Dm Plant Specifications

7/28/2019 Dm Plant Specifications

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HAZIRA PIPE MILL LIMITED

COATING PLANT

TECHNICAL SPECIFICATION

FOR

DM PLANT

ESSAR ENGINEERING SERVICES LIMITED

HAZIRA

TSP NO: 1010460000TSP45H003-R00 APRIL, 2010 FORMATNO: EESL(H).PRA.DM.025.F01



HAZIRA PIPE MILL

LIMITED

0.6 MTPA,PIPE PLANT

TECHNICAL SPECIFICATION FORD M PLANT

TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERINGSERVICES LTD. HAZIRA

TSP No.:- 1010460000TSP45H003-R00 Page 1 of 40 C o n f i d e n t i a l

CONTENTS

Chapter no. Description Page no.

1.0 GENERAL INFORMATION 2

2.0 SCOPE OF WORK 2

3.0 TECHNICAL SPECIFICATION 5

4.0 STANDARDS & CODES 21

5.0 PAINTING 25

6.0 DELIVERY 27

7.0 WORKMANSHIP AND PERFORMANCE GUARANTEE 27

8.0 HSE REQUIREMENTS 28

9.0 DOCUMENTS TO BE SUPPLIED 29

ANNEXURES

I SITE CONDITIONS 32

II FORMAT FOR DEVIATION FROM TENDER DOCUMENT 33

III TENDER QUALIFICATION CRITERIA 34

IV OVERALL SUPPLY & IMPLEMENTATION SCHEDULE 34

V TECHNICAL DATA SHEETS TO BE FILLED BY VENDORS 35

VI FEED WATER QUALITY 40

VII DM WATER QUALITY 40

VIII SCHEME OF DM PLANT 1 No



HAZIRA PIPE MILL

LIMITED

0.6 MTPA,PIPE PLANT


TSP NO: 1010460000TSP45H003-R00



1.0 GENERAL INFORMATION

Hazira Pipe Mill Limited (HPML), a group company of ESSAR is setting up a pipe

plant of 0.6 MTPA capacities near to the existing M/s. Essar Steel Ltd plant at Hazira.

The plant will consist of H-SAW Mill, L-SAW Mill & Anti corrosion coating facilities.

To meet the DM water requirement of plant, DM plant has one stream [1 x 100%] and

OBR of 140 m3 operating on 20 hrs. basis is planned.

This specification is intended to cover the design, manufacture, testing atmanufacturer's works and delivery at site properly packed for transport, erection,

commissioning and site testing, transit insurance, storage, commissioning,supervision of erection for the DM water package and accessories .

It is not the intent to specify completely herein all the details of design, constructionof the equipment, erection supervision, commissioning and testing requirements.However, the equipment shall conform in all respects to high standards of engineering, design and workmanship and be capable of performing in continuouscommercial operation up to the Seller’s guarantee ensuring high degree of reliability,ease of operation and maintenance of the equipment in a manner acceptable to theBuyer who will interpret the meaning of drawings and specifications and shall beentitled to reject any work or material which in his judgment is not in full accordancetherewith.

In the event of conflict between requirements of any two clauses of the specificationdocuments or requirements of different codes / standards, specified, the morestringent requirement as per the interpretation of the Buyer shall apply.

All necessary co-ordination with regard to sub-contracted equipment shall be carriedout by the Seller. The Buyer will communicate only with the Seller for all matterspertaining to this contract.

2.0 SCOPE OF WORK

2.1 The scope of Seller shall comprise design, engineering, procurement, manufacture,

inspection and testing at Seller or his sub-Seller’ works, packing, loading, forwarding,transport and delivery to site, supervision of erection & commissioning, painting,testing, carrying out performance and guarantee tests at site of the systems /equipment inclusive of all Mechanical, Electrical, Instrumentation & Control systems,equipment structural works, furnishing input data to the Buyer / Project Manager,necessary to put into commercial operation a highly reliable safe, efficient andenvironmentally compliant, D M Water Plant for HPML. The systems and equipmentshall conform to the technical requirements as specified in separate sections.

2.2 The Seller shall perform all the works specified in accordance with this specification.Further, the Sellers performance of the works under the Contract shall be inaccordance with good engineering and construction practices, notwithstanding thefact that every item involved may not be specifically mentioned, or the itemmentioned may be inadequate for its intended purpose. Details and items which arenot specifically mentioned herein shall also be adequately and properly performed by



HAZIRA PIPE MILL

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TSP NO: 1010460000TSP45H003-R00



the Seller at no extra cost if such details and / or items are reasonably necessary to

complete the package.

2.3 All equipment shall be new, and of reputed and approved make. The make of allbought out equipment, as well as major sub-Seller shall be as of approved makes.

2.4 The intent of this specification is to relieve the Buyer of the necessity of engaging or supplying any labor, service, equipment or material required to complete the PlantWater Systems package.

2.5 The Seller shall render complete engineering services for the project includingcomplete basic and detailed engineering, design submission and documentation asspecified as required for a good design and installation ensuring efficiency,

operability, availability, maintainability and reliability of the plant. Prior tocommencement of the engineering work all aspects of design, viz., criteria for selection and sizing of all equipment and systems, design margins, analysis anddesign calculations, etc. shall be stated by Seller in design basis reports. As part of design submissions, the design basis reports shall be submitted by Seller for approval by Buyer. The approved design basis reports shall form the basis for thedetailed engineering work.

2.6 The Seller shall prepare and submit detailed equipment general arrangementdrawings, equipment loadings, embedment, pockets, etc necessary for preparation of civil construction drawings. The scope of design services to be provided alsoincludes preparation of design basis reports. All design calculation and detailed drg.

for civil works are included in scope of work.

2.7 At any stage during the performance of the works, the Buyer may require up-gradation / improvements in the Contracted plant and consequent modification in theequipment / system designs in view of additional information available at a later date(s) or feedback(s) received during execution / operation of similar units. If sodesired by Seller, Buyer shall make the necessary design modifications and carry outthe up-gradation / improvements in the plant.

2.8 During the course of review of detailed engineering, it may be essential in Buyersopinion to obtain data and information on similar equipment and plants engineered bySeller. In case, Buyer so desires the Seller shall submit such analogous data andinformation to the Buyer.

2.9 The Seller shall co-operate with the Buyers other Sellers and Engineer and freelyexchange with them such technical information as are necessary to obtain the mostefficient and economical design and to avoid unnecessary duplication of efforts. TheEngineer shall be provided with copies of all correspondences addressed by theSeller to other Sellers and Engineer in respect of such exchange of technicalinformation.

2.10 The Seller shall submit to Buyer all major items that he deems necessaryto be sub-contracted. The Seller shall not change Sub- Sellers without

prior approval of the Buyer.

2.11 The scope of work shall include all the piping work including various types of Valve including large size butterfly valves, rubber expansion joints, pipe fittings,



HAZIRA PIPE MILL

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TSP NO: 1010460000TSP45H003-R00



hangers & supports for smooth and trouble free operation.

• Rubber Expansion joints of suitable design with required integral piping atpumps discharge. The rubber expansion joints shall be supplied with controlunits and consisting of stretcher bolt plates, bolts, nuts, washers, lock nuts,retaining ring and two (2) nos. companion flanges for each expansion jointsalong with bolts and nuts.

• DM water discharge piping upto DM water storage tank .

• Piping between various equipment/tanks relevant to each of the systemscovered under various sections of the specification. All pipes in this D.M plantshall be of MSRL.

• Air release valves wherever required.

• All drains and vents with valves for the pipelines as mentioned abovementioned to suit lay out requirement.

• Any other piping & valves, which are not specifically mentioned butessentially, required for the system to be complete in all respects.

• The Seller shall refer attached PFD No. 1010860000BEN45H0011 for clarityon scope of supply.

2.12 The Seller shall also submit to the Buyer monthly progress reports andany other reports as required by Buyer / Statutory authorities.

2.13 Supervision of erection of the complete plant & equipment as supplied under thisSpecification.

2.14 Deployment of all manpower required for supervision of erection, commissioningand other services to be rendered under this specification

2.15 Tools and tackles including all special tools and tackle, as required, for the entire

Plant.

2.15.1 Furnishing all documents, engineering & construction drawings, design basisreports, optimization study reports, design calculations, equipment data sheets frommanufacturers, quality assurance plans, testing procedures, operation andmaintenance manuals, commissioning procedures, ‘As built” drawings, etc.

2.16 Training of Buyers personnel (engineers and technicians) covers, training in allaspects including system design, installation, testing, commissioning, operationand maintenance.

2.17 The scope matrix related with Mechanical is as per Table-1 & for Instrumentation &

Automation is as per Table-2 & Table-3 at Sr.No. 3.14 of this document

2.18 The above list of work is not exhaustive. Any additional works, whether or not



HAZIRA PIPE MILL

LIMITED

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TSP NO: 1010460000TSP45H003-R00



specifically described in this document and incidental to complete in all respects

shall be deemed to be included in the scope of work.

2.19 Seller shall provide process calculation for the resin quantity selected for SAC (Strong Acid Cat ion), SBA (Strong Base Anion) & MB (Mixing Bed).

2.20 Seller shall submit list of recommended spares required for smooth operationand maintenance of DM plant for two years period.

2.21 Control panel for the DM plant is in vendor scope.

2.22 MOC of all pipes for DM plant shall be of MSRL.

EXCLUSIONS

a) Construction of tanks.

3.0 TECHNICAL SPECIFICATION

3.1 The DM plant shall be sized for a total output (OBR) of 140 m3 with 1X100% streamto meet the DM requirements of the plant. For deciding DM Plant design capacity,Seller shall consider less than 4 hrs as time for regeneration of water.The Feed water quality will be as per Annexure VI. The DM plant shall essentiallyinclude but not be limited to the following:-

a) 1x100% Activated carbon filter.2x100% air blowers

b) 1x100% capacity Strong Acid Cation units

c) 1x100% capacity Degasser towers,2x100% air blowers for each degasser,1x100% degassed storage tanks and2x100% degassed water pumps.

d) 1x100% Strong Base Anion unit.

e) 1X100% capacity Weak Base Anion units

f) 1x100% capacity MB units

g) 2x100% capacity MB air blowers.

h) 2 x 100 % capacity DM regeneration pumps.

i) One (1) No, neutralizing pit of effective capacity based on 120% of maximumdaily regeneration wastes from one stream.

j) 2 x 100% neutralizing pumps. The pumps shall be of horizontal centrifugal type.

k) 1x100% DM water storage tank with 2 X 100% DM Water transfer pumps.



HAZIRA PIPE MILL

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TSP NO: 1010460000TSP45H003-R00



l) One (1) No. neutralizing chemical tank (with a provision to lead acid / alkali

depending on the nature of DM regeneration effluents.

One safety shower and eye wash fountain. Acid/Alkali Dosing System

3.2 Acid Regeneration System for Cation, MB & Neutralization Pit

One (1) No. Acid measuring cum dilution tank, each for Cation units, MB unit &neutralization pit.

Metering pumps or Ejectors with associated accessories

3.3 Alkali Regeneration System for SBA, MB, WBA & Neutralization Pit.

One (1) No. Alkali measuring cum dilution tank, each for SBA, WBA units, MB units &Neutralization Pit.

Metering pumps or Ejectors with associated accessories

3.4 Activated Carbon Filters

¾ Total Numbers One (1) x 100% capacity

¾ Type Vertical

¾ Air Blowers 2 x 100% capacity

¾ Material of Construction of vessel: MSRL

¾ No of Streams : 1

¾ Operating hrs per day : 20 hrs.

¾ Back wash cycle : After 20 hrs operation.

¾ Capacity of each stream : 7 m3/hr

3.5 SAC (STRONG ACID CATION):


¾ No of Streams : 1

¾ Operating hour per day : 20 hrs

¾ OBR :140 m3

¾ MOC of the vessel : MSRL



HAZIRA PIPE MILL

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a) AMT (ACID MEASURING TANK) FOR SAC (STRONG ACID CATION)

¾ Capacity of tank : Suitable for one regeneration.

¾ No of tanks : 1

¾ MOC of tower & tank : MSRL

¾ Metering pumps with ejector assembly:2 Nos

3.6 DEGASSER SYSTEM

¾ Type :Forced draught

¾ No. required :One (1) x 100%

¾ Capacity of stream : 7 m3/hr

¾ Degassed Water Tank

o Quantity :One (1)

o Material of Construction ::MSRL

¾ Degassed Blowers

o Quantity :2 x 100%

¾ Regeneration pumps: 2 Nos

3.7 WBA (WEAK BASE ANION)


¾ No of streams : 1


¾ OBR : 140 m3

¾ MOC of vessel : MSRL

a) CMT (CAUSTIC MEASURING TANK) FOR WBA (WEAK BASE ANION)


¾ No of tanks : 1


¾ Metering pumps with ejector assembly : 2 Nos



HAZIRA PIPE MILL

LIMITED

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TSP NO: 1010460000TSP45H003-R00



3.8 SBA (STRONG BASE ANION)


¾ No of streams : 1


¾ OBR : 140 m3

¾ MOC of vessel : MSRL

a) CMT (CAUSTIC MEASURING TANK)


¾ No of tanks : 1


¾ Metering pumps with ejector assembly: 2 Nos

3.9 MB (MIXED BED)

¾ Capacity of tank : 7 m3/hr

¾ No of stream :1

¾ Operating hrs per day : 20 hrs

¾ OBR : 420 m3

¾ MOC of the vessel : FRP

¾ Blower : 2 Nos

a) AMT (ACID MEASURING TANK) FOR MIXING BED

¾ Capacity of tank : Suitable for the one regeneration

¾ No of tank : 1



b) CMT (CAUSTIC MEASURING TANK) FOR MIXING BED


¾ No of tank : 1





HAZIRA PIPE MILL

LIMITED

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TSP NO: 1010460000TSP45H003-R00



3.10 NEUTRALISATION PIT:

Pumps: 2 Nos

a) AMT (ACID MEASURING TANK) FOR NEUTRALISATION PIT


¾ No of tank : 1



b) CMT (CAUSTIC MEASURING TANK) FOR NEUTRALISATION PIT


¾ No of tank : 1



3.11 DM WATER STORAGE TANK:

Capacity of Storage tank: 50 m3

MOC of the tank: MSRL

Civil drawing of the storage tank is in vendor scope.

Silica Gel & PP Ball are in vendor scope.

DM Water t ransfer pumps:

Quantity: 2 Nos.

Flow rate: 7 m3/hr.

Head: 30 mwc.

3.12 Pumps for pumping water from degasser to WBA: 2 Nos

3.13 Regeneration of water from DM storage tank: 2 Nos

3.14 The guaranteed quali ty shall be as follows:

Activated Carbon Filter (ACF):

The quality of treated water from each ACF at design flow rate shall be guaranteedunder correction as below:Residual Chlorine, colour, and Organics: Nil.

DM Plant

The quality of DM water at the outlet of mixed bed units at design flow rate shall be



HAZIRA PIPE MILL

LIMITED

0.6 MTPA,PIPE PLANT


TSP NO: 1010460000TSP45H003-R00



guaranteed under correction as follows:

a) Conductivity at the outlet not greater than 1 μmho/cm @25 Deg c

b) pH 6.8 – 7.2c) Hardness Nild)Total Alkalinity <1 mg/le) Chloride <1 mg/lf) Sulphate < mg/l

3.15 INSTRUMENTATION & CONTROL SYSTEM

Measurement Requirement

• Inlet and outlet pressure indicators for vessels and discharge pressureindicators for various pumps.

• Conductivity transmitter at outlet of each ion exchange unit.

• Conductivity comparators shall be provided for SAC / SBA /MB.

• Flow transmitters at outlet of each ion exchange unit

• Flow Integrator at SAC, SBA & MB.

• pH analyzer at SBA, MB, SAC & Neutralization pit outlets.

• Differential pressure switches¾ Pressure switches¾ Flow switches at filter outlet.¾ Density indicators for regenerant chemical solutions.

¾ Tanks including degassed water storage tanks and DM regeneration tank -level indicators and level switches with protection interlocks for associatedpumps.

¾ Instrumentation & control cables and erection hardware.

The Instrumentation & Control System shall facilitate the safe, reliable, efficient andeasy operation of the DM plant.

The scope of the Seller shall include the complete design, engineering, documentsgeneration and submittal, manufacturing, shop testing, supply, unloading, storage &handling, erection, field calibration, testing and commissioning at site of theInstrumentation & control (I&C) system for the DM plant. The scope shall include

submission of O&M manuals, obtaining statutory approvals and training of Buyerspersonnel. For other equipments supplied by others (as detailed later in this sectionof the specification as per Annexure-2), the scope shall include supply andengineering of field instrumentation, cabling and operation & control of the referredequipments from the DM plant.

Systems/Equipments to be provided by the Seller:

a) Instrumentation Cables along with all the accessories including cable trays, lugs,ferrules, conduits etc. between field instrument, JB and also Electrical Switchgears.

b) Local Control Panels as applicable.

c) Complete Field Instrumentation including all Field sensors, Field instruments withmounting accessories & erection hardware, final control elements i.e. control valveswith position feedback transmitter, On-Off valves with accessories etc.



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d) Sellers scope includes the field instruments, cabling up to the panel, all engineering

(logics, graphic screens, etc.) for implementing the operation, monitoring, interlocksand protection of the above systems in the system. It shall be responsibility of DMplant vendor to successfully & timely commissioning of the DM plant. Please refer Table -2 for the scope matrix.

e) Any other I & C equipment not specified but necessary to meet the specifiedfunctional requirements of the system shall be provided by Seller.

f) Sellers scope also includes the field instruments, cabling from field instruments toDM plant panel for storage tank instruments as per Table – 3

g) Control room GA finalization as per panel data available.

h) Instrumentation earthing scheme/requirements.

i) Cable engineering.

Table - 1

SCOPE OF SUPPLY

Sr.No.

DescriptionDesign &

engineeringMaterialsupply

MaterialErection

ErectionSupervision

Commis-sioning &

Supervision

1 Activated carbon filters SELLER SELLER ESSAR SELLER SELLER

2Strong acid cation (SAC) withacid measuring tanks (AMT)

SELLER SELLER ESSAR SELLER SELLER

3 Degasser system SELLER SELLER ESSAR SELLER SELLER

4Weak base anion with causticmeasuring tank (CMT)


5Strong base anion with causticmeasuring tank (CMT)


6Mixing bed (MB) with acid &caustic measuring tank


7Neutralisation Pit with 2 pumps& acid & caustic measuring tank


8 2 Pumps for degasser SELLER SELLER ESSAR SELLER SELLER

9 Regeneration pumps ( 2 Nos) SELLER SELLER ESSAR SELLER SELLER

10 Two years recommended spares SELLER SELLER NA NA NA

11 Piping SELLER SELLER ESSAR SELLER SELLER

12 Flow meter SELLER SELLER ESSAR NA NA

13 Ph meter SELLER SELLER ESSAR NA NA

14 Conductivity meter SELLER SELLER ESSAR NA NA

15 Tools & tackles-

SELLER - - -



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Table - 2

INSTRUMENTATION & CONTROL SCOPE OF SUPPLY

Sr.No.

DescriptionDesign &

engineeringMaterialsupply

MaterialErection

ErectionSupervision

Commis-sioning &

Supervision

1Field Instruments includingerection hard wares & Mountingaccessories


2Cables & cable trays from fieldinstruments to Junction Box (JB)with erection hardware


3

Cables & cable tray from

Junction Box (JB) to ControlPanel with erection hardware SELLER SELLER ESSAR SELLER SELLER

4 Cable glands & lugs SELLER SELLER ESSAR SELLER SELLER

5Cable & cable tray with erectionhardware between DM PlantMCC and control panel


6 Control Panel SELLER SELLER ESSAR SELLER SELLER

7Field junction Box (JB) with allnecessary mounting accessories& erection hardware


8 Two years recommended spares SELLER SELLER NA NA NA

DOCUMENTATION

1Hook up & installation drawingsfor instruments containing allnecessary details

SELLER NA NA NA NA

2 Instrument location drawingcontaining all necessary details

SELLER NA NA NA NA

3 Operation & control Philosophywith description/ write up

SELLER NA NA NA NA

4 Logic block diagram & interlockwith functional description

SELLER NA NA NA NA

5 List of soft signals to be

interfaced with Main plant DCSSELLER NA NA NA NA

6 Technical specification & datasheet for all instruments

SELLER NA NA NA NA

7 Technical specification & datasheet for cables & JB

SELLER NA NA NA NA



HAZIRA PIPE MILL

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Table- 3

INSTRUMENTS RELATED TO STORAGE TANKS

SR.NO.

TANK DESCRIPTION INSTRUMENTS QTY.(Nos)

1 DM water storage tank

Level switch-External Cage Float operated(HH,H,L,LL)

4

Level indicator (Float & board type) 1

Level transmitter 1

2 Neutralisaton Pit

Level indicator (Float & board type ) 1

Level switch-External Cage Float operated

(HH,H,L,LL) 4

Level transmitter 1

3For each chemical dilution tanksin the DM plant

Level indicator (Float & board type ) 1

Level switch-External Cage Float operated(HH,H,L,LL)

4

Level transmitter 1

4Cable engineering & supply from all tank related instruments to DM plant control

system

100Mtr each per instruments

(Vendor to provide

unit rate for thesame)

5 Engineering & supply of JBs for all tank related instruments

1 no. each for DI& AI per tank

(Vendor to provideunit rate for the

same)

The Essential Spares shall be supplied as detailed below.

•

For all field Instruments, a min of one (1) or 20% of the quantity of each type or range, whichever is higher is to be provided.

Information to be furnished with the offer

• Proposed operation and control philosophy of the plant.• P & ID with BOQ

Information to be furnished after the award of contract

a) Write-up on the Operation philosophy.b) Description and write-up of control and interlocking system.

c) Complete GA diagrams and layout diagrams with foundations details of allpanels, desks and consoles, wherever applicable; control room layoutdrawing.

d) Detail wiring diagrams of all panels, system cabinets, etc. wherever



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applicable.

e) List of final I/O of Complete DM plantf) Flow chart for sequential operation, logic diagrams and control schemes.g) Quality assurance/quality control plan.h) Complete Instrument Schedule.i) Data sheets & technical literature for instruments/ equipments. j) Instrument installation diagram showing all erection hardware.k) Power supply arrangement for field mounted instruments/panels/sub systems.l) Shop and site Test Records.m) Cable Schedule and interconnection diagram.n) 'As built' drawings.o) Operation & maintenance manual

General Instrumentation Requirement:

Field instruments, analyzers and local gauges shall be provided to meet theprotection, interlock and monitoring functions of the plant. General guidelines for selection of field instrumentation are listed below. Seller shall submit data sheets for all instruments for approval by the Buyer during detailed engineering stage.

1. All transmitters should be electronic smart type.

2. Transmitters & Junction-Box protection class should confirm to IP 65 as per

IEC.

3. All transmitters should have integral local display meter 4. Operating transmitter voltage should be 12-36 VDC

5. Accuracy of transmitter should be with in ± 0.5%

6. Standard output signal range for electronic transmitter should be 4-20 mA.

(2-wire type)

7. Measuring element & all wetted parts for Transmitter & Gauges shall be

SS-316, unless process media necessitates use of other materials.

8. Sensing Element of all field devices shall be able to withstand the specified

over-pressure range of 125% (for at least 30 mins.) without affecting their elastic

characteristic & performance.

9. All measurements are in metric unit.

10. RTD element should be Pt-100 3 wire Duplex system and confirm to DIN

standard

11. All field instruments shall be provided with SS tag indicating followings:

• Instrument Tag

• Model No.

• Instrument Range/Set-point

• Input/Output signal



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12. Fail safe positions, limit switches should be weather proof. Limit switches

contacts shall be 2NO+2NC & Rating shall be 230VAC, 5Amp.

13. Junction-Box & Remote Control Panel colour should confirm to shade of

Siemens Gray(RAL7035).

14. Erection material such as SS tube & Fittings, Junction Box, cable trays,

cables, and cable glands shall be vendor’s scope.

15. For local Temperature measuring bimetal thermometers Dial size shall be 150

mm. Sensing elements, Capillary & Thermo well MOC shall be SS-316.

16. All the Gauges shall be of +/- 1.0% accuracy type.

17. For pressure gauge dial size shall be 150 mm. Sensing elements MOC shall

be SS- Burdon type.

18. All the Gauges shall have external zero adjustment facility & minimum IP65

housing. Gauges shall have linear scale & dial colour shall be white.

19. All the Gauges shall be supplied with shatter proof glass type.

¾ pH MeasurementSolid state/micro processor based system with system accuracy of 0.02 pH, autotemperature compensation, auto zero check, manual zero and span calibration,integral indicator, automatic ultrasonic cleaner, iso potential adjustment having flow

type cells. Housing for electrode and analyser shall be IP65. Output shall be isolated4-20 mA DC linear signal. Accessories shall include preamplifier, screened junctionbox for electrode.

¾ Conductivi ty MeasurementSolid state/micro-processor based system with an accuracy of +/-1 %FSD, autotemperature compensation, auto calibration, zero check and integral indicator having gate valve insertion type (with drawable) cell for hotwell conductivitymeasurements and flow line (screwed) type cell for other services. Housing for celland analyser shall be weather and water proof. Output shall be isolated 4-20 mADC linear signal.

Cables:Individual pair shielded & overall shield twisted pair copper cables shall be used for analog signals & overall shielded cables shall be used for digital signals. All thesecables shall be armoured. All the insulation including overall sheath shall be FRLSquality. The wire size shall be 1.5sq.mm. Ferruling indicating terminal numbers ontermination side shall be followed. Colour coding shall be as per IEC189-2. Only sleeve type ferruling with printed terminal numbers shall be used.Cross ferruling shall be adopted.

Instrumentation Cables:Instrumentation cables shall be 1100VAC grade, stranded high conductivity

annealed, tinned copper, twisted pair (with min. 20 twists for meter) extruded PVCinsulated with overall and / or individual screening, extruded PVC inner sheathed,galvanized steel wire armoured, extruded outer sheathed with FRLS PVC compound.The conductor size shall be minimum1.5 sq.mm. Triplex cables similar to



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instrumentation cables may be used for RTDs. Instrumentation cables carrying digital

signals shall have overall screening along with drain wire and analogue signalcarrying cables shall have each pair screening and overall screening along with eachpair drain wire and overall drain wire. Shield shall have 25% overlap and 100%coverage. Shield thickness shall be 0.06 mm (min.) and tinned copper drain wire of 0.8mm dia. Nominal.

Control Cables:Control cables shall be 1100V AC grade, multicore, minimum 1.5 sq.mm crosssection, stranded copper conductor having 7 strands, PVC insulated, inner FRLSPVC sheathed of type ST-1, galvanized steel wire armoured and outer sheath madeof FRLS PVC compound of type ST-1. In situations where accuracy of measurementor voltage drop in control circuit, warrant, higher cross sections as required shall be

used. For all the CT & PT cables, minimum 2.5 sq.mm cables shall be used.Solenoid valve Power supply cables shall be minimum 2.5 sq.mm.

LIST OF SUB-VENDORS FOR INSTRUMENTATION AND CONTROL SYSTEM

1. ULTRASONIC TYPE LEVEL SWITCHES/TRANSMITTERSa) Nivo Controls Pvt Ltd.b) SB Electro Mechanics Ltd.c) E & H.d) Emerson Process Managemente) Kisler & Morse

2. INSTRUMENT CABLESa) TCLb) Deltonc) Fort Globster Industriesd) Universal Cables Ltde) Reliance Cablesf) Gems Cabg) Cords Cable Industriesh) Polycab

3. CONTROL CABLESa) Deltonb) TCLc) Universal Cables ltdd) Reliance Cablese) Gems Cab.f) Cords Cable Industriesg) Polycab

4. DISPLACEMENT TYPE LEVEL TRANSMITTERSa) Dresser Masoneilanb) Emerson Process Managementc) Magnetrol

d) Yamatakee) Endress & Hauser



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5. ILLUMINATED PUSH BUTTONS

a) EAOb) H & Bc) L & Td) Ronane) Tata Honeywellf) Siemens

6. LEVEL GAUGESa) Chemtrols Engg.b) Levconc) Sigma Instruments co.d) Technomatic (India) pvt. ltd.

e) Teleflo Instruments co. ltd.

7. LEVEL SWITCHESa) Bells Control Ltd.b) Levconc) Magnetrold) Placka

8. POSITION TRANSMITTERa) Endress & Hauser b) Yamatakec) Siemens

d) Gulde

9. PRESSURE INDICATORSa) Bells Controls ltd.b) General Instrumentsc) A.N. Instrumentsd) Gauges Bourdone) Industrial Eqpt. co.f) Waaree Instruments Ltd.g) Odion

10. PRESSURE SWITCHESa) Indfoss (India) Ltd.b) Switzer Instruments ltd.c) Varma Trafagd) A.N. Instrumentse) Waaree Instruments Ltd

11. PUSH BUTTONSa) Honeywellb) Larsen & Toubro ltd.c) Siemens ltd.d) Tele Mechanic

12. RELAYSa) Jyothib) ABB



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c) Paramount

d) Omrone) SIEMENS

13. TEMPERATURE INDICATORSa) G.I.Consortiumb) Bells Controlsc) Waaree instruments ltdd) Dresser-USA

14. TERMINAL BLOCKSa) Phoenixb) Weidmueller

c) Wago

15. MINIATURE CIRCUIT BREAKERSa) Siemensb) ABBc) L & T

NOTES:

Wherever the make is not specified for any item, the Seller shall indicate 2 or 3reputed makes, out of which Buyer shall select any one which is acceptable, suggestan acceptable make. This shall have no price implication.

3.15 ELECTRICAL DESIGN REQUIREMENTS

The scope of work includes Supply, Detailed design, Manufacture, Testing at Works,Transportation to site including freight and insurance charges, Storage at site, Super vision of Erection, Testing and Commissioning of all the Electrical equipment likemotors, junction boxes and other electrical items power and control cablesassociated with the DM plant package as per the specification given below:

Detailed Engineering including but not limited to preparation of equipment-wisedetailed technical specification conforming to relevant IS standards, estimation of billof quantity, Quality Plan, Manufacturing and delivery schedule, Inspection andtesting requirements, packing and transportation requirements, storage and handlingrequirements, documentation requirements, General Arrangement drawings, SLDs,Schematics, Electrical load list containing Rating, Duty, Full load and Starting currentfor motors etc., for procurement and installation of DM Plant package relatedelectrical equipment are included as part of DM Plant package.

All equipments supplied / designed as part of DM plant package shall fully conform tothe latest version of IS standards at the time of placement of order and shall alsoconform to relevant Indian statutory regulations / standards.



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• All Motors associated with DM Plant package (included in the scope of supply of the

selected DM Plant vendor).• Cable carrier system including but not limited to cable trays, bends, cable tray

supports, conduits, fire stops/breaks for Power, control & instrumentation cables inDM Plant area.

• Fire stops are basically fire proof sealing of cable entry into a building or through abarrier wall to prevent spread of the fire from one area/room to the adjacentarea/room. Fire breaks are fire proofing compound coating provided along the run of the cable length at regular intervals (say 10 to 15 meters) to prevent spread of thefire along the cable route within a given area.

• Marshalling boxes, Junction boxes and power distribution boards as required for DM

Plant Package.

• Secondary Earthing of all equipment supplied under DM Plant package.

• All equipments designed / supplied as part of DM Plant package shall meet therequirements of relevant IS standards and local statutory requirements as applicable.

• DC load requirement for DM Plant package equipment to be furnished by Vendor during detailed engineering.

TERMINAL POINTS

The DM Plant Control panel/ Junction box/ Marshalling box will be the terminal pointfor the DM Plant package.

EXCLUSIONS

• Cables and cable carrier system for other than DM Plant package (i.e. frompurchaser's equipment to bidder equipment).

• Primary earthing (Earth pits)

DRIVE MOTORS

• All motors shall be suitable for 380V, ±10%, 3ph, 50 Hz ±5% AC supply.

• The motors being supplied under this contract shall comply with the specification M4-203-01 & the following specific requirements:

• Motors shall be capable of starting and accelerating the load with the applicablemethod of starting without exceeding acceptable winding temperatures, when thesupply voltage is in the range of 80-110% of the rated voltage.

• Motors above 200KW shall be provided with vibration pads on which purchaser will

mount his vibration monitoring device.

• All motors covered under the scope of this specification shall be designed towithstand at least 5% harmonics in supply voltage.



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• The maximum double amplitude vibration for the motors shall be limited to the

following:

• a) For 380V motors with speed upto 1500 rpm - 40 microns

• b) Above 1500 rpm and upto 3000 rpm - 15 microns

• Winding of motors rated above 30 kW shall be provided with space heaters suitablefor 230V, 1Ph, 50Hz AC supply.

• All motors above 2.2 kW shall be delta connected & those motors below 2.2kWshould be star connected. All the six terminal leads shall be brought out in the mainterminal box with shorting strips provided.

• All motors shall be suitable for bi-directional rotation.

• Separate terminal box shall be provided for space heaters, RTD’s & thermistors. Themain terminal box shall be rotatable in four positions at 90deg.

• All motors above 15HP shall be provided with on line greasing facility.

• All motors shall be suitable for restarting against a residual voltage of 40% inopposition to the supply voltage & minimum starts of 3 equally spaced starts per hour or 2 cold starts & 1 hot restart /hour.

• Maximum noise level measured at a distance of 1.0M from the outer surface of anymotor shall not exceed 85 db(A).

• In addition to the data listed under enclosed data sheet for motors, the vendor shallfurnish the following information after the award of contract:

• Negative phase sequence current (unbalance current (I2) withstand capability curvefor large motors.)

• Thermal time constant (Heating time constant) for all motors.

Earthing System

• Secondary Earthing of All equipment covered under DM Plant package specificationshall be in vendor's scope. Only primary earthing (i.e. earth pits / providing risersfrom the main earth grid) will be provided by the purchaser.

SPARES

• BIDDER shall propose a list of recommended spares with recommendedquantity and unit prices for two years trouble free operation for all theelectrical equipment included in their scope.

• BIDDER shall include the price for the following start up and essential

spares In their quoted price for DM Plant.For Motors

(i) Bearing – two sets of each type



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(ii) Cooling fan- one no. of each type.

4.0 Standards & Codes:

4.1 All equipment, system and services covered under this specification shall complywith all currently applicable statutes, regulations and safety codes. Nothing in thisspecification shall be construed to relieve the Seller of his responsibility.

4.2 The standards not indicated in the specification are also acceptable, if they areestablished to be equal or superior to the standards indicated in the specification.

4.3 If the Seller offers equipment and systems conforming to other InternationalStandards than those specified in the specification, the English translation of suchstandards shall be furnished by the Seller. In such a case, if such standards areacceptable to the buyer the stipulations of the English version of the Standards shallalone be binding and not the stipulations in the original language.

4.4 In the event of any conflict between the codes and the standards referred toelsewhere in the specification and the requirements of this specification, morestringent of the two shall govern.

4.5 The indicative list of Codes and standards is furnished below for reference of theSeller

Sr. No. TITLE OF STANDARD1 American National Standard Institute (ANSI)

2 American Society for Testing Materials (ASTM)

3 American Society of Mechanical Engineers (ASME)

3.1 ASME Section I – Code of practice for Power Boiler

3.2 ASME section II (Part A, B and C) - Materials (Ferrous, NonFerrous and filler materials respectively.)

3.3 ASME Section V – code of practice for Non Destructive Testing

3.4 ASME Section VIII – Code of practice for Pressure vessels.

3.5 ASME Section IX – code of practice for Welders’ PerformanceQualifications

3.6 MSS –SP-58859-Hangers and Supports.

3.7 ANSI B 16. 104 – Valve leakages acceptance.

3.8 ASME B16.1Cast iron pipe flanges and flanged fittings, class 25,125,250, 800

3.9 ASME B16.10Face-to-face and end-to-end dimensions of valves

3.10 ASME B16.11Forged steel fittings, socket-welding and threaded

3.11 ASME B16.25Butt welding ends

3.12 ASME B16.28Wrought steel butt welding short radius elbows and returns

3.13 ASME B16.34Valves – flanged, threaded and welding end

3.14 ASME B16.5Pipe flanges and flanged fittings



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3.15 ASME B16.9

Factory-made wrought steel butt welding fittings3.16

ASME B31.1Power piping

3.17 ASME B36.10MWelded and seamless wrought steel pipe

3.18 ASME B36.19MStainless steel pipe

3.19 ASME PTC8.2Centrifugal pumps

3.20 ASME PV CODE 8DIV.1 Pressure vessels – division 1

3.21

ASME PV CODE 9

Welding & brazing qualifications

3.22 ASTM A 105 / A105MSpecification for carbon steel forging for piping applications

3.23 ASTM A 106Specification for seamless carbon steel pipe for high temperatureService

3.24 ASTM A 182 / 182MSpecification for forged or rolled alloy steel pipe flanges, forgedfittings and valves and parts for high temperature service

3.25 ASTM A 193 /A 193MSpecification for alloy steel and stainless steel bolting materials

for high temperature service

3.26 ASTM A 194/A 194MSpecification for carbon and alloy steel nuts for bolts for highpressure or high temperature service or both

3.27 ASTM A 216 / A216MSpecification for steel castings, carbon suitable for fusionwelding or high temperature service

3.28 ASTM A 234 / A234MSpecification for piping fittings of wrought carbon steel and alloysteel for moderate and high temperature service

3.29 ASTM A 312 / A 312MSpecification for seamless and welded austenitic stainless steel

Pipe

3.30 ASTM A 333 / A 333MSpecification for seamless and welded steel pipe for lowtemperature service

3.31 ASTM A 403 / A403MStandard specification for wrought austenitic stainless steelpiping fittings

4EJMAStandards of the expansion joint manufacturers association

5.1EN 287 PT1 Approval testing of welders – fusion welding – steels

5.2EN 288 PT3Specification and approval of welding procedures for metallicmaterials – welding procedure tests for the arc welding of steels

6 American Welding Society ( AWS)



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7 Indian Boiler Regulations (IBR)

8 BS 848 – Fans for general purpose9 National Fire Protection Association (NFPA)

10 Hydraulic Institute Standards (HIS)

11 Heat Exchange Institute (HEI)

12 Tubular Exchange Manufacturer’s Association (TEMA)

13 ASME Power Test Codes (PTC)

13.1 Performance Test codes for fired steam generators (PTC 4)

13.2 Performance Test Codes for Steam Turbines (PTC 6)

13.3 ASME Performance Test Code for Centrifugal Pumps (PTC 8.2)

13.4 ASME Performance Test Code for Feed water heaters (PTC 12.1)

13.5 ASME Performance Test Code for Condensers (PTC 12.2)

13.6 ASME Performance Test Code for deaerator (PTC 12.3)

14 International Organisation for Standardisation (ISO)

14.1ISO – 7919 – Part –2: Land based steam turbines andgenerators in excess of 50 MW with normal operating speeds of 1500 r/min, 1800 r/min, 3000 r/min, 3000 r/min, 3600 r/min

14.2ISO – 10816 – Part 2: Land based steam turbines andgenerators in excess of 50 MW with normal operating speedsof 1500 r/min, 1800 r/min, 3000 r/min, 3000 r/min, 3600 r/min.

15. Deutsche Industrie Normen (DIN)

16. VDI

17. Tariff Advisory Committee (TAC) of India

18. Loss Prevention Association (LPA) of India

19. Indian Standards (IS)19.1 IS 5: Colours for ready mixed paints and enamels

19.2 IS:104: Ready mixed paint, brushing, Zinc Chrome, priming

19.3IS:158: Ready mixed paint, brushing, bituminous, black, leadfree,acid, alkali, water and heat resisting

19.4 IS 277: Galvanised Steel sheets

19.5 IS 702: Industrial Bitumen

19.6IS 803: Code of practice for design, fabrication, erection of vertical mild steel cylindrical welded oil storage tanks.

19.7IS 807: Code of practice for design, manufacture, erection,testing (structural portion) of cranes and hoists

19.8 IS 1239: Mild steel tubes, Tubulars and other wrought steelFittings, specification – Part 1

19.9 IS 1303: Glossary of terms relating to paints

19.10IS:1477: Code of practice for painting of ferrous metals inbuildings (Parts I & II)

19.11 IS 2062: Steel for general structural purposes

19.12IS:2074: Ready mixed paint, air drying, red Oxide Zinc Chrome,Priming

19.13 IS 2266: Steel wire ropes for general engineering purposes

19.14IS:2338:Code of practice for finishing of wood and woodbased materials (Parts I & II)

19.15 IS 2379: Colour code for identification of pipelines

19.16IS:2524: Code of practice for painting of non-ferrous metals in buildings(Parts I & II)

19.17 IS:2395: Code of practice for painting of concrete, masonry



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and plaster surfaces (Parts I & II)

19.18 IS: 2932: Enamel,synthetic, exterior (a) undercoating (b) finishing19.19 IS 3041: Silica Gel

19.20IS:3140: Code of practice for painting asbestos cement buildingProducts

19.21 IS 3588: Electric axial fans

19.22IS 3589: Seamless or electrically welded steel pipes for water gas and sewage (168.3 mm to 2032 mm outside diameter)

19.23 IS 3938: Electric wire rope hoists

19.24 IS 4671: Expanded polystyrene for thermal insulation purposes

19.25 IS 4894: Centrifugal fans

19.26IS 5120: Technical requirements for roto dynamic specialpurpose pumps

19.27 IS 5290: Specification for landing valves

19.28IS 5312: Specification for Swing check type Reflux (Non return)valves for water works purposes – Part –1: Single door Pattern.

19.29IS 7413: Code of practice for application and finishing of thermalindustrial application and finishing of thermal insulation

19.30 IS 7938: Code for Air receivers

19.31IS 8154: Pre formed calcium silicate insulation (for temperaturesupto 650 Deg C)

19.32 IS 8183: Bonded mineral wool

19.33IS 9137: Code of acceptance test for centrifugal, mixed flow andaxial pumps – Class C

19.34 IS 11989: Code for Air driers19.35 IS 13834: Cranes classification.

19.36IS 14164: Industrial application and finishing of thermal insulationmaterial at temperature above –80 Deg C and upto 700 Deg C –Code of practice

19.37IS 14846: Sluice valve for water works purposes (50 mm to 1200mm size) – Specification

20 Underwriter Laboratories (UL) 555 – Fire dampers

21 Oil Industry Safety Directorate (OISD)

22 American Petroleum Institute

22.1 API 617: Centrifugal Compressors for Petroleum, Chemical andGas Service Industry Services

22.2 API 672: Packaged Integrally Geared Centrifugal Air compressors for Petroleum, Chemical and Gas IndustryServices.

23 American Water Works Association (AWWA).

NOTE:The above list of codes and standards is indicative and for the guidance of thepackage. Codes and standards indicated in the respective sections and datasheets shall also be referred for completeness. Seller to indicate any additionallist of codes and standards, which he deems necessary for the design of his

equipment/system.



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5.0 PAINTING

PREPARATION OF SURFACES: All surfaces to be painted shall be thoroughly cleaned of all grease, oil, loose millscale, dust, rust and any other foreign matter. Mechanical cleaning by power tool andscrapping with steel wire brushes shall be adopted to clear the surfaces. However, incertain locations where power tool cleaning cannot be carried out, sand scrappingmay be permitted with steel wire brushes and/or abrasive paper. Cleaning withsolvents shall be resorted to only in such areas where other methods specified abovehave not achieved the desired results. Cleaning with solvents shall be adopted onlyafter written approval of the Engineer

PRIMER PAINT:

After the surface is prepared, one coat of Zinc Phosphate primer conforming to IS:2074 shall be applied. After this first coat is dried up completely, second coat of redoxide primer shall be applied. Primer shall be applied by brushing to ensure acontinuous film without ‘holidays’. The dry film thickness of each coat shall beminimum 25 microns.

FINISH PAINT:Synthetic enamel paint conforming to IS: 2932 shall be used for finish coats. Thecolour/shade shall be as approved by the ENGINEER. After cleaning the dust on thedried up primer, first coat of synthetic enamel shall be applied. After this first coatdries up hard, the surface is wet scrubbed cutting down to a smooth finish andensuring that at no place the first coat is completely removed. After applying second

coat, allowing the water to get evaporated completely, third finish coat of syntheticenamel paint shall be applied.



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SUGGESTED COLOUR CODES FOR PAINTING:

Notes:

1.0 This colour code basically refers to IS: 2379 for piping with necessary modifications

2.0 For any item left out, colour coding will be decided after Buyer’s approval.

SL.NO. ITEM/SERVICE COLOUR IS-5 COLOUR(BAND)

IS-5

1.0

Structures,platforms, galleries,ladders andhandrails

Dark Admiralty

Grey632

2.0Fans, pumps,motors,compressors

Light Grey 631

3.0

Tanks (without

insulation andcladding)

a. Outdoor Aluminium - - -

b. Indoor Light grey 631 - -

4.0

Vessels & all other proprietaryequipment (withoutinsulation &cladding)

Light grey 631

5.0 Switchgear

Light grey

(Powder coated)

6.0Control & relaypanels

Light grey(Powder coated)

631/7078 of IS1650

7.0 Machinery guards Signal red 537

8.0 Water

a. D M Water Sea green 217 Light orange 557

b.Bearing coolingwater

Sea green 217 French blue 166

c.Potable & filteredwater


d. Service &clarified water


e. Raw water Sea green 217 White -



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6.0 DELIVERY

The delivery of all the materials covered under this specification shall be for HPMLand as per the address mentioned in the LOI/ Purchase Order. The delivery period is 4 months from the date of placement of order/Issue of LOI.Unless requested by Buyer, Seller shall dispatch material with all its attachments,documents etc as a single lot with logical identification of packing.

All material shall be packed suitable for prevention of damage during transit anddeterioration during storage.

7.0 WORKMANSHIP AND PERFORMANCE GUARANTEE

PERFORMANCE TESTS

7.1 Upon the completion of ‘Reliability (Trial) Operation’ and issuance of ‘ProvisionalTaking Over Certificate’ by the Buyer, or at such time as may be otherwise mutuallyagreed to by the parties concerned, the Seller shall notify in writing to theBUYER/PROJECT MANAGER / CONSULTANT that the DM Plant Package is readyfor performance tests but only after liquidating all the major and minor defects.

7.2 The performance tests shall be conducted at site for the Package including all major equipment and systems supplied by the Seller. The Sellers commissioning Engineersshall make the Package ready for such tests and assist the Buyer in operation during

the tests. The test will be commenced after the ‘stable operation has been attained atthe end of ‘Reliability operation’. The date of commencement of the performancetests shall be as soon as practicable on completion of the ‘reliability operations’ or asmay be mutually agreed upon between the Seller and Buyer.

7.3 The performance test instruments shall be of precision type with instrumentaccuracy limits as required and defined in the applicable performance test codessuch that measurement uncertainty does not exceed the values agreed to by theSeller in the Schedule of Performance Guarantees. The performance testsshall be carried out as per test codes agreed in schedule of performanceguarantees.

7.4 All test instrumentation for the performance tests as required shall be supplied by theSeller on loan basis. All costs associated with the supply, calibration, installation andreturn of the test instrumentation / data loggers / computers etc. are deemed to havebeen included in the contract price. The test shall be in accordance with thosespecified or as per agreed performance test codes. Batch calibration will not beaccepted.

7.5 Any special equipment, tools and tackles required for successful completion of theperformance tests shall be provided by the Seller.

7.6 Reporting Of Test Results

The report (s) shall include as a minimum, the following:i. Description of the test proceduresii. Standards that were used



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iii. Instrumentation details and calibration

iv. Full schematic diagrams with indication of instrument test location andidentification tag of same.v. Test logs and summary of test readings used for performance calculationsvi. Full set of correction curvesvii. Computation of test results.viii. Computations to prove measurement uncertainty is within acceptable limits.ix. Conclusions of performance tests : test passed or not

8.0 HSE REQUIREMENTS

Pollution

The Seller shall offer a plant so as to meet the pollution control requirements of statutory authorities. Emissions and discharges of solid, liquid, gaseous and other effluents from the area of the Sellers scope of work shall fully comply with allrequirements and limits specified in Environmental (Protection) Act, 1986, MinimumNational Standards (MINAS), along with all latest amendments to all of the aboverequirements, stipulations of the Gujarat Pollution Control Board (GPCB) and Ministryof Environment and Forests (MoEF) and any other central or local statutoryrequirements regarding environmental pollution and its abatement. The hazardouswaste material handling and disposal plan shall be submitted by the Seller as per thepollution control board norms.

Noise Contro l

The criterion for environmental noise is that the design of the station and itscomponents shall not exceed, in any continuous mode of operation, the levelstipulated by MoEF and/or Pollution Control Board at any point on the site boundary.Presently the norm is such that the noise level shall not exceed 85 dBA at 1.5 m fromthe equipment surface and 50 dBA at the plant boundary.

DM Regeneration WastesRegeneration waste be collected and treated in neutralizing pit and shall bedischarged to ETP

All monitoring equipment shall be handed over to the Buyer after Commissioning.



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9.0 DOCUMENT TO BE SUPPLIED

The Seller shall furnish a comprehensive and detailed schedule of drawings anddesign documents, which shall be submitted by him after award of Contract indicatingsubmission dates against each document.

The list shall be subject to the approval of the Buyer.

The documents shall be divided into two categories:For approvalFor information / reference only

SL.NO.

DESCRIPTION APPROVAL(A)/INFORMATION(I)

I GENERAL

1.0 Project network schedule A

2.0 Monthly progress report I

3.0 Equipment list I

4.0Detailed painting specification including colour code scheme. This shallcontain surface treatment, coating, thickness, colour, type and brand of paint for all equipment required at shop and at the site.

A

II MECHANICAL EQUIPMENT/PIPING SYSTEMS

1.0 Detailed piping layout drawings (plan and section) A

2.0 Piping bill of materials (system wise) A

3.0Loading plan drawings indicating pipe load intensities and concentratedloads (magnitudes and locations)

A

4.0Catalogues for valves & specialties, hangers and supports and shockabsorbers

I

5.0 Line sizing calculations including pressure drop Calculations A

6.0 Valve & specialties list A

7.0 Piping schedule A8.0 Detailed data sheets for valves & specialties. A

III WATER SYSTEMS

1.0 Water balance diagram A

2.0 General arrangement (GA) A

3.0 Flow diagrams / PIDs

4.0 Technical specification for all major equipment A

5.0Performance / Characteristic curves for all pumps, fans, butterfly valves,etc

I

IV QUALITY , INSPECTION , SHOP AND SITE TESTING

1.0Quality assurance plan for all the systems/ equipments/ componentsincluding materials

A

2.0 Preliminary and final shop test schedule for all the systems/ equipment/ I



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components.

3.0 Material test certificates and performance test certificates for allequipment tested at works. I

4.0Procedure for tests before taking-over which shallinclude performance guarantee tests, unit characteristic test , reliabilitytest etc.

A

5.0Inspection test reports including test certificates as called for in qualityassurance plan for all the systems/equipment/ components.

I

V OPERATION AND MAINTENANCE MANUALS

1.0Operation and Maintenance manuals for all the systems/ equipment/components of the plant.

I

VI AS BUILT DRAWINGS / DOCUMENTATION I

Documents submitted during bid stage, shall be revalidated or revised as requiredand submitted as certified document for approval / information of the Buyer.

System schematic drawings, pipeline and instrumentation diagramsDesign basis reportsSpecification for major bought-out itemsEquipment data sheets and general arrangement drawingsMaterials for constructionLayout drawingsOperation logic diagramsTypical control circuitsProtection schemes

Quality assurance Plans

The Seller shall submit to the Buyer instruction manuals for all equipment coveredunder the contract at least thirty (30) days before the first shipment of the equipment.

In addition, the Seller shall provide at least six (6) months before the time of commissioning and before taking over of the plant and equipment, a consolidatedmanual for the complete plant detailing out instructions for operation andmaintenance.The operating manuals and maintenance instructions manual shall besubmitted in the form of one (1) original and adequate copy (hard bound) as well astwo (2) copies in compact disks (CDs). The instruction manuals shall be subject to

approval of the Buyer.

If after the commissioning and the initial operation of the plant, the instructionmanuals require modifications / additions, the same shall be incorporated by theSeller and the updated final version of the manuals shall be submitted.

The Seller shall submit to the Buyer, a preliminary plant handbook which shallcontain all approved design basis and design calculations, the design andperformance data of various plant, equipment and systems covering the completeproject including single line flow diagrams,

“As-built” Documentation

The Seller shall provide and keep up to date “As built drawings of all structuresconstructed and all equipment and accessories and miscellaneous metal workserected or installed. These drawings shall show all changes and revisions from theoriginal drawings and specifications, including the exact “As-built” locations, sizes



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and kind of equipment and accessories, miscellaneous metal works, embedded

piping and electrical systems and other concealed items of work. These drawingsshall be kept in Seller’s field office but shall be made available at all times for reviewof the BUYER. At the end of every work, all entries, changes or revisions made in thedrawings by the Seller shall be checked and approved by the Engineer. Reproducibleprints with requisite copies of all “As-Built” drawings shall be progressively handedover to the Buyer after taking over of the plant by the Buyer. In addition, all the as-built drawings / documents shall be submitted to the Buyer in the form of CDs.

Seller shall note that document as per Annexure III are required for consideringthe evaluation of o ffer.

The technical data sheet (Annexure V) is mandatory for considering the

evaluation of the offer



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Annexure I

SITE CONDITIONS

Following site conditions shall be borne in mind during designing / fabrication of

equipment / units as well as erection and commissioning and testing.

The meteorological details of the site shall be indicated below.

Temperature

Mean yearly Temperature : 26.6 ºC

Maximum Absolute Temperature : 45.6 ºC

Mean Yearly maximum daily Temperature : 42.3 ºC

Mean Yearly minimum temperature : 10.9 ºC

Rainfall

Maximum rainfall in 24 hours : 459mm

Avg. annual rainfall : 1,203.5mm

Seismic Zone : Zone-III, IS 1893 part 1&4

Wind

Predominant wind Direction : South to West

Avg. speed : 12.2 Km/h



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Annexure II

FORMAT FOR DEVIATION FROM TENDER DOCUMENT

Sl.No.

Clause No. Tenderer’s Deviations Reason for Deviation

We hereby certify that the above mentioned are the only deviations from the tender documents.

Signature :

Name :

Designation :

Company seal



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Annexure III

TENDER QUALIFICATION CRITERION

Attached Separately

Annexure IV

OVERALL SUPPLY & IMPLEMENTATION SCHEDULE

SI.No.

WORK DESCRIPTION WEEKS FROMStart Fish

1.0 Design & Engineering

2.0 Equipment Manufacture

A Structural (for items fabricated at works)

B Mechanical

C Bought out items

i) Ordering on sub vendors

ii) Manufacturing schedule & progressstatus

iii) Delivery

3.0 Equipment delivery at site

A Structural (for items fabricated at works)

B Mechanical



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Annexure V

TECHNICAL DATA SHEETS TO BE FILLED UP BY SELLER

1.0 Activated Carbon filter

a) Size of each unit (dia. x HOS) m x m

b) Design flow rate (gross) m3/hr

c) Pressure drop across the unit inclusive of frontal piping, fittings, valves & instruments

i) Clear condition kg/cm2

ii) Design flow rate (gross) kg/cm2

d) Backwash flow rate m3/hr

e) Air blower’s capacity and discharge pressure m3/min/kg/cm2

f) Design Pressure kg/cm2

2.0 Strong Acid Cation Units

a) Size of each unit (dia x HOS) m x m


c) Gross output between regenerations m3

d) Productive output between regenerations

i) Base offer m3

ii) Alt offer m3

e) Resin make & models

f) Resin quantity per unit lit

g) Type of regeneration

h) Regeneration level kg/ m3

i) Derated exchange capacity kg/ m3

j) Quantity of 30% HCl/unit/regeneration m3



HAZIRA PIPE MILL

LIMITED

0.6 MTPA,PIPE PLANT


TSP NO: 1010460000TSP45H003-R00



3.0 Degasser Unit

a) Size of each unit (dia c HOS) m x m


c) Size of degassed water tank (diaxHOS) m x m

d) Degassed water pumps

i) Capacity / pump m3/hr

ii) Head mlc

e) Degasser air blowers

i) Capacity / blower m3/min

ii) Discharge pressure kg/cm2

4.0 Strong Base Anion Units




d) Productive output between regenerations

i) Base offer m3

ii) Alt offer m3






j) Quantity of 48% NaOH/unit/regeneration m3



HAZIRA PIPE MILL

LIMITED

0.6 MTPA,PIPE PLANT


TSP NO: 1010460000TSP45H003-R00



5.0 Weak Base Anion Units




d) Productive output between regenerations m3

i) Base offer m3

ii) Alt offer m3






j) Quantity of 48% NaOH/unit/regeneration m3

k) Bidder to indicate details of layered bedvessel if in case the option is offered

6.0 Mixed Bed Units




d) Productive output between regenerations m3

i) Base offer m3

ii) Alt offer m3


i) Cation resin lit

ii) Anion resin lit

f) Resin Quantity per unit

i) Cation resin lit





HAZIRA PIPE MILL

LIMITED

0.6 MTPA,PIPE PLANT


TSP NO: 1010460000TSP45H003-R00



DATA SHEETS FOR PUMPS

SL.NO. ITEMS UNIT BIDDER

1. Designation

2. Number offered

3. Design capacity m3/hr.

4. Differential head mlc

5. Shut-off head mlc

6. Hydrostatic test pressure kg/cm2 (g)

7. Number of stages

8. Pump efficiency at duty point %

9. Pump speed rpm

10. Pump BKW (KW)

11. Power input to driver at duty point kW

12. NPSH required mlc

13. Driver efficiency %

14. Suction nozzle

15. Size mm

16. Discharge nozzle

17. Size mm

18. Type of coupling

19. Minimum capacity for continuous

operation m3/hr.

20. External water requirement for sealing

& cooling Required.

21. Weight of bare pump kg

22. Weight of driver kg

23. Weight of common base plate kg

24. Moment of inertia of pump rotor kg-m2



HAZIRA PIPE MILL

LIMITED

0.6 MTPA,PIPE PLANT


TSP NO: 1010460000TSP45H003-R00


Annexure – VI

FEED WATER QUALITY

S.NO PARAMETERS UOM

CLARIFIED WATER

FEED TO DM

1 TEMP Deg Cent 25-30

2 PH 7.6 – 8.33 CONDUCTIVITY at 25 Deg.Cel Micro mho / cm 550

4 TURBIDITY NTU 40

5 TOTAL SUSPENDED SOLIDS PPM 40

6 TOTAL HARDNESS AS CaCO3 Mg/l 150

7 Ca HARDNESS AS CaCO3 Mg/l 75

8 Mg HARDNESS AS CaCO3 Mg/l 75

9 CHLORIDES AS Cl Mg/l 55

10 TA AS CaCO3 Mg/l 100

11 FREE CHLORINE AS CI Mg/l 0.3

Note-- Plus 10% design margin shall be added on above Ionic load(Feed water)

for Design

Annexure VII

DM Water Quality

Feed Water Quality to DM pH 6.8-7.2

Conductivity@25DegC < 1 μS/cm

Hardness Nil

Total alkalinity <1 mg/l

Chloride <1 mg/l

Sulphate <1 mg/l