each isolator pole and Earth Switch operating Earth pads mechanism shall be provided with 2 nos. grounding pads with 2 nos. M10 bolts. Grading ring Applicable Standards To be provided (if required). a) Insulators IS: 2544 / IEC b) Isolators IS:9921/ IEC 129
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The 132 kV Nominal rated circuit breakers shall comply with following requirements:
Description Application & No. Of Phase Type Rated voltage / frequency Rated current Short circuit breaking current & Duration Making current Operating duty/reclose duty 1.2/50 sec lightning impulse voltage withstands: Phase to earth Across Isolating Contact 1 minute power frequency with stand voltage: voltage:Minimum 31 mm per kV L-L L rms with Total Cree page / protected Cree page protected Cree page not less than 50% of total Cree page First pole to clear factor Small inductive current breaking Over voltage factor while switching off above current 1.3 To switch the associated transformers magnetizing currents. Not more than 2.3 p.u. Motor charged spring operated mechanism or Type of operating mechanism by a self contained pneumatic mechanism or by electro hydraulic mechanism. Operating mechanism to be suitable for Antidumping feature required No. of trip coils per pole 220 V DC voltages Yes 2 nos. 650 kV peak 750 kV peak Requirements Outdoor / 3 phases SF6 gas puffer type, Electrically trip free. 132 kV / 50 Hz 2000 Amps 40 kA for 3 sec. 100 kA (peak) 0-0.3 sec-CO-3 min-CO CO 0-3 0 min -CO-3 minCO (for none auto reclose duty)
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Phase to phase spacing No. of aux. contacts Rating of aux. contacts Environment at the location of installation Reference ambient temperature Gas evacuation & filling unit required Total break time (max.) To suit layout (3600 00 mm) 10 NO+10NC (min) 10 A at 220 V DC Polluted and dusty 50C Yes < 3 cycle Outdoor, weather & vermin proof, conforming to IP-55 55 degree of protection, sheet steel (2.5 mm thick) clad lad with hinged type front door with locking device, housing operating Control cubicle mechanism other controls/ selection such as Local-Remote Remote selector switch, Close-NormalClose Trip control switch, thermostat controlled space heater with ON-OFF OFF switch, all aux. contacts wired d up to terminal block with 20% spare terminals shall be provided. Hot dip galvanized supporting steel structures Support structures specifically designed for breaker mounting shall be supplied. Local test switch required Mechanical position indicator per pole required Operation counter required Control / Auxiliary power supply a. Control supply b. AC power supply Ear thing pads Each equipment shall be provided with 2nos. grounding pad with 2nos.M10 bolts. Yes Yes Yes 220 V DC 415 V 3 ph/240 V 1ph, 50 Hz
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Applicable Standards
Description Circuit breakers Insulators Large hollow porcelain insulators Hot dip galvanizing Spec. and acceptance sulfa Hexafluoride (Sf6) Requirements IEC-60056 IS: 2544 IS: 5621 IS: 2629, 2633 IEC 376, 376A & 376B
Technical Requirements for Current Transformers

Description Application Type Construction Nominal system voltage & Frequency Highest system voltage Current ratio/No. of cores Short time thermal rating Dynamic rating Class of insulation Maximum temp. rise of winding Cantilever strength of CT at the terminal Impulse withstand voltage 1 minute power frequency With stand Total Cree page distance for insulator Protected Cree page Requirements Outdoor Oil filled immersed hermetically sealed Live Tank. Single pole unit, upright mounting 132 kV, 50 Hz 145 kV As per single line diagram/Schedules 40 kA for 3 secs. 100 kA (p) Oil immersed class A 50deg C above ambient of 45 deg C 800 kg. To Be Assessed By Contractor 750 kV (p) 275 kV rms Minimum 31 mm per rated kVrms L-L For very heavy polluted atmosphere. not less than 50 % of total Cree page
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Oil level gauge, filling & drain Plugs pressure release device To be provided Weather-proof, proof, conforming to IP 55 degree of protection otection sheet steel clad minimum 2 mm with adequate number shorting type terminals. To be provided. To be provided. To be provided. 2 nos. to be provided with M10 bolts To be provided if required IS: 2075 & IEC 185 IS: 2099 IS 5621 & IS: 2544 IS: 335 IS: 2633 & IS: 2629
Secondary terminal box a) For individual CT b) Power factor testing terminals c) Common marshalling box for a set of 3 nos. CTs Grounding pads Grading ring Applicable standards Current transformers Bushings Large hollow porcelains insulators Insulating oil Hot dip galvanizing
Technical Requirements Capacitor Voltage Transformer:

Description Application Nominal/Highest system voltage Power frequency System neutral ear thing type Coefficient of ear thing Rated primary voltage Rated secondary voltage No. of secondary windings Application Rated burden Requirements Outdoor 132 kV / 145 kV 50 Hz Effectively earthed 0.8 132000 / 3 V 110 / 3 V Two Metering / protection 100 VA / 100 VA (To be calculated in Detail Egg)
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Rated power factor Accuracy class Rated voltage factor Class of winding insulation Max. Winding temp. at rated burden Total Creepage Protected Creepage 2/50 micro sec. impulse voltage One minute power frequency Voltage withstand One minute power frequency voltage For secondary winding Cantilever strength for insulators 0.8 0.2 / 3P 1.2 continuous & 1.5 for 30 sec. Oil immersed class-A Should not exceed IS limits minimum 31 mm per 145 kV not less than 50 % of total Creepage 750kV (p) 275 kV rms 2 kV 800 kg (To Be assessed by W.Pbox, conforming to IP 55 degree of protection, sheet steel clad (minimum 2mm thick) complete with fuse / MCB,terminals& wiring for neutral shorting and ear thing shall be provided. 2nos. M10 bolts
Secondary terminal box
Grounding pads Applicable standards a. Coupling capacitors and capacitor b. Capacitor voltage Transformer c. Bushings / insulators e. Insulating oil f. Hot dip galvanizing
As per IS standard IS: 3156 & IEC 186 IS: 2099, IS-5621, IS-2544 2544 IS: 335 IS 2629 & 2633
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Technical Requirements for Surge Arrestor
The surge arrestor shall comply with the particulars indicated hereunder.
Installation System voltage a) Nominal b) Highest Type of earthing Type of arrestor Rated arrestor voltage Rated frequency Nominal discharge current of 8/20 micro Second wave shape Performance Data Impulse current with stand a) Low current long duration discharge b) Virtual duration of rectangular wave c) Line discharge class (As per IEC TC 37 WG WG-4 1985) Arrestor Housing a) One minute power Frequency with stand voltage b) 1.2/5 micro second impulse Min. total Creepage Min Protected Creepage Minimum cantilever strength Minimum prospective symmetrical fault current (as per IEC 99) Accessories required a) Discharge counter b) Grading rings c) Leakage current detector d) Insulating base Applicable Standards a) Surge arrestor for alternating current systems Outdoor 132 kV 145 kV Effectively earthed Gapless To Be selected After insulation coordination and surge arrestor selection calculation in Switchyard contractors scope 50 Hz 10 kA
Class-3 2000 mic.sec Class-3
275 kV rms 750 kV (p) 31 mm per 245kV (minimum) not less than 50 % of total Creepage 800 kg (To be assessed by Contractor 40 kA for 3 sec Yes Yes Yes Yes IS: 3070
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b) Large hollow porcelain insulators IS 5621 & IS2544
Technical Requirements for Insulators and Hardware

Description Bus post insulator Type Rated Voltage/Voltage class a) Nominal System Voltage Minimum failing Load Unit Solid core KV KV KN Data
145 132 31 mm / rated kV L-L L (For Heavy Polluted Classification Of Site) > 50 % of Creepage distance 800
b) Total Creepage distance
mm
Protected Creepage Cantilever strength Withstand voltages a) Dry 1 min power frequency b) Dry 1.2/50micro sec. impulse c) Wet 1 min power frequency d) Wet 1.2/50micro sec. impulse Power Frequency Flashover a) Dry Flashover Voltage b) Wet Flashover Voltage Puncture voltage Disc Insulator Voltage class Type Creepage distance Electromechanical strength With stand voltages a) 1 min power frequency (dry) b) 1 min power frequency (wet) c) 1.2/50 micro sec impulse (dry) d) 1.2/50 micro.sec impulse (wet)
mm kg kV
kVp kV kVp kV kV 1.3 times corresponding flashover voltages. 11KV fog type 430 mm per disc 8200(min) kg 85 kV 50 kV 125 kV 125 kV
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Puncture Voltage Insulator string assembly Requirement in items 1.1 to 1.3, 1.5 & 1.6 above shall be complied with Applicable standards 1. Post insulators 2. Suspension insulators 3. Insulators fittings 4. Hot dip galvanizing process
1.3 times corresponding flash over voltage.
IS: 2544 IS: 731 IS: 2486 IS: 2629 & 2633
Bus conductors, clamps, connectors and hardware. As specified earlier, bus conductors of AAAC or Aluminum tube of required size shall be supplied. The clamps and connectors shall be suitable for the termination arrangement of the respective equipment. The hardware for the insulator string shall be suitable for the insulators ors chosen. All the equipment shall be smooth polished, and corona free.
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20. LIST OF APPROVED VENDORS
Following is the indicative list of vendors. Bidder to note that the prior approval shall be obtained from owner before placement of purchase orders.
Sl. No A A.1 Equipment / System MECHANICAL EQUIPMENT STEAM GENERATOR AUXILIARIES Steam Generator Burners and Associated System Vendor
Primary air / Induced Draft /Secondary Air Fans
3 4 5 6
Safety Valves for all systems. Attemperator Steam Trap and Strainers Valves (IBR) for all systems/applications.
Non IBR Valves for all systems/applications.
CS / SS SMLS Pipes and CS Tubes for all systems piping.
CS ERW Pipes for all systems piping.
10
Mechanical Seals
1. As per qualifying criteria 1. Coen Bharat 2. Air Oil 3. BHEL 1. FLAKT 2. Andrew Yule 3. BHEL 4. Reitz 1. BHEL 2. Tyco Sanmar 3. FaingerLeser 1. BHEL 2. Mazda 1. Greaves Cotton 2. Otokiln 3. Spirax 1. BHEL 2. L&T (Audio) 1. BHEL 2. KSB 3. L&T 4. BDK 1. BHEL 2. TISCO 3. Maharashtra Seamless 4. Jindal 1. SAIL 2. Ajanta Tubes 3. Jindal Pipes Ltd. 4. TATA 1. Sealol Hindustan 2. Dura Metallic (I) Ltd 3. Tyco Sanmar
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11
Oil Pumps (Screw)
1. Boremann 2. DELTA 3. ROTO 1. Techno Consultants, Mumbai 2. VK Pumps 3. Kishor Pump 1. Techno Consultants, Mumbai 2. VK Pumps 3. Kishor Pump 1. BHEL 1. JN Marshall 2. Reliance Heat Transfer 3. BHEL 1. KeldEllentoft 2. Bachman Industries Ltd. 3. Metallic Bellows 1. BHEL 2. Thermax limited 3. Alstom
12
Mechanical Agitators Chemical dosing system including dosing pumps Silencers Sample Coolers
13 14 15
16
Expansion Joints
17 A.2 1 2
ESP STEAM TURBINE AUXILIARIES Steam Turbine Lube Oil Pumps (Horizontal Centrifugal) Oil Vapor Extraction Fans Turbine oil Purification Equipment Feed Water Heaters Quick Closing Extraction Non Return Valves Deaerator
1. As per qualifying criteria 1. KSB, Pune 2. Sulzer, Mumbai 3. Kirloskar Ebara, Pune 1. Radiant Engg. Mumbai 2. C. Doctor, Ahmedabad 3. Ventura Fabrication, Mumbai 1. Alfa Laval 2. Penn Walt 1. L&T 2. BHEL 3. Deutsche Babcock 1. Hopkinsons, UK 2. BHEL, Trichy 1.L&T 2. BHEL 3. Deutsche Babcock 4.BGR 1. KSB Pumps 2. Sulzer
3 4 5 6
Condensate Extraction Pump
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3. Kirloskar Brothers 1. Sulzer 2. KSB Pumps 3. Kirlosker Ebara 1. GEA Cooling Tower, Chennai 2. Godavari 3. BHEL 1. Lloyd Insulation 2. Minwool Rock Fibres, Hyderabad 3. Khandelwal Insulations, Mumbai 1. FlenderGraffenStaden, France 2. Lufkin Industries, USA 3. MAGG Gear Co. Ltd., Ltd. Switzerland 4. RenkTackeReheine, Germany 1. Kop-Flex, USA 2. Flexibox, England 3. ZurnIndutriesinc., USA 1. Sulzer 2. Mather & Platt 3. SihiHalbergMachinenbau GMBH & Co., Germmany 4. Kirloskar Ebara, , Pune (through SIEBURG, Secunderabad) 1. Kirlosker 2. Delta Corporation Ltd., Mumbai 3. Hagllundsdension Ltd., Ltd. Hyderabad 4. Dynamitcs Hydraulic Ltd.,Bangalore 1. Tecno Consultants, Mumbai 2. Manoj Sales Corporation, Delhi 3. ENPRO Engineers, Pune
Boiler Feed Water Pump
10
Condenser and auxiliaries
11
Thermal Insulation and Cladding
12
Gear Box (Turbine+)
13
Couplings (Multi Membrane)
14
Lube Oil Pumps & Emergency Oil Pumps
15
Jacking Oil Pump
16 A.3
Chemical (LP) Dosing System BALANCE OF PLANT EQUIPMENT
Raw Water Pumps, Cooling Water Pumps, Water Treatment Plant Pumps & Pumps for all Balance of Plant
1. Sultzer 2. KSB 3. Mather & Platt
A.3.1
Material Handling System
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Coal
1. Elecon Engineering Co. Limited, VallabhVidya Nagar 2. TRF Limited Jamshedpur 3. Sayaji Iron & EngineeringLimited, Vadodara 4. L&T Limited 5. IC 6. McNally Bharat 1. Sayaji Iron & Engineering Limited, Vadodara 2. L&T Limited, Chennai 3. McNally Bharat 4. IC 1. Indiana Conveyors PrivateLimited, Mumbai 2. TecproSystems, New Delhi 3. EleconEngg. Gujarat, Gujarat 4. BHP, Gurgaon 1. Nirlon Limited, Mumbai 2. MRF Limited, Chennai 3. Hilton Limited, New Delhi 1. Greaves Cotton Limited, Mumbai 2. Elecon Engineering Limited, Limited VallabhVidyanagar 3. FMG Limited, Calcutta 4. New Allenberry IndustriesLimited, Calcutta 1. Greaves Cotton Limited, Mumbai 2. Voith 3. Elecon Engineering Limited, Limited VallabhVidyanagar 4. Fluidomat 1. Power Build Limited, Vallabh Vidyanagar 2. Shanti Gears Limited, Limited Coimbatore 3. New Allenbury Limited 1. Elecon Engineering Limited, Limited VallabhVidyanagar 2. Fenner (India) Limited, Chennai 3. GMB Mfg. (P) Limited, Calcutta 1. Hosch 2. Kaveri Ultra Polymers Limited, Limited Mumbai 3. Technofab Industries Limited, New Delhi 1. Electromag Devices, Mumbai
Vibrating Screen
Belt Conveyors
Belt
Reduction Gearbox
Fluid Coupling
Helical Geared Motors
Flexible Coupling
9 10
Belt Scrappers Thruster Brake
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2. Sterling Controls, Mumbai 3. Technocrats 4. Speed O Control 1. Thermax 2. Andrew Yule & Co. Ltd, Calcutta 3. ABB Limited 4. F. Harley & co. Calcutta 1. TPS Manufacturing Co. Ltd., Ltd. New Delhi 2. F. Harley & co. Calcutta. 3. Kaveri ultra polymers Limited, Mumbai 1. TRANSWEIGH 2. Jenson & Nicholson 1. Electromag Devices Limited, Limited Mumbai 2. Sterling Control Limited, Mumbai 3. Electrozovad Limited, Calcutta 1. Electromag Devices Limited, Limited Mumbai 2. Sterling Controls Limited, Mumbai 3. Electrozavod Limited, Calcutta 4. POWERBUILD 1. Electromag Devices Limited, Mumbai 2. Power build Limited, VallabhVidyanagar 3. Sterling Controls Limited, imited, Mumbai 1. Hosch / Tega 2. Kaveri ultra polymers 3. Scorpio Pune 1. Vega 2. E + H 1. AG Associates, Mumbai 2. Jayshree, Pune 3. Kana Electronic, Pune
11
Dust Extraction System & Bag Filters
12 13 14
Dust Suppression System On Line Belt Weigher Magnetic Separators
15
Electronic Metal Detector
16
Vibrating Feeders
17 18 19 A.3.2
Skirt sealing system Level Indicators Safety Switches (Belt Sway, Pull Cord, Zero Speed) Ash Handling Plant
Ash Handling System Supplier
MS Pipes
1. MacawberBeekay, New Delhi 2. ABB Ltd. 3. FFE Minerals, Chennai. 4. Indure 1. SAIL 2. Jindal 1. Kay 2. Everest 3. Swam 1. Dezurik
3 4
Roots Blowers For Silo Fluidising Knife Gate Valves
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2. Fouress 1. Acco 2. ABB 3. RIECO 1. HyquipRotolex 2. Des Equipment 3. RIECO 4. Dyna speed (hosur) 1. Flexican Bellow 2. Lonestar Industries 3. Stenflex, Germany 4. Flexotherm 1. MacawberBeekay 2. Scorpio Engg Bangalore 3. Sanmar Weighing System, Chennai 1. Nivo Controls 2. Vega 3. E + H 1. ABB 2. Andrew Yule 3. BHEL 1. Atlas Copco 2. Kirloskar Pneumatic 3. Ingressol Rand 4. Chicago Pneumatic 1. MacawberBeekay 2. Melco 3. WAM Mumbai 1. Paharpur 2. Shriram Tower Tech 3. Encon technologies Pvt. Ltd. 4. GEA cooling towers technologies(I) 1. Ion Exchange (I) limited 2. Thermax Limited 3. Doshi ion 4.Aquwa 1. Chicago Pneumatics 2. Kirloskar Pneumatics 3. Ingersoll Rand 4. Atlas Copco 5. Khosla
Vent Filter
Rotary Feeder
Metallic Expansion Joints
Telescopic Chute
Level Switches
10
Centrifugal Fans
11
Air Compressor (Ash Handling)
12
Ash Conditioner
13
Cooling Tower
14
Water Treatment Plant
15
Plant Air Compressors
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16
Air Drying Unit
1. PSA, Nitrogen 2. Indcon Ltd., Delhi 3. Chicago Pneumatics 1. Carrier 2. Voltas 3. Blue Star 1. Voltas 2. Blue Star 3. SK Systems, Bangalore 4. AeroventProjects,Mumbai 1. Agni Heavy Engg. Industries, Chennai 2. Tyco 3. Bell Cerabrus, Calcutta 1. BabubhaiNarottamdas 2. Penwalt India 3. IEC Fabchem, Chennai 1. Mukund 2. WMI Cranes 3. Tekfrens (India) Ltd. 4. Unique 1. WH Brady 2. Mumbai Cranes 3. Indef. 4. KalingaEnggs. 1. OTIS 2. KONE 3. Bharat Bijalee 1. As per qualifying criteria 1. BHEL 2. ABB 1. Siemens 2. Areva 3. ABB 4. Cromptom 1. BBL 2. Alstom 3. CGL 4. Emco 5. Areva 1. CGL 2. Bharat Bijlee
17
Air Conditioning System
18
Ventilation System
19
Fire Protection & Detection System
20
Chlorination System
21
E.O.T Crane
22
Hoists
23 A.4 1 2
Passenger Lift ELECTRICAL EQUIPMENT Alternator AVR
6.6 kV switchgear & 11 kV
Generator Transformer
Auxiliary Transformer / station transformer
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3. Voltamp 4. Areva 1. L&T 2. Siemens 3. Schneider 4. ABB 1. L &T 2. Siemens 3. schneider (Note: make of all MCCs shall be one make i.e. either L & T or Siemens) 1. L &T 2. Siemens (Note: make of all DBs shall be one make i.e. either L & T or Siemens) 1. ENPRO 2. Controls & Switchgear (C&S) 3. Star Drive 4. Techno Electrical 5. Intelec 1. ABB 2. Siemens 3. Areva 4. GE 5. Multilink 1. ABB 2. GEC 3. Siemens 1. Conserve equivalent Satek 2. Chloride (Plante-YKP Series) 1. AMCO 2. Chloride 3. HB nife 1. Chabi 2. Sabnife 3. Mastek 1. BHEL 2. CGL 3. ABB 1. NELCO 2. L & T 1. NELCO,
LT Switchgear (415V PCCs)
MCCs
MLDBs / MPDBs
Generator Busduct
10
Relays protection
11 12 13 14
Control & Relay Panels and Synchronizing Panel Energy Meters Batteries (Ni-cd) Batteries (Maintenance free lead acid VRLA type) Battery Chargers
15
16 17 18
HT Motors (11 kV) HT VFD L T VFD
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2. AMTEX 3. L & T 1. Siemens 2. Bharat Bijlee 3. NGEF 4. CGL 1. Kirloskar Electric 2. BHEL 1. Philips 2. CGL 3. BAJAJ 1. CCI 2. Universal 3. Torrent 4. Gemscab 1. CCI 2. Universal 3. Asian 4. Fort Gloster 1. Elecmech 2. Controls & switchgear (C & S) 3. Star Drive 4. Techno Electrical 1. Tata Liebert 2. Siemens 3. Hirel 4. D B power 1. Siemens 2. BPL 3. CGL 4. Philips 1. Elecmech 2. ELM 3. C & S 4. Telemechanique 1. Indiana 2. Steelmite Engineering 3. APT Engineering 4. Equivalent 1. Raychem Engg. 1. Siemens
19
LT Motors
20
DC Motors
21
Lighting Fixtures
22
HT cables
23
LT cables
24
LT Busduct
25
UPS
26
Plant communication system (PA System)
27
Local control stations / PB
28
Cable trays
29 30
Cable jointing / Terminating kits Power contactors
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2. L & T 1. Siemens 2. L & T 1. Siemens 2. L &T 3. ABB 1. Siemens 2. L & T 1. MDS 2. Indo-Asian 3. Siemens 1. SR Narkhede Engineering 2. RSI Switch Gear 3. ESSEN Electricals 1. BHEL, Jhansi 2. BBL 3. CGL 4. VOLTAMP 1. DY Engineers 2. India Electrical Syndicate 3. Unique Engineering 1. BHEL, Bhopal 2. Larsen & Toubro Ltd., Hyderabad 3. Siemens 1. BHEL, Jhansi 1. ABB 2. Prayog Electricals 3. Pragathi Electricals 4. KAPPA 1. BHEL 2. P.S. Electricals 3. Prayog Electricals 4. Pragathi Electricals 1. Shakti Textile 2. NFE Private Limited 3. Vijay Fire Protection System 4. Agni Controls 1. TELK 2. EASUN 3. CGL 1. Bells 2. General instruments
31 32 33 34
Switchfuse Units Overload Relays Timers / Auxiliary contactors MCCBs
35
Neutral Grounding Resistors
36
Dry Type Transformers
37
Earthing Materials
38 39
DC Starter Cubicles Generator Terminal Boxes &Busducts
40
CTs & PTs
41
NGT
42
Generator CO2 Equipment
3 A.5 1
Transformer Tap Changers CONTROL AND INSTRUMENTATION Pressure gauges
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3. Premier Instt. & Control Ltd., Coimbatore 4. Precision Instrument 5. Waaree 1. Bells 2. General instruments 3. Pyro Electric 4. Waaree 1. Switzer 2. Bells 3. Premier Instruments 1. General instruments 2. Altop industries 3. Toshniwal Brothers, Mumbai 1. Chemtrols 2. Levcon 3. S.B.Electromechanicals 4. Technomatic (I) Pvt. Ltd.,Mumbai 1. BHEL 2. Hydeastep 1. Rosemount 2. Yokogawa 3. E & H 4. ABB 1. Instrumentation Ltd 2. Masoneilan 3. Fisher Xomox 4. Dresser India 1. Micro precision 2. Star Mech 3. Hydro pneumatics 4. Instrumentation Ltd., Palghat 5. Engineering Specialties 1. Micro precision 2. Star Mech 3. GIC 4. Hydro pneumatics 5. Instrumentation Ltd., Palghat 6. Engineering Specialties 1. Blue star 2. Rosemount 3. Eureka
Temperature gauges
Differential pressure gauge
RTD and Thermocouples
Level gauges Drum level gauges / Drum level switches / EDLI Electronic transmitters (SMART)
Control valves
Flow orifices
10
Flow nozzles / Venturi
11
Rotameters
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1. Switzer 2. S.B.Electromechanicals 3. Levcon 4. V.Automat 1. Yokogawa 2. Rosemount 3. Endress + Hauser 1. Moorco 2. Smith meter 1. Rockwin flow meter 2. Fisher rosemount 1. Microprecision 2. Levcon Instruments (P) Ltd., , Chennai 3. ChemtrolsEngg. Pvt. Ltd.,Mumbai 1. Arca 2. IL 3. TYCO 1. Jaisun& Hutchison 2. Syspro 3. Pyrotech 4. Industrial controls & appliances 5. RITEL 1. ASCO 2. Rotex 3. Avcon 4. FESTO 1. Emersa 2. Bells Controls Ltd., Chennai 3. Forbes Marshall 4. Kent 1. Rosemount 2. Bells 3. C.G. ElsagBelley 4. ABB Instruments 1. Udey Pyro 2. Delton 3. Universal Cable 4. Toshniwal 1. IIC 2. ICA 3. Minilec 1. ShavoNorgren
12
Flow switches
13 14 15
Vortex flow meter Positive displacement meters Turbine flow meters
16
Float & board type level indicator
17
PRDS
18
Control panel
19
Solenoid valves
20
pH /Conductivity Analysers
21
I / P Converters
22
Instrument Cables
23 24
Annunciators Air Filter Regulator
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2. Placka 3. NUCON 4. ABB 1. OEN 2. L&T 3. Siemens 4. GEC Alsthom 5. OMRON 1. Kaycee 2. EAO 3. GEC Alsthom 1. Allen Bradley (except SLC 5000) 2. Siemens 3. ABB 4. L&T 1. Hartmann & Brown (H&B) 2. Forbes Marshall 1. Hartmann & Brown (H&B) 2. Yokogava 1. Switzer 2. Ind Foss 1. Honeywell 2. Bchl. 3. Osna Electronics (P & F) 4. Kana 1. Masoneilan 2. Chemtrol 3. V. Automat 1. Max Control (DNA) ofUSA/BHEL 2. ABB 3. Siemens 4. Tata Honeywell 1. Bently Nevada 2. SKF Condition Monitoring Inc., , USA 3. Shinkawa 1. Mital India 2. Industries 3. Kalindi Bright 4. Steels & Tubes 1. Placka Instruments & Controls 2. Reliance Engineering &Electrical Corporation 3. Alcobex 4. Multimetal Limited
25
Relays
26
Selector Switches
27
Programmable Logic Controller (PLC) CO / CO2 Analyser Oxygen Analyser Pressure Switch / Temperature Switch Limit Switches / Proximity Switches
28 29 30
31
32
Displacer type level transmitter
33
Distributed Control System (DCS)
34
Turbovisory Instruments (Vibration / Speed Axial Shift etc.)
35
Stainless Steel Tubes
36
Copper Tubes (Bare & PVC Sheathed)
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1. Reliance Engineering 2. Quality Industries 3. Multimftal Ind. 4. Placka Instruments / Valtex 1. Baliga 2. Flexpro 3. FCC 1. TI 2. Profab Engineering 3. Indiana 4. A.V. Engineering 1. Baliga 2. Sterling Switch Gears 3. Ex-Protecta 1. Elemex 2. Tosha 3. Connect Well O. English Electric 1. Dceloc 2. Excel 3. Hydropneumatics 4. Baldota 1. BDK 2. DewranceMcneii 3. L & T 4. Microprecision 1. Hartmann & Brown (H&B) 2. Yokogawa Blue star 1. Hartmann & Brown (H&B) 2. Yokogawa Blue star 1. Yokogawa Blue star 2. Duraj 3. Land, UK 1. Radix 2. Lectrotek 3. BentlyNeveda, USA 4. Rochester Instruments SystemLtd. UK 1. FouressEngg (I) Ltd. Bangalore 2. Instrumentation Ltd., Palghat 3. ARCA Controls India Pvt. Ltd.,Mumbai 4. Fisher Xomox, Chennai 1. * V Automat & Controls Pvt. Ltd., Ltd. New Delhi 2. ChemtrolsEngg. Pvt. Ltd., Mumbai
37
Compression Fittings (Brass & Stainless Steel)
38
Flame Proof / Weather Proof Cable Glands
39
Cable Trays
40
Flame Proof / Weather Proof Junction Boxes Terminal Blocks
41
42
Pneumatic Header
43
Isolation Valves
44 45 46
SOX / NOX Steam and water analyzer system SPM Monitor
47
Temperature Scanners
48
Desuperheater Nozzles Level Transmitters (* Only upto 300 Class)
49
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3. Dresser India 4. Magnetrol, India 50 Trip Solenoid Valves 1. IMI Norgen, Germany 1. H. Guru, Bangalore 2. General Instruments Consortium, Consortium Chennai 3. Bells Controls Ltd., Chennai 4. A.N. Instruments, Chennai. 1. General Instruments Consortium, Consortium Chennai 2. Nuovofina, Italy 1. Levecon 2. Chemtrol, Mumbai 3. S.B. Electromechanical, Pune 1. Emerson 2. CG Hortman& Brown, Gurgaon 3. Kent 4. Polymekon 1. Encon (India) 1. E + H 2. Vega 1. Festo 2. NUCON 1. Pelco 1. Lotus funk Germnay 1. L&T 2. ABB 3. Siemens 1. AUMA 1. PYROTECH 1. FOSROC 1. FOSROC 1. SenHarvic 2. Agew Section Make: 1. Indal 2. Hindalco
51
Mercury in Steel Dial Thermometers
52 53
Bimetallic Thermometers Liquid level switches
54
Dissolved Oxygen Analyzer
55 56 57 58 59 60 61 62 A.6 1 2 3 4
Cooling Tower Fans Ultrasonic level Transmitter Pneumatic Cylinder CCTV (Survillance) Wireless Control System (PLC) VVVF MOV actuator Control Desk CIVIL Grouting material Construction Chemicals / Waterproofing material Steel door & windows Aluminium doors, window & ventilation &aluminium tee grid false ceiling
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3. Jindal Fabrication &Fixing Agency: 1. Offteck Interior, Mumbai 2. Ajit India Pvt. Ltd, Mumbai 1. Indiana 2. Agew 3. Senharvic 4. Ferro Steel 1. Radiant 1. Luxalon 2. Amstrong 3. New Kem 1. Prince 2. Kissan 1. Hindustan 2. Neycer 3. Parryware "A" 1. ARK 2. Jaguar 3. ESSCO 1. Johnson 2. Kajaria 3. Nitco 4. Bell 1. Amstrong 2. Krishna Vinyle 1. Nitco 2. Somani 1. Johnson & Johnson orEquivalent
Rolling shutter
6 7 8 9
Fire proof doors False Ceiling Sanitary: RW & Severe pipe PVC pipes Chinaware fillings
10 A.7 1
CP Fittings FLOORING Ceramic Tiles
2 3 4
PVC Flooring Mosaic Tiles Acid Resistance Tiles
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21. MANDATORY SPARES
21.1 Spare re Management
Item wise price of Mandatory sparesis to be submitted along with ith offer and their price validity for 2 years from date of LOI. In the event of any equipment being changed during engineering, Bidder shall supplymandatory spares pertaining to that equipment without any extra cost to Owner. Bidder shall guarantee to Owner that before going out of production of spare parts for the equipment furnished he shall give at least twelve (12) months advance notice to owner so that the latter may order his s requirement of spares in one lot if he so desires. Supplier shall clearly indicate the spares which are not applicable as per this list to the equipments he offered. Supplier shall include the balance spares in the list of recommended spares applicable for f whole TPP as per his experience, which are not covered in the following list.
21.2 STEAM GENERATOR AND AUXILIARIES

ITEM / DESCRIPTION Steam drum Manhole cover gasket Coal Feeder Head pulley grease seal Tension roll grease seal Belt Belt scraper Gaskets O rings Coal Pulverizer Rollers Grinding ring/race Bearings 3 sets for each mill 3 sets for each mill 8 sets for each type 32 nos. 32 nos. 4 nos. 4 nos. 16 sets 48 sets 2 sets QUANTITY
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Reduction gear Shaft 4 sets 2 nos.
21.3 Centrifugal fans (for each type)

ITEM / DESCRIPTION Shaft Set of bearings Impellers Couplings QUANTITY 1 nos. 1 nos. 1 nos. 1 nos.
21.4 Coal Burners

ITEM / DESCRIPTION Complete assembly Coal burner nozzle QUANTITY As per OEM As per OEM
ITEM / DESCRIPTION Oil Burners Flexible hoses Burner assembly Gaskets Seal rings Insertion/retract drive
QUANTITY LDO As per OEM 1nos. 16 nos. 2 nos. 2 nos.
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21.5 Regenerative Air Preheater
ITEM / DESCRIPTION Bearing Elements Lube oil pump & motor Seals Filters for lube oil system Moisture separator & oil lubricator Fluid Coupling QUANTITY 4 sets 2 sets for each type 2 sets 2 sets each 2 sets 2 sets 4 sets
21.6 Steam Coil Air Preheater

ITEM / DESCRIPTION Gaskets QUANTITY 4 sets
21.7 Oil Burners

ITEM / DESCRIPTION Flexible hoses Gun assembly Gasket Seal rings Insertion/retract drive QUANTITY 2 sets 1 set 2 sets 2 sets 2 set
21.8 Dampers (for each type)

ITEM / DESCRIPTION Bearings Seals QUANTITY 1 sets. 2 sets.
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21.9 Pressure parts
ITEM / DESCRIPTION Tubes (each type for complete boiler) (Straight) Tube bends (each type for complete boiler) QUANTITY 4% of population 4% of population (Minimum 4 Nos.)
21.10 Safety valves (Each type type)

ITEM / DESCRIPTION Disc Disc holder Adjusting ring Guide Overlap collar QUANTITY 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos.
21.11 Valves
ITEM / DESCRIPTION Globe valves 1/2 inch (for 800# & 1500# class & material) Globe valves 1 inch (for 800# & 1500# class and material) Globe valves 3/4 inch (for 800# & 1500# class &material) 1 inch and 2 inch (for 800# & 1500# class & material) Stem for each type & size valve Disc for each type & size valve Gland packing stud for all sizes of valves Yoke bush for each type & size valve QUANTITY 5% of population (2 Nos. min.) 5% of population (2 Nos. min.)
5% of population (2 Nos. min.)
4 Nos. each 2 sets 2 sets 2 sets 2 sets
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Packing set for each type & size valve Sealing ring for all valves of above Drum gauges gloss ports 2 sets 2 Nos. each 1 set
21.12 Safety Valve

ITEM / DESCRIPTION Drum safety valve a) Stem. b) Disc Superheated safety valve a) Stem. b) Disc 1 no 1 no 1 no 1 no QUANTITY
21.13 ELECTROSTATIC PRECIPITATOR (ESP)

ITEM / DESCRIPTION Discharge/emitting electrodes Collecting plates Heating element for insulator shaft Heating element for hoppers Level indicator (Ash) Main fuses Auxiliary fuses Main contactors OEN relay QUANTITY 8 nos. 15 nos. 2 nos. 2 nos. 2 nos. 5 nos. 5 nos. 5 nos. 5 nos.
21.14 For filter chamber

ITEM / DESCRIPTION QUANTITY
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Supporting Insulators Heating element for supporting Insulators Packing set for supporting insulator Shaft insulator Lead-in insulator Heating element for insulator shaft Geared motor for rapping system including coupling Heating element for hopper heater 5 nos. 5 Nos. 5 nos. 3 nos. 2 nos. 2 nos. 2 nos. 6 nos.
21.15 For control panel & rectifier of ESP

ITEM / DESCRIPTION Main fuses Main contractor. OEN relay SVR connector back to back Auxiliary fuses Firing module card Power supply card Controller QUANTITY 5 nos. 5 nos 5 nos. 2 set 5 nos. 2 nos. 2 nos. 2 nos.
21.16 STEAM TURBINE GENERATOR AND AUXILIARIES Turbine

ITEM / DESCRIPTION a) b) c) d) Front journal bearing for turbine Rear journal bearings for turbine Front journal bearing for exciter Rear journal bearings for exciter QUANTITY 1 No. 1 No. 1 No. 1 No.
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e) f) g) h) i) j) Thrust journal bearing (if separate) Thrust pads Gland Seals Gaskets I/H converter Solenoid valves for governing system 1 No. 1 Set 1 Set 1 Set 1 Set 1 Set
Generator
ITEM / DESCRIPTION a) Journal Bearing QUANTITY 1 Set
Control Systems (Atrs)

ITEM / DESCRIPTION a) b) Actuator of each type Card of each type Simatic plug plug-in card set (CPU + POWER SUPPLY + AI/AO+ DI/DO) QUANTITY 1 Set 1 Set
TSI System
ITEM / DESCRIPTION a) b) Electronic Card Vibration control plug in card (Vibration wave position and power supply) Electronic Card Thrust (Dual voting axial displacement) QUANTITY 1 No. 1 No.
Governing system electronic module Vibration monitoring system stem electronic module
1 Set 1 Set
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Condenser
ITEM / DESCRIPTION a) Condenser tubes bundle (K Type) 1 No. Condenser tubes bundle (D Type) 1 No. b) c) d) Gaskets of all sizes Standby ejection nozzles Main ejection nozzles QUANTITY 1 No. 1 No. 1 set 1 No. 1 set
CEP
ITEM / DESCRIPTION a) b) c) d) e) f) Shaft Impeller Shaft Sleeve Thrust bearing Wearing rings Mechanical Seal QUANTITY 1 set 1 set 2 sets 1 set 2 set 1 set
Other spares for STG

Servo Motor for Control Valves one set of spares for Servomotor consists of
ITEM / DESCRIPTION a) Pilot Piston Control Slide b) Pilot Piston Control Sleeve c) Pilot Piston Guide Bushes d) Pilot Piston Bearings e) Pilot Piston Springs f) Seal Kit for Power Piston Mechanical Oil Seals for MOP Mechanical Oil Seals for AOP Mechanical Oil Seals for EOP Mechanical Oil Seals for JOP Spares for coupling consisting of QUANTITY 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 Set
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Input coupling bolts Output Coupling Bolts Spares for Oil Centrifuge consists of Seals ,O rings, Gasket Friction Pads Bowl Disc. Shear Coupling Heating Element Solenoid Valves Coil 1 Set 1 Set 1 Set 1 Set 2 Nos. 2 Nos. 1 Set. 1 No.
FEED WATER PUMPS

Mandatory spares as below for each type of pumps.
ITEM / DESCRIPTION Line shaft bearings Bearing bushes / rubber bearings Shaft sleeves (at bearings) Gland Packing Coupling with fixing bolts Impeller shaft sleeve Stuffing box bearings Thrust bearing Impeller Casing wear rings Impeller wear rings Shaft sleeves (packed box) Shaft sleeves (mechanical seals) Throat bushings All gaskets & O rings Mechanical seals Stuffing box packing Balancing Disc with sleeves QUANTITY 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set
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DEAERATOR
Spray nozzle inside deaerator (if spray type is offered) Gaskets Springs for relief valves 5% of population 1 Set 1 No.
21.17 WATER SYSTEM / WATER TREATMENT PLANT CENTRIFUGAL PUMPS

WTP supply degassed water pumps, regeneration water pumps, effluent pumps, transfer pump per category.
WTP supply degassed water pumps, regeneration water pumps, effluent pumps, transfer pump per category Set of Impellers (Full Dia) Shaft with Keys Set of Shaft Sleeve Set of Case Wear Rings Set of Impeller Wear Rings Set of Bearings (Drive End) Set of Bearings (Non Drive End) Set of Throat Bushing Set of Throttle Bushing Set of Gaskets Set of Labyrinths Set of Oil Seals 1 1 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 4 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump
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Constant Level Oiler Deflectors Impeller Nut Coupling Spares (Flex Element, Bushes, Pins, and Packings etc.) 1 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 4 for each size and type of pump
Alkali Unloading Pumps, Acid unloading pumps Set of Impellers (Full Dia) Shaft with Keys Set of Shaft Sleeve Set of Case Wear Rings Set of Impeller Wear Rings Set of Bearings (Drive End) Set of Bearings (Non Drive End) Set of Throat Bushing Set of Throttle Bushing Set of Gaskets Set of Labyrinths Set of Oil Seals Constant Level Oiler Deflectors Impeller Nut Coupling Spares (Flex Element, Bushes, Pins, and Packings etc.) Set of Mechanical Seal (Complete Assembly) 1 for each size and type of pump 1 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 4 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 1 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump 2 for each size and type of pump
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PLUNGER/RECIPROCATING/METERING PUMPS
Alum, Sodium Sulphate, Morpholine Dosing
ITEM / DESCRIPTION Plunger Bearings Stuffing Box Packing Suction Valve Discharge Valve Cross head shoe Cross head bushes Nuts & Bolts for connecting rod Shear pin & Gudgeon pin QUANTITY 1 set for each size and type of pump 2 sets for each size and type of pump 2 sets for each size and type of pump 1 set for each size and type of pump 1 set for each size and type of pump 1 set for each size and type of pump 2 sets for each size and type t of pump 1 set for each size and type of pump 2 sets for each size and type of pump
Small component such as Special Gaskets, O O-Ring, Ring nuts for 2 sets for each size and type of pump stuffing box packing etc. Spares kit for safety valve consisting of seat, spring, gaskets etc. 2 sets for each size and type of pump
LOBE TYPE / ROOTS BLOWERS

Air Scouring Blowers
ITEM / DESCRIPTION Complete rotor assembly including impeller, wheel, hub, nuts bolts and shaft etc. Shaft Sleeve Bearings Stuffing Box packing rings, mechanical seal for sealing, set of gaskets and oil seals V-belts (if applicable) QUANTITY 1 sets 1 sets 2 sets 1 sets 1 sets
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Other parts such as coupling pins, coupling bushes etc. 1 sets
CENTRIFUGAL BLOWERS
Degasser Blower
ITEM / DESCRIPTION Complete rotor assembly including impeller, wheel, hub, nuts bolts and shaft etc. Shaft Sleeve Bearings Stuffing Box packing rings, mechanical seal for sealing, set of gaskets V-belts (if applicable) Other parts such as coupling pins, coupling bushes etc. QUANTITY 1 set 2 set 2 set 2 set 2 set 2 set
AGITATORS
Agitators for all chemical dosing tanks: For each category: (Alum, Sodium Sulphate, Caustic, Salt, Morpholine)
ITEM / DESCRIPTION Bearings Coupling with coupling pins and coupling bushes Oil seal QUANTITY 1 set 1 set 1 set
PRESSURE FILTERS
ITEM / DESCRIPTION Strainers Filter Bed Material QUANTITY 10 % of total quantity 10% of total quantity
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Laterals 10% of total quantity
MIXED BED
ITEM / DESCRIPTION Resin Laterals Strainers Grommet Resin Trap Element QUANTITY 10 % of SAC resin total quantity & 10% of SBA 10 % of quantity 5 dozens 10 Nos. 1 No
ITEM / DESCRIPTION Diaphragm Valves Line Diaphragms For Hand And Pneumatic Operated Valves
QUANTITY 5 Nos. Of each size and type 6 Nos. Of each size and type
21.18 FIRE PROTECTION AND DETECTION SYSTEM Diesel Engine

ITEM / DESCRIPTION Fuel injection nozzle Piston ring Springs Fuel Filter assembly Lubricating oil filter assembly Engine packing & gaskets QUANTITY 1 set 1 set 1 of each type 1 set 1 set 1 set
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Pumps
ITEM / DESCRIPTION Casing wear rings Impellers wear rings Shaft sleeves Gaskets Packing QUANTITY 2 Sets for each pump. 2 Sets for each pump. 2 Sets for each pump. 2 Sets for each pump. 1 Set for each pump.
Strainers
ITEM / DESCRIPTION Strainer elements QUANTITY 2 Nos. for each strainer
21.19 AIR CONDITIONING AND VENTILATION SYSTEM

Following mandatory spares shall be provided for pumps:
ITEM / DESCRIPTION Impeller Impeller wear ring Casing wear ring 2 Nos. for each pump Shaft sleeves 2 Nos. for each pump Packing 1 Set for each pump Gaskets 2 Nos. for each pump Strainer elements QUANTITY 1 Nos. 2 Nos. for each pump 2 Nos. for each pump 2 Nos. for each pump 1 Nos. for each pump 2 Nos. for each pump 2 Nos.
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21.20 E.O.T. CRANE AND HOIST TROLLEYS
ITEM / DESCRIPTION Bearings for each size of motor used in the crane. Bearings used in gear boxes in crane (one no. of each size bearing). Main hook bearing. Bearing used for long travel. Bearing used in cross traverse wheel. Brake lining with rivets for each size of brake. Brake shoes with lining for each size of brake. Thruster for brake of each size. Oil seals for all gear boxes Contactors of each size Coils for each of the above contactors. Main & auxiliary contacts for each of the above contactors (One set consists of contacts for one contactor) Overload relays for each motor. Timers of each type. Carbon brushes for each slipring motor. Carbon brush holder for each slipring motor. Set of fuse links of each size. Contact element assembly complete with fixed and moving contacts for master controllers. Contact element assembly complete with fixed and moving contacts for rotary and counter weight and lever type limit switches. (One set consists of contacts required for three type limit switches) Limit switches of each type Set of fixed moving contacts for the above limit switch.(One set consists of contacts required for three type limit switches) Uncut cams. for above QUANTITY 1 Set 1 Set 2 Nos. 2 Nos. 2 Nos. 2 Sets 1 Set 1 No. 2 Sets 2 Nos. 2 Nos. 2 Sets 3 Sets 2 Nos. 6 Sets 3 Sets 5 Sets 12 Nos.
2 Sets
2 Nos. 2 Sets 2 Sets
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Spare solenoid for electromagnetic brakes. (One set consists of one number of each size) Spare coils to form one complete for electromagnetic brake unit for each size. Main current collector for runway conductors. Bracket with insulator for current collector. Insulator for runway conductor support. Set of brake springs for each size of brake used on the crane. Control transformer of each type. MCB of each type
1 Set 1 Set 6 Nos. 1 No. 6 Nos. 2 Sets each. 1 No. 1 No.
21.21 FUEL, BED MATERIAL HANDLING SYSTEM Spares for Belt Conveyors (For each size and type belt conveyor)
ITEM / DESCRIPTION Carrying idler rollers Return idler rollers Impact idler rollers with impact rings Guide roller for self-aligning aligning carrying idlers Guide roller for self aligning return idlers Blade tip for scrapper blades (external & internal) Self aligning carrying idler transform Self aligning return idler frame bracket Bearings & seal kit for carrying roller Bearings & seal kit for return roller Bearings & seal kit for impact roller Thrust Bearings for self aligning carrying roller Thrust Bearings for self aligning return roller QUANTITY 50 nos. 20 nos. 15 nos. 10 nos. 10 nos. 2 Sets. 2 nos. 2 Sets. 20 Sets. 20 Sets. 20 Sets. 2 Sets. 2 Sets.
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Motor bearings Skirt board segments Conveyor Belt 1 set/size/each type 20 Nos. 50 m each type
Spares for Crushers

ITEM / DESCRIPTION Shaft seals Breaker bar Set of bearings V belts Replaceable liner Shear pins Disc spring Gun metal bush for pinion QUANTITY 1 set / crusher 1 set / crusher 1 set / crusher 1 set / crusher 1 set / crusher 1 set / crusher 1 set / crusher 1 set / crusher
Spares for Vibrating Screens

ITEM / DESCRIPTION Screen cloths springs QUANTITY 1 set / screen 1 set / screen
Spares for Electronic metal detector

ITEM / DESCRIPTION Fuses Lamps with holder Solenoid for sand bag marker QUANTITY 1 Set 1 Set 1 Set
Spares for Magnetic separator

ITEM / DESCRIPTION Cartridge fuse without fuse fixing QUANTITY 1 Set
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Indicating lamp
1 Set
Spares for online belt weigher

ITEM / DESCRIPTION Transformer assembly Slow blow fuses Load cell LED display Transistor Connector strap QUANTITY 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set
Spares for Dust extraction system

ITEM / DESCRIPTION Filter bags Solenoid valves QUANTITY 10 nos. for each type 5 nos.
Spares for Gear reducers and coupling

ITEM / DESCRIPTION Piston rings Seals and Gaskets O Rings Bearings V Belts Air filter element Oil filter element Valve seat inlet and discharge Suction & Discharge valves QUANTITY 1 Set. 1 Set. 1 Set. 1 Set. 1 Set. 1 No. 1 No. 1 No each type. 1 No.
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Vent Filter
ITEM / DESCRIPTION Filter bags Filter (Insert) cages Solenoid valves/Diaphragm valves QUANTITY 10 Nos. 10 Nos. 2 Nos.
Blower (for each blower)

ITEM / DESCRIPTION Inlet air filter cassette Bearings Oil seals / O rings Gaskets V belts QUANTITY 1 No. 1 Set 1 Set 1 Set 1 Set
Rotary Feeder (for each valve)

ITEM / DESCRIPTION Bearings Felt seals Chain links Gland packing QUANTITY 1 Sets 2 Sets. 10 Nos 2 Sets.
Ash Conditioner (for each conditioner)

ITEM / DESCRIPTION Lip seals Oil seals Paddles with shaft QUANTITY 1Set. 1Set. 1 No./1 Set, if twin shaft
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Bearings Coupling bush Nozzles Gear box 1Set. 1Set. 1Set. 1 No.
ITEM / DESCRIPTION Bends
QUANTITY 2 nos. (each type)
Valve (for each type and each size)

ITEM / DESCRIPTION Seals O rings Bearings QUANTITY 4 sets 4 sets 1 sets
COMPRESSED AIR AND INSTRUMENT AIR SYSTEM

ITEM / DESCRIPTION Compressor suction filler element Lubricating oil filter assembly Gaskets Suction & discharge valve assembly Valve plate Bearings Wear rings Pre-filter & after-filter elements for air drying plant Purge control valves QUANTITY 2 Sets 2 Sets 2 Sets 2 Sets 2 Sets 2 Sets 2 Sets 2 Sets 1 Sets
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21.22 ELECTRICAL Generator and auxiliaries
ITEM / DESCRIPTION Excitation system & AVR Rotating diode with fuse Rectifier bridge assembly consisting of thyristors and fuses of each type Fuse failure device Thyristor failure device PCB - each type for AVR Exciter field suppression resistors Each type of control & selector switch Flexible bus bar connections of LT & HT Bus duct earth type Seal and gaskets for generator main connection and bus busducts of each type Bus support insulator of each type Expansion bellows Motor bearings of each type Motor Actuators : Power supply unit (if any) Torque switch Position limit switch Motor bearings nos. nos. nos. set 1 2 2 1 set set nos. nos. no. of each type set nos. nos. set set set set 1 1 1 1 1 1 1 1 1 1 1 1 QUANTITY
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21.23 TRANSFORMER
(Separate spares for each type of generator transformer, unit ration transformer & auxiliary distribution transformer).
ITEM / DESCRIPTION Buchholtz relay Explosion vent diaphragm Winding temperature indicator Magnetic oil level gauge Dial type thermometer Dial type oil temperature indicator Gasket Silica gel breather One valve of each type HV bushing of each rating LV bushing of each rating Neutral bushing Bushing CT of each rating Transformer oil in sealed drums QUANTITY nos set nos nos nos nos nos nos nos nos nos set nos % of total 1 1 1 1 1 1 1 1 1 1 1 1 1 10% of total quantity supplied
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21.24 KV SWITCHGEAR
ITEM / DESCRIPTION Bus bar support insulator of each type Bus seal-off bushing of each type P.T. fuse for H.T side of each type Push button Local/Remote selector switch Breaker control switch Voltmeter selection switch of each type Indicating lamp of each type pe (red, green & amber) Ammeters of each range (Supplier to list the same in an Annexure) Voltmeters KW meter KWH meter nos. 1 Timers CTs of different ratio (Supplier to list the same in an Annexure) Cable boxes of each type Fuses of different rating Breaker closing coil Breaker tripping coil Breaker fixed contact assembly Spring charging motors complete with closing and tripping springs and spring charge / discharge limit switches Auxiliary contact assembly Arc quenching assemblies 3 pole IDMTL O/C relay nos. nos. nos. nos. nos. nos. nos. nos. QUANTITY 4 4 2 Min. 10% of total requirement 1 no. (whichever is greater) of each type min. 10% of total requirement 1 no. of each type (whichever is greater) min. 10% or 1 no.(whichever) is greater Min. 10% or 1 no. (whichever is greater) Min. 20% or 1 no. (whichever) is greater Lot (1 of each range) nos. nos. nos. nos. 1 1 1 1 Lot (1 of each range) nos. nos. nos. nos. nos. nos. nos. nos. nos. 2 each 12 each Min. 20% or 1 no. (whichever) is greater min. 20% or 1 no.(whichever) is greater Min. 20% or 1 no. (whichever) is greater Min. 20% or 1 no. (whichever) is greater Min. 20% or 1 no. (whichever) is greater 1 1
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3 pole IDMTL O/C relay with high set unit 1 pole IDMTL E/F relay 1 pole IDMTL E/F relay with high set Definite time E/F relay Restricted E/F relay 1 pole u/v relay Motor protection relay Auxiliary relays Trip relay Antidumping relay Trip coil supervision relay Auxiliary relay with 4 N/O + 4 N/C Auxiliary relay with 2 N/O + 2 N/C Test terminal blocks for meters Test terminal blocks for relays
nos. nos. nos. nos. nos. nos. nos. nos. nos. nos. nos. nos. nos. nos. nos.
1 1 1 1 1 1 Min. 20% or 1 no. (whichever) is greater Min. 20% or 1 no. (whichever) is greater Min. 20% or 1 no. (whichever) is greater Min. 20% or 1 no. (whichever) is greater Min. 20% or 1 no. (whichever) is greater Min. 20% or 1 no. (whichever) is greater Min. 20% or 1 no. (whichever) is greater 2 2
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21.25 L.T. SWITCHGEAR Push buttons
ITEM / DESCRIPTION Start Stop QUANTITY nos. nos. Min. 20% or 1 no. (whichever is greater) Min. 20% or 1 no. (whichever is greater)
Selector switches
ITEM / DESCRIPTION Ammeter Voltmeter Indication lamps Indicating lamp holders with series resistors for 230 V control centers Lens covers of all colours Red Green Amber Ammeters (approx. 10% of total no. for all ranges) Voltmeters nos nos nos nos nos min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) QUANTITY nos nos min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater)
Main switches
ITEM / DESCRIPTION A.C. 25A 32A 63A 125A 250A 400A D.C. QUANTITY nos nos nos nos nos nos nos min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater)
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25A 32A 63A 125A Fuses Power circuit fuses of each rating Control circuit fuse nos nos min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) nos nos nos nos min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater)
Contactors
ITEM / DESCRIPTION A.C Contactors 32A 40A 70A 110A 200A 300A D.C. Contactors 100 A Coils 100 A Auxiliary relay Device nos. : 94 30 74 86 nos. nos. nos. nos. min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) nos. min. 20% or 1 no.(whichever is greater) nos. min. 20% or 1 no.(whichever is greater) nos. nos. nos. nos. nos. nos. min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) min. 20% or 1 no.(whichever is greater) QUANTITY
Meters
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KW
min 10% of total requirement or 1 no. (whichever is greater for each type) Min 10% of total requirement or 1 no. (whichever is greater for each type)
KWH Main power contacts (moving) 800 A -
Min. 20% of total requirement or 1 no. (whichever is greater for each type) Min. 20% of total requirement or 1 no. (whichever is greater for each type) 10% (atleast 1 each) 10% (atleast 1 each) 10% (atleast 1 each) 10% (atleast 1 each)
1250 A Arc. chutes (of each type) Arcing contacts fixed (of each type) Arcing contacts moving (of each type) Bus support insulators (of each type)
Protection relays
ITEM / DESCRIPTION IDMTL over current relay IDMTL earth fault relay Instantaneous under voltage relay Definite time relay Overall diff. Relay Motor protection relay Gen. protecting relay Spring charge motors Control transformers Fuse bases of each size Rows of terminal blocks of each type D.C resistance elements nos. No. No. QUANTITY min. 10% each min. 10% each min. 10% each min. 10% each One min. 20% each One. 2 per switchgear 10% 5% (atleast 1 in each) 10% 2
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BATTERY CHARGER
ITEM / DESCRIPTION Controller cards of each type used SCR, diodes, capacitors, resistors etc. A.C fuse links D.C fuse links Contactors, contactor coil and contact kit Indicating lamps, toggle switches, push buttons etc Potentiometer set sets of each type nos. of each type nos. of each type sets of each type nos. nos. QUANTITY 1 3 2 2 1 3 3
BATTERY
ITEM / DESCRIPTION Containers with covers & cells Level indicators Inter cell connectors Nuts, bolts, washers nos. nos. nos. set QUANTITY 5 5 5 5
UPS
ITEM / DESCRIPTION Control cards Invertor transistor / IGBT QUANTITY no. of each type no. 1 2
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30 MWSri Gomathi Energy Technical Tenderspecifications

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30 MWSri Gomathi Energy Technical Tenderspecifications

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SRI GOMATHI ENERGY Pvt Ltd

IIC Technologies Limited

Technical Specification Description

Hogging ejector ................................ ................................................................................................ .................................................. 54 3|Page

Owners ENGINEER Project Site Location

STEAM TURBINE, AUXILIARIES

Lubrication oil supply and drain system

Rotating Electrical Machines

Procedure for routine performance test of steam turbines

Reduction gear box

Indian Boiler regulations (IBR)

Ash Handling System

Compressor and Root blower

ASME sec VIII IS 7938

3.11 Inter cooler / after cooler

3.12 COMPRESSED AIR AND INSTRUMENT AIR SYSTEM

3.13 E.O.T. CRANE AND HOIST TROLLEYS

3.14 FIRE PROTECTION AND DETECTION SYSTEM

(a) Undercoating (b) Finishing

MSS - SP 55 ISO 1940 API 605 AWWA C 207

3.15 WATER TREATMENT PLANT

Steel pipe flanges for water works service

3.18 CONTROL & INSTRUMENTATION

3.19 Temperature Measurement

3.20 Pressure Measurement

3.21 Flow Measurement

3.22 Instrument Switches and Contacts

3.24 Apparatus, Enclosure and Installation Practice in Hazardous Area

3.25 Sampling System

3.27 Control Valves

Casting Welded end connection Forging Defect removal Cleaning CV test

3.28 Instrument Tubing

3.30 Cable Trays and Conduits

3.31 Surge protection

3.32 Instrument end connections

3.33 SURFACE PREPARATION AND PAINTING

To be indicated by bidder 1:3

Fuel oil pump Unloading cum forwarding pump

GUARANTEE PARAMETERS (AT MCR OPERATION)

Normal operation at 60% Boiler MCR (BMCR)

Boiler turn down ratio for auto control

1.7 1.8 1.9 2.0

TPH C Bar C 145

Flue gas temperature at APH outlet

Drum Plate Furnace Tubes Super heater Superheater outlet header

SA 210 Gr A1 SA 106 Gr B SA 106 Gr B SA 516 Gr 70 SS 304 IS 2062 SA 335 P91

Continuous, Base load

Number of turbines in operation

1.1.3 1.1.4 1.1.5

Generation Main steam inlet pressure

Main steam inlet temperature

Bleed off pressure

Design life of Turbine & Auxiliaries

Cylinder, rotor & blade test on forge master:

Performance tests as specified Start-Up Spares For STG Unit

CONDENSER & AIR EVACUATION SYSTEM FOR EACH TURBINE

Shell design temperature

Turbine exhaust hood temperature high trip setting

Tube thickness in condensing zone BWG

Tube thickness in air cooling zone BWG

Minimum tube sheet thickness mm

Minimum tube support plate Thickness mm

Minimum steam impingement baffle thickness mm