C3a-Broad Scope Boiler 150506

JSW ENERGY (VIJAYANAGAR) LIMITED
Spec. No.
TCE.4857A-C510-01
BTG PACKAGE FOR 2 x 300 MW COAL BASED

THERMAL POWER STATION AT TORANAGALLU,
BELLARY (KARNATAKA)
TITLE
BROAD SCOPE FOR STEAM GENERATOR

1.0
VOLUME II Part
-I
SECTION: C3a
SHEET 1 OF 1527
OF
GENERAL
a. The scope of Bidder shall comprise design, engineering, material selection,
manufacturing, testing at works, supply
CFR Chennai port , erection
supervision & commissioning supervision, , performance testing at site, and
other related items of work for the Steam generator and auxiliaries inclusive of
mechanical, electrical, instrumentation & control systems, furnishing input for
civil and structural works, necessary for putting into commercial operation a
highly reliable, safe, efficient and environmentally compliant Main Plant
equipment for 2 x 300 MW Malaxmi Thermal Power Project at Meramundali
and Kharagprasad villages, Denkanal District , Orissa state. India The systems
and equipment shall conform to the technical requirements specified in
separate sections of the specification.
b.
Contractor shall perform all the works specified or necessary to complete the
works in accordance with this specification. Further, SECs Contractors
performance of the works under the Contract shall be in accordance with good
engineering practices, notwithstanding the fact that every item involved may
not be specifically mentioned or the item mentioned may be inadequate for its
intended purpose. Details and items, which are not specifically mentioned
herein, shall also be adequately and properly performed by SECContractor
at no extra cost if such details and / or items are necessary to complete the
intent of this specification or otherwise to complete the Steam generator and
auxiliaries. The intent of this specification is to relieve the JSWEVLNPPL of
the necessity of engaging or supplying any labour, service, equipment or
material to complete the Steam generator in respect of the works furnished by
JSWEVL NPPL as specifically itemized under Clause 3.0 of this section.
1.1
MECHANICAL WORKS
1.1.1
Steam generator island

a. Complete steam generating unit with milling and draught plant for pulverised
coal firing system, along with ignition and support firing system and low NOx
burners, all control, protection and monitoring devices, refractories and
insulation and cladding as required.
b. Steam generator structure, water circulation system, superheating and
reheating systems
c. Light and Heavy Fuel oil system for warm-up and flame stabilisation
d. Air and flue gas system
e. Pulverised coal preparation and firing system
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TCE FORM 329 R3
Spec. No.
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TITLE

f.
VOLUME II Part
-I
SECTION: C3a
SHEET 2 OF 1527
OF
Steam and water system including initial SG fill system
g. SG blow down system

h. Soot blowing system
i.
Complete power cycle piping (main steam from Boiler outlet up to Turbine , cold
reheat from the HP turbine to Boiler and hot reheat from Boiler up to Turbine )
boiler feed discharge piping from last HP heater outlet to Boiler , auxiliary
system piping including the main header as well as all piping in SG island with
hangers and supports, valves, fasteners etc., as required for the boiler island
and connected systems.
j.
Auxiliary Pressure Reduction Station
k. High Pressure (HP) dosing system for drum water with tanks, pumps, piping,
valves, and fittings.
l.
Closed Cycle DM water cooling system
m. Air Pre heaters

n. Dust precipitation and collection system (Electrostatic Precipitator)
o. Thermal insulation and cladding
p. Sky climber for furnace inspection
q. Equipment to meet the safety requirements
r.
All other accessories and auxiliaries as required.
s. Mill reject hoppers and spouts and Mill reject handling system
t.
Staircases on either side and platforms
u. Design and installation of vibration isolation system as required with dampers

for Mills, PA Fan, ID fan and FD fan, as required.
v. Design and provision of Inertia block in RCC grade M25 over the vibration
isolation system for the above mentioned equipment, as required.
w. All equipment base plates, lifting lugs, foundation bolts, sleeves, nuts, inserts,
embedded plates and grouts (cement and grouting by JSWEVLNPPL ) as
required for efficient installation of all equipment
x. .
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1.1.2
VOLUME II Part
-I
SECTION: C3a
SHEET 3 OF 1527
OF
Other Auxiliary Systems

a. Auxiliary piping system, auxiliary steam piping, auxiliary cooling water, fuel oil,
Mill inerting, atomising steam, scanner air system , etc
b. Pipe supports and associated structural works , including pipe racks, trestles,
trenches, etc. as required including all temporary frames for transport and
erection.
c. All lifting and handling equipment to facilitate the handling of all equipment
which are in the scope of supply during erection/ maintenance/ overhaul during
the plants lifetime. This shall include hoist trolley and monorail for equipment
such as ID, FA and PA fans, air pre-heaters, ESP and mills. The sliding rails
and pulling system required for equipment handling where applicable.
d. Steam and water analysis system: CEMS, SOx, NOx, SPM, CO and CO2All
necessary equipment for, monitoring and control of pollution of air and water
from/within the main plant equipment to the environment for meeting applicable
regulations.
e. Nitrogen bottles (adequate number for refilling), storage, handling and
distribution system for preservation purpose of boilers.
f.
High Energy Arc (HEA) igniters shall be provided to ignite the fuel oil and shall
consist of transformers, control cabinets, cabling, etc.
g. Interconnecting structures and platforms to elevators in Steam Generator

island.
h. Supply and application of paints and thermal and acoustic insulation as
required for the entire main plant equipment.
i.
Site safety requirements.
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1.2
VOLUME II Part
-I
SECTION: C3a
SHEET 4 OF 1527
OF
ELECTRICAL WORKS
1.2.1
All drive motors both (AC and DC)
1.2.2
Electrical system for ESP (ESP switchgear, Rectifier transformers and control
panels), power and control cables and cable trays
1.2.3
Soot Blower MCC and power and control cables for soot blowers
1.2.4
Motor Operated valves with integral starter
1.2.5
Starter Panels for DC motors
1.2.6
Junction Boxes/Marshalling boxes
Note:
1.3
1.3.1
All the 6.6kV Switch gear, 415V MCC and 220V DC distribution boards, Power
cables up to motor terminal and Local Push Button Stations will be under the
JSWEVLs scope. However, MCC for ESP and Sootblower shall be in SECs
scope. For more details, please refer to DIVISION OF WORK (DOW)
BETWEEN MAIN PLANT SUPPLIER (SEC) & JINDAL (JSW) FOR 2X300MW
POWER ROJECT signed on March 24, 2006.
CONTROL & INSTRUMENTATION SYSTEM SG Package .(Boiler)

I&C scope shall include complete instrumentation & control system for boiler and
its auxiliaries. All control , interlock & protection (CLCS, OLCS) etc shall be
incorporated in the DCS supplied by SEC (Unless otherwise specified, all the
requirements indicated below are on per unit basis.)
Control system
Boiler Controls to be implemented in DCS are as follows.
a)
b)
c)
Burner management system including boiler protection

Secondary Air Damper Control system
Soot Blowing System including Soot Blower pressure and
temperature control.
f)
Fuel feeder control system
Any specific control/monitoring panels are provided by SEC for Flame
scanner/soot blower control/coal feeder control etc., such panel shall have
interfacing facility with DCS supplied by SEC.
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SECTION: C3a
SHEET 5 OF 1527
OF
1.3.2
All primary sensors like flow elements, temperature sensors.
1.3.3
All field instruments process switches, transmitters, local gauges etc.
1.3.4
All sensors related to Boiler Protection and critical controls shall be

triple/double and sensors for balance control loops shall be single.
1.3.5
All final control elements like control valves, de-superheaters, control dampers
and actuators, de superheaters, etc.
1.3.6
All SG specific field instrumentation, and integral instrumentation
1.3.7
The steam and water analysing system including sample conditioning and
Analyzers. This includes steam, condensate & feed water analysers
1.3.8
All Gas analysers including Carbon Monoxide analysers, Zirconia type Oxygen
Analysers, particulate analysers at Stack. (The numbers shall refer to I&C
section).
1.3.9
All machinery monitoring instruments like bearing temperature, vibration

monitoring systemm in X-Y directions of all HT motor-driven equipments and
Drives.
1.3.10
All junction boxes, transmitter racks, cubicles, enclosures, local panels,

marshlling panels, pneumatic and process hook up hardwares and other
erection materials and accessories as required for the complete installation of
the instruments
1.3.11
Cable
a) The I&C cables from sensor to JB or field equipment to JB will be in SECs
scope. , If any panels are provided by SEC then cable up to panel will be in
SECs scope(like flame scanner panel). Cabling/cable from JB/Panel to
DCS will be in JSWEVLs scope.
b) Compensating cable, special cable, pre-fabricated cable, Fibre optic cable
are in SECs scope.
1.3.1.12
JSWEVL will provide redundant bulk feeders of adequate rating for UPS and
DC requirements . JSWEVL will provide only 220VDC and 220 VAC UPS
control supply. Any other voltage level required will have to be derived by SEC.
.
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VOLUME II Part
-I
SECTION: C3a
SHEET 6 OF 1527
OF
1.3.1.13
Burner management system including Igniters, digital (microprocessor based)

flame scanners, etc.
1.3.1.14
Smart transmitters (pressure, DP, flow, level, , temperature etc).
1.3.1.15
Painting of impulse tubes, transmitter racks etc.
1.3.1.16
Furnace flue gas temperature probes, Electromatic relief valve controller, metal
Temperature measurements, local and remote Feeder control cabinets etc
1.3.2.18
Drum instrumentation including two numbers conductivity type, bi-colour

Electronic Drum Level indicators with two numbers control room mounted Bicolour indicators , Level guages , bi-colour indicator in firing floor etc.,
1.3.2.19
All special measurements including , speed measurements for HT Drives,

Feeders , Load cell measurement etc., All special thermocouples including
penthouse thermocouples with flexible extension lengths.
1.3.2.20
All dedicated PG test points as per the ASME Code.
1.3.2.21
Services shall include, testing , PG-Test , Guarantees etc., for all the
equipment supplied. Services
shall
also include all the required
documentation in soft and hard copies in JSWEVLs format , including As-Built
Document and preparation of Contract Document
1.3.2.22
Inspection, FAT (factory acceptance test) , SAT (site acceptance test) of critical
equipment as per JSWEVL approved procedures.
1.3.2.23
Spares, Special maintenance and erection tools and tackles required for
installation, operation and maintenance of C&I equipment & system.
1.3.2.24
Instrument air distribution, as required.
1.4
CIVIL STRUCTURAL AND ARCHITECTURAL WORKS

Inputs required for the civil design is included in the scope. However all civil
works other than that mentioned below are excluded from the Scope.
i)
Design and provision of Inertia block in RCC grade M25 over the
vibration isolation system for, Mills, , PA fFan, ID fFan and FD fFan ifas
required
ii)
Provision of Insert plates in inertia block at locations Furnished by

JSWEVL ifas required
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SECTION: C3a
SHEET 7 OF 1527
OF
iii)
iv)
Checking Civil drawings furnished by JSWEVL for interference with

piping/Equipment, Adequacy of openings, Location and size of insert
plates/Pockets furnished by SEC.
1.5
PROJECT MANAGEMENT / SERVICES Refer to Steam turbine generator

section
1.5.1
SEC shall identify a separate and independent project management team

headed by a Project Manager for the execution of this project.
SEC shall provide effective management of the Contract, which shall be
compatible with the JSWEVLs requirements as set out in this specification.
SEC shall allow access to his works and those of his sub-contractors at all
times to permit the JSWEVL / Consultants participation, if JSWEVL /
Consultant considers it necessary in monitoring the Contract. The Project
Manager shall also work with other Contractors who interface with this
Contract in order to ensure the smooth completion of the project. Such
participation up to its completion
shall not, in any way affect the SECs
obligations to complete the supply and supervision works in accordance with
the Contract.
1.5.2
Management Organisation
1.5.2.1
SEC shall describe how his management organisation shall

meet the
requirements detailed herein. He shall include an organisation chart
illustrating how the management structure / lines of authority Will function
during the Contract.
1.5.2.2
The SEC shall submit the names, qualifications and experience of the
proposed managerial and senior supervisory staff to be employed on the
Contract. The SEC shall indicate the number of staff, rating and seniority to
be employed to manage and supervise the Contract and list separately for
head office and site office based locations. In particular how staff are
planned to be deployed with respect to the Contract period timescale shall be
stated.
1.5.2.3
SEC shall inform the JSWEVL any proposed changes in the Senior Staff
category.
1.5.2.4
JSWEVL reserves the right to evaluate and audit the SECs management
systems and controls in the areas set forth in this section.
1.5.2.5
SEC shall constitute a separate commissioning supervision team in

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TITLE
VOLUME II Part
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SECTION: C3a
SHEET 8 OF 1527
OF
commissioning checks, commissioning and tying/cascading /connecting with

other system, etc. SEC shall have a separate planning and progress
monitoring team to enable timely completion of the project.
1.5.3
Engineering Services
1.5.3.1
SEC shall render complete engineering services for the project including
complete detailed engineering, design submission and documentation as
specified and as required for a good design and installation ensuring
efficiency, operability, availability, maintainability and reliability of the plant.
Prior to commencement of the engineering work all aspects of design, viz.,
criteria for selection and sizing of all equipment and systems, design margins,
analysis and design calculations, etc. shall be stated by the SEC in design
basis reports. As part of design submissions, the design basis reports shall
be submitted by the SEC for approval by the JSWEVL / Consultant. The
approved design basis reports
shall form the basis for the detailed
engineering work.
1.5.3.2
At any stage during the performance of the Contract, if the system warrants
improvements in the Contracted plant and consequent modification in the
equipment / system designs the SEC shall make the necessary design
modifications and carry out the / improvements in the plant with the approval
of JSWEVL/Consultant at no extra cost to the JSWEVL.
1.5.3.3
During the course of review of detailed engineering, it may be essential in

JSWEVLs opinion to obtain data and information on similar equipment and
plants engineered by the SEC. In case, JSWEVL so desires the SEC shall
submit such analogous data and information to the JSWEVL.
1.5.3.4
SEC shall cooperate with the JSWEVLs other Contractors and the
Consultant and freely exchange with them such technical information as are
necessary to obtain the most efficient and economical design and to avoid
unnecessary duplication of efforts. JSWEVL shall be provided with copies of
all correspondences addressed by SEC to other Contractors and the
Consultant in respect of such exchange of technical information.
1.5.3.5
SEC shall furnish a comprehensive and detailed schedule of drawings and

design documents, which shall be submitted by him after award of Contract
indicating submission dates against each document. The list shall be subject
to the approval of the JSWEVL / Consultant.
The documents shall be divided into two categories:
(a)
(b)
For approval
For information / reference only
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SECTION: C3a
SHEET 9 OF 1527
OF
1.5.3.6
Documents submitted during bid stage, shall be revalidated or revised as

required and submitted as certified document for approval / information of the
JSWEVL/Consultant, after award of Contract. Such documents shall include
but not limited to the following:
(a)
System schematic drawings, pipeline and instrumentation diagrams
(b)
Design basis reports
(c)
Specification for major bought-out items
(d)
Equipment data sheets and general arrangement drawings
(e)
Materials for construction
(f)
Layout drawings
(g)
Operation logic diagrams
(h)
Typical control circuits
(i)
Protection schemes
(j)
Quality assurance plan (for works & erection etc)
(k)
Project engineering, procurement, supply, and commissioning schedule
(l)
Inputs required for Civil/Structural Design.
1.5.4
Operating Manuals and Maintenance Instructions
1.5.4.1
SEC shall submit to e JSWEVL / Consultant, instruction manuals for all

equipment covered under the Contract at least thirty (30) days before the first
shipment of the respective equipment.
1.5.4.2
The operating manuals,erection manuals and maintenance instructions shall

be in sufficient detail to enable the JSWEVL to erect,commission, operate,
maintain, dismantle, re-assemble, adjust or replace all equipment and
components during the lifetime of the plant. The manuals shall be specifically
prepared for the contracted plant. Mere collection of manufacturers standard
leaflets shall not be acceptable as manuals. However, this can be enclosed
along with O & M manual.
1.5.4.3
In addition, the SEC shall provide at least six (6) months before provisional
taking over of the first unit, a consolidated manual for the complete main plant
detailing out instructions for operation and maintenance.
1.5.4.4.
The operating manuals and maintenance and erection instructions manual

shall be submitted in the form of one (1) reproducible original and fifteen (15)
copies as well as two (2) copies in Compact Disks (CDs). One (1) hard copy
and one (1) copy in CD shall be furnished to Consultant. The instruction
manuals shall be subject to approval of the JSWEVL.
1.5.4.5
If after the commissioning and the initial operation of the plant, the instruction
manuals require modifications / additions, the same shall be incorporated by
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SECTION: C3a
SHEET 10 OF
OF
the SEC and the updated final version of the manuals shall be submitted to
JSWEVL.
1.5.4.6
SEC shall submit fifteen (15) sets of spare parts catalogues.
1.5.5
Plant Handbook and As-Built Documentation

(a)
Plant Handbook
SEC shall submit to JSWEVL, a preliminary main plant handbook
preferably in combination of A4 and A3 size sheets which shall contain
all approved design basis and design calculations, the design and
performance data of various plant, equipment and systems covering the
scope of his supply including single line flow diagrams, within twelve (12)
months from Notice to Proceed ( NTP) The final main plant handbook
complete in all respects shall be submitted by SEC three (3) months
before start-up and commissioning activities. The main plant handbook
shall be submitted in form of one (1) reproducible original and fifteen (15)
copies along with two (2) copy in Compact Disks (CDs).
(b)
As-built Documentation
SEC shall provide and keep up to date As built drawings of all
structures constructed and all equipment and accessories and
miscellaneous metal works erected or installed. These drawings shall
show all changes and revisions from the original drawings and
specifications, including the exact As-built locations, sizes and kind of
equipment and accessories, miscellaneous metal works, embedded
piping and electrical systems and other concealed items of work. These
drawings shall l be kept in SECs field office but shall l be made
available at all times for review of JSWEVL/Consultant. At the end of
every work, all entries, changes or revisions made in the drawings by the
SEC
shall be checked and approved by the Consultant. One
reproducible prints with fifteen (15) copies of all As-Built drawings shall
be progressively handed over to JSWEVL after taking over of the plant
by JSWEVL.
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1.5.6
Sub-Contractors
1.5.6.1
SEC shall submit to the JSWEVL a list of all major items/works that he
deems necessary to be sub-contracted for approval. The SEC shall not
change Sub-Contractor without prior approval of the JSWEVL.
1.5.6.2
SECs orders to the Sub-Contractors shall quote the JSWEVLs Contract

reference and station name, and instruct the sub-Contractors to quote that
number and name and also the order number in all correspondences.
1.5.6.3
A copy of all orders (which may be un priced) placed on Sub-Contractors and

of all orders placed by Sub-Contractors shall l be submitted to JSWEVL.
1.5.6.4
SEC shall be responsible for maintaining an up-to-date list of all sub-orders

and inter work orders and shall l make this available to JSWEVL as required.
1.5.6.5
JSWEVLs Contract reference and station name, shall l be added to all inter
works and sub-orders.
.
1.5.6.6
SECs shall ensure that their Sub-Contractors follow the requirement of the
specification and have adequate control over all aspects covered by the
specification.
1.5.7
Progress Reports
1.5.7.1
During the design, engineering and manufacturing, supply, erection, testing

and commissioning stages the SEC shall submit to JSWEVL/Consultant
reports and information on the progress of works by him and by the SubContractors of all plant and materials required for the execution of the works.
The progress of work shall be linked to the Project Schedule.
1.5.7.2
The detailed procedure and requirements for progress reporting - shall be

agreed with JSWEVL during the early phase of the works, as part of regular
Contract / project status reporting.
1.5.7.3
SEC shall also submit to JSWEVL monthly progress reports and any other
reports as required by JSWEVL / Lenders / Statutory authorities.
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1.5.8
VOLUME II Part
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SECTION: C3a
SHEET 12 OF
OF
Access for Progress Monitoring

JSWEVL or his nominated representatives shall be entitled at all reasonable
times to visit all premises where design and manufacturing of the plant is being
carried out in order to monitor and verify progress with intimation to e SEC.
1.6
MISCELLANEOUS
a. Design and engineering
b. Consents, licenses and approvals from relevant statutory authorities other than
those obtained by the JSWEVL.
c. Packing & forwarding,inland transportation and shipping to Indian port.),
d. , Assessment of lost / damaged items in transit and helping JSWEVL to lodge
insurance claims and replacement of lost / damaged items in transit.
e. Taking custody of all the materials till the plant is officially taken over by the
JSWEVL after complete erection and successful trial run and commissioning.
f.
g. Supervising Trial run and commissioning of individual equipment/ sub-systems
and the plant as a whole to the satisfaction of the JSWEVL including supply of
temporary equipment and services for chemical cleaning, steam blowing, etc.
h. Provision for preservation of individual equipment after trial run and
commissioning (e.g. nitrogen blanketing) as necessary till take over of the
equipment.
i.
Supply of the paints on all the equipment to be erected under this specification
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Deployment of all skilled manpower required for, supervision of erection and

commissioning, and other services to be rendered under this specification
k. Deployment of all erection tools & tackles, and all other implements in
adequate number, capacity and size
l.
m. Supply of necessary calibrated instruments for carrying out performance tests
of plant and equipment.
n. Taking approval of applicable statutory authorities by paying the requisite fee to
e.g., Boiler Inspector only , etc. for respective portions of work under the
jurisdiction of such statutes or laws, for which JSWEVL shall give all due
supports. In order to get approvals by Electrical and Factory inspectors, SEC
shall give all due supports (e.g. documentation) to JSWEVL.
o. Quality assurance and Quality Control of all work executed at site
p. Co-ordination and project management.
q. .
r.
Supply of lubricants/consumables and all temporary provisions till Provisional

Takeover.
s. Mandatory spare parts, as specified, for the Main Plant equipment.

t.
Tools and tackles including all special tools and tackle, as required, for the
Main Plant equipment.
u. Furnishing all documents, engineering & construction drawings, design basis

reports, optimisation study reports, design calculations, equipment data sheets
from manufacturers, quality assurance plans, testing procedures, operation
and maintenance manuals, commissioning procedures, As built drawings, etc.
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v. Conduct of shop and site tests as required. Conducting trial runs of the plant as
specified .
w. Conduct of performance tests for the entire main plant equipment and for the
individual equipments as required.
x. Conducting of various site acceptance tests on electrical, instrumentation and
control systems of generator, excitation system, bus ducts, field instruments
etc.
y. Supply of all cable termination / jointing kits, insulating materials, cable glands,
lugs, junction boxes, suitable sizes of cable boxes and insulating paints for
items in the scope of supply of SEC.
z. Furnishing of civil interface/loading, mechanical, electrical and instrumentation
coordination drawings indicating the details like providing of cut outs, Insert
plates, embedment of foundation bolts and providing of sleeves etc.
aa. Training of the plant JSWEVLs personnel on main plant operation and
maintenance.
bb. All other facilities/services as described in the section on 'Site Services' as per
DOW.
cc. Following documents to be submitted prior to six months start of erection to
the JSWEVL/Engineer for approval.
(a) All field quality plan for erection of complete equipment/system.
(b) Erection manual, NDT manual and welding procedure manual for all piping.
(c) .
dd. SEC should strictly submit monthly micro level equipment/material supply
programme to JSWEVL/ENGINEER before 2 nd of the particular month based
on their L1 network.
NOTE:
The above list of work is not exhaustive. The scope of work as detailed in DOW
and the above scope put together shall form the scope of supply. In addition all
other mutually agreed documents, letters,correspondences etc also shall
constitute part of Contract. Any additional works, whether or not specifically
described in this document and incidental to complete the power plant in all
respects shall be deemed to be in the scope of work of the Main Plant
Package Contractor SEC.
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2.0 Terminal points and DOW- Please refer to appendix at the end of
C3.bTurbine Generator Section.
section
Steam Turbine and Generator

a. Each steam turbine and its auxiliaries will comprise:
i)
HP turbine, extraction condensing reheat steam turbine, stop & control

valves for main steam and reheat steam, lubricating and control oil
systems with tank, pumps, fans, cooler, filter, etc., turning gear system,
gland sealing system with gland steam condenser, exhauster, etc.,
exhaust hood spray system and integral drain system including flash
tanks
ii)
Turbine supervisory, protection and governing system
iii)
Automatic turbine run-up system and automatic turbine testing system

(provided in DEH)
iv)
Turbine oil purification system
v)
Steam turbine acoustic enclosure (removable type) if required to

attenuate the noise levels within the specified limits with necessary
ventilation and lighting system
b. Steam condensing equipment including surface condenser and accessories

with necessary condenser air evacuation system
c. Condenser cooling waters terminal point shall be at inlet and outlet butterfly
valves. Companion flanges bolts, nuts and gaskets. Rubber expansion joints
are also in SECs scope.
d. Regenerative feed water heating plant including LP heaters, drain cooler/drain
condensate pump if applicable, deaerator, HP heaters, 2 x 100 % condensate
extraction pumps with drives and 3 x 50 % boiler feed pump sets including
drives. Variable speed hydraulic coupling will be provided for the BFPs for each
unit
e. HP bypass and LP bypass with spray arrangement (capable of bypassing 60%
BMCR steam flow)
f.
Hot-well make-up lines from the terminal points provided by the NPPL
g. Thermal insulation and cladding as required
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h. Compressed air system piping as per the DOR

i. Chemical dosing system for feed / condensate cycle
j.
Primary elements for control of condensate and feed cycle system
k. Complete condensate cycle and feed water cycle piping, extraction steam &
heater drain piping, auxiliary system piping for turbine island, with hangers and
supports, valves, drains, vents, sampling points, instrument tapings, etc., as
required for steam turbine and generator auxiliaries and connected systems
l.
All consumables like oil for turbine oil system, lube oil for equipments, grease
and chemicals required up to completion of trial operation, performance test
and handing over to JSWEVL
m. Design data, basic design and detailed design of turbine pedestal

n. All equipment base plates, lifting lugs, foundation bolts, sleeves, nuts, inserts,
embedded plates and secondary grouts (cement will be provided by JSWEVL)
as required for efficient installation of all equipment.
1.1.2
Other Auxiliary Systems

a. Auxiliary piping system, auxiliary steam piping, circulating DM cooling water etc
as per the TERMINAL POINTS FOR MAIN PLANT EQUIPMENT SUPPLIER
b. Pipe supports and associated structural works, including pipe racks, trestles,
trenches, etc. as required including all temporary frames for transport and
erection.
c. All lifting and handling equipment to facilitate the handling of all equipment
which are in the scope of supply (Excluding Station Building Crane) during
erection/ maintenance/ overhaul during the plants lifetime. The sliding rails and
pulling system required for equipment handling where applicable and trolleys
for feed water heater tube/shell and boiler feed pump impeller removal.
d. 300 filled in H2 cylinders for generator cooling (Common for both units)
e. Carbon-dioxide bottles (adequate number for refilling and for generator
purging), storage, handling and distribution system and piping to steam
generator area.
f.
Supply and application of paints and thermal and acoustic insulation as

required for the entire main plant equipment.
g. Site safety requirements.
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h. Circulation cooling water shall be closed type and its temp. shall not be more
than 38 deg. C.
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1.2
VOLUME II Part
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SHEET 18 OF
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ELECTRICAL WORKS
1.2.7
Electrical Generators including their accessories such as cooling system,

Generator fire protection system, excitation system, automatic voltage regulator,
NG Cubicle etc.
1.2.8
Generator Control panel and Generator Protection Panels
1.2.9
All drive motors both (AC and DC)
1.2.10 Motor Operated valves with integral starter

1.2.11 Starter Panels for DC motors
1.2.12 Junction Boxes/Marshalling boxes
Note: All the 6.6kV Switch gear, 415V MCC and 220V DC distribution boards, Power
cables up to motor terminal and Local Push Button Stations will be under the
JSWEVLs scope.(Except 415 V Soot blower MCC & ESP MCC and related cable)
1.3
CONTROL & INSTRUMENTATION SYSTEM STG Power Block.

I & C scope shall include complete instrumentation & control system for Turbine
generator. Distributed Control System (DCS) shall be provided for complete control
of Turbine & Its auxiliary systems. The DCS shall have necessary interface with the
JSWELs BOP PLCs. Details of I & C for Turbine are given in subsequent clauses
of this document. The control room will be provided by the JSWEVL at Central
Control Building. SEC shall provide Electronic panel room layout for the
equipment supplied by him for JSWELs Engineering.
1.3.1
CONTROL & INSTRUMENTATION SYSTEM STG.(Turbine)

(Unless otherwise specified, all the requirements indicated below are
on per unit basis).
1.3.1.1
Control system
State of the art Distributed Digital Control System (DCS) for turbine
integral controls including the following :
a)
b)
c)
EHTC (Governing System)

ATRS( Startup and shutdown sequence of TG including start /stop
logic for all the TG auxiliaries)
Automatic Turbine testing system.
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d)
e)
f)
g)
h)
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Turbine protectionPLC
HP/LP Bypass system including HP/LP Bypass protection & interlock
Turbovisory system
Turbine analog controls including gland steam , Lube oil temperature
etc.,
Turbine Stress Evaluator/ Controller
DCS shall comprise data acquisition system, closed loop and open loop
controls, data highways / gateways for connecting packaged and other control
sub systems, operator stations with visual display units and control devices,
printers, engineering work stations, , etc.
In DCS, SEC shall ensure Sub Group Control based automated sequence
control for the Turbine start-up and shutdown. DCS shall have proper interfacing
withJSWELs BOP PLC
1.3.1.2 Control room mounted equipment like panels, consoles, stations, panels
cabinets, interposing relay cabinets , racks, etc.
1.3.1.3 All primary sensors like flow elements, temperature sensors.
1.3.1.4 All field instruments process switches, transmitters, local gauges etc.
All sensors related to Turbine protection, Governing system,shall be double/triple
and sensors for balance control loops will be single. However, the sensor for
turbine vibration and bearing temperature measurement shall be single.
1.3.1.5 All final control elements like control valves, de-superheaters, and actuators, etc.
All final control elements will be pneumatically operated except for Governing
valves and HP/LP Bypass valves which will be hydraulically operated.
1.3.1.6 All TG specific field instrumentation, and integral instrumentation.
1.3.1.8 All machinery monitoring instruments like bearing temperature, vibration
monitoring system in X-Y directions of all HT motors-driven equipment.
1.3.1.9 Turbovisory system including Turbine vibration measurements.
1.3.1.10
.
1.3.1.11
All junction boxes, transmitter racks, cubicles, enclosures, local panels,

Marshalling cubicles, panels, pneumatic and process hook up hard wares and
other erection materials and accessories as required for the complete
installation of the instruments.
Cable
a) The I&C cables from sensor to JB or field equipment to JB will be in SECs
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SECs scope(like vibration monitoring panel). Cabling from JB/Panel to DCS

will be in JSWEVLs scope.
b) Compensating cable, special cable, pre-fabricated cable, Fibre optic cable
etc up to field JB
1.3.1.17
JSWEVL will provide redundant bulk feeders of adequate rating for UPS/DC
supplies. JSWEVL will provide only 220VDC, 220 VAC UPS control supply.
Any other voltage level required will have to be derived by SEC.
1.3.1.13
Earthing system (separate electronic and frame earth) .For Terminal points
refer mutually agreed Terminal Points document
1.3.1.14
Emergency Fire protection push buttons and Emergency Turbine Trip push
Buttons.
1.3.1.15
Smart transmitters (pressure, DP, flow, level, temperature)
1.3.1.16
All dedicated PG test points as per the ASME Code
1.3.1.17
Services will include erection and commissioning supervision, PG-Test ,

Guarantees etc., for all the equipment supplied. Services will also include all
the required documentation in soft and hard copies in JSWEVLs format ,
including As-Built Document and preparation of Contract Document
1.3.1.18
Inspection, FAT(factory acceptance test), SAT(site acceptance test) as per

mutually agreed procedures.
1.3.1.19
Spares ,Special maintenance and erection tools and tackles required for
installation, operation and maintenance of C&I equipment & system.
1.3.1.20
Instrument air distribution as required.
1.4
CIVIL STRUCTURAL AND ARCHITECTURAL WORKS

Inputs required for the civil design is included in the scope. However all civil
works other than that mentioned below are excluded from the Scope.
v)
Design and provision of Inertia block in RCC grade M25 over the
vibration isolation system for Steam Turbine Generator, BFP as required
vi)
Provision of Insert plates in inertia block at locations Furnished by

JSWEL as required
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Checking Civil drawings furnished by JSWEVL for interference with

piping/Equipment, Adequacy of openings, Location and size of insert
plates/Pockets furnished by SEC.
1.5
PROJECT MANAGEMENT / SERVICES
1.5.1
SEC shall identify a separate and independent project management team

headed by a Project Manager for the execution of this project.
SEC shall provide effective management of the Contract, which shall be
compatible with the JSWEVLs requirements as set out in this specification.
SEC shall allow access to his works and those of his sub-contractors at all
times to permit the JSWEVL / Consultants participation, if JSWEVL /
Consultant considers it necessary in monitoring the Contract. The Project
Manager shall also work with other Contractors who interface with this
Contract in order to ensure the smooth completion of the project. Such
participation up to its completion
shall not, in any way affect the SECs
obligations to complete the supply and supervision works in accordance with
the Contract.
1.5.2
Management Organisation
1.5.2.1
SEC shall describe how his management organisation shall

meet the
requirements detailed herein. He shall include an organisation chart
illustrating how the management structure / lines of authority will function
during the Contract.
1.5.2.2
The SEC shall submit the names, qualifications and experience of the
proposed managerial and senior supervisory staff to be employed on the
Contract. The SEC shall indicate the number of staff, rating and seniority to
be employed to manage and supervise the Contract and list separately for
head office and site office based locations. In particular how staff are
planned to be deployed with respect to the Contract period timescale shall be
stated.
1.5.2.3
SEC shall inform the JSWEVL any proposed changes in the Senior Staff
category.
1.5.2.4
JSWEVL reserves the right to evaluate and audit the SECs management
systems and controls in the areas set forth in this section.
1.5.2.5
SEC shall constitute a separate commissioning supervision team in

consultation with JSWEVL/Consultant before taking up of testing, precommissioning checks, commissioning and tying/cascading /connecting with
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other system, etc. SEC shall have a separate planning and progress
monitoring team to enable timely completion of the project.
1.5.3
Engineering Services
1.5.3.1
SEC shall render complete engineering services for the project including
complete detailed engineering, design submission and documentation as
specified and as required for a good design and installation ensuring
efficiency, operability, availability, maintainability and reliability of the plant.
Prior to commencement of the engineering work all aspects of design, viz.,
criteria for selection and sizing of critical equipment and systems, design
margins, analysis and design calculations, etc. shall be stated by the SEC in
design basis reports. As part of design submissions, the design basis reports
shall be submitted by the SEC for approval by the JSWEVL / Consultant. The
approved design basis reports
shall form the basis for the detailed
engineering work.
1.5.3.2
At any stage during the performance of the Contract, if the system warrants
improvements in the Contracted plant and consequent modification in the
equipment / system designs the SEC shall make the necessary design
modifications and carry out the / improvements in the plant if applicable with
the approval of JSWEVL/Consultant at no extra cost to the JSWEVL.
1.5.3.3
During the course of review of detailed engineering, it may be essential in

JSWEVLs opinion to obtain data and information on similar equipment and
plants engineered by the SEC. In case, JSWEVL so desires the SEC shall
submit such analogous data and information to the JSWEVL.
1.5.3.4
SEC shall cooperate with the JSWEVLs other Contractors and the
Consultant and freely exchange with them such technical information as are
necessary to obtain the most efficient and economical design and to avoid
unnecessary duplication of efforts. JSWEVL shall be provided with copies of
all correspondences addressed by SEC to other Contractors and the
Consultant in respect of such exchange of technical information.
1.5.3.5
SEC shall furnish a comprehensive and detailed schedule of drawings and

design documents, which shall be submitted by him after award of Contract
indicating submission dates against each document. The list shall be subject
to the approval of the JSWEVL / Consultant.
The documents shall be divided into two categories:
(b)
(a)
For approval
For information / reference only1.5.3.6 Documents submitted during bid stage,
shall be revalidated or revised as required and submitted as certified
document for approval / information of the JSWEVL/Consultant, after award of
Contract. Such documents shall include but not limited to the following:
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1.5.4
VOLUME II Part
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SHEET 23 OF
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(a)
System schematic drawings, pipeline and instrumentation diagrams
(b)
Design basis reports
(c)
Specification for major bought-out items
(d)
Equipment data sheets and general arrangement drawings
(e)
Materials for construction
(f)
Layout drawings
(g)
Operation logic diagrams
(h)
Typical control circuits
(i)
Protection schemes
(j)
Quality assurance plan (for works & erection etc)
(k)
Project engineering, procurement, supply, and commissioning schedule
(l)
Inputs required for Civil/Structural Design.
Operating Manuals and Maintenance Instructions
1.5.4.1
SEC shall submit to e JSWEVL / Consultant, instruction manuals for all

equipment covered under the Contract at least thirty (30) days before the first
shipment of the respective equipment.
1.5.4.2
The operating manuals,erection manuals and maintenance instructions shall

be in sufficient detail to enable the JSWEVL to erect,commission, operate,
maintain, dismantle, re-assemble, adjust or replace all equipment and
components during the lifetime of the plant. The manuals shall be specifically
prepared for the contracted plant. Mere collection of manufacturers standard
leaflets shall not be acceptable as manuals. However, this can be enclosed
along with O & M manual.
1.5.4.3
In addition, the SEC shall provide at least six (6) months before provisional
taking over of the first unit, a consolidated manual for the complete main plant
detailing out instructions for operation and maintenance.
1.5.4.4.
The operating manuals and maintenance and erection instructions manual

shall be submitted in the form of one (1) reproducible original and fifteen (15)
copies as well as two (2) copies in Compact Disks (CDs). One (1) hard copy
and one (1) copy in CD shall be furnished to Consultant. The instruction
manuals shall be subject to approval of the JSWEVL.
1.5.4.5
If after the commissioning and the initial operation of the plant, the instruction
manuals require modifications / additions, the same shall be incorporated by
the SEC and the updated final version of the manuals shall be submitted to
JSWEVL.
1.5.4.6
SEC shall submit fifteen (15) sets of spare parts catalogues.
1.5.5
Plant Handbook and As-Built Documentation
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(a)
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SHEET 24 OF
OF
Plant Handbook
SEC shall submit to JSWEVL, a preliminary main plant handbook
preferably in combination of A4 and A3 size sheets which shall contain
all approved design basis and design calculations, the design and
performance data of various plant, equipment and systems covering the
scope of his supply including single line flow diagrams, within twelve (12)
months from Notice to Proceed ( NTP) The final main plant handbook
complete in all respects shall be submitted by SEC three (3) months
before start-up and commissioning activities. The main plant handbook
shall be submitted in form of one (1) reproducible original and fifteen (15)
copies along with two (2) copy in Compact Disks (CDs).
(b)
As-built Documentation
SEC shall provide and keep up to date As built drawings of all
structures constructed and all equipment and accessories and
miscellaneous metal works erected or installed. These drawings shall
show all changes and revisions from the original drawings and
specifications, including the exact As-built locations, sizes and kind of
equipment and accessories, miscellaneous metal works, embedded
piping and electrical systems and other concealed items of work. These
drawings shall l be kept in SECs field office but shall l be made
available at all times for review of JSWEVL/Consultant. At the end of
every work, all entries, changes or revisions made in the drawings by the
SEC
shall be checked and approved by the Consultant. One
reproducible prints with fifteen (15) copies of all As-Built drawings shall
be progressively handed over to JSWEVL after taking over of the plant
by JSWEVL.
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1.5.6
Sub-Contractors
1.5.6.1
SEC shall submit to the JSWEVL a list of all major items/works that he
deems necessary to be sub-contracted for approval. The SEC shall not
change Sub-Contractor without prior approval of the JSWEVL.
1.5.6.2
SECs orders to the Sub-Contractors shall quote the JSWEVLs Contract

reference and station name, and instruct the sub-Contractors to quote that
number and name and also the order number in all correspondences.
1.5.6.3
A copy of all orders (which may be un priced) placed on Sub-Contractors and

of all orders placed by Sub-Contractors shall l be submitted to JSWEVL.
1.5.6.4
SEC shall be responsible for maintaining an up-to-date list of all sub-orders

and inter work orders and shall l make this available to JSWEVL as required.
1.5.6.5
JSWEVLs Contract reference and station name, shall l be added to all inter
works and sub-orders.
1.5.6.6
SECs shall ensure that their Sub-Contractors follow the requirement of the
specification and have adequate control over all aspects covered by the
specification.
1.5.7
Progress Reports
1.5.7.1
During the design, engineering and manufacturing, supply, erection, testing

and commissioning stages the SEC shall submit to JSWEVL/Consultant
reports and information on the progress of works by him and by the SubContractors of all plant and materials required for the execution of the works.
The progress of work shall be linked to the Project Schedule.
1.5.7.2
The detailed procedure and requirements for progress reporting - shall be

agreed with JSWEVL during the early phase of the works, as part of regular
Contract / project status reporting.
1.5.7.3
SEC shall also submit to JSWEVL monthly progress reports and any other
reports as required by JSWEVL / Lenders / Statutory authorities.
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1.5.8
VOLUME II Part
-I
SECTION: C3a
SHEET 26 OF
OF
Access for Progress Monitoring

JSWEVL or his nominated representatives shall be entitled at all reasonable
times to visit all premises where design and manufacturing of the plant is being
carried out in order to monitor and verify progress with intimation to SEC.
1.6
MISCELLANEOUS
a. Design and engineering
b. Consents, licenses and approvals from relevant statutory authorities other than
those obtained by the JSWEVL.
c. Packing & forwarding,shipping to Indian port.
d. Assessment of lost / damaged items in transit and helping JSWEVL to lodge
insurance claims and replacement of lost / damaged items in transit.
e. Taking custody of all the materials till the plant is officially taken over by the
JSWEVL after complete erection and successful trial run and commissioning.
f.
Supervising Trial run and commissioning of individual equipment/ sub-systems

and the plant as a whole to the satisfaction of the JSWEVL including supply of
temporary equipment and services for chemical cleaning, steam blowing, etc.
g. Provision for preservation of individual equipment after trial run and

commissioning (e.g. nitrogen blanketing) as necessary till take over of the
equipment.
h. Supply of the paints on all the equipment to be erected under this specification
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JSW ENERGY (VIJAYANAGAR) LIMITED

BTG PACKAGE FOR 2 x 300 MW COAL BASED

BROAD SCOPE FOR STEAM GENERATOR

Steam generator island

Consultants: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

JSW ENERGY (VIJAYANAGAR) LIMITED

BTG PACKAGE FOR 2 x 300 MW COAL BASED

BROAD SCOPE FOR STEAM GENERATOR

Steam and water system including initial SG fill system

g. SG blow down system

Auxiliary Pressure Reduction Station

Closed Cycle DM water cooling system

m. Air Pre heaters

All other accessories and auxiliaries as required.

Staircases on either side and platforms

u. Design and installation of vibration isolation system as required with dampers

TCE FORM 329 R3

JSW ENERGY (VIJAYANAGAR) LIMITED

BTG PACKAGE FOR 2 x 300 MW COAL BASED

BROAD SCOPE FOR STEAM GENERATOR

Other Auxiliary Systems

g. Interconnecting structures and platforms to elevators in Steam Generator

Site safety requirements.

TCE FORM 329 R3

JSW ENERGY (VIJAYANAGAR) LIMITED

BTG PACKAGE FOR 2 x 300 MW COAL BASED

BROAD SCOPE FOR STEAM GENERATOR

All drive motors both (AC and DC)

Motor Operated valves with integral starter

Starter Panels for DC motors

Junction Boxes/Marshalling boxes

CONTROL & INSTRUMENTATION SYSTEM SG Package .(Boiler)

Burner management system including boiler protection

TCE FORM 329 R3

JSW ENERGY (VIJAYANAGAR) LIMITED

BTG PACKAGE FOR 2 x 300 MW COAL BASED

BROAD SCOPE FOR STEAM GENERATOR

All primary sensors like flow elements, temperature sensors.

All field instruments process switches, transmitters, local gauges etc.

All sensors related to Boiler Protection and critical controls shall be

All SG specific field instrumentation, and integral instrumentation

All machinery monitoring instruments like bearing temperature, vibration

All junction boxes, transmitter racks, cubicles, enclosures, local panels,

TCE FORM 329 R3

JSW ENERGY (VIJAYANAGAR) LIMITED

BTG PACKAGE FOR 2 x 300 MW COAL BASED

BROAD SCOPE FOR STEAM GENERATOR

Burner management system including Igniters, digital (microprocessor based)

Smart transmitters (pressure, DP, flow, level, , temperature etc).

Painting of impulse tubes, transmitter racks etc.

Drum instrumentation including two numbers conductivity type, bi-colour

All special measurements including , speed measurements for HT Drives,

All dedicated PG test points as per the ASME Code.

Instrument air distribution, as required.

CIVIL STRUCTURAL AND ARCHITECTURAL WORKS

Provision of Insert plates in inertia block at locations Furnished by

Consultants: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

JSW ENERGY (VIJAYANAGAR) LIMITED

BTG PACKAGE FOR 2 x 300 MW COAL BASED

BROAD SCOPE FOR STEAM GENERATOR

Checking Civil drawings furnished by JSWEVL for interference with

PROJECT MANAGEMENT / SERVICES Refer to Steam turbine generator