SPEC NO.

TATA CONSULTING ENGINEERS LIMITED

TITLE

SECTION: C22

STEAM GENERATOR, STEAM TURBINE GENERATOR AND AUXILIARIES ERECTION, COMMISSIONING AND TESTING

22.0

ERECTION, COMMISSIONING AND TESTING REQUIREMENTS General Requirements

22.1 22.2 22.3

The VENDOR shall erect all equipment/systems covered in this specification. Transferring levels and coordinates from the master bench marks provided by the PURCHASER is the responsibility of the VENDOR. The erection work shall include grouting of foundation bolts, base plates, etc. touch up and finish painting. Only open space for storage shall be provided by the PURCHASER inside the plant boundary. VENDOR shall make all arrangements for proper storage of equipment. Calibration and commissioning of all instruments and control equipment supplied under this contract shall be executed by the VENDOR. Hardwares required for erection of all instruments and control equipment covered under this contract shall be supplied by the VENDOR. The entire works will be carried out with necessary precautions to meet the rules of local statutory authorities to have the utmost protection to men and material. A full fledged safety engineer shall be provided by the VENDOR to be in charge of the supervision of safety requirements at site. It is the VENDORs responsibility to provide safety to his personnel and equipment. Grouting the bases of all equipment and structural steel members erected by the VENDOR is covered in his scope and supply of all grouting materials in the VENDORs responsibility. Concrete/ cement mortar cubes/briquettes, etc., shall be tested for their strength by the VENDOR at his cost. Grouting permits will have to be cleared by the PURCHASER only after which the VENDOR shall undertake grouting work. Works such as machining and bedding of packers, minor rectification of foundation bolts, reaming of holes, drilling for dowels, making new dowel pins, etc., if required are also covered in the VENDORs scope. Pre-commissioning checks, individual loop checks, power initialisation, verification of system functioning, trouble shooting final solutions to application and/or instrument problems etc., is SUPPLIERS
ISSUE R0
TCE FORM 329 R4

22.4

22.5

22.6

22.7

22.8

SPEC NO.

TATA CONSULTING ENGINEERS LIMITED

TITLE

SECTION: C22

STEAM GENERATOR, STEAM TURBINE GENERATOR AND AUXILIARIES ERECTION, COMMISSIONING AND TESTING

responsibility. All the required software and hardware changes shall be incorporated as required for successful commissioning to Purchasers satisfaction. Pre-commissioning and commissioning activities like leak test of furnace, ducts, ESPs, hydro test of the SG, chemical cleaning of the SG and Pre boiler system, steam blow out etc are in the scope of the Vendor. 22.9 VENDOR shall submit a detailed PERT network for all activities. This master network shall be comprehensive and detailed in all aspects. After review and approval of this network by the PURCHASER, this approved network shall be the basis for all erection work. Based on this master network, the VENDOR shall develop sub-networks and bar charts for all activities. The START and COMPLETION dates of all construction activities and milestone activities shall be closely adhered to. The VENDOR shall abide by general safety and security rules formulated by the PURCHASER. Vendor shall furnish the detailed safety manual for erection & commissioning of the steam generator, steam turbine generator. The VENDOR shall maintain records of all non-consumable items such as tools, tackles, Machineriers etc. with all the incoming and outgoing gate passes corresponding to each items/equipments belonging to him to facilitate easy identification and take-over while closing the site office. Supply and erect metallic tags on the equipment/valves/instruments and accessories supplied by the VENDOR. The tags and connecting wires shall be of stainless steel and the size of the tags shall be adequate to accommodate tag number. Construction water and construction power will be made available by the PURCHASER at one point in the plant. Further connections required from this point onwards shall be included by the SUPPLIER in his scope. The SUPPLIER will be provided with power for construction on chargeable basis and construction water shall be arranged by bidder himself. Specific Requirements

22.10

22.11

22.12

22.13

ISSUE R0
TCE FORM 329 R4

SPEC NO.

TATA CONSULTING ENGINEERS LIMITED

TITLE

SECTION: C22

STEAM GENERATOR, STEAM TURBINE GENERATOR AND AUXILIARIES ERECTION, COMMISSIONING AND TESTING

22.14

Supply of adequate quantity of consumables required for the job, viz., , drill bits, tapes, scaffolding, , oil, kerosene, grease, lubricants, cotton waste, chemicals etc., required for erection, commissioning and testing till handing over is covered under this contract. Welding electrodes and gas for field erection will have to be arranged by the vendor only for construction. However, fuel oil for firing in the steam generator, construction water and power required during commissioning and testing will be supplied by the PURCHASER. DM water required during commissioning will be made available at the plant battery limit and further distribution shall be carried out by the VENDOR. All temporary piping and accessories shall be in VENDORs scope. The VENDOR shall prepare isometric drawings for installation and routing of impulse pipes from the tapping point location to each instrument and device supplied by him. The VENDOR shall furnish an installed drawing to the PURCHASER. During erection, commissioning and testing activities like hydro test, acid cleaning etc., all the effluents shall be made available up to the treatment facility provided by OTHERS. Acid cleaning if required for the reasons attributable to the SUPPLIER will be done by the SUPPLIER without extra price. During steam blowing operation VENDOR shall make provision for silencers to attenuate the noise level within the acceptable limits. Testing Requirements (a) The VENDOR shall set up his own instrument laboratory. The calibration equipment shall cover complete range and shall have the desired accuracy of not less than 0.1%. All the calibration equipment shall have the certification from National Physical Laboratory (NPL) or IDEMI for the duration of the Contract period. (b) The VENDOR shall follow the standard procedures for calibration of various instruments and as set by the manufacturer of instruments and as instructed by the PURCHASER including any requirements of field calibration. First, the calibration shall be carried out independently by the VENDOR and later in presence of PURCHASER and get certified. Proper documentation in this
ISSUE R0
TCE FORM 329 R4

22.15

22.16

22.17

22.18 22.19

SPEC NO.

TATA CONSULTING ENGINEERS LIMITED

TITLE

SECTION: C22

STEAM GENERATOR, STEAM TURBINE GENERATOR AND AUXILIARIES ERECTION, COMMISSIONING AND TESTING

regard shall be PURCHASER.

maintained

and

handed

over

to

the

(c) All the instruments shall be calibrated for the entire range of the instrument for which it is designed. Calibration shall include test for repeatability. After first commissioning, the instruments shall be tested for calibration again to check whether the instrument maintains its zero and maximum of the range. (d) All switches shall be tested for the actuation of both normally open and normally closed contacts at the desired set points and also for the fixed differential settings. (e) All the float operated level switches shall be tested for the movement of the float and linkages to make or break the switch contacts by filling up with water before installation. For such tests necessary testing set up required shall be arranged by the VENDOR. All the conductivity type probes and switches shall be tested for performance before installation. (f) All control valve/control damper positioners supplied by the VENDOR and connected to the control system (loops) supplied by OTHERS shall be calibrated based on the input data furnished by PURCHASER. For all electrical actuators of the valves, functioning, setting and performance of limit switches/torque switches at various positions shall be checked before and after installation of the actuators. The positioner shall be calibrated.

(g)

(h) Pneumatic actuators shall be calibrated at site. (i) All valves/Dampers/Actuators/Control valves/Pipes & fittings are to be properly cleaned, serviced, manually operated before being erected in position.

ISSUE R0
TCE FORM 329 R4