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TECHNICAL SPECIFICATION FOR

FIRE PROTECTION SYSTEM, DUST


SUPPRESSION SYSTEM & PLANT WATER
SYSTEM

TECHNICAL SPECIFICATION
VOLUME- II
SECTION-2

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 1 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Sl. No.

PARTICULARS

Page No.

1.00.00

INTENT OF THE SPECIFICATION

2.00.00
3.00.00

SYSTEM DESCRIPTION

SCOPE OF SUPPLY, WORK AND SERVICES

4.00.00

TERMINAL POINTS

20

5.00.00

EXCLUSIONS & FACILITIES PROVIDED BY OTHERS

21

6.00.00

DESIGN AND CONSTRUCTIONAL REQUIREMENTS

22

7.00.00

LAYOUT REQUIREMENTS

36

8.00.00

OPERATION & CONTROL PHILOSOPHY

37

9.00.00

CODES AND STANDARDS

40

10.00.00

PERFORMANCE GUARANTEES

43

11.00.00

QUALITY ASSURANCE , INSPECTION AND TESTING


DRAWINGS, DATA/ INFORMATION TO BE SUBMITTED BY
ALONG WITH THE BID
DRAWINGS, DATA/ INFORMATION TO BE SUBMITTED
AFTER THE AWARD OF CONTRACT
Annexures

44

12.00.00
13.00.00

50
52

ANNEXURE-I

SCOPE SUMMARY SHEET Fire Protection System

1 page

ANNEXURE-II

LIST OF SUB VENDORS

6 pages

ANNEXURE-III

TECHNICAL SPECIFICATION FOR LOW VOLTAGE MOTORS


TECHNICAL SPECIFICATION FOR LOW VOLTAGE
CONTROL CABLES
TECHNICAL SPECIFICATION FOR PANELS

5 pages

ELECTRICAL LOAD LIST FORMAT


TECHNICAL
SPECIFICATION
INSTRUMENTATION
SOURCE WATER ANALYSIS

1 page

ANNEXURE-IV
ANNEXURE-V
ANNEXURE-VI
ANNEXURE-VII
ANNEXURE-VIII
APPENDIX-IA
APPENDIX-IB
APPENDIX-IC

FOR

CONTROL

&

5 pages
7 pages

38 pages
2 pages

FIELD QUALITY PLAN


LIST OF ITEMS REQUIRING QUALITY PLAN AND SUBSUPPLIER APPROVAL
MANUFACTURING QUALITY PLAN

1 page
1 page
1 page

Attachments (Drawings)
VCT-EQ1A-C5-MZPT1-610-0106
VCT-EQ1A-C5-MZPT1-610-0104
VCT-EQ1A-C5-MZPT1-610-0101
VCT-EQ1A-C5-MZPT1-610-0102
Client
Project

Water Balance Diagram

1 SHEET

Scope and Concept Diagram for FDAPS, DS, SW & PW System

1 SHEET

P & ID for Fire Water Pumping System

1 SHEET

Flow scheme for Fire Protection System

1 SHEET

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 2 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Sl. No.
VCT-EQ1A-C5-MZPT1-610-0103
VCT-EQ1A-C5-MZPT1-456-0101
WM-TPT1-115-0100
MI-TSC1-812-8006
MI-TSC1-801-8007

Client
Project

PARTICULARS

Page No.

Block Diagram for Fire Detection and Alarm System

1 SHEET

Flow Scheme for Service Water Treatment System

1 SHEET

Plot plan
PLC SYSTEM CONFIGURATION FOR FIRE PROTECTION
SYSTEM (FIRE WATER PUMPS)
UPS SYSTEM FOR FIRE PROTECTION SYSTEM (FIRE
WATER PUMPS) PLC

1 SHEET

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

1 SHEET
1 SHEET

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 3 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
1.00.00

INTENT OF SPECIFICATION

1.01.00

This specification is intended to cover the design, engineering, manufacture and assembly,
inspection, shop testing at manufacturers works, proper packing and transportation to site,
unloading at site, site storage, handling at site, construction / erection, site testing and
commissioning of Fire Detection and Protection system, Dust Suppression system, Service
Water system, Potable Water system and sump pumps/de-watering pumps as detailed in
the scope of work for the Coal handling plant at SEW Vizag port Terminal, EQ-1A, AP state
of India.

1.02.00

It is not the intent to completely specify all details of design and construction herein.
Nevertheless, the equipment and installation shall conform to high standards of engineering
design and workmanship in all respects and shall be capable of continuous operation in a
manner acceptable to the Purchaser.

1.03.00

In the event of any conflict between the detailed specification of equipment and specification
data sheet of the equipment, the specification data sheet shall govern. In the event of
conflict between the General technical specification and the detailed technical specification
of the equipment, the latter shall govern. Henceforth, the terms Bidder and Sub-Contractor
will

be

used

interchangeably

in

this

document

as

applicable.

Any deviation or variation from the Scope requirement and/or intent of the specification shall
be clearly defined under Deviation Schedule of the Bid Proposal Sheets irrespective of the
fact that such deviation/variations may be standard practice or a possible interpretation of
the specification by the Bidder. Except for these deviations/variations covered under
Deviation Schedules which are accepted by the Purchaser before the award of the Contract,
it will be the responsibility of the Bidder to fully meet the intent and the requirements of the
specification within the quoted price. No other departure of the specification whatsoever
from the specification except for the declared deviation submitted by the Bidder with his
proposal shall be considered. Bids not complying with requirement shall be treated as nonresponsive and hence liable for rejection. The interpretation of the Purchaser in respect of
the scope, details and services to be performed by the Bidder, shall be binding, unless
specifically clarified otherwise by the Purchaser in writing before the Award of Contract.
2.00.00

Client
Project

SYSTEM DESCRIPTION

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 4 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
2.01.00

Fire Detection & Protection system


The type of fire Detection & protection system envisaged for various areas / buildings /
equipment facilities of this proposed plant are tabulated in Annexure-1 (Allocation summary
sheet for fire protection system).
Fire Protection system for the proposed plant shall be in accordance with TAC India (Tariff
Advisory Committee) / NFPA (latest edition).

2.01.01

Fire Water pumping system


Fire water pumps for this proposed plant will be installed in fire pump house taking suction
from fire cum service water storage tank. Fire water pumps shall be of horizontal centrifugal
type. Fire water pumping system for this proposed plant shall have the following

Electrical Motor Driven main Pumps, 2 Nos. of 273 m3/hr capacity at rated head of 95
MWC.

Diesel Engine Driven stand by Pump, 1 No. of 273 m3/hr capacity at rated head of 95
MWC complete with Diesel Engine control panels with battery and battery chargers.

Jockey pumps (2 Nos. of 20m3/hr. each) at rated head of 105 MWC. Jockey pumps
(1W+1S) pressure set points shall be selected to maintain the minor pressure losses in
the entire network as per the desired functional requirements.

All these pumps shall be controlled and monitored by a dedicated programmable logic
control system.

Necessary piping & fittings, valves, strainers, instruments, cables to complete the system.

Recommended Material of construction for Fire Pumps

2.01.02

i. Casing

Cast iron grade IS 210 FG-260

ii. Impeller

Bronze IS 318, Gr.II or equivalent

iii. Shaft

Carbon steel (EN 8 (BS 970) / IS 1570 Gr.40)

Fire hydrant system (Indoor / Outdoor)


Fire hydrant system for this plant shall consist of aboveground ring mains, hydrant valves,
risers and above ground branch headers with isolation valves. Fire water network for this
proposed plant shall be designed in order to cover entire Plant area including all buildings.
Ring main with individual tap-offs for the other Fire Protection System such as HVWS and
MVWS shall be provided. Suitable sectionalization valves shall be provided to ensure no
disturbance in the total system when a particular line segment or system has to be closed for

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 5 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
maintenance. All the Tap offs shall be provided with isolation valves as envisaged. Landing
valves shall be provided with Isolation valves.
The firewater ring main distribution system is envisaged to feed all water-based fire protection
system such as hydrant system and deluge water spray system.
The hydrant system consists of outdoor hydrants, hose cabinets, water monitors and indoor
hydrants. The fire water supply shall be provided by a tee-off from the firewater ring main
distribution system.
External hydrants shall be located all around the periphery of the buildings and outdoor
equipment & storage areas. Outdoor type fixed water monitors shall be provided for locations
where water cannot reach from hydrant hoses.
The following areas shall be protected by hydrant system.
a) Coal Handling Areas Transfer towers, conveyor galleries, wagon tippler area, ship
loader and jetty/berth area, coal stock pile etc.
b) Workshop and Stores Building
c) Fire water pump house
d) Cable trenches at SS-1 & ER-1
e) Miscellaneous buildings and Structures as per codes.
2.01.03

Water Spray system (Deluge system)


The spray system shall consist of High Velocity Water Spray System (HVWS) and Medium
Velocity Water Spray System (MVWS). High Velocity Water Spray System is provided to
extinguish fires involving liquids with flash points of 65C or higher and shall be installed where
such flammable fluids constitute the hazard.
a. Automatic High Velocity Water Spray system (HVW Spray system)
The location of wet pilot type deluge valve shall be kept away from the equipment to be
protected. The detection system shall consist of heat sensing detectors of fusible type
(quartzoid bulb) mounted on water filled detector pipe network around the equipment to be
protected. Another network of water projectors shall be mounted around the equipment to
be protected and this network shall be connected to the water supply mains through the
deluge valve. The deluge valve shall be normally kept closed by the water pressure from
the downstream of deluge valve in the detector network against the water pressure in the
mains. When heat sensing detectors fuse due to bursting of quartzoid bulb, pressure in the
detector network drops thus causing the deluge valve to open and activate the spray

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 6 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
system. Fast acting butterfly valves shall be provided at the downstream of the deluge
valve, so that the butterfly valves can be kept closed and operated manually in the event of
fire, if there is any malfunction of deluge valve. Gate valve shall be provided in the
upstream of deluge valve, further, fast acting butterfly bypass valve to deluge valve is to be
provided.
HVW spray system shall be provided for 2 nos. of 5 MVA transformers.
b. Automatic Medium Velocity Water Spray system (MVW Spray system)
In order to avoid total flooding of the area in the event of fire in a particular zone, the area
shall be divided into number of zones. Each zone shall have separate water supply network
controlled by a deluge valve. The fire in the cable trench and coal conveyors shall be
detected by a detection system which shall give an electrical signal for the operation of the
deluge valve. In the event of fire in a particular zone, the deluge valve of corresponding
zone and those of adjacent zone on either side shall be opened. The number of zones shall
be decided during detailed engineering. Opening of deluge valve shall result in starting of
pump. Fast acting butterfly valves shall be provided as a bypass to deluge valve, so that
this valve can be kept closed and can be operated manually, if there is any malfunction of
deluge valves. Isolation valves on upstream and downstream side of deluge valve shall
also be provided. The cable galleries shall have number of rows of cable trays and each
row shall have number of tiers of cable trays. Each of the cable rows shall be provided with
a network of water distribution piping and nozzles. The distribution network shall consist of
distribution header for each row of cable tray and on these header drop pipes located at an
interval not exceeding 3m shall be provided so as to cover all the tiers.
MVW spray system shall be provided for coal conveyors & cable trenches.
2.01.04

Portable Fire extinguishers


Portable Fire Extinguishers of both floor mounted and trolley mounted with suitable capacity,
rating and medium in adequate numbers shall be provided for the entire coal handling Plant
including all buildings and berth area, equipments based on the hazard occupancy for this
proposed plant.

2.02.00

Fire Detection, Alarm & Control System


Fire Detection and Alarm system shall be designed as per NFPA 72 and relevant IS
standards. Fire detection and alarm system for the proposed plant shall be Analogue

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 7 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Addressable type consisting of interface modules, various types of fire detectors, repeater
stations, local fire alarm panels and interconnecting cables. Manual call points and Notification
appliances will be provided for total plant areas and as mentioned in Annexure1 (Scope
Summary sheet).All the fire protection system shall be provided with interfacing modules for
alarm signals and automatic system activation and operation and also fire pumps status
signals from Fire protection pump PLC system.

Scope summary sheet attached herewith as Annexure-1 shall be referred to for various
protection and detection system applicable for the plant facilities.

2.03.00

Dust Suppression System


The dust control system to be furnished under this specification is required for control of
fugitive dust emissions from dust generation points at transfer towers and coal stock pile. Dust
control is achieved by dust suppression system.

Contractor shall guarantee and offer dust control system which shall inhibit dust concentration
in the ambient air inside the buildings within acceptable limits as per internationally recognized
hygienic Standards/Codes, MOEF and state pollution control board.

2.04.00

Service Water System


Service water system shall be provided for complete coal handling plant and jetty/berth area
and buildings. The system shall comprise of water treatment/conditioning plant as envisaged
considering the source water quality (attached as Annexure-VIII with this document).

2.05.00

Service Water Treatment System


Service water shall be produced from the treated sewage water which shall be fed to the feed
water tank. Service water treatment shall consist of pressure sand filters and activated carbon
filters in series. Feed water shall be chlorinated before it enters in to the filtration plant.
Necessary dosing tanks, dosing pumps and all other accessories shall be provided. Pressure
sand filter shall be provided mainly to remove the suspended solids and activated carbon
filters shall be provided to eliminate the organic material, oil & grease, residual chlorine and
other impurities.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 8 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Product water from the filters shall be collected in the fire water cum service water tank and
back wash water required for the filter back wash shall be taken from this tank. Separate set of
back wash pumps shall be provided for the filter back wash. Necessary air blowers shall be
provided to clean the filter bed as and when required. The waste backwash generated during
the backwash of the filters shall be collected in the backwash collection and shall be disposed
suitably by waste back wash transfer pumps.
Normally filters provided shall be 2 x 100%, i.e., during normal service operation one filter is
working and other is standby but if required both the filters shall be put in to service mode.
Hence all the headers provided shall be designed for both the filters working condition. All the
headers shall be designed for 250 m3/h of the filter water. However, the capacity shall be
finalized based on discussion during detailed engineering.
2.06.00

Potable Water system


Potable water system shall be provided for complete coal handling plant and jetty/berth area
and buildings. The system shall comprise municipal water feed water tank, Potable water
pumps, PW overhead tanks with connections up to the facilities user points as identified in the
Scope and Concept Diagram for FFS, DSS, SWS & PWS (DWG. No. VCT-EQ1A-C5-MZ-PT1610-0104).

2.07.00

Sump Pumps
Two sets of sump pumps located at respective drain pit/sump shall be provided at Wagon
tippler complex, ER-1, SS-1 cable trench pits, fire water pumps area. Pumps shall be
submersible type of pumps.

2.08.00

Coal Pile Run-Off System


Coal stockpile run-off system shall constitute of 2-chamber coal settling sumps of suitable
capacity along with disposal 2x100% pumps of adequate capacity. The pump discharge will be
lead to nearest storm/plant water drain system.

2.09.00

Water Source
Water supply connections for dust suppression, service water system shall be taken from
common fire cum service water storage tank. Further network of piping including all pumps,
tanks, necessary accessories, supports and fittings etc. for distribution of water for dust
suppression and service water system in all Transfer towers, berth area, control rooms etc.
shall be part of the system scope.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 9 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
3.00.00

SCOPE OF SUPPLY, WORK AND SERVICES

3.01.00

Fire Protection System


The scope shall include but not limited to the following for full functioning and system
completeness. Onsite fire protection system shall be provided for the proposed plant as
described in scope summary sheet, Annexure -1.

3.01.01

Storage tank level control and level transmitter.

3.01.02

Fire water Pumps


A. Two (2) sets of Electrical motor driven main pumps of capacity 273 m3/hr each at 95
MWC head complete with motor, base plate, foundation bolts and other accessories.
B. One (1) set of Diesel engine driven stand by pump of capacity 273 m3/hr at 95 MWC
head complete with base plate, foundation bolts, diesel engine, Diesel engine control
panel with batteries and battery chargers, diesel oil tank, exhaust gas system, piping
and fittings for diesel supply, return and drain lines, and other accessories.
C. Two (2) sets of Electrical motor driven jockey pumps of capacity 20m3/hr at 105 MWC
head complete with motor, base plate, foundation bolts and other accessories.
D. One (1) lot of valves (gate & check), piping, fittings, pipe support material, bolts / studs,
washers and nuts.
E. One (1) EOT crane for handling fire water pumps.

3.01.03

Hydrant system
A. One (1) lot of single headed hydrant valves (Indoor and outdoor) complete with all the
accessories.
B. One (1) lot of water monitors (75 mm size having nozzle bore of 38 mm) with isolation
GATE valves complete with all the accessories.
C. One (1) lot of 15 m long hoses with male and female instantaneous couplings for
external hydrants.
D. One (1) lot of 7.5 m long hoses with male and female instantaneous couplings for
internal hydrants
E. One (1) lot of branch pipes, nozzles as per the TAC guidelines.
F. One (1) lot of hose boxes required for placing hoses, branch pipes, and nozzles etc. as
per the TAC guidelines.
G. One (1) lot of Underground piping (corrosion protected as per IS 10221- wrapping &
coating) with pipe support material, fittings, bolts and nuts

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 10 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
H. One (1) lot of above ground piping (painted Two coats of grey zinc primer, two coats of
coal tar rubber paint/coal tar epoxy being saline atm.) with pipe support material, fittings,
bolts and nuts.
I.

One (1) lot of sectionalization isolation valves with mating flanges, gaskets, bolts and
nuts.

J. One (1) lot of drain valves and air release valves


K. One (1) lot of Hume pipes for underground pipe road crossings.
L. One (1) lot of pressure gauges and pressure switches.
3.01.04

HVW & MVW spray system


A. One (1) lot of deluge valves with automatic, remote and manual operation trim assembly
complete with manifold, pressure switches, pressure gauge, solenoid valve, water motor
alarm gong etc.
B. One (1) lot of isolation valves for upstream of deluge valves with mating flanges,
gaskets, studs/bolts and nuts.
C. One (1) lot of butterfly valves as by-pass and downstream valves for deluge valves.
D. One (1) lot of High velocity spray nozzles or projectors
E. One (1) lot of Medium velocity spray nozzles or sprayers
F. One (1) lot of quartzoid bulb (QB) detectors as detection system for HVW spray
protected equipments.
G. One (1) lot of above ground piping (painted Two coats of grey zinc primer, two coats of
coal tar rubber paint/coal tar epoxy being saline atm.) with pipe support material, pylon
supports, fittings, bolts/studs, washers and nuts.
H. One (1) lot of above ground galvanized (As per IS 4736) piping (at downstream of
deluge valve) with pipe support material, pylon supports, fittings, bolts/studs, washers
and nuts.
I.

One (1) lot of isolation valves with mating flanges, gaskets, bolts/studs, washers and
nuts.

3.01.05

Portable fire extinguishers


One (1) lot of following extinguishers with all the accessories shall be provided
Sl. No
1

Type of Fire extinguisher


CO 2 type

Capacity
4.5 kg
(Conforming to IS 2878)

Client
Project

Trolley mounted Mobile type CO 2

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

22.5 kg

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 11 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
(Conforming to IS 2878)
3

Dry chemical powder type

5 kg
(Conforming to IS 2171)

Trolley

mounted

Mobile

type

dry

chemical powder type


3.02.00

50 kg
(Conforming to IS 10658)

Dust Suppression System


Complete dust suppression system for control of fugitive dust shall be provided for following
facilities.

Transfer tower 1

Transfer tower 2

Transfer tower 3

Transfer tower 4

Transfer tower 5

Coal stock pile

Along with pumps, electrical works, drives, hoisting arrangements, piping, fittings, valves and
supports etc. as briefly specified below.
A. Plain water dust suppression around stockyard through sprinklers. The system shall
comprise of 2 Nos. DSS pumps of capacity 125m3/hr (1w + 1sb). Capacity of the pumps
shall be finalized based on discussion during detailed engineering.
B. Dry fog type dust suppression system at conveyor discharge shall be tapped from service
water lines feeding WT, SR & SL etc. However, this concept shall be finalized during
detailed engineering stage.
C. Air compressors and receivers of suitable capacity shall be provided; located at two
separate locations (one set near TT-2 and other set near TT-3 or TT-4 area); each location
having 2 Nos. Air compressors (1w+1sb), for dry frog dust suppression system.
The capacity of air compressors located at TT-3 shall also include additional service air
requirement catering to compressed air requirement at water treatment plant area.
3.03.00

Service Water System and Water Treatment System


2x100% service water pumps of 85 m3/hr. capacity at rated head of 35 MWC along with
level & pressure switches and piping up to terminal points of water treatment system (Refer
Water treatment system Flow Scheme, Dwg. No. TM-PT1-456-0101) and other user points
in the plant area. Capacity and head of the service water pumps shall be finalized based on
discussions during detailed engineering.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 12 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Complete service water distribution system with water supply system, valves, quick couplings,
hose pipes with nozzle, piping, pumps, drive motors with canopy, couplings with enclosure,
electrical works, including supporting structures, handling for equipments, civil and structural
works and necessary accessories shall be provided throughout the coal handling plant area in
Contractors scope.
Water treatment/conditioning plant shall have stream capacity of 2 x 50m3/hr. which shall be
finalized during detailed engineering (1 stream working and another standby) with provision to
operate both the stream simultaneously. The treatment plant shall have:
A. One (1) no of feed water storage tank of RCC construction (By Purchaser) complete with
all the accessories.
B. Two (2) nos. of hypo dosing tanks for feed water along with two (2) nos. (1W+1S) dosing
pumps complete with all the accessories
C. Two (2) nos. (1W+1S) filter feed pumps complete with all the accessories
D. Two (2) nos. (1W+1S) pressure sand filters complete with all the accessories
E. Two (2) nos. (1W+1S) of blowers for pressure sand filters complete with all the accessories
F. Two (2) nos. (1W+1S) of activated carbon filters complete with all the accessories
G. Two (2) nos. (1W+1S) filter backwash pumps complete with all the accessories
H. One (1) no. of filter water cum fire storage tank of RCC construction (By Purchaser)
complete with all the accessories.
I.

One (1) no. of filter back wash water collection tank of RCC construction (By Purchaser)
complete with all the accessories

J. Two (2) nos. (1W+1S) SSF back wash transfer pumps complete with all the accessories
3.04.00

Potable Water System


Potable water system for this facility shall be provided for the following areas

SS1 building user points

EQ berth user points

Wagon Tippler complex user points

Potable water system shall comprise of RCC feed water tank (provided by others), potable
water pumps, Potable water Overhead Tanks with connections to respective areas user points.
Along with pumps, electrical works, drives, piping, fittings, valves and supports etc. as briefly
specified below.
A. 2 Nos. PW pumps of capacity 5 m3/hr (1w + 1sb) at 50 MWC. Capacity of the pumps shall

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 13 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
be finalized based on discussion during detailed engineering.
B. 3 Nos. of HDPE Overhead tanks of capacity 2 cu.m each with floating valve, drain valve,
vent and overflow provisions.
C. Necessary piping, valves, pipe supports and required accessories to complete the system
from the RCC feed water tank to the user points.
3.05.00

Sump Pumps
Total 2x100% (1W+1S) sump pumps of 25 m3/hr. capacity at rated head of 25 MWC along with
level switches and piping up to nearest drain (max. up to 50.0 meters from outside the building)
shall be provided at Wagon tippler complex, Sump pumps/de-watering pumps for SS-1, ER-1
and fire water pump house area.
The pumps shall be of wet pit types, vertical shaft and impeller shall be specially designed to
pass large solids or unscreened liquids. The construction and material shall be suitable for
pumping coal/dust contaminated water with a minimum of maintenance. All bearings of the
pump shall be located above the water level.
The piping system shall be designed to suit operations of pumps including standby pump.
Capacity and head of these pumps shall be decided during detailed engineering, all these
pumps shall be submersible type.

3.06.00

Electrical Scope
Bidder shall supply the below specified Electrical equipments.
A. LT panels for Dust suppression system (Single incomer Scheme) in Stockpile area &
Transfer tower T1, T2, T3, T4 & T5. Panels shall be in line with attached Technical
Specification for LV Switchgear
B. LT panel for Fire Protection system Pumps (2 incomer scheme)
C. All motors along with terminal boxes in line with attached Technical Specification for
Induction Motors.
D. Supply, laying and termination of LV power & control cables, cable accessories, cable
carrier system between bidder supplied equipments shall be in Bidders scope.
E. Cabling & Cable carrier system between bidders supplied equipments shall be in bidders
scope.
F. Special cables & cable carrier system as required for Dust suppression system
G. Total Six (6) nos. of 3ph 415 V AC feeders suitably rated l be provided by Purchaser for
dust suppression panels located in above mentioned areas. Quantity and of the feeders
shall be finalized at later stage after finalization of quantity, capacity and head of the
pumps. Any other voltage AC/DC if required the same shall be derived by Bidder using 415

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 14 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
V AC. Bidder shall clearly indicate in his offer the No. of LT panels along with location and
power supply requirements.
H. Junction Boxes as required.
I.

Local Push Button stations.

J. Valve actuators with integral starters


K. Above Ground Earthing.
Purchaser will terminate one (1) nos. of 415V LT power cables up to the Bidder supplied 415V
Dust suppression system LT panels and two (2) nos. of 415V LT power cables up to the Bidder
supplied 415V Firefighting LT panels placed in above mentioned locations. Further the
complete electrical scope is by Bidder.
Specific Electrical requirements:
All the electrical equipment shall be capable of continuous operation at specified rating without
overheating under the following conditions:

Voltage variation:

10%

Frequency variation:

5%

Combined voltage and


Frequency variation

10%

The voltage level of motors is considered based on the following:


i)

For the drives rated > 110 KW

: 6.6 KV

ii)

For the drives rated < 110KW

: 415 V

Degree of protection for various enclosures as per IEC shall be as follows:i)

Indoor motors

IP 54

ii)

Outdoor motors

IP 55 (With Suitable
canopy)

Note: Bidder shall furnish the electrical load list as per the attached format.

Optional Quote:
Bidder shall provide optional price for energy efficient motors along with the bid.
3.07.00

Control & Instrumentation


The Scope of Control & Instrumentation control systems under this package are as below.
Please refer to enclosed Annexure VII for detailed specification for Control &

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 15 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Instrumentation systems
Fire Water system

Dust Suppression System


for CHP Transfer Towers
(TT)

Dust Suppression System


for Coal Stock Pile.
Service Water System for
WT, SR & SL etc.
Potable Water system
Diesel Engine driven Fire
Fighting Pump

UPS

PLC based Control System with Front panel


mounted Graphical User Interface (GUI) of 12
sized for operator Interface.
This will be controlled by E1 Package PLC (By
owner) located at SS1. Bidders scope includes
all the required field instrumentation for
successful operation of DSS System up to Field
Junction Boxes including Junction boxes and
cabling up to JBs.
PLC based Control System with table mounted
Graphical User Interface (GUI) of 21 sized for
operator Interface
Shall be controlled and operated by Fire water
system PLC.
One (1) Diesel engine local control panel with
battery and battery charger, same will be
controlled and operated by Fire water system
PLC
Dedicated Package UPS System of desired
rating shall be provided by bidder along with
each of the PLC Based Control System

A. One (1) lot complete instrumentation and control cables as required with in bidders battery
limits of each system
B. One (1) lot of automatic operating devices, manual actuation devices / abort switches,
audio-visual safety warning devices, instrumentation associated control systems.
C. Fire Protection system (Fire water Pumps) & Stockyard DSS System PLC system
interfaced to SS1 PLC (provided by Owner) to transfer data through Modbus TCP /IP.
Communication through redundant fiber optic cable. All necessary hardware required at
SS1 PLC end and FFS PLC shall be in Owners scope. In addition to soft connectivity, hard
wired interface with SS1 PLC (provided by Owner) shall also be provided. Exact signal
exchange shall be decided during award stage.
D. All the necessary interface Software / hardware like switches, converters servers &
F.O.Cable etc. as required at both ends i.e SS1 PLC End and Respective Local Control
Systems, to establish two-way link between PLC / Micro Controller and the E1 Package
PLC System located at SS1 Control Room area shall be taken care by Owner .However
Bidder has to provide .necessary ports and Power supply facilities to these accessories at
his PLC End.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 16 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
E. All the control panels shall be accessible and located near their respective equipment and
shall be complete with all the required controls, interlocks, indicating lamps etc. Further,
necessary controls, indications and annunciations for all the above equipment shall be
provided at Fire Protection system (Fire water Pumps) PLC system in Fire water pump
house.
F.

Standalone UPS system of adequate capacity with 60 min battery back-up shall be
provided for the Fire Protection system (Fire water Pumps) PLC system & DSS PLC
System, local panel, Instruments and GIU equipment etc. The battery shall be Ni-Cd type.

G. Owner shall provide one number of NTP Server based time signal from main SS1 PLC
system which shall be interfaced with Fire Protection system & DSS (Fire water Pumps)
PLC system for uniform time tagging purpose. however required cable and accessories
shall be in bidder scope.
H. Graphics of the Fire Protection system (Fire water Pumps) PLC system shall be replicated
on the SS1 PLC OWS in CCR by Owner. However, the graphic software for the above
purpose shall be included in the FDAPS vendor scope.
I.

All instrumentation cables within the battery limits of FDPS & DSS Systems are in the
scope of Bidder. Also all instrument cable shall be armored type. Inner and outer sheath
shall be FRLS PVC compound. All the loop cables, connecting various detectors, DVs,
MCPs, Hooter, LHS etc shall be fire survival type. data sheets shall be finalized DDE.

J.

All 415V LT switchgear incomer/bus tie/outgoing power feeder breakers etc. shall be
controlled and monitored from Fire Protection & DSS system (FPS & DSS) PLC system.
Necessary signal exchange for the above, please refer signal interface specified in
enclosed Annexure-VII. Each above breaker is provided with multi-function meter for
monitoring analogue values through RS 485 protocol. The same shall be interfaced with
Fire Protection system (Fire water Pumps) PLC system and necessary provision shall be
provided.

K. All other motor feeders shall be controlled from Fire Protection system (Fire water Pumps)
PLC system. The MCC to PLC Interface cabling shall be by Owner
L.

PLC system configuration shall be redundant in CPU, communication system, power


supply modules and redundancy in digital and analogue output modules only for critical
loops (which shall be finalized during detailed engineering).

M. Separate Laptop shall be provided by bidder as engineering tool for programmable


functions with required software for Fire Protection System (Fire Water Pumps) PLC.
Please refer to enclosed PLC System Configuration for Fire protection system & DSS
Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 17 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
System and Scheme for Standalone UPS System.
All the above shall be accessible and located near their respective equipment and shall be
complete with all the required controls interlocks, indicating lamps etc. Further, necessary
controls, indications and annunciations for all the above equipment shall be provided at
Fire Protection System (Fire Water Pumps) PLC system located in raw/fire water pump
house.
3.08.00

Fire Detection and Alarm System


Fire detection and alarm system required for Coal handling areas including conveyors,
Transfer towers, Wagon tippler complex shall be by the bidder. Fire detection & alarm
system for this coal handling areas shall be hooked up with the plant main fire alarm system
panel (provided by others) located in SS1 building.
A. One (1) Lot of fiber optic linear heat sensing cable with necessary control unit and
interface modules.
B. One (1) lot of automatic photoelectric smoke detectors if applicable.
C. One (1) lot of heat detectors of various types if applicable
D. One (1) lot of response indicators
E. One (1) lot of fault isolator modules, monitor modules and control modules as required.
F.

One (1) lot of deluge valve local control panels with necessary interlocks, relays,
instrumentation for all the fire protection system operated by deluge valve.

G. One (1) lot of all the necessary instruments for monitoring / controlling such as pressure
gauges, pressure switches, pressure transmitters, solenoid valves, level switches, level
indicators, limit switches etc. to complete the system.
H. All the above control panels / devices / modules shall be accessible and located near their
respective equipment and shall be complete with all the required controls, interlocks,
indicating lamps etc. Further, necessary controls, indications and annunciations for all the
above equipment shall be hooked up at Main Fire Alarm Panel (MFAP) located in SS-1
(provided by others)
I.

One (1) lot of indoor, outdoor manual call points.

J.

One (1) lot of hooters / sounders.

K. One (1) siren.


L.

One (1) lot of complete terminal boxes, junction boxes.

M. One (1) of necessary relay modules, input and output modules.


N. One (1) lot of complete detector, control and network cables with cable carrying and
supporting system.
O. One (1) lot complete cable installation accessories
Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 18 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
3.09.00

Scope of services
Bidder shall provide the following services under the scope of this specification.

3.09.01

Design, engineering, manufacture and assembly, inspection, shop testing at manufacturers


workshop, transportation to site, unloading at site, site storage, preservation, handling at
site, construction / erection, site testing and commissioning of the proposed fire protection
system.

3.09.02

Fire protection system & Stockyard DSS System shall be interfaced with the E1 Package
PLC. E1 package contractor, FPS and Dust suppression contractor shall provide required
input and cooperate for successful interfacing.

3.09.03

Though the minimum basis for system capacity selection is given in this document, bidder
shall re-assess and submit design criteria and capacity selection calculations for all the
systems for review and approval.

3.09.04

Bidder to provide the total water demand required for dust suppression, fire protection,
service water, potable water as input to enable the design of storage tank.

3.09.05

Hydraulic analysis for ensuring adequacy of the completed system shall be within the
Bidders scope.

3.09.06

Surface preparation, application of primer, intermediate and final painting at shop and site
as applicable.

3.09.07

The following civil works shall be included in Bidders scope.

Excavation and back filling for laying of underground pipes

Construction of deluge valve sheds as envisaged

Construction of pedestal supports wherever required

Grouting of all foundations

Making openings in the walls for routing of pipes

Sealing/Making good of the openings

Laying of sleeve pipes for pipes crossing roads

Base Frame for all the equipment & Anchor bolts are in bidder scope.

Bidder to consider Passive Fire Protection System in their scope - Optional Price (Unit price
per meter square) shall be provided for the same by bidder.

3.09.08

Transportation and delivery of all materials and equipment by rail / road to site.

3.09.09

Carrying out erection, testing and commissioning, and performance test of all equipment
and accessories.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 19 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
3.09.10

Providing certified copies of test reports for all tests and examinations specified and also for
the mandatory tests and analyses required by the applicable material specification for the
materials used.

3.09.11

Bidder shall furnish training to the Owners operation and maintenance personnel at his
work shop / his sub-vendors works and at site.

3.09.12

Obtaining necessary authority approvals from various agencies Chief Fire Officer,
Hyderabad. OISD guidelines or applicable international codes/practices/Local authorities as
applicable.

3.09.13

Consumables
Supply of all consumables as applicable for commissioning and performance test shall be
included in the scope of bidder and the same shall be supplied by the bidder at appropriate
time.

3.09.14

Lubricants
All flushing oil required together with the first fill of oil / lubricants / grease as applicable for all
parts of the equipment where lubrication is required shall be provided by the bidder up to taking
over. All types of lubricants of equivalent grade of other makes shall be readily obtainable
locally.

3.09.15

Spare Parts
Necessary Spare Parts listed in this specification under clause 1.04.00 shall be supplied
a. Start-up & commissioning spares, bidder shall provide the list of these spares.
b. Recommended spares for 2 years of trouble free operation. Bidder to provide the list
with Unit price as per FOR site basis.
Start-up & commissioning spares shall be considered as included in the Bidders Offer Price for
this Package.

3.09.16

Special tools and tackles


One (1) lot of special tools and tackles as listed in Appendix I2 of section 1,shall be supplied
by the bidder for operation and maintenance.
a. Supply of all erection hardware.
b. Name plate, Tag plates, rating plate, caution tag for each equipment

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 20 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
4.00.00

TERMINAL POINTS

4.01.00

Mechanical:
A.

Source water supply at one point by municipality/VPT; treatment/conditioning and


metering (1w+1sb) in Bidders scope.

B.

One service water receiving terminal point at wagon tippler complex for usage by WT
and SAC facilities; required TP data is flow: 62m3/hr and pressure 2bar.

C.

Four service water receiving terminal points at each Stacker-cum-Reclaimer area for
usage by Stacker-cum-Reclaimer facilities; required TP data is flow: 4.5m3/hr. for each
stacker/reclaimer and pressure 2bar for each TP.

D.

One service water receiving terminal point at center of the travelling length of Ship
loader/Jetty area for usage by Ship loader/Jetty facilities; required TP data is flow:
7.0m3/hr and pressure 2bar.

E.

Fire detection & alarm system for coal handling areas shall be hooked up with MFAP
located in SS1 buidling.

4.02.00

Electrical
A. At LT panels incomer of Fire water pump house MCC.
B. At LT panels incomer of Dust suppression system MCC
C. Riser of underground earthing strip or above ground earthing strip.

4.03.00

Civil
Fire Water Pump house and fire water pumps foundations shall be provided by the Purchaser.
Further, the service cum fire water storage tank will also be provided by others (RCC tank)
Potable water system RCC feed tank will also be provided by others.
Bidder to provide necessary nozzle details for his pumps/equipment, foundation load data for
civil design. However base plates, foundation bolts, embedded parts etc. as required shall be in
the scope of Bidder.

4.04.00

Client
Project

Controls & Instrumentation

Fire Protection system

Outgoing signal terminal block / Port for


Interface from FPS PLC to E1 Package
PLC

Dust Suppression System for


CHP Transfer Towers (TT)

This will be controlled by E1 Package PLC


(By owner) located at SS1. Bidders scope

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 21 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM

Dust suppression System for


Coal Stock Pile

Service Water System for WT, SR


& SL etc.
UPS

includes
all
the
required
field
instrumentation for successful operation of
DSS System up to Field Junction Boxes
including Junction boxes and cabling up to
JBs.
Outgoing signal terminal block / Port for
Interface from DSS PLC to E1 Package
PLC
Shall be controlled and operated by Fire
water system PLC.
Redundant 1 Ph 230 V AC feeders of
desired rating will be provided by Owner up
to Bidders UPS. Reception and terminating
the same with necessary auto changeover
circuitry shall be by Bidder.

5.00.00

EXCLUSIONS & FACILITIES PROVIDED BY OTHERS

5.01.00

Construction of pump house, pump foundations, fire water storage tank and other civil
structures in the port facility are excluded except mentioned in the scope.
Fire tenders are excluded from the scope of bidder.

5.02.00

Electrical
A. Switchgear / MCC
B. Power & control cables beyond Bidder supplied equipment.
C. Cable trays / trenches for power, control and instrumentation cabling beyond bidders
supplied equipment.
D. Underground Earthing.
E. Lightning Protection

5.03.00

Raw / Fire water pump house area CCTV system interface to Fire protection System (Fire
Water pumps) PLC splice box (patch card) connection cable

5.04.00

MCC to PLC Interface cabling. This will be done by E1 Package bidder as per approved
Drive Philosophy.

5.05.00

FPS, DSS System PLC Interface with E1 Package system PLC is excluded from Bidders
scope. Necessary cabling and Hardware required at both ends shall be taken care by E1
Package Supplier. However Bidders shall have all the provisions required for Interfacing at
his end.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 22 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
6.00.00

DESIGN AND CONSTRUCTIONAL REQUIREMENTS

6.01.00

Fire Protection system


The fire protection system shall be designed as per recommendations of TAC and NFPA
guidelines. As per TAC regulations, the electric generating stations (other than Hydro) come
under the Ordinary Hazard category. Hence the entire fire protection system shall be designed
accordingly, wherever NFPA and TAC guidelines are not available, other codes and standards
(refer clause 2.09.00) as applicable shall be followed

6.01.01

Fire water pumps


Fire water pumps for this proposed shall consist of

Electrical Motor Driven main Pumps, Two nos. of 273 m3/hr. capacity each at rated head
of 95 MWC.

Diesel engine driven stand by Pump, one no. of 273 m3/hr. capacity at rated head of 95
MWC. Diesel Engine control panels with battery and battery chargers will be provided.

Jockey pumps (2 Nos. of 20m3/hr. each) at rated head of 105 MWC. Jockey pumps
(1W+1S) pressure set points shall be selected to maintain the minor pressure losses in
the entire network as per the desired functional requirements.

Recommended Material of construction for Fire Pumps

6.01.02

i. Casing

Cast iron grade IS 210 FG-260

ii. Impeller

Bronze IS 318, Gr.II or equivalent

iii. Shaft

Carbon steel (EN 8 (BS 970) / IS 1570 Gr.40)

Hydrant system
Hydrants (external, internal and water monitors) shall be provided as per the
recommendations of TAC. Hydrant protected areas shall be as per the scope summary
sheet enclosed as Annexure 1.
Fire hydrant system for this plant shall consist of aboveground ring mains, hydrant
valves, risers and above ground branch headers with isolation valves. In case of
underground piping, proper coating and wrapping shall be carried out as per IS: 10221
and TAC recommendations.
The pressurized hydrant pipe work feeds water to a number of hydrants (indoor as well
as outdoor) and to outdoor type fixed water monitors around the plant and buildings.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 23 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
All hydrants served by the ring main system shall be positioned at strategic locations
around the plant and located in such a way that all buildings and risk areas shall be
suitably protected by them.
Hose pipes of suitable lengths along with standard accessories like hose boxes, central
hose houses etc. shall be provided.
Each internal hydrant valve shall be provided with individual hose box having glass
front containing hoses, branch pipes, nozzles, and spanners etc. as per TAC
guidelines.
For outdoor or yard hydrants, required hoses , branch pipes, nozzles etc shall be kept
in a hose box alongside of hydrants or the required accessories for 10 hydrants each
can be grouped and kept in a central hose house at strategic locations as per TAC
guidelines.
In case of fire, these hoses are coupled to the respective hydrant valves through
instantaneous coupling and the hydrant / landing valve is opened to direct a jet of water
to the seat of fire.
The water required for the hydrant system shall be supplied from the Fire water pumps
located in the Fire water pump house.
It shall be ensured that the sufficient quantity of water is available for fire protection
purposes as per the guidelines of TAC.
Ring main shall be terminated with Isolation valves and a blind flange at all tap offs
consisting of 3 or 4 hydrants, for every other fire protection system tap off and the
corners to enable future expansion / modification by the Owner.
Interconnection for fire hydrant system with isolation valve with M/s Adani and M/s
Vedanta hydrant system as per VPT requirement.

Material of construction
i. Hydrant valves

Stainless steel (conforming to IS: 5290)

ii. Water monitors

As per IS 8442

iii. Hoses

Non-percolating type (type-A or equivalent)


(As per IS 636)

Client
Project

iv. Branch pipes Nozzles

SS 316 conforming to IS: 6529

v. Nozzles

SS 304 conforming to IS: 6529

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 24 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
6.01.03

HVW Spray system


HVW spray system shall be provided for transformers.
Water requirement of HVW spray shall be estimated considering the total surface
area of the equipment including bottom surface, radiators and conservators in case of
transformer. All the surfaces of the transformers / equipments are covered with a
spray density of 10.2 lpm/m2 as per TAC guidelines. Water required for HVWS system
for the transformer shall be considered as the one of the maximum water demand
criteria of HVW spray system for this plant.
The system shall automatically detect control and extinguish any out-break of fire and
simultaneously gives audible alarm.
Water line forms a ring around the equipment to be protected with projected outlets at
various points fitted with nozzles. Water under pressure is directed to the projector
network through a deluge valve from a pipe network laid exclusively for the spray
system.
The system shall be hydraulically so designed the minimum water pressure at any
remote projector shall be 3.5 kg/cm2 and not greater than 5.0 kg/cm2 and the velocity
in the feed pipes shall not exceed 10 m/s. Discharge density of 10.2 lpm/m2 of
projected surface area for transformers / equipment shall be used as per TAC
recommendations.
In case of detection of fire in transformers/equipment, deluge valve in spray water line
shall be opened by operation of quartzoid bulb detectors (bulbs thermally expand on
the rise of temperature and bursts) and spray water system shall come into operation
automatically, pressurized water shall be discharged through the nozzles forming an
emulsion & impinge on the surface to be protected. The system shall have remote
and manual actuation facilities also.
All the materials, equipment, devices shall be of approved standards (UL Listed/ FM
approved / BIS approved) and shall be in accordance with TAC guidelines.
Body of projectors and the detection sprinkler bulbs shall be of Stainless steel or
Brass with chrome plating.
An Isolation valve shall be provided at both the upstream (gate valve) and
downstream (butterfly valve) of each of the deluge valve. The size shall be as that of
Deluge valve. Further, butterfly bypass valve to deluge valve shall be provided.

6.01.04

Client
Project

MVW Spray system

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 25 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
MVW spray system shall be provided for the following areas.
1. Coal Conveyors gallery, Conveyor tunnel
2. Cable trenches
Operation of MVWS system shall be automatic. Upon detection of fire either by the
detectors, deluge valve in the spray line shall be opened automatically. In the event of
fire detection, the protected areas shall be sprayed with water. Suitable zoning shall be
done to limit the extent of spray coverage and each zone shall be operated with a zonal
deluge valve. MVWS protected areas such as coal Conveyors shall be divided in
different zones to facilitate operation in 3 zones simultaneously one forward and one
behind the affected zone to avoid the spread of fire to other zones.
The system shall be hydraulically so designed the minimum water pressure at any
remote sprayer is not less than 1.4 kg/cm2 and not greater than 3.5 kg/cm2 and the
velocity in the distribution pipes shall not exceed 5 m/s. The minimum water pressure at
any projector or nozzle shall be 1.4 bar for conveyors. Discharge density of 10.2 pm/m2
shall be provided for conveyors as per TAC recommendations.
All the materials, equipment, devices shall be of approved standards (UL Listed/ FM
approved / BIS approved) and shall be in accordance with TAC guidelines. Body of
nozzles shall be of Stainless steel or Brass with chrome plating.
An Isolation valve shall be provided at both the upstream (gate valve) and downstream
(butterfly valve) of each of the deluge valve. The size shall be as that of Deluge valve.
Further, butterfly bypass valve to deluge valve shall be provided.
6.01.05

Portable fire extinguishers


In addition to various types of fire protection system described above, Mobile (trolley mounted)
& portable (floor or wall mounted) fire extinguishers of different types shall be provided at
various locations and inside the off-site buildings as per TAC recommendations. Distribution of
these extinguishers in various locations shall be as per the TAC guidelines.
Portable fire extinguishers of the following type shall be provided.
Sl.

Type of Fire extinguisher

Capacity

Quantity *

CO 2 type

4.5 kg

10 Nos

No
2

(Conforming to IS 2878)
3

Client
Project

Trolley mounted Mobile type

22.5 kg

CO 2

(Conforming to IS 2878)

Dry chemical powder type

5 kg

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

5 Nos

10 Nos

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 26 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
(Conforming to IS 2171)
5

Trolley mounted Mobile type dry

50 kg

5 Nos

chemical powder type

(Conforming

to

IS

10658)

(*Extinguisher quantities shall be worked out based on finalized building layouts and in
accordance with TAC recommendations)
6.01.06

Fire detection, alarm and control system


Analogue addressable type fire detection, alarm and control system shall comprise of:
Programmable / configurable PC station with historical archive facility and printer.
Various types of fire detectors
Power supplies, battery and battery charger.
Complete interconnecting cabling between fire detectors, devices, junction boxes
and panels.
In addition to the above, manual call points and hooters shall be provided at
strategic locations within the total plant area. Suitable provision shall be made to
interchange signals from for fire pump status.
The fire detection system shall indicate the fire location and shall display the
occurrences visually and audibly both locally and centrally at substation.
Fire detection, alarm and control system shall cover the following areas:
1.

LHS type detection system for Cable galleries, coal conveyors, coal
tunnels, protected by MVW spray system.

2.

Quartzoid bulb heat detection system for Equipment protected by HVW


spray system

All fire panels shall be provided with Ni Cd battery and battery chargers. Battery
shall be capable of 24 hours back-up supply in case of power supply failure.
The fire detection & alarm system apart from exhibiting audio & visual alarms and
initiation of extinguishing system in the relevant areas shall also carry out the
control function such as shut down of draft fans, air conditioning & ventilation
system damper/equipment, shut down of power supply and tripping of transformer
(as per transformer manufacturer recommendation) etc as envisaged for system
safety.
Detector cables and other control cables shall be armored, screened and twisted
FRLS type in external areas and shall be of unarmored FRLS type inside the

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 27 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
buildings in conduits. Detectors Loop cables and FAPs interface cables shall be
Fire survival cable.
6.02.00

Dust Suppression system

6.02.01

Dry Fog Dust Suppression (Transfer Towers- 1,2,3,4,5)


At specified locations dry fog dust suppression system shall be provided which comprises spray
nozzles discharging plain water & air in a fine spray to form dry fog to capture air borne dust
particles and direct them into the main coal flow. This dry fog shall be discharged through spray
heads at the dust suppression zones.
The dry fog dust suppression system shall consist of the following:
a. Fogging system & controls consisting of:
Spray assemblies.
Pressure regulating units
Flow activation system
Instrumentation for auto spray
b. Compressed air system consisting of:
air compressors (screw type).
Air receivers
Applicable instrumentation & valves.

6.02.02

Plain Water Dust Suppression System(Coal Stock pile)


Water shall be drawn from the water storage tank by electric motor driven pumps(1W+1S) and
discharged via a pipe network system through spray heads. Spray heads shall comprise of
swiveling type spray units spaced at an interval of approximately 40 meters around each coal
pile. Manually operated globe valve shall be provided to control water supply to each spray unit.
Pressure at inlet to spray unit shall not be less than 4.5 kg/cm2(g), orifice plates shall be
provided if required for the spray nozzles where the residual pressure is more than 4.5
kg/cm2(g)

6.03.00

Service Water System


Service water connections are to be provided in conveyor galleries and tunnels at 50 meter
intervals. Adequate number of these connections shall be provided in all transfer towers within
1mts of ER-1, SS-1, berth office, workshop, stores, gate house and any other buildings. 32 NB
globe valve and quick coupling. One (1) no. hose pipe with nozzle shall be provided in each
building.

6.04.00

Client
Project

Water Treatment System

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 28 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Description

Details

Feed water tank


Type

Rectangular above ground.

Effective capacity

One (72) hour retention time

Material of construction

RCC

Hypo dosing tank


Effective Capacity

Each twenty four (24) hours storage volume at


dosing concentration

Material of Construction

FRP

Agitator type

Vertical

MOC of agitator
Dissolving basket

SS
In SS Construction with 10 mm dia holes on
50mm triangular pitch.

M.O;C. for piping valves, & fittings.

CPVC PN 10

Free board

0.30 m

Dosing pumps
Type

Diaphragm / plunger type with stroke


adjustment metering pumps.

MOC of wetted parts

PP/ SS

Minimum dosing rate to be considered.

3 ppm

Capacity of each dosing pump

To be decided by the Vendor

Stroke

Variable 0 - 100%

Pressure relief piping

Back to solution tank

Pressure relief valve

SS316, one per pump

Pressure gauge

Diaphragm type

Suction strainer

One per pump

Tank cover

Flat, hinged/removable cover

Tank bottom
Level gauge

As indicated in the flow scheme

MOC of pipes, valves and fittings

Client
Project

Flat sloped

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

CPVC PN 10

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 29 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Pressure sand filters
Quantity

(1W+1S)

Capacity

To provide filter water of 50 m3/h when one


filter is working
When both the filters are working then 100
m3/h

Design Code

IS 2825 or ASME Sec VIII Div 1

Design Pressure

Pump Shut off Head+ 5% Margin


60o C

Design Temperature
Material of construction

IS:2062 for shell and IS:2002, Gr I/ SA 515 Gr


70 for dish, internally epoxy coated.

Filter Medium
Supporting bed

Sand and Gravel


Rounded and graded gravel free from clay
and lime stone

Backwash frequency

Once in 24 hours

Activated carbon filters


Quantity

(1W+1S)

Capcity

To provide filter water of 50 m3/h when one


filter is working
When both the filters are working then 100
m3/h

Design Code

IS 2825 or ASME Sec VIII Div 1

Design Pressure

Pump Shut off Head+ 5% Margin


60o C

Design Temperature

Client
Project

Material of construction

IS:2062 for shell and IS:2002, Gr I/ SA 515 Gr


70 for dish, internally epoxy coated.

Internal/ External painting

Two (2) coats of high built epoxy zinc


phosphate DFT 500 microns/ Three (3) coats
of chlorinated rubber paint DFT 500 microns

Filter Medium

Granular Activated Carbon as per AWWA


8604 De-chlorination grade.

Supporting bed

Rounded and graded gravel free from clay


and lime stone

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 30 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Backwash frequency

Once in 24 hours

Activated Carbon Media Depth

1200 mm (min)

(Excluding supporting bed depth)


Freeboard

75% of bed depth


< 12 m 3 /hr/m2 (max)

Surface flow rate


Outlet Chlorine, ppm as Cl 2

Less than 0.1

Outlet water, oil, colour, odour

NIL

Mode of backwash

Flow reversal from feed line

Waste back wash tank


Type

Rectangular above ground.

Effective capacity

Total back wash water produced in one day


when all the filters are working

Material of construction

RCC

Fire cum service water tank


Type

Rectangular above ground.

Effective capacity

1500 m3. Which includes 1100 m3 of fire


water storage requirement

Material of construction
Pumps

RCC
Filter Feed
pumps

Back wash
pumps

Waste back
wash
transfer
pumps

Quantity

2 Nos
(1W+1S)

Capacity,

25 m3/h

Bidder to
decide

Bidder to
decide

10%

10%

10%

Bidder to
decide

Bidder to
decide

Bidder to
decide

Horizontal
centrifugal

Horizontal
centrifugal

Horizontal
centrifugal

m /hr
Design margin on flow
Discharge pressure, mwc

Type

2
Nos 2
Nos
(1W+1S)
(1W+1S)

MOC

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 31 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Casing

CI to IS 210
FG 260

CI to IS 210
FG 260

CI to IS 210
FG 260

Impeller

SS316

SS316

SS316

Performance Criteria:
Product water quality: The quality of water at various equipment outlets shall be as follows:

Pressure Sand Filter (PSF)


Maximum TSS

Activated Carbon Filter (ACF)


Residual
organics

6.05.00

< 5 ppm

Chlorine,

color

& Not traceable

Sump Pumps
Sump pumps along with level switches & piping up to nearest drain (max upto 50.0 mtrs. from
outside the building) shall be provided at wagon tippler complex, SS-1, ER-1 and fire water
pump house area.

The capacity of each pump shall not be less than 25 M3/hr. Minimum 10% margin on capacity
and 20% margin on computed head shall be considered for selection of pumps.
Size of the sump pit shall not be less than 2.0 meters x 2.0 meters x 1.8 meters deep. One no.
of settling pit shall also be provided before sump pit so that water without heavy coal particles
goes into sump pump pit. High and low level switches shall be provided in the sump pump pit.
Capacity and head of these pumps shall be decided during detailed engineering, all these
pumps shall be submersible type.
6.06.00

Piping, valves, fittings and accessories

6.06.01

Piping & Fittings


Mild steel as per IS: 1239 (Part-I) medium grade (up to 150 NB) & as per IS: 3589 Gr.
410 (200 NB and above) or Equivalent for pipes normally filled with water.
Mild steel as per IS: 1239 (Part-I) medium grade (up to 150 NB) & as per IS: 3589
Gr.410 (200 NB and above) or Equivalent and galvanized as per IS: 4736 for pipes
normally empty and periodically charged with water and foam system application.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 32 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Minimum pipe thickness shall be 6.30 mm for pipes of 200 NB to 350 NB, 7 mm for 400
NB and 8 mm for beyond 400 to 600 mm.
Unless otherwise specified all elbows/bends shall be of long radius type.
The material shall conform to ASTM A 234 Gr. WPB or ASTM A 105 or equivalent and
dimensional standard conforming to ANSI B 16.11 (socket & threaded type), ANSI B
16.9 (for butt welded fittings) and ANSI B 16.5 (for flanges and flanged fittings) as the
case may be. Further, galvanized malleable cast iron fittings as per IS: 1879 in Cast iron
fitting as per BS-1641 are also acceptable.
The fittings shall be galvanized as per IS: 4736 for galvanized pipe application. In case
of branching connections from GI mains for spray piping network, socket may be welded
for more than two pipe reduction instead of standard tees.
Fabricated fittings shall not be acceptable up to pipe size to 300 NB. For sizes 350 NB
and above, fittings may be fabricated as per BS: 2633 / BS: 534.
Welding of galvanized iron pipes / fittings shall be permitted provided the same is carried
out by means of special electrodes suitable for the above application.
After, welding welded portions shall be applied with three coats of zinc silicate
treatment/rich paint over one coat of suitable primer.
Pipes and Fittings Summary
Sr.
No.

Particulars

Design Data

Manufacturer

As per the approved Supplier list

Underground piping
Mild steel as per IS 1239 (Part-I)
medium grade for sizes 150 NB and
below &

2.1

2.2

Pipe specification

Pipe to pipe joints

IS 3589 Gr. 410 for sizes 200 NB and


above (wall thickness min 6.30 mm for
pipes of 200 NB to 350 NB, 7 mm for
400 NB and 8 mm for above 400 NB up
to 600 NB)
Butt welded for sizes 50 NB and above
&
Socket welding for sizes below 50 NB

2.3

Client
Project

Pipe to valve joints

Flanged with neoprene gaskets in


between. Flanges shall be drilled to

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 33 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Sr.
No.

Particulars

Design Data
ANSI B16.5 150#

2.4

Pipe fittings

ASTM A234 Gr. WPB for sizes 65 NB


and above
ASTM A105 for sizes 50 NB and below

2.5
3

Wrapping & Coating

Wrapping and coating to be done in line


with IS-10221

Above ground piping (normally filled with water)


Mild steel as per IS 1239 (Part-I)
medium grade for sizes 150 NB and
below &

3.1

3.2

Pipe specification

Pipe to pipe joints

IS 3589 Gr. 410 for sizes 200 NB and


above (wall thickness min 6.30 mm for
pipes of 200 NB to 350 NB, 7 mm for
400 NB and 8 mm for above 400 NB up
to 600 NB)
Butt welded for sizes 50 NB and above
&
Socket welding for sizes below 50 NB

3.3

3.4

Pipe to valve joints

Pipe fittings

Flanged with neoprene gaskets in


between. Flanges shall be drilled to
ANSI B16.5 150#
ASTM A234 Gr. WPB for sizes 65 NB
and above &
ASTM A105 for sizes 50 NB and below

3.5

Bolts, nuts and washers

Hot dip galvanized MS

3.6

Pipe supports

Required

Above ground piping (normally empty)


Mild steel as per IS 1239 (Part-I)
medium grade for sizes 150 NB and
below &

4.1

Pipe specification

IS 3589 Gr. 410 for sizes 200 NB and


above and galvanized as per IS 4736
(Wall thickness min 6.30 mm for pipes
of 200 NB to 350 NB, 7 mm for 400 NB

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 34 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Sr.
No.

Particulars

Design Data
and 8 mm for above 400 NB up to 600
NB)

4.2

Pipe to pipe joints

Butt welded for sizes 50 NB and above


&
Socket welding for sizes below 50 NB

4.3

4.4

Pipe to valve joints

Pipe fittings

Flanged with neoprene gaskets in


between. Flanges shall be drilled to
ANSI B16.5 150#
ASTM A234 Gr. WPB for sizes 65 NB
and above &
ASTM A105 for sizes 50 NB and below

6.06.02

4.5

Bolts, nuts and washers

Hot dip galvanized MS

4.6

Pipe supports

Required

Valves & other Accessories


Valves & Specialities shall be used to start, stop or regulate the flow. All valves/specialties
below 50 mm size in service water/dust suppression/ potable water lines should be plug
type of proven make.
Bib cocks provided for potable water system shall be made of Copper Alloy / Cast Iron.
a. Strainers
Strainers shall be of Y Type.
Strainer wire shall be of SS (AISI316) and Strainer Body as per IS: 2062 (tested).
Strainer area shall be at least 4 times the cross section at the pipe end.
Strainer shall be of 30 SWG & 30 mesh and pressure drop across the strainer at
design flow shall be limited to 10 MWC in clean condition.
Strainers in DS system shall be of duplex type designed with 3 way valves so that
one filter can be cleaned while the other is in operation. Suitable vent and drain
valves shall also be provided. Screen opening area shall be at least four times the
pipe cross sectional area. Pressure drop in clean conditions shall not exceed 1.5
MWC at full flow.

Material of construction
Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 35 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
i. Body

Cast iron grade IS 210 FG-200

ii. Wire mesh

SS 316

b. Gate Valves
Gate valves shall be of rising spindle type conforming to IS 14846 / 780 with MOC
as per the below.

Material of construction
i. Body

Cast iron IS 210 Gr. FG 200 or CI ASTM A 216


Class B

ii. Stem

Steel ASTM A 276 Type 410/304/316 or Leaded


Tin Bronze IS 318 LTB2

iii. Disc

ASTM A 217 Gr. CA 15 or Bronze

iv. Seat Ring

ASTM A 217 Gr. CA 15 or Bronze

v. Hand wheel

Cast iron IS 210 Gr. FG 200 or CI ASTM A 216


Class B

vi. Packing

Asbestos

c. Check / Non return Valves

Check / Non return Valves shall be of reflux swing disc type conforming to IS
5312 with MOC as per the below.

Material of construction
i. Body

Cast iron IS 210 Gr. FG 200

ii. Flap

Cast iron IS 210 Gr. FG 200

iii. Body ring

Leaded Tin Bronze IS 318 LTB2

iv. Flap Ring

Leaded Tin Bronze IS 318 LTB2

v. Gasket

Rubber

vi. Packing

Rubber

All valves shall be as per applicable IS/BS codes & approved by TAC for specific
fire protection system.
Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 36 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Flanges: Flanges and counter flanges shall conform to ANSI B 16.5 CI 150.

6.06.03

Pipe supports

All piping supports shall be designed with incidental structural sub framing.

The supports shall be spaced in accordance with standard engineering practice as


outlined in applicable codes and standards.

The location of the supports shall not increase the forces and moments on the
equipment beyond their allowable values.

7.00.00

LAYOUT REQUIREMENTS
The layout shall be strictly in compliance with TAC requirements especially regarding to
clearances of fire ring mains from buildings/ structures, spacing of hydrants, etc.

8.00.00

OPERATION & CONTROL PHILOSOPHY

8.01.00

Fire Protection system & Dust Suppression Systems


Fire Protection system (FPS)

Dust Suppression System for


CHP Transfer Towers (TT)

Dust suppression System for


Coal Stock Pile

Service Water System

Client
Project

Operation, Control & Monitoring of FPS


system is by dedicated PLC based Control
System with Front panel mounted
Graphical User Interface (GUI) of 12 sized
for operator Interface. This PLC will
Located near to the E1 Package PLC in
SS1 First Floor
The Operation, Control & Monitoring of
DSS of CHP Transfer tower by E1 Package
PLC (By owner) located at SS1. Bidders
scope includes all the required field
instrumentation for successful operation of
DSS System up to Field Junction Boxes
including Junction boxes and cabling up to
JBs.
The Operation , Control & Monitoring of
DSS of Coal Stockpile is by dedicated PLC
based Control System with Front panel
mounted Graphical User Interface (GUI) of
21 sized for operator Interface. This PLC
will Located near to the E1 Package PLC in
SS1 First Floor
Shall be operated and controlled by Fire
fighting system PLC.

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 37 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
The fire pumps control system will be from microprocessor based programmable logic control
(PLC) system, local control panels for Diesel engine drive fire water pumps, local/remote
instruments, instrumentation & control cables , erection hardware and Standalone UPS
System with Maintenance Bypass Switch for PLC system.PLC based control system will be
provided for implementation of control logics of the Fire Water Pumps, covering the total
functional requirement of sequential control, interlock, monitoring, alarm & data logging.

PLC system configuration will be redundant in CPU, communication, Power supply modules
and non-redundancy in I/O modules for normal loops and for critical loops redundancy at
output card level can be achieved externally by extra hardware only.
1 no. Graphical Interface Unit (GIU) based Operator Station will have minimum 12 size of
Panel Mounted type will be provided.
Comprehensive annunciation and indication scheme integrated in PLC will be provided such
that, it will be possible for the operator to locate and identify the fault from the GIU.

One no. Lap top will be provided as engineering tool for programmable functions with required
software for Fire Protection System (Fire Water Pumps) PLC.

Diesel Engine driven fire pump local control panel will be accessible and located near their
respective equipment and will be complete with all the required controls, interlocks, indicating
lamps etc. and further interface Fire Protection System (Fire Water Pumps) PLC system.
8.01.01

Specific C&I Requirements


All panels, desks cabinets and enclosures will comply with the protection classes as indicated
below:

Indoor air conditioned (A.C) areas : IP 32

Indoor non A.C areas:

Ventilated enclosures : IP 42

Non ventilated : IP 55

Outdoor : IP-55/ IP 65 (As per the requirement)

All equipment/systems located in the field will be suitable for continuous operation without loss
of function, departure from specification or damage at the ambient temperature of 50 Deg C
Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 38 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
and relative humidity of 90%. For hazardous area, instruments will be intrinsically safe and
field instruments will be explosion proof as per relevant area classification.

All junction boxes, power supply distribution boards, marshalling cabinets (if applicable),
instrument erection materials, interposing relays, accessories and process hook-up hardware
will be supplied.

Standalone package UPS of adequate capacity with 60 min battery back-up will be provided
for the PLC system and GIU, equipment, instruments etc.

Individual pair shielded and overall shielded twisted pair copper cables will be used for analog
signals and overall shielded cables will be used for digital signals. Individual and overall
screened quadruplet cable will be used for RTDs through LJB to PLC control system. The wire
size will be 0.5 sq. mm and the color coding will be as per IEC.
8.01.02

Stand-alone Uninterrupted Power Supply System (UPS)

One set of suitably rated, 415/240V AC, 1-phase, 50 Hz, standalone UPS will be provided for
each of the Fire Protection System(Fire Water Pumps) & Coal Stock Pile Dust suppression
system PLC system and GIU,equipments, instruments etc. The UPS will comprise of 1x100%
charger, 1 set Ni-Cd battery with accessories with 60 minutes backup time, 1x100% static
inverter, 1 no. static switch, 1 no. manual bypass switch,1 no. 240V, single phase voltage
stabilizer and 1 no. 240V AC UPS distribution board.

On loss of AC input supply to the charge, the battery bank will supply all the UPS loads for
minimum 60 minutes. The UPS system will be designed to draw power from mains supply at a
minimum power factor of 0.85 while working at rated load in normal operating UPS
configuration.
In the event of failure of UPS system the load is transferred to the bypass line by manual
bypass switch.
Regulated standby AC supply will be derived from standby supply through a servo controlled
voltage stabilizer.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 39 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
8.01.03

Instrumentation Cables:
All instrumentation cable shall be 1100V grade, Single pair, multi pair, quadruplets, Traid as
required, stranded plain , annealed, high conductivity copper conductor (class 2 as per IS
8130), extruded PVC compound type-A insulated, cores identified by colour and coding,
individual pair/quadruplets twisted, cores wrapped by non-hygroscopic material by taping or
extrusion, non-metallic rip cord under wrapping , individual pair/quadruplet/Traid screened with
aluminum mylar tape of 0.04 mm thick or copper tape of 0.04 mm thick or copper laminated
plastic tape with 30% overlap, provided with 1.0 mm2 tinned copper drain wire for each cabling
element, cabling elements suitably grouped, colour coded, cables overall screened with tinned
copper wire braids of 0.15 mm dia with minimum coverage of 85% or aluminum mylar tape of
0.04 mm thick with overlap of 30%, inner sheathed with extruded PVC compound type ST1,
armoured with steel strips/wires and outer sheathed with extruded FRLS PVC compound type
ST1 complying with IEC 60189 - Part 1&2. The cross section of cable conductor shall be 1.0
sq.mm. inner and outer sheath shall also be FRLS PVC compound for field instruments,
however for detector loop cables & FAPs/Repeater Panel Fire survival cable shall be used.

8.01.04

Operating Philosophy of Fire Pumps


Normally Fire protection system headers will remain charged with water at the desired
pressure. In the event of fire, when any hydrant or any fire protection system such as MVWS
system operate or any leakages in any part of the network, the resultant fall in header pressure
will initiate the automatic sequential operation of Fire Pumps with Electrical Motor driven Jockey
pumps starting first to maintain the system pressure. In case of further fall of header pressure,
Electrical motor driven main pumps will cut-in to operation automatically to supply water to the
system. Failure to start of main pumps on demand will result in further fall in header pressure or
if the header pressure still falls even when pumps are running then this signal will actuate the
stand-by diesel engine driven pump to start automatically.

This complete sequential operation of fire pumps will be signaled with an alarm in the

PLC

based control panel.

Each Pump can also be started manually from local controls during emergency and/or testing. If
the Pump is in running condition then it will be stopped manually.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

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TECHNICAL SPECIFICATION FOR


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SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
Diesel engines of fire water pumps will have their own control panels for automatic as well as
manual operation.

All necessary instrumentation i.e. pressure indicators / switches, pressure transmitters flow
indicators / switches, etc. shall be provided as required. Pressure monitoring provision at
highest elevation and at farthest hydrant shall be provided.

Provision shall be made for manual operation of all the deluge valves at the deluge valve
stations.

FPS & DSS PLCs shall be interfaced with E1 Package PLC

for critical status signals.

Provision for both soft and hard interface shall be provided. Exact signal interchange can be
worked out during detail engineering.
9.00.00

CODES & STANDARDS

9.01.00

Fire Protection system

The work in the scope of this specification shall be carried out as per relevant latest
edition of the applicable codes and standards. The bidder shall indicate in his bid the
particular standard that has been followed against each work.

In the unlikely event that certain items/equipments/design calculations are not explicitly
mentioned in this specification but are called for as per local statutory codes, the same
shall be deemed to be included in Bidders scope of work and his proposal.

In respect of aspects requiring statutory clearances, local statutory norms shall be strictly
followed. Responsibility for obtaining permissions from local authorities lies with the
Bidder.

In the event of any conflict between the codes and standards referred above, and the
requirements of this specification, the requirements which are more stringent in
accordance with international industry practice shall govern.

In case of any change of codes, standards and regulations up to the date the Bidder
proceeds with manufacturing, the EPC Contractor shall have the option to incorporate the
changed requirements. However, in respect of aspects requiring statutory clearances, any
change in the statutes subsequent to LOI / LOA shall call for price implication which has
to be mutually agreed between EPC Contractor and Bidder before the Bidder carries out

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


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Date:20-10-2014

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SYSTEM
modifications to the equipment to meet the statutory requirements.

Sr. No.

Client
Project

Description

Tariff Advisory Committee (TAC)

National Fire Protection Association (NFPA)

Hydraulic Institute Standards (HIS)

IS 2190 Selection, installation and maintenance of First-Aid Fire


Extinguishers

IS: 5120 - Technical requirement for roto-dynamic special purpose pumps.

IS:1710 - vertical turbine pump for clear, cold fresh water

British Standards (BS) & relevant IS standards

American National Standard Institute (ANSI)

American Society of Mechanical Engineers (ASME)

10

American Society for Testing and Materials (ASTM)

11

American Institute of Steel Construction (AISC)

12

Japanese Industrial Standards (JIS)

13

American Welding Society (AWS)

14

National Electrical Manufacturers Association (NEMA)

15

Institute of Electrical and Electronics Engineers (IEEE)

16

Federal Occupational Safety and Health Regulations (OSHA)

17

Instrument Society of America (ISA)

18

National Electrical Code (NEC)

19

International Electro-Technical Commission Publications

20

Applicable DIN Standards

21

Electric Power Research Institute (EPRI)

22

Standards of Manufacturers Standardization Society (MSS)

23

American Water Works Association (AWWA)

24

Anti-friction Bearings Manufacturer's Association (AFBMA)

25

American Gear Manufacturer's Association (AGMA)

26

International Standards Organization (ISO)

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


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Date:20-10-2014

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Sr. No.
27

Description
Diesel engine manufacturers association (DEMA)

Applicable codes and standards shall be subject to the Purchasers approval. The Bidder shall
submit a complete list of codes and standards that shall be employed. Due attention shall be
paid by the Sub-Contractor to investigate and comply with the laws, regulations, rules,
applications in the country of the proposed plant which is under Sub-Contractors responsibility
to follow them.
The sub-contractor shall submit to the purchaser neatly bound sets of the Standards Book as
per document submittal schedule. The Standards Book shall incorporate all applicable
equipment, material and other codes and standards covering the Sub-Contractors supply under
this contract. The standards shall be provided in or translated in the English language. If such
translations are not available, the Sub-Contractor shall include the standard in the original
language plus a summery in English attached thereto.
In case of any change in codes, standards & regulations between the date of bid submission
and the date, when the Sub-Contractors proceed with fabrication, the Purchaser shall have
option to incorporate changed requirements or to retain the original standard. It shall be the
responsibility of the Sub-Contractor to bring to the notice of Purchaser such changes and advise
Purchaser of the resulting effect. In addition, the Sub-Contractor shall consider any applicable
local regulations.
9.02.00

Dust Suppression System


The design, manufacture, inspection and testing of Dust Control & Miscellaneous Systems shall
comply with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment is to be installed. The Dust Control & Miscellaneous Systems shall
conform to the latest edition of the following standards and codes. Other internationally
acceptable standards/codes, which ensure equal or higher performance than those specified,
shall also be accepted. Nothing in this specification shall be construed to relieve the contractor
of the required statutory responsibility. In case of any conflict in the standard and this
specification, the decision of the Employer shall be final and binding.

Client
Project

IS:778 : Gun Metal gate, globe & check valves for general purpose.

BS:5150 :Cast Iron Gate Valve for water works purposes

BS:5152 :Cast Iron Globe Valve for water works purposes

BS:5312 :Cast Iron Check Valve for water works purposes

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


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Date:20-10-2014

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SYSTEM

IS:1239 : Mild Steel tubes & fittings.

IS:2379 :Colour for the identification of pipe line.

IS:2906 :Sluice valves for water work purposes.

IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm)

IS:5312 : Swing check type reflux (non return) valves.

IS:1520 : Horizontal centrifugal pump for clean, cold fresh water.

Bidder shall be responsible for achieving the emission levels as per the applicable norms.
10.00.00 PERFORMANCE GUARANTEES
10.01.00 The bidder shall guarantee the successful and satisfactory operation of the equipment offered
under this contract and shall meet the ratings and performance requirements as stipulated
in this specification and derived during engineering for the equipment. The Purchaser
reserves the right to reject the equipment should the performance values fall short of those
indicated in the technical data sheets. In case of such option of rejection being exercised by
the Purchaser, the bidder shall replace the equipment which shall meet the guaranteed
values.
10.02.00 The bidder shall further guarantee that the equipment offered by him shall be free from defects in
design, material and workmanship.
10.03.00 Bidder shall guarantee the Fire fighting system based on the following tests
-

Pressure holding test with pump running for operation of minimum


number of nozzles.

All tests required as per TAC/NFPA for firefighting system.

11.00.00 QUALITY ASSURANCE, INSPECTION AND TESTING

QUALITY ASSURANCE PROGRAMME


To ensure that the equipment and services under the scope of contract whether manufactured
or performed within the Bidders works or at his sub-contractors premises or at the owners site
or at any other place of work are in accordance with the specifications, the Bidder shall adopt
suitable quality assurance programme to control such activities at all points, as necessary.
Such programmes shall be outlined by the Contractor and shall be finally accepted by the
Owner / authorized representative after discussions before the award of the contract. The QA
programme shall be generally in line with ISO-9001/IS-14001. A quality assurance programme
of the contractor shall generally cover the following:

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

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SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
a.His organization structure for the management and implementation of the proposed
quality

assurance programme

b. Quality System Manual


c. Design Control System
d. Documentation Control System
e. Qualification data for bidders key personnel.
f. The procedure for purchase of materials, parts, components and selection of subcontractors services including vendor analysis, source inspection, incoming rawmaterial inspection, verification of materials purchased etc.
g. System for shop manufacturing and site erection control including process controls
and fabrication and assembly controls.
h. Control of non-conforming items and system for corrective actions.
i. Inspection and test procedure both for manufacture and field activities.
j. Control of calibration and testing of measuring testing equipments.
k. System for Quality Audits.
l. System for indication and appraisal of inspection status.
m. System for authorizing release of manufactured product to the owner.
n. System for handling storage and delivery.
o. System for maintenance of records, and
p. Furnishing of quality plans for manufacturing and field activities detailing out the
specific quality control procedure adopted for controlling the quality characteristics
relevant to each item of equipment/component as per format enclosed at Annexure-I
to this section.
GENERAL REQUIREMENTS - QUALITY ASSURANCE
All materials, components and equipment covered under this specification shall be procured,
manufactured, erected, commissioned and tested at all the stages, as per a comprehensive
Quality Assurance Programme. An indicative programme of inspection/tests to be carried out by
the contractor for some of the major items is given in the respective technical specification. This
is, however, not intended to form a comprehensive programme as it is the contractors
responsibility to draw up and implement such programme duly approved by the Owner. The
detailed Quality Plans for manufacturing and field activities should be drawn up by the Bidder
and shall be submitted to Owner for approval. Schedule of finalization of such quality plans
shall be finalized before award.
Manufacturing Quality Plan shall detail out for all the components and equipment, various

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

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tests/inspection, to be carried out as per the requirements of this specification and standards
mentioned therein and quality practices and procedures followed by Contractors Quality Control
Organization, the relevant reference documents and standards, acceptance norms, inspection
documents raised etc., during all stages of materials procurement, manufacture, assembly and
final testing/performance testing. The Quality Plan shall be submitted on electronic media e.g.
floppy or E-mail for review. Once the same is finalized, hard copies shall be submitted for
approval. After approval the same shall be submitted in compiled form on CD ROM.
Field Quality Plans shall detail out for all the equipment, the quality practices and procedures
etc. to be followed by the Contractors site Quality Control Organization, during various stages
of site activities from receipt of materials/equipment at site.
The Bidder shall also furnish copies of the reference documents/plant standards/acceptance
norms/tests and inspection procedure etc., as referred in Quality Plans along with Quality Plans.
These Quality Plans and reference documents/standards etc. shall be subject to Owners
approval without which manufacture shall not proceed. These approved documents shall form a
part of the contract. In these approved Quality Plans, Owner shall identify customer hold points
(CHP), i.e. test/checks which shall be carried out in presence of the Owners Engineer or his
authorized representative and beyond which the work shall not proceed without consent of
Owner/Authorized representative in writing. All deviations to this specification, approved quality
plans and applicable standards must be documented and referred to owner along with technical
justification for approval and dispositioning. Format for List of items requiring Quality Plan and
Sub Supplier Approval is attached as Appendix-IB.
The contractor shall submit to the Owner field welding schedule for field welding activities. The
field welding schedule shall be submitted to the Owner along with all supporting procedures, like
welding procedures, heat treatment procedures, NDT procedures etc. at least ninety days
before schedule start of erection work at site.
No material shall be dispatched from the manufacturers works before the same is accepted
subsequent to pre-dispatch final inspection including verification of records of all previous
tests/inspections by Owners Engineer/Authorised representative and duly authorised for
despatch issuance of MDCC.
All material used for equipment manufacture including casting and forging etc. shall be of tested
quality as per relevant codes/standards. Details of results of the tests conducted to determine
the mechanical properties, chemical analysis and details of heat treatment procedure
recommended and actually followed shall be recorded on certificates and time temperature
chart. Tests shall be carried out as per applicable material standards and/or agreed details.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

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SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
All welding and brazing shall be carried out as per procedure drawn and qualified in accordance
with requirements of ASME Section IX/BS-4870 or other International equivalent standard
acceptable to the owner. All welding/brazing procedures shall be submitted to the owner or its
authorized representative for approval prior to carrying out the welding/brazing.
All brazers, welders and welding operators employed on any part of the contract either in
Contractors/his sub-contractors works or at site or elsewhere shall be qualified as per ASME
Section-IX or BS-4871 or other equivalent International Standards acceptable to the Owner.
Test results or qualification tests and specimen testing shall be furnished to the Owner for
approval. However, where required by the owner, tests shall be conducted in presence of
owner/authorized representative.
For all pressure parts and high pressure piping welding, the latest applicable requirements of
the IBR (Indian Boiler Regulations) shall also be essentially complied with. Similarly, any other
statutory requirements for the equipments/systems shall also be complied with.
All the heat treatment results shall be recorded on time temperature charts and verified with
recommended regimes. No welding shall be carried out on cast iron components for repair.
Unless otherwise proven and specifically agreed with the owner, welding of dissimilar materials
and high alloy materials shall be carried out at shop only.
All non-destructive examination shall be performed in accordance with written procedures as
per International Standards, The NDT operator shall be qualified as per SNT-TC-IA (of the
American Society of non-destructive examination). NDT shall be recorded in a report which
includes details of methods and equipment used, result/evaluation, job data and identification of
personnel employed and details of co-relation of the test report with the job.
All the sub-vendors proposed by the Contractor for procurement of major bought out items
including castings, forging, semi-finished and finished components/equipment, list of which shall
be drawn up by the Contractor and finalized with the Owner shall be subject to Owners
approval.

The contractors proposal shall include vendors facilities established at the

respective works, the process capability, process stabilization, QC systems followed, experience
list, etc. along with his own technical evaluation and shall be submitted to the owner for approval
prior to any procurement.

Such vendor approval shall not relieve the contractor from any

obligation, duty or responsibility under the contract.


For components/equipment procured by the contractors for the purpose of the contract, after
obtaining the written approval of the owner, the contractors purchase specifications and
inquiries shall call for quality plans to be submitted by the suppliers along with their proposals.
The quality plans called for from the vendors shall set out, during the various stages of

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

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SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
manufacture and installation, the quality practices and procedures followed by the vendors
quality control organization, the relevant reference documents/standards used, acceptance
level, inspection of documentation raised, etc.
(a) Such quality plans of the successful vendors shall be finalized with the owner and such
approved Quality Plans shall form a part of the purchase order/contract between the Contractor
and Vendor. Within three weeks of the release of the purchase orders/contracts for such bought
out items/components, a copy of the same without price details but together with the detailed
purchase specifications, quality plans and delivery conditions shall be furnished to the owner by
the Contractor.
Owner reserves the right to carry out quality audit and quality surveillance of the systems and
procedures of the Contractors or their sub vendors quality management and control activities.
The contractor shall provide all necessary assistance to enable the owner carry out such audit
and surveillance.
The contractor shall carry out an inspection and testing programme during manufacture in his
work and that of his sub-contractors and at site to ensure the mechanical accuracy of
components, compliance with drawings, conformance to functional and performance
requirements, identity and acceptability of all materials parts and equipment. He shall carry out
all tests/inspection required to establish that the items/equipments conform to requirements of
the specification and the relevant codes/standards specified in the specification, in addition to
carrying out tests as per the approved quality plan.
Quality audit/surveillance/approval of the results of the tests and inspection shall not, however,
prejudice the right of the owner to reject the equipment if it does not comply with the
specification when erected or does not give complete satisfaction in service and the above shall
in no way limit the liabilities and responsibilities of the Contractor in ensuring complete
conformance of the materials/equipment supplied to relevant specification, standard, data
sheets, drawings, etc.
For all spares and replacement items, the quality requirements as agreed for the main
equipment supply shall be applicable.
Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the
approval of the owner/ authorized representative.
QUALITY ASSURANCE DOCUMENTS
The Contractor shall be required to submit two hard copies and two sets on CD ROM of the
following Quality Assurance documents within three weeks after dispatch of the equipment.
a. Material mill test reports on components as specified by the specification and

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


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Date:20-10-2014

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approved Quality Plans.
b. The inspection plan with verification, inspection plan check points, verification
sketches, if used and methods used to verify that the inspection and testing points in
the inspection plan were performed satisfactorily.
c. Sketches and drawings used for indicating the method of traceability of the
radiographs to the location on the equipment.
d. Non-destructive examination results reports including radiography Interpretation
reports.
e. Factory test results for testing required as per applicable codes and standard
referred in the specification and approved Quality Plans.
f. Inspection reports duly signed by QA personnel of the Owner and Contractor for the
agreed Customer Hold Points.
g. During the course of inspection, the following shall also be recorded:
When some important repair work is involved to make the job acceptable, and the
repair works remain part of the accepted product quality.
h. All the accepted deviation shall be included with complete technical details.
INSPECTION, TESTING AND INSPECTION CERTIFICATES
The word Inspector shall mean the Engineer and/or his authorized representative and/or an
outside inspection agency acting on behalf of the owner to inspect and examine the materials
and workmanship of the works during its manufacture or erection.
The Engineer, his duly authorized representative and/or an outside inspection agency acting on
behalf of the Owner shall have access at all reasonable times to inspect and examine the
materials and workmanship of the works during its manufacture or erection and if part of the
works is being manufactured or assembled on other premises or works, the Contractor shall
obtain for the Engineer and for his duly authorized representative permission to inspect as if the
works were manufactured or assembled on the Contractors own premises or works.
The Contractor shall give the Engineer/Inspector fifteen (15) days written notice of any material
being ready for testing. Such tests shall be to the Contractors account except for the expenses
of the Inspectors. The Engineer/Inspector, unless the witnessing of the tests is virtually waived,
shall attend such tests within fifteen (15) days of the date on which the equipment is noticed as
being ready for test/inspection failing which the contractor may proceed with test which shall be
deemed to have been made in the inspectors presence and he shall forthwith forward to the
inspector duly certified copies of test reports in two (2) copies.
The Engineer or Inspector shall within fifteen (15) days from the date of inspection as defined

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


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Date:20-10-2014

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herein give notice in writing to the Contractor, or any objection to any drawings and all or any
equipment and workmanship which is in his opinion not in accordance with the contract. The
Contractor shall give due consideration to such objections and shall either make modifications
that may be necessary to meet the said objections or shall inform in writing to the
Engineer/Inspector giving reasons therein, that no modifications are necessary to comply with
the contract.
When the factory tests have been completed at the Contractors or sub-contractors works, the
Engineer/Inspector shall issue a certificate to this effect fifteen (15) days after completion of
tests but if the tests are not witnessed by the Engineer/Inspectors, the certificate shall be issued
within fifteen (15) days of the receipt of the Contractors test certificate by the
Engineer/Inspector. Failure of Engineer/Inspector to issue such a certificate shall not prevent the
Contractor from proceeding with the works. The completion of these tests or the issue of the
certificates shall not bind the Owner to accept the equipment should it, on further tests after
erection be found not to comply with the contract.
In all cases where the contract provides for tests whether at the premises or works of the
Contractor or any sub-contractor, the Contractor, except where otherwise specified shall provide
free of charge such items as labor, material, electricity, fuel, water, stores, apparatus and
instruments as may be reasonably demanded by the Engineer/Inspector or his authorized
representatives to carry out effectively such tests on the equipment in accordance with the
Contractor and shall give facilities to the Engineer/Inspector or to his authorized representative
to accomplish testing.
The inspection by Engineer and issue of Inspection Certificate thereon shall in no way limit the
liabilities and responsibilities of the Contractor in respect of the agreed Quality Assurance
Programme forming a part of the contract.
To facilitate advance planning of inspection in addition to giving inspection notice, the Contractor
shall furnish quarterly inspection programme indicating schedule dates of inspection at
Customer Hold Point and final inspection stages. Updated quarterly inspection plans shall be
made for each three consecutive months and shall be furnished before beginning of each
calendar month.
All inspection, measuring and test equipments used by contractor shall be calibrated periodically
depending on its use and criticality of the test/measurement to be done. The Contractor shall
maintain all the relevant records of periodic calibration and instrument identification, and shall
produce the same for inspection by Purchaser. Wherever asked specifically, the contractor shall
re-calibrate the measuring/test equipments in the presence of Purchaser Engineer.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


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Bidder shall perform the required test such as Functional test, performance guarantee test as
required for taking over and final acceptance from the owner. Also performance guarantee test
shall be as per the performance guarantee requirements indicated in clause 2.10.00 Section
2.
12.00.00 DRAWINGS, DATA / INFORMATION TO BE SUBMITTED ALONG WITH THE BID
The bidder shall submit following drawings / documents (but not limited to) with the bid:
Scope of work, terminal points and exclusions
Duly filled-in technical data sheets
Technical write-up for the system offered
List of drawings / documents attached
Time schedule for design, engineering, manufacture, delivery, erection, testing and
commissioning
Expected pump performance curves showing capacity Vs head, efficiency, power
consumption and required submergence, clearly indicating the guaranteed point of
operation
Complete assembly drawings of pump sets showing plan, elevation and crosssectional views including the location of pump seals and thrust bearings etc
Flow diagrams and equipment layouts drawings for hydrant system, HVW and MVW
spray systems indicating the details of pipe work, valves, specialties, controls and
instruments including bill of materials thereof. Dimensioned outline and crosssectional drawings of the major equipments shall be furnished indicating the
construction materials, weights, dimensions, loads and thrusts transmitted on the
foundations
Certified dimensioned drawings for hydrant valves along with technical leaflets /
drawings etc. to demonstrate suitability of type of equipment for the intended use
outlined in the specification
Illustrative drawings to indicate the location of external hydrant hoses and pump shed
in the yard
Bill of materials and prices
Piping, valve and instrument lists
Manufacturers catalogues for automatic inert gas extinguishing system.
Electrical load list
Technical data sheets for motors actuators
Technical data sheets for control & instrumentation cables
List of tests the Bidder proposes to carry out in shop and at site after installation
including those pertaining to the sub vendor
Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


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Date:20-10-2014

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List of start-up and commissioning spares shall be part of main supply and price to
be included.
List of recommended spare parts for 2 years of trouble free operation of the system
shall be quoted as optional price.
List of all maintenance tools, tackles and accessories required for maintenance of the
offered equipment including bought out components
List of consumables
Painting schedule
Test and Inspection Plan
Test and inspection Procedure
Commissioning procedure
List of deviations from the specification, if any
Guaranteed auxiliary power consumption
List of routine tests along with the sample test reports
List of type of tests conducted with the date and place of tests (format shall be
furnished after order)
Detailed reference list of customers already using the equipment offered during the
last 5 years with particular emphasis on units of similar design and rating
Detailed manufacturers quality assurance standards & program and ISO 9000
series or equivalent National Standards
A bar chart indicating design, engineering, procurement, manufacture, testing,
delivery, installation, testing and commissioning activity / duration of fire protection
system offered

13.00.00 DRAWINGS,DATA /

INFORMATION

TO

BE

SUBMITTED

AFTER

AWARD

OF

CONTRACT
Sr. No

LIST OF DRAWINGS,

DOCUMENTS / INFORMATION TO

BE

SUBMITTED BY THE MANUFACTURER

Client
Project

Drawing / document submission schedule

Final version of the technical documents / drawings listed in clause above


as applicable

Foundation drawings with dead load as well as operating load and other
data required

GA drawings of the equipment, dimensional and sectional drawings of


equipment giving details of materials

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 52 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
5

Cross sectional drawings of major equipment indicating the assembly of


all the major equipment

Piping layout drawings and isometric drawings including pipe support


drawings

Bearing schedule of all bearings giving specification and number of all


bearings used in the equipment supplied under this specification

Instructional manuals for operation, maintenance, repair, replacement and


spare parts ordering

Piping and valve schedule

10

Test procedures and details of test to be conducted

11

Write up for controls and interlocks provided


Controls and instrumentation:

12

a. schedule of instruments and control indicating operating parameters,


ranges, make, model no etc.

13

b. technical data sheets for all instruments and controls

14

c. installation drawings for instrumentation

15

Complete bill of materials

16

Catalogues

17

Test Reports for the tests conducted not earlier than 5 years shall be
furnished for all equipment in detail (along with relevant
drawings/procedures/photographs). The tests shall be conducted as per
IEC standards. Parameters guaranteed for every equipment shall be duly
verified vis--vis the submitted test certificates.
List of routine tests along with sample test reports.
List of type tests conducted with the date and place of tests (format
enclosed).

Client
Project

18

Electrical load list

19

Motor actuator & cable data sheets

20

GA drawings & performance curves for motors

21

Motor control wiring drawings

22

Motor operation manuals/catalogues

23

Cable & interconnection Schedules for Power, control & instrumentation.

24

QA Plan

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 53 of 54

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM, DUST
SUPPRESSION SYSTEM & PLANT WATER
SYSTEM
25

Programming software license and software copy in CD.

26

The C&I Drawings / documents shall have the following as a minimum


a) PLC configuration
b) PLC specifications and technical details of all hardware along
with catalogues
c) Junction Box details with location drawing.
d) Specifications/data sheets of Field Instruments along with
Catalogues .
e) Loop /Signal Flow diagram for each type of Instruments
f)

Power supply distribution scheme

g) Instrument cable termination details.


h) Instrument cable routing layout.
i)

General Arrangement of Local Control Room

j)

Power consumption & Heat dissipation details of PLC panel.

k) Control Valve Specification/Datasheet & sizing calculations,


Actuator details along with catalogues.
l)

Electrical actuators with Integrals Specifications/Datasheets

m) Flow element Sizing calculations & dimensional drawings.


n) PLC panel internal wiring drawing
o) Complete Instruments schedule/ Instrument list and Bill of
materials of PLC & Instruments.
p) Quality Assurance (FAT & SAT {including PG test}) Procedure
For Instruments/PLC/equipment

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014

Page 54 of 54

Project : SEW VIZAG PORT COAL HANDLING FACILITY AT EQ 1A BERTH

FIRE PROTECTION SYSTEM - ALLOCATION SUMMARY SHEET


Annexure - 1 / Rev-00

Water System

Sr.No

Protected Area
Outdoor
Hydrant

Water Monitors

Indoor
Hydrant

Foam System

HVW Spray
System

MVW Spray
System

Outdoor Foam
Water Hydrant
System

Foam water
Sprinkler
System

Fixed Foam
Water Spray
System
Cooling System

Detection System

Manual Call
Station

Photoelectric
Smoke Detector

Heat detector

Spot Type Heat


Detector

LHS cable
Detection

QB Detection

Notification
Appliances

CO2 type
(4.5 kg)

Mobile type CO2


(22.5 kg)

Dry Chemical
Powder type
(5 kg)

VIZAG PORT COAL HANDLING SYSTEM


1

Coal Handling Plant

Conveyors
Coal Stock Pile

o
o

Transfer Towers(TT-1, 2, 3, 4, 5)

o
o

CHP Control room

o
o

Berth area

Sub station (SS-1)

Electrical room (ER-1)

Transformers

Cable trenches at SS-1 and ER-1

Ware house

Workshop

o
o

Notes:
1. Number of fire extinguishers shall be based on the actual arrangement of the rooms/building layouts.
2. Number of Indoor hydrants shall be based on the actual arrangement of the building layouts.
3. Automatic fixed water spray system to be provided with manual release provision.
4. HVWS system for Air preheater and Steam turbine bearing housing shall be manual actauted only.
5. Hydrants shall be strategically located around the plant areas as per TAC regulation requirements
6. This sheet is based on the buildings that are considered in preliminary developments of Plot plan , same shall be updated upon the finalization of buildings or areas later.

TPSC INDIA

Page 1 of 1

o
o

o
o

Mobile type Dry


Chemical Powder
type
(50 kg)

Annexure-II
SUB VENDOR LIST

LIST OF SUB VENDORS


S. No.

Package Name

Supplier/Vendor

Horizontal Centrifugal pumps

KBL/M&P/Grundfoss

Diesel Engine

KOEL / Greaves

Pipe

Jindal/Tata/Apollo/Prakash

CI Gate Valve (Rising


spindle)
CI Non-Return valve (Swing
check type)
CI Butterfly valve (Wafer
type)
CI Deluge valve (wet pilot
type)
CI/MS "Y" Strainer, SS Mesh

Air release valve

Kalpana/Shiva Durga

10

Ball valve/Glove valve

Sant/Zoloto/Kartar

11

SS Hydrant (Landing)Valve

Safeguard/Safex/Newage/GEI

12

SS Branch pipe with nozzle

Safeguard/Safex/Newage/GEI

13
14

RRL Hose, IS-636, Type-A,


with SS coupling
MS Hose box

15

Water moitor

Newage/Safex/HD Fire

16

Pipe fittings /flanges

Shree Krishna / Manish / KGN / Doshi

17

M5 Package

Sureland Fire & security Limited

5
6
7

Koley/Kalpana/Kartar
Koley/Kalpana/Kartar
Koley/Kalpana/Kartar
HD Fire/Kidde/Tyco
Emerald/Sarojini

Safeguard/Safex/Newage/GEI
GEI / Safeguard

UTC Fire & Security


Extinct fire Engineers Pvt Limited
Agnice Fire Protection Limited
Tyco Fire & Security
Thermosystems pvt Limited
Newfire Engineers Pvt Limited
Minimax India Limited

Spraying system
F. Harley
APC system
B

ELECTRICAL ITEMS

Power & Control Cables

Universal cables

Annexure-II
SUB VENDOR LIST

S. No.

Package Name

Supplier/Vendor
RPG cables
Fort Gloster
Nicco
Polycabs
Torrent
KEI
RPG / Asian Cables
CCI
Delton
Radiant
Plaza cables
Diamond
Cord cables
Reliance engineering
Finolex or Equivalent

Motors

BHEL
CGL
WEG
Alstom
ABB
Kirloskar
Bharat Bijilee
Jyoti Motors or equivalent

DBs

C&S
MDS
MK
Hager
Havells
Positronics or Equivalent

Cable Trays & Supports

Techno

Annexure-II
SUB VENDOR LIST

S. No.

Package Name

Supplier/Vendor
Vatco
Dolphine
Indiana
Rabi Engg
Arun Engg
Jamana Metal or equivalent

Glands

Comet
Sunil
GMI
FCG
SMI or equivalent

Cable Lugs

Dowels
Electromech
Commet
Multi or equivalent

Battery

AMCO batteries
Exide industries or Equivalent

Battery charger

Chabbi Electrical private Limited


Hi rel
Exide / Caldyne Industries

Terminal Blocks

Connect well
Elemex

Control & Instrumentation

UPS

TATA - LIEBERT
Larsen & Toubro Limited
Hi - Rel
Dubas
DB Electronics
HBL

Annexure-II
SUB VENDOR LIST

S. No.

Package Name

Supplier/Vendor
Siemens
Solid state controls or Equivalent
Finolex

Pressure gauges

GIC
Pyro Electric
Wika
AN Instrument

Pressure Switches

Switzer
Indfoss
DELTA
SOR

Level Switches

Magnetrol
Levcon
V Automat
E&H
Masonelin

Solenoid valves

Herion
Asco
Rotex
SMC Pneumatic

Flow meters

ABB
E&H
Krohne

Instrumentation cables

Paramount
KEI
Delton
Incab
Cord
Diamond
Associated Cables

Annexure-II
SUB VENDOR LIST

S. No.

Package Name

Supplier/Vendor
TCL or equivalent

10

Smart Transmitter (P, L, F,


DP)

Rosemount (3051 model),


Yokogawa-Japan,
Fuji,
ABB (2600 model)

11.

Flow Elements

Microprecision,
IL-Palghat

12

On/Off Valves (Ball/

IL, MIL,

Butterfly Valves)
Fouress,
Fisher Sanmar
14.

Annunciation System

IL-Kota,
Procon

15.

Interposing Relays

Honeywell,
Omron,
H&B,
OEN,
Phoenix,
Rockwell (AB)

16

Transducers

Siemens,
ABB,
Meco,
Automatic Electric Ltd.

17

Electrical
Panel
(Ammeter, Voltmeter)

Meter

Automatic Electric,
Meco,
ABB

18

Selector Switches & Control


Switches.

Kaycee,
Siemens,
Alstom,
L&T

19.

Terminal Blocks

Phoenix,

Annexure-II
SUB VENDOR LIST

S. No.

Package Name

Supplier/Vendor
Wago

20.

Erection Hardware, Impulse


and Pipings, fittings

Microprecision,
Wesmec Engg.,
MetPress,
SMC Pneumatic,
Sapag

21.

Flow Meters

ABB,
E & H,
Krohne

22.

LIE/LIR

IL Kota,
Pyrotech,
Rittal

23.

Anti-surge Controller

MTL,
P & F,
Phoneix

Dust Suppression System

Spraying system
F. Harley
APC system

Sump Water Pumps

Weir minerals
KBL
SAM
Flowmore

Note: - In the event the Supplier requires any change in the above list it shall take Owners prior approval.

TECHNICAL SPECIFICATION FOR


Low Voltage AC Squirrel Cage Motor

ANNEXURE-III
TECHNICAL SPECIFICATION
FOR LV MOTOR

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 1 of 5

TECHNICAL SPECIFICATION FOR


Low Voltage AC Squirrel Cage Motor

LOW VOLTAGE AC SQUIRREL CAGE MOTOR


1.0

General
Motors Shall conform to IS:325. Motors shall be Horizontal foot mounting type. The motor
characteristics shall be such that it shall be suitable for continuous running with full load at 75%
of voltage for 5 mins. Motors shall not stall due to voltage dip with system causing momentary
drop in voltage to 70% of the rated value. Duty class shall be S1 duty.
The squirrel cage motors will be connected to the driven load directly through flexible / fluid/
hydraulic scoop coupling for conveyor drive CR-2B motor. Motor shall be suitable for 415 volt +/10%, 3phase, 50Hz +/-5% and combine variation of 10%. 415 volt power supply is solidly
grounded system.

The motor shall be suitable for direct online start.

Motors shall be of TEFC type with degree of protection IP- 55 and provided with protection
guard. Motors shall be for operation in saline, humid atmosphere and containing fine abrasive
dust. All fasteners used shall be corrosion resistant against salinity.

Motor shall be capable of withstanding occasional overloads of 50% for 2 minutes. Motors shall
be suitable for running at 120% speed for 2 minutes.

The starting torque of the motors shall be as per system and operational requirement. The
starting torque of motor shall be co-ordinated with the requirement of the driven equipment on
the basis of minimum voltage of 80% rated voltage at motor terminals. There shall be sufficient
margin of motor torque over the torque requirement to obtain proper accelerating torque so that
the starting time is minimized. The pull out torque of the motors shall be more than 250%. The
starting current of motor shall not exceed 7.20 times full load current at rated voltage given in IS
325 Double shaft extension shall be provided for motors with brakes.

Brakes, limit switches, speed relays etc. as required for individual equipment shall be provided
by the tenderer.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 2 of 5

TECHNICAL SPECIFICATION FOR


Low Voltage AC Squirrel Cage Motor

The noise level shall conform to the requirements of IS:12065 and the amplitude of vibration
shall be within the limits specified in IS:12075.
Lifting arrangement shall be provided for motors.
2.0

Class of Insulation
Motors shall have class F insulation and permissible temperature rise limited to class B.
Windings shall be vacuum impregnated to make them non hygroscopic and oil resistant. Motors
shall have fungus protection including special treatment of insulation and metal against fungus,
insects, and corrosion. Motors to be installed in coastal areas and tropical treatment should be
given.

3.0

Winding
Motor winding leads shall be brought out through seal off bushings. Cable shall not be used for
connecting the windings to the terminal boxes.
Both the winding leads of each phase shall be brought out to the terminal box with necessary
shorting links for achieving desired winding connections at site.

4.0

Bearing
All motor shall be provided with adequate grease lubricated ball or roller bearings as required to
ensure reliable operation. The bearings shall be housed in dust-tight bearing end shields and
shall be provided with easily accessible grease nipples and valves for ejecting excess grease.
The bearings should be provided with labyrinth seals to prevent loss of grease or entry of dust
and moisture. Bearing life shall be more than 50000 hours.

5.0

Terminal Boxes
All motors shall be provided with cable termination boxes with removable undrilled gland plates
suitable for terminating aluminium armoured cables of required size. Double compression glands
should be provided. The box shall be good quality and fabricated out of minimum 2mm thick MS
steel, properly painted and gasketed.
Unless otherwise approved, the terminal boxes shall be capable of being turned through 360 deg
in steps of 90 deg, the position for the main terminal box will be on the right hand side as seen
from drive end of the motor however it should be interchangeable from left to right at site.
All six terminals to be brought to Terminal Box with removable connecting links to form star or
delta. Terminal box shall be of IP-55 degree of protection

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 3 of 5

TECHNICAL SPECIFICATION FOR


Low Voltage AC Squirrel Cage Motor

6.0

Cooling and Cooling Fans


The motor shall be in general fan cooled type having the fans as integral parts of the motors
themselves.

The cooling fans for each motor shall be of such design that the motors can turn in any direction
without/with minor medication at site.
7.0

Earthing
Two separate earthing terminals on opposite sides of motor body.

8.0

Paint & Finish


All ferrous surfaces shall be subjected to the pre-treatment of degreasing, pickling for complete
rust removal, phosphating, corrosion resistant primer painting.

The paint shall be epoxy based and shall be suitable for withstanding specified site conditions.

All fasteners used in the construction of the equipment shall be corrosion resistant against
salinity.
9.0

Tests
Test to be carried out as per IS: 325.

Routine tests to be carried out in presence of employer/engineer and 15 days advance intimation
should be given. Type test certificates of identical rating / model to be furnished.
10.0

Name-plate Marking
At least the following information shall be shown on motor name plate:

Client
Project

Manufacturers Name, Type, Manufacturers Serial Number and Frame Reference

No. of Phases and Phase Connection

Rated Voltage, Rated Current, Rated Power out put in kW/HP

Rated Load Power Factor

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 4 of 5

TECHNICAL SPECIFICATION FOR


Low Voltage AC Squirrel Cage Motor

11.0

Rated Speed, Rating Frequency (and speed range for VVFD controlled motors)

Class of Insulation and Temperature Rise

Bearing identification numbers (in case of ball/roller bearing and recommended


lubricant).

In addition to the manufacturers standard name plates, a metal tag for


motor identification number (6 digit, 12 mm high) shall be fixed to each
motor.

Space Heater
Motor shall be provided with anti condensation space heater for motor more than 30kW. The
space heater shall operate at voltage 240V, single phase, 50 Hz AC supply.
The space heater leads are to be terminated inside a separate terminal box with IP55 degree of
protection . Double compression brass glands shall be provided for entry of space heater into the
terminal box

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 5 of 5

TECHNICAL SPECIFICATION FOR


POWER AND CONTROL CABLES

ANNEXURE-IV
Technical specification for Cables

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 1 of 5

TECHNICAL SPECIFICATION FOR


POWER AND CONTROL CABLES

Cables
1.0

Power and Control Cables


A.

General

The cables shall be heavy duty armoured type XLPE insulated (Power Cables) / PVC
insulated (control cables).
All cables shall be designed and manufactured such that no damage occurs during
transportation, installation and operation of the cables under stipulated conditions.
The cables shall be suitable for laying in trays, pipes, ducts, closed trenches and directly buried
underground.
The cables shall be designed so that the conductor temperature does not exceed 90 deg. C for
XLPE Power cables and 70 deg. C for PVC control cables while carrying steady state rated
current.
B.

C.

H.T. Cables (System Particulars)


a) Voltage Grade / Normal System Voltage

: 33 KV (E) and 6.6 KV (UE)

b) Highest system voltage

: 36 kV and 7.2 KV

c) Frequency

: 50 Hz + 3%

LV Cables (System Particulars)


a) Power Cables
i.

Voltage Grade

: 1100 V

ii.

Normal system voltage

: 415V + 10%

b) Control Cables
i.

Voltage Grade

: 1100 V

ii.

Normal system voltage

: 110V + 10%,

240V+ 10% &

24V+ 10%
2.0

Conductors
A. Power Cables
The conductors shall be composed from electrical purity aluminium and shall confirm to IS:

8130 conductors shall be stranded and circular in cross section upto the size of 25 sq.mm.
and above shall stranded & shaped.
Minimum cross section of conductors for power cable shall be 6 sq.mm for aluminium and 2.5
sq.mm for copper
Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 2 of 5

TECHNICAL SPECIFICATION FOR


POWER AND CONTROL CABLES

B. Control Cables

The conductor shall be of plain annealed high conductivity copper stranded wires which before
stranding shall be generally circular in section, smooth, uniform in quality and free from scale
spills, splits and other defects. The conductors shall confirm to IS:8130. The stranded conductor
shall be clean and reasonably uniform in size and shape and its surface shall free from
sharp edges. Minimum Control cable size shall be 2.5 sq. mm.
3.0

Insulation
The insulation shall consist of the following:
A) PVC Insulation (For Control Cables)
a) Compounded polyvinyl chloride; or
b) Suitable co-polymers, of which major constituent shall be vinyl chloride;
c) Mixtures of polyvinyl chloride and suitable co-polymers which have been suitably

compounded and processed so as to comply with the requirements of the relevant


standards.
B) XLPE Insulation (For HT & LT Power Cables)

The insulation shall be chemically cross linked polyethylene conforming to the physical,
electrical and ageing properties as required by IS:7089 (Part I & II). Only natural unfilled
compounds shall be used for insulation of cables. the insulation shall be free from micro voids
and shall be heat resistant.
4.0

Inner Sheath
For all cables having two or more cores, the individual cores shall be laid up and then be
surrounded by common covering applied either by extrusion or wrapping or filling material
containing a thermoplastic material. A proofed or plastic tape may be applied over the
common covering when a wrapped common covering is employed. It must be ensured that the
circularity of the cable is maintained.

5.0

Armouring
Armouring shall be arranged over the inner sheath for the cable consisting of two or more
cores. The armour of cables shall be either of galvanized steel wires or galvanized steel
strips. In case of high voltage grade cables, armouring shall be arranged over the bedding.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 3 of 5

TECHNICAL SPECIFICATION FOR


POWER AND CONTROL CABLES

6.0

Outer Sheath
A tough outer sheathing of PVC insulating material in standard colours shall be provided over the
armouring to offer a high degree of mechanical protection against abrasion. For high voltage
grade cables, outer sheathing shall consist of a complete layer or layers of suitably
compounded hessian materials. Additional compound shall be applied under and over each
layer. in order to prevent adhesion, a coating of lime wash or other suitable material shall be
applied to the outside of the cable.

7.0

Colour Scheme for Identification of Cores


Cores shall be identified by colour scheme of PVC XLPE insulation. The following colour
scheme shall be adopted:
Phase A
Phase B
Phase C
Neutral
Earth

:
:
:
:
:

Red
Yellow
Blue
Black
Green/Yellow

For cables having more than five (5) cores, two adjacent cores (counting and directional) in
each layer may be coloured blue and yellow respectively and the remaining cores may be
light grey
8.0

Manufacturer's Identification
The manufacturer shall be identified throughout the length of the cable by manufacturer's
name or trade mark, voltage grade and year of manufacture of the cable indented or embossed
on the cable. The indentation or embossing shall be done only on the outer sheath.

9.0

Packing and Marking


The cable shall be wound on a wooden drum and packed as per the requirement of IS:
10418-1982. The ends of the cable shall be sealed by means of non-hygroscopic sealing
material.
The cable shall carry the following information either stenciled on the drum or contained in a
label attached to it:

Client
Project

Reference to Indian Standard

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 4 of 5

TECHNICAL SPECIFICATION FOR


POWER AND CONTROL CABLES

10.0

Manufacturer's name or trade-mark

Type of cable and voltage grade

Number of cores

Nominal cross-sectional area of conductor

Cable code

Length of cable on the drum

Number of lengths on the drum (if more than one)

Direction of rotation of drum (by means of an arrow)

Gross mass

Year of manufacture.

Despatch
The cables shall be despatched in suitable drums with weather-proof packing.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 5 of 5

TECHNICAL SPECIFICATION FOR


LT SWITCHGEAR PANELS

ANNEXURE-V
Technical specification for
LT Switchgear Panels

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 1 of 7

TECHNICAL SPECIFICATION FOR


LT SWITCHGEAR PANELS

LT Switchgear Panels (PCC, MCC, MLDB & ACDB)


1.0

Panel Enclosure & Construction


Switchgear shall be made of cold rolled annealed sheet steel metal (2 mm thick for load
bearing members and Min. 1.6 mm thick for doors and covers) enclosed, indoor, floor
mounted, free standing type.
All sections of the enclosure shall conform to IP: 54 degree of protection. Switchgear shall be
suitable for cable entry from bottom / top as per site requirement. Gaskets shall be used
between all adjacent units and beneath all covers to render all the joints effectively dust proof.
Gaskets shall be used between all adjacent units and beneath all covers to render all the joints
effectively dust proof.
Operable height for any switch/push button/ meter / indications shall be within 300 mm - 1800
mm.
All LT switchgear panels shall have 20% spare feeders.

A.

Bus Bars

MCC shall have three phase and neutral bus bars of rated current capacity and short circuit
withstand capacity of 50 kA for 1 sec. Busbars shall be of electrical grade aluminium or copper
and provided with heat shrinkable insulating sleeves.
The buses shall be so supported and braced as to be capable of safely withstanding the
maximum thermal and magnetic stresses corresponding to the short circuit currents specified.
The main horizontal busbars shall be located at the top in a separate chamber extending the
entire length of the same. Busbar chambers shall have separately screwed cover. All busbars,
links, etc., shall be adequately shrouded to prevent accidental contact. Power shall be
distributed to each module or compartment by a set of vertical busbars. The vertical busbars
shall run behind the modules and individual modules shall be fed from the vertical busbars
through connections, which shall be adequately shrouded. It shall be possible to easily remove
the shroud for inspection and maintenance.
Bus supports shall be arc resistant, non-tracking, made out of low absorption synthetic resin
bonded insulation or equivalent having high insulation strength and high creepage surface.
Appropriate colour codes (Red, Yellow, Blue and Black) shall be used to identify the various

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 2 of 7

TECHNICAL SPECIFICATION FOR


LT SWITCHGEAR PANELS

phases of the busbars and the neutral.

B.

Wire ways

A horizontal wire way, extending the entire length, shall be provided at the top for inter-panel
wiring.
A full height vertical wire way with cable supports for mounting cable clamps shall be provided
for each section to facilitate cabling.
The wire way shall be liberally sized to accommodate all power and control cables and shall
have a hinged and lift-off type cover at the front for access.
C.

Panel Heater

Anti-condensation heater with thermostat control shall be provided in the MCC.


D.

Earth Bus

An earth bus shall run along the entire length of the panel which shall be connected to the
system earth.
2.0

Component Specification
MCC and Local Control Panels shall have all the required switchgear, protection, controls and
auxiliary components as required for plant operation. These shall be selected considering Type
2 co ordination as per IS/IEC standards. Functional requirement and interfacing with field
controls, safety devices and Central control system shall be taken care in selection of the
components and panel wiring.
A. Air Circuit Breaker

The circuit breakers shall be of electrically operated (and also having facility for manual
operation), lair break type and shall be of draw out design conforming to the Indian
Standards/International Standards. All the breakers of the switchgear shall be from the same
family of breakers having the desired rating to ensure the uniformity of the design,
maintenance and spares & inter-changeability. The circuit breakers shall have breaking
capacity of 50 kA and shall withstand system fault level of 50 kA for short time duration of 1
sec. In ACB Icw for 1 sec. = Ics = Icu to ensure complete selectivity.
ACB shall have microprocessor based protection release for over current, short circuit, earth
fault, under voltage, overvoltage protection.
Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 3 of 7

TECHNICAL SPECIFICATION FOR


LT SWITCHGEAR PANELS

ACB/Protective Releases shall have data communication port (MODBUS RTU) for
PLC/SCADA interface for remote operation control and monitoring from Central Control Room.
ACB on/off/trip status should be communicated to PLC at central control room for remote
operation control and monitoring.
B. Multi-function meters

Digital multi-function meters shall be provided for incoming & outgoing feeders as per SLD.
These meters have accuracy class of 0.5 or better.
The digital metering unit shall have provision to display the following:
o

Phase and line voltage

Phase and line current

kVA, kW, kVAR, kVAH, kWH and kVARH,

Maximum Demand kVA, kW

Power factor

Phase Angle

Frequency

Harmonics

Alarm output relay

Multi function meters shall be with inbuilt transducers and have data communication ports
(MODBUS RTU) for PLC/SCADA interface for remote operation, control and monitoring from
Central Control Room.
C. Moulded Case Circuit Breakers

MCCBs shall be 3 pole (A.C.) units having a breaking capacity of 50 kA capable of


withstanding system fault level of 50 KA for short time duration of 1 sec. current rating shall be
as per the full load current of the associated or rated current of connected equipment. For
motor feeder feeders, the MCCBs shall have characteristics compatible with associated motor
starting/running requirements and overload relay. In MCCB, Ics = Icu to ensure complete
selectivity. All LT Switchgear shall be according to Type 2 coordination as per IEC 60947.
The MCCBs shall have auxiliary contacts for on off indication as well as for testing of the
associated contactors control circuit without energizing the power circuit using test push
button. (in the off / open condition of the MCCB). MCCB on/off/trip status should also be
communicated to PLC at central control room for remote monitoring.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 4 of 7

TECHNICAL SPECIFICATION FOR


LT SWITCHGEAR PANELS

D. Contactors

Contactors for A.C. shall be 3 pole air break electromagnetic types suitable for making and
breaking locked rotor current of the motor which is equal to around six (6) times the full load
current. Reversible motor contactors shall be mechanically and electrically interlocked with
each other. On/off/trip status should also be communicated to PLC at central control room for
remote operation control and monitoring
E. Overload Relays

The contactors shall be provided with 3 element (A.C.) ambient temp. Compensated time
lagged hand reset type bimetallic thermal overload relays with adjustable setting range and
single phase prevention. Overload relay shall have least one NO & NC change-over contact.
Relays shall be either direct connected or CT operated depending on the rated feeder current.
The relays shall be so chosen that it will not operate during the starting time of the motor.
Healthy/trip status should also be communicated to PLC at central control room for remote
monitoring
F. Auxiliary Contactors / No Volt Relays

The auxiliary contactors and no volt relay shall be provided as per circuit requirement. The
contact rating shall be 10 Amp. 240V AC. The auxiliary contactors shall have at least 5
contacts in contact combinations as per Purchaser's requirement.
G. Push Buttons

Push buttons rated 10 Amp 240V AC shall be of purchaser's approved make and type with
silver tipped contacts to withstand minimum 1000 switching operations per hour. Push button
life shall be more than 10 million operations. The push buttons shall have at least 2 NO and 2
NC contacts. On/off/selected position status should also be communicated to PLC at central
control room for re On/off/selected position status should also be communicated to PLC at
central control room for remote operation control and monitoring mote operation control and
monitoring
H. Space Heater

The space heaters for panels shall be suitable for continuous operation on 240V AC 50 Hz,
single phase supply and shall be automatically controlled by thermostats. Provision for power
supply to space heaters for motors shall be kept in motor feeders rated 75 kW and above.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 5 of 7

TECHNICAL SPECIFICATION FOR


LT SWITCHGEAR PANELS

I.

Indicating Lamps

The indicating lamps shall be panel mounting large industrial LED type and shall be
interchangeable. Indicating lamps shall be with translucent lamp covers. The lamp covers shall
be mounted flush on the front panel door and shall be replaceable from the front of the cubicle.
J.

Current Transformers and Potential Transformers

Instrument Transformers for ammeters and relays as required shall be dry cast resin type and
of reputed and approved make and type conforming to IS:2705 and IS:3156.
3.0

Measuring Instruments
All electrical measuring instruments shall be of accuracy class of 1%. Variations of
characteristics that may be caused by temperature changes shall be minimum. Measuring
instrument shall show no mechanical distress under continuous load conditions at ambient
temperature of 45C.
All meters shall be of the direct reading, flush mounted, square pattern with removable covers.
The exposed metal portions of all cases shall have the same finish, trim and general
appearance. The meters shall be housed in either phenol-moulded or steel enclosures.

4.0

Auxiliary Equipment
A. Auxiliary Relays

Auxiliary relays shall generally be used for interlocking and multiplying contacts. Auxiliary
contacts shall be capable of carrying the maximum estimated current. In any case their rating
must not be less than 5A - for 20 V A.C. at a power factor between 0.3 and 1, and 2 A for 110
V D.C. (inductive load).
B. Push Buttons

Push button colours shall be as follows:

Stop, Open, Emergency

Red

Start Close

Green

Trip Circuit `Healthy' check

Black

Push buttons rated 10 Amp A.C. shall be of purchaser's approved make and type with silver
tipped contacts to withstand minimum 1000 switching operations per hour. Push button life

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 6 of 7

TECHNICAL SPECIFICATION FOR


LT SWITCHGEAR PANELS

shall be more than 10 million operations. The push buttons shall have at least 2 NO and 2 NC
contacts. On/off/selected position status should also be communicated to PLC at central
control room for re On/off/selected position status should also be communicated to PLC at
central control room for remote operation control and monitoring mote operation control and
monitoring
C. Control Switches

The control switches shall be rotary, back connected type having a cam operated contact
mechanism, phosphor bronze contacts shall be used on the control switches. Unless otherwise
stated, circuit breaker control switches shall be 3-position spring return to `neutral' from `ON'
and `OFF' positions. On/off/selected position status should also be communicated to PLC at
central control room for remote operation control and monitoring.

Client
Project

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED


Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 1

Date:28-04-2014

Page 7 of 7

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

10-02-2015

Electrical Load List Format- (ANNEXURE-VI)


Quantity

Sl. Description of Load


no.

Total

Working

Standby

Voltage

Rating

Shaft Power

(Volts)

(kW)

(kW)

P.F.

Efficiency

uni/bi

(%)

directional

Page 1 of 1

Starter
required
Yes (Y)
No (N)

Type of
Feeder
Motor(M)
Power(P)

Operating condition
Starting

Continuous

Stopping

Remarks
Intermittent

TECHNICAL SPECIFICATION FOR C & I OF


FIRE PROTECTION SYSTEM AND DUST
SUPPRESSION SYSTEM

ANNEXURE-VII
TECHNICAL SPECIFICATION FOR CONTROL & INSTRUMENTATION OF DSS & FFS

CONTENTS
Sr.
No
01

Particulars

Page
No.
02

03

FIRE PROTECTION INSTRUMENTATION


PROGRAMMABLE LOGIC BASED CONTROL
SYSTEM(PLC)
PRIMARY & SECONDERY INSTRUMENTS

04

CONTROL CABINETS / PANELS / DESKS

17

05

PROCESS CONNECTION & PIPING

18

06

OPERATION & CONTROL PHILOSOPHY

20

07

CABLES

22

08

TESTING & GUARANTEE REQUIREMENT

24

09

POWER SUPPLY SYSTEM

33

10

ELECTRICAL ACTUATORS WITH INTEGRAL STARTERS

34

02

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SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

07
12

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01. FIRE PROTECTION SYSTEM & DUST SUPPRESSION SYSTEM INSTRUMENTATION


1.01.00 INTENT OF THE SPECIFICATION
The intent of this specification is to procure the FPS & DSS Control & Instrumentation System
as a single point responsibility, in line with the requirement and intent of the specification
elaborated herein for compatibility with C&I of E1 Package PLC located at SS1 to ensure
operability, maintainability, reliability and acceptability to the Owner for the entire life of the VZG
PORT EQ1A BERTH Facilities
1.02.00 SCOPE OF WORK, SUPPLY & SERVICES
a) The scope of work in accordance with this specification shall cover design, engineering,
manufacturing / procurement, Testing (both at factory & site), supply, storage, erection and
commissioning of the systems / equipment under FPS & DSS scope. The scope shall also
include interconnection with SS1 PLC and other control systems, calibration, tuning of the
controllers / control loops, testing, commissioning and putting the instrumentation and control
system together with all accessories, auxiliaries, and associated equipment in a fully integrated
operational condition fulfilling the intent and requirement of the specification.
b) The Vendor shall read this specification in conjunction with the requirement of the mechanical
and Electrical systems specification to ascertain the complete scope of work and services under
the FPS & DSS C&I system.
c) The scope of supply & services of the FPS & DSS - control & Instrumentation supplier shall
include the following but not limited to:
I PLC / Microprocessor based control & monitoring system under FPS & DSS package namely.
Fire Fighting system

Dust Suppression System for


CHP Transfer Towers (TT)

Dust Supppression System for


Coal Stock P[ile
Potable & Service Water System

PLC based Control System with Front panel


mounted Garphical User Interface (GUI) of
12 sized for operator Interface.
This will be controlled by E1
Package PLC (By owner) located at SS1.
Bidders scope includes all the required field
instrumentation for successful operation of
DSS System up to Field Junction Boxes
including Junction boxes and cabling up to
JBs.
PLC based Control System with Front panel
mounted Garphical User Interface (GUI) of
12 sized for operator Interface
This will be controlled by E1 Package PLC
(By owner) located at SS1. Bidders scope
includes all the required field instrumentation
for successful operation of DSS System up
to Field Junction Boxes including Junction
boxes and cabling up to JBs.

II These PLCs shall be Interfaced with the E1 Package PLC System located at SS1 over
MODBUS TCP /IP through Redundant Fibre Optic Link.

Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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Rev

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III All the necessary interface Software / hardware like switches, converters servers & F.O.Cable
etc as required at both ends i.e SS1 PLC End and Respective Local Control Systems , to
establish two-way link between PLC / Micro Controller and the E1 Package PLC System located
at SS1 Control Room area shall be taken care by Owner .However Bidder has to provide
necessary ports and Power supply facilities to these accessories at his PLC End.
IV Supply & erection of fiber optic Cable as required for interfacing shall be by Owner.
IV Process connection & Piping for FPS , DSS for CHP & Stock Pile , Potable & Service Water
Systems ,
V Panels / Control desk / local panels with all hardware.
VI Field sensors, instruments, Smart transmitters, LIE / LIR, Junction Boxes, etc.
VII The secondary instruments like indicator, recorder, electrical meters and any other as enquired
or specified shall also be supplied, erected and tested by the Bidder.
VIII Control valves & actuators as specified
IX The Vendor shall supply, erect & commission, industrial Grade adequately sized Standalone
UPS for PLC / Micro Controllers as per the requirement of the System.
X Furniture in control room
XI Separate earth pit shall be provided for C&I electronic system. It shall not be clubbed with the
plant electrical earthling.
XII Spare parts and consumables as specified
XIIIAll OEM software & software licenses.
XIVElectrical actuators with integral starters
1.03.00 DESIGN CRITERIA
a) All equipments, systems and accessories furnished under these specifications shall be from
the latest proven product range of a qualified manufacturer whose successful performance has
been established by a considerable record of satisfactory operation in Ports. The list of subvendors / suppliers for C&I items is attached.
b) The PLC / Microprocessor based system, GUI based Man Machine Interface (MMI) etc. shall
be of latest design (shall not be more than three year old system) and should have proven
track record and shall be subject to Owners approval. PLC based Systems provided under
this (FPS & DSS) package shall be of same make and model. PLCs shall be suitable for
programming languages conforming to IEC 61131-3 programming software.
c) A separate electronic earth pit shall be provided for C&I system, which shall be isolated from
the plant electrical earth pit. The details of the earthing system shall be finalized during detailed
engineering.
d) The Vendor shall conduct integrated test at manufacturers works and inspection, checking &
pre-commissioning tests and Site Acceptance Test at site for all Instrumentation and Control
Equipment supplied under this contract to the complete satisfaction of the Owner / Owners
representative as detailed in relevant sections of the specification.
e) Microprocessor /PLC based control and monitoring system for FPS & DSS Plant package
shall cover the total functional requirements of modulating control (CLCS), sequence control
(OLCS) with their measurement system interlocks & protection, monitoring, alarm, data
logging, fault analysis, etc.

Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Doc. No: VCT-EQ1A-C5-MZ-PT1-610-

Rev

11-0101, Rev. 0

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f) The PLC / Microprocessor based system of FPS & DSS shall be interfaced with the SS1 PLC
system through Fiber Optic cable with Ethernet based MODBUS TCP-I/P protocol. The
communication shall be seamless and without requiring any protocol conversion. FPS & DSS
Vendor is required to ensure that the communication link with the SS1 PLC is established and
commissioned and that the requisite data / information are displayed on the assigned OWS at
CCR.
g) The design of the control system and related equipment shall adhere to the principle of fail
safe operation at all system levels and provide reliable and efficient operation of the plant under
dynamic conditions and attainment of maximum station availability.
h) Suitable arrangement, with required hardware & software, to receive NTP Server based time
signal from Owners PLC for time synchronization. The associated cable & cabling for clock
signals up to SS1 PLC in Central control room shall be under the owner.
i) All equipments/systems located in the field shall be suitable for continuous operation without
loss of function, departure from specifications or damage at the ambient temperature of 50 C
and relative humidity of 90%.
j) Even after the guarantee period, the Vendor shall be responsible for providing spare parts and
other required support during the service life of the plant.
k) For hazardous area, instruments provided shall be intrinsically safe and field instruments shall
be explosion proof as per relevant area classification.
l) Indicating type process switches deriving contact from pointer shall not be acceptable.
Wherever blind switches are provided. Separate gauges for local indication shall be provided to
facilitate easy operation I maintenance.
m) Field Junction boxes (JBs) will be made of galvanized, wall / column/structure mounted type
shall have cable entry only at the bottom and sealed with fire proof compound: rail mounted
cage clamp: IP 55 degree of protection for enclosure. JBs shall be min 1.6 mm thick sheet
metal of cold rolled steel.Field Junction boxes will be suitable to specified area; and will have
20% spare terminals in each junction box. Double compression type cable glands and blind
plugs will be provided with each JB. Separate JB will be used for analog and digital signals and
also for signals with different Voltages.Junction type will be screwed at four corners for door or
door handle will be SS.Self locking with common key. Door gasket will be of synthetic rubber.
1.04.00 CODES & STANDARDS
The following specific codes and standards shall be applicable:
Instrumentation Symbols and indent.
Binary Logic Diagrams for Process Operation
Graphic symbols for PLC, shared display inst. logic & Comp.
System
Annunciator sequences and spec.
Environmental Conditions
Vibration, Axial Position & Bearing Temperature Monitoring
Systems
Valves Seat Leakage
Air Purge System
Temperature Measurement

Guide for the design and installation of cable system in power


Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

ISA S 5.1
ISA S 5.2
ISA S 5.3
ISA S 18.1
ISA S 71.04
API 670
ANSI B 16.104
ISA S 12.4 /
NFPA 496
ANSI MC 96.1 /
IEC 751
NEMA

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FIRE PROTECTION SYSTEM AND DUST
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generating station (cable trays, support system, conduits, test
standards etc.)
Performance Testing of UPS.
Hardware testing of digital computer.

IEEE guide to software requirement specifications.


Classification of hazardous area.
Classification of hazardous area
Degree of Protection by Enclosure
Note:

IEEE 422
lEC 146
ISA AP 55.1
1982/
ANSI
MC8.1 1975
IEEE.
.830.
1984
NFPA 70-1984
Art 500 Vol.6
NEC/USA Art
5001978
IEC
529/IS:13947

All other relevant codes, as applicable, are to be used along with the above basic codes and of
latest version.The codes and standards specified above are indicative but not exhaustive.

1.05.00 REDUNANCY CRITERIA AND SPARE CAPACITY


a) Redundancy of components and systems shall be dictated by availability criteria to ensure the
system availability target as well as safety considerations in critical applications.
b) Dual / Triple redundancy for sensors and transmitters will be used for critical applications if
required.
c) Sensor redundancy (1 out of 2) requirement shall be indicated in the respective control system.
In case of large deviation in analog input between two transmitters, alarm shall be generated for
operator intervention.
d) The controller/processor, power supply modules, communication modules, data-bus shall be
furnished with 100% hot stands by with bump less transfer facility. The controller shall be 32 bit,
1 M Bytes RAM (min.). The quantities of controllers shall be subject to fulfillment of spare
capacity of controller and worst loading conditions. Battery backup for RAM duration not less
than 120 hours for continuous operations during power failure shall be provided.
Each
controller shall have 30% spare functional capacity to implement additional function blocks, over
and above implemented logic/ loops under worst load conditions
e) Each controller shall have spare capacity to handle minimum 30% additional inputs/ outputs of
each type, over and above implemented capacity. Each of the corresponding communication
controllers shall also have same spare capacity as that of controller.
For controller, the worst loading condition shall include the following tasks:
i.
All process inputs scanning and processing is in progress and all the data is
transmitted over the main data bus every one (1) second.
ii.
All closed loop controls in operation
iii.
All open loop controls in operation
iv.
All output devices are in operation with rated performance/speed.
v.
Control/information request is initiated on all control operating stations.
vi.
In burst mode operation (in case of major equipment trip), 100 digital alarms are
generated per second for a period of 10 seconds
a) 100% redundancy shall be provided for all input/output cards, used for executing closed
loop/sequential interlock and open loop functions for critical applications. No redundancy at I/O
card level is required for other control loops and for Data Acquisition/Monitoring functions. .
In addition to above, 20% wired input/output spare channel should be provided for each I/O
modules.
b) Wherever redundant I/O modules/cards are used as per specification requirement, both (1:1
Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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c)

d)
e)

f)

redundant) input or output modules shall execute the designated functions parallely. The offered
system shall have facility to enable final output from any of redundant input/output modules, in
case both modules are healthy. In case, one of redundant cards/modules is unhealthy, the
system shall detect the same and the input & output to the system shall be through healthy
card.
Wherever redundant sensors are employed, each sensor shall be wired to separate input
module so that even if one input module fails, the signal shall be available from the other input
module
Contact interrogation voltage shall be 24V DC.
20% spare relays of each type and rating, mounted and wired in relays cabinets. All contacts of
relays shall be terminated in terminal blocks of relay cabinets, additionally in each of the relay
cabinets, 20% spare terminal blocks shall be 'provided so that additional relays can be mounted
and wired. In case Vendors system employs marshalling cabinet for all inputs, the spare
terminals, fully wired up to marshalling cabinets are also to be provided.
Wired-in "usable" space for 20% modules in each of the system cabinets for mounting electronic
modules shall be provided by the Vendor. Empty slots between individual modules/group of
modules, kept for ease in maintenance or for heat dissipation requirement as per standard
practice of Vendor shall not be considered as wired-in "usable" space for I/O modules. Field
Terminal assemblies, PCB/ Connectors (if any in the offered system), corresponding to the I/O
modules shall be provided for above-mentioned 20 % blank space.
The spare capacity as specified above shall be uniformly distributed throughout all controller
systems. The system design shall ensure that above-mentioned additions shall not require any
additional controller/processor/Peripheral drivers in the system delivered at site. Further, these
additions shall not deteriorate the system response time/ duty cycle, etc. from those stipulated
under this specification and shall meet other redundancy / functional requirement.

1.06.00 PROTECTION, CLASS OF CABINETS / PANELS, ENCLOSURES ETC.


a) All panels, desks cabinets & enclosures furnished at least comply with the
requirementsof
protection classes as indicated below.
1)
In-door Air-conditioned (A.C.) areas IP32
2)
In-door Non A.C. areas:
a)
Ventilated enclosures
IP42
b)
Non Ventilated.
IP 55
3)
Out-door
IP55 / IP65
(As per the requirement)
a) Distribution boxes, junction boxes, terminal boxes and all other field mounted equipment to be
furnished as per this specification shall have weather protection conforming to IP 65.
b) The design of panels, cabinets, enclosures and packaging density of components mounted
therein shall be such that the temperature rise does not exceed 10 deg. C above the ambient
under the worst conditions.
c) The design of panels housing electronic hardware shall be suitable for mounting of flame and
smoke detectors.
d) Enclosures for peripheral equipments like printers, etc. shall take care of noise and shall ensure
minimum possible noise disturb to the working personnel.
e) Permanently fastened, stainless steel nameplate stamped with the tag number and other
necessary details shall be furnished on all gauges, control valves, switch devices, temperature
elements, and solenoid valves. Junction boxes, panels, cabinets, enclosures, console Inserts
etc.

Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Doc. No: VCT-EQ1A-C5-MZ-PT1-610-

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1.07.00 STANDARDIZATION
To ensure smooth and optimal maintenance including efficient spare parts management, the
Vendor shall ensure that all the PLC / Micro Controllers and various C&I
instruments/equipments like all 4-20mA electronic transmitters/transducers, control hardware,
control valves, actuators etc. being furnished for FDAP equipment system including its
auxiliaries, are of the same make, series and family. The make and models are subject to
owners approval.
The Vendor shall supply and install all necessary furniture including ergonomically designed
industrial grade chairs & desks, stands and other mounting accessories for use at the control
room.
02. PROGRAMMABLE LOGIC BASED CONTROL SYSTEM
2.01.00 PLC PROCESSOR
a)

b)
c)
d)

e)

The processor unit shall be capable of executing the following functions:i.


Receiving binary and analog signals from the field and operator initiated commands
from OWS/ control panel.
ii.
Implementing all logic functions for control, protection and annunciation of the
equipment and systems.
iii.
Implementing modulating control function for certain application as specified
elsewhere in the specification.
iv.
Issuing control commands.
v.
Providing supervisory information for alarm, various types of displays, status
information, trending, historical storage of data etc.
vi.
Performing self-monitoring and diagnostic functions.
The controller shall provide all basic functions for binary gating operations, modulating controls,
storage, counting, timing, logging, transfer operations and comparison functions
The programmable system shall be delivered completely programmed for the complete and
reliable operation of the plant.
The PLC unit shall be provided with two processors (Main processing unit and memories) one
for normal operation and one as hot standby. In case of failure of working processor, there shall
be an appropriate alarm and simultaneously the hot standby processor shall take over the
complete plant operation automatically. The transfer from main processor to standby processor
shall be totally bumpless and shall not cause any plant disturbance whatsoever. In the event of
both processors failing, the system shall revert to fail safe mode. It shall be possible to keep
any of the processors as master and other as standby. The standby processor shall be updated
in line with the changes made in working processor.
The memory shall be field expandable. The memory capacity shall be sufficient for the
complete system operation and have a capability for at least 20% expansion in future.
Programmed operating sequences and criteria shall be stored in non volatilesemi conductor
memories like EPROM. All dynamic memories shall be provided with buffer battery backup
which shall be for at least 360 hours. The batteries shall be lithium or Ni-Cd type.

2.02.00 MAN MACHINE INTERFACE (MMI)


a) Front panel mounted 12 size Graphical user interface (GUI) shall be provided as Man Machine
Interface . This shall facilitate control & monitoring and programming function for PLC system.
GUI shall perform control; monitoring and operation of all auxiliaries/ drives interacting with PLC
based control system. It shall be possible to use the same as programming station of the PLC.
Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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b)

c)

d)

e)

f)

g)

h)
i)

j)

One Lap top to be provided as engineering tool for programmable functions with required
software for Fire protection System & Dust Suppression System (FPS & DSS) PLC. It shall
basically perform the following functions
1)
Operator interface for PLC based control system - Operator functions shall as
minimum include local/ remote selection, A/M selection, open/ close operation,
sequence auto, start/ stop selection, ON/OFF, bypassing criteria etc.
2)
Supervisory functions like:Mimic displays, which shall depict the process in graphical form and shall cover all
he process areas being monitored.
3)
Alarm monitoring / reporting, generation of logs, calculations, printing of logs &
reports etc.
4)
Historical storage & Retrieval
5)
Programming station shall have access to the processor of the control system for
programming. Programming shall not require special computer skills. It shall be
possible to do the programming, self-diagnostics, testing of sequence, simulation
and any sequence modification.
The programming language shall conform to IEC-61131-3 standard.
Programming shall be possible in any of the following formats:
i.
Flow-chart or block logic representing the instructions graphically.
ii.
Ladder diagrams.
A forcing facility shall be provided for changing the states of inputs and outputs, timers and flags
to facilitate fault finding and other testing requirements on off-line. It shall be possible to display
the signal flow during operation of the program. Programming shall be possible OFF line also. A
NORMAL / TEST / PROGRAM / OFF lockable selector switch shall be provided. In case of test
mode of operation, all outputs should be blocked.
In addition to the above, GUI as OWS and 1 (One) No. printer to be supplied by Bidder to be
located adjacent to the Control System in the central control room for central monitoring of the
FPS & DSS systems. These PLCs / Controllers shall be connected to SS1 PLC and replica of
FPS & DSS Graphics shall be implemented in SS1 PLC. The Vendor shall supply necessary
hardware & software and provide complete engineering support to achieve this.
Priority of different commands shall be as follows:
Manual intervention shall be possible at any stage of operation. Protection commands shall
have priority over manual commands and manual commands shall prevail over auto commands.
In PLC controller, memory should exist as to where the sequence was aborted due to power
supply failure so that further operation from that point can restart after power supply restoration.
This restart after recovery of the power supply shall be through operator intervention so as to
enable verification of readiness of other related equipments.
All necessary software required for implementation of control logic, operator station displays /
logs, storage & retrieval and other functional requirement shall be provided. The programs shall
include high-level languages as far as possible. The Vendor shall provide sufficient
documentation and program listing so that it is possible for the Owner to carry out modification
at a later date.
The Vendor shall provide all software required by the system for meeting the intent and
functional/parametric requirements of the specification.
Industry standard operating system like UNIX/WINDOWS NT etc. to ensure openness and
connectivity with other system in industry standard protocols (MODBUS TCP-IP/ OPC etc.) shall
be provided. The system shall have user oriented programming language & graphic user
interface.
All system related software including Real Time Operating System, File management software,
screen editor, database management software. On line diagnostics/debug software, peripheral
drivers software and latest versions of standard PC-based software and latest WINDOWS
based packages etc. and any other standard language offered shall be furnished as a minimum.

Project
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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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The programming software shall conform to IEC-61131-3 standard.
k) All application software for PLC system functioning like input scanning, acquisition, conditioning
processing, control and communication and software for operator interface of monitors,
displays, trends, curves, bar charts etc. Historical storage and retrieval utility, and alarm
functions shall be provided.
l) The Vendor shall provide software locks and passwords to Owners engineers at site for all
operating& application software so that Owners engineers can take backup of these software
and are able to do modifications at site.
2.03.00 INPUT/OUTPUT MODULES
a) Input Output modules, as required in the Control System for all type of field input signals (4-20
mA, RTD, non changeover/change over type of contact inputs etc.) and outputs from the control
system (non changeover/change over type of contact, 24/48 VDC output signals for energizing
interface relays, 4-20 mA output etc.) are to be provided by the Vendor.
b) Suitable optical couplers between the plant input/output and controller shall be provided on the
I/O cards. The isolation shall ensure that any inadvertent voltage or voltage spikes (as may be
encountered in a plant of this nature) shall not damage or mal-operate the internal processing
equipment.
c) The Input/output system shall facilitate modular expansion in fixed stages. The individual
input/output cards shall incorporate indications on the module front panels for displaying
individual signal status.
d) Individually fused output circuits with the blower fuse indicator shall be provided. All input/output
points shall be provided with status indicator. Input circuits shall be provided with fuses
preferably for each input, alternatively suitable combination of inputs shall be done and provided
with fuses such that for any fault, fuse failure shall affect the particular drive system only without
affecting other systems.
e) All input/output cards shall have quick disconnect terminations allowing for card replacement
without disconnection of external wiring and without switching of power supply.
f) The Vendor shall provide the following monitoring features:
a)
Power supply monitoring.
b)
Contacts bounce filtering.
Optical isolation shall be provided between digital input and output signals whereas galvanic
isolation shall be provided for analog signals.
In case of power supply failure or hardware fault, the critical outputs shall be automatically
switched to the fail-safe mode. The fail-safe mode shall be intimated to the successful Vendor
during detailed engineering
g) Further, keying-in of individual wire connectors shall be provided to ensure that only the correct
card is plugged on the I/O module. It shall be possible to remove I/O module without
disconnecting wiring from field inputs or outputs. There shall be at least 20% spare capacity
available on input, output and memory modules, over and above the system requirement.
h) Binary Output modules shall be rated to switch ON/OFF coupling relays of approx. 3 VA at 24
VDC. 24V DC coupling relays to be provided in all PLC control panel/Remote I/O panels in FF
Vendor scope. The contact rating shall be suitable for control circuit where the contacts of these
relays are connected. Analog output modules shall be able to drive a load impedance of 500
Ohms minimum.
i) Output module shall be capable of switching ON/OFF inductive loads like solenoid valves,
auxiliary relays etc. without any extra hardware.
j) Only one changeover contact shall be provided in MCC for control and interlock requirement.
Further multiplication, if required, shall be done by the Vendor in PLC system.
k) All input field interrogation voltage shall be 24V DC or 48 V DC.
l) In case of loss of I/O communication link with the main processing unit, the I/O shall be able to
Project
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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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go to predetermined fail safe mode (to be decided during detailed engineering) with proper
annunciation.
m) The maximum number of inputs/outputs to be connected to each type of module shall be
asfollows:
1

Analog input module

Analog output module

Binary input module

16

Binary output module

16

Note: For binary inputs, one changeover contact is counted as 2 inputs.


2.04.00 DATA COMMUNICATION SYSTEM
a) The Data communication System shall include a redundant System Bus with hot back-up and
other applicable bus systems like cubicle bus, local bus, I/O bus etc. Refer to the PLC
configuration drawing no. STPP-5311-I-01-06-8006.
b) The Data communication system shall have the following minimum features:
i)
Redundant communication controllers shall be provided to handle the
communication between I/O Modules and PLCs and between PLCs and operator
work station.
ii)
The design shall be such as to minimize interruption of signals. It shall ensure that a
single failure anywhere in the media shall cause no more than a single message to
be disrupted and that message shall automatically be retransmitted. Any failure or
physical removal of any station/module connected to the system bus shall not result
in loss of any communication function to and from any other station/module.
iii)
Built-in diagnostics shall be provided for easy fault detection. Communication error
detection and correction facility (ECC) shall be provided at all levels of
communication. Failure of one bus and changeover to the standby system bus
shall be automatic and completely bump less and the same shall be suitably
alarmed / logged.
iv)
Data transmitting speed shall be sufficient to meet the responses of the system in
terms of displays, control etc. plus 25% spare capacity shall be available for future
expansion.
2.05.00 SYSTEM REACTION TIME
a) The reaction time of the programmable control system from input signals at the input cards to
output of the associated signals or commands of the output card inclusive of programmed logic
processing, comprising a mixture of logic gates, arithmetic operations and other internal
operations shall be less than 100 milli seconds under the most arduous control system
operating conditions, unless faster response is required by the process, which shall be
adequately provided.
2.06.00 OPERATOR INTERFACE DISPLAYS/LOGS
a) The GUI based operators station shall be responsible for handling all commands as well as in
generating desired displays, logs, reports, alarms and printouts. Security
in different levels
shall be provided to prevent unauthorized access to the system.
The details shall be finalized during detailed Eng. stage. However, following minimum displays /
Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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logs shall be provided.
2.07.00 Plant Schematics:
Facility for overlaying displays with other displays on mimics, performing control actions in
mimic diagram (graphics) shall be provided. Adequate number of mimic diagrams shall be
provided in each OWS.
The displays at the operator console shall be classified into overview Display, group
point display, alarm display and trend display.

display,

2.08.00Shift/Daily Log
The printing of the logs shall be initiated automatically at prescribed time intervals, or initiated on
demand by the occurrence of predefined events. A Shift/daily log shall be provided to furnish
data for routine analysis of plant performance. This log shall be automatically printed at
specified time each day and on demand at any time.
2.09.00 Power Supply
The PLC system shall be powered from the Stand alone UPS (240V AC, 1 phase, 50 Hz)
source. Necessary 3Ph Feeder of desired rating shall be made available to bidder near to the
UPS.
2.10.00 Sequence of events recording
Sequence of events recording function (in built with PLC based system) for all inputs connected
to it with resolution of 1milli second with facility of historical storage
2.11.00 Annunciation System
Only OWS based alarm system shall be provided with audio alarm facility (beep/tone
generator). The annunciation sequence shall conform to ISA sequence ISA-2A.)
2.12.00 SOFTWARE DOCUMENTATION AND SOFTWARE LISTINGS
All technical manuals, reference manuals, users guide etc., in English required for
modification/editing/addition/deletion of features in the software of the PLC System shall be
furnished. The Vendor shall furnish a comprehensive list of all system/application software
documentation after system finalization for Owners review and approval.
2.13.00 SOFTWARE LICENCES
The Vendor shall provide software license for all software being used in PLC. The software
licenses shall be provided for the project (e.g. organization or site license) and shall not be
hardware/machine-specific.
2.14.00 Software Upgrades
As a customer support, the Vendor shall periodically inform the designated officer of the Owner
about the software upgrades/new releases that would be taking place after the system is
commissioned so that if required, same can be procured & implemented at site.

Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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2.15.00 SPECIFICATIONS OF GUI (Graphic User Interface)
a)
Workstations
S.No.
Features
OWS / Other workstations
1.
Type / Size
12 Color TFT
2.
Resolution
800 X 600 Pixels or better
3.
RAM
32 MB expandable
4.

Comm Port

RS 232 / 485

5.
6
7.
8.
9.
10.
11.

12.

b)
S.No
1
2

Printers
Features

Color Laser Printer


A3
6 PPM(Color)
24 PPM (B&W)

Paper Size
Printing Speed (min.)- in
normal mode for A4 size
paper
Type

Resolution (black) (min.)

600 dpi

Heavy duty, at least


50000 pages/month

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SEW INFRASTRUCURE LIMITED
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Color Laser
Printer
A4
4 PPM (color)
16 PPM (B&W)
Heavy duty, at
least
30000
pages/month
600 dpi

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03. PRIMARY AND SECONDARY INSTRUMENTS
3.01.00 LOCAL / FIELD INSTRUMENTS
The instrumentation/control equipment and accessories shall be from the latest proven design
for which the performance
and
high
availability have been demonstrated
by
a
considerable record of successful operation in similar industry service applications. The Vendor
shall furnish sufficient evidence to fully satisfy the Owner in this regard.
3.02.00 SPECIFICATIONS OF ELECTRONIC TRANSMITTERS FOR PRESSURE, D.P, FLOW AND
LEVEL

S.
No
1.

a)
Features

ELECTRONIC TRANSMITTERS
Essential/Minimum Requirements

Type of Transmitter

2.
3.

Accuracy
Output signal range

4.

Turn down ratio

5.

Stability

6.

Zero and span drift

7.
8.

9.

Load impedance
Response Time (time taken from change
in physical parameter input change to
transmitter output reaching 63.2% of its
total change including dead time).
Housing

10.
11.
12.
13.

Over Pressure
Connection (Electrical)
Process connection
Span and Zero

14.

Accessories

Microprocessor based 2 wire type, Hart


protocol compatible.
0.075% of calibrated span ( minimum)
4-20 mA DC (Analog)
along with
superimposed digital signal (based on HART
protocol)
10:1
for
vacuum/very
low
pressure
applications.
30:1 for other applications.
0.1% of calibrated span for six months for
Ranges up to and including70 Kg/cm.
0.25% of calibrated span for six months for
Ranges more than 70 Kg/cm (g).
+/- 0.015% per deg.C at max span.
+/-0.11% per deg.C at min. Span.
500 ohm (min.)
100 ms or better

Weather proof as per IP-55 with durable


corrosion resistant coating.
150% of max. Operating pressure
Plug and socket type
1/2 inch NPT (F)
Continuous, tamper proof, Remote as well as
adjustability manual from instrument with zero
suppression and elevation facility.
-Diaphragm seal, pulsation dampeners, syphon
etc. as required by service and operating
condition.
-2 valve manifold for absolute pressure
transmitters (3-valve manifold for gauge/
vacuum pressure transmitters) and 5 valve
manifold for DP/level/flow transmitters.

Project
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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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S.
No

15.
16.
17.

Features

Essential/Minimum Requirements

Diagnostics
Power supply
Adjustment/calibration/maintenance

-For hazardous area, explosions proof


enclosure as described in NEC article 500.
Self Indicating feature
24V DC 10%.
Total two (2) no. of hand- held type universal
calibrators per unit, compatible with HART
protocol, shall be provided.

Notes
In case it becomes necessary to use a DP transmitter for pressure measurement then a 3-valve
manifold should be used in place of 2-valve manifold.
LVDT type is not acceptable.
Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm seals shall be
provided. Parts below the diaphragm shall be removable for cleaning. The entire volume above the
diaphragm shall be completely filled with an inert liquid suitable for the application.

3.03.00 SPECIFICATION FOR FLOW ELEMENTS


a)
Features

ORIFICE PLATE
Essential/Minimum Requirements
Concentric as per ASME PTC-19.5 (Part-II), ISA RP-3.2, 1960 or BS-1042

Type
Material
Thickness
Material of branch
pipe
Root valve type
Root valve material
Root valve size
Impulse pipe of same
material up to root
valve
Tappings

316 SS
3 mm for main pipe diameter up to 300 mm and6 mm for main pipe dia
above300 mm.
Same as main pipe
Globe
316 SS
1 inch
Required

Flanged weld neck. 3 pairs. of tapping.

Beta Ratio
0.34 to 0.7
Beta Ratio calculation
Yes
to be submitted
Assembly drg. and
Yes
flow Vs DP Curves
Accessories
Root valves, flanges, Vent/drain hole(As required)
Vendor shall submit certified flow calculation and differential pressure vs. flow curves for each
element for Owner's approval. Sizing calculation, precise flow calculation for all the flow elements,
fabrication and assembly drawings and installation drawings shall be submitted for Owner's approval.
One Flow element of each type shall be calibrated in the test laboratory for validation of commutated
flow calculations.

Project
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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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3.04.00 SPECIFICATIONS FOR PRESSURE GAUGE, D.P. GAUGE, TEMP. GAUGE AND LEVEL
GAUGE
S.
N
o

Features

Sensing
Element
material

Essential/minimum requirements

Pr. Gauge/
DP Gauge/ Draught
gauges
Bourdon
for
high
pressure,
Diaphragm/Bellow
for
low pr. Of 316 SS

Temperature
Gauge

Level Gauge

Tempered
toughened
Borosilicate gauge glass
steel armoured reflex or
transparent type.

Body material

Die-cast aluminium

Dial size

150mm

Mercury
in
steel
for
below 450C
and inert gas
actuated for
above 450C
of SS bulb
and capillary.
Die-cast
aluminium
150 mm

End connection

1/2 inch NPT (M)

3/4" NPT (M)

Accuracy

1% of span

1% of span

Scale

Linear,
270
arc
graduated in metric units

Range
selection

8
9

Over range test


Housing

1
0
1
1
1
2

Zero/span
adjustment
Identification

1
3

Material
Bourdon/
movement

and

Forged carbon steel/304


SS
Tubular covering entire
range
Process connection as
per ASME PTC and
drain/vent 15 NB
2%

Linear, 270
Linear vertical
arc graduated
in C
Cover 125% of max. of
Cover 125%
Cover 125% of max. of
scale
of max. of
scale
scale
Test pr. for the assembly shall be1.5 to the max. Design pr. at 38C.
Weather and dust proof
Weather and
CS/304 SS leak proof
as per IP-55
dust proof as
per IP-55
Provided
Provided
-Engraved with service legend or laminated phenolic name plate

Accessories

of

Blow out disc, siphon,


snubber,
pulsation
dampener,
chemical
seal (if required by
process) gauge isolation
valve
316 SS / 304 SS

SS
Thermowell

Gasket for all KEL-F


shield for transparent
type vent and drain
valves of Steel/SS as per
CS/Alloy
process
Requirement.

316 SS / 304
SS

*Bicolour type level gauges will be provided for applications involving steam and water except for
condensate and feed water services.
Project
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Length of gauge glass shall not be more than 1400 mm. If the vessel is higher, multiple gauge glasses
with 50 mm overlapping shall be provided.
Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm seals shall be
provided. Parts below the diaphragm shall be removable for cleaning. The entire volume above the
diaphragm shall be completely filled with an inert liquid suitable for the application.
3.05.00 PROCESS ACTUATED SWITCHES
FEATURES

Sensing Element

ESSENTIAL / MINIMUM REQUIREMENTS


Pressure/ Draft Switches/
Temperature
Level switches
DP Switches
switches
Piston actuated for high
Vapor pressure
Capacitance types for oil
pressure and diaphragm
sensing, liquid
and dirty medium, water,
or bellows for low pr./
condensate application.
filled
bellow
vacuum
type with SS
bulb
and
Float type switches for
capillary (10 m
applications as decided by
minimum)
Owner during detailed
engineering.

Material

316 SS

End connection

inch NPT (F)

Bulb 316 SS/


capillary
304
SS
inch NPT (F)

Over range proof


pressure
Repeatability

150% of max. design pr.

No. of contacts

2 No.+2NC. SPDT snap action dry contact

Rating of contacts

60 V DC, 6 VA (or more if required by DDCMIS)

Elect. Connection

Plug in socket.

Set point/ dead


band adjustment
Enclosure

Provided over full range.

Accessories

Siphon,
snubber,
chemical seal, pulsation
dampeners as required
by process
Suitable for enclosure/
rack mounting or direct
mounting

Mounting

Capacitance/ Conductivity/
Ultrasonic type for acid
and alkali application.
.
316 SS

Manufacturer standard
150% of
pressure

max.

design

+ 0.5% of full range

Weather and dust proof as per IP-55


Thermo well of
316
SS
and
packing glands

All mounting accessories

Suitable for rack


mounting or direct
mounting

Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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Power Supply
24 V DC or as required by the instrument supplier, to be arranged by Vendor
(
wherever
required )
Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm seals shall be
provided. Parts below the diaphragm shall be removable for cleaning. The entire volume above the
diaphragm shall be completely filled with an inert liquid suitable for the application.
3.06.00 Instrument Air System
The instrument Air Supply System for various pneumatic Control & Instrumentation devices like
pneumatic actuators, power cylinders, I/P converters, pneumatically operated valves etc. shall
be complete in all respect with necessary Air Filter Regulators, valves, piping/tubing etc.. Each
pneumatic instrument shall have an individual air shut off valve. The pressure-regulating valve
shall be equipped with an internal filter, a 50 mm pressure gauge and a built in filter-housing
blow down valve.
Filter shall be of minimum 5-micron size & sintered bronze material.
3.07.00 Air Filter Regulator (AFR)
Constant bleed type AFR with an accuracy of +0.1%, inlet pressure range of 5-8 kg/ cm2 and
suitable spring ranges (AFR) for use with petitioners in control valves, control damper, E/P
convertors and shut off valves for phosphor bronze filter element; Filtering particles above
five microns. Weather and water proof enclosure. Material of accessories will be SS.
Air filter regulators shall be provided in the:
1)
2)
3)
4)

Air supply line to valve positioners / power cylinders


Air supply line to electric to pneumatic converters.
Air supply line to pneumatic interlocked block valves.
For each instrument rack, field instruments enclosure for purging.

3.08.00 Electro-Pneumatic Convertors (E/P or I/P)


Two wire type E/P convertors with an accuracy of +0.5% accepting 4-20 mA dc signals from
control system and converting to 0.2 to 1 kg/cm2 air pressure to operate valve positioner of all
final control elements; Housed in cast aluminium casing (with polyurethane paint); NEMA 4 or
equivalent degree of protection for enclosure. Material of accessories will be SS.
3.09.00 Interposing Relays (IPR)
Electromagnetic type IPRs with plug-in type connections, suitable for channel/rail
mounting in cabinets; coil rating 24V D.C; 2 set of change over contacts rated for 0.2A 220 V
DC/5 A 240 V AC. Freewheeling diode
across relay coil and self reset type status LED
indicator flag (electronic) shall be provided.
3.10.00 Solenoid Valves
Solenoid valves shall be provided with control valves / pneumatic control valves hooked up with
process interlock requirements and where direct tripping is involved. The number of ways for
solenoid valve shall be provided as indicated below:
Solenoid Valve coils shall be Class-H high-temperature or Class-F construction as applicable
and shall be designed for continuous duty. Three-way solenoid valves shall be designed for
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universal operation so that the supply air may be connected to any port.
04. CONTROL CABINETS / PANELS / DESKS
4.01.00 CONTROL CABINETS / PANELS / DESKS
a) All PLC and other system cabinets shall be located in air conditioned environment. The Vendor
shall ensure that the packaging density of equipment in these cabinets is not excessive and abnormal temperature rise, above the cabinet temperature during normal operation or airconditioning failure, is prevented by careful design. This shall be demonstrated to the Owner
during the factory testing of the system. The Vendor shall ensure that the temperature rise is
limited to 10 deg.
b) Ventilation blowers shall be furnished as required by the equipment design and shall be sound
proof to the maximum feasible extent. If blowers are required for satisfactory system operation,
dual blowers with blower failure alarm shall be provided in each cabinet with proper enclosure
and details shall be furnished with proposal. Suitable louvers with wire mesh shall be provided
on the cabinet.
c) The cabinets shall be designed for front access to system modules and rear access to wiring
and shall be designed for bottom entry of the cables.
d) The cabinets shall be totally enclosed, free standing type with double door and shall be
constructed with minimum 2 mm thick steel plate frame and 1.6 mm thick CRCA steel sheet or
as per supplier's standard practice for similar applications, preferred height of the cabinet is
2200 mm. The cabinets shall be equipped with full height front and rear doors. The floor
mounting arrangement for shall be furnished by the Vendor and subject to approval during
detailed engineering.
e) Adequate spray coats required for corrosive marine atmosphere of inhibitive epoxy primersurface shall be applied to all exterior and interior surfaces. A minimum of 2 spray coats of final
finish colour shall be applied to all surfaces. The final finished thickness of paint film on steel
shall not be less than 65-75 micron for sheet thickness of 2 mm and 50 microns for sheet
thickness of 1.6 mm. The finish colors for exterior and interior surfaces shall conform to following
shades:
(a.)
Exterior: - As per RAL 7032. However this shall be finalized by owner during
detailed engineering.
(b.)
Interior: - Glossy white or as decided by owner during engineering.
f) In addition, the Vendor shall also review and comply to the painting requirement as specified in
technical specifications
g) Cabinets shall be designed for a grounded installation on the building structure. Any isolation
from the building ground, which is required by equipment design, shall be provided internal to
the cabinet.
h) Ammeters will be provided on control panel for all motors rated 30KW and above. Ammeters
and voltmeters shall be suitable for 4-20 mA DC signals derived from Analog Output cards of
PLC.
I) All control desks, Back up panels & Local panels, shallbe furnished fully wired with necessary
provision for convenience outlets, internal lighting, grounding, ventilation, space heating, antivibration pads, internal piping & accessories as required for completeness of the system.
j) The bottom of desk & cabinets shall be sealed with bottom plate, compression cable glands
(double for field and single for inside rooms) and fire proof sealing material to prevent ingress of
dust and propagation of fire.
k) All wiring shall be arranged to enable the removal of instruments/devices without unduly
disturbing them. Sufficient number of power receptacles with disconnect switches shall be
installed within all panels/desk
l) PC racks shall be properly grounded. The grounding scheme shall be as approved by Owner.

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m) PC based OWS (Operator Work Station) of PLC shall be mounted on table type control desk to
house PC/ keyboards/ mouse etc. In case industrial touch panel based systems is accepted, the
same shall also be mounted on table type control desk. The profile and dimension shall be
decided during detailed engineering and shall be subject to Owner's approval.
05. PROCESS CONNECTION AND PIPING
5.01.00 GENERAL
a) The Vendor shall provide, install and test all required material for completeness of process
connection, Impulse Piping System and Air Piping System as on required basis. The installation
& source connection of various items shall generally as per installation drawings and source
correction drawings to be prepared by the Vendor and approved by the owner during detail
engineering.
b) All materials, furnished and the installation thereof shall conform to the latest editions of
American National Standard Code for Pressure Piping, Power Piping, ANSI B 31.1, ANSI
B16.11, ASME Boiler and Pressure Vessel Codes, IBR and other applicable ASME, ANSI and
state standards.
5.02.00 IMPULSE PIPING, TUBING, FITTINGS, VALVES AND VALVE MANIFOLDS
a) All impulse pipes shall be of seamless type conforming to ANSI B36.10 for schedule numbers,
sizes and dimensions etc. The material of the impulse pipe shall be same as that of main
process pipe.
b) Stainless steel tube shall be provided inside enclosures & racks from tee connection to valve
manifold and then to instrument. The wall thickness of the tube shall be in accordance with the
ANSI B31.1 standard. The bedding radius of tubes shall be greater than 6D.
c) All fittings shall be forged steel and shall conform to ANSI B16.11.
d) The source shut-off (primary process root valve) and blow down valve shall be of 1/2 inch size
globe valve type for all applications except for air and flue gas service wherein no source shutoff valves are to be provided.
e) The valve manifolds shall be of 316- stainless steel with pressure rating suitable for intended
application. 2 valve manifold and 3-valve manifold shall be used for pressure measurements
using pressure transmitters/ pressure switches and diff. pressure transmitter/ switches
respectively. 5-valve manifold shall be used for remaining applications like DP, flow and level
measurements.
f) For PR./D.P gauges in fluid application two-way globe valve on each impulse line to the
instrument and in A/F application two-way gate valve on each impulse line to the instrument
shall be provided near the instrument. These shall be in addition to the three ways gauge cock
provided along with the pr. / D.P gauges.
5.03.00 AIR SUPPLY PIPING
a) All pneumatic piping, fittings, valves, air filter cum regulator and other accessories required for
instrument air for the various pneumatic devices/ instruments shall be provided.
b) This will include as a minimum air supply to pneumatically operated control valves, actuators,
instruments, continuous and intermittent purging requirements of Local Instrument Enclosures
(LIEs) etc.
c) Instrument air supply shall be provided for continuous purging requirements of local instrument
enclosures (LIEs) and any other instrument supplied by the Vendor which requires instrument
air. Also for intermittent purging requirements of local instrument enclosures (LIEs) all pipings,
fittings valves etc. shall be provided for service air supply to LIEs housing air and flue gas
transmitters. Service air supply shall also be provided for any other instrument supplied by the
Vendor requiring service air.
d) For individual supply line and control signal line to control valve, 1/4-inch size light drawn
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tempered copper tubing conforming to ASTM B75 shall be used. The thickness of cu-tubing
shall not be less than 0.065 inch and shall be PVC coated. The fittings to be used with copper
tubes shall be of cast brass, screwed type.
e) All other air supply lines of 1/2 inch to 2 inch shall be of stainless steel with threaded ends. The
threads shall be as per as finalized during detailed engineering.. Fittings material shall be of
stainless steel.
5.04.00 Purge Air Connection for Impulse Lines
a) The continuous purging with instrument air provision shall be provided for Impulse lines
handling dusty medium (excepting instrument air and service air instruments) at the process
source connection end.
b) For intermittent purging with service air, necessary arrangements shall be provided. The SS
three way valve provided in the SS tubing shall be used for isolating the transmitter &
connecting the service air quick disconnect line.
c) Purging arrangement is not required for Instrument air and service air measurement
applications.
d) Purge air lines shall be of mild steel hot dipped galvanized inside and outside as per IS1239,
heavy duty with threaded ends.
5.05.00 INSTALLATION AND ROUTING
All instrument piping, tubing and its accessories shall be supported in a safe manner to prevent
excessive vibrations and anchored sufficiently to prevent undue strain on connected equipment.
Instrument piping & tubing shall not be routed across equipment removal areas, above or below
monorails, cranes, removable gratings, cable trays.
5.06.00 Instrument Piping System
For steam and liquid measurements, the impulse pipe should preferably slope downward from
source connection to instrument and instrument shall be installed below the source point. If due
to any reason instrument is installed above the source point, the impulse pipe should slope
upwards continuously and a 'pigtail' should be provided at the instrument to assure water seal
for temperature protection. For vacuum measurements instrument shall be installed above
source point and impulse pipe should slope upwards.
5.07.00 LOCAL INSTRUMENT ENCLOSURE AND RACKS
a) Transmitters and switches, devices, etc. (except for all fuel oil applications which shall be
mounted close to be tapping points) mounted in the field shall be suitably grouped together and
mounted (i) local instruments enclosure in case of open areas of the plant like boiler area, etc.
and (ii) In local instrument racks in case of covered areas. Gauges are to be mounted on a
channel or a frame or a rack (Gauges shall not be mounted directly on process pipe). These
local instrument enclosures and racks shall be furnished as per the actual requirements
finalized during detailed engineering stage. The exact grouping of instruments in a particular
instrument enclosure/instrument rack shall be as finalized during detailed engineering stage
subject to Owner's approval.
b) Vibration dampeners shall be installed for each enclosure / rack.
c) The enclosures shall be constructed of 3 mm sheet plate and shall be of modular construction
with one or more modules and two end assemblies bolted together to form an enclosure.
Channel and frame shall be 3mm thick. Double inter locking doors shall be provided. The doors
shall be the three-point locking type constructed of not less than 1.6 mm thick steel. Doors shall
have concealed quick removal type pinned hinges and locking handles. Door locks shall accept
the same key.
d) Gaskets shall be used between all mating sections to achieve protection class of IP-55.
Project
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06.

OPERATION AND CONTROL PHILOSOPHY

6.01.00 GENERAL:
a) Control , Monitor & Operation of FPS , DSS of Stock Pile & Potable and Service Water system
will be from Common Control Room located at First Floor of SS1. All the related PLCs /
Controllers will be installed in this control room only beside E1 Package Control Systems.
PLC/Controller system configuration will be redundant in CPU, communication, Power supply
modules and non-redundancy in I/O modules for normal loops and for critical loops redundancy
at output card level can be achieved externally by extra hardware only.
b) Comprehensive annunciation and indication scheme integrated in PLC will be provided such
that, it will be possible for the operator to locate and identify the fault from the Operator work
station monitor (GIU).
c) Overall operation of the all equipment of FPS , DSS & PWS, SWS Systems will be controlled
from the SS1 control room through GIU based OWS of respective PLCs.
6.02.00 Local Operation From Field
In addition to the control room operation / monitoring facility, local emergency stop operation
shall be possible for all types of drives from local pushbuttons (LPB) to be provided along with
the drives. This emergency push button shall be wired directly to MCC / Switchgear. Status of all
emergency stop pushbuttons for unidirectional drives (pump/fan etc) shall be monitored in the
respective control system.

6.03.00 The signal exchange between the switchgear and the control system.
The following tentative list is for initial information. Signal exchange shall be finalized during
detailed engineering.
S. No.
DESCRIPTION
(1)PLC INTERFACE FOR UNIDIRECTIONAL LT DRIVE
(a)
Start Command
(b)
Stop Command
(c )
ON Feedback
(d)
OFF Feedback
(e)
SWGR / MCC Disturbance (Overload relay
operated/ control supply fail/Emergency LPBS
stop)
(f)
Switchgear/MCC Available (switchgear/MCC in
remote)
(2)PLC INTERFACE FOR BIDIRECTIONAL LT DRIVE
(a)
Open Command
(b)
Close Command
(c )
Swgr/MCC
Disturbance
(Overload
relay
operated/ control supply fail/Emergency LPBS
stop)
/Valve Actuator Disturbance
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SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

DI

DO

X
X

X
X
X

X
X

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S. No.
(d)

DESCRIPTION
DI
DO
Switchgear/MCC Available (switchgear/MCC in
X

remote)
/Valve Actuator Available
(e)
Open limit switch feedback
X

(f)
Close limit switch feedback
X

(g)
Open Torque switch feedback
X

(h)
Close Torque switch feedback
X

(i)
Position Transmitter (For inching type Drive)
AI
X
(3)PLC INTERFACE FOR UNIDIRECTIONAL HT DRIVE/LT BREAKER CONTROL
DRIVE
(a)
Start Command
X

(b)
Stop Command
X

(c )
ON Feedback
X

(d)
OFF Feedback
X

(e)
Swgr Disturbance (Overload relay operated/
X

control supply fail/Emergency LPBS stop)


(f)
Electrical Trip
X

(g)
Switchgear Available (breaker in service position,
X

switchgear in remote & breaker spring charged)


(h)
HT drive (Motor) ammeter
AI
(4)PLC INTERFACE FOR SOLENOID DRIVE (Single coil)
(a)
Energize or De Energize
X

(b)
Open limit switch feedback
X

(c)
Close limit switch feedback
X

(5)PLC INTERFACE FOR SOLENOID DRIVE (Double coil)


(a)
Energize
X

(b)
De Energize
X

(c)
Open limit switch feedback
X

(d)
Close limit switch feedback
X

(6)PLC INTERFACE FOR PNEUMATIC DRIVE


(a)
Command to I/P converter
X
AO
(b)
Position Transmitter
AI
X
(c)
Open limit switch feedback
X

(d)
Close limit switch feedback
X

(e)
Command to Solenoid valve (Wherever
X

applicable)
(7)PLC INTERFACE FOR 11KV / 3.3KV /415V SWITCHGEARINCOMING BREAKERS
(a)
Open Command
X

(b)
Close Command
X

(c )
Open Status
X

(d)
Close Status
X

(e)
Remote Position
X

(f)
Service Position
X

(g)
Switchgear Disturbance
X

(Control Supply fail/ Spring charged fail/trip coil


unhealthy)
(h)
Electrical Trip
X

(i)
Analogue values through Multi Function meter
through Daisy to PLC
(8)PLC INTERFACE FOR 11KV / 3.3KV/415V SWITCHGEAR TIE BREAKERS
Project
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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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S. No.
(a)
(b)
(c )
(d)
(e)
(f)
(g)

DESCRIPTION
DI
Open Command
X
Close Command
X
Open Status

Close Status

Remote Position

Service Position

Switchgear Disturbance

(Control Supply fail/ Spring charged fail/trip coil


unhealthy)
(h)
Electrical Trip

(i)
Analogue values through Multi Function meter
through Daisy to PLC
(9)PLC INTERFCAE FOR 11KV / 3.3KVSWITCHGEAROUT GOING POWER FEEDERS
(a)
Open Command
X
(b)
Close Command
X
(c )
Open Status

(d)
Close Status

(e)
Remote Position

(f)
Service Position

(g)
Switchgear Disturbance

(Control Supply fail/ Spring charged fail/trip coil


unhealthy)
(h)
Electrical Trip

(i)
Analogue values through Multi Function meter
through Daisy to PLC

DO

X
X
X
X
X

X
X
X
X
X

X
-

07. CABLES
7.01.00 CABLES (RTD and Fiber optic cables)
7.02.00 General
a) The Vendor of FDAP C&I system shall supply, erect terminate and test all Inst Cables, Fiber
Optic cables and any other special cables required for instrument and equipment under
Vendors scope and ensuring completeness of the control system. The Vendor shall also supply
all Inst Cables cables, Fiber Optic cables required for FDAP package.
b) Vendor shall supply all cables, cable erection and laying hardware like cable trays,
supports, flexible conduits, cable glands lugs pull boxes etc. on as required basis for
completeness of C&I systems under the specification..
c) All internal wires shall be provided with tag & identification Nos. etched on tightly fitted
ferules at both ends in Owners approved format. All wires directly connected to trip
devices shall be distinguished by one additional red color ferrule.
d) All external connection shall be made with one wire per termination point. Wires shall not be
tapped or spliced between terminal points.
e) All floor slots of desk/panels/cabinets used for cable entrance shall be provided with removable
gasket gland plates and fire proof sealing material to prevent dust entry and propagation of fire.
Split type grommets shall be used for prefabricated cables.
7.03.00 Fiber Optic Cable
Optic Fiber cable shall be 4/8/12 core with 100% spare core, galvanized corrugated steel taped
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armored, fully water blocked with dielectric central member for outdoor/indoor application so as
to prevent any physical damage. The cable shall have single-mode type. The outer sheath shall
have Flame Retardant, UV resistant properties and are to be identified with the manufacturers
name, year of manufacturer, progressive automatic sequential on-line marking of length in
meters at every meter on outer sheath. The Attenuation at 1310 / 1550 nm shall be 0.4 / 0.25
dB/km. The bandwidth shall be equivalent to 100 Tera Hz. The core diameter and cladding shall
be 8-9 m and 125 m respectively with 1% tolerance.
The cable core shall have suitable characteristics and strengthening for prevention of damage
during pulling viz. Steel central member, Loose buffer tube design, 4 fibers per buffer tube
(minimum), Interstices and buffer tubes duly filled with Thixotropic jelly etc. The cable shall be
suitable for a maximum tensile force of 2000 N during installation, and once installed, a tensile
force of 1000 N minimum. The compressive strength of cable shall be 3000 N minimum& crush
resistance 4000 N minimum. The operating temperature shall be 20 to 700C.
All testing of the fiber optic cable being supplied shall be as per the relevant IEC, EIA and other
international standards. Penetration of water resistance and impact resistance shall be as per
IEC standard.
7.04.00 INSTRUMENTATION CABLE TECHNICAL REQUIREMENTS
a) Conductor of control and instrumentation cables shall be made of multi stranded plain annealed
copper of 99.25% conductivity.
b) PVC. insulation for the conductor area A 300mm2 shall be suitable for continuous conductor
temperature of 70 Deg C and short circuit conductor temperature of 160 Deg C
c) Outer sheath of all the cables shall have the following FRLS properties.
Oxygen index of min. 29 at room temperature and the temperature index value shall be
minimum 250C at oxygen index of 21 (As per ASTMD 2863/1EC/lEEE/lS)
Acid gas emission of max. 20% (as per IEC-754-IIIS).
Smoke density rating shall not be more than 60% during Smoke Density Test as per
ASTMD-2843I1ECIIEEE/IS.
The cables shall pass the hydrolytic stability and ultraviolet test as per DIN 53387. The
measured values of ultimate tensile strength and elongation after the test shall not be less
than 60% of that measured before the test.
d) In addition to manufacturer's identification on cables as per ISI/EC, following marking shall also
be provided over outer sheath:
i)
Cable size and voltage grade - To be embossed
ii)
Word 'FRLS' at every 5 meter - To be embossed
iii)
Sequential marking of length -To be embossed / printed of the cable in meters at
every one meter.
The embossing / printing shall be progressive, automatic, in line and marking shall be legible
and indelible.
e) All cables shall meet the fire resistance requirement as per IEEE -383 with cable installations
made in accordance with 'Flammability Test' and as per Category-B of IEC 332 Part -3.
f) Allowable tolerances on the overall diameter of the cables shall be +2mm maximum over the
declared value in the technical data sheets.
g) In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not
acceptable.
h) The cross-sectional area of the metallic screen strip/tape shall be considered in design
calculations.
i) The Voltage drop for cables shall be limited to 5%.
j) For low voltage digital signals to instrumentation and control system and for the analog signals,
instrumentation cables with following specification shall be provided

Project
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k) All instrumentation cable shall be 1100V grade, Single pair, multi pair, quadruplets, Traid as
required, stranded plain , annealed, high conductivity copper conductor (class 2 as per IS 8130),
extruded PVC compound type-A insulated, cores identified by colour and coding, individual
pair/quadruplets twisted, cores wrapped by non-hygroscopic material by taping or extrusion,
non-metallic rip cord under wrapping , individual pair/quadruplet/Traid screened with aluminum
mylar tape of 0.04 mm thick or copper tape of 0.04 mm thick or copper laminated plastic tape
with 30% overlap, provided with 1.0 mm2 tinned copper drain wire for each cabling element,
cabling elements suitably grouped, colour coded, cables overall screened with tinned copper
wire braids of 0.15 mm dia with minimum coverage of 85% or aluminum mylar tape of 0.04 mm
thick with overlap of 30%, inner sheathed with extruded PVC compound type ST1, armoured
with steel strips/wires and outer sheathed with extruded FRLS PVC compound type ST1
complying with IEC 60189 - Part 1&2. The cross section of cable conductor shall be 1.0 sq.mm.

08. TESTING AND GUARANTEE REQUIREMENT


8.01.00 TESTING AND GUARANTEE REQUIREMENT
8.02.00 General Requirements
The instruments / equipments being supplied by the Vendor shall either be physically tested by
owners representative or owner shall verify the Vendors test report. In both the cases owners
approval / acceptance is necessary before dispatch the material to site. The Vendor shall furnish
the type test reports of all type tests as per relevant standards and codes as well as other
specific tests indicated in the table below.
a) Submission of type test results and certificate shall be acceptable provided.

I.

The same has been carried out by the Vendor/ sub-vendor on exactly the
same model /rating of equipment.

ii.

There has been no change in the components from the offered


equipment & tested equipment.

iii.

The test has been carried out as per the latest standards along with
amendments..

b) In case the approved equipment is different from the one on which the type test had been
conducted earlier or any of the above grounds, then the tests have to be repeated and such
tests shall be borne by the Vendor/ sub-vendor.
For the type tests to be conducted, Vendor shall submit detailed test procedure for approval by
owner. This shall clearly specify test setup, instruments to be used, procedure, acceptance
norms (wherever applicable), recording of different parameters, interval of recording precautions
to be taken etc. for the tests to be carried out.
8.03.00 SPECIAL REQUIREMENT FOR SOLID STATE EQUIPMENTS/ SYSTEMS
The minimum type test reports, over which are to be submitted for each of the major C&I
systems shall be as indicated below:
i)

Surge Withstand Capability ( SWC) for Solid State Equipments/ Systems

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All solid state systems/ equipments shall be able to withstand the electrical noise and surges
as encountered in actual service conditions and inherent in a the plant. All the solid state
systems/ equipments shall be provided with all required protections that needs the surge
withstand capability as defined in ANSI 37.90.1/ IEEE-472. Hence, all front end cards which
receive external signals like Analog input & output modules, Binary input & output modules etc.
including power supply, data highway, data links shall be provided with protections that meets
the surge withstand capability as defined in ANSI 37.90.1/ IEEE-472. Complete details of the
features incorporated in electronics systems to meet this requirement, the relevant tests
carried out, the test certificates etc. shall be submitted along with the proposal. As an
alternative to above, suitable class of EN 61000-4-12 which is equivalent to ANSI 37.90.1/
IEEE-472 may also be adopted for SWC test.
ii)

Dry Heat tests as per IEC-68-2-2 or equivalent.

iii)

Damp Heat tests as per IEC-68-2-3 or equivalent.

iv)

Vibration tests as per IEC-68-2-6 or equivalent.

v)

Electrostatic discharge tests as per EN 61000-4-2 or equivalent.

vi)

Radio frequency immunity test as per EN 61000-4-6 or equivalent.

vii)

Electromagnetic Field immunity as per EN 61000-4-3 or equivalent.

Test listed at item no. v, vi, vii, above are applicable for electronic cards only as defined under item (i)
above.
8.04.00

REQUIREMENTS OF FACTORY ACCEPTANCE / AUTHORIZATION-TO-SHIP-TEST (ATST)


FOR PLC
a) Authorization-to-ship-test (ATST) shall include all required tests to fully demonstrate to Owners
satisfaction that each equipment/sub-system/system as well as software modules furnished as
per this specification for PLC, fully meets the functional, parametric and other requirements of
this specification and Owners approved drawings/documents under all operating regimes. The
parametric requirements shall be as per specifications requirement.
b) Vendor to note that ATST procedure given below in subsequent clauses are only indicative in
order to help the Vendor in understanding the requirements and help him in submitting a
detailed procedure based on these guidelines meeting all the specification requirements.
c) The Authorization-To-Ship-Test (ATST) shall include all reasonable exercises which the
combination of equipment and software can be expected to perform. These tests shall be
divided into, as a minimum, but not limited to the following categories:
Pre power on checks
Power on check
Hardware tests
Functional Tests
Parametric tests
Specific tests on electronic hardware
Power failure auto-restart tests

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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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8.05.00 Pre power on checks
These tests shall include but not be limited to the following:
a) Visual Checks:
These tests will include checking of individual cubicles, peripherals, etc. for damages; proper
inspection of cubicles, internal cabling, tuning, door arrangements, louvers, fans etc.
b) Hardware verification:
These tests will include verification of location of each card and module in Control System, HMI,
Time synchronization with master clock systems, etc. Verification of no. of modules as per the
approved BOM and corresponding layout drgs.On sub system basis.Verification of spare
capacity in the cubicle for installation of new modules.
Verification of system technical documentation as per approved list.
8.06.00 Power on check
To observe the start up and automatic loading initialization of software when system is
energized
8.07.00 Hardware tests
These tests shall include but not be limited to the following tests:
a) Verification of healthiness of all modules e.g., I/O modules, controller modules, processors,
peripherals, etc.
b) System configuration:
i.
Verification of system configuration with reference to approved configuration
diagrams including verification of controller configuration, group/ sub-group
segregation; grouping of controllers both for CLCS & OLCS, communication
controller, I/O redundancy, verification of multiple measurement scheme,
MMIPIS configuration, etc.
ii.
Verification of features of complete PLC based control system like on line
removal of I/O and controller modules, etc. in line with specification
requirements.
c) Simulation of inputs:
To verify conversion calculations, scan rates, operators functions, corrections of calculations.
For simulation of inputs for I/O modules, this test will be carried out for min. 1 no. of each type.
d) Accuracy & Repeatability test:
Accuracy and repeatability for analog inputs shall be demonstrated by statistical analysis using
the point values read every scan cycle for a total of 10 percent of each type of analog input.
e) Demonstration of the manual and auto switchover from master to standby system bus,
controllers, I/Os, processors etc.
f) Diagnostics Tests:
Complete on-line diagnostic tests on MMIPIS, individual peripherals, Control System,
programmer stations, etc.
8.08.00 Functional Tests
The following tests shall be carried out on Vendors PLC based control System.
a) Functional tests of CLCS:
i. Verification of proper signal acquisition, conditioning and distribution.
ii. Verification of proper realization of controller functions like bump less transfer from
auto to manual and vice versa (as stated above), functional checking of bias circuit
(wherever provided), etc.
iii. Verification of response of control system by simulating changes in the system inputs.
b) Functional tests of OLCS:
i. Verification of proper signal acquisition, conditioning and distribution.

Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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ii. Verification of proper realization of logic functions, sequence control functions, running
of complete start up program sequence in all modes of operation, shut down program,
etc.
iii. Verification of logic computation in controller by simulating inputs.
c) Functional tests for MMIPIS
iv. Verification of all types of displays, logs including their formats, bar graphs, X-Y
plots etc. Verification of all function keys on keyboards and availability of all operator
functions.
v. Verification of event generation and handling capabilities of MMIPIS processors by
simulating various types of events/data and observing associated event sequence
display and alarm signaling boxes.
vi. Checking historical storage and retrieval functions including long term storage.
vii. Checking healthiness of processor, main memory.Testing of initialization and loading
of configuration data, etc.
viii. Verification of all programmers stations functions for MMIPIS and Control System as
specified.
ix. For SER function, verification of resolution of SOE inputs, contact bounce filtering time,
time synchronization with master clock, data base modification, SOE report, printout,
off-line & on line diagnostic features etc. For this purpose a test-simulator to generate
sequences of 1 ms resolution for 100 points (or as decided by owner) distributed in
different panels shall be made available during testing.
x. Testing of each peripheral viz., CRTs, printers, optical disks, hard disk drive, floppy
drive, etc.
xi. Testing of power supply to PLC, tolerance of PLC w.r.t. voltage & frequency limits as
specified, performance of PLC with power supply break as specified.
xii. Verification of switchover of main processor/controller to stand by processor/controller.
xiii. Verification of switchover of peripherals
xiv. Verification of degree of protection of various cabinets as per specification.
xv. Verification of spare capacity w.r.t. Spare wired-in space in cabinets/ cubicles,
terminal blocks, peripherals, etc. in line with spec. Requirements as stipulated under
scope of work.
8.09.00 Parametric tests
Following tests shall be carried out to test Vendors PLC based control system w.r.t.
specification requirements.
a) For control system (CLCS+OLCS):
i. CPU loading
ii. Cycle time/controller reaction time.
iii. Memory spare capacity
b) For MMIPIS
i. CPU loading
ii. Spare duty cycle
iii. Spare memory capacity
c) Spare duty cycle for system bus
d) Various display response time
e) System accuracy
f) Demonstration of system reliability
g) Display update time on OWS CRT
h) SOE Input Resolution
8.10.00 Power failure auto restart test
Verification of availability of all system functions automatically after restoration of power after
Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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power failure to PLC. Verification of restoration of all data which was stored in the system at the
time of power loss.

Y
Y
Y
Y

Y
Y
Y
Y

Y
Y

Material Test certificate

Insulation Resistance (R)

Y
Y
Y
Y

Hydro Test(R)

Test as per standard(R)

Y
Y
Y
Y

IBR Certification (if applicable )(R)

Calibration (R)

1. PR Gauge (IS-3624)
Y
2. Temp. Gauge (BS-5235)
Y
3. Pr./D.P.Switch(BS-6134)
Y
4.Electronic
Y
Transmitter(IEC-770)
5. Temp. Switch
Y
R-Routine Test A- Acceptance Test

Process / Electrical connection


(R)

Dimensions (R)

ITEMS

Make, Model, Type, Rating (R)

8.11.00 The following minimum criteria shall be followed during all tests
a) Integrated Test Set-Up
For integrated testing of the total PLC based system, the Vendor shall employ an I/O simulator,
which will be capable of generating I/O signals in a pre-defined manner. The intent of using this
PC-based I/O simulator is to avoid the cumbersome process of physical connection of I/Os
through potentiometers, switches, Lamps/ LEDs etc. The exact configuration/ set-up shall be as
finalized during detailed engineering. (The testing of the I/O system i.e. accuracy check etc.
shall be done separately on a random basis).
b) The PLC based control system shall be able to perform all specified functions without any
interruption and/or degradation.
c) The results of all ATS Tests shall be properly documented by the Vendor and submitted to
Owner in requisite number of copies with all annexure.
d) Following the tests, if in the opinion of the Owner, the system has not been adequately
manufactured, programmed, tested or debugged the Vendor shall make good all deficiencies
including system parametric specifications of display response time, processor duty cycle, SOE
resolution, etc., and re-run the test to fully satisfy the Owner regarding full compliance with
specification requirements and requisite quality standards.
e) Upon successful completion of Authorization-To-Ship Test, the Owner will provide the Vendor
with a written authorization for shipment of the system equipment to the project site.
All final documentation as per requirement of this specification shall be available at the time of
Authorization-To-Ship-Test and this shall be dispatched along with the equipment in required
number of copies.
Vendor shall note that no payments towards dispatch of equipment and subsequent activities
shall be due and payable to the Vendor till the Vendor is able to successfully demonstrate to
Owners satisfaction that the PLC and parts thereof fully meet the Authorization-To-Ship Test
requirements.
8.12.00 Testing of Instruments
TEST

Y
Y
Y
Y
Y Test applicable

Project
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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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Note: 1) This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted alongwith
relevant supporting documents.

Y
Y
*
*
*
*
Y Test applicable

Material test certificate (R)

Hydro test (R)

IBR Certification as applicable (R)

Insulation Resistance (R)

Calculation for accuracy (R)

Non-destructive testing (R)

WPS approval (R)

Process / Electrical connection (R)

6. Orifice plate(BS1042)

Requirement as per standard (R)

Make, Model, Type, Rating (R)

ITEMS

Calibration (R)

Dimensions (R)

TESTS

Y
*
*

R-Routine Test
A- Acceptance Test
Note: ** - If applicable
1) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed
quality plan indicating the Practices and Procedure adopted along with relevant
supporting documents.

8.13.00 TEST REQUIREMENT FOR C&I SYSTEMS


S.
Item
Test
No
Requirement

Col 2

Col 3

Col 4

Col 5

Owners
Approval
Req. on
test
Certificate
Col 6

BS-6447
/
IEC-60770
Mfr. standard

Yes

No

Yes

Battery##

As per standard
( col 4)
As per standard
( col 4)
As per standard
( col 4)

No

Electronic
transmitter
E/P converter

IS-10918

No

Yes

UPS ( Applicable for each model and rating )


Degree
of
IS-13947
protection test
Load Test
Approved
Procedure

No

Yes

Yes

Yes

Col
1
1

Standard

Test To Be
Specifically
Conducted

Project
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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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Voltage Stabilizer

Audible
Noise
Test
Fuse
Clearing
Capability
Relative
harmonic content
Radio
interference
Synchronous
transfer test
Temp rise test
without
redundant fans

IEC 60146-2

No

Yes

Approved
procedure
Approved
procedure
IEC 60146-2

Yes

Yes

No

Yes

No

Yes

IEC 60146-2

No

Yes

Approved
procedure

Yes

Yes

Input
Voltage
Variation Test
Over Load Test

No

Yes

No

Yes

Insulation Test

Approved
procedure
Approved
procedure
IEC 60146

No

Yes

Restart Test

IEC 60146-2

No

Yes

Short
Circuit
current capability
Output voltage &
frequency
tolerance
Voltage /Current
Division

IEC 60146-2

No

Yes

IEC 60146-2

No

Yes

IEC 60146-2

No

Yes

Efficiency Test
Over Load Test

IEC 60146-2
Approved
procedure
Approved
procedure

Yes
No

Yes
Yes

No

Yes

Approved
procedure
IS-13947

No

Yes

No

No

IS-13947

No

No

IEC
1131
and
approved drg
/ doc

No

Yes

Temp rise test


without
redundant fans

Local Gauges

Process actuated
Switches
PLCs

Input
voltage
variation test
Degree
of
protection test
Degree
of
protection test
As per standard (
Col 4)

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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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9
10

LIE
/
LIR
Junction Box
Cables

Degree
of
protection test
Type test

IS-13947

No

Yes

As
per
standard
&
Specification

yes

Yes

The Vendor shall submit for Owners approval the reports of all the test as per latest IS10918 carried out within last five years from the date of Bid opening and the test(s) should
have been either conducted at an independent laboratory or should have been witnessed
by a client. The complete type test reports shall be for any rating of Battery in a particular
group based on plate dimensions being manufactured by supplier.
8.14.00 C& I Guarantee Requirement(Demonstration)
The Vendor shall demonstrate that the system/ equipment supplied by him is functional as
an integrated system and meets all functional and parametric requirements.
8.15.00

Functional Requirement for each PLC based Control System


-

Each PLC based control system shall be tested with the entire field instrument,
peripherals and communication connected.
All CLCS, OLCS, protection & Interlock shall be tested and demonstrated.

a)The following parametric tests for each PLC based system shall also be conducted under
worst case loading conditions as (details of which shall be as approved by owner during
detailed engineering.
(i)

For control system


- CPU loading, Cycle time/controller reaction time and memory spare
capacity

(ii)

For MMIPIS
- CPU loading, spare duty cycle, spare memory Capacity

(iii)

Spare duty cycle for system bus

(iv)

Various display response time

(v)

System accuracy

(vi)

Display update time

b) For the parametric test, the following requirements shall be met

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DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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TECHNICAL SPECIFICATION FOR C & I OF


FIRE PROTECTION SYSTEM AND DUST
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i

Under worst case loading conditions of control system control


system processor shall have 20% free time when measured over
any one minute period.

(ii)

System Bus Spare Duty Cycle (Free Time). The Vendor shall furnish all
necessary data to fully satisfy the Owner that the processor spare duty
cycle figures quoted by the Vendor are realistic and based on
configuration and computation capability of the offered system and
these shall be actually achieved in the fully implemented system as
commissioned at project site.
The system bus shall have min. 50% free time during the worst case
loading conditions of control system, MMIPIS and the system Bus,
measured over any 2 seconds interval

(iii)

Display Response Time


The system shall acknowledge all operator requests in one of the
following manner within one second of pressing of the last button
Commencement of the requested displayOR Acknowledgment of
operator request in a suitable manner.
The display response time as defined above, under the worst case
loading conditions shall not be worse than the following:
All control related displays

1 sec

Point Details Display(single point)

1-2 sec

Bar chart display (20 points, current data)

2-3 sec

Operator guide/plant start-up guide message


display (full screen of alphanumeric
information and a maximum of ten numbers of
dynamic data items)

1-2 sec

Plant mimic display of fair complexity with all


dynamic data items e.g., values, macros, line
segment, etc.

2-3 sec.

Group review display (current values of twenty


points)

2-3 sec.

X-Y plot display (2 X-Y- plots and a single


display requiring both historical as well as
current data)

3-4 sec.

X-T plot display (Trend of 3 analog points and


a single display requiring both historical as
well as current data)

3-4 sec.

Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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Plant Summary display (e.g., bad point
summary, limit check removed point summary.
Assume the whole data base search is
required and the summary display contains ten
points only).

3-4 sec.

The response time for screen update after the execution of the
control command from the time the command is issued (for example
command to start a motor to the time the screen is updated) shall be
two seconds (excluding the drive actuation time).
(i
v)

System Accuracy Requirements


The overall system accuracy from signal input terminals to output
presentation on display and printers for the least accurate input
range and maximum scan rate shall be not worse than +/- 0.1% of
full scale of the engineering process range +/- LSB. For this
purpose, the number of decimal places on display for testing
purpose shall be sufficient to cover 0.01% of full scale range.

(v
)

Display Updated Rates


All displays shall be updated at least every two seconds.

(v
i)
8.16.00

The redundancy & spare capacities of the system shall be


demonstrated.

Availability Tests
The Vendor shall guarantee 99.7 percent system availability for a continuous period of 90
days. An availability guarantee test shall be conducted to assure this level of availability. If
the accrued down time exceeds 0.3 percent of 90 days, during availability test run, a new
90 days test run shall start at the time when the system becomes available again. Loss of
availability (unavailable system) shall be defined as the loss of the system's guaranteed
accuracy and repeat ability or of any system function, except however, that the loss of a
function for not more than five percent of the points shall not be considered loss of
availability. Loss of a function for not more than five percent of the points shall be treated
as partial unavailability and the corresponding outage time shall be weighted with respect
to the function and the percentage of the points for which the function is unavailable. Loss
of each function shall have one weighing factor and unavailability of each equipment,
peripheral device or process I/O card etc. shall have another weighing factor. The
guaranteed accuracy and repeat ability and system parametric requirements specified in
clauses on system parametric requirements shall be maintained for the entire 90 days run
without any manual recalibration or any other changes made to the system.
Downtime shall start upon loss of a system function and shall end upon full restoration of
the affected system function.
The Vendor shall submit the Availability Test procedure for Owner's approval. The details
regarding outage time, weighing factors for various system functions equipments to
calculate the down time, test duration etc., shall be discussed and finalized during detail
engineering.

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SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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09. POWER SUPPLY SYSTEM (UPS)
9.01.00 ELECTRICAL POWER SUPPLY
a) The requirements of Electrical Power Supply system for FPS & DSS System PLCs are
specified as below. The Vendor shall be responsible for engineering and furnishing a complete
and operational system fully meeting the intent and requirements of this specification and
owner's approved drawings. All equipment and accessories required for completeness of this
system shall be furnished by the Vendor whether these are specifically mentioned herein or not.
All the equipments and sub systems offered shall be from reputed experienced manufacturers.
All system cabinets, enclosures, & distribution boards shall be manufactured, assembled, wired
and fully tested as a complete assembly as per the requirements of this specification at the
manufacturers works.
b) The Vendor shall furnish all required equipment cubicles and wiring required for conversion
and/or stabilization of the power sources provided by the Owner to all other levels which may be
necessary for meeting the individual requirement of equipment/system furnished by him
including the panel/desk mounted equipment. The steady state & in-rush KVA for each major
equipment being supplied by the Vendor shall be indicated separately.
c) All standards, specifications and codes of practice referred to herein shall be the latest editions
including all applicable official amendments. In case of conflict between this specification and
those (IS / IEC codes, standards etc.) referred to herein, the former shall prevail. All work shall
be carried out as per the following standards and codes.
d) The power supply system shall be designed to meet the entire electrical power requirements of
PLC and various C&I systems supplied by FDAP vendor and shall be configured as described
below:
e) The Power Supply system for FPS & DSS System PLCs shall consist of the following
system(s): a. Standalone UPS System (For each of the FPS & DSS PLCs)
Each PLC based control system shall have separate dedicated standalone Package UPS
system supplied by Vendor. This standalone UPS shall cater to the load of control system,
communication system along with its associated peripherals & accessories, and critical
loads of I&C System.The KVA rating of UPS shall be as required by expected loads and
include 10% spare capacity guaranteed at 50 deg. C ambient and load power factor of 0.8
lagging. The Standalone UPS shall be located in control room where PLCs are located.
The UPS system (240 volts, 1, 50 Hz Supply) consisting of the following. Input for each
UPS ( I.e 415V AC, 50 HZ, 3 phase, 4 wire system) shall be fed from owners MCC:
1. 1 set Ni-Cd battery with accessories for 1 hour duty cycle at 100% of selected UPS
rating
2. 1 X 100 % capacity float cum boost charger
3. 1 X 100% capacity static inverter.
4. 1 no static switch
5. 1 no manual bypass switch
6. 1 no 240V,1 voltage stabilizer
7. 1 no 240V AC UPS Distribution board.
Please refer to enclosed Doc No. 2 for Scheme for Standalone UPS System

Project
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

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10. ELECTRICAL ACTUATORS WITH INTEGRAL STARTERS
10.01.0 ELECTRIC ACTUATORS WITH INTEGRAL STARTERS
10.01.01
10.01.02

TYPE
The actuators shall have integral starters along with over load relays with built in SPP
(Single Phasing Preventer). A 415, 3 phase 4 wire power supply shall be given to the
actuator from switch board through a switch fuse unit. Control voltage of the motor starter
shall be 110 V AC / 24 V DC, derived suitably from 415V power supply.

10.01.03

In case vendors standard control voltage for Open/Close contactors is 110V AC, the same
is acceptable if suitable Opto Isolation circuit is provided with coupling relays for 24 V DC
command inputs.

10.02.00

INTERFACES
Open/Close command termination logic with position & torque Limit Switches, positioned
circuit shall be suitably built in the PCB inside the actuator.
For Binary Drive:- Open/Close command & status thereof and disturbance
monitoring signal (common contact for Overload, Thermostat, control
supply failure, L/R selector switch at local & other protections operated)
shall be provided.
Interface with the control system shall be through hardware signal only.
Inter posing relays provided (with coil burden 2.5 VA) in the actuator shall
be energized to initiate opening and closing, by 24V DC signal from the
external control system.
For Modulating Drive:- the command to actuator shall be in form of 420mA signal. The necessary positioning circuit and motor protection shall
be provided
Open/close command termination logic shall be suitably built inside
actuator.

10.03.00 RATING
Supply Voltage & frequency: 415V +/- 10%, 3 Phase, 4 Wire 50HZ +/-5%.
Sizing:For Open/Close at rated speed against designed differential pressure at
90% of rated voltage.
For isolating service:- three successive open-close operations or 15 mins,
whichever is higher. For regulating service 150 starts per hour or required
cycles, whichever is higher.
10.04.00 CONSTRUCTION

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Enclosure:
Totally enclosed weatherproof minimum IP-55 degree of protection.
Gear Train :
Metal (Fiber gears are not acceptable)) self-locking to prevent drift under
torque switch (where ever applicable) spring pressure when motor is deenergized.
Manual Wheel:
Shall disengage automatically during motor operation.
10.05.00 MOTOR
Type :
Squirrel cage induction motor suitable for Direct On Line (DOL) starting.
Enclosure:
Totally enclosed, self ventilated IP-55 degree of protection.
Insulation
Class B or better. Temperature rise 70 Deg C. over 50 Deg C ambient
Bearings:
Double shielded, grease lubricated antifriction.
Earth Terminals:
Two
Protection:
Single Phasing Protection, Over heating protection through Thermostat
and wrong phase sequence protection shall be provided over and above
other protection features standard to vendors design Suitable means
shall be provided to diagnose the type of fault locally.
10.06.00 POSITION/TORQUE SWITCHES
Four nos. (2 each in open and close position) position limit switches and two nos. (one
in open and other in close direction) torque switches each having two nos. NO and two
nos. NC contacts shall be provided. A single shaft shall actuate all contacts of limit
switches at each position.
10.07.00 LOCAL OPERATION
It shall be possible to operate the actuator locally also. Lockable local/remote selection
shall be provided on the actuator.
10.08.00 POSITION INDICATOR

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To be provided for 0 to 100% travel.
10.09.00 POSITION TRANSMITTER (FOR MODULATING/INCHING TYPE)
As required. Suitable for stabilized 4-20 mA signal, 2 wire inductive type, 24 volts DC operated.
10.10.00 WIRING
Suitable voltage grade copper wire.
10.11.00 TERMINAL BOX
9 pin plug and socket (1 no. per actuator to suit 4 pair 0.5 sq.mm. copper
overall shielded (16 mm OD), instrumentation cable) suitably mounted in
the starter box itself to terminate open/close command and status
feedback signals with external control systems.
Additional one number 9 pin plug and socket (to suit 4 pair 0.5 sq.mm
copper (16 mm OD) individual and overall shielded instrumentation cable)
suitably mounted in the starter box itself for actuators with 4-20 mA
position transmitters.
Necessary glands for power cables shall be provided.
10.12.00 TERMINAL BLOCK
650V grade. For power cables.
10.13.00 SPACE HEATER :
Space heater of suitable rating. The supply shall be derived from the main power supply
available in the actuator.

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Annexure-VIII

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM AND DUST SUPPRESSION
SYSTEM
FIELD QUALITY PLAN
SL. NO.

ACTIVITY AND
OPERATION

1.

2.

MANUFACTURER/
SUB-SUPPLIER

3.

MAIN-SUPPLIER

SIGNATURE

Project

CHARACTERISTICS
CLASS OF
AND INSTRUMENTS
CHECK #
4.

APPENDIX- IA

TYPE OF
CHECK

QUANTUM
OF CHECK

REFERENCE
DOCUMENT

ACCEPTANCE
NORMS

5.

6.

7.

8.

LEGEND: * RECORDS, INDENTIFIED WITH TICK () SHALL BE


ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR, C=MINOR;
A SHALL BE WITNESSED BY SEW FQA, B SHALL BE WITNESSED BY ABIR
ERECTION / CONSTRUCTION DEPTT. AND C SHALL BE WITNESSED BY
MAIN SUPPLIER (A & B CHECK SHALL BE SEW CHP STAGE)

FORMAT OF
RECORD
9.

REMARKS

D*

10.

DOC. NO.:

FOR
ABIR
USE

REVIEWED BY

REV 2

APPROVED BY

APPROVAL SEAL

Rev-0

SEW INFRASTRUCURE LIMITED


DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Date: 10/01/2013

Section-2

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM AND DUST SUPPRESSION
SYSTEM
LIST OF ITEMS REQUIRING QUALITY PLAN AND SUB-SUPPLIER APPROVAL
Sl.
No.

Item

QP/ Insp.
Cat.

QP No.

QP Sub.
Schedule

QP
approval
schedule

Proposed subsupplier

APPENDIX- IB

Place

Subsuppliers
approval
status /
category

Subsupplier
Details
submission
schedule

LEGENDS

1. SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY SEW)


A For these items proposed vendor is acceptable to SEW. To be indicated with letter A in the list along with the condition of approval, if any.
DR For these items Detailed required for SEW review. To be identified with letter DR in the list.
NOTED For these items vendors are approved by Main Supplier and accepted by SEW without specific vendor approval from SEW. To be identified with NOTED.
2. QP/INSPN CATEGORY:
CAT-I : For these items the Quality Plans are approved by SEW and the final acceptance will be on physical inspection witness by SEW.
CAT-II : For these items the Quality Plans approved by SEW. However no physical inspection shall be done by SEW. The final acceptance by SEW shall be on the basis review of
documents as per approved QP.
CAT-III : For these items Main Supplier approves the Quality Plans. The final acceptance by SEW shall be on the basis certificate of conformance by the main supplier.
UNITS/WORKS : Place of manufacturing Place of Main Supplier of multi units/works.
Project
Doc. No:
Rev-0
SEW INFRASTRUCURE LIMITED
DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Date: 10/01/2014

Section-2

Remarks

TECHNICAL SPECIFICATION FOR


FIRE PROTECTION SYSTEM AND DUST SUPPRESSION
SYSTEM
APPENDIX- IC
MANUFACTURERS NAME AND
ADDRESS
MFGR.s
LOGO

SL.
NO.

MANUFACTURING QUALITY PLAN


ITEM :

QP NO.:
REV.NO.:
DATE:
PAGE: . OF.

SUB-SYSTEM:

COMPONENT &
OPERATIONS

1.

CHARACTERISTICS

2.

3.

4.

TYPE OF
CHECK
5.

MAIN-SUPPLIER

SIGNATURE

PACKAGE

CONTRACT NO. :
MAIN-SUPPLIER:

QUANTUM
OF CHECK
M
C/L

REFERENCE
DOCUMENT /
ACCEPTANCE NORMS

6.

7.

ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.


** M: MANUFACTURER/SUB-SUPPLIER C: MAIN SUPPLIER, L: SEW
P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE,
CHP: SEW SHALL IDENTIFY IN COLUM L AS W

FORMAT
OF
RECORD
8.

LEGEND: * RECORDS, INDENTIFIED WITH TICK ( ) SHALL BE

Section-2:

MANUFACTURER/
SUB-SUPPLIER

CLAS
S

PROJECT

AGENCY
M

D*

C
**

REMARKS
L

9.

DOC. NO.:

FOR
SEW
USE

REVIEWED BY

10.

REV CAT..

APPROVED BY

APPROVAL
SEAL

SWP-1

SWP-2