tce pg 72 Vol III A

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

(APPDCL)

2X800 MW COAL FIRED POWER PLANT

NEAR KRISHNAPATNAM, NELLORE DIST.,

ANDHRA PRADESH, INDIA

STEAM GENERATORS & AUXILIARIES SPECIFICATION

VOLUME – III

TCE CONSULTING ENGINEERS LTD 73/1, ST. MARK’S ROAD

BANGALORE 560 001 INDIA

November 2007

MAIN PLANT & AUXILIARIES SPECIFICATION

STEAM GENERATORS & AUXILIARIES

VOLUME – IIIA

SPEC. NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD VOLUME IIIA

TCE.5103A-C-510-01

2X800 MW TPP NEAR KRISHNAPATNAM

STEAM GENERATORS AND AUXILIARIES

CONTENTS

SHEET 1 OF 3

TCE FORM 329 R3

ISSUE

R0

VOLUME – III A – CONTENTS

SECTIO

N NO.

SPECIFICATION NO. REV

.NO.

TITLE NO. OF

SHEETS

D1 TCE.5103A-C-510-01 R0 MECHANICAL DESIGN REQUIREMENTS

D1.1 TCE.5103A-C-510-01 R0 SG & AUXILIARIES – DESIGN REQUIREMENTS

17

D1.2 TCE.5103A-C-510-01 R0 SPECIFIC PIPING REQUIREMENTS 15

D2 TCE.5103A-C-500-01 R0 I & C DESIGN REQUIREMENTS 107

D3 TCE.5103A-C-500-01 R0 ELECTRICAL DESIGN REQUIREMENTS 10

DATA SHEETS A R0

A1 TCE.5103A-C-500-01 R0 DESIGN PARAMETERS OF SG AND AUXILIARIES

5

A2 TCE.5103A-C-500-01 R0 UTILITY REQUIREMENTS 1

A3 TCE.5103A-C-500-01 R0 STEAM GENERATOR PRESSURE PARTS 1

A4 TCE.5103A-C-500-01 R0 REGENERATIVE AIR PREHEATER 1

A5 TCE.5103A-C-500-01 R0 CENTRIFUGAL FANS 1

A6 TCE.5103A-C-500-01 R0 AXIAL FANS 1

A7 TCE.5103A-C-500-01 R0 SOOT BLOWING SYSTEM 1

A8 TCE.5103A-C-500-01 R0 COAL BURNERS 1

A9 TCE.5103A-C-500-01 R0 COAL MILLS 1

A10 TCE.5103A-C-500-01 R0 FUEL OIL BURNERS AND IGNITORS 1

A11 TCE.5103A-C-500-01 R0 FUEL OIL PUMPS 1

A12 TCE.5103A-C-500-01 R0 ELECTROSTATIC PRECIPITATOR 2

A13 TCE.5103A-C-500-01 R0 DUCT & DAMPERS 1

A14 TCE.5103A-C-500-01 R0 CHAIN PULLEY BLOCK (HAND OPERATED) 2

A15 TCE.5103A-C-500-01 R0 ELECTRICALLY OPERATED HOISTS 2

A16 TCE.5103A-C-500-01 R0 POWER PLANT PIPING & VALVES 9

A17 TCE.5103A-C-500-01 R0 STRAINERS 2

A18 TCE.5103A-C-500-01 R0 SHELL AND TUBE HEAT EXCHANGERS 2

A19 TCE.5103A-C-500-01 R0 THERMAL INSULATION FOR HOT SURFACES 2

A20 TCE.5103A-C-500-01 R0 FLASH TANK 1

A21 TCE.M4-203-01 R8 INDUCTION MOTORS

5


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CONTENTS

SHEET 2 OF 3

TCE FORM 329 R3

ISSUE

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A22 T CE.M4-203-02 R8 INDUCTION MOTORS -ADDITIONAL REQUIREMENT FOR HT MOTOR

5

A23 TCE.M4-203-11 R7 D.C. MOTORS

3

A24 TCE.M4-203-06 R4 MOTOR OPERATED VALVE ACTUATORS

6

A25 TCE.M4-219-01 R7 CONTROL CABINETS

2

A26 TCE.M4-219-11 R6 LOW VOLTAGE SWITCH GEAR

6

A27 TCE-M4-203-71 R1 VARIABLE SPEED DC/AC DRIVES 9

DATA SHEETS B

B1 TCE.5103A-C-510-01 R0 STEAM GENERATOR PERFORMANCE DATA 11

B2 TCE.5103A-C-500-01 R0 HEAT RELEASE AND OTHER DATA 3

B3 TCE.5103A-C-500-01 R0 STEAM GENERATOR PRESSURE PARTS 5

B4 TCE.5103A-C-500-01 R0 REGENERATIVE AIR PRE HEATER 3

B5 TCE.5103A-C-500-01 R0 STEAM COIL AIR PRE HEATER 2

B6 TCE.5103A-C-500-01 R0 CENTRIFUGAL FANS 2

B7 TCE.5103A-C-500-01 R0 AXIAL FANS 2

B8 TCE.5103A-C-500-01 R0 SOOT BLOWING SYSTEM 3

B9 TCE.5103A-C-500-01 R0 FUEL OIL BURNERS AND IGNITORS 2

B10 TCE.5103A-C-500-01 R0 COAL BURNERS 2

B11 TCE.5103A-C-500-01 R0 COAL MILLS 3

B12 TCE.5103A-C-500-01 R0 ROTARY GEAR/SCREW PUMPS 2

B13 TCE.5103A-C-500-01 R0 FUEL OIL HEATERS 2

B14 TCE.5103A-C-500-01 R0 AIR AND FLUE GAS DUCTS AND DAMPERS 2

B15 TCE.5103A-C-500-01 R0 ELECTROSTATIC PRECIPITATOR 7

B16 TCE.5103A-C-500-01 R0 INSULATION/REFRACTORY 2

B17 TCE.5103A-C-500-01 R0 SEPERATOR DRAIN RECIRCULATION PUMPS

1

B18 TCE.5103A-C-500-01 R0 ATMOSPHERIC DRAIN TRANSFER PUMP 1

B19 TCE M4-105-01 R10 HORIZONTAL CENTRIFUGAL PUMPS 1

B20 TCE.5103A-C-500-01 R0 DRAWING AND DETAILS 3

B21 TCE.M4-113-54 R5 ELECTRICALLY OPERATED HOISTS 3


TCE.5103A-C-510-01



CONTENTS

SHEET 3 OF 3

TCE FORM 329 R3

ISSUE

R0

B22 TCE.5103A-C-500-01 R0 FOUNDATION LOADING AT COLUMN BASES 1

B23 TCE-M4-219-11 R6 LOW VOLTAGE SWITCHGEAR 8

B24 TCE-M4-203-06 R4 MOTOR OPERATED VALVES ACTUATORS 2

B25 TCE-M4-203-11 R7 D.C. MOTORS 2

B26 TCE-M4-203-71 R1 VARIABLE SPEED DC/AC DRIVES 4

B27 TCE-M4-219-01 R1 CONTROL CABINETS 1

B28 TCE-M4-203-01 R8 INDUCTION MOTORS 5

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

2 X 800MW TPP NEAR KRISHNAPATNAM

VOLUME IIIA

TCE-5103A-C-510-01

STEAM GENERATORS & AUXILIARIES SECTION D1.1 SHEET 1 OF 17

ISSUE R0

CONSULTANTS: TCE Consulting Engineers Limited TCE FORM NO. 329 R4

1.0 MECHANICAL DESIGN REQUIREMENTS General 1.1 The steam generator shall be designed for maximum continuous rating

(SGMCR capacity) as specified in Data Sheet- A1. Bidder shall offer super critical pressure type once trough steam generators of proven design.

1.2 The steam generators and its auxiliaries shall be designed for outdoor

installation. 1.3 The steam generator unit shall be capable of operating on sliding pressure

/modified sliding pressure mode. The load range for the sliding pressure unit operation shall be from 40% steam generator maximum continuous rating (SGMCR) to 100% TGMCR. However it shall also be possible to operate the steam generator with modified sliding pressure mode, with constant pressure mode operation between 90% TGMCR to 100 % SGMCR.

1.4 Steam generator shall be designed to meet the Indian Boiler Regulations

(IBR) requirement. Wherever IBR is not specific about material, design, manufacture, inspection and testing requirements, ASME or equivalent reputed international code shall be used.

Steam Generator Structure

1.5 The steam generator structure shall be designed to support all loads located on the structure including the load transferred from the furnace buck stays, seismic and wind loads. In addition, other loadings may be introduced on the structure from piping, enclosures, adjacent structures and equipment.

Furnace

1.6 The furnace shall be designed such that the heat release rates shall not exceed the values specified in Data Sheet-A1 of Vol III. The distance between centre line of bottom most coal burner and furnace hopper working point shall be not less than 3 meters. The configuration of the furnace shall be such that flame impingement on any section of the furnace is avoided over the entire load range.

1.7 The furnace shall be designed for a pressure as indicated in Data sheet-A1,

to withstand pressure regimes without permanent deformations. The furnace shall be made of gas tight welded membrane walls and the tube panels bent, where required for openings of wall blowers, observation ports, access doors and instruments. To minimise the wear of membrane walls, geometry that causes notch effect shall be avoided.

1.8 The furnace walls shall be either spiral wound and vertical tubes or vertical

rifle tubes, as per the manufacturer’s practice. Bending radius for tubes shall be as large as possible and minimum 1.5 times of external diameter.

1.9 The furnace shall have hopper bottom with stainless steel seal plates suitable

for connection to an ash hopper. A suitable sealing arrangement shall be



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provided for connecting to water impounded wet type bottom ash hopper. The clear width of the hopper throat shall not be less than 1100mm. The elevation of hopper bottom shall be not less than 9.0 m from ground level.

1. 10 All openings of wall blowers, observation ports, access doors and

instruments shall be designed to prevent infiltration of air into the unit. Casing

1. 11 A gas tight enclosure shall be designed for the entire steam generator from the lower furnace to the economiser exit. In areas where welded wall construction is used, no skin casing is required, but skin casing of steel plates shall be used for all enclosures and behind all wide spaced tubes where refractory is used. Frames shall be furnished around all openings in the steam generator, designed to allow for expansion between the welded wall or inner skin casing and an outer aluminium lagging.

Furnace Wall Evaporator and Steam System 1.12 The system shall be designed for a continuous operating capability as

specified in Data Sheet-A1 of Vol III. Bidder shall clearly bring out the design features that individual evaporator tubes to have uniform temperature distribution, to minimize the peak tube metal temperature, unit temperature variation between adjacent enclosure tubes and prevent departure from nucleate boiling in evaporator sections. The Bidder shall also indicate about the precautions to be taken.

1.13 The furnace wall system shall be of materials specified in the Data Sheet- A3

of Vol III. The Bidder shall enclose a calculation sheet for tubes, pipes and headers, stating dimensions, material, tolerance, design pressure and design temperature, design tension, operating pressure and operating temperature as well as fatigue factors and necessary wall thickness either with the bid or at contract stage.

1.14 The furnace wall system shall be made of seamless tubes. A careful and safe

fixing and suspension of tubes and tube banks shall be available to prevent misalignment and rubbing during operation. Design details shall be included in the Bid document.

1.15 Suitable allowances shall be provided for all the water wall tubes and steam

tubes to counter the erosion conditions. 1.16 The furnace support system shall be so designed to transfer the weight of the

entire furnace to the structural steel so as to accommodate inherent movement and expansions during operation without imposing any constraints. Further, construction of furnace walls shall be no way create differential thermal expansion on the furnace wall tubes. The bidder shall furnish details of furnace support system including systems of transfer of furnace wall loads and construction of steam generator support system in his bid.



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1.17 The furnace walls shall be equipped with buck stays arranged at suitable spacing to take up the forces due to positive and negative gas pressure expansions. The furnace buck stays design pressure shall be as specified in Data sheet A1 of Vol III.

Separators , Storage Tank and Circulating Pumps

1.18 A water–steam separator system shall be provided with an adequately

dimensioned collecting vessels and cyclone separators for use during steam generator start- up and low loads.

1.19 The water / steam separators shall be arranged at the evaporator outlet and

shall be so sized to ensure adequate steam separation. The water /steam mixture shall be fed into the separators by connecting pipe work which shall enter tangentially around the circumference at an inclined angle to ensure mixture moving spirally downwards and the water/steam separation is done by means of applied centrifugal force .The water shall be led downwards to the collecting vessel and the steam escapes centrally upwards to the connections towards the first superheater stage.

1.20 A certain water level shall be maintained in the collecting vessel during low

load operation and the surplus water volume must be drained off. The draining of the water shall be controlled.

1.21 The water received in the separators shall be re-circulated to the economizer

inlet via 1X100 % glandless hermitically sealed re-circulation (start up) pump .The water level in the collecting vessel shall be maintained by the provision of control valve(s) at the outlet of the re-circulation pump. Suitable arrangement shall be incorporated to provide adequate NPSH to the pump under all operating conditions during operation. At higher loads the re-circulation pump shall not be in operation and the entire flow from the evaporator is directed to the superheater. It shall also be possible to start the steam generator without the re-circulation pump.

1.22 The bidder shall provide detail construction features of the re-circulation

pumps offered. 1.23 To assure the adequate cooling of the furnace tubes of the evaporator during

start-up or in low load operation, a minimum flow rate of approximately 40 % TGMCR shall be maintained.

1.24 Since during the normal operating range the separator and the associated

system are not in operation, an appropriate warm- up system shall be provided to switch over to the operation with separators, in case of such requirements.

1.25 Bidder shall furnish complete details of start- up and low load operation

system with separators and drain system and shall also provide detailed flow diagrams/ P & I diagrams for the system offered.



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Atmospheric Flash Tank 1.26 To facilitate start-up of the steam generator, an atmospheric flash tank shall

be provided. The flash tank shall receive excess water from the separator during start-up. The flashed steam shall be led to the atmosphere through a silencer above the boiler roof and the remaining condensate shall be led into a condensate collection tank. The condensate from the condensate collection tank shall then be transferred to the condenser by the provision of 2X100% condensate transfer pumps for minimizing the make-up water requirement.

1.27 The flash tank shall also receive other start-up drains from :

a) Economiser system b) Superheater system c) Reheater system d) Soot blower system e) Oil heating system f) Mill steam system

1.28 The flash tank shall be adequately sized to take care of the total drain in the complete steam generator and power cycle piping system.

Superheater(SH) and Reheater (RH) 1.29 The superheater and reheater shall be of proven design and shall be

designed to maintain superheat and reheat steam temperatures at superheater and reheater outlet over the entire steam temperature control range (i.e. from 40% SGMCR to 100% SGMCR rating for SH and 60% TGMCR to 100% SGMCR rating for RH ) under the following conditions:

- With the steam generator heat absorption surface condition varying

from clean up to normally expected and permissible fouling limits. - With minimum possible use of de-superheating spray. - With permissible and normally expected unbalance or stratification in

flue gas flow. - With all specified mode of fuel burning.

1.30 Only the proven material for long periods of operations for the required

pressure and temperature conditions shall be adopted. Suitable allowances in tube thickness shall be provided considering erosion due to fly ash, laden flue gas. Bidders shall furnish satisfactory explanations with the list of experience for the materials of construction of SH and RH tubes used.

1.31 Clearances between the tube elements shall be convenient for cleaning and

maintenance. 1.32 For horizontal tube bundles the arrangement shall be such as to permit free

expansion without constraints.



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1.33 The superheater and reheater elements shall be arranged to ensure the uniform steam distribution and minimum steam temperature variation across the width of the steam generator at all operating conditions and loads. Bidder shall indicate the expected temperature variation.

1.34 The attemperators are to be of spray type fitted with an inner removable

lining, so arranged that the lining could be removed readily without recourse to extensive cutting of the construction welds. Ample provision shall be allowed to enable internal inspection of the vessel by means of the intrascope. Complete superheater and reheater temperature control system with necessary piping, block, control, isolation, drain, vent, check valves and instrumentation and controls shall be provided.

1.35 In case of RH temperature control is by means of damper control of the flue

gases or gas recirculation, the bidder shall furnish list of such installations where the systems installed by the Bidder are in operation.

1.36 The superheater and reheater supports or hangers exposed to hot gases

within the setting shall be of a heat-resistance material suitable for long life under the service condition.

1.37 Auxiliary steam tap-off connection for soot blowing shall be either from

intermediate superheater header or from cold reheat line or from auxiliary steam header. In case the steam is tapped off from the cold reheat line or from auxiliary steam header, CONTRACTOR shall furnish a list of installation where such systems are in vogue and also the same shall be reflected appropriately in the turbine cycle heat balance diagrams. Suitable allowance shall be provided for the super heater and reheater tubes to counter the erosion condition.

Economiser 1.38 It shall be ensured that the economiser design pressure exceeds the steam

generator design pressure by an amount of at least equal to the pressure drop (friction and static) through the economiser at the 100% SGMCR condition.

1.39 The economiser shall be of non-steaming and bare tube type. The tube

banks shall be of in line design. The design of the economiser shall be such that the tube elements can be easily replaced when necessary. Suitable allowance shall be provided for economizer tubes to counter the erosion. In order to achieve high boiler availability, all tubes in the economiser, HP superheaters and reheaters shall be easily replaceable. Bidder shall submit the procedure for the replacement for the PURHSER/ENGINEERS review during detailed engineering stage.

Headers

1.40 All headers in high temperature gas path shall be located outside the gas path.



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1.41 The header vents, drains, pressure gauges, water and steam safety valve connections shall be of weld-end type. Instruments as required including test connections shall be provided.

1.42 All headers shall be thoroughly cleaned and be free of scale by shot blasting

inside. All connections of pipes to headers for field welding shall be made by means of welding transition piece between headers and piping. In case pipe and header end covers are of flat type design, end cover thickness and welding should be considered appropriately and bidder shall obtain prior approval from the PURCHASER/ENGINEER.

1.43 All valves that require operation during start-up or shutdown of the steam

generator shall be electric motor operated, except as specifically stated otherwise. All motor actuators shall be designed to meet the torque requirement due to maximum differential pressure. In addition to these motorised valves, any other service which calls for motor operation shall be motorised and those motorised valves shall be listed in the bid.

1.44 Drains from all headers shall be fed to the atmospheric flash tank. 1.45 Field welds in large diameter thick walled headers or pipes shall be avoided

to the extent possible 1.46 Preservation of SG either by N2, dry air or treated water shall be considered

by the Bidder.

1.47 The requirement of dry air / treated water and its qualities for filling shall be indicated in the Bid. The preservation system shall include all the piping, valves, vents and drains, pipe supports and instruments etc to make the system complete.

Air and Flue Gas System 1.48 The air and flue gas system shall be designed to meet the requirements of

100% SG MCR conditions and for the fuels specified in Project Information in Section B, Volume II. The entire flue gas system including the SG flue gas passes shall cope with explosions and/ or implosions, which might occur even at typical or extreme conditions.

1.49 The air and flue gas system shall consist of two (2) 50% capacity FD fans of

axial blade pitch controlled, two (2) 50% capacity PA fans of axial blade pitch controlled, two (2) 50% capacity centrifugal ID fans with variable frequency drives and inlet guide vane control or axial fan with blade pitch control mechanism. 2 x 50% capacity trisector regenerative air preheater (RAPH), with associated drive motors, cold air, hot air, tempering and flue gas ducting and dampers to handle the steam generator requirements. Alternatively BIDDER may offer 2x50% bisector RAPH for primary air system and secondary air system separately. The air preheater shall be provided with air motors with air receiver for coasting down operation. The air receiver capacity shall be such that during black out condition the air receiver shall be



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able to supply adequate air for safe shutdown of RAPH. Bidder shall make provision for installing the 2X50% steam coil air preheaters (SCAPH) in the bypass air duct so that same can be installed, if required, in future.

1.49.1 The air preheaters shall be of regenerative type with vertical main shaft,

counter flow, enclosed in a gas tight insulated casing. The design shall ensure that the air preheaters shall be capable of operating for extended periods of time without blockage of flow areas between heating element plates.

1.49.2 All the element sections shall be basketed with cold end elements suitable for replacement.

1.49.3 Provision shall be made for ease of adjustment of seals externally without need for working from inside.

1.49.4 An adequate number of access doors for inspection and maintenance and observation ports with vapour proof lighting shall be provided.

1.49.5 The structure shall be strong and light in weight and shall be sufficiently flexible to operate without difficulties under conditions of large temperature gradients through the rotor in the axial direction.

1.49.6 The heat transfer plates used in different layers shall be of differing material combination depending upon suitability to withstand extremes of temperature condition. Use of corrosion resistant materials shall be considered to avoid corrosion at the back end.

1.49.7 A suitable structural steel framing for handling the heater element basket shall be provided. This shall include a trolley beam extended beyond the platform to enable lowering of elements to the ground floor. A hoist and trolley shall also be furnished.

1. 49.8 The air heater design shall be such that on-load cleaning by suitable steam soot blower is feasible. The location of the blower shall be on the flue gas side. For off-load cleaning, water washing spray nozzles on an extended fixed arm on both hot and cold ends shall be provided. The locations can be either on air or flue gas side.

1.50 The general design requirements for the fans shall be as follows : 1. 50.1 The rotor shall be over speed tested at least 10% above maximum

operating speed and shall be dynamically balanced. The fan shafts are to be supported in bearings on either side independent of the casings.

1. 50.2 All constants speed fans shall be designed for under frequency operation

upto 47.5 Hz without any reduction in its performance. 1. 50.3 Forced oil lubrication system (if offered) for the fans and motors shall consist

of 2 x 100% oil pumps each with motor, 2 x 100% oil coolers and filters; one (1) oil tank and electric heater with thermostat etc.



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1. 50.4 Flow induced pulsation should be avoided by suitable design of fan and

connecting duct work. 1. 50.5 Suitable design of shaft sealing shall be provided to prevent ingress of

atmospheric air. 1.51 Each bearing is to be provided with oil pressure indicator and a screwed

drain plug. Adequate sealing arrangement shall be provided at each end of the bearing housing to prevent leakage of lubricating oil.

1.52 Silencer shall be provided at the inlet of FD and PA fans with weather hood

and inlet screen. 1.53 An adequate number of interconnecting, isolating and control dampers with

drives shall be provided on all cold air, hot air, seal air and flue gas ducting before and after equipment on these systems to permit proper operations. The control dampers shall be pneumatically operated and isolation dampers shall be electrically operated. Alternatively Bidder can supply electrically operated control dampers if it is cost effective. Bidder shall submit the basis of selection in their Bid

1.54 The gas and air ducts shall be designed for wind loads as specified for the

steam generating unit proper and their own weight including fly ash load which may get deposited at the duct bottom, insulation and lining. The top of the ducts shall be crowned to ensure proper drainage.

1.55 The duct work shall be free to expand, but it shall be rigid against wind and

seismic disturbances. Adequate provision shall be made for all expected expansion or contraction.

1.56 All gas and air ducts consist of turning vanes / baffle plates, stiffening

devices, expansion joints, interior bracings, access doors and brackets, support structures and hangers as necessary.

1.57 Aerofoils shall be provided in the air ducts for the measurement of total air

flow. 1.58 Locking devices shall be provided to dampers to permit locking in both open

and shut positions. 1.59 Electrically operated guillotine type isolation dampers along with drives shall

be provided as specified in Data Sheet-A12. The inlet dampers for ID fans shall be located in horizontal duct of main inlet duct to avoid fly ash build up when in closed position.

1.60 Flue gas duct layout shall be designed considering the following aspects:

- The change of direction of flue gas duct shall be gradual to avoid ash collection at the bottom of the duct and also to prevent erosion by local concentration of fly ash.



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- The number of direction changes of the flue gas duct shall be

minimal to minimise the ash collection points. - However, the air preheater, economiser and duct hoppers shall have

provision for removal of fly ash during maintenance period when the steam generation is out of operation. To facilitate such fly ash removal, a 100% gas tight isolation gate near the hopper bottom shall be provided. The hopper bottom shall be blanked with a blind chute suitable for unloading fly ash from all the above mentioned hoppers.

Dust Precipitation and Collection System

1.61 One electrostatic precipitator (ESP) shall be provided for the steam generator. The electrostatic precipitator shall be designed to limit the dust concentration as specified in Data Sheet – A12. ESP shall be complete with supporting structural frames, collecting and discharge electrodes, shaft insulators, bush insulators, independent rapping system for collecting and discharge electrodes with automatic rapping controls, high voltage transformers, rectifiers, bus sections with sectionalising and grounding switches and controls, fly ash collecting hoppers with accessories etc. An Energy Management System (EMS) shall be provided to optimise the power consumption. The Bidder shall furnish the details of EMS.

1.62 For personnel protection, key interlocks shall be provided to prevent the

opening of any inspection and/or access doors until after de-energising of all high voltage equipment that can be reached and/or made contact with, through the inspection and/or access door.

1.63 Each hopper shall be provided an arrangement to facilitate emergency

poking. 1.64 The hoist with supporting structure/beams to permit easy removal of each

transformer-rectifier from its operating position to grade level shall be provided.

1.65 The rapping system shall be designed for selective remote automatic or

manual operation at adjustable intervals. Necessary rapping arrangement with controls shall be provided for perforated gas distribution plate at inlet to the ESP.

1.66 Electrical System of ESP

Transformer Rectifier Equipment

1. 67.1 These shall be suitable for indoor/outdoor installation. Key interlocking shall be provided on access door or cover to the links required for changing the high voltage connections or the high voltage switch operating mechanism to prevent access while the transformer-rectifier is energised.



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1. 67.2 Primary taps shall be included on the transformer. The transformer shall have suitable shielding of the high voltage coil to accomplish proper voltage division in the transformer to take care of surge conditions.

1. 67.3 Each output leg of each transformer-rectifier set shall serve one bus section

and both bus sections served by each transformer-rectifier set shall be in the same field.

1. 67.4 Transformer rectifier assemblies shall be mounted in a heavy gauge welded

steel tank designed for a minimum of 0.5 Kg/cm2 test pressure and full vacuum.

1. 67.5 All silicon rectifier cells shall be conservatively rated for compatibility with

maximum circuit load and demands requirements. 1. 67.6 In the event of arcing, the filter voltage shall be switched off for several half

cycles to ensure a satisfactory extinction of the arc. 1. 67.7 Supporting insulators shall be located in heated compartments that are

maintained above the dew point of the flue gas. They shall be located out of the dirty gas stream. These shall be protected from weather by either a common top housing or individual compartments. Each compartment shall be pressurised and ventilated by heated filtered air furnished by one or motor driven blowers.

Control Cubicles

1.67.8 Automatic control cubicles shall be furnished for indoor mounting. The

automatic controls shall have full control from 10% of the power set rating to full rating.

The control system should be capable of:

a) Evaluating sparking by intensity and wave shape. b) Regulate power at the threshold of sparkling. c) Break a power arc within around ten- (10) milli sec of its occurrence. d) Automatically control the arc response so that power is restored within

around one hundred twenty (120) milli secs. And e) Modify the current wave shape permitting greater power input prior to

reaching spark over threshold.

1. 67.9 Adequate numbers of indicating instruments and alarms shall be provided on the control cubicles.

1. 67.10 Rapper control system for each bus section or pairs of bus sections served

by a single transformer-rectifier shall :



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a) Provide manual adjustments of the timing and frequency of operation and the rapping intensity from the control cabinets,

b) Provide rapper diagnostic system including miniature indicating lights,

digital indicators, etc.

Motors

1. 67.11 Drive motors of the rapping mechanism for collecting and discharge electrodes and fans shall comprise 415V, 3 phase, 50 Hz, rated direct-on-line induction motors with IP-55 enclosure.

In general, motors shall conform to Specification as specified elsewhere in this specification.

1.67.12 The storm water drain piping shall be provided up to the grade levels for ESP. Start-up/Warm-up and Support Oil System

1.68 The start-up/warm-up and flame stabilization oil system shall be as described under.

1.68.1 Warm up oil system shall be designed for burning light diesel oil (LDO).This

system design capacity should be sufficient to raise steam parameters of the steam generator to meet auxiliary steam for fuel oil heating / atomising in the shortest possible time to enable quick changeover to heavy fuel oil ( HFO) firing. However, this system shall have minimum capacity of 7.5% of MCR rating of one steam generator. LDO will also be utilised as flushing medium for flushing out fuel oil pipe lines and headers during long unit outages.

1.68.2 The system shall be common for both SG units and shall consist of two (2)

100% capacity LDO pressurising pumps (1 working + 1 standby) common for both units, suction strainers, compressed air atomised burners, LDO and air piping, valves and fittings, instrumentation, safety and control systems. The LDO pressuring pumps shall be located in fuel oil pump house (FOPH).

Support Oil System

1.69 The support oil system shall use heavy fuel oil (HFO) /LSHS/ HPS as

specified for start up/warm-up and flame stabilization. 1.70 The fuel oil burning system shall consists of 3 pressuring pumps common for

two units ( 2 working + 1 stand by ), suction piping , valves and fittings, filtration units, fuel oil heaters and matching pressure filters, steam atomised burners, fuel oil safety and burner shut off valves, fuel oil pressure and temperature control valves, fuel oil metering units, fuel oil atomising and blow-off steam headers at burners, atomising steam pressure control valves, piping and valves necessary for bypass and isolation, fuel oil burner header recirculation control valve, recirculation piping with valves upto the fuel oil tanks, as identified in the enclosed sketch. The fuel oil pressuring pumps shall be located in FOPH.



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1.71 The oil burning system shall be designed for 25 % SG MCR rating. The fuel oil burners shall be positioned to provide support to any of the coal burners at low loads for flame stabilization as and when required.

1.72 All pumps, strainers and / or pump strainer assembly units shall be provided

with drip pans. 1.73 Drain oil connection and pumping system shall be provided in steam

generator area and in fuel oil pump house. An oil drain header of size not less than 150 NB shall be provided to collect drain oil from pans, strainers, pumps, pipes, etc. and return the same to the drain oil tank. The drain header shall be laid just above the ground and shall be generously pitched towards the drain tank. All oil drain lines shall have a size not less than 25 NB and shall be electrically traced. The drain oil pump suction and delivery lines shall have a size not less than 25 NB and shall be electrically traced. The drain oil tank shall be provided with heating coil and accessories/instruments.

The suction and discharge filters, the fuel oil pumps and the fuel oil pipes shall be equipped with electric heat tracing. The atomising / blow off steam system and steam oil heaters will be supplied with auxiliary steam from auxiliary steam system.

1.74 The screw type pressurising pumps (if required) shall be provided with a

spring loaded relief valve and it shall be built-in with the pump, the discharge end of the valve being connected to the pump’s suction side. The relief valve shall be capable of allowing the full discharge of the pump through it. The relief valve set pressure shall be adjustable. The pressurising oil pumps and the fuel oil pipes shall be equipped with electric heat tracing. Flexible hoses (armoured type) shall be provided for oil and steam connections

1.75 The complete oil supply system shall meet the requirements of Indian

Petroleum Rules. Specific approval from Chief Controller of Explosives shall be obtained by the CONTRACTOR.

Ignition System

1.76 High Energy Arc (HEA) igniters shall be provided to ignite LDO and HFO.

One HEA ignitor for each fuel oil gun shall be provided. The igniter system offered shall be of well proven design of reputed make. Ignition system shall be complete with all electrical gadgets viz., transformer control cabinets, igniters, cabling, etc. to make the system complete by itself and shall be integrated with BMS.

Adequate number of flame scanners shall be provided for fuel oil and coal firing. Two (2) 100%, one AC and one DC motor driven scanner air fans shall be provided for the flame scanner cooling.

1.77 The heavy fuel oil from the storage tank shall be drawn by the fuel oil

pumps through suitable suction strainers and shall be pumped through heaters of requisite capacity to raise the oil temperature to the level



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required for satisfactory operation of the burners. The oil shall be taken to the steam generator units and recirculated back to the storage tanks. Arrangement of the fuel oil system including oil recirculation system shall be such to avoid cold zone in any part of the system.

1.78 Drain oil connection and pumping system shall be provided both in steam

generator area and in fuel oil pump house. In the fuel oil pump house area, an oil drain header of size not less than 150 NB shall be provided to collect drain oil from pans, strainers, pumps, pipes, etc. and return the same to the drain oil tank. The drain header shall be laid just above the ground and shall be generously pitched towards the drain tank. All oil drain lines shall have a size not less than 25 NB and shall be electrically traced. The drain oil pump suction and delivery lines shall have a size not less than 25 NB and shall be electrically traced. The drain oil tank shall be provided with heating coil and accessories/instruments.

1.79 The oil burners shall be provided with their discriminating flame

sensing devices so that the admission of oil may be automatically shut off and oil gun withdrawn in case of flame failure. The flame sensing devices shall be self contained and shall be unaffected by dirt, oil film and ambient conditions. The oil firing scheme shall incorporate automatic purge interlock to facilitate restarting after such conditions. Automatic ignition system to initiate the flame in the furnace shall be included. However, facility for the manual operations shall also be provided. Ignition system shall be complete with ignitors suitable for ignition of heavy oil directly. Necessary piping, valves, control and instrumentation and all other equipment necessary for the completeness of this system shall be provided.

Coal Pulverising and Firing System

1.80 The coal firing system shall be designed to meet the requirement of steam generator at 100% SG MCR condition, with blended coal from domestic coal and imported coal, the proportion of which will be normally about 70: 30. The range of domestic and imported coals are furnished in Section B, Volume II.

1.81 The coal pulverising and firing system shall consist of medium speed coal

mills with drives, coal feeders with drives, coal isolation gates at bunker outlet, feeder inlet, coal piping with flexible couplings from mill outlets to coal burners, coal burners with shut-off gates and drives, air registers with drives, coal mill hot air and coal / air discharge isolation gates and drives, two (2) x 100% seal air (SA) fans complete with air ducting to all coal mills/feeders, isolation, interconnecting and control dampers on seal air ducting as required, insulation, supports and hangers etc.

1.82 The coal mills shall be designed for direct firing of crushed coals. 1.83 The coal mills and bunker bays shall preferably be arranged on the steam

generator front or rear. Bidder shall ensure equal distribution of the pulverised fuel among the burners from the coal mill as much as possible in order to have low NOx.



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1.84 Forced oil lubrication system for the coal mills and motors shall consist of 2 x

100% oil pumps each with motor, 2 x 100% oil coolers and filters etc. with necessary piping and valves.

1.85 The number and capacity of coal mills and feeders shall be selected based

on the following :

(a) With one mill as standby and other mills running at 90% of their MCR, the system shall be able to meet 100% coal firing rate using worst coal. Also, with two mills as standby, 100% TGMCR shall be met using design coal.

(b) Minimum three mills shall be in operation for load range of 60%

TGMCR to 100% SGMCR

(c) Each coal mill shall be provided with a separate coal feeder and its

capacity shall not be less than the capacity of the coal mill 1.86 Dampers shall be provided on coal pipes at mill outlet, on cold air and seal

air ducts and gates on hot air to coal mills. These dampers shall be pneumatically operated where as gates shall be electrically operated.

1.87 The CONTRACTOR shall quantify the operating hours between major overhauls of the coal mill and the coal throughput in tonnes, when handling worst blended coal.

1.88 Sealing air (SA) fans shall deliver air into a common seal air header from where each coal mill and feeder set shall be supplied with the seal air.

1.89 For drawing coal samples (iso kinetic sampling of coal) for testing the fineness of the ground coal, a minimum of four tapping points at right angles to each other shall be provided on the straight length of pipe at each coal mill outlet. Compressed air purging connections shall be provided at the tapping points to clear the opening prior to sample collection

1.90 Two coal isolation gates shall be provided at each bunker outlet. The gates

shall be of dust-proof, rack and self-cleaning type pinion with all parts in contact with coal of minimum type 410 weldable stainless steel. The gate at the outlet of the bunker shall pneumatically / electric motor operated; where as the gate nearer the feeder shall be manually operated.

1.91 The down spout from feeder outlet to mill inlet shall be provided with

pneumatically / electric motor operated isolation gate

1.92 Two isolation gates shall also be furnished in each coal burner pipe one nearer to the coal mill and the other nearer to the furnace / wind-box (if applicable) for facilitating on-line maintenance work of coal piping/coal mill. The gate nearer to the coal mill shall be pneumatically / electric motor operated, and the following gate shall be manually operated.



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1.93 The coal feed pipe from the coal mills to the coal burners shall be of wear resistant, weldable steel and of minimum thickness not less than 12 mm on straight length and 20 mm (but not less than one and a half times the straight pipe thickness) at outer radius of bends. The bends shall be basalt lined or ceramic lined to prevent erosion.

1.94 Each pipe between bunker outlet and feeder inlet shall be provided with a

flanged filler piece for connection of an angle type diverter chute to permit emergency dumping of coal from the bunkers. One carbon steel diverter chute connection piece with flanged outlet shall be furnished.

1.95 A dresser or equal coupling shall be provided on each feeder inlet to permit

bunker and feeder expansion movements. The inner ring shall be of stainless steel.

1.96 Adequate and suitably located poke holes shall be provided to clear the feed pipes to the mills when they get choked. Soot Blowing System 1.97 The soot blowing system shall consist of motor operated steam soot blowers

of the rotary and retractable type, with drives, pressure reducing, isolation and relief valves, steam traps, thermal drain valves, complete piping, supports and hangers, insulation, motor control centers and soot blower instrumentation and control system. The system shall be of self-draining type. Bidder can consider either conventional type of soot blowing system or “Smart soot blowing system” (lower consumption of steam and less erosion, software based, selective soot blowing) and furnish the details of the same along with his bid.

1.98 The soot-blowers shall be suitable for remote automatic sequential and local

operation. Auxiliary Steam System

1.99 Auxiliary steam system shall consist of piping, valves etc required for supplying auxiliary steam to the equipment covered under bidder’s scope of works. Auxiliary steam shall be tapped off from auxiliary steam header.

Refractory and Insulation

1.101 The refractory shall be selected appropriately at various locations in the furnace (viz., bottom ash hopper, burner zone, goose neck, cage roof, pent house etc.) considering the gas temperature, oxidising /reducing atmosphere and erosion. CONTRACTOR shall substantiate the basis of selection of refractories in the bid document.

1.102 Thermal insulation and cladding shall be provided for the entire steam

generator, flue gas / air ducting, etc. The insulation selected shall meet the requirement specified.



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1.103 The steam generator shall be provided with 1.2mm corrugated aluminum

cladding and the ducts shall have plain aluminum cladding

Auxiliary Cooling Water 1.104 The auxiliary cooling water system shall be supplied for each SG unit. The

system shall consist of complete piping to all equipment requiring cooling water. Each cooler / bearing shall be supplied with isolating valves at the inlet and throttling type valves at the outlet.

Vibration and Noise Levels

1.105 The design of steam generator and its auxiliaries shall ensure maintenanceof vibration and noise levels within the limits specified in the following paragraphs over the entire operating range and during load fluctuations:

1.106 The gas path design shall prevent the generation of excitation forces

conducive to resonant vibration. 1.107 Constant speed fans shall be supported on conventional block foundations.

However STG, BFP & Mill foundation shall have vibration isolation system 1.108 Coal mills, ID, FD, PA, and GR fans (if applicable) vibrations at the bearings

shall meet the requirements of ISO 10816 Part 3. 1.109 The ducting shall be adequately stiffened to absorb pressure pulsations.

Guide vanes shall be provided at bends as required to prevent turbulence. Guide vanes in the gas duct shall be properly designed to minimise erosion. Fan induced duct vibrations shall be avoided.

1.110 The measured noise level produced by any rotating equipment shall not

exceed 85 dBA at a distance of 1.5 m from its boundary in any direction under any load condition.

1.111 The noise produced in valves and piping associated with handling

compressible and incompressible fluids shall be attenuated to 85dBA at a distance of 1.5 m from the source by the use of low noise trims, baffle plate silencers/line silencers, acoustic lagging (insulation), thick-walled pipe work as and where necessary. All pipes and valves downstream of pressure control valve (including pressure control valve) shall be one schedule higher than needed by pressure considerations to attenuate the noise. For safety relief valves the allowable noise level shall not exceed 115 dBA for one quarter hour or less per day. The CONTRACTOR shall outline the methods adopted to limit the vibration and noise levels within specified values.

Safety Provisions

1.112 The Safety valves shall be provided on superheater and reheater headers and its number and capacity shall conform to the code requirements. Bidders shall furnish details in his bid as to how the design capacity of various safety valves are selected meeting the code requirements.



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1.113 In addition to the safety valves required by the code, electromatic relief valve

of 10% capacity for remote operation shall be provided on superheater outlet header or on superheater outlet pipe. The valve shall also be capable of automatic operation on rise in pressure to a value corresponding to a pressure setting lower than that of the superheater safety valve. Each valve shall be complete with controller, solenoid, pilot valve and piping with two shut-off valves.

1.114 All steam safety valves shall be provided with adequately sized atmospheric

relief to 1.0 m above the steam generator roof. Weather shields shall be provided at points where the relief pipes pass through the roof. The electromatic relief valve, first spring loaded safety valve and start up vents in super heater shall be provided with silencers.

1.115 Staircases on either side of mills, and ESP with walkways and galleries shall

be provided so that all areas of mills and ESP are safely and conveniently accessible for operation and maintenance.

1.116 Staircases shall be provided at front and rear of steam generators to quickly

approach various floors. All staircases / platforms shall be provided with 2 rail safety handrails of 100 cm high and made of 32 mm GI pipe.

1.117 The minimum width of staircase shall be 1000 mm and the minimum width of

platforms shall be 750 mm. The minimum width of interconnecting walkway between mill maintenance platform and the steam generator gallery shall be 1200 mm. All platforms and staircases shall be provided with gratings and only operating floor (burner floor) shall be provided with chequered plates.

1.118 Actuators for remote operation of shut-off gates at the air inlets to coal mills

and shut off gates at outlet of coal mills shall be provided to allow positive shut-off in the event of fire in the mills.

Control Valves For System

1.119 All control valves shall be sized such that the valves are controllable over entire operating regime viz. low load to full load. Those control valves, which require to be operated during cold, warm, and hot start conditions shall also be controllable during this mode of operation. To meet the above requirements if the CONTRACTOR provides more than one control valve, the controllable ranges of the control valves shall overlap to ensure bump less transfer from one control valve to other. For other requirements of the control valve refer relevant C and I section.

Burner Blow out System 1.120 The fuel oil and atomising steam pressure shall be such that there should

not be any oil traces entering the atomising steam system. The BIDDER shall explain in his bid the special features provided on this aspect.

SPEC. NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

2 X 800MW TPP NEAR KRISHNAPATNAM VOLUME: IIIA

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CONSULTANTS: TCE Consulting Engineers Limited

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1. SPECIFIC PIPING REQUIREMENTS This Section covers the basic requirements for the all the piping systems, valves and specialities and thermal insulation to be provided for the power plant.

1.1 LINE SIZING 1.1.1 Sizes of pipelines shall be selected such that the velocity of fluid in pipes

does not exceed the following limits under conditions of maximum possible volumetric flow:

Steam Superheated steam 75 m/s Saturated steam 40 m/s Wet steam/Exhaust steam 30 m/s Water Pump suction 1.5 m/s Pump delivery 3.0 m/s Boiler feed pump discharge 6.0 m/s Service/Potable water 1.5 m/s Oil LDO 2 m/s Air Compressed air 15 m/s 1.1.2 Lower values of velocities than those stated above shall be used to

determine line size if dictated by considerations of pressure drop, NPSH, surges, water hammer, etc.

1.1.3 The design flows considered in line sizing shall not be less than the rated

capacities of equipment to which the piping is connected such as pumps, blowers, compressors, valves, flow limiting orifices, etc., or, the system heat and/or mass balance diagrams.

1.1.4 Sizes of Boiler feed pump suction piping shall be selected to meet the

NPSH requirements of the pumps under transient conditions prevailing on loss of steam supply to feed water tank. Similarly for all pumps, NPSH requirements shall be satisfied in line sizing.



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1.2 MATERIALS The material specifications of pipelines of various systems shall be as

specified in Data Sheet - A attached to this specification. 1.3 WALL THICKNESS 1.3.1 The calculation of wall thickness required for pipelines subject to internal

and/or external pressure shall be based on the formulae and recommendations as given in the applicable codes. Adequate allowances shall be made towards thinning due to bending, weakening at branch connections, threading, commercial tolerances on pipe wall thickness, corrosion and erosion, etc. and the same shall be subject to approval by ENGINEER. In any case a minimum corrosion allowance of 1.0 mm shall be considered while selecting the thickness.

1.3.2 In case of carbon steel materials, the nominal wall thickness of pipeline

shall be not less than the minimum acceptable values given below:

--------------------------------------------------------------------------------------------------------- NB mm 15 20 25 32 40 50 65 80 100 125 (inch) (1/2) (3/4) (1) (1 1/4) (1.5) (2) (2.5) (3) (4) (5) --------------------------------------------------------------------------------------------------------- Min. 3.2 3.2 3.6 3.6 3.6 3.6 3.6 4.0 4.5 5.4 thickness, mm ---------------------------------------------------------------------------------------------------------- NBmm 150 200 250 300 350 400 450 500 600 (inch) (6) (8) (10) (12) (14) (16) (18) (20) (24) ---------------------------------------------------------------------------------------------------------- Min. 5.4 6.35 6.35 6.35 7.1 7.1 7.1 8.0 8.0 thickness, mm ----------------------------------------------------------------------------------------------------------

> NB 600 mm to NB 950 mm - 10.00 mm > NB 950 mm to NB 1200 mm - 12.00 mm

Sizes of NB 32(11/4”), NB 65(21/2”), and NB 125(5”) shall not be used in the piping system.

1.4 FLEXIBILITY ANALYSIS 1.4.1 Formal flexibility analysis calculations shall be carried out in case of

pipelines subjected to restrained thermal expansions or contractions. The following piping systems shall be analysed : (a) Pipelines with a maximum operating temperature equal to or

greater than 150?C



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(b) Regardless of their operating temperatures, all pipelines

connected to sensitive rotating equipment such as turbines, feed pumps etc. for which limiting values of pipe reaction have been specified by the equipment manufacturer

(c) Any other pipeline which in the opinion of the

OWNER/ENGINEER requires a formal analysis. 1.4.2 If it is deemed necessary by the boiler or turbine vendor, a surge analysis

shall be carried out by the Contractor to evaluate the effect of closure of valves that are hydrostatically or pneumatically actuated. The pressure rise in the pipeline, additional forces and moments at terminal points and additional stresses shall be calculated. If the stresses or the forces and moments exceed the allowable value, suitable shock absorbers shall be provided by the Contractor.

1.5 LAYOUT AND DETAILING 1.5.1 All pipelines with size greater than NB 50 mm are considered as shop

fabricated piping and detailed piping layout drawings shall be prepared for all such pipelines. The drawings shall be to scale and shall be prepared as plan & sections and shall carry the following minimum details:

1.5.1.1 Fully dimensioned layout with locating dimensions referred to plant axes

and coordinates 1.5.1.2 Details of all stub connections and other welded attachments as required

for anchors, restraints, hangers supports, etc. 1.5.1.3 Slope, drains and vents, all vents and drain lines shall be extended to

nearest drain 1.5.1.4 Edge preparation details of weld ends 1.5.1.5 Mounting and orientation of valves and specialities and maintenance

space requirements 1.5.1.6 Location and tag numbers of hangers, supports, restraints, anchors, etc. 1.5.1.7 Location and magnitude of cold cuts, if any 1.5.1.8 Pipe sizes, materials, design parameters, shop and field test

requirements 1.5.1.9 Insulation details



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1.5.1.10 Tolerances, if any 1.5.1.11 Any specific requirements on shop fabrication and/or field erection 1.5.1.12 Any other detail considered necessary by the Owner / Owner’s

representative. 1.5.2 Pipelines with a size of NPS 50 mm or smaller are regarded as field

routed. CONTRACTOR shall however indicate any specific requirements he may have in regard to the routing of these pipelines.

1.5.3 Detailed bills of material shall be prepared for all piping systems. In case

of shop fabricated piping, the bill of material shall correspond to the layout drawing prepared.

1.5.4 While routing piping, the following requirements shall be taken into

account: 1.5.4.1 All piping shall be routed so as to avoid interference with other pipes and

their hangers and supports, electrical cable trays, ventilation ducting, structural members, equipment, etc. Adequate clearances shall be ensured with respect to the above to accommodate insulation and pipe movements.

1.5.4.2 All piping shall be grouped where practicable and shall be routed to

present a neat and aesthetic appearance. 1.5.4.3 The piping shall be arranged to provide clearance for the removal of

equipment requiring maintenance and for easy access to valves and other piping accessories required for operation and maintenance. Layout drawings shall indicate valve orientations and availability of access to valves and specialities. Layout of all piping shall ensure that all valves including motor operated valves are located as to be accessible conveniently for operation. Valves for operation and maintenance shall have 1.0 m clear approach space. If any of the valves are not accessible, suitable access platform shall be provided by the CONTRACTOR.

1.5.4.4 Piping shall generally be routed above ground but, where specifically

indicated/approved by the ENGINEER the pipes may be arranged in trenches or buried. Pipes at working temperatures above the ambient shall however not be buried.

1.5.4.5 Where steel piping is required to be buried, the pipe work shall be

protected from soil corrosion by suitable anti-corrosive treatment as specified.



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1.5.4.6 Overhead piping shall have a minimum vertical clearance of 2.3 metres above walkways and working areas and 7.0 metres above roadways unless otherwise approved by the ENGINEER.

1.5.4.7 Drains shall be provided, at all low points and vents at all high points as

per actual layout regardless of whether the same have been shown in the flow diagrams or not. Pipelines shall be sloped towards the drain points.

1.5.4.8 Besides at low points, tell tale drains shall be provided at other points as

necessary to remove on-line valves and specialities from piping for repair and replacement. Wherever spray water is introduced into steam piping, at a suitable location downstream, drain pots shall be envisaged along with motor operated drain valves and high and low level switches. The drain valves shall be interlocked with the level switches for automatic operation. For operating temperatures of greater than 400oC, drip leg with drains, operated by a motor operated valve shall be provided. At all other drain locations (operating temperatures less than 400oC) traps shall be provided. All traps shall be provided with strainers, isolating, bypass and free blow valves. Traps shall be thermodynamic type.

1.5.4.9 Provision shall be made while preparing piping layout to accept control

valves, flow measurement element and any other on-line speciality or equipment. Sufficient upstream and downstream lengths shall be provided for flow measuring devices, control valves, desuperheaters and other specialities as required by the respective equipment manufacturer.

1.5.4.10 At all the screwed valves and screwed connections on equipment, unions

shall be provided to facilitate disassembly. Likewise, unions shall also be provided at suitable points on straight length of screwed pipelines.

1.5.4.11 At all points where pipes pass through concrete floors or brick or other

walls, suitable floor collars or wall boxes shall be provided. The CONTRACTOR shall design and furnish the details of the floor collars to the ENGINEER/OWNER.

1.5.4.12 In the case of flanged pipe work, boxes shall be large enough to permit

the passage of the flange. 1.5.4.13 All pipe racks shall be provided with walkways of 750 mm wide. 1.5.4.14 All pipe bends shall have a radius of five nominal pipe diameter unless

otherwise specified by the Owner / Engineer

1.5.4.15 All oil piping shall be arranged such that these shall be below of away from the high temperature steam pipes or other heated surfaces.



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1.5.4.16 All bearing oil drain lines and cooler outlet water flow lines shall be provided with visual indicator with rotational wheel (if possible) for observation of flow from a local platform or operating floor.

1.5.5 Hangers and Supports 1.5.5.1 All piping supports, guides, anchors, turnbuckles, rod hangers, spring

hangers, rollers, with incidental structural subframing shall be designed by the CONTRACTOR.

1.5.5.2 The hangers and supports shall be spaced in accordance with standard

engineering practice as outlined in applicable codes and standards. 1.5.5.3 The CONTRACTOR shall ensure that the location of the hangers and

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

1.5.5.4 If severe vibration of piping is encountered in systems over which the

CONTRACTOR has control or if the piping system is to be subjected to shock loading, hangers shall be supplemented by vibration-control equipment of an approved design.

1.5.5.5 At locations where lateral or axial movement is expected, the hangers

shall be provided with suitable linkages to permit swing. All hangers shall be designed to be vertical in the hot position unless otherwise approved by the ENGINEER.

1.5.5.6 In order to minimise any horizontal force components of the dead weight

or any binding of the pin or rocker joints used on the hangers, the hanger rods should be as long as possible. In critical piping systems, the length of the hanger assembly capable of swinging shall not be less than 20 times the maximum expected pipe movement in the horizontal plane at the hanger location. It is recommended in case of main steam piping to provide for a hanger rod length of atleast 5-6 metres wherever feasible.

1.5.5.7 Constant support type of hangers shall be adopted at all locations on

critical piping excepting where the smallness of vertical movements of pipe justifies the use of variable spring hangers.

1.5.5.8 As far as practicable, connections of hangers to supporting structure shall

be achieved without welding to structural members. If welding is inevitable, adequate factor of safety shall be considered in the design and specification of the weld.

1.5.5.9 The attachment of support brackets to brick walls shall be avoided as far

as possible and where this is not possible, details of the attachment shall



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be furnished to the ENGINEER for his approval. Under unavoidable circumstances, when medium or heavy brackets are bolted to walls, back plates of adequate size and thickness shall be furnished to distribute the load against the wall. Where the use of a back plate is not practical, the brackets shall, be fastened to the wall in an approved manner.

1.5.5.10 Diameter of hangers for piping NB 50 mm and smaller shall not be less

than 10 mm and for piping with size NB 65 mm and larger shall not be less than 13 mm.

1.5.5.11 All components for hangers such as turn buckles, clamps, etc. shall be of

forged steel.

1.5.6 Fittings and Flanges 1.5.6.1 Branch connections in piping shall be made by the use of wrought or

forged seamless fittings such as tees, laterals and crosses. Small stubs as may be required for instrument, drain and vent connection may be provided in the form of weld outlet fittings or forged couplings. Intersection welds are acceptable only in the event of non-availability of fittings.

1.5.6.2 Wherever pipe bends are employed for change of direction the same

shall be to a radius of 5 times the pipe diameter. 1.5.6.3 Mitred bends may be adopted for piping systems upto a design pressure

10 bar (g) only. Mitre angle shall not exceed 22.5 degrees. 1.5.6.4 Slip-on type of flanges may be only upto a maximum pressure rating of

ANSI 300 lbs. In case of higher pressure ratings, weld-neck type of flanges shall be employed.

1.5.7 Dimensional Standards 1.5.7.1 Uniform dimensional standards for all piping components shall be

employed to ensure compatibility with each other. 1.5.7.2 Nominal pipes sizes and pipe outside diameters shall generally be as per

ANSI B36.10. In case of deviation CONTRACTOR shall bring it to the specific attention of ENGINEER for prior approval stating reasons for the deviation.

1.5.8 Instrument Connections 1.5.8.1 Unless otherwise called for by OWNER all thermowell stubs shall have

an internal threading to M33 x 2.



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1.5.8.2 All stubs for pressure or flow measurement for pipelines with a maximum working pressure equal to or above 62 bar(g) or with a maximum working temperature equal to or above 350?C shall be NPS 25 mm and double root valves shall be used.

1.5.8.3 Stubs for pressure or flow measurement on pipelines with a maximum

working pressure less than 62 bar (g) and a maximum working temperature less than 350?C shall be of NPS 15 mm size and single root valves can be used.

1.5.8.4 Measurement stubs on fuel oil lines shall be of NPS 25 mm size and

provided with two root valves. 1.5.9 Drain and Vent Connections 1.5.9.1 Drain and vent connections on pipelines shall be atleast of NPS 25 mm

size. 1.5.9.2 For pressure and temperature conditions as defined in Clause 5.8.2,

double isolating valves shall be used on drain and vent lines. For pressure and temperature conditions as defined in Clause 5.8.3, single isolating valves are considered adequate. Where with single root valve, instrument and root valve are not accessible, double root valve shall be provided with one root valve near the tap off and the second root valve with instrument at accessible point. For fuel oil drain and vent lines double isolation valves shall be provided irrespective of the pressure and temperature.

1. 6 WELDING AND HEAT TREATMENT

All heat treatment, welding, post and pre weld temperatures shall be as per the code ASME B31.1.

1.7 INSPECTION & CLEANING 1.7.1 All pipes shall be hydrotested at shops for pressures as per standards

and all erected piping shall be tested 1.5 times the design pressure. All other inspection requirements shall be as per the enclosed data sheet – A1.

1.7.2 All hot bent, forged formed, fabricated and straight pipes shall be

chemically cleaned, pickled or wire brushed and punged with air blast or shot/grit blast to remove all sand and scale from the inner surface as applicable.

1.7.3 The Contractor shall carryout the following cleaning after hydrotest.



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(a) All piping shall be mass flushed, in addition to the specific cleaning operations as described below, as required.

(b) Main steam, HP bypass piping shall be steam blown. (c) Extraction steam, condensate, boiler feed suction and

discharge, heater drains and vents shall be alkaline flushed. (d) Auxiliary steam piping and associated steam lines, heavy fuel

oil piping shall be steam blown. (e) Compressed air piping shall be blown by air. (f) Turbine lubricating oil piping shall be pickled

1.7.4 Contractor has to arrange chemicals, pumps, piping, valves, dummy

devices, oil etc for acid cleaning, steam blowing, alkali boil out, oil flushing etc.,

1.7.5 Weld repair in valve shall be done as per the standard welding practice. Major weld repair record of critical valve shall be made available.

1.8.0 PAINTING AND CORROSION ON PROTECTION 1.8.1 All uninsulated piping systems, hangers and supports shall have two

coats of red oxide Zinc Chromate primer (conforming to IS 2074) with minimum dry film thickness (DFT) of 25 microns per coat and two coats of finish paints using enamel paint to give a minimum total DFT of 100 microns (after two coats of primer and two coats of finish paint). Shades shall be as per IS 5 or as indicated by Owner /Engineer. Service of the pipe/line designations shall be painted on all pipes at visible locations.

1.8.2 Before application of paint, Contractor shall clean the pipes of all mill

scale, dirt dust, soot, grease, rust etc. 1.8.3 All pipe lines, piping components shall be adequately protected against

corrosion during manufacture, fabrication, shipment and storage by appropriate protective paint.

1.9 UNDERGROUND PROTECTION 1.9.1 Where pipelines are buried, underground protection shall be provided for

the piping system as indicated any one of the methods given below: (a) Coal tar primer, coal tar enamel, inner wrap of fibre glass, final

outer wrap of enamel impregnated fibre glass. Total thickness of coating shall not be less than 4.0 mm.

(b) With anti-corrosive tape of 4 mm thick conforming to IS-

10221 and AWWA C 203-93. 1.9.2 Pipe surfaces shall be cleaned by shot or sand blasting before

application.



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1.9.3 Tests to be carried out after application

(a) Bond/Adhesion test (b) Holiday test

1.10 SPECIFIC REQUIREMENTS OF PIPING SYSTEMS

These shall be as detailed out in data Sheet A 1.11 THERMAL INSULATION 1.11.1 CONTRACTOR shall provide thermal insulation for all hot piping and

equipment with fluid temperatures greater than 60?C. 1.11.2 Specific requirements of thermal insulation are detailed out in Data

Sheet-A. Further, the insulation thickness indicated in Data Sheet - A shall be regarded as minimum acceptable thickness. These minimum acceptable thickness are OWNER’s estimate based on use of mineral wool blankets as insulating material with a surface temperature of 60?C or less over the insulation finish and Contractor is advised to ensure that the thickness envisaged by OWNER are adequate to guarantee a surface temperature measured over the finish of not greater than 60?C. In case the Contractor estimates that higher insulation thickness are required, the same shall be included and clearly indicated in the offer under the ‘Schedule of Technical Deviations’ of this specification. If Contractor is adopting calcium silicate insulation, the thickness shall be calculated with maximum thermal conductivity as given in IS-8154 and temperature shall be over the finish (aluminium cladding).

1.11.3 Contractor shall submit with his offer a schedule of insulation thickness

proposed by him along with supporting calculations. The calculations shall be based on thermal conductivity values certified and guaranteed by the insulation supplier who shall base his guarantee on actual tests conducted by recognised test houses. Calculation of insulation shall be based on standard BS 5970/IS 3677. No credit would be claimed by the insulation manufacturer over and above those actually recognised by international standards. However, if the CONTRACTOR is offering insulation material with superior thermal conductivity this value shall be suitably substantiated by tests.

1.11.4 CONTRACTOR shall demonstrate to the OWNER/ENGINEER the

surface temperature of the insulation at site. For indoor piping, the temperature shall be measured at the middle of one segment of pipe run at different points. These temperatures shall be taken as representative temperatures for that length of piping. If the temperature measured is



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higher than that guaranteed, the whole length shall be replaced or additional thickness added to meet the surface temperature. Two measurements shall be taken at the measuring points (one at the top and another at the bottom).

1.11.5 Contractor should take care while fixing the insulation mats, no welding

shall be permitted on HP/LP cylinder & steam chests for fixing nuts, bolts, lugs, for their mats. The strip on the casing, stop valves, where provided and instructed by manufacturer shall be used to weld the insulation pins for thermal insulation.

1.12 VALVES 1.12.1 Design And Construction Features The following design and construction features of valves shall be

complied with. 1.12.1.1 All gate and globe valves shall be of rising stem, outside screw and yoke

type. The design of valves shall ensure a streamlined passage and gate valves shall have low pressure drop. The seats and discs shall be easily renewable and/or shall be suitable for easy refacing and grinding. Valve discs shall be of such design as to keep the seats tight when the valve body is subjected to pressure, temperature variations and piping stresses. Gate valves shall close in both flow directions.

1.12.1.2 All globe valves shall be capable of being closed against pressure. 1.12.1.3 All valves end details shall be as specified in data sheets. In the case of

all end-welded valves, the stub ends of the valves shall project from the valve body a sufficient amount to ensure that the welding process will not distort the valve body and internal parts.

1.12.1.4 Valves for regulating duties shall be of the globe type with tapered plug

type disc. 1.12.1.5 Hardness of disc seating surface shall be minimum of 350 BHN and a

minimum differential hardness of 50 BHN shall be provided between disc and seat to prevent galling. This is not applicable for stellited seats.

1.12.1.6 Check valves of sizes 400 mm NB and larger shall have dash pot

arrangement. 1.12.1.7 All gate and globe valves shall have back-seating arrangement to

facilitate easy replacement of packing with the valve in service.



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1.12.1.8 All valves shall be so designed that the hand-wheel moves in a clockwise direction to close the valve. The face of the hand-wheel shall be clearly marked with the words 'OPEN' and 'CLOSE' and an arrow to indicate the direction for opening. All hand-wheels shall be fitted with name plate.

1.12.1.9 Piston lift check valves shall have accurately guided pistons so that the

pistons are cushioned in their cylinders as they move up. 1.12.1.10 All gate, globe, Y-type and angle valves intended for manual

operation and falling under the following categories shall be equipped with a gear operator for ease of operation and to ensure fast and tight closure:

ANSI PRESSURE RATING VALVE SIZES FOR WHICH GEAR OPERATOR IS REQUIRED ----------------------------------- ---------------------------------------------- Class 300 and below 350 mm and larger Class 600 and above 200 mm and larger ------------------------------------------------------------------------------------------------

1.12.1.11 All gate valves falling in the following categories shall be provided with integral bypass valve. Bypass size shall conform to MSS-SP-45 as a minimum standard unless otherwise specified in data sheet. The bypass valve shall be hand operated unless otherwise specified in data sheet. Pipe for bypass shall be at least Schedule 80 seamless and of a material of the same nominal chemical composition and physical properties as that used for the main line. Orientation of bypass arrangement shall be subject to the approval of OWNER/ENGINEER.

ANSI PRESSURE RATING VALVE SIZES FOR WHICH

BYPASS IS REQUIRED ------------------------------------ ----------------------------------------- Class 600 and over 200 mm and larger Class 300 & 150 350 mm and larger ------------------------------------------------------------------------------------------------

1.12.1.12 All gate valves of ANSI pressure rating class 150 and 300 shall have

solid or flexible wedge and ANSI pressure rating class 600 and above shall have flexible or parallel slide type of wedge.

1.12.1.13 Valves with flexible wedge shall have provision for relieving the

pressure in the neck of the valve when the valve is in the closed position.

1.12.1.14 All valves of ANSI pressure rating upto class 600 shall have bolted

bonnet construction and class 900 and above shall have bonnet



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construction of the pressure seal type. Pressure seal valves shall have stainless steel inlay in the gasket area and silver-plated gaskets or other acceptable proven features.

1.12.1.15 All carbon steel valves of ANSI pressure rating upto class 150 and 300

shall have stainless steel trim (13% Cr) unless otherwise specified in Data Sheet and ANSI pressure rating class 600 and above shall have stellited trim.

1.12.1.16 All alloy steel valves shall have stellited seats. 1.12.1.17 All valves of ANSI pressure rating upto class 900 and higher shall

have yoke with anti-friction bearing arrangement. 1.12.1.18 Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be

provided with a non-detachable locking arrangement. The locking arrangement provided shall be subject to approval by the OWNER.

1.12.1.19 Valves operating under vacuum conditions shall have glands with

water sealing. The inlet and outlet connections shall be NB 15mm. The CONTRACTOR shall indicate the maximum and minimum sealing water pressure and the required flow rate.

1.12.1.20 Motor actuators for motor operated valves shall meet requirements

indicated elsewhere in the specification. 1.12.1.21 All HP valves of size 50- NB and blow shall be of minimum class 1500

welded bonnet type irrespective of design requirements. 1.12.1.22 All the valves in the turbine extraction line shall be selected for one

rating higher than the design requirement. 1.12.2 Cleaning Prior to factory inspection, all manufacturing waste, such as metal

chips and filings, welding rods and stubs, rags, debris and all other foreign matter shall be removed from the interior of each valve. All mill scale, rust, oil, grease, chalk, crayon, paint marks and other deleterious material shall be removed from the interior and exterior surfaces. At the time of shipment, valves shall be clean inside and outside.

1.12.3 Inspection and Tests 1.12.3.1 Inspection and tests shall be as per the relevant section.



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1.12.3.2 Defects in excess of acceptance standards shall be removed by suitable means. If removal of surface defects does not result in reduction in wall thickness below 5% of intended thickness of metal at that location, the area shall be blended smoothly into the surrounding surface. Where defect removal results in a wall thickness below the above, resultant cavity may be repaired by welding. The procedure and operator shall be qualified as per applicable standards. Major weld repairs shall be stress relieved or heat treated in accordance with ASME Section VIII Division I-UCS 56.

1.12.3.3 The required area shall be re-examined and the acceptance

standards shall be as in the original examination. 1.12.3.4 Weld repairs made as a result of radiographic examination shall

be radiographed after welding. Repairing a particular area more than 2 times is not permitted and the component shall be rejected. The acceptance standards for welds shall be as per ASME Boiler and Pressure Vessel Code, Section VIII, Division I, UW - 51.

3.12.3.5 Prior approval shall be obtained from the OWNER/ENGINEER before

taking up major weld repairs (major weld repair - when depth of repair exceeds 20% of thickness or 1 inch whichever is smaller). Mapping of major weld repairs is also required.

1.12.3.6 All valves shall be tested hydrostatically for strength, tightness of seats

and tightness of back seating at the pressures indicated in data sheets, in accordance with MSS-SP 61, "Hydrostatic Testing of Steel Valves". Water used for hydrostatic testing of valves with stainless steel components shall not have chloride content exceeding 20 ppm. Clean potable water may be used for testing of all other valves.

1.12.3.7 All valves except check valves shall be tested for seat tightness by air

at a pressure of 6 bar (g) on both sides of seat. 1.12.3.8 All check valves shall also be hydrotested at 25% of the seat hydro

test pressure. 1.12.3.9 All valves shall be checked for correctness in respect of specified end

details as per applicable standards. 1.12.4 Painting and Corrosion Protection Two coats of primer of thickness 35 microns for each coat shall be

applied to all steel and cast iron exposed surfaces as required to prevent corrosion, after release has been given for painting and before despatch. The use of grease or oil, other than light grade mineral oil, for corrosion protection is prohibited. Bores of all valves shall be



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covered immediately after testing, draining and drying with suitable plastic end covers to avoid ingress of foreign materials.

1.12.5 Temporary piping and accessories All temporary piping, fitting, accessories, valves, specialities etc.

required for the various erection and commissioning activities such as chemical cleaning, steam blowing, hydraulic test etc shall be in the scope of the bidder.

SPEC NO.

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2 X 800 MW TPP AT KRISHANAPATNAM

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM -CONTENTS

SECTION: D 2 SHEET 1 OF 1

CONSULTANTS : TCE CONSULTING ENGINEERS LIMITED

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SUB -SECTION

TITLE NO.OF SHEETS

D 2.1 SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY 6 D 2.2 SCOPE AND TERMINAL POINT-SYSTEM / EQUIPMENT / SERVICES 9 D 2.3 DESIGN, PERFORMANCE AND FUNCTIONAL REQUIREMENTS 27 D 2.4 SPECIFICATION FOR DCS / INSTRUMENTS TO BE SUPPLIED 19 D 2.5 TESTS AND INSPECTION FOR INSTRUMENTATION AND

CONTROL EQUIPMENT 3

D 2.6 OTHER SERVICES 2

LIST OF TABLES SUB-SECTION

TITLE NO. OF SHEETS

TABLE - 1 AVAILABILITY REQUIREMENTS 1 TABLE - 2 LAYOUT AND MAINTENANCE REQUIREMENTS 2 TABLE- 3 ERECTION, TESTING AND COMMISSIONING REQUIREMENT 6 TABLE- 4 CODES AND STANDARDS 5 TABLE- 5 LIST OF ESSERNTIAL SPARES 4 TABLE- 6 TRAINING TO BE PROVIDED FOR OWNER’S PERSONNEL 1 TABLE- 7 TESTS FOR I & C SYSTEM EQUIPMENT 14 TABLE- 8 INSTRUMENT INSTALLATION 2 TABLE- 9 DATA TO BE FURNISHED WITH BID 1 TABLE- 10

DATA TO BE FURNISHED AFTER AWARD OF CONTRACT 5

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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM -

SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

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1.0 SYSTEM DESCRIPTION 1.1 The instrumentation and control (I&C) system for the project will be a comprehensive

system integrating the functions of plant monitoring, control and protection to facilitate the task of integration, co-ordination and autonomous operation of the plant sub systems/equipment namely Steam Generators (SG), Steam Turbine Generator (STG) and their associated auxiliaries, balance of the plant equipment / systems like plant electrical system, utility plants like coal handling plant, Ash handling plant, DM water plant and compressed air plant etc..

1.2 The plant I&C system is envisaged to be configured by interfacing main plant control

system namely DCS interfaced with other different plant control systems namely SG Integral control system, STG Integral control system and other utility and auxiliary plant control systems (both unit specific and plant common systems) and provided with different special plant monitoring and analysis systems to provide supervisory and reporting facilities to plant personnel and management.

1.3 The plant I&C system is envisaged to permit centralised operation and monitoring of the

power plant from the central control room (CCR) being described subsequently in detail. The system will consist of a functionally distributed microprocessor based system (DCS) with facility for VDU (Video Display Unit) / Keyboard & Large Video Screen based operation, control and monitoring.

1.4 The overall I & C system design objective is to ensure the following: (a) Maximise safety for the plant personnel and equipment (b) Safe, reliable, efficient and easy operation of the plant under all operating

conditions (c) Maximise availability and efficiency of the plant through system redundancy. (d) Consistent control & instrumentation philosophy – usage of standard functional

modular hardware and software design. (e) Ability to operate under all specified conditions (start-up, normal operation,

disturbances and shut down) automatically and/or by remote manual control from relevant control room.

(f) Malfunction of any component or loss of supply leading to fail-safe condition (g) Provide accurate and reliable information to the plant operators and management. (h) Provide the operators the following facilities: (i) Complete information for plant equipment status / abnormal and critical

conditions.

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(ii) Alarm notification. (iii) Logging of equipment/component failure duration and data availability for

failure analysis. (iv) Historical data storage and retrieval facility for long term monitoring of plant

equipment performance. 1.5 Special plant monitoring and analysis systems being envisaged will include the

following: (a) Vibration monitoring and analysis system (b) Performance analysis, diagnostics and optimisation system (c) Computerised maintenance management system (d) Security and surveillance system (e) Management Information System (MIS) (f) Flame Monitoring & Analysis System (g) Boiler Tube Leak Detection System 2.0 PLANT OPERATION PHILOSOPHY 2.1 OPERATION FROM CENTRAL CONTROL ROOM (CCR) 2.1.1 All equipment associated with main plant viz. SG, STG and their associated auxiliaries,

balance of plant equipment systems and other different utility and auxiliary systems will be operated /monitored from VDU/Keyboard based Operator stations (OS) mounted on Unit Control Desk (UCD) in CCR. The OS will be table top mounted type. Operation from OS will permit to call for the various types of displays for all parameters as required on the screen and to carry out all types of operations. CCR operation/ monitoring facility through OS/LVS will include the following as an additional facility, which will be primarily operated and monitored from respective utility plant located local control room:

(a) Limited Operation & Complete monitoring of plant common Coal Handling Plant. (b) Limited Operation & Complete monitoring of plant common DM water plant &

effluent treatment plant etc. (c) Limited Operation & Complete monitoring of plant common Ash Handling Plant. (d) Complete operation and monitoring of plant common Switchyard system. (e) Complete operation and monitoring of unit specific Electro-Static Precipitator.

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(f) Complete operation and monitoring of unit specific Mill reject Handling system. (g) Limited Operation & Complete monitoring of unit specific DG Set. (h) Complete monitoring of unit specific A/C & Ventilation System. 2.1.2 In addition to VDU/KB operation from OS, limited back up operation/ monitoring facility

will be provided on the Unit Control Panel (UCP) in CCR, for safe operation/shutdown of the power plant. UCP operation/ monitoring facility to include but need not be limited to the following:

(a) Emergency stop push buttons for boiler, STG and all HT & major auxiliaries for

safe shutdown of the plant in the event of failure of VDU/KB based OS equipment. (b) Audio-Visual window based hardwired annunciation for system / equipment faults. (c) Push buttons associated with hardwired annunciation system located both on

UCD & and in UCP. (d) Digital Display Unit for selected important plant parameters. (e) Large Video Display Screen suitable for both operation and monitoring. (f) PA system and telephone sets. 2.1.3 Operation, control and monitoring requirement of Station Electrical system / equipment

are detailed in Section D 3, Volume IIIA. 2.2 LOCAL OPERATION 2.2.1 OPERATION FROM LOCAL CONTROL ROOM (CCR) 2.2.1.1 The utility and auxiliary systems viz., Coal handling plant / Ash handling plant /

Switchyard plant / DM Water plant & Effluent treatment plant / A/C & Ventilation System etc., will be primarily operated & monitored locally from respective utility plant located local control rooms (LCR). However, facility for operation and monitoring from CCR as detailed above in Clause 2.1.1, Section D 2.1 above are also envisaged. Utility plant operation / monitoring will be primarily through VDU/ KB based OS mounted on Control Desk (CD). The OS will be table top mounted type. Operation from OS will permit to call for the various types of displays for all parameters as required on the screen and to carry out all types of operations. Control Desk shall also accommodate PA & Telephone sets.

2.2.1.2 Two (2) no.s OS will be provided for each utility plant local control room. 2.2.1.3 In addition to VDU/KB based OS, Large Display screen are also envisaged for both CHP

& AHP local control room.

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2.2.1.4 In addition to VDU/KB operation from OS, back up operation/ monitoring facilities will be

provided in the Back Up Control Panel for both CHP and AHP local control room(s). Back up Control Panel operation/ monitoring facilities to be provided will include the following:

(a) Coloured Mimic diagram (b) Push buttons with lamps for all major plant equipments. (c) Audio-Visual window based hardwired annunciation for system / equipment faults. (d) Push buttons associated with annunciation system. (e) Digital Display Units for selected important parameters. (f) Large Video Display Screen suitable for both operation and monitoring. (g) PA system and telephone sets. 2.2.1.5 DG set will be primarily operated and monitored from DG set control room with facility

for remote start/stop operation with status/alarm monitoring in CCR. 2.2.1.6 Switchyard will be operated and monitored from Switchyard building. All operation

/monitoring from Switchyard building will be through VDU/Keyboard based OS. 2.2.1.7 In general, for no auxiliary and utility plant system/equipment, local control panel based

operation and monitoring is envisaged. Any specific deviation in this regard shall be subject to OWNER’s approval.

2.2.1.8 For ESP control system, VDU/KB based operation /monitoring facility may be provided if

felt needed by Bidder. However, primary operation /monitoring facility will be from DCS based OS from CCR.

2.2.2 Local Operation From Field 2.2.2.1 In addition to the control room operation / monitoring facility, local start/stop operation

from local pushbuttons (LPB) shall be provided for all uni-directional drives as a testing and maintenance facility. The local pushbuttons for various drives shall be hooked up to control system as indicated below:

(a) All emergency stop pushbuttons shall be wired directly to MCC/Switchgears. (b) Status of all emergency stop pushbuttons for unidirectional drives (pump/fan etc)

shall be monitored into the respective control system. (c) Local start pushbuttons (for pump/fan etc.) commands shall be connected to the

control system to ensure interlock/protection requirement.

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2.2.2.2 Local / remote operation location selection will be carried out from control room through

OS. 3.0 PLANT CONTROL PHILOSOPHY 3.1 The control requirements of the main power plant comprising SG, STG with associated

auxiliaries (except for SG & STG Integral control systems) , balance of plant system/equipment like CW/ACW/Misc. water systems, plant electrical system, compressed air system etc. to be implemented in microprocessor based Distributed Control System (DCS) being provided by Purchaser.

3.2 SG Integral control system will include Burner Management System (BMS) & Boiler

protection system and will be an independent microprocessor based control system. BMS & Boiler Protection system will be a fail-safe type system conforming to SIL 3 with certification from authorised agency.

3.2 STG Integral control system will include STG Governing Control & Turbine protection

system and will be an independent microprocessor based control system. BMS & Boiler Protection system will be a fail-safe type system conforming to SIL 3 with certification from authorised agency.

3.3 PLC based control systems are envisaged for all other unit specific and plant common

utility and auxiliary plants like detailed below which are not covered in DCS based control systems.

(a) Plant Common Coal Handling Plant. (b) Plant Common Ash Handling Plant (c) Plant Common Switchyard system (d) Plant Common DM water plant (e) Plant Common Effluent treatment plant etc. (f) Unit Specific ESP Control system (If DCS based control is not provided) (g) Unit Specific Mill reject system (If DCS based control is not provided) (h) Unit Specific DG Set (i) Unit Specific Fire Protection & Detection system (j) Unit Specific A/C & Ventilation system (j) Any other plant system/equipment not covered in plant DCS system.

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3.4 SG Integral Control system (For BMS & Boiler protection system) and STG Integral Control System (For STG Governing Control & Turbine Protection) will be interfaced with plant DCS through redundant bi-directional OPC link with Ethernet based TCP-I/P protocol. However for time critical signals hardwired interfacing is envisaged.

3.5 All PLC based utility plant control systems will be interfaced with plant DCS through

redundant bi-directional OPC link with Ethernet based TCP-I/P protocol. 3.6 In general, no plant system/equipment will have relay based control system. 3.7 CCR operation / monitoring of equipment/systems under SG and STG Integral control

systems, utility plants / plant common systems detailed above will be through plant DCS system OS /LVS.

3.8 All different plant control systems like SG /STG Integral Control systems, plant DCS,

PLC based control systems for utility plant/systems and other special monitoring and analysis systems like CMMS, MIS etc. are interfaced through redundant interfacing for proper functioning.

3.9 Each unit Turbo Supervisory System to be interfaced with respective unit plant DCS. 3.10 A common time synchronisation system is envisaged (by Purchaser) for time

synchronising of all programmable control systems like SG / STG Integral control system, plant DCS, PLC control systems etc. for the whole station.

SPEC. NO ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD VOLUME: IIIA

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SCOPE OF WORK / TERMINAL POINT-SYSTEM/EQUIPMENT/SERVICES

SECTION:D 2.2 SHEET 1 OF 9


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1.0 INSTRUMENTATION & CONTROL EQUIPMENT SYSTEM / EQUIPMENT/SERVICES TO BE FURNISHED

The Scope includes design, manufacturing, supply, erection, testing and commissioning

of specified Instrumentation and Control System Equipment complete with all hardware, software and accessories and other services including the following, to operate the steam generator plant and auxiliaries efficiently, reliably and safely as detailed in this section and also under System description/Operation philosophy in Section-D 2.1, Design philosophy in Section – D 2.3, relevant technical specification in Section –D 2.4 and Testing requirements in Section-D 2.5 with enclosed Tables. The offer shall comply with the latest applicable codes and standards as prevailing on the date of submission of the bids.

(i) SG Integral control system for Burner Management System (BMS) & Boiler

Protection System. The system shall be fail-safe type conforming to SIL 3 with certification from authorised agency and implemented in an independent microprocessor based system (either TMR type or any other approved configuration by IEC).

(ii) Furnace Flame Monitoring and Analysis System for each unit. (iii) Boiler Tube Leak detection system (iv) System cabinets and Marshalling cabinets (v) Field Instruments including pipe mounted items and accessories within battery

limits. (vi) Final control elements within battery limits. (vii) Supply, laying & termination of complete Instrumentation, Control, Compensating,

Special cables, Pre-fabricated cable etc., together with preparation of all cabling related engineering documents like Cable Schedule, Inter-connecting Schedule etc. as specified.

(viii) Auxiliary Power Supply System (ix) Maintenance and Erection Tools and Tackles (x) Essential Spares (xi) Erection, Field Testing And Commissioning Including Erection Hardware (xii) Inspection and testing of I&C system equipment included in Bidder’s scope. (xiii) Engineering Documentation (xiv) Training Of Owner’s Personnel


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(xv) Provision of Performance Guarantee Test Instrumentation (xvi) Co-ordination with other Vendors 2.0 SG INTEGRAL CONTROL SYSTEM HARDWARE 2.1 I/O Modules: As required considering the requirements detailed in Section D 2.3 2.2 Distributed Processing Units (Controllers): As required considering the requirements

detailed in Section D 2.3 2.3 Engineering Station: 1 no for program development and modification unit complete with

VDU unit and keyboard / mouse. 2.4 Plant DCS Interfacing Requirement 2.4.1 One (1) no independent redundant bi- directional OPC link with Ethernet based TCP- I/P

protocol for interfacing SG Integral Control System with plant DCS. Interfacing cable as required with accessories are included in Bidder’s scope.

2.4.2 Independent redundant bi- directional OPC link for interfacing numerical protection relays

under Bidder’s scope of supply with plant DCS. Interfacing cable as required with accessories are included in Bidder’s scope. [@-]

2.4.3 OPC link shall be of latest version suitable for time stamped data transfer for alarm and

events. 2.4.4 @- Communication protocol will be decided during detail engineering stage. It is the

Bidder’s responsibility to offer communication link with protocol suitable for communication between DCS & Bidder supplied numerical relays.

3.0 BOILER TUBE LEAK DETECTION SYSTEM A microprocessor based Boiler tube leak detection system complete with all hardware,

software and accessories shall be provided for each unit. The requirements are detailed in Section D 2.4 of this specification.

4.0 FURNACE FLAME MONITORING SYSTEM Furnace flame monitoring and thermo graphic flame analysis system complete with all

hardware, software and accessories including display arrangement in CCR (central control room) shall be provided for each unit. The system is detailed in Section D 2.4 of this specification.

5.0 SYSTEM CABINETS AND MARSHALLING CABINETS


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System cabinets and Marshalling cabinets for control/ monitoring systems under Bidder’s scope of supply shall be complete with all instruments and control equipment duly mounted and pre-wired. The specification for these items are given in Section-D 2.4 of this specification..

6.0 FIELD INSTRUMENTS AND ACCESSORIES All primary elements, field mounted instruments and accessories, racks, field

termination cabinets / junction boxes, etc. as required for the services detailed below shall be supplied. The guidelines for provision of these items and technical specification for the same are detailed in Section 2.3 & D 2.4 respectively of this specification.

(a) All pipe mounted primary element within Bidder’s scope as required for the

complete plant I&C system. (b) All primary sensors / instruments as required for the I&C system under Bidder’s

scope. (c) All primary sensors / instruments integral to Bidder’s equipment such as pipe/tube

metal temperature elements, fuel feeder flow sensing etc. (examples are indicative and not exhaustive) required for monitoring /control in Purchaser’s DCS.

(d) Stubs / tapping points with root valves etc. for all pipe / equipment mounted

measuring points for all primary sensor / instruments required for monitoring /control in Purchaser’s DCS. Exact requirement of all such stubs / tapping points with root valves will be decided during detail engineering stage and Purchaser’s decision towards the same will be final.

7.0 FINAL CONTROL ELEMENTS All final control elements as required are included in Bidder’s scope. The technical

requirements are detailed in Section D 2. 3 & 2.4 of this specification. 8.0 INSTRUMENTATION AND SPECIAL CABLES Supply, laying & termination of complete Instrumentation, Control, Compensating, Special

cables, Pre-fabricated cable, Fibre optic cable etc., together with preparation of all cabling related engineering documents like Cable Schedule, Inter-connecting Schedule etc. The technical requirements of cables are covered in Section D 2.4 of this specification. Governing rule for Bidder’s cabling scope will be all I&C cables between the equipment where both the end equipments are in Bidder’s scope of supply. This will include but limited to the following applications:

(a) Between Sensor / Instruments under Bidder’s scope and Junction Box (b) Between Bidder’s scope Junction Box and Control/ Marshalling cabinets.


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(c) Between Bidder’s scope Control cabinets and Switchgear / MCC for command & feedback for Uni-directional Drives.

(d) Between Bidder’s scope Control cabinets and Motorised Valve actuators for

command & feedback. (e) Between Bidder’s scope Local Push Button and Control/ Marshalling cabinets /

Switchgear / MCC (f) All power supply distribution cables between Bidder’s scope Power Distribution

Box and Individual I &C equipment (All incomer cables to Bidder’s Power Distribution Box by Purchaser).

(g) All power supply cables for powering of solenoid valves under Bidder’s scope. 9.0 AUXILIARY POWER SUPPLY SYSTEM 9.1 230 V AC UPS and 24 V DC power supply for total plant I&C system equipment will be

provided by Purchaser. The details of the above power supply system are covered in Section D 3- Electrical section. Bulk power supply through redundant feeders will be provided for Vendor’s application. Bidder’s scope involves complete distribution of power supply required for I&C equipment under Bidder’s scope.

9.2 24V DC or 220 V DC supply system shall be utilized for equipment like trip valves /

equipment used for trip/ safety circuit application. All other solenoid valves shall be of either 24 V DC or 230 V AC.

9.3 + 24V DC supply shall be utilized for all the control equipment of I&C system. 9.4 Power supply monitoring shall be provided in the Purchaser’s DCS. 10.0 MAINTENANCE AND ERECTION TOOLS AND TACKLES The Bidder shall include in his offer all special maintenance and erection tools and

tackles as required for the system being offered. The details shall be furnished. 11.0 ESSENTIAL SPARES Bidder’s scope of supply includes I&C system essential spares as detailed in Section D 2,

TABLE-5. 12.0 ERECTION, FIELD TESTING AND COMMISSIONING INCLUDING ERECTION

HARDWARE 12.1 The CONTRACTOR shall erect, test and commission all Instrumentation and

Control Equipment supplied under the scope of this specification to the complete satisfaction of the PURCHASER. The requirements are covered in Section D 2, TABLE-3 of this specification.


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12.2 Impulse pipes, fittings and air supply and signal piping/tubing shall be supplied for all the

instruments under the scope of this specification. The guidelines for selection of size, material & rating depending upon service conditions and instrument installation are specified in Section D 2, TABLE-8.

13.0 INSPECTION AND TESTING FOR I&C SYSTEM EQUIPMENT 13.1 The Purchaser or Purchaser’s representative reserves the right to inspect and approve

the material, equipment and workmanship at all stages of manufacturing of all the main I&C equipment including the SG Integral Control System. Contractor shall call for inspection / witnessing the conductance of test of the equipment well in advance (minimum 21 days) to the Purchaser. Purchaser will indicate his preference regarding the inspection of the equipment. It is Contarctor’s responsibility to schedule the inspection & testing of different equipment / systems in a properly phased manner.

13.2 Inspection and testing requirements for different I&C system equipment (as applicable)

are tabulated in Section D 2.5 and Section D 2, TABLE-7 of this specification. Testing requirements not explicitly specified for any equipment but required for establishing the satisfactory performance / functioning of the equipment / system are deemed to be included in the scope of work of Contractor.

13.3 The following minimum equipment shall be considered for Inspection (witness) at

manufacturer’s works (Contractor’s and sub suppliers) by Purchaser as specified: (a) BMS & Boiler Protection System (b) All control valves / control dampers (c) Flame Monitoring And Analysis System (d) Boiler Tube Leak Detection System (e) Transmitters 13.4 The Contractor shall conduct site tests for following equipment / systems: (a) Site Acceptance tests including Trial Operation, Performance Guarantee Test &

Availability Guarantee Test for BMS & Boiler Protection System. The CONTRACTOR shall prove the guarantee of the system and equipment supplied.

(b) Flame monitoring & Analysis System (c) Boiler Tube Leak Detection System 14.0 ENGINEERING DOCUMENTATION 14.1 Bid data to be submitted are detailed in Section D 2, TABLE-1 of the specification.


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14.2 CONTRACTOR shall prepare and submit various engineering documents for OWNER /

CONSULTANT review and approval. These are detailed in Section D, TABLE-2 of the specification.

15.0 TRAINING OF OWNER’S PERSONNEL The CONTRACTOR shall provide training to Owner’s personnel as specified in Section D

1.6 and Section D, TABLE-6 of the specification. 16.0 PERFORMANCE GURANTEE TEST INSTRUMENTATION The CONTRACTOR shall provide plant PG test instrumentation as specified in Section D

1.6 of the specification. 17.0 CO-ORDINATION WITH OTHER VENDORS Vendor shall co-ordinate with Vendor’s of other equipment wherever technical

interactions are required. 18.0 GENERAL 18.1 Uniformity of Hardware 18.1.1 To provide smooth and optimal maintenance, easy interchange ability and optimal spare

parts management of I&C instruments/equipment, the bidder shall ensure that all the similar equipments shall be of the same make, series and family of hardware

18.1.2 Following equipments shall be of same make, series and family of hardware at minimum: (a) Pressure and Temperature Gauges (b) All pressure, Differential pressure, level & flow transmitters of differential pressure

type & Temperature transmitter. 18.2 All the systems in the Bidder’s scope shall work satisfactorily taking into account all the

required interconnections. Measurement and control equipment offered shall be complete in all respects and any equipment / accessories not explicitly indicated in this specification, but considered essential for proper functioning of equipment and process shall be included in the Bidder’s scope of work and supply.

18.3 Any I&C equipment required during any stages for the efficient / safe / reliable operation of

the plant either during detailed engineering / commissioning / after commissioning shall be installed and commissioned by the Bidder with in the quoted price.

18.4 Before taking over the plant by the Owner, all the instruments, system and auto control

loops shall run satisfactorily for at least one month at varying loads without disturbing any adjustment. During this period, supervision and maintenance of total instrumentation


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equipment shall be the scope and responsibility of the Contractor’s personnel. 18.5 Availability of Spares & Services Spares and services for SG Integral Control System shall be available for 15 years from

the date of handing over of plant by the Contractor. Bidder shall furnish the guarantee for the same in the bid offer. The guarantee shall be re-confirmed by Contractor on post contract execution phase from respective equipment / system vendor. The guarantee shall be absolute and shall be a criteria for vendor selection by Contractor.

19.0 TERMINAL POINTS

Area / System By Owner By Contractor 19.1 Plant DCS Complete system NIL 19.2 BMS / Boiler Protection Complete system NIL 19.3 SER System Complete system Within battery limits of scope. 19.4 Time Synchronisation

System Complete system NIL

19.5 Control Desk, Cabinets,

Panels NIL Cabinets / Panels-Within

battery limits of scope 19.6 Field Instruments and

accessories Outside Bidder’s scope As specified-within battery

limits of scope. 19.7 Final control elements Outside battery limit

requirement Complete requirement within battery limits of scope.

19.8 SWAS System with

Analysers Complete system NIL

19.9 Gas Analysers Complete system NIL 19.10 Erection hardware &

accessories Outside Bidder’s scope As specified-within battery

limits of scope. 19.11 Unit Control Panel with

panel mounted hardware / instruments

Complete system NIL

19.12 Hardware Annunciation

System Complete system NIL

19.13 Large Screen Display Complete system NIL


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System 19.14 Boiler Tube Leak

Detection System NIL Complete System

19.15 Smart Transmitter

Maintenance Facility Complete system except for Bidder’s scope

Provision of HART protocol signal from Bidder’s scope transmitters from Marshalling cabinet

19.16 Vibration Monitoring &

Analysis System Complete system except for Bidder’s scope

Provision of vibration pad on equipment bearing within battery limit.

19.17 Furnace Flame

Monitoring & Analysis System

NIL Complete System

19.18 PADO System Complete system NIL 19.19 CMMS System Complete system Provision/ arrangement of

equipment data for equipment outside battery limit.

19.20 MIS System Complete system NIL 19.21 I&C Cables Complete system NIL 19.22 Furniture Complete system except for

Bidder’s scope For Engg. Station for I&C equipment in Bidder’s scope.

19.23 Auxiliary Power Supply

System Complete system except for Bidder’s scope

Distribution within Bidder’s scope.

19.24 Maintenance & Erection

tools Outside Bidder’s scope Complete requirement for

Bidder’s scope. 19.25 Laboratory & Test

Instruments Complete system NIL

19.26 Essential Spares Other than Bidder’s scope. As specified 19.27 Consumables Complete system NIL 19.28 Erection, Field Testing

& Commissioning Other than Bidder’s scope. Complete requirement for

Bidder’s scope. 19.29 Inspection & Testing Other than Bidder’s scope. Complete requirement for


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Bidder’s scope. 19.30 Training of Owner’s

personnel Outside battery limit requirement

Complete requirement for Bidder’s scope.

19.31 Power Plant PG Test

Instrumentation NIL Complete requirement

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1.0 BASIS FOR PROVISION OF INSTRUMENTS / TAPPING POINTS 1.1 Pressure indicators shall be provided wherever indicating type Pressure transmitters are

not envisaged. The applications include: (a) Suction and discharge lines of pumps / fans, including on header section, if two

or more pumps are employed for the same service. (b) All input and output lines of process equipments. (c) Inlets and outlets of heat exchangers (both the fluid media) and de-super

heaters. 1.2 Pressure Switches shall be avoided as far as possible and in place, smart pressure

transmitters with soft limit value monitoring in DCS shall be provided. The applications will include the following:

(a) On all process lines / Equipments where parameter abnormality / status

including pre trips alarms to be communicated to the operator in control room. (b) For all permissives and protection conditions governed by safety operation of

the equipments. e.g. pr. adequate, pr. very high / very low conditions. (c) For all interlock conditions, governing starting of standby equipment or

subsequent equipments for safety operation of the system. (d) Inlet and outlet of filters / strainers. 1.3 Differential Pressure Switches (indicating type) shall be provided for the following

applications: (a) Across filters/strainers for remote monitoring (b) Across condenser for remote monitoring and interlocks. 1.4 Smart Pressure Transmitter shall be provided for all control applications included in

Bidder’s scope and as demand by the process. Pressure stubs with isolating valves shall be provided for mounting Pressure Transmitters.

1.5 Differential Pressure Transmitter shall be provided for all the requirements of Diff.

pressure, flow, level measurement. Pressure stubs with isolating valves shall be provided for mounting differential Pressure Transmitters.

1.6 Temperature indicators (Thermometers) shall be provided (a) On all process lines where local indication is warranted by the system either for

monitoring or testing.

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(b) On the inlet/outlet equipments such as desuper-heaters, Heat Exchangers & Coolers for both the fluid media.

(c) Differential temperature indicator shall be provided across BFP suction and

discharge service. 1.7 Temperature Elements: Thermocouples / RTDs shall be provided for casing metal

temperature monitoring and bearing temperature monitoring of 6.6 kV drives/motors. (a) All thermocouples and RTDs as required for implementation of control &

monitoring in Bidder’s system, shall be supplied. (b) The elements shall be duplex type with integral thermowell (except for metal

thermocouples). K Type Thermocouples shall be used for all temperature measurements wherever possible. However, for high temperature flue gas services R or S type thermocouple shall be provided. For metal thermocouples suitable MS pads, clamps, flexible extension lengths etc. shall be provided. Temperature elements in boiler and air ducts shall be in protective tubes.

(c) All temperature elements shall be supplied with associated junction box. (d) Compensating cable shall be provided with all thermocouples for terminating to

the control system eg. DCS. (e) Six nos. (2 nos. per phase) Resistance temperature detectors (RTD’s) shall be

provided for all 6.6 kV motors, for winding temperature monitoring. Each element shall be 3 wire type, duplex with thermowell assembly. RTDs shall be terminated in the external terminal box, for connection to DCS system.

(f) 1 no. duplex PRT-100 type RTD shall be provided for each bearing of HT

equipment and its driving equipment (motor). (g) All RTDs shall be PRT-100 type with each element being 3 wire type, duplex

with thermowell assembly. RTDs shall be terminated in the external terminal box, for connection to DCS system.

(h) For process temperature up to 200 degree C, RTD shall be used. Beyond 200

degree C temperature thermocouple to be used. 1.8 Level gauges shall be provided on all tanks and the maximum length of one gauge glass

shall not exceed 1 meter. The gauge glasses shall be stacked to cover the complete height of the tanks including over flow level. There shall be an overlap of minimum 100mm, when more than one level gauge is required.

1.9 Level switches: The instrument shall be provided for the following applications: (a) On all equipments (storage vessel) where parameter abnormality/status has to

be communicated to the operator in the control room.

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(b) All permissive, interlock and protection conditions governed by the safety operation of the equipment.

(c) The instrument shall be external cage type with SW connection with isolation

facility for surface mounted tanks and top mounted with still pipe for all sumps. Still pipes shall be provided with adequate supports.

(d) Conductivity type level switches shall be used for all heaters and drain pots. (e) Radar type level switches shall be used for bulk material bunkers. 1.10 Level Transmitters Stubs with impulse pipes, root valves for mounting Level transmitters

shall be provided on process equipments where continuous remote monitoring and/or control of level is envisaged. Wherever necessary standpipes or float chambers shall be provided and also makeup line for filling up the constant level vessel shall be provided.

(a) The instrument shall be displacement type for all low pressure and vacuum

applications involving two phase media viz: condenser, hotwell and LP heaters level measurements. Optionally, radar type shall be used.

(b) The instrument shall be differential pressure type or torque tube type for other

applications. (c) Radar type level transmitter shall be used for fuel oil storage tanks. (d) Admittance or Radar type shall be for sludge and slurry applications. 1.11 Flow Glasses shall be provided at the outlet of the pipe lines and shall be employed

under the following conditions: (a) Coolers (b) The instrument shall be rotary type with glass mounted for indication (c) Upto 6 inch on-line flow glasses shall be supplied and above 6 inch bypass type

flow glasses shall be provided. Sight flow and variable flow indicators shall be used for low pressure and low

temperature applications. 1.12 Speed Measurement shall be provided, where variable speed drives are to be

controlled from remote (e.g. BFPs, feeders, ID fans etc). 1.13 Flow elements shall be provided as detailed in Table-3. 1.14 Digital Display Unit (DDU) shall be provided for main steam pressure, temperature, fuel

flow, MW Export, MW Target, MVAR and frequency, condenser vacuum, Instrument air pressure, GPS Time, Weather Report (Room Temperature, Humidity, Barometer, Air purity etc).

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1.15 Pneumatically Operated Control Valves 1.15.1 Pneumatically Operated Control Valves shall be provided for all control application. If the

process demands any other control, then control valves shall be provided for those applications also. Where a single control valve can not meet the turn down ratio as dictated by the process, control valves with split range application shall be provided. All bypass valves of control valves shall be motor operated valves suitable for inching operation provided with position transmitters. All integrated bypass valves shall be motor operated. Electro-pneumatic positioners shall be used for all pneumatic control valves. Pressure test points & drains shall be provided across each control valve.

1.15.2 In case during detailed engineering, pneumatic control elements get converted to

electrically operated items, thyristor reversing unit based electronic power positioner (EPP) are in Bidder’s scope. In case, for these EPPs, power supply other than what is available if required, the same shall be supplied, by the Bidder.

1.15.3 The pneumatically operated control valves shall be provided with Smart Positioners,

diagnostics and HART compatibility. Control Valve diagnostics shall be transmitted through this HART Protocol to DCS.

1.16 Solenoid Valves shall be provided for all pneumatic control valves hooked up with

process interlock requirements and where direct tripping is involved. All solenoid valves shall be uniformly rated for 24VDC or 220V DC. The number of ways for solenoid valve shall be provided as indicated below :

(a) On line two (2) way solenoid valves shall be provided, where process line

of less than 2 inch with low pressure & temperature application is involved. (b) Three (3) way solenoid valves shall be provided commonly, where the pressure

is admitted or exhausted from a diaphragm valve or single acting cylinder. E.g.: Pneumatic operated spray water block valve.

(c) Four (4) way solenoid valve shall be provided for operating double acting

cylinders (If applicable). E.g.: Pneumatically operated on-off type dampers. (d) Dual coil, latch, unlatch type Solenoid valves shall be supplied for equipment

trips/critical applications. (e) Five-way, dual coil solenoid valves shall be used for Oil guns. 1.17 Position Transmitters shall be provided for all motorised inching valves .Position

transmitters shall be 24 VDC, 2 wire, non-contact type. 1.18 Electro-Pneumatic positioners shall be provided for all pneumatically operated control

valves, power cylinders etc., for converting controller output of 4-20 mA to appropriate pneumatic signal.

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1.19 Air Filter Regulators along with gauges shall be provided in each of the: (a) Air supply line to valve positioners /power cylinders (b) Air supply line to pneumatic interlocked block valves (c) Transmitter Racks 1.20 Interposing relay (To be mounted in Control room cabinet) for interface to the following: (a) Solenoid valve (two relays per valve) - Relays with contact rating of 2 Amps. (b) DC Starter (two relays per drive) - Relays with contact rating of 0.2Amps. (c) Hardwired signal exchange – as required. 1.21 Analytical Instruments-Withdrawable Type Conductivity Analyser; (a) Provision for mounting the above analyzer shall be made at the condenser hot

well along with necessary mounting arrangements/ accessories as required.

(b) For other analytical measurements, the sampling tapping points as called for,

shall be provided. 1.22 Vibration Monitoring system: For all HT rotating equipment bearings and for steam turbine bearings 1.23 Junction Boxes/Field termination cabinet: 1.23.1 All JBs /FTCs shall be SS. Junction Boxes shall be provided for (a) Termination of all sensors located equipment wise. (b) Termination of Duplex Thermocouples / RTDS (c ) Termination of limit switch, torque switch, position transmitter and control

demand, independently for each valve. 1.23.2 FTCs shall be provided for: (a) Connecting group of JBs area wise. (b) FTC shall be designed to provide multiple units in Boiler and Turbine areas.

FTCs reduce the number of cables entering the control room. Depending on the size of the multi core cable, one or two cables shall link to marshalling cabinet in the control room.

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1.24 Instrumentation & control cables and Prefabricated Cables with Anti-Rodent treatment shall be supplied to:

(a) Connect field instruments to field junction boxes/Local Panels. For switches,

both the SPDT contacts of switches shall be wired upto the J.B. (b) Connect limit switches, torque switches and position transmitters to their

respective field junction boxes. (c) Compensating cable shall be supplied for connection between the element and

the respective junction boxes / system cabinets as per guidelines. (d) Prefabricated cable for connecting between system cabinets, marshalling

cabinet to system cabinet, system cabinet to Relay Rack, system cabinets to Operator work stations , system cabinets to Engineering work stations etc. shall be in Bidder’s scope.

(e) Entire I&C cable within the battery limits. 1.25 Auxiliary Power Supply System (APSS) The power supply system shall conform to the requirements indicated in Electrical

portion of this specification. The power requirements of the various systems in the scope shall be consolidated and power supply shall be envisaged.

A list indicating the loads to be connected to different voltages shall be furnished. Bidder

shall distribute the power for his I&C system. All power supply in the cabinets shall be redundant and have auto change over facility or diode auctioneering.

1.26 Instrument Air Supply System Dry instrument air shall be distributed to various equipments of I&C system like control

valves, Analyzer purging, Transmitter racks, pneumatic On-Off dampers. The Bidder shall supply total Instrument air requirement Calculations, and design of Air compressor system along with the Bid.

1.27 Impulse pipes/tubes & fittings Impulse pipes, fittings and air supply and signal piping/tubing shall be supplied for all

the instruments under the scope of this specification. Instrument piping shall be designed for maximum design pressure and temperature of the process. Pressure measurement connection shall be ½’’ or 12mm pipe connection. Instrument on Vacuum system at CEP inlet should have vent lines connected to high point in the condenser. Instrument air tubing shall be copper, PVC coated to avoid oxidation at the surface of the tubing.

1.28 Instruments for Performance Testing

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All instruments required for performance testing to prove the guaranteed performance of the plant shall be supplied by the BIDDER for the Performance Test. These test instruments shall have test certificates from reputed test house, valid for the duration of the performance test.

1.29 System cabinets & marshalling cabinets shall be provided for all the systems in Bidder’s

scope. 1.30 Stand pipes required for hot well, deaerator, heaters, GSC, drain pot, etc. shall be

provided by Bidder. 2.0 SELECTION OF RANGES FOR INSTRUMENTS 2.1 The ranges of the instruments shall be selected based on the following philosophy

indicated below: 2.2 For pressure and draft measurements, the maximum operating pressure will be within 70

to 80% of the maximum scale range. All pump suction measurement and steam pressure measurements in extraction steam and in heaters will cover the negative pressure range also and all draft gauges will cover the negative pressure as well as the positive pressure as the case may be.

2.3 For temperature measurement, the maximum operating temperature will be within 80 to

90% of the maximum scale range. 2.4 For pressure switches and temperature switches, the set points shall fall within 40% to

70% of the scale range selected. 2.5 For level measurement, the maximum of the range will cover the overflow point or six

inches from the top of the vessel and the minimum of the range will be six inches above the bottom of the vessel. Also, the gauge glasses will be stacked with overlap to cover permissive, alarm and trip levels.

2.6 For flow measurement, the maximum range shall be fixed at about 10 to 15% above the

maximum operating flow. 2.7 For electro-chemical measurements (conductivity, pH, dissolved O2, Silica etc.), the

maximum range will be around 10 to 15% higher than the recommended alarm settings. 2.8 For gas analysers (if included in scope), the maximum range will be around 10 to 15%

higher than the recommended alarm settings. 3.0 PG TEST POINTS 3.1 Pressure, temperature and flow test points shall be provided in line with latest

performance test code requirements. 3.2 In addition, pressure and temperature test points shall be provided for the following

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services: (a) At the discharge of all pumps and fans (b) At the inlet and outlet of the heat exchangers for the fluid media involved (c) Adequate number at the Combustor at different zones (d) At the inlet and outlet of each control valve 3.3 Pressure test points shall be complete with root valves and shall terminate with a nipple. 3.4 Temperature test points shall be provided with thermowell with a cap and chain. 4.0 SIZE OF TAPPING POINT STUB, NO. AND SIZE OF ROOT VALVES FOR

DIFFERENT TYPE OF MEASUREMENTS Sl. No Qty. Of Root

Valves Stub & Root Valve Size

Service Conditions

A. Pressure & Differential Pressure Measurement (i) 2 25 NB >=62 bar OR 425 degree C (ii) 1 15 NB < 62 bar AND425 degree C. B. Level Measurement B1-Level Gauge And Switch (i) 2 25 NB >=62 bar OR 425 degree C (ii) 1 15 NB < 62 bar AND 425 degree C. B2-Level Transmitter (Displacement Type) (i) 2 40 NB >=62 bar OR 425 degree C (ii) 1 40 NB < 62 bar AND 425 degree C. B3-Standpipe For Level Measuring Instrument (i) 2 80 NB >=62 bar OR 425 degree C (ii) 1 80 NB < 62 bar AND 425 degree C. C-Flow Measurement

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(i) 2 25 NB >=62 bar OR 425 degree C (ii) 1 25 NB < 62 bar AND 425 degree C. D. Sampling System Measurement (Steam & Water Service) (i) 2 25 NB >=62 bar OR 425 degree C (ii) 1 25 NB < 62 bar AND 425 degree C. 5.0 SPECIFIC INSTRUMENTATION REQUIREMENTS FOR STEAM GENERATOR 5.1 Redundant speed sensor shall be provided with each coal feeder and shall provide an

output to the feeder speed control. All feeder speed sensor tachometer-feedback circuits shall be suitably shielded from any electrical and mechanical interference.

5.2 A no-coal flow detector complete with amplifier and pick-up located at the outlet of each

coal feeder shall be provided to detect no-coal flow. 5.3 Coal flow measurement with the help of conveyor speed and active load cells shall be

provided for each feeder. The coal flow rate along with the integrator shall be made available in plant DCS.

5.4 Super-heater tube metal thermocouples shall be provided on every fourth tube

connected to the intermediate super-heater outlet headers, the intermediate reheat outlet headers & the final super heater/ reheater outlet header.

5.5 Furnace gas temperature probes on each side of furnace for monitoring of gas

temperature at the furnace outlet. The probes shall be moveable type. 5.6 Furnace flame monitoring system with UV type flame scanners. The system shall

conform to NFPA requirements. 5.7 Digital Flame Scanners (microprocessor based) shall be supplied to cover 100% Oil and

coal firing .The scanner electronics shall be mounted in Control room and shall include the following signals to Purchaser’s DCS: 4-20 mA output for Flame intensity. 4-20 mA output for Flame Quality Serial MODBUS connection to the DCS

6.0 SG INTEGRAL CONTROL SYSTEM PHILOSOPHY 6.1 MEASUREMENT SYSTEM (MS) 6.1.1 The MS shall have the following features:

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(a) Linearisation for temperature measurement i.e. mv Vs Deg. C (b) Square root extraction for flow measurement, where the measurement is in

differential pressure. (c) Integration for totalising the flow measurement, whenever applicable. (d) Compensation for variation in pressure or temperature or density for flow / level

measurement. E.g.: Feed water flow / Boiler drum level. (e) Limit value monitor for generation of contacts for alarm/interlock purpose. E.g.:

Boiler Tube metal, Bearing, winding temperature measurements (f) Each of the analog transmitters shall be Smart type with the following:

(i) 4-20mA DC signal with 24V DC interrogation. (ii) HART protocol based digital communication (g) All these Transmitters shall be hooked up to a PC based Centralised Calibration

system, which shall have Diagnostic and Configuration software. This system shall be located in MEE room.

(h) All contact inputs shall be interrogated with 24 / 48 V DC. 6.2 CONTROL SYSTEM-DESIGN FEATURES (a) No single random fault in the entire automation and control system will cause a

load loss, forced outage or unit trip. (b) No two simultaneous faults shall lead to or potentially cause damage to plant (c) Safety related instrumentation and control shall be designed with a fail- safe

mode. (d) No single fault shall jeopardise the functioning of the entire system. (e) The control and automation system and the field instruments and actuators as

well as it’s support systems, power supplies and data networks shall be immune to the electromagnetic interference and shall conform to the internationally accepted standards.

(f) To meet the operational and safety requirements, the control system hardware

and software shall conform to a modular, hierarchical architecture. 6.3 CLOSED LOOP CONTROL SYSTEM (CLCS) 6.3.1 The CLCS shall control the process variables automatically both under steady state and

dynamic conditions with in the limits specified under guarantee clauses over the entire

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operational range of the equipment/system. 6.3.2 The CLCS shall have the following features: (a) Provision of predictive and/or adaptive controls in addition to PID controls as

required by the system. (b) Set point adjustments and indication from operating CRTs for process variables

which need to be changed during load changes, start-up, shutdown, normal or under any other emergency conditions.

(c) Fixed set point at the software level/hardware level (only changeable by the

maintenance engineer) and indication for those process variables which need not be changed with respect to load or otherwise.

(d) Bias adjustment with indication where a single controller is controlling more than

one final control element (control valve, control damper, speed drive etc.) to maintain the same process variable.

(e) Auto and manual control facility shall be transferable in both directions without

bump of the value of the process variable to control the parameter during manual operation. Both master Auto Manual station and Auto / Manual station for individual control element shall be provided in CRTs. Manual control facility will include operation from Back Up Control Panel also in addition to operation from operator station.

(f) Characterisation of final control element to suit the various applications with

respect to load or otherwise as dictated by the process. (g) Function generator to provide necessary characterisation or variation of set points

with respect to load, speed or any other requirement. (h) Soft Auto /Manual station interlocks to drive the final control elements to a suitable

position for safe plant operation in the event of process/equipment abnormal conditions.

(i) Blocking/Interlocking function as dictated by process/equipment. (j) Monitoring of loop failures or any hardware failure in the loops. (k) Fail safe operation of final control elements in case of failure of motive power or

signal. 6.4 OPEN LOOP CONTROL SYSTEM (OLCS) 6.4.1 Protection, interlock and sequence controls constitute OLCS. This system shall enable

the operator for safe start up and shutdown and carryout normal operation both from control room and local areas. Protection and Interlock shall be provided for all the equipment and system to safeguard the equipment against abnormal conditions which

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may result in the failure and less utility of the equipment and protect the operating personnel. Controls shall be provided to start/shutdown various systems and/or any equipment with associated auxiliaries and to operate the Unit on line with optimum number of operations and higher safety.

6.4.2 The OLCS shall have the following features as a minimum: 6.4.2.1 Features-General Requirements (a) The logic and sequence control shall be Digital distributed �icroprocessor based

and programmable. (b) Enable the operator to start/stop various unidirectional motors, to open/close

various valves and dampers and carry out inching operation of bypass valves or any other similar equipment both from control room and local areas.

(c) The system shall be designed based on the philosophy of command to energise a

relay or solenoid valve. (d) Where there is more than one pump or fan for the same service (say 2 pumps),

auto standby features shall be provided to select the standby unit and this standby unit shall start automatically on failure of running pump or on applicable process criteria (say low discharge pressure) with an annunciation.

(e) All the contacts of the sensors used in protection circuit shall be monitored. (f) Triple redundant sensors shall be provided when used in protection circuits for

major critical equipment and 2 out of 3 logic shall be derived for further use in protection circuit

6.4.2.2 Features-Interlock Requirements (a) Permissive conditions for a equipment start shall be provided. The permissive

conditions within the equipment are bearing temperature normal, winding temperature normal, adequate suction pressure, bearing vibrations normal, bearing lubrication oil pressure normal, switchgear in service, switchgear not in test, no protection trip command persisting (as applicable) etc.

(b) The permissive conditions from a process system related equipment are

establishment of free path for the flowing medium under all start-up, emergency and shutdown conditions, closure of discharge valve for the starting of first of the identical pumps/fans and then opening the valve after the operating condition is established etc.

(c) Selection of standby equipment and starting the equipment automatically on the

tripping of running equipment and/or desired process parameter conditions (say loss of discharge pressure or low level in the discharge tank etc.)

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(d) Isolation of the tripped equipment from the main process. (e) Any other conditions for safe starting and shutting down the equipment. 6.4.2.3 Features-Sequence Control Requirements Sequence control shall be provided to start and stop the equipment and the associated

auxiliaries. The sequence control shall have the following features: (a) Once the start-up or shutdown of an equipment is initiated either manually or

automatically from the system, the control of associated auxiliaries shall be automatic with facility for manual operation at each stage (step).

(b) Criteria check up for each stage of operation with monitoring and displaying. (c) Bypass facility for each criteria when only the feedback signal/display is incorrect

but the actual condition is fulfilled. This activity shall be logged and annunciated in control system (DCS).

(d) Adequate time delay between the steps as dictated by the process to establish an

operating parameter or healthiness of an equipment. (e) Normally, the auxiliaries of the standby equipment should be running (as

applicable) so that the standby equipment is started without loss of time. 6.4.2.4 Features-Protection Control Requirements The following minimum protection shall be provided for the various equipment/system as

applicable to trip the equipment. (a) Any condition which endangers the safety of the plant personnel (b) Any of the permissive conditions becoming abnormal thereby producing a

dangerous condition in operating the equipment. (c) The conditions from process such as dry flow conditions, flashing conditions or

any other conditions that may create cavitation. 6.5 REDUNDANCY AND AVAILABILITY REQUIREMENTS 6.5.1 Measurement system (MS), Closed Loop Control System (CLCS) and Open Loop

Control System (OLCS) shall all be configured with redundancy at processor modules, communication modules, data bus and power supply modules.

6.5.2 For Measurement System, redundancy at sensor level and I/O module level is not

required

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6.5.3 Both CLCS & OLCS shall be configured with I/O channels redundancy for each

sensor/signals. Where redundant sensors are provided redundant I/O channels shall be provided for each sensors/signals.

6.5.4 For all CLCS loops triple redundant sensors shall be provided. This will include sensors

provided for compensation also. Similarly for critical protection logic requirements triple redundant sensors for 2 out of 3 logic shall be provided to avoid spurious tripping.

7.0 SENSOR REDUNDANCY- PHILOSOPHY 7.1 Two out of three measurements philosophy shall be adopted for the control of all closed

and critical open loop variables for reliability of operation. The control system shall select the median value for the normal control purpose.

7.2 In case of deviation of one transmitter output from the other two, the same shall be

automatically isolated and average output of the remaining transmitters shall be fed to the control and measurement system and the control loop in this case shall be maintained on auto, with an alarm on the operator’s monitor as well as maintenance engineer’s monitor. In case of failure of the two remaining transmitters in circuit, deviation of one transmitter output is more than the preset limit compared to the other transmitter, there shall be automatic bump less transfer and changeovers shall have suitable alarms.

7.3 For signal compensations, separate signals from separate transmitters shall be used for

measurement and control. 7.4 Sensor Redundancy For OLCS 7.4.1 All sensors for the following causes of trips shall be triple. (a) Unit trips, (b) Boiler trips, (c) Turbine trips (d) Trip of any auxiliary which will lead to substantial (50%) loss of unit availability. 7.4.2 All sensors for the following causes of trips shall be dual (requirement specified at Clause

10.8.1 will have priority of application). (a) All HT equipment trips. (b) All LT equipment trips. 7.4.3 Single sensors shall be provided for the following:

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(a) Alarm (b) Permissive (c) Measurement 7.4.3 Sensor Redundancy For CLCS: Triple redundant sensors shall be provided. 8.0 SG INTEGRAL CONTROL SYSTEM EQUIPMENT / SYSTEM –FUNCTIONAL

REQUIREMENT 8.1 DISTRIBUTED PROCESSING UNIT (DPU) 8.1.1 Processor will be minimum 32 bit with floating point arithmetic capability. It will have

adequate capacity of volatile memory to store dynamic plant data, control programmes and self- diagnostic routines. Also it will have adequate capacity of non- volatile memory to store programmes, standard software to perform control data acquisition and diagnostic functions. Battery back up (if applicable) for duration not less than 50 hours shall be provided. Memory expandability of 150% of offered capacity shall be provided.

8.1.2 Processor shall have the following functional capabilities as a minimum: (a) Mathematical Functions: To meet the functional requirement of the control

system and provision to add more algorithms by the purchaser. (b) Logic Functions : For performing Boolean operations and time delay

requirements (c) Control Techniques: Shall include Multivariable, feed forward, feedback,

cascade, auto tracking, ratio and bias, dynamic dead band, proportional, integral, derivative and their combinations, auto inching, auto limits, blocks, run- ups, run downs, over rides, analogue hold and any other techniques as may be necessary.

(d) Point Status and Quality feed back. 8.1.3 INPUT/OUTPUT MODULES 8.1.3.1 Digital Input Modules shall have the following features:

(a) Signal isolation (optical) (b) Fuse protection (c) Contact bounce protection (d) Field cable monitoring

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(e) Short circuit protection (f) Configurable as status input, latched input (g) Alarming of abnormal state (h) The interrogation voltage for digital inputs shall be 24 V DC The number of channels per DI module shall be maximum 32 8.1.3.2 Digital output Modules shall have the following features: (a) Individually fused (b) Individual contact suppression (c) Configurable as momentary, latched or pulse-width modulated outputs (d) Individually definable default state (e) Output read back verification (f) Short circuit protection The number of channels per DO module shall be maximum 32 8.1.3.3 Analog Input Modules shall have the following features:

Analog inputs can be 4-20 mA DC, RTD ( Pt 100 ) , Thermocouple (a) Signal isolation (Galvanic/ Opto-coupler) (b) Fuse protection and fuse failure detection (c) Transmitter power supply at 24 V DC (d) Input filtering for noise level (e) Cold junction compensation for thermocouples (f) Transmitter monitoring for parity, wire break and limit values (g) Monitoring of A/D conversion (h) Conversion to engineering units (i) Test for normal or extended range (j) Detection of open circuit for thermocouples

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(k) Detection of open circuit for thermocouples (l) Alarm limit testing for high, high-high , low, and low-low substituted values The number of channels per AI module shall be maximum 16 8.1.3.4 Analog Output Modules shall have the following features: (a) Analog outputs shall be 4-20 mA DC (b) Direct or reverse operation (c) Loop check back of output (d) Default options upon failure The number of channels per AO module shall be maximum 16 8.2 Design Features/Requirements of Process Controllers (DPU) 8.2.1 Microprocessor based multiloop controllers with input/output ports/cards shall be used

with configuration and control software. All open/close control loops shall be easily configurable using user-friendly software. Controllers shall be able to operate in either manual, auto, cascade mode. Mode changeover in either direction shall be bumpless. The controller shall also have facility for slow and fast ramping of set point and output.

8.2.2 The controller should be capable of implementing complex and advanced control

strategies through the use of exhaustive set of control algorithm/software blocks. These shall include PID, adaptive, feed forward, dead time, lead-lag compensation, high-low signal selection, curve fitting, real time computational capability etc. In addition the controller shall be able to perform batching, sequencing, interlocks and logic functions. Failure of one loop shall not result in failure of other loops.

8.2.3 The distributed processing unit shall be provided with redundant floating power supply.

The power supply modules, which are vital to the system’s continuous operation, shall have the means to receive power from two (2) independent power sources. Suitable battery back up shall be provided for protection of volatile memory (for 72 hours).

8.2.4 The system shall have 1:1 redundancy with respect to the processor modules, power

supply modules, communication modules and network interface. The system shall be designed in such a manner that in the event of failure of the primary controller, the entire configuration of the failed controller shall be instantaneously and automatically transferred to the back-up controller without operator’s intervention. Mode changeover in either direction shall be bumpless. Simultaneously, a message should appear on the video-monitors of the Operator's/Engineer's work station indicating the failure.

8.2.5 The system shall be capable of accepting commands from Purchaser’s DCS system OS

and shall be capable of sending the feedback to DCS OS through MMI system of DCS.

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8.3 ENGINEERING STATIONS (ES) (a) To generate control software through logic diagrams with out any programming

knowledge (b) To generate graphic display and control displays, facility to change/enter all the

attributes of analog and digital I/O points, calculated and Boolean variables and constants like scan rate, process range

(c) To test, configure/reconfigure process interface modules/cards (d) CLCS tuning (e) To accumulate I&C faults to analyse downtimes and time to repair (f) To run offline system diagnostic programmes (g) On- line fault detection through diagnostics (h) Other maintenance Engineer's functions. 8.4 DCS SYSTEM PERFORMANCE REQUIREMENTS 8.4.1 DCS System performance requirement (Under worst loading conditions) shall be as

follows: (a) Scanning rate of analog signals Maximum 1 sec for measurement (b) Scanning rate of digital signals Maximum. 50 ms (c) Scanning rate of pulse signals Max. 50 ms (d) Loop execution time for CLCS Maximum 250 ms (For all Loops) (e) Loop execution time for OLCS Maximum 50 ms (For all Loops) (f) Controller output update for CLCS Every 250 ms (For all CLCS Loops) (g) Controller output update for OLCS Every 50 ms (For all OLCS Loops) (h) Controller Loading Max. 50 % 8.4.2 Worst Loading Conditions for SG Integral Control System: The worst loading condition shall include the following tasks: (a) All process inputs scanning and processing is in progress and all the data is

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transmitted over the main data bus every one second. (b) All closed loop controls in operation (c) All open loop controls in operation (d) All output devices are in operation with rated performance/speed. (e) Control/information request is initiated on control VDU. (f) In burst mode operation, 100 digital alarms are generated per second for a period

of 10 seconds. 8.5 DCS System Reliability / Availability Requirement shall be as per the standard specified

in code. 9.0 BMS AND BOILER PROTECTION SYSTEM 9.1 A microprocessor based independent fail safe fault tolerant control system shall be

provided for BMS & Boiler protection system. System shall be fail-safe type with minimum Safety-Integrity Level 3 as defined in IEC 61508 and independent for each boiler.

9.2 BMS & Boiler protection shall be either of TMR (triple modular redundant) type or any

other approved configuration as approved by the IEC code. 9.3 The system shall be certified from an authorised agency. Copy of certification with all

conditions specified shall be submitted by Bidder with Bid offer. 9.4 System shall be provided with redundant power supply modules with power supply

provided through redundant feeders. 9.5 System shall have an integrated sequence of event recording and alarming facility with a

resolution of 1 mili-second for all input signals. 9.6 The system shall be able to provide fault diagnostics covering up to 99% on all the

possible internal failure of hardware. 9.7 System shall be able to carry on-line modification of application programme. Necessary

tools for engineering modification shall be provided. 9.8 Protection system output shall be directly hardwired to field control elements. 9.9 Where the same field sensor signal is used for both Boiler protection and plant DCS, field

sensor shall be directly connected to the protection system and the input signal to plant DCS shall come as an output from protection system.

10.0 TRUE TMR FEATURES

Prabhu_Balaji

Rectangle

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10.1 True TMR configuration essentially means that there shall be three parallel processing

channels each with dedicated Input modules, Controller, Output modules, Communication modules, power supply modules, and relay. The outputs from the relays shall be finally wired out, in 2 out of 3 mode.

10.2 The communication Buses, Sensors and Power supply shall also be triple. 10.3 There shall be extensive, on-line, software validation between the three processing

channels such that the system availability is 99.7%. 10.4 The three processing channels shall be physically located in three separate cabinets. 10.5 There shall be continuous hardware cyclic checking upto the relays and suitable

diagnostics to identify any faults and annunciate. 11.0 SPARE PHILOSOPHY FOR SG INTEGRAL CONTROL SYSTEM I/O CHANNELS: (a) Spare I/O Channels: All types of I/O modules shall be provided with 10 % spare

channels. Spare channels shall be wired and shall be distributed among the control processors.

(b) 10% hot spare I/O modules (installed) shall be provided. (c) 10% spare slots for I/O modules distributed among the control processors. 12.0 SPECIFIC DESIGN REQUIREMENTS 12.1 VALVE ACTUATOR / CONROL SYSTEM / MCC INTERFACE All the On-Off valves of SG Package shall be provided with integral actuators. The

required actuator power supply shall be from the switchgear. The actuators shall accept potential-free contact command signals from Control system (eg. DCS) and following feed back signals (potential) shall be provided to control system (eg.DCS):

(a) Open Position (b) Close Position (c) Open Torque actuation (d) Close Torque actuation (e) Actuator trouble (f) Actuator ready to start 12.2 UNI-DIRECTIONAL LT DRIVES/ CONTROL SYSTEM / MCC INTERFACE

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LT drives like Pumps and Fans shall have the following interface with Control system and

MCC (a) 24 V DC Logic level On-Off commands from control system to MCC (b) Feed backs from MCC to control system shall include: (i) On/Running (ii) Off/Stop (iii) Trip (iv) MCC Ready 12.3 All motorised bypass valves & Bypass Dampers shall be inching type and shall be

provided with non-contact type position Transmitters. 12.4 For all the variable frequency drives, all the analog and digital signal exchanges with

Purchaser’s DCS / control system shall be provided, as required. 12.5 Local Stop push button (Shrouded type) shall be provided for all HT and LT drives for

emergency stopping of the drives. The contact pf the push button shall be wired directly to MCC to initiate trip. All such contacts shall be suitably connected to control system for reporting of local operation.

12.6 Two Emergency trip push buttons with front covers, for each Boiler shall be provided in

the control room in UCP. 12.7 All field instrument, local panel / cabinet enclosures shall be IP-65 12.8 Individual (one for each transmitter) purging line connected to the impulse line before the

root valve with required accessories shall be provided for all Air and Flue gas transmitters impulse lines.

12.9 ACTUATORS for control valves: 12.9.1 All regulating type final control elements shall have actuators of pneumatic type

excepting LP/HP bypass and Turbine governor valve, which shall be hydraulic type. Actuators shall be provided with air failure lock to obtain the required fail safe condition, control contacts as warranted, adjustable minimum / maximum stops, local position indication and two (2) wire electronic position transmitters with solenoid valves wherever necessary and air filter regulator. Fail safe action of the final actuator shall be as follows:

(a) Modulating control- Stay put (b) ON/OFF control -Move to safe-end-position

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12.9.2 All actuators shall be provided with hand wheel for local operation. 12.10 CONTROL VALVES: 12.10.1 The control valves shall be capable of handling at least 130 percent of required

maximum flow at full open condition. Control valves shall be provided with manual isolating and bypass valves for facilitating maintenance wherever alternative flow paths are not available.

12.10.2 SMART Positioners shall be used for all regulating services. Two wire electronic position

transmitters and limit switches shall be provided on the valve wherever required depending upon the system requirement. SMART Positioners shall be provided with HART protocol and Diagnostic features.

12.11 All the cables in the Hot Zone (combustor region) shall be fire survival cable conforming

to IEC 331standard.The cables in other areas shall be FRLS, conforming to IEC 332 standard.

12.12 For coal Feeders, three (3) number Feed Rate signals shall be provided from each

Feeder Cabinet to DCS. 12.13 Feeder calibration is very critical and Bidders shall envisage a scientifically correct Feed

rate signal computation method and a proven method of calibration. The Owner / Project Manager personnel have to be trained specially on this.

12.14 KKS Tagging philosophy is to be followed uniformly. 12.15 The “Test Position” of each DC starter shall be monitored and alarmed in DCS. 13.0 GENERAL TECHNICAL REQUIREMENTS 13.1 The general engineering and calculations shall be made as per prevailing Indian,

International standards acceptable to Owner / Project Manager. Wherever such standards are not available, they shall be as per the best practice in India and abroad.

13.2 All measurements shall be in metric units 13.3 All the electronic circuitry shall be built-up with plug in modules providing maximum

flexibility and easy servicing. 13.4 Anti-vibration mountings and shock absorbers shall be provided for cabinets, desk and

panels. 13.5 The cabinets surface shall be thoroughly degreased, smoothed, filled and painted with

rust resistant primer to present a smooth and flat finish. Front of cabinets shall be primed and filled as required at least two coats of primer and minimum two coats of final colour above the primer coating to present a smooth and mat finish.

13.6 SS Legend plates shall be provided on the cabinet front and back, desk face, unit control

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panel, local panels, junction boxes, transmitter racks, FTCs, Remote I/O rack, instruments, Control valves etc., for all items supplied to identify the equipment. Overall dimensions of the nameplates shall be decided by the text of legend, maintaining overall consistency and clarity and avoiding size variations.

13.7 The cabinets shall be upright; floor mounted, front open type with removable door and

shall have ventilation with steel mesh. The outside colour of all instrumentation cabinets, control desks, consoles, local cabinets, marshalling cabinets, system cabinets, junction boxes, Transmitter racks, FTCs etc. shall be of light grey shade no. 631 of IS: 5, 1978 or equivalent international code. The inside colour of all these cabinets shall be brilliant white.

13.8 The cabinets shall be made from CRCA Steel sheet with a minimum thickness of 2 mm.

Removable eye lifting lugs shall be furnished and installed on all cabinets. 13.9 All Critical control valves shall be provided with anti-cavitation trim. Control valves /

dampers shall be supplied with all accessories including non-contact type position transmitters and E/P Positioners. Combination of I/P + Pneumatic positioner is not acceptable. All inching valves shall be supplied with position transmitters integral with the valve positioner.

13.10 All Temperature sensors shall be Duplex type and field mounted temperature transmitter

shall be provided for all temperature measurement for control applications. This will include equipment bearing temperature measurements also.

13.11 Switches (pressure, temperature, level & flow etc.) shall be provided only for critical

equipment trip such as BFP/ CEP trip etc. Wherever possible, transmitters shall be provided with required redundancies for all other purposes.

13.12 Where multiple functions like monitoring /control/alarm etc. are sought to be performed

based on a parameter value, in minimum dual sensor shall type be provided. 13.13 All outdoor field equipment shall be provided with epoxy painting. 13.14 Individual continuous purging shall be provided for all Air and Flue gas transmitters. The

tap points for these services shall be “Y” shaped. The purging line shall be shall be connected near the root valve only and not at the Transmitter end.

13.15 All local cabinets / utility plant control panels with bottom cable entry shall be provided

with suitable pedestals for easy cabling. The panels shall be designed for ease of operation of operating hardware and monitoring the indicators.

13.16 All local panel indicating lamp/indicating type Push button should be of cluster LED type

only. All local panels shall be of double door type instead of double leaf type to avoid ingress of dust in dust prone areas.

13.17 All motorised bypass valves shall be inching type and shall be provided with position

transmitters of non-contact type.

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13.18 Conductivity type dedicated level switches shall preferably be used for heater level

applications. 13.19 Spring-loaded terminals shall be used for termination of instrumentation cables at field

JBs, FTCs and local panels. 13.20 Instrumentation cables shall be laid in separate cable trays. 13.21 Cable number tags and markings will be provided at every 30 meters along the entire

length of cable. 13.22 All JBs, FTCs and similar equipment in Boiler, STG and other areas shall not have top

entry to avoid dust entry. No equipment shall have top entry for cables. 13.23 All the switches, wherever provided shall be provided with 2nos. changeover contacts

and both shall be wired upto Junction Boxes. 13.24 The Instrumentation & Control (I&C) equipment/system offered shall be of proven

system The models of all instruments, field sensors, final control elements, flow elements, control system equipment and monitoring system equipment as covered in this section shall be field proven, i.e. installed, commissioned and successfully operating for a minimum period of 3 years. The Bidder shall furnish list of installations and user’s certificates to prove the same and shall be subjected to Purchaser's approval.

13.25 All the systems in the BIDDER’s scope shall work satisfactorily taking into account

all the required interconnections. 13.26 Any other control and instrumentation / equipment not specifically included but required

for plant operation/performance, along with the scope shall be identified. 13.27 Grouping of instruments in JBs in Vendor scope is subject to Purchaser’s approval. 13.28 All stubs, root valves, within Bidder’s battery limits are included in Bidder’s scope. 13.29 Suitable expanders shall be provided for small diameter pipes to enable mounting

of temperature instruments to have minimum immersion lengths of 3 inches. 13.30 Vendor shall furnish set points for all instruments mounted on his pipe/equipment. 13.31 Vendor shall size the control valves/flow elements in his scope as per latest applicable

standards. 13.32 Vendor shall provide dedicated sensors for all pre-trip alarms. Vendor shall provide

sensors for fault monitoring and alarming for the equipment within the scope. 13.33 Technical features of instrument types not covered in Section D 2.4 shall be subject to

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Purchaser/Consultant’s approval. 13.34 IBR certificates as applicable for control valves, flow elements, thermowells, etc., shall

be furnished. 13.35 Signal Exchange Between Bidder’s Equipment / System and Purchaser’s System (a) All the signals required for interlock / alarm / SER purpose (to be implemented

in the Purchaser's DCS) shall be hardwired. (b) All binary outputs provided from Bidder’s cabinet/local panels/sensors for

connection to Purchaser’s system shall be potential free contacts with a rating of 0.2 amps at 220 V DC or 5 amps at 240 V AC. All check backs to Purchaser’s system shall only be potential free contacts.

(c) All analog outputs provided from Bidder’s cabinet / local panels/sensors for

connection to Purchaser’s system shall be isolated 4-20 mA DC. (d) Command outputs from Purchaser’s control system (DCS) to Bidder’s

motorised valve actuator integral starter will be logic level signal (24 V DC) and necessary interposing relays suitable to accept 24 V DC logic level command signal shall be provided in Bidder’s MOV actuator.

14.0 CODES AND STANDARDS 14.1 All equipment, systems, software and services covered under this specification shall

comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. All codes and standards referred in this specification shall be understood to be the latest version on the date of offer made by the Bidder, unless otherwise specified. If such standards are not existing for any equipment or system, the same shall comply with the applicable recommendations of the following professional institutes:

(a) National Electricity Manufacturers Association (NEMA) (b) The Institute of Electrical and Electronic Engineers (IEEE). (c) Instrumentation Systems and Automation Society (ISA). (d) American National Standards Institute (ANSI). (e) Deutsche Industries Norman (DIN). (f) International Electrochemical Commission (IEC). (g) International Consultative Committee on Telephone and elegraphy (CCITT). (h) Verin Deutschar Eisecnhuttenleutte (VDE)

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(i) Indian Standard Institute (ISI). 14.2 Standards not indicated in the specification are acceptable (subject to approval by the

Owner / Owner’s Representative) if they are established to be equal or superior to the standards indicated in the specification.

14.3 The VENDOR shall furnish English translation of all standards to which the equipment

and systems offered conform to. 14.4 The specific codes and standards applicable are listed in Section C, TABLE-5.


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TITLE

1.0 SPECIFICATIONS FOR INSTRUMENTS TO BE SUPPLIED ARE AS FOLLOWS. 1.1 Pressure Indicators/DP indicators Direct reading, pipe mounted Pressure gauges of die-cast aluminium body, with

6 inch(150mm) phenolic dial (white dial with black numerals), 316 SS/304 SS Bourdon tube for high pressure application and 316SS Diaphragm/bellow for low pressure applications, AISI 304 movements and micrometer type adjustable aluminium pointer an accuracy of +/-1.0% of span including accessories like siphons for steam services, snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services and name plate, etc. Material of accessories shall be SS. IP65 or equivalent degree of protection for enclosure. Over range protection shall be 50% above maximum pressure. Armoured capillary of 10 M shall be provided as required. Process connection shall be ½’’NPT (F).

1.2 Pressure Switches/DP Switches Non indicating type, field mounted Pressure Switches of aluminium casing (epoxy

coated), and 316 SS element and repeatability of +/-1% of span, including accessories like siphons for steam services, snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services, name plate & mounting brackets. Material of accessories shall be SS. Auto reset micro switch with internal adjustment for set values with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or equivalent degree of protection for enclosure. Over range protection 50% above maximum pressure. Scale for setting shall be provided. Piston actuated for high pressure applications and diaphragm/bellows for low pressure/vacuum. Process connection ½’’ NPT (F).

1.3 Pressure Transmitters/DP Transmitters/Flow transmitters(DP type/Level

transmitters/DP type (SMART) Micro-processor based 2 wire indicating type (LCD display), rack mounted with

accuracy of +/-0.075% of span, external zero and span adjustment, self diagnostics, temperature sensor for compensation. Power supply 24 V DC; output signal of 4-20 mA DC. IP 65 or equivalent degree of protection. Aluminum housing with epoxy coating, Accessories like snubbers for pump discharge applications and chemical diaphragm. 10 m PVC covered SS armoured capillary for corrosive and oil services, three way manifold, nameplate etc. Material for accessories shall be SS. Turn down ration 30:1. Load impedance 700 ohm (min).Process connection-1/2’’NPT (F). 2 valve manifold for absolute pressure, 3 valve manifold for gauge/vacuum and 5 valve manifold for DP/level/flow measurements. For HFO, LFO applications, SS capillary with ANSI RF flanged ends shall be provided.

1.4 Thermometers Mercury in steel below 450 deg. C. and inert gas actuated for above 450 deg.C. of SS


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bulb and capillary. Body material-Die-cast aluminium. Dial size-150 mm with white dial and black numerals and process connection-1/2’’NPT (F). Accuracy-+/- 1% of span. IP 65 protection class. Accessories include nameplate, mounting brackets and SS Thermo well. Process connection-3/4’’NPT (F).

1.5 Thermo wells Pipe/equipment mounted temperature test wells of 316 SS with a process connection

of M33x2 thread or 150 RF flanged. Accessories like name plate, plug with chain, etc. shall be provided. Material of accessories shall be SS. Thermowell shall be hex head of barstock assembly. In case flanged wells are required for any specific application, the same shall be supplied as required. The thermo well construction shall meet the ANSI 19.3 (latest) requirements. Thermo well shall be designed such that the resonant frequency is above the exciting frequencies generated by vortex shedding in the process fluid. All Test thermo well shall have the plug of SS316.

1.6 Thermocouple Assembly Duplex, K – Type, 16 AWG or R type, 24 AWG with accuracy as per IEC-751/ANSI-C-

96.1, ungrounded type depending on operating temperature range. Response time of 2 to 6 sec, Spring loaded mineral insulated thermocouple assembly with 316 SS thermo well housed aluminium casing (epoxy coated) having a process connection of M33 x 2 thread. Material of accessories (name plate, etc.) shall be SS. IP 65 or equivalent degree of protection for enclosure. Thermo well with hex head (with screwed cover & SS chain) bar stock assembly with ungrounded junction. For metal temperature measurement, thermocouple pads weldable to M.S pipes shall be provided with 15 m thermocouple extension wires. Element size shall be 18 AWG. Insulation resistance at 540 Deg C shall not be less than 5 M ohms. Temperature devices provided with thermo wells shall be calibrated with the associated thermo well as an assembly. The thermo well construction shall meet the ANSI 19.3 (latest) requirements. All pent house thermocouples shall be supplied with 15mts flexible extension length. Thermowell material for abrasive process application like coal –air mixture, flue gas etc. shall have tungsten carbide coating. For high temperature flue gas applications such as platen super-heater and de-super heater inlet / outlet etc. T/C shall be provided with ceramic assembly.

1.7 Resistance Temperature Detectors (RTD) Duplex type, PT – 100, with accuracy of +/-0.5% of span, response time 1-2 seconds;

Spring loaded mineral insulated three (3) wire RTD assembly with 316 SS Thermo well housed in aluminium casing (epoxy coated) having a process connection of M33 x 2 thread or 150 RF flanged. IP 65 or equivalent degree of protection for enclosure. Material of accessories (name plate, etc.) shall be SS. Thermo well with hex head with screwed cover & SS chain, barstock assembly. Element lead size shall be 18 AWG. The insulation resistance at 540 Deg C shall not be less than 5M ohms. Repeatability over full range shall be better than 0.02%. RTDs shall be ungrounded. RTD shall be supplied as an assembly complete with thermo wells meeting ANSI 19.3


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(latest) requirements. 1.8 Level Gauges Tubular type level gauges for low pressure up to 7 kg /sq.cm & reflex type for high

pressure water & steam services & vacuum services with automatic ball check valves, illuminator (240 AC), pyrex / tempered toughened borosilicate glass, mica shield, brass guard rods & brass holders. Body material: Forged carbon steel/304SS. Accuracy- +/- 2% with vertical scale.4. Material of accessories (name plate, etc.) shall be SS. Tubular glass OD shall be 5/8”. Vent & drain valves shall be provided. Connection shall be screwed or flanged (ANSI class 150 RF).

1.9 Level Switches External cage magnetic float operated level switches for tanks and vessels and top

mounted level switches for sumps and underground tanks. The top mounted level switches shall be supplied with still tubes to suit the requirement. Micro switch with 2 SPDT contacts rated for 0.2 A, 220 V DC. Material of float & float chord shall be 316 SS & cage material shall be fabricated steel and the material of accessories shall be SS. IP 65 or equivalent degree of protection for enclosure.

Accessories like name plate, drain valve for external case type level switches, mating flange, gaskets (asbestos), fasteners, bolts & nuts, etc. shall be supplied.

Conductivity type electronic Probe type level switches shall be supplied for Drain pots. The required pressure vessel assembly for mounting probes are included in the scope.

1.10 Displacement type Level Transmitter Displacer type level switches shall be provided for level measurements of the vessel

under vacuum or low pressure applications viz for condensate and feed water system. The displacer tube material shall be K-monel. The float movement shall be transmitted to the pivot mechanism by only torque device incorporating positive seal between float cage interior and the transmitting mechanism without the use of stuffing boxes. Accuracy including combined effect of linearity, hysterisis and repeatability shall be +/-0.75% of span or better. Protection class shall be IP-65. Output-4 to 20mA signal superimposed with HART protocol.

1.11 Flow Glasses Online flow glasses for pipe size up to 6” with a rotary wheel (not a flapper type)

suitable for installation on vertical or horizontal pipelines, material Pyrex tempered glass. Body material shall be carbon steel, rotor & wetted parts shall be bronze. The material of accessories shall be SS. IP 65 or equivalent degree of protection for enclosure. Upto 50 Nb size, connection shall be screwed & above 50 mm Nb size it shall be flanged - ANSI, 150 RF. Accessories like name plate, mating flanges with gaskets (neoprene), bolts & nuts, etc. shall be supplied.


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1.12 Flow Switches Indicating, Differential pressure, flapper type on line flow switches for line sizes up to

80 mm with an accuracy of +/-0.5% of span and dial size of min. 50 mm having 316 SS flapper/SS 316 bellows housed in die cast aluminium. Micro switch with adjustable range with 2 SPDT contacts rated for 0.2 A, 220 V DC. IP 65 or equivalent degree of protection for enclosure. The material of accessories shall be SS. Repeatability shall be +/-0.5% of span. Over range protection shall be 50% above maximum flow. Setting shall be tamper proof external adjustment & scale shall be provided for setting. Range spring & orifice plate shall be SS 316 for DP type. NPT for sizes below 2” & for sizes above 2” ANSI 150 RF shall be provided. Accessories like nameplate, mating flanges with gaskets, bolts & nuts, pipe assembly with orifice plate, etc. 5 way manifold, pipe, fittings (DP type), etc. shall be supplied.

1.13 Flow Elements 316 SS long radius, welded type flow nozzles as per ASME PTC 19.5 or BS-1042 for

all steam and feed water services with D and D/2 pressure tappings; 316SS concentric orifice plate assembly as per ASME PTC 19.5 or BS-1042 for all water services with flange tap connections. Beta ratio of 0.34 to 0.7 for orifice and around 0.7 for flow nozzles. The material of accessories shall be SS. Refer to Table-5 for provision of flow elements. All the flow elements shall have 3 pairs of differential pressure tappings complete with root valves. Orifice plate shall be 3 mm thick for nominal pipe diameter up to 300 mm & 6 mm thick for pipe diameter > 300 mm. The thickness of the flow nozzle shall be as per the application. The flow elements shall be supplied as assemblies with High/low pressure tappings, root valves as required. Performance Guarantee flow elements shall be provided separately. Butt welded edges shall be prepared as per ANSI 16.25 & flanged connections shall be as per ANSI 16.5 standards. Orifice assembly complete with nipples & valves to be supplied by Bidder shall be one meter long with ANSI class 150 RF SS flanges at the ends including gaskets, bolts & nuts. Isolating valves shall have SW end connection. Accessories like nameplate, gaskets, bolts & nuts, reservoirs (condensing chambers), 6 nos. shut off valves per assembly, nipple, welding adapters, etc. shall supplied. Bidder shall submit assembly drawing and flow vs DP curve for each flow element.

1.14 Magnetic Flowmeter Inline type with indicating top mounted transmitter with flange connection. Accuracy:

0.5% of flow rate or volume flow. Repeatability 0.1% of flow rate/volume flow. Transmitter shall be smart with LCD display and superimposed HART on 4-20mA DC output. Data storage shall be in EEPROM. Shall have diagnostic capabilities. Touch control facility on the indicator for checking the rate/volume and diagnostic messages. Material: Case-Al.alloy with corrosion resistant, flow tube and extension pipe- Stainless steel (SS 304) and Lining-fluro carbon. The flow rate shall be available in DCS/PLC and flow integration shall be implemented in DCS/PLC to indicate volume flow.


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1.15 Anubar ( Impact Head Type) Element shall be tubular, insert type with minimum four impact ports facing upstream

direction, located precisely for measurement of average flow velocity. The material of the sensor shall be SS 316. Accuracy shall be +/ - 1% of the actual value or better. Repeatability shall be + /- 0.1 of actual value or better. Online retracting facility and flushing arrangement shall be provided. The sensor shall be supplied with complete mounting hardware and support plugs and valve manifolds ( ½” NPT) for DP transmitter connection. The specification of DP transmitter is specified elsewhere.

1.16 Pressure and Differential Pressure Transmitter Racks Open type transmitter racks to mount all pressure, differential pressure and flow

transmitters with vibration dampener: air supply lines and header shall be provided with bulk head fittings to receive impulse lines; Also provided with blow down/drain header. The material of accessories shall be SS. Drains shall be connected upto suitable Owner / Project Manager’s drain header. The quantity shall be as required for the specified Pressure and Diff. Pressure transmitter.

1.17 Junction Boxes (JB) All JBs shall be Galvanised. Wall/column mounted junction boxes having 32 (2x16)

terminals and cable entry only at the bottom and sealed with fireproof compound; Screwed terminal type; IP 65 or equivalent degree of protection for enclosure. Separate terminal blocks shall be used for analog and digital signal and also for signals with different voltages. Removable gland plate shall be supplied. JB shall have single lockable door with gasket, able to open side ways, with common keys. Painting inside shall be glossy white & outside - IS-5 shade 631. Shield bus for screw connection shall be provided. Terminal size shall be suitable for 0.5 sq. mm to 2.5 sq. mm wire. Terminal blocks shall be vertical. JB shall have provision to add 10% additional terminals. Accessories like metal tag (SS), clamps, fixtures, bolts (SS), nuts (SS), gaskets (neoprene), lock & key, fireproof compound for sealing, etc. shall be supplied. The grouping of instruments in JBs is subject to Owner / Project Manager’s approval. All the field Junction boxes shall have single doors and provision for locking. The doors shall not have screwed type of locking, but turnable hinge based. The JBs are subject to approval prior to manufacturing All JBs shall be provided with individual canopies to avoid ingress of water. All the TBs used shall be 6.6polymide to withstand corrosion and the metallic portion shall be coated against rust / corrosion.

1.18 Field Termination Cabinet (FTC) FTCs shall be galvanized, out door located, free standing vertical type with IP-65

enclosure and with 2 mm thick sheet metal of cold rolled steel; double door with neoprene gaskets; ant vibration pads of 15 mm thick; fluorescent lighting; fire detection for each cabinet; fire proof compound (50 mm thick) for sealing cable entry (bottom,


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front, rear). The colour of the cabinets shall be indicated at detailed engineering stage. The type of terminal shall be made up of 6.6 polyamide and the metallic portions shall be coated against corrosion. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by Bidder, subject to approval by Owner / Project Manager/ Consultant. Door shall have concealed type hinges and swing of 180 Degree & lockable. The doors shall be provided both on the front and rear. Channels, bolts & nuts shall be zinc plated and passivated. Two coats of primer paint and black colour paint shall be applied. Fluorescent lamp of 40W shall be provided and shall be operated by the door switches as well as by manual switches. The marshalling cabinets, the terminal blocks, the terminals and the electronic hardware if any, shall have identification numbers. Each cabinet shall be provided with one each 3 pin receptacles for 240 V AC, 1P, 50 c/s and receptacles for +24V DC. Cabinet shall be delivered totally wired. Preparation of interconnection schedule (ICS) between FTC and marshalling cabinets is in Bidder’s scope and cabling will be by Owner / Project Manager. Cabling between FTCs & JBs is in Bidder’s scope. The format of ICS shall be given to the Bidder during detailed engineering stage.

1.19 Interposing Relays (IPR) Electro magnetic type IPRs with plug-in type connections, suitable for

channel/rail mounting in cabinets; coil rating 24V D.C; 2 set of silver plated Change over contacts rated for 0.2A 220 V DC. Freewheeling diode across relay coil (copper) and self reset type status indicator flag (electronic) shall be provided. All relays shall be mounted in IPR cabinet & relay base (silver plated) internally wired to the external cabling termination block in IPR cabinet. Wiring connection shall be cage-clamp & termination shall be suitable for0.5 sq. mm to 2.5 sq. mm size wiring. Facility to simulate relay operation manually shall be provided. Relays of different contact interrogation voltages shall be separated by a barrier in IPR cabinet. Accessories like name plate (SS) with tag & service inscription, relay base mounting rail/channel, nuts & bolts, etc. shall be supplied. In each cabinet, a DC Voltmeter shall be provided to check the Field Interrogation voltage.

1.20 System Cabinets These cabinets shall house signal-conditioning cards, input/output cards, processor

cards & associated power supply units. Indoor located, free standing vertical type system cabinets with IP-32 enclosure and with 2 mm thick sheet metal of cold rolled steel; double doors with neoprene gaskets; ant vibration pads of 15 mm thick; blower & louvers in each cabinet with brass mesh; fire proof compound (50 mm thickness) for sealing cable entry (bottom); fire detector for each cabinet. Beacon lamp shall be provided in each cabinet to indicate the cabinet having fault condition. The racks in system cabinets shall have provision along with plug in sockets/back plane to house accommodate the spare slots/modules as specified elsewhere. The colour of the cabinets shall be indicated at detailed engineering stage. Doors shall have concealed type of hinges and swing of 100o. to, on the side to help the operator.


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Power supply distribution shall be provided on per cabinet basis with all associated MCBs, protections, etc. The system cabinets, racks in system cabinets, slots in the racks & the terminals shall have identification numbers. A stainless steel metal tag (plate) shall be fixed to the inside of the door & the layout of the racks, slots & details of the card type/service shall be inscribed on this metal tag. Each cabinet shall be provided with one each 3 pin receptacles for 240 V, 1P, 50 C/S and receptacles for +24V DC. Cabinet shall be delivered totally wired. All electronics shall be mounted & wiring connections at these hardware shall be terminated by Bidder. Quantity shall be as required. One of the doors shall be provided with folder to keep the relevant engineering document of the cabinet.

All cabinets shall have common key for the locks.

In each cabinet, a 24 VDC Voltmeter shall be provided to check the Field Interrogation voltage.

1.21 Marshalling Cabinets Indoor located, free standing vertical type marshalling cabinets with IP-32 enclosure

and with 2 mm thick sheet metal of cold rolled steel; single/double door with neoprene gaskets; anti vibration pads of 15 mm thick; fluorescent lighting; blower & louver in each cabinet with brass mesh; fire detection for each cabinet; fire proof compound (50 mm thick) for sealing cable entry (bottom, front, rear). The colour of the cabinets shall be indicated at detailed engineering stage. The type of terminal shall be Phoenix / Weid ueller / WAGO. The terminal blocks shall be cage clamp type. Fused terminal blocks hinged at one end to facilitate easy isolation shall be provided wherever necessary. All cabinets shall be provided with spare terminals for the spare inputs/outputs as specified else where in the specification.. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by Bidder, subject to approval by Owner / Project Manager/ Consultant. Door shall have concealed type hinges and swing of 180 Degree & lockable. The doors shall be provided both on the front and rear. Channels, bolts & nuts shall be zinc plated and passivated. Two coats of premier paint and black colour paint shall be applied. Fluorescent lamp of 40W shall be provided and shall be operated by the door switches as well as by manual switches. The marshalling cabinets, the terminal blocks, the terminals and the electronic hardware if any, shall have identification numbers. Each cabinet shall be provided with one each 3 pin receptacles for 240 V AC, 1Ph, 50 c/s and receptacles for +24V DC. A system cabinet and associated cabinets shall be supplied on a skid to avoid outside interconnecting cables. Cabinet shall be delivered totally wired. Preparation of interconnection schedule (ICS) between marshalling cabinets & JBs/FTCs and JBs to Instruments is in Bidder scope. The format of Interconnection Cable Schedule (ICS) shall be submitted by the Bidder during detailed engineering stage for approval by Owner / Project Manager.

All cabinets shall have common key for the locks.

All the terminals shall have no screws and the cables shall be gripped by spring. Each terminal shall have LED indication with fuses to indicate and isolate earth faults.


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1.22 Local Panels 1.22.1 Indoor/Outdoor located, free standing vertical type local panels with 2 mm thick sheet

material of cold rolled steel; ant vibration pads of 15 mm thick; fluorescent lighting; Double doors with neoprene gaskets at every 1.5 m; blower & louvers in each section with brass mesh; fire proof compound (50 mm thick) for sealing cable entry (bottom); fire detector for each section; space heater with thermostatic control for each section (strip type). IP 65 degree of protection for enclosure. Removable cover plates with locking facility shall be provided along the bottom of the front desk continuously to facilitate maintenance work. The length of each cover plate shall not exceed 1 m. Fluorescent lamp of 40 W shall be provided from one end of the panel to the other end at continuous length and shall be operated by the door switches as well as by manual switches. Nameplates shall be provided for all instruments/inserts with Tag. No. & short description of service engraved. These shall be phenolic overlays (1.6 mm thick), black background with white lettering & shall be fixed to the panel by stainless steel screws (counter sunk). Each section of the panels shall be provided with one each 3 pin receptacles for 240V AC, 1P, 50 c/s & 230 V AC, 1P, 50 c/s. Panel shall be delivered totally wired. All instruments, inserts and annunciation windows shall be mounted & wiring connections at these hardware shall be terminated at site by Bidder. Quantity shall be as required.

1.22.2 All the Terminal Blocks shall be rust proof and corrosive resistant for outdoor mounted

panels. Terminal Blocks housing material shall be 6.6 polyamide and metallic portion shall be coated against rust/corrosion.

1.22.3 In each Local Panel, a 24 V DC Voltmeter shall be provided to check the Field

Interrogation voltage. 1.23 24V DC Distribution Board The function of the 24V DC distribution board is sub distribution of 24V DC power

derived from 230V UPS to all the utilities viz., DCS cabinets, ISAS cabinets and all other 24V DC requirements. Redundant feeders shall be provided for each utility through diode auctioneering using diodes of high peak inverse voltage. The cabinets shall be free standing, vertical cabinets designed for indoor location. Material of construction shall be 2mm thick CRCA. Fluorescent lighting, fire detector and space heater shall be provided for each cabinet. Isolating switches and HRC cartridges fuses shall be provided for individual feeder isolation. Ammeter and voltmeter shall be provided for the incoming feeders to the distribution boards. Features for any other type of Distribution board to be supplied by Bidder shall be subject to Owner / Project Manager’s approval.

Each terminal shall have LED indication with fuses to indicate and isolate earth faults.

1.24 Control Valves


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1.24.1 Balanced, modulating, globe type, cage guided, single ported, diaphragm type of actuator with hand wheel, SMART Pneumatic positioner, air filter regulator, air lock device, solenoid valve as applicable, limit switches and position transmitters completely tubed with junction box. Pneumatic positioner shall be suitable for accepting 4-20mADC signal. Pneumatic (PVC coated copper) tubing complete with accessories, fittings, If any up-gradation of the offered system is envisaged before completion of the job to meet the specified requirements, the same shall be incorporated in the system, with the approval of the OWNER without any additional cost. Positioner shall be provided with input/output/bypass gauges. Local position indicator & Non-contact type position transmitter with 2 wire, 4-20mA DC output. All limit switches/position transmitters, E/P converter signals etc., shall be wired out to external block of actuator and respective junction boxes.

1.24.2 Control valves shall be sized to have an opening of 15% at minimum flow condition

and 85% at maximum flow condition. Noise level shall not exceed 85 dB at a distance of about 1.5 M from the valve. In case of predicted noise level above 85dBA, suitable low noise trim shall be provided. Noise reduction shall be achieved through an inherent Trim design and not through external means.

1.24.3 Leakage class for double seated valve shall not exceed 0.05%, and single seated valve

shall not exceed 0.01%. 1.24.4 Either extended type bonnet or cooling fin type bonnet shall be provided for service

above 200 Degree C and for other service the bonnet type shall be standard. 1.24.5 The end connections shall be socket welded for sizes below 50 NB and butt welded for

sizes 50 NB and above. Flanged connection shall be provided for DM water services, with suitable rubber lined interfaces.

1.24.6 Water seal shall be provided for valves that could be subjected to below atmospheric

conditions. 1.24.7 Generally stem and guide material(trim) shall be SS 316 stellited, and plug and

seat material shall be 17-4 PH SS, except for specific applications like DM water, HP bypass services. Refer to enclosed table for selection of control valve body material and actuator type. The trims supplied shall be suitable for quick changing. Actuator housing shall be of pressed steel construction.

1.24.8 Trim shall be designed such that trim exit velocity shall be limited to avoid cavitation.

Feed control valves and Spray control valves shall have a leakage class of VI and all other valves shall have a leakage class of V.

1.24.9 The action of valves on failure of operating media shall be determined by the process

requirements with regard to safe operation and emergency shut down requirements. 1.24.10 Control valve sizing shall be accompanied with data sheets. Following size calculation

details shall be furnished for Control valves:


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1.25 Pneumatic block valves Balanced, on off, plug type, single ported, gate valve. Body material shall be ASTM A

216 GR WCB with end connection socket welded for sizes 50 NB and below & butt welded for sizes above 50 NB and flow direction shall be horizontal.

Bonnet: Std. type of material ASTM A 216 GR WCB & packing material GRAFOIL.

Trim : Cage guided, metal seated with flow characteristic of quick opening with stem, plug, seat and guide material of SS 316.

Actuator : Diaphragm (Nitrile) type with handwheel & travel indicator and adjustable stop. It shall be sized for shut off differential pressure. Accessories like air filter regulator, solenoid valve, limit switch with Nema 4 enclosure, etc. shall be supplied. Actuators & accessories requiring tubing shall be mounted and tubed.

1.26 Control Damper Drives Pneumatic actuator type, located in flue gas/air area with damper shaft bearings

mounted externally. Bearings are grease lubricated. Blades (SS) shall be linked together. Accessories like position transmitters (2 wire) with 4-20mA DC output, Local Position indicator, position locks, limit/torque switches, etc. shall be supplied, after integrating, calibrating & testing at works. Smart Positioners with all required accessories, required for the positioning of control damper drives shall be provided. Spare cams for accommodating any change in characteristic to achieve better process control during commissioning shall be supplied as required.

All the field mounted Damper accessories ( position indicator, limit switches etc.,) shall comply to NEMA -4.

1. 27 SMART Positioners of Control Valves. 1.27.1 Positioner shall be microprocessor based with digital communication by means of

HART protocol. Positioner has to be 2-wire, 4-20 mA loop powered by the control system and capable of split ranging operation.

1.27.2 The SMART positioner shall be suitable for both single acting and double acting

actuators. The SMART positioner shall be fully modular in construction with Encapsulated printed wiring board and pressure gauges inside the positioner cover to protect from transit/site damage.

1.27.3 SMART positioner shall preferably be of the same make as the Control Valve, to

ensure repeatability in Calibration, serviceability and proper maintenance of the Control System.

1.27.4 SMART positioner shall be a Double stage positoner. The first stage of the positioner

shall be typically a flapper-nozzle that serves as a high-gain pre-amplifier. This sensitivity shall be maintained over a wide range of dynamic conditions. Second stage


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shall be a power amplifier that provides power to drive the actuator. Preferably this shall be a pneumatic relay. Spool Driven type SMART positioners are not preferred due to Higher Dead Band and Poor responsiveness. The SMART positioner shall have pressure sensors to measure the pneumatic outputs to the actuator.

1.27.5 The control algorithm for the positioner shall use feedback signal from the motion of the

pneumatic relay beam instead of pressure feedback to minimize pneumatic related effects and for stable and smooth response of the control valve. The SMART positioner shall have user adjustable tuning sets to identify the optimum tuning for the total valve assembly. SMART Positioner with HART Communication facility shall communicate all the valve diagnostics to DCS.

1.27.6 The electrical housing shall be designed to meet NEMA 4X,IEC 60529 IP66. 1.28 Air Filter Regulator (AFR) Constant bleed type AFR with an accuracy of +/-0.1%, inlet pressure range of 5-8 kg

/sq.cm and suitable spring ranges (AFR) for use with positioners in control valves, control damper, E/P converters and shut off valves, transmitter purging lines etc; Filtering particles above five microns having phosphor bronze filter element. Material of accessories shall be SS. Built in blow down valve shall be provided. AFR shall have automatic drain feature. All accessories shall be supplied. Degree of protection shall be IP65.

1.29 Position Transmitters 24VDC operated Non contact LVDT type with 4-20 mA DC 2 wire system with an

accuracy of ±1%; range adjustment and zero adjustment to be provided; IP65 degree of protection for casing. The output shall be linear. All accessories shall be SS.

1.30 Solenoid Valves Direct operated solenoid valves, pilot operated for higher sizes with shut off class

(leakage) VI, body material of bronze, plunger material of 316 SS rated for continuous duty. IP 65 class for enclosure. Insulation class of 'F' for the solenoid. Body ratings shall suit the pressure and temperature conditions.

1.31 Cables 1.31.1 Individual pair shielded & overall shield twisted pair copper cables shall be used for

analogue signals & overall shielded cables shall be used for digital signals. All these cables shall be armoured. All the insulation including overall sheath shall be FRLS quality. The wire size shall be 0.5sq.mm. Ferruling indicating terminal numbers on termination side shall be followed. Colour coding shall be approved by Owner / Project Manager.

Only sleeve type ferruling with printed terminal numbers shall be used. Cross ferruling shall be adopted.


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

tinned copper, twisted pair (with min. 20 twists for meter) extruded PVC insulated 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 minimum 0.5 sq.mm. Triplex cables similar to instrumentation cables can be used for RTDs. Instrumentation cables carrying digital signals shall have overall screening along with drain wire and analogue signal carrying cables shall have each pair screening and overall screening along with each pair drain wire and overall drain wire.

1.31.3 Control Cables Control cables shall be 1100V AC grade, multicore, minimum 1.5 sq.mm cross section,

stranded copper conductor having 7 strands, PVC insulated, inner FRLS PVC sheathed of type ST-1, galvanized steel wire armoured and outer sheath made of FRLS PVC compound of type ST-1. In situations where accuracy of measurement or 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.

1.31.4 Compensating Cables 1.31.4.1 All Compensating cables shall be single or multicore cable (ANSI type KK) twisted and

multiple shielded thermocouple extension compensating cable and shall be of Flame Retardant Low Smoke type (FRLS). All Compensating cable ( Chromel - Alumel) of FRLS type shall conform to additional test to Prove the FRLS Characteristics as mentioned in the FRLS Instrument Cable specifications

1.31.4.2 Compensating Cable: (a) Reference ANSI ISA 96.1 (b) Conductor 16 SWG shield alloy (c) Insulation Insulated with heavy duty, self extinguishing type, PVC, cores

colour coded, extruded PVC sheathing, insulation of each wire with high grade 0.6mm, 105 deg C PVC, Voltage grading of 1100V.

(d) Lay Twisted pair with 75 mm maximum lay. (e) Shielding Shielding shall be single pair-cable assembly only, Multiple

pair-each pair and cable assembly 2.35MIL, Thick combination Aluminium Mylar tape and 7 strand 20 SWG tin


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coated copper drain wire. Insulation, coverage shall be 100% and total shield isolation shall be such as to isolate from all other fields.

1.31.4.3 Thermocouple Extension Cable 1100V AC, twisted pair (20twist/meter), 1.5 sq.mm dia. Thermocouple extension

wires, PVC insulated, aluminium Mylar tape shielded/PVC jacketed/ armoured & overall PVC jacketed/FRLS. Features such as colour coding, thermo electric characteristics, etc. shall be as per ANSI –MC 96.1, 1975. Alternatively thermocouple extension wires with 1100 V AC twisted pair ,1.5 sq.mm, PTFE insulated copper braiding & PTFE outer jacket , shall be considered for turbine area.

1.32 Wiring, Termination and Accessories 1.32.1 All the cables are to be treated with anti-rodent treatment properties, voltage grade

shall be 1100V. 1.32.2 Prefabricated Cable :

Used for interconnection between system /marshalling cabinets. Used for panel external wiring, tinned copper conductor of 0.5 sq.mm cross section with seven strands twisted pair with 20 twists/meter. Insulation material shall be PVC, heat resistant with flame retarding properties with thickness not more than 0.5 sq.mm Voltage grade shall be 1100V AC. Each prefabricated cable shall have a minimum of 5 cores as spares and these shall not be connected to end connectors.

1.32.3 Terminal Block (TB): Cageclamp type , 600V V AC grade, vertically mounted, size of 0.5 sq.mm to 1.5 sq.mm for instrument wires and 100V AC 1.5 sq.mm to 2.5 sq.mm for control wires. Clearance between TBs shall be 150 mm and between TB and bottom plate shall be 250 mm, flame resistant, non-hygroscopic, decarbonised. Insulation between adjacent terminals or between terminals & framework shall be 2 KV RMS for 1 minute. Power supply and signal TB shall be separate. Signals shall be grouped in TBs in the same order as that in field junction box so as to provide neat cable layout and wiring. High voltage and low voltage signals shall be provided on separate TBs, which are mounted separately.

TBs housing material shall be 6.6 polyamide and metallic portion shall be coated against corrosion. There shall be no double decker terminals.

1.33 Boiler Drum Level Gauge Bi-colour type (Red for steam & green for water) with tungsten halogen illuminator,

local bicolour read out – 2 nos., one at each end shall be provided for each drum. No. of ports shall be at least one for every 2 inches. Isolating & drum valves shall be provided with chain & pulley mechanism in addition to hand wheels. Material of body


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TITLE

- 316 SS, cover - carbon steel. Visible range covers alarm & trip levels recommended. Power supply for the illuminator shall be fed from 110 V AC, UPS.

1.34 Electronic Water Level Indicator (EWLI) 1.34.1 Two (2) systems per boiler drum operating on the principle of resistivity; single

pressure vessel at each end; 4-nos. isolating valves with limit switches per vessel & 2 nos. blow down valves with limit switches per vessel shall be provided. Thermal equilibrium shall be established with boiler drum. Vessel material shall be forged carbon steel of ANSI rating 2500. The size of the tapings at the drum & the isolating valves shall be the same. These tapings shall not be shared for any other instruments.

1.34.2 No. of electrodes per vessel shall be such as probe to probe distance not to exceed 50

mm. Material of electrode-tip shall be titanium; body SS 316, insulation high purity ceramic, gasket monel-silver. Electrodes shall be arranged in 2 different rows staggered to provide maximum resolution. Solid state/micro processor based detector system and control unit with independent power supply for each unit; bicolour type display unit of 4 nos., two (2) nos. display shall provided at the control room and two (2) nos. display units at detector unit. Range of display to cover HH & LL trip levels. One set of alarm for high and low conditions and trip contacts for high high and low low conditions with adjustable settings. Self diagnostic features included. All the cables shall be provided by the Bidder. Alarm and trip contacts shall be fail-safe type.

1.34.3 The detector unit shall house redundant power supply units and electronic cards

connected to electrodes for measurement of boiler drum level. Alarm contacts (SPDT) rated for 0.2A, 220 V DC shall be provided low and high water level. For each pressure vessel, alarm settings shall be adjustable. The power supply shall be independent for each unit. A green lamp is illuminated for water and a red lamp for steam. The lamp rating is of 0.5 W. Each window shall have two lamps connected in parallel. Two (2) numbers display units shall be provided at the control room. Each drum shall have both fault lamp with reset push button and lamp test switch. The other two (2) number display units provided at the detector unit. Each shall have only lamp test switch. Bidder to supply EWLI of Owner / Project Manager approved make.

1.35 Furnace Temperature Probe Duplex k-type thermocouple with mineral insulation & SS sheath located in furnace

below SH panels; minimum of 2 nos. Probe housing shall be weather proof & corrosion resistant. Accuracy shall be +/-0.5% of span. The junction shall be ungrounded with response time of 2 to 5 seconds. Starter box shall be provided with IP65 enclosure & 3 mm thick sheet. Electric motor with chain drive shall be provided for the lance. The traverse of the probes from opposite sidewalls shall cover the full cross section of the furnace. Automatically controlled cooling system shall be provided for the lance. Loss of cooling water shall be detected & provided as a contact. Accessories like limit/torque switches position transmitters, etc. shall be provided.


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All the field mounted accessories (limit switches etc.,) shall comply to NEMA-4 1.36 Electromatic Relief Valve (EMRV) Controller Electronic type with pressure high & low switches. One no. for each EMRV.

Man/Auto/Off selection with lamps for auto/manual positions shall be provided. IP65 or equivalent degree of protection for enclosure. Enclosure material will be epoxy coated die cast aluminium. Power supply will be 220 V DC & output signal will be ‘pressure high’ potential free contact for solenoid valve energisation. One no. solenoid valve (for each EMRV) of 220 V DC single coil with limit switches shall be supplied. Other features of solenoid valve shall be in line with that specified under ‘Solenoid Valves’ in this section. Terminals in terminal block of the controller & solenoid shall accept cable of 0.5 to 2.5 Sq.mm. Switch contact rating shall be boosted using relays.

1.37 Colour Graphic Video Display Unit

21" (unless specified otherwise) colour TFT monitor with mouse / track ball facility shall be provided. Resolution shall be 1280 x 1024 pixels minimum. Number of characters per line shall be minimum 80 and number of lines per display page shall be minimum 48. Total number of characters shall be minimum 256 graphic characters + ASCII. Minimum Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. Main memory capacity shall be 8 MB with minimum 80 MB Hard disc capacity and shall have a DVD / CD RW drive. The system shall support Seven (7) types of audible alarms (3 Process related, 2 no system related and 2 keyboard related). The VDUs shall be table top mounted type. The VDU's shall be fully assignable and functionally interchangeable. All VDU's shall have dedicated keyboard.

1.38 Keyboard Flat Membrane type Keyboard shall be provided for operator interface with process for

plant control and display functions to access plant data in conjunction with Operator station VDUs. The keyboard shall have a minimum of 80 configurable keys for assigning most frequently used displays. A minimum of Sixty-four (64) of those keys shall have two independently lit LED's used for event-specific alarm annunciation.

1.39 Optical Disk Drive Unit / CD ROM drive (Read & Write) Optical disk drive unit shall be provided to store the required plant data and historical

data in a reliable high performance medium for retrieval/archival whenever necessary. Type of disk shall be random access, re-writable magneto optical in nature with formatted capacity of 8 GB and minimum 19,600 tracks per second. Data transfer rate shall be minimum 5 MB per minute and seek time shall be 22 milli seconds or better. Data error check features of parity check, CRC check shall be included. Facility shall be provided for direct transfer of bulk data from BMU to optical disk drive unit. The approximate quantity shall be as follows:


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1.40 Colour graphic printer: Shall serve as a hard copy device to copy diagrams from the colour CRT’s for

documentation and graphic diagram development functions. Minimum 7 colours to be provided. Multiplexer unit shall be provided to facilitate printing of graphics from any of the OS / ES VDUs. All printers shall be of A3 size. Noise levels for the Printers at 1 meter distance shall be < 45 dB.

1.41 Bulk Memory Unit (BMU) The BMU shall have the following features: (a) Two discs in hard stand by mode (b) Fixed disk drives with one controller per drive (c) Disk capacity to meet functional requirements of the control system with a

minimum formatted disk capacity of 80 GB. (d) Data transfer rate shall be 1.5 MB/second (e) Average access time shall be less than 40 milliseconds. (f) Error checking and Error recovery feature 2.0 FURNACE FLAME MONITORING AND ANALYSIS SYSTEM 2.1 FLAME MONITORING-GENERAL 2.1.1 Furnace flame monitoring and analysis system shall provide analysis of flame

conditions on continuous on-line basis and shall guide the plant operation personnel regarding the nature of flame and combustion process and the corrective action required.

2.1.2 The system to be provided shall include all necessary hardware, software, firmware

and interfaces required for implementing a fully functional system. Bidder’s offered system shall include but not limited to the details specified in subsequent paragraphs.

2.1.3 Furnace flame monitoring and analysis system shall be independent for each unit. 2.2 FLAME MONITORING-DESIGN AND FUNCTIONAL REQUIREMENT 2.2.1 The flame monitoring and analysis system shall provide flame condition monitoring and

thermo-graphic analysis of the flame in the furnace and also for each burner. 2.2.2 The system shall be complete with video camera, signal conditioning cards, amplifiers,


TCE 5103A-C-510-01






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special cables. etc. with all necessary equipment and accessories. 2.2.3 Sufficient number of cameras shall be provided so as to cover all burner flames so as

to be able to carry out thermo-graphic analysis. 2.2.4 Flame monitoring cameras shall be provided with advance/ retract facilities with cooling

arrangement through water etc. Advance/ retract unit shall be designed for suspended use.

2.2.5 Necessary protection for automatic camera retraction on loss of cooling medium etc.

shall be incorporated. 2.2.6 The analysis software should be capable of outputting direct message on video monitor

of the exact nature of fault. 2.2.7 The system shall have facility to store bulk data for 5 years duration with facility for re-

trieval of the same. The system shall have facility to share all the data in the hard disk/ back up media and provide user friendly utilities to retrieve and analyze stored data.

2.2.8 The system shall be provided with redundant UPS power supply. The power supply

provision shall be such that on failure of one power supply the other power supply shall cater to the requirement of the equipment so as never to hinder the functioning of the system in any manner due to power supply failure.

2.3 FLAME ANALYSIS SYSTEM HARDWARE/ SOFTWARE/ INTERFACING

REQUIREMENT 2.3.1 Each Furnace flame analysis system shall include all hardware and software as

required for proper functioning of the system including but not limited to the following: (a) Video camera unit for each burner (with advance/retract facility

mounted) (b) One (1) no Server (With PC, Video Display Unit, Keyboard /Mouse) (c) One (1) no user station (With PCs, Video Display Unit, Keyboard/

Mouse and Colour Laser Printer) (d) Flame analysis software with all relevant user’s license. (e) Bulk data storage and retrieval facility (f) Redundant OPC communication link with all necessary hardware and

software. (g) System cables etc.


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2.3.2 All software user licenses shall be valid for entire life of power plant. User should not have to pay any recurring license fee during the usage period of the system.

2.3.3 It shall be possible to upgrade the installed system with the latest available version of

the software model during the plant life. 2.4 DESIGN DATA 2.4.1 Server Unit (a) Pentium latest model & version (b) Memory-1024 MB RAM (c) Hard Disk Drive-80 GB or Higher (d) DVD / CD ROM Drive-50X (e) DAT Drive-Required (f) Network Interface- Required (g) Server Operating System-Required (h) External Modem- Required, 56 k V.90 2.4.2 User Station PC: Industrial grade PC of latest model / configuration with Owner’s/

Consultants approval. 2.4.3 Video Display Unit (Server PC / User Station PC): 29" colour TFT LCD monitor with mouse / track ball facility shall be provided.

Resolution shall be 1280 x 1024 pixels minimum. Number of characters per line shall be minimum 80 and number of lines per display page shall be minimum 48. Total number of characters shall be minimum 256 graphic characters + ASCII. Minimum Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. The VDUs shall be of table top mounting type. All VDU's shall have dedicated keyboard. .

2.4.4 Colour laser printer : Colour laser printer shall serve as a hard copy device to copy diagrams from the colour

VDU for documentation and graphic diagram development functions. Minimum 7 colours to be provided. Interfacing- RS 232C/ 422A. Size- A3. Noise levels for the Printers at 1 meter distance shall be < 45 dB.

2.4.5 Bulk data storage and retrieval facility as required.


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2.5 SYSTEM IMPLEMENTATION 2.5.1 System implementation shall take into account the stabilisation of fuel firing equipment

characteristics while in service for some period (say plant commissioning period) and the varying characteristics coal being available in the plant. However, the system shall be user tested at site. It is the Contractor’s responsibility to demonstrate the proper functioning of the system to User’s personnel.

2.5.2 It is preferred that Contractor’s implementation team will involve ultimate user’s O&M

personnel during system implementation. 3.0 BOILER TUBE LEAK DETECTION SYSTEM 3.1 Tube leak detection system for each unit shall be independent and shall consist of

number of high grade audio electronic microphone type audio detectors with a display sound level range of 50 to 150 dB and head amplifiers with a maximum operating temperature of 90oC to be provided. The number of sensors shall be as required to cover complete boiler tube zones (but minimum 24 nos.) The measurement system shall have adequate number of channels corresponding to number of sensors and an accuracy of logarithmic conversion + 2% shall be provided. The display unit shall match the display unit in the CRT. The output shall be 4-20 mA / channel. The level of leakage shall be displayed in the form of bar charts and alarms shall be generated on occurrence of tube leakage. One speaker, power supply failure alarm and steam leak alarm shall be provided.

SPEC NO.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD VOLUME: IIIA TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TEST AND INSPECTION FOR INSTRUMENTATION AND

CONTROL EQUIPMENT


CONSULTANT: TCE CONSULTING ENGINEERS LTD.

ISSUE R0

TITLE

1.0 TESTS AND INSPECTION FOR INSTRUMENTS 1.1 After Manufacturing, all instruments shall be tested and calibrated at Factory.

CONTRACTOR shall be responsible in obtaining test certificates related to calibration of all the Instruments and submit for Owner/Engineer’s approval. CONTRACTOR shall allow despatch of these instruments only after passing applicable Factory Acceptance test and approved by Owner/Engineer. The details of the tests to be carried out for the different instruments / field equipments/ Systems shall be as indicated in the Section D 2, TABLE-7 and any other tests as required by the Standards and Codes.

2.0 TESTS AND INSPECTION FOR SG INTEGRAL CONTROL SYSTEM 2.1 Tests will include the following: (a) Factory Acceptance Test (FAT): To be carried out at SG Integral Control system CONTRACTOR’s / Sub-

Vendor’s works and witnessed by Owner/Engineer, successful completion of which will be the basis for ‘Authorisation for Shipment to Site’. FAT shall be preceded by a pre-FAT inspection/test by Vendor.

(b) Site Test (SAT): Involves tests for site commissioning, guarantee tests for system performance &

availability to be conducted in the presence of Owner. 2.2 Factory Acceptance Test (FAT) 2.2.1 FAT shall be a complete integrated test of the SG Integral Control system and carried

out at CONTRACTOR’s / Sub-Vendor’s works on completion of manufacturing of the system. The test shall be performed with the completely assembled system and performing all the functions, it is expected to perform while in actual service. The various tests to be performed for the tootal system together with the guideline for Factory acceptance test (FAT) procedure are detailed in Section D 2, TABLE-7. The CONTRACTOR shall submit a detailed "Factory Acceptance Test Procedure" in line with the above specified guidelines for Owner / Consultant approval.

2.2.2 FAT shall be preceded by a ‘Pre- FAT Inspection/ Test’ to be carried out by Contractor/

Vendor. Pre-FAT inspection / test shall be carried out as per approved FAT procedure detailed above and shall submit ‘Pre- FAT Inspection/ Test’ report for Owner/Consultants review and approval. Owner/ Consultant shall witness the actual FAT on the basis of successful completion of ‘Pre- FAT Inspection/ Test’.

2.3 Site Test (SAT) 2.3.1 Tests to be conducted at site will involve the following:

SPEC NO.




CONTROL EQUIPMENT



ISSUE R0

TITLE

(a) Site Pre-commissioning Tests comprising the following to be conducted by

Contractor at site: (i) Calibration of monitoring and control equipment (ii) Integrated loop test wiring, Simulation input from site (b) Trial Operation of the SG Integral Control system functioning. (c) Performance Guarantee Test for SG Integral Control system. 3.0 TRIAL OPERATION OF THE DCS SYSTEM 3.1 Trial operation test of SG Integral Control system shall be conducted on completion of

installation as per specification requirements, checking and satisfactory pre-commissioning tests detailed at 2.3.1 (a) above.

3.2 Test shall be conducted at site by Contractor’s personnel in the presence of the Owner /

Consultant. 3.3 Test duration shall be of 14 days out of which 72 hours shall be continuous operation

performing all the specified functions. 3.4 The trial operation shall be considered successful provided that each item of equipment

can operate continuously at the specified characteristics for the period of trial operations. During this period, any modifications / repairs as required shall be carried out. If the total interruption period (outage time) is more than 4 hours, the trial operation duration shall be extended by the period of interruption.

4.0 PERFORMANCE GUARANTEE TEST FOR I&C SYSTEM 4.1 After successful trial operation, the OWNER shall conduct performance guarantee test

for a period of 14 days in the presence of CONTRACTOR’s commissioning engineer. During the test, the system shall run with 100% availability. Contractor shall also furnish the guaranteed process parameters and the acceptable deviations before conducting the performance test.

4.2 Following tests to be performed during the PG test: 4.2.1 Redundancy checks for processor, communication, power supply and 1/O modules.

This check shall be conducted in a sequence as mutually decided between the Client and the contractor. During each redundancy check, the plant operation shall not be disturbed and the control loops shall continue in auto mode. The trending of control parameters shall be in service during these checks and the over shoot / under shoot of the controlled parameters shall be less than 1%. These checks shall be logged

SPEC NO.




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(removal and relocation of modules/cables) in the system in addition to being made available to the operator in operator station.

4.2.2 Response time for each type of update as per the specification shall be checked on line

by suitably recording each activity. 4.2.3 Time synchronisation with master clock shall be tested. 4.2.4 Specified communication links shall be established and proven. 4.3 PG Test Methodology 4.3.1 If the performance of the system deviates from the specification requirements, the

contractor shall be given a maximum period of 3 days depending on the gravity of the defect as mutually agreed, to carryout the modification without disturbing the plant operation.

4.3.2 Contractor shall declare the system fit for checking after completing the modification /

rectification. The specific test shall be repeated for proper functioning. 4.3.3 Contractor shall be given maximum of three attempts each not exceeding 3 days for any

subsequent defects found. After 3 tests for each activity, if the system still deviates from the specified requirements, the warranty period may be extended depending on the gravity of the defect, during which period the contractor shall rectify / modify the system to meet the specified requirements.

4.3.4 During the test, any modules / equipment fails, the contractor immediately within four

hours shall replace the faulty module / equipment and the test shall be repeated after extended continuous running of 96 hrs.

4.3.5 The total duration for the site acceptance tests i.e site pre-commissioning tests and Trial

operation test together shall not exceed 30 days including the repetition of tests and duration for replacement / rectification.

4.3.6 During all the above tests, Contractor shall ensure that the disturbance to the process is

minimum. 4.4 PG Test Result Interpretation 4.4.1 The failure of any one of the hard or soft copy device shall not be taken as non-

availability of the system. However, the mean time to repair shall not exceed that specified by the CONTRACTOR.

4.4.2 The PG test shall be repeated if the test results deviate from the guaranteed values. All

the special equipment, tools and tackles required for the successful completion of the PG test shall be provided by CONTRACTOR as part of the total scope of services.

SPEC NO.




CONTROL EQUIPMENT



ISSUE R0

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Ready stock of all types of modules / PC boards shall be available as part of the total scope of services for immediate replacement during the period.

4.3 The SG Integral Control system PG test shall be carried out to Owner’s satisfaction. The

last 5% of the total supply payment will be released only after successful completion of PG test.

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –OTHER SERVICES



TCE FORM 329 R3

ISSUE R0

TITLE

1.0 TRAINING OF OWNER'S PERSONNEL 1.1 The CONTRACTOR shall at no extra to the OWNER, undertake to train engineers

selected and deputed by the OWNER. These engineers shall be given special training in shop, laboratory and drawing office of the CONTRACTOR, where the Instrumentation and Control Equipment will be designed, and manufactured and in any other power plant where similar type of equipment designed, manufactured and supplied by them is under installation, test, operation or maintenance, to enable the engineers to become fully familiar with the equipment offered.

1.2 The type of training with number of personnel to be trained and the duration of training to

be provided for different I&C system equipment are detailed in Section D 2, TABLE- 6. 1.3 CONTRACTOR's personnel at site, shall continuously and intensively instruct and train

adequate number of the OWNER's operating and maintenance personnel at site during erection and commissioning of the equipment to enable them to take over the proper operation and maintenance of the equipment after commissioning.

1.4 The CONTRACTOR shall include in his bid, the charges for providing training to

purchaser's personnel as above. 1.5 CONTRACTOR shall include in his bid a detailed description of the proposed training for

the OWNER's personnel. 2.0 INSTRUMENTS FOR PERFORMANCE TESTING 2.1 All instruments required for performance testing to prove the guaranteed performance of

the Instrumentation and Control Equipment as specified in Section-D 2.5 or for the Performance Guarantee test of the plant shall be provided by the CONTRACTOR for the duration of the Performance Test. These test instruments shall have test certificates, from reputed test house, traceable to International /National standards and shall be valid for the duration of the performance test.

3.0 QUALITY ASSURANCE 3.1 BIDDER shall furnish a detailed Quality Assurance/ Quality Control Plan (QA/QC) for

each Instrument/System covered under this specification for OWNER / PROJECT MANAGER/ Consultant review and approval. The QAP shall be subject to Owner / Consultant’s approval.

3.2 BIDDER shall offer for inspection as specified. 4.0 PERFORMANCE GURANTEES 4.1 The BIDDER shall guarantee that material and workmanship of all components in the

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –OTHER SERVICES



TCE FORM 329 R3

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TITLE

system cabinets, control units and instruments supplied shall be in accordance with his latest design practices, unless otherwise specified in this specification.

4.2 Bidder shall guarantee for proper functioning of all field instruments like local gauges /

indicators, switches, transmitters etc., and control equipments like control valves/dampers etc. under Bidder’s scope of supply within specified accuracy / performance.

4.3 Bidder shall guarantee for proper functioning of SG Integral Control System under

Bidder’s scope of supply within specified performance condition. 4.4 Bidder shall guarantee for proper functioning of Furnace Flame Monitoring and Analysis

system under Bidder’s scope of supply. 4.5 Bidder shall guarantee for proper functioning of Boiler Tube Leak Detection System under

Bidder’s scope of supply.

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 1: AVAILABILITY REQUIREMENTS

SECTION: D2-T1 SHEET 1 OF 1


TCE FORM 329 R3

ISSUE R0

TITLE

1.0 AVAILABILITY REQUIREMENTS 1.1 All equipment and systems covered in this specification shall be designed for maximum

reliability and availability. 1.2 All equipment and systems shall be of proven design using material with well

established physical and chemical properties and as appropriate to the service intended. 1.3 To ensure high reliability of the trip circuit and to avoid spurious trippings of the plant,

multiple input logic system, (e.g.,2 out of 3 logic) shall be provided for important and vital trip functions.

1.4 Protection circuits shall be independent of other systems such as interlock, measurement,

control, etc. 1.5 From availability considerations, all circuits for the same type of equipment shall be housed

in different cabinets. 1.6 Adequate redundancy shall be built in at various levels to increase the system availability

and reliability. 1.7 BIDDER shall quote a highly reliable equipment/ configuration to perform the functional

requirements as specified. 1.8 The system shall be designed with extensive self-diagnostics and trouble shooting

features. Adequate facility shall be provided for quick repair/maintenance and on-line replacement of faulty modules. This shall not result in spurious trips. Where a major equipment/ unit trips likely to be inhibited when the card is pulled out, it shall be identified by VENDOR during detailed engineering stage.

1.9 In case of control system, auto and manual circuits shall be independent from each

other in all respects, including power supply, so that in case of any fault in the auto circuit, the manual circuit shall always be available to control the plant.

1.10 Components used in the equipment and systems shall be designed with higher rating than

required for the normal operating conditions in order to have higher availability of the system.

1.11 Control valves/dampers shall be driven to the fail safe position or stayput position in case of

control system failure, as specified. This arrangement is necessary to avoid system upsets and subsequent loss of operation.

1.12 Easy access shall be provided for all components in the equipment and systems offered to

reduce the maintenance period. 1.13 All components shall be subjected to a burn-in test before they are assembled. Completely

assembled system shall be subjected to a continuous working test. This test will help in eliminating the weak components in the system, thus increasing reliability and availability.

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 2: LAYOUT AND MAINTENANCE REQUIREMENT



TCE FORM 329 R3

ISSUE R0

TITLE

1.0 LAYOUT REQUIREMENTS 1.1 All the cabinets supplied by Bidder shall have the same height, depth and colour. The

VENDOR shall submit a layout drawing clearly indicating all the dimensions of the system cabinets, doors, knockout doors, floor opening required for cable entry, etc.

1.2 Computer grounding will be separate from station grounding. 1.3 Any specific recommendation regarding the location and limiting distances between the

different equipment to be located in the annexe of the control room shall be detailed and the layout for the same shall be furnished during detailed engineering stage for PURCHASER’s/ CONSULTANT’s approval.

1.4 The location of junction boxes will be finalised during the detailed engineering stage.

Purchaser reserves the right to change the grouping of instruments in each junction box during detailed Engineering stage.

1.5 The local panels to be supplied shall be mounted indoors and near the corresponding

equipment. 1.6 The exact routing of impulse pipes will be decided at site during erection depending upon

the location of tap points. PURCHASER reserves the right to approve the suitable location of the field mounted junction boxes.

1.7 All equipment and I&C equipment piping supplied by the VENDOR shall be supported

adequately to prevent vibration and anchored sufficiently to prevent undue strains on the equipment. Hangers and supports shall be so installed as not to interfere with free expansion and contraction of the piping between anchors. Suitable spring hangers, vibration dampeners, etc. shall be provided wherever necessary. In addition, care should be taken that the arrangement of piping, and supports shall provide for safety under working stress and shall protect the piping from detrimental sagging, mechanical injury, abuse to unusual service conditions from sources other than those due to pressure, temperature and vibrations.

1.8 Straight length requirement before and after control valves, flow element and de-

superheater shall be provided as per latest applicable standard codes. 1.9 The tapping point instruments shall be located at appropriate location to meet the

purpose of the instrument provided for. Eg. The pressure switch to open a discharge valve of a centrifugal pumps after a pump start shall be located between pump and discharge valve; the stub for temperature sensing at a desuperheater outlet for temperature control shall be located after a straight run of min. three (3) meters to ensure through mixing of the fluids and temperature is measured at a location of laminar flow.

2.0 MAINTENANCE REQUIREMENTS

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 2: LAYOUT AND MAINTENANCE REQUIREMENT



TCE FORM 329 R3

ISSUE R0

TITLE

2.1 All equipment supplied by BIDDER shall be designed for ease-of-maintenance to help achieve a high meantime between-failures (MTBF). All equipment shall be of modular design to assure a short mean-time to repair (MTTR).

2.2 The following specific provisions shall be made to achieve the above objective : (a) The Vendor shall furnish the details of the maintenance requirements of

each equipment, indicating list of parts which require regular maintenance and frequency of maintenance for these parts. Based on VENDOR’s experience, documentation giving a recommended maintenance program to achieve a high MTBF for the equipment shall be furnished.

(b) The VENDOR shall furnish sufficient documentation to ensure efficient

maintenance and trouble-shooting of equipment and modules. This shall include wiring diagrams and schematic diagrams of all electronic assemblies for the system cabinets supplied, supplemented with concise description of theory of operation of individual subsystems. Expected faults, trouble shooting hints, check-out lists and a list of sub-components prone to failure shall also be provided.

(c) All equipment shall have extensive self-diagnostic features, test points and clearly

labelled error indicating lamps which help in speedy identification of faulty modules/components.

(d) Provision shall be made for isolation of subsystems/modules which are

identified to be faulty, thus enabling on-line replacement without taking equipment off-line.

(e) Adequate number of test equipments, test sockets, test cables, digital voltmeters,

3-pen recorders, signal generators, card extenders, etc., shall be provided by the VENDOR to facilitate ease in maintenance.

(f) Necessary maintenance equipment tools and special erection tools which are not

specifically mentioned in the specification but are normally required for ease in maintenance and to have minimum down time, shall be included in the BIDDER’s scope.

(g) Components of same function shall be as far as possible interchangeable. (h) Standardisation concept shall be used in setting the components for the systems. (i) All the documentation shall be in English language. (j) All documentation shall be provided on DVD-ROM in addition to the printed

documents.

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 3: ERECTION, TESTING AND COMMISSIONING

REQUIREMENT



TCE FORM 329 R3

ISSUE R0

TITLE

1.0 GENERAL 1.1 The erection of instrumentation system shall be carried out generally conforming to

sound engineering practices. However, the Bidder shall select and adopt methods and procedures for equipment erection to suit the nature of equipment and erection, involved according to the best modern practice and his own experience.

2.0 SCOPE OF WORK FOR ERECTION 2.1 The Bidder shall be required to erect all cabinets, consoles, desks, all cables, conduits,

equipment of Programmable control systems (DCS/ PLC etc.) required for completion system covered in this specification.

2.2 The Bidder shall provide all supervisory, skilled, semiskilled and unskilled labours

including instrument tube fitters, licensed cable jointing mechanics etc., tools and tackles, consumable, erection materials required for the complete installation, transport vehicles, hydraulic jacks, welding sets, mobile cranes, blowers and other necessary equipment for timely efficient erection and testing.

2.3 The Bidder shall maintain proper record of the materials at the place of storage for quick

identification as and when required. 2.4 The Bidder shall carry out all repairs to damages that might have suffered during transit

or in subsequent storage and replacement of all lost parts. 2.5 The Bidder shall furnish a detail erection schedule, which shall be finalised along with

the offer keeping in view the overall erection and commissioning schedule. The erection schedule as agreed with the PURCHASER shall be strictly adhered to by the Bidder.

2.6 The erection work shall include but not limited to the following: (a) Transportation of the tested and calibrated equipment to the place of installation

without any damage. (b) Installation of DCS / PLC equipment as per bill of material and as per relevant

approved G.A and disposition drawing. (c) Installation of the necessary cable and racks with posts, brackets, and

fasteners. (d) Installation and termination of electrical, measuring, control, power supply, and

signal lines, from the available / to be erected marshalling cabinets to I/O cabinets System cabinets as per relevant interconnecting and terminating drawings prepared by the successful Bidder. This includes laying of all control cables, compensating cables etc.

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(e) Supply, fabrication and erection of structural steel plates, angles, pipes required

for supporting cable trays complete with bolts and nuts. (f) Providing identification of cable by engraved Aluminium tag plates at both ends

inside the cabinets, consoles as per cable schedule. (g) Supervision of preparation of separate earthing pits as recommended by the

DCS/ PLC etc. system supplier, laying and connection of the earthing cables from different equipment to the respective earthing pit.

3.0 ERECTION 3.1 Cabinets and desk 3.1.1 The Bidder shall arrange for the transportation and handling of cabinets and desks from

stores to work site suitably without any damage. If any damage is observed before handling, this shall be brought to the notice of the PURCHASER.

3.1.2 Before installation of cabinets and desks, the necessary openings and inserts required

to be made on the floor by the Bidder shall be checked and then after proper alignment, the cabinets and desks shall be installed on the floor by the Bidder. All necessary civil work to be carried out for this shall be in Bidder’s scope of supply.

3.1.3 The cabinets and desks shall be cleaned by blowing air to remove dust or foreign

particles. 3.1.4 The Bidder's scope of work and supply shall also include tightening of wires,

replacement of broken items and retouching of damaged painted surface of cabinets those has taken place during transport from store to work site and during installation.

3.1.5 The Bidder's scope of work and supply shall also include tightening of wires,

replacement of broken items and retouching of damaged painted surface of cabinets those has taken place during transport from store to work site and during installation.

3.2 Cables, cables trays and conduits 3.2.1 All electrical work shall conform to the rules and regulations of Indian Electricity Act. 3.2.2 All cables shall be tested for insulation level. Cable ends shall be properly cleaned. 3.2.3 The entry to and exit from pipes shall be smooth and free from burr where cables are

run through pipes. Cable shall be pulled into the pipes in such a way that there shall be no damage to the cables.

3.2.4 Flexible conduits shall be provided wherever necessary.

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3.2.5 Cable in hot areas shall have proper heat protection. 3.2.6 A minimum distance of 300 mm shall be kept between instrument / signal cables and

power cables. 3.2.7 Each tray shall be filled with a maximum of three layers of cables (two for instrument

and control cables and one layer for power cables for I&C equipment) providing 20% spare space in the number of layers specified.

3.2.8 Instrument Cable Trays, shall be erected vertically as far as possible to avoid dust

accumulation. 3.2.9 All the cables laid shall be tied individually to the Tray. 3.2.10 Thermocouple cables shall be run completely independent of all other cables with

minimum separation as per relevant standard and with cross over at right angles. 3.2.11 The cabling accessories shall include cage-clamp type terminal blocks, splicing

materials, crimping tools, cable support grips, insulating tapes, GI flexible conduits, conduit fittings, GI perforated covered trays, supports, accessories, and cadmium plated trays & cable glands.

4.0 SPECIFIC REQUIREMENTS FOR ERECTION, TESTING, CALIBRATION AND

COMMISSIONING 4.1 ERECTION REQUIREMENTS 4.1.1 The actual location of transmitter racks, junction boxes and other instruments shall be

decided by the Bidder depending on the site conditions considering the layout and maintenance aspects.

4.1.2 The Bidder shall get prior approval as per approved quality assurance plan of the

Purchaser / Purchaser’s Representative before any installation work starts. If any work is carried out by the Bidder before prior approval from Purchaser / Purchaser’s Representative and modification is sought by Purchaser / Purchaser’s Representative later, then the work shall be redone by Bidder without any cost / material implications to the Purchaser / Purchaser’s Representative.

4.1.3 Impulse / sample piping, air supply and pneumatic tubing, cable trays and equipment

shall be supported rigid enough to prevent vibration and anchored sufficiently to prevent strains on equipment installed. Supporting clamps shall be provided at-least at every one metre distance for better rigidity. Impulse / sampling piping shall be provided with adequate slope, (preferably 1:10). Hanger and supports shall be so installed as not to interfere with free expansion and contraction of the piping and tubing between anchors. Suitable vibration dampners, etc., shall be provided wherever necessary. In addition, care shall be taken that the arrangement of impulse / sampling piping, air supply and pneumatic tubing from detrimental sagging, mechanical injury, abuse due to unusual

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service conditions from sources other than those due to pressure, temperature and vibrations. All impulse lines of joints shall be welded type unless otherwise specified. Argon arc welding shall be employed.

4.1.4 All the panels, desk, cabinets supplied by the Bidder shall be welded or bolted to the

floor channel. 4.2 TESTING REQUIREMENTS 4.2.1 The Bidder 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 Contract Period.

4.2.2 The Bidder 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 calibrations shall be carried out independently by the Bidder and later in the presence of Purchaser who shall certify the same. Proper documentation in this regard shall be maintained and handed over to the Purchaser.

4.2.3 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.

4.2.4 All instruments and control equipment shall be calibrated to read correctly to the

satisfaction of equipment supplier / Purchaser. 4.2.5 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. 4.2.6 All the float operated level switches shall be tested for the movement of the float and

linkages to make to break the switch contacts by filling up with water before installation. For such tests, necessary testing set up required shall be arranged by the Bidder. All the conductivity type probes and switches shall be tested for performance before installation.

4.2.7 Air leak tests shall be performed on all flue gas impulse / sample lines, air supply and

pneumatic lines. Necessary equipment such as portable compressor, connecting pipes, materials, cables and test gauges shall be provided by the Bidder.

4.2.8 Hydro test shall be performed for all other impulse lines / sampling lines. Necessary

equipment such as hydro test pumps and temporary piping to the required point, fill pump etc., materials such as temporary gaskets, miscellaneous fasteners, etc. tools and tackles including test pressure gauges, etc. are to be provided by the Bidder.

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4.2.9 For all electrical actuators of the valves, functioning, setting and performance of limit switches / torque switches of various positions shall be checked before and after installation of the actuators. The position transmitters for inching applications shall also be calibrated.

4.2.10 Pneumatic actuators shall be calibrated at site for Vendor supplied valves. 4.3 COMMISSIONING REQUIREMENTS 4.3.1 Prior to taking the instruments in service, all impulse lines, sampling lines and air supply

lines shall be blown as required with the establishment of adequate line pressure and temperature conditions to keep the lines thoroughly clean.

4.3.2 On-line [i.e, without removing control valves from the pipe] calibration of the positioners

and stroking of control valves/control dampers whether supplied by the VENDOR or by others and connected to the control systems (loops) supplied by the VENDOR shall be carried out as required by PURCHASER/SUPPLIER during control system tuning.

4.3.3 Pre-commissioning checks, individuals loop checks, power initialisation, verification of

system functioning, trouble shooting final solutions to application and / or instrument problems, etc., is Bidder’s responsibility. All the required software and hardware changes shall be incorporated as required for successful commissioning to Purchaser’s satisfaction.

4.3.4 Any other tests as may be directed by the Purchaser/Purchaser’s Representative. 4.3.5 After delivery of the equipment, the Bidder shall locate all the equipment including

electronic cards in its final position, check all the power wiring, grounding and interconnection cables, all in accordance with manufacturer’s recommendations. The Bidder shall perform initialisation of system power, field loading of system configuration / software and data base, demonstration of system functionality to verify conformance with manufacturer’s instructions and specifications, tuning of control loops, implementation of any configuration changes including hardware, software and additional tappings / instruments, cabinets as required and providing general trouble shooting and final solutions to application and / or instrument problems.

4.4 LOOP TESTING 4.4.1 The action of the DCS / PLC controller is set as prescribed. Controller settings for

various modes of operation (Proportional band, reset and rate action) are at nominal value.

4.4.2 For current signals, 4 – 20 mA shall be injected and checked the loop for 0%, 25%,

50%, 75% and 100% of full scale inputs. 4.4.3 For temperature loops with thermocouples, a known milli volt signal shall be injected

and the output display shall be checked for input signals of 0%, 25%, 50%, 75% and

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100%. 4.4.4 For temperature loops with RTDs, a known resistance shall be injected in the control

cable through decade resistance box and output display shall be checked for 0%, 25%, 50%, 75% and 100%.

4.4.5 For field mounted switches for alarms / interlocks, the action shall be simulated by

disconnecting the wires / shorting the terminals and the function of the associated system shall be checked.

4.4.6 Any equipment required by the Bidder for testing, calibration and commissioning shall

be brought by the Bidder at site. The list of such equipment shall be furnished along with the offer.

5.0 COMMISSIONING 5.1 The Bidder shall take care to complete all pre-commissioning activities and simulation

tests after erection to suit the over all start up of respective plant equipment. 5.2 The pre-commissioning activities of the system shall be completed at least two (2) days

in advance as per the schedule of plant start-up. 5.3 The controllers shall be tuned as per the process requirement. The list of set points,

alarms / interlocks, settings for the controllers shall be furnished in the standard format and handed over to the PURCHASER.

5.4 Control loops shall be put in auto mode as per the operational requirement of different

phases. 5.5 Bus Worst loading conditions calculation shall be proved at the time of commissioning. 5.6 Before taking over of the plant by the PURCHASER, all the system and auto control

loops shall run satisfactorily for at least one month at varying loads without disturbing any adjustment. During this period, supervision and maintenance of the system shall be the scope and responsibility of the Bidder.

5.7 The performance test shall be carried out for the system offered and certificates to these

effects shall be approved by the PURCHASER.

SPEC NO.


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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 4: CODES AND STANDARDS



TCE FORM 329 R3

ISSUE R0

TITLE

SL.No DESCRIPTION CODE / STANDARD

1 Instrumentation Symbols And Identification. ISA S 5.1 2 Graphic Symbols For DCS, Shared Display Instrumentation Logic &

Comp. System ISA S 5.3

3 Graphical Symbols for Diagrams, Binary Logic Elements IEC 617-12 4 Diagrams, Charts, Tables IEC 113 5 Industrial Measurement & Control – Terms & definition IEC 902 6 Pressure, Vacuum And Differential Pressure Gauges IS-3624 / BS 1760

Class I 7 Instrument And Apparatus For Pressure Measurement ASME PTC- 19.2 8 Instrument And Apparatus For Temperature Measurement ASME PTC- 19.3 9 Temperature Measurement -Thermocouples ANSI ISA 96.1 /

ASTM E 230-03 / IEC 751

10 Temperature Measurement By Electrical Resistance Thermometers

(RTD) IS: 2806

11 Industrial Platinum- RTD DIN 43760 / IEC 751

/ IS 2848

12 Temperature Measurement- Thermocouples , Extension wires / cables ANSI ISA: 96.1

13 Measurement Of Fluid Flow By Means Of Orifice Plates & Nozzles ISO 5167 14 Industrial Process Control Valves IEC 534 15 Control Valve Sizing ISA S 75.01 16 Control Valve Procedure Capacity Test ISA S 75.02 17 Uniform Face – Two Face Dimensions for Flanged Globe Style CV

Bodies ISA S 75.03

18 Valves Seat Leakage ANSI B 16.104

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19 Measurement & Control, Electrical sensors, Elec. Position Sensors

& Signal Converters for IS Two Wire DC Systems. DIN 19243

20 Vibration, Axial Position & Bearing Temperature Monitoring

Systems API 670

21 Electronic Transmitters BS: 6447 22 Compatibility Of Analog Signals For Electronic Industrial Process

Instruments ISA - S 50.1 / ANSI MC 12.1

23 Electronic Equipment For Use In Electrical Power Installations VDE: 0160 24 Safety Requirement For Electrical And Electronic Measuring And

Controlling Instruments ANSI C 39.5 - 1974

25 Electromagnetic Susceptibility Of Process Control Instrumentation SAMA PMC 33.1 /

IEC 801 26 Dynamic Response Testing Of Process Control Instrumentation ISA -S 26 27 Electronic Equipment For Furnaces VDE: 0116 Section

8.7 28 Electrical Indicating Instruments ( Direct Acting) IS: 1248 29 Panel Mounted Indicating And Recording ElectricalInstruments,

Dimensions For IS: 2419

30

SWC ( Surge Withstand Capability) Test ANSI -C37.90.1 / IEEE - 472 / IEC - 225-4

31 Annunciator Sequences And Specification. ISA S 18.1

32 Specifications And Guides For The Use Of General Purpose Annunciators ISA S 19.1

33 Environmental Conditions ISA S 71.04 34 Basic Environmental Testing Procedures For Electronic And

Electrical Items IS- 9000 / IEC 16000

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35 Damp Heat Cycling Test IS -2106 36 Classification Of Hazardous Areas NFPA 70, Article 500 37 Classification Of Hazardous Areas For Electrical Installations IS : 5572 ( Part-1 ) 38 Electrical Instruments In Hazardous Dust Locations ISA-RP 12.11 39 Protection Class For Enclosures, Cabinets, Control Panels & Desks IS- 2147 / IEC 529 40 Types Of Enclosures NEMA ICS Part-6 (

With Rev.14/80) 41 Flame Proof Enclosure For Electrical Apparatus IS : 2148 42 Intrinsically Safe Apparatus NFPA 496 43 Purged And Pressurised Enclosure For Electrical Equipment In

Hazardous Locations NFPA Art. 496

44 Contact Rating - AC Services NEMA ICS 2 , Part-2-

125 , A 6000 45 Contact Rating - DC Services NEMA ICS 2 , Part-2-

125 , N 600 46 Edge Socket Connectors IEC 130 -11 47 Racks, Panels & Associated Equipment ANSI C 83.9 48 Miniature Circuit breakers For Voltages Not Exceeding 1000 V IS: 8828 49 Plain End Steel Tubes, Welded & Seamless General Table –

Dimensions & Masses / Length ISO 4200

50 Pipe Threads ANSI B 2.1 51 Dimensions Of Fittings ANSI B - 16.11 52 Material For Socket Welded Fitting ASTM A-105 53 Nomenclature For Instrument Tube Fittings ISA-RP-42.1 54 Binary Logic Diagrams For Process Operation ISA S 5.2

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55 Preparation Of Function Chart For Control System IEC 848 56 Functional Diagramming Of Instrument & Control Systems SAMA PMS 22.1 57 Quality Control Standard for Control ANSI FCI 70.02 58 Process Control Security Requirements IEC 62443 59 Boiler Safety Interlocks NFPA -85B & 85C 60 Turbine Water Damage Prevention ASME-TDP-1980 61

Safety Requirements For Turbine Protection VDE: 0116 Section-87 VDE: 0160

62 Water And Steam In Power Cycle ASME PTC 19.11 63 Standard Methods Of Sampling System ASTM D 1066-69 64 Submerged Helical Coil Heat Exchangers For Sample Coolers ASTM D 11 65 Hardware Testing of Digital Process computers ISA RP-55.1- 1983 66 Standard Digital Interface For Programmable Instrumentation IEEE - 488.2 -1990 67 IEEE Guide To Software Requirements Specifications IEEE 830

68 Standard For Local Area Networks : Carrier Sense Multiple Access with Collision Detection CSMA-CD And Supplements A,B,C and E IEEE 802.3

69 Standard For Local Area Networks-Token Ring Access Method And Physical Layer Separation IEEE 802.5

70 Wiring Cables For Telecommunication And Information Processing

System VDE: 0815

71 Conductors For Insulated Electrical Cables And Flexible Cords IS: 8130 72 Rules For Testing Insulated Cables And Flexible Cables VDE: 0472 73 Colour Coding of Instrumentation Cables BS-5308 (Part-2) /

IEC-189 (Part-2)

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74 Guide For Design And Installation Of Cable Systems In Power

Generating Stations (Insulation, Jacket Material) IEEE 422

75 Instrumentation Cables And Internal Wiring IS- 1554 (Part-1) /

IS-5831 76 Guide For Design And Installation Of Cable Systems In Power

Generating Stations (Cable Trays, Support Systems, Conduits) IEEE 422 / NEMA VE-1 / NFPA-70

77 Guide For Design And Installation Of Cable Systems In Power

Generating Stations (Cable Trays, Support Systems, Conduits) Test Standards

NEMA VE-1

78 Requirement Of Vertical Tray Flame Tests IEEE 383 79 UPS - Performance Testing IEC - 146 80 Air Purge System ISA S 12.4 / NFPA

496

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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 5: ESSENTIAL SPARES



TCE FORM 329 R3

ISSUE R0

TITLE

SL. NO. ITEM/DESCRIPTION QUANTITY / UNIT (NOTE-1, 2)

1.0 Field Instruments / Elements / Equipment (Gauges, Switches, transmitters etc.)

1.1 Local Gauges 10% for each type, size and range but minimum 2 no

1.2 Field Switches 10% for each type and range but minimum 2 no 1.3 Transmitter 10% for each type and range but minimum 2 no

1.4 Temperature Element (RTD) with Thermowell

10% for each type, range and Immersion length but minimum 2 no

1.5 Temperature Element (T/C) with Thermowell

10% for each type, range and Immersion length but minimum 2 no

1.6 Air Filter Regulator 10% for each type and range but minimum 2 no 1.7 Junction Box. 10% for each size but minimum 2 no 1.8 Flow Elements 2 no shut off valves for each flow element 1.9 I/P Converter 10% for each type and range but minimum 2 no 1.10 Position Transmitter 10% for each type and range but minimum 2 no 1.11 Limit Switches 10% for each type and rating but minimum 2 no 1.12 Positive Displacement Flow Meter 1.12.1 O rings 2 no. of each size 1.12.2 Gaskets 2 no. of each size 1.12.3 Measuring Mechanism 1 no

1.13 Furnace Temperature Probe- Thermocouple 1 no

2.0 SG Integral Control System-BMS And Boiler Protection System (Each)

2.1 Power Supply modules/Cards 10% for each type and range but minimum 2 no

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2.2 Network Cards /Switches 10% for each type and range but minimum 2 no

2.3 Communication Interface Cards 10% for each type and range but minimum 1 no

2.4 All other electronic modules 10% for each type and range but minimum 1 no

2.5 Controller card (For Integrated Controller card) / Processor Module for Controller

2 nos.

2.6 I/O Cards (Each Type) 10% for each type and range but minimum 2 no

2.7 Interposing Relay 10% of total quantity

3.0 Panels, local panels, System /Marshalling cabinets

3.1 Fuses 50 nos of each type and rating

3.2 Miniature Ckt. Breaker (MCB) 10 nos of each type and rating

3.3 Male/ Female parts of pre-fabricated cables 10 nos. of each type

3.4 Space Heater 10% of total quantity but minimum 1 no

3.5 Smoke Detector 10% of total quantity but minimum 1 no

3.6 Terminal Blocks 20% of total quantity.

3.7 Terminals in Terminal blocks 10 nos of each type

3.8 Cable clamps 5 nos of each type.

3.9 Blowers 1no

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3.10 Cabinet Cooling Fans 4 nos. of each type/rating

4.0 Control valves and Pneumatic Block valves (for each Valve)

4.1 Plug and steam assembly 1 no. of each type

4.2 Seat ring 1 no. of each type

4.3 Packing and gaskets 2 sets. of each type

4.4 Pilot relay 1 no. of each type

4.5 Actuator diaphragm 1 no. of each type

4.6 O-rings 2 sets of each size for positioner

4.7 Feedback linkage 1 no of each type

4.8 Control valves (Electrical operated- if supplied) – Interfacing modules 1 no. or 10% of total qty. whichever is higher.

5.0 Control Dampers (for each damper)

5.1 Actuator diaphragm 1 no. of each type

5.2 O-rings 2 no. of each size for positioner

5.3 Feedback linkage 1 no of each type

5.4 Packing and gaskets 1 no. of each type

6.0 Solenoid Valve (For each valve)

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6.1 Solenoid Valve Coil 2 nos of each rating and insulation

6.2 Solenoid Valve Plunger 1 no of each type

6.3 Seat 1 no of each type and size

6.4 Gaskets 2 sets of each type and size

6.5 O-rings 5 sets of each type and size

7.0 Steam Tube Leakage Detection System

7.1 Sensor 2 nos. or 10% of total quantity whichever is higher for each type and range.

7.2 Each type of card 10 % of total quantity but minimum 1 no

7.3 Any other items As per the manufacturer’s recommendation.

8.0 Flame Monitoring And Analysis System

8.1 Camera 10 % of total quantity for each type but minimum 1 no

8.2 Other Spare parts As per the manufacturer’s recommendation for 3 years operation.

NOTES: 1. Fractions are to be rounded-off to next higher integer. 2. Qty. indicated is applicable for each unit. There are 2 units in the project. 3. SPARES requirement for any equipment/system not specified above, the

Contractor shall supply the spares for the supplied system/sub-system/instruments as per the manufacturer’s recommendation.

SPEC NO.


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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 6: TRAINING TO BE PROVIDED FOR OWNER’S

PERSONNEL



TCE FORM 329 R3

ISSUE R0

TITLE

SL.

NO. TYPE OF TRAINING NO. OF

PERSONS DURATION OF

TRAINING

1.0 SYSTEM MAINTENANCE TRAINING

1.1 I&C Engineers In BMS/ Boiler Protection System Hardware & Software

4 2 Weeks Each

1.2 I&C Engineers In Furnace Flame Monitoring and

Analysis System- Hardware, Software & Analysis 4 1 Week Each

1.3 I&C Engineers In Boiler Tube Leak Detection System-

Hardware, Software & Analysis 4 1 Week Each

1.4 For All Other Instruments/ Systems 4 Adequate

Training

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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7: TESTS FOR I&C SYSTEM EQUIPMENT



ISSUE R0

TITLE

TCE FORM 329 R4

PART-A: TESTS FOR I&C SYSTEM EQUIPMENT

SL. NO

INSTRUMENT / EQUIPMENT

TESTS TO BE CONDUCTED

1. Pressure indicators Calibration Hydro test (1.5 times max. Pr.) 2. Pressure switches Calibration test /Hydro test/Contact rating test/ Accuracy test /

Repeatability Test 3. Pressure Transmitters Calibration test /Hydro test/Leak test/Over range test /

Accuracy test /Repeatability test. 4. Differential Pressure

Indicators Calibration test /Hydro test/Leak test/Over range test / Accuracy test/Repeatability test.

5. Differential Pressure

Switches Calibration test /Hydro test/Leak test/Over range test/ Accuracy test/Repeatability test.

6. Differential Pressure

Transmitters Calibration test /Hydro test/Leak test/Over range test/ Accuracy test/Repeatability test.

7. Thermometers Calibration test /Material test//Accuracy test/Bore concentricity :

±5% of wall thick/Hydrostatic test for TW (1.5 times max. pr.). 8. Temperature switch Calibration test/Material test//Accuracy test/Bore concentricity :

1.5% of wall thick/Hydrostatic test for TW (1.5 times max. pr.)/Contact rating test.

9. Resistance

temperature detector assembly

Calibration/Material test/Accuracy test/Bore concentricity test/Insulation test (<500 M at 500 V, DC) as per ISA, Hydro test for TW. Bore concentricity : ±5% of wall thick, Accuracy test

10. Thermocouple

assembly Calibration/Material test/Insulation test (<500 at 500 V, DC) as per ISA, Hydro static test (1.5 times max. pr.) More concentricity ±5% of wall thick

11. Temperature

transmitters Calibration test/Accuracy test/Ambient temperature error test

12. Thermowells Material test /Bore concentricity : ±5% of wall thick/ Hydrostatic

test for TW (1.5 times max.pr) 13. Interposing relay Functional test/temperature rise test/high voltage test/ limits of

operation test/insulation test.

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TCE FORM 329 R4

PART-A: TESTS FOR I&C SYSTEM EQUIPMENT SL. NO



14. Level gauges Hydrostatic test/Material test/Seat leakage test / Ball check test 15. Level switches

(magnetic) Material test/Contact rating test/Hydro test / Calibration test

16. Level gauges (Probe) Material test /Contact rating test /Hydro test / Calibration test 17. Flow switch Material test / Hydro test/ (1.5 time max. pr) / function test 18. Flow glasses Material test /Hydro test/ (1.5 time max. pr) / function test 19. Variable are flow metes Calibration test / Material test / Hydrostatic test (1.5 time max.

pr) 20. Flow element 100% Radiography test / Hydro test / Calibration test / IBR

certificate 21. Control valves (a) IBR certificate Form III C (b) Hydrostatic test : IBR/MSS-SP-61/ANSI B 16.34 (Note 1) (c) Seat leakage test : As per ANSI B 16-104 (Note-1) (d) CV test : As per ISA procedure (Note 1) (e) Magnetic particle test : As per ANSI B 16.34 special class

(applicable for pr.> 70 bar & tem < 4000C (f) Liquid penetration test : As per ANSI B 16.34 special

class (applicable for pr > 70 bar & temp < 4000C (g) Calibration and Hysteresis test (Note-1) NOTE-1: These tests shall be witnessed by PURCHASER /

CONSULTANT 22. Pneumatic Block

Valves: (a) IBR certificate Form III C

(b) Hydrostatic test : ANSI B 16.34 (Note 1) (c) Seat leakage test : As per ANSI B 16-104 (Note-1)

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ISSUE R0

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TCE FORM 329 R4




(d) CV test : As per ISA procedure (Note 1) (e) Magnetic particle test : As per ANSI B 16.34 special class


class (applicable for pr > 70 bar & temp < 4000C (g) Radiography test : As per ANSI B 16.34 special class (h) Calibration and Hysteresis test (Note-1) (i) Actuator leakage test (Note-1) Note-1: These tests shall be witnessed by PURCHASER /

CONSULTANT 23. Pressure Regulating

Valves (a) IBR certificate Form III C

(b) Hydrostatic test : ANSI B 16.34 (Note 1) (c) Seat leakage test : As per ANSI B 16-104 (Note-1) (d) CV test : As per ISA procedure (Note 1) (e) Magnetic particle test : As per ANSI B 16.34 special class


class (applicable for pr > 70 bar & temp < 4000C (g) Radiography test : As per ANSI B 16.34 special class (h) Calibration and Hysteresis test (Note-1) (i) Actuator leakage test (Note-1) Note-1: These tests shall be witnessed by PURCHASER /

CONSULTANT 24. Position Transmitters Calibration/ Hysteresis and Accuracy test

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25. I/P Converters Calibration test/Accuracy Test 26. Solenoid Valves Hydro test/Seat leakage test/CV test/Coil insulation test 27. Air Filter Regulators Calibration test/Accuracy test 28. Junction Boxes Test for degree of protection/Material test 29. Transmitter Racks Hydro test, Air leak test for tubing/Piping & fittings, IBR

certificate required for impulse pipes, tubes and fittings of all steam & water services

30. Transmitter Racks Verification of degree or protection. Test for enclosure type,

Type tests & routine tests as per relevant Indian standards. 31. Compensating cable Thermo-emf characteristic/Continuity test/Measurement on

capacitance, inductance and loop resistance / insulation resistance /high voltage test as per latest IS/Tensile and elongation test/Oxygen index test /Any other test applicable

32. Local Panels Verification of degree of protection / Electrical tests as detailed

under “Wiring, Terminations & Accessories”/Type tests & routine tests as per relevant Indian standards.

33. Marshalling Cabinets Verification of degree of protection / Electrical tests as detailed


34. System cabinets Verification of degree of protection / Electrical tests as detailed


35. Wiring Termination and

Accessories

35.1 Routine test Conductor resistance test (*) / High voltage test (*)/Impulse

dielectric test/Insulation test/Humidity test/Temperature rise tests on power circuits/Short time current tests on power circuits.

35.2 Type test Annealing test (*) / Test for insulation and sheath (*)/Flame

retardance test – (a) Oxygen index, (b) Flammability/Test for acid gas generation/Test for water absorption (*)/Wet dielectric test.

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Note (*) – As per IS-1554 35.3 Test for terminal blocks Test for moulding for flame resistant, Non-hygroscopic and

Decarbonised / Insulation test between terminals / Insulation between terminal block and frame

36 DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS 36.1 Measurement &

Control System (a) Simulated Functional test for the complete system (As

per FAT procedure. Note-1) (b) System performance & tests for monitoring functions (As

per FAT procedure. Note-1) (c) Surge withstand capability test as per ANSI C37.9A /

IEEE 4721 BE MMA 219 or equivalent. (d) Damp heat cycling test as per is 2106, part 1I- 1962 or

equivalent. (e) Dielectric strength test (high pot tests as per NEMA ICSI.

part ICS-109) ANSI C39.51/UL 508 or equivalent, (f) Radio frequency interference test as per SAMA PMC

33.1 or equivalent. (g) Immunity to noise test as per IEEE SWC test 587 or

equivalent. (h) Burn in test & temperature rise test for 120 hrs. (i) Continuity test & short circuit test for current limiters. (j) Under voltage and over voltage test (Note-1). Note-1: Test to be witnessed by Owner or Owner’s

representative. 36.2 Data bus system (a) Functional test for the complete system (Both hardware &

software) simulating worst condition (As per FAT procedure. Note-1).

(b) Noise test-surge withstand capability test as per IEEE or

equivalent.

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(c) Quality assurance and tests shall be as per latest BS-

5750 and ESS-1980 or equivalent. Note-1: Test to be witnessed by Owner or Owner’s

representative. 36.3 Central Processing

Unit for Man Machine Interface

(a) Main memory test of 12 hours duration to demonstrate the capability of memory Read-Write function under worst pattern at various voltage levels

(b) Main memory parity detection test of 12 hours duration to

demonstrate that parity detection feature performs properly to the Owner’s satisfaction

(c) Logic tests for 12 hours duration to demonstrate the

hardware commands, interrupt structures and hardware failure detection

(d) Count down registers and pulse counter test of 8 hours

duration to demonstrate the accuracy of all time count down registers

(e) Bulk memory Data transfer test of 36 hours duration to

demonstrate possible combinations of transfer from/to bulk memory including checks for illegal writing, reading and wrong transfer indications

(f) Voltage and speed variation checks (g) Bulk memory parity detection test of 12 hours duration to

demonstrate the proper functioning of parity detection feature

(h) Functional test for complete system (Both hardware and

software) simulating worst conditions (As per FAT procedure. Note-1).

(i) Noise test-surge withstand capability test as per IEEE or

equivalent. (j) Quality assurance and tests shall be as per latest BS-

5750 and ESS-1980 or equivalent.

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(k) Design, construction, components, materials, finishes and testing of electronic equipment as per EES - 1980 (General specification of electronic equipment) or equivalent.

Note-1: Test to be witnessed by Owner or Owner’s

representative. 37 Colour Graphic Video

Display Unit (VDU) (a) Functional tests (As per FAT procedure. Note-1).

(b) Test for capabilities of VDU including error detection for

the complete system (Both Hardware & Software) simulating worst conditions

(c) Noise test (d) Surge withstanding capacity as per IEEE or equivalent (e) Quality assurance as governed by BS 5750 or equivalent. (f) Design, construction, components, finishes and testing of

electronic equipment as per EES-1980 (General specification of electronic equipment) or equivalent.


representative. 38 Keyboard (a) Test for satisfactory operation of keyboard controls, push

buttons and all associated functions (As per FAT procedure. Note-1).

(b) Quality assurance as governed By BS5750 or equivalent

for functional test for the complete system simulating worst conditions

(c) Design, construction, components Materials finishes and

testing of electronic equipment as per EES-1980 (General specification for electronic equipment) or equivalent


representative.

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39 Printers (a) Noise level test for the printer (b) Test of interlock performance and error detection feature, (c) Quality assurance as governed by BS 5750 or equivalent (d) Design, construction, components, finishes and testing of

electronic equipment as per EES-1980 (General specification of electronic equipment) or equivalent

40 Floppy/Tape Drive Unit

/ Bulk Memory Unit / DVD, CD drive Unit / DAT Drive

(a) Noise test

(b) Surge withstanding capacity as per IEEE or equivalent (c) Quality assurance as governed by BS 5750 or

equivalent (d) Design, construction, components, finishes and testing

of electronic equipment as per EES-1980 (General specification of electronic equipment) or equivalent

(e) Test of Control unit and drive for all features, Date

checking features. 41 Vibration Monitoring &

Analysis System (a) Simulated Functional test (Note-1)

(b) Tests for Server, VDU, Printer, Keyboard Note-1: Test to be witnessed by Owner or Owner’s

representative. 42 Flame Monitoring &

Analysis System (a) Simulated Functional test (Note-1)


representative. 43 PADO System (a) Simulated Functional test (Note-1)

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representative. 44 CMMS System (a) Simulated Functional test (Note-1) (b) Tests for Server, VDU, Printer, Keyboard Note-1: Test to be witnessed by Owner or Owner’s

representative. 45 MIS System (a) Simulated Functional test (Note-1) (b) Tests for Server, VDU, Printer, Keyboard Note-1: Test to be witnessed by Owner or Owner’s

representative. 46 Security & Surveillance

System (PSS) (a) Simulated Functional test (Note-1)


representative. 47 Boiler Tube Leak

Detection System (a) Simulated Functional test (Note-1)

(b) Tests for Server, VDU, Printer, Keyboard

PART-B: GUIDELINES FOR FACTORY ACCEPTANCE TEST (FAT) FOR DCS / PLC / MICROPROCESSOR BASED PROGRAMMABLE TYPE SYSTEMS

1 GENERAL REQUIREMENTS Factory acceptance test (Fat) procedure : Ref. Note -1 & 2 2 TEST REQUIREMENTS

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(a) Test shall be performed with the completely assembled system and also with

complete i&c software and performing all functions expected out while in actual service and with system configuration as finalised.

(b) Process input / output conditions and other load on the system to be stimulated

either by hardware / software. (c) All system software & application software to be loaded and operational on the

system prior to fat refer relevant sections. 3 TEST DOCUMENTS / DRAWINGS (a) Total system configuration drawings (b) Fat procedure consisting of : (i) Test equipment (ii) Test environment (iii) Test configuration (iv) Test procedure (v) Test schedule (vi) Test venue (vii) Test reports- specimen copies (c) Function design specification for each eqipment / system 4 PRELIMINARY CHECKS (a) General appearance check & bill of mateirals check (b) Construction check as per over all general arrangement drawings (c) Dimensional check (d) Labelling, terminal arrangement and equipment identification check (e) Power supply voltage level check & power 'leds - on check

SPEC NO.


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(f) Cooling fan operation check (g) Grounding network check 5 SYSTEM HARDWARE CHECKS (a) Power supply under voltage and over voltage check (± 10%) (b) Processor & main data bus network redundancy check , (c) Communication coupler redundancy check (d) Communication module of the controller to network redundancy check, (e) Power supply redundancy check (f) Hardware on-line maintainability check , 6 CONTROLLER ENGINEER FUNCTIONAL CHECK (a) Closed loop control simulation check (b) Open loop control simulation check (c) Control loop response check (d) Bumpless auto manual transfer check (e) VDU – graphic overview check (f) VDU- trend check (g) VDU- real time trend check (h) VDU- mimics check (i) VDU- check for operating control directly from mimics (j) VDU- function keys check (k) VDU- touch screen function check (l) VDU- analog control display check

SPEC NO.


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ISSUE R0

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(m) VDU- sequence control display check (n) VDU- operator guidence message check (o) VDU/ backpanel ‘operation priority’ check (p) VDU- alarm management function check (q) VDU logging function check (r) VDU / response / updating check (t) Keyboard lock function check (u) VDU interchangebility & assignability check (v) Printer assignability & back-up function check (w) Floppy disk / compact disk / optical disk unit storage & retrieval check (x) VDU assignability check for hard copier function (y) Plant performance calculation check (z) Communication interface to other’s system simulation check (aa) Ser interface data dump function check (bb) Data bus distance building check (refer note- 3) 7 MAINTENANCE ENGINEER FUNCTION CHECK (a) Graphic display building function check (b) Closed loop control system modification check (c) Open loop control system modification check (d) Alarm display prioritisation check (e) System security check

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(f) System alarm check (g) System diagnostic function check (h) Point detail configuration check (i) Control loop tuning check (j) System self documentation check 8 SYSTEM PERFORMANCE REQUIREMENTS (a) System response time (b) Controller responsiveness (c) Input off - normal detection responsiveness (d) Operator crt responsiveness (e) Command initiation (f) Command formatting (g) Command execution and data display for monitoring (h) Printer responsiveness (i) System accuracy requirements 9 AUTHORISATION TO SHIP TEST (a) Includes all features of operation tests (b) Simulation of inputs / outputs: to verify conversion accuracy, scan rates, operator

panel functions, correctness of calculations. (c) Operation test : to verify that the system performs all operations specified (d) Power consumption test (e) Power failure test : to observe the consequence of total power failure (f) Accuracy and repeatability test

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ISSUE R0

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(g) Function test (h) Format test : to verify printouts and display formats (i) Manual & auto switch over from master to standby (j) All diagnostic and s/w debug tests shall be performed in the presence of the

owner / project manager / consultant representative with the system fully assembled and all parts interconnected together with simulated anolog / digital inputs.

(k) Surge withstand capacity test as per relevant standard (l) Management information system function check NOTES: 1 The intent of the fat is to demonstrate and ensure that the I&C system meets all the

functional requirements as intended in the specification / contract. A completed integrated test of the system shall be carried out at vendor's works in the presence of owner / project manager / consultant, on completion of integration/manufacturing of the system. The shipment of I&C equipment to site will be effected only after the fat has been accepted by the owner / project manager / consultant.

2 Fat procedure shall be prepared by vendor and to be submitted for owner / project

manager’s / consultant's approval well in advance prior to the commencement of fat 3 Fat shall be conducted with the distance between the processor and other supporting

peripherals as per the final layout in the control room. 4 Duration of fat shall be minimum three (3) weeks. the fat procedure shall be subject to

owner / project manager’s approval. 5 For closed loop controls vendor shall also demonstrate the performance using simulation

software to cover the relative performance of the boiler and turbine parameters. 6 During the course of fabrication the owner / project manager shall have access to the

plant for inspection. at all times, the owner / project manager / consultant shall have the right to inspect for quality control.

7 Pre-Shipment inspection

The complete system shall be examined at the factory for workmanship, assembly and fat, mechanical safety, materials, wiring, connections, parts, finish, operation and strict conformance to this specification and approved design layouts and detail drawings . All tests including functional tests shall be conducted as per “ is “ and this specification.

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 8: INSTRUMENT INSTALLATION



TCE FORM 329 R4

ISSUE R0

TITLE

1.0 IMPULSE LINE/TUBE FITTINGS & ACCESSORIES 1.1 Nipple shall be provided for root valve size more than ½ inch and nipple size shall be

same as the root valve size. Reducer/adapter shall be provided to suit instrument connection, where nipple, root valve size is more than ½ inch.

1.2 Bulk head fitting socket welded type to be provided at instrument rack/ enclosure. 1.3 All instrument impulse tube size should be ½” ss. Impulse tube shall be tig welded from

root valve to instruments. Anchor fasteners shall be provided for installation of standpipe whenever required.purge line shall be connected near root valve only. Purge rotameter, backpressure regulator, air filter regulator for purge air shall be located near instrument.

2.0 FITTINGS 2.1 All fittings except the last fitting connecting to the instrument shall be socket welded.

The size of the fittings shall be same as the impulse line size. 2.2 The fitting connecting to the instrument shall have a size and thread to suit the

instrument connection. 3.0 DRAIN 3.1 Drain shall be provided for all water/steam and non-inflammable / non-corrosive fluids

only. 4.0 DRAIN VALVE 4.1 Two numbers of globe drain valves shall be for process conditions of 425oc or 62 bar

and higher. 4.2 One number globe drain valve shall be provided for process conditions of less than

425oc and 62 bar. 4.3 The valve size shall be same as impulse piping/tubing size. 5.0 FUNNEL WITH DRAIN HEADER 5.1 Funnel with drain header shall be provided in the racks for blowing/draining out the

process fluid in the impulse tubings. 5.2 The drain header of the rack shall be connected to the nearest floor level or plant drain. 5.3 The size of the drain header shall be 1”.

SPEC NO.


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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 8: INSTRUMENT INSTALLATION



TCE FORM 329 R4

ISSUE R0

TITLE

5.4 When instruments are mounted local to the tapping point and are not mounted in the rack, or panel or enclosure. The drains shall be connected to the nearest floor level or plant drain.

6.0 INSTRUMENT CONNECTION 6.1 Type of the valve shall be needle valve with built in drain valve. 6.2 Sizing of the valve shall be ½”. 6.3 Right/left threaded fittings shall be provided for installation/removal of instruments

without disturbing the tubing/piping. 6.4 A suitable adapter shall be provided to install the instruments on ½” right-left threaded

fitting 6.5 A ½” vent line with a ½” isolation valve shall be provided in the instrument rack for air

and compresible fluids or otherwise if the installation call for eg., for liquid service where the transmitter is located at a higher elevation than the tapping point.

6.6 For air/flue gas measurement a drain pot with plug shall beprovided in place of drain

valves. 7.0 PURGING SYSTEM 7.1 Purging system shall be provided for flue gas measurements 7.2 Instrument air connection shall be provided at each instrument for air & flue service for

continuous purging. 7.3 One air filter regulator, purge rotameter and a blow down device per instrument shall be

provided in the transmitter rack. 7.4 The purge line shall be connected to each instrument through a ½” isolating valve.

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 9: DATA TO BE FURNISHED WITH BID



TCE FORM 329 R4

ISSUE R0

TITLE

TABLE-9: I&C DATA TO BE FURNISHED WITH THE BID

SL. NO

DATA TO BE FURNISHED

1.0 P&ID (Process and Instrumentation drawings) indicating primary and secondary

Instruments and the destination/functionality of the signals for main Plant and for each Utility package.

2.0 Clause wise confirmation / deviation list with respect to I & C requirements specified in

sections. 3.0 Confirmation certificate for the latest version of software and hardware offered. 4.0 Codes and applicable standards followed for the project. 5.0 Letter confirming support of spares for 15 years for the offered I&C equipment 6.0 Technical details of including configuration diagram with copy of certification from

authorised agency for the offered BMS & of Boiler Protection System 7.0 Technical details of including configuration diagram for the offered Flame Monitoring and

Analysis system 8.0 Technical details of including configuration diagram for the offered Boiler Tube Leak

Detection System 9.0 Heat load and power supply requirement for the offered I&C system equipment

(Preliminary; Final after award of contract). 10.0 Number of panels/ cabinets to be located in control room/ electronic cabinet room with

dimensions. 11.0 List of recommended control loops with a brief write up to be implemented in Purchaser’s

DCS (Refer Note no 3, 4 & 5 of Section D 2, TABLE-10, Data to be furnished after award of contract).

SPEC NO.


TCE. 5103A-C-510-01


INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 10: DATA TO BE FURNISHED AFTER AWARD OF

CONTRACT



TCE FORM 329 R3

ISSUE R0

TITLE

SL NO

DATA TO BE FURNISHED Category

1.0 Process & Instrumentation Diagram (PID) indicating primary sensors and

secondary instruments, functional usage / destination reference (alarm, control etc) for SG Package systems.

A

2.0 Purchase specification for all I&C equipment including BMS / Boiler

Protection System A

3.0 BMS / Boiler Protection system configuration drawing / system architecture

drawing indicating all elements. A

4.0 System Configuration Diagram with interfacing details for following analysis

systems: A

(a) Flame monitoring and Analysis system A (b) Boiler Tube Leak Detection System A 5.0 Hardware and software design manual for BMS / Boiler Protection system A 6.0 Input / Output list for BMS & Boiler Protection System A 7.0 Drive List for BMS & Boiler Protection System A 8.0 I/O Assignment for BMS & Boiler Protection System including nest loading. A 9.0 Hardware design manual for Flame monitoring and Analysis system & Boiler

Tube Leak Detection System A

10.0 Bill of quantity for (a) BMS & Boiler Protection System I (b) Flame monitoring and Analysis system I (c) Boiler Tube Leak Detection System I 11.0 Factory Acceptance Test (FAT) procedure / Availability test procedure /PG

test procedure for all C & I equipment. A

12.0 QAP for all equipments A 13.0 GA drawings of control panel / local panel with cabinet internal layout. I

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ISSUE R0

TITLE

SL NO


14.0 List Of Panels/ Cabinets and Control Room Mounted Equipments I 15.0 Marshalling philosophy / cabling philosophy A 16.0 Wiring diagrams for panel, local panel, junction boxes, actuators, starters

etc. I

17.0 List of JBs and FTCs. With locations and terminal details. I 18.0 Heat load and Power consumption data for I&C equipments I 19.0 Earthing Scheme 20.0 Essential & start-up Spares list A 21.0 Cable List I 22.0 Interconnection cable schedule (ICS) and cable schedule between Jbs to

Marshalling cabinets. I

23.0 O & M Manual for all I&C equipment : I (a) Field Instruments (b) Systems (i) BMS / Boiler Protection System I (ii) Flame monitoring and Analysis system I (iii) Boiler Tube Leak Detection System I 24.0 Equipment wise vendor details including Address, Contact person,

Telephone nos. I

25.0 Complete graphic diagrams for SG and its auxiliaries control and monitor at

plant DCS operator consoles (Process mimics indicating Analog and digital parameters).

A

26.0 Measurement Point Schedule A 27.0 Complete Input/Output signal list for Purchaser’s DCS tag database A

SPEC NO.


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28.0 Drive List A 29.0 Solenoid Valve List A 30.0 List of Alarm And Trip Set Points A 31.0 Recommended Control Schemes with write up for (NOTE 3, 4 & 5) A (a) Modulating Control Schemes (b) Interlock / Protection Logic Diagrams 32.0 Actuator Wiring Diagram A 33.0 Standpipe details A 34.0 Control Valve Data Sheet & Sizing Details A 35.0 Inputs to Vendor’s system from PURCHASER’S system with terminal details A 36.0 Outputs from Vendor’s system to PURCHASER’S system with terminal

details A

37.0 Flow Elements Data Sheet & Sizing Details. A 38.0 Equipment Location Details I

NOTES: 1. All the drawings shall be submitted in both soft and hard copies. 2. All engineering documents (item 9.0) formats shall be approved by Owner / Project

Manager. 3 Recommended schemes along with write-up for all the controls as deemed necessary

for the steam Generator & auxiliaries, to be implemented in Purchaser’s DCS shall be furnished by Vendor.

3.1 Recommended Analog Controls for Bidder’s Equipment/ Systems for

implementation in Purchaser’s DCS :

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TITLE

3.1 (i) This includes all auto controls like Furnace pressure, drum level, air/fuel flow, HPBP,

windbox air damper, Auxiliary pressure reducing desuperheating station and SH steam temperature controls.

3.1 (ii) Recommended schemes along with write up to be submitted by Vendor shall be

‘Final Schemes’ for straightaway implementation, clearly indicating sensor tag nos. legend, interlock requirements, settings for time delays controller etc. Each block in the scheme shall be clearly explained in the associated detailed write-up. Each functional block in the scheme shall be accompanied by associated characteristic curve for implementation. All the control system requirements shall be clearly brought out with no “Holds” to avoid any future correspondence. Review of the schemes will not be done by Purchaser. Vendor shall account for any delays in implementation of these controls in Purchaser’s system for want of information/ clarification.

3.2 Recommended logic diagrams for control systems to be implemented in

Purchaser’s DCS for drives [ON/ OFF, inching, open/close, solenoid etc.] 3.2 (i) This includes controls of all HT drives, LT drives, motor operated valve, solenoid

valves, protection & auto-standby of HT & LT drives 3.2 (ii) Schemes shall be ‘Final Schemes’ for straightaway implementation, clearly indicating

sensor tag nos. legend, settings for time delays switches etc. Each block in the scheme shall be clearly explained in the associated detailed write-up. All the control system requirements shall be clearly brought out with no “Holds” to avoid any future correspondence.

3.2 (iii) Review of the schemes will not be done by Purchaser. Vendor shall account for any

delays in implementation of these controls in Purchaser’s system for want of information/clarification.

3.3 Sequence logic for boiler auxiliaries start up/shut down/load up/load down. 3.3 (i) This includes controls like Furnace safeguard supervisory system (includes BMS

system) for fuel control at boiler, Boiler protections and soot blower controls. 3.3 (ii) Vendor shall furnish functional block diagram clearly identifying the various steps

for the sequential and auto starting, sequential and auto shut down of the Boiler auxiliaries as demanded by turbine operational requirements at the different stages of operation. A detailed write-up clearly explaining the above shall also be furnished.

3.3 (iii) Vendor shall ensure that the source instrument requirements indicated in the

recommended schemes match exactly with the instruments indicated in the flow schemes and instrument list submitted by Vendor. Wherever source instruments are in Purchaser’s scope, the same shall match with the stubs provided as indicated in Vendor flow schemes.

SPEC NO.


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3.3 (iv) All the required set points shall be indicated on the recommended schemes. 4.0 The SG vendor shall list all the recommended control schemes and logic

diagrams which are required for the protection and control of SG auxiliaries (which have to be implemented in Purchaser’s system) one below the other in a single place. Against each loop the Vendor shall clearly list the following under separate columns:-

(a) Tag Nos. along with service descriptions of sensors required for

implementation of the loop, which have already been provided by SGV on his piping/equipment.

(b) Service descriptions for sensors/instruments to be provided by Purchaser on

SG vendor’s piping. (c) Service description for sensors/instruments to be provided by Purchaser on

Purchaser’s piping. 5.0 The recommended schemes shall be functional block diagrams which can be easily

understood and implemented. LEGEND: A- For Approval, I- For Information

SPEC. NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD 2x800 MW TPP NEAR KRISHNAPATNAM

VOL-III A

TCE-5103A-C-510-01 STEAM GENERATORS & AUXILIARIES ELECTRICAL DESIGN REQUIREMENTS

SECTION: D3 SHEET 1 OF 10

ISSUE R0


3.0 Design Requirements

3.1 Motors

3.1.1 All the drive motors covered under this specification shall comply with the requirements of enclosed specification TCE.M4-203-01, TCE.M4-203-02 Section-D along with its data sheet-A

3.1.2 All motors rated 160 kW and below shall be suitable for 400V or

415V, 3 phase, 50 Hz, AC supply. Motors rated 160 kW above upto and including 1500kW shall be rated for 3.3 kV, 3ph 50Hz system. Motors rated 1500kW above shall be suitable for 11kV, 3 ph 50Hz system.

3.1.3 Referring to the specification TCE.M4-203-01, following may be

noted.

(a) Table – I under clause no. 9.5 indicating the sizes of cables and terminal boxes etc. are only for guidance. Suitable double compression cable glands and terminal boxes shall be supplied based on the final cable sizes to be intimated to the VENDOR during detailed engineering.

3.1.4 With reference to specification TCE.M4-203-02 cl.no.4.2 following

may be noted. For all HT motors, in addition to the thermometers specified for the bearing, duplex type thermocouple shall be provided for each bearing. The terminals of these thermocouples shall be brought to a junction box.

3.1.5 All motors covered under the scope of this specification shall be

designed to withstand atleast 5% harmonics in supply voltage. 3.1.6 The minimum phase to phase and phase to earth clearances for

415V motors in the respective terminal boxes shall be as follows : Phase - Phase Phase - Earth 25.4mm 19.0 mm 3.1.7 Motors rated 1000 kW and above will be provided with differential

protection. These motors shall be provided with star connected stator windings. Three numbers of current transformers for differential protection will be supplied by switchgear VENDOR, one


VOL-III A



ISSUE R0


for each phase, shall be mounted in a separate compartment in the neutral side terminal box. The three phases will be connected to form the star point after they pass through the CTs. The CTs shall be of relay accuracy. The technical parameters of these CTs will be informed to the successful BIDDER during detailed engineering.

3.1.8 Maximum noise level measured at a distance of 1.0 m from the outer

surface of any motor shall not exceed 85 db (A). 3.1.9 Cable boxes of all HT motors shall be of phase segregated type with a

short circuit with stand capability of 40kA for 0.25 Sec. The cable box shall be suitable for either heat shrinkable type of terminating kit or other type of kits, the details of which will be informed to successful BIDDER. These cable boxes shall be provided with quick disconnecting type of terminal connectors to facilitate easy disconnection and removal of motors without requiring unsealing or disturbing the external cable connection. The type of cable for HT motors will generally be with Aluminium conductor, XLPE insulated and armoured.

3.1.10 Variable Frequency drive shall be provided for ID fans. When FD fans

of centrifugal type is offered, the same shall be provided with VFD .The VFD shall be as per enclosed section-D, TCE.M4-203-71 and associated data sheets.

3.2 Motor operated valve actuators 3.2.1 All the motor operated valve actuators and dampers along with their

motors specified under this specification shall comply with the specification TCE.M4-203-06. All motor operated valves shall be provided with integral starters. PURCHASER will provide only switch fuse supply from the MCC for these valve motors.

3.3 DC motors 3.3.1 All the DC motors covered under the scope of this specification

shall comply with the enclosed specification TCE.M4-203-11. 3.4 Starter panel for DC motors 3.4.1 Starters for motors of Generator auxiliaries such as JOP, EOP,

Cooling system etc., shall be included by VENDOR. The necessary interlocks, protection, etc., for the operation of these motors are


VOL-III A



ISSUE R0


included in VENDOR’s scope. These auxiliaries are operated from DCS.

3.4.2 The constructional features of these panels shall comply with the

requirements of specification TCE.M4-203-11, Section – D. 3.5 LT Switchgear 3.5.1 MCCs for feeding the auxiliary loads of Boiler such as Boiler MCC,

Boiler valve and Damper control MCC, soot blower MCC and ESP MCC shall be included in Bidder’s scope. These MCCs shall be provided with suitable quantity and type of outgoing feeders for the auxiliary loads and any control panels envisaged in the SG system.

Bidder shall furnish a list of drives requiring DC or emergency power supply so that feeders for the same can be arranged from Purchaser’s DC / Emergency switchboards. The bus bars, incomer and bus coupler breakers shall be sized based on LV side current of the auxiliary transformer plus 20% margin rounded off to the next standard rating in the case of transformer fed switchboards and based on the full load current with 20% margin for all other switchboards. The incomers and bus couplers shall be ACB type for rating greater than 630A. In addition following feeders shall be provided in the each switchgear.

(a) Spare feeders – Minimum one no. feeder of each rating and

type at the time of handing over the plant. Any additional quantity required for any increase/changes during detailed engineering stage shall also be duly considered.

(b) 240V, 1 phase motor space heating module - 1 No. on each bus section

(c) 240V, 1 phase panel space heating module - 1 No on each bus section

(d) 400/110V Test supply module – 1 No. on each bus section (b) &(c) are applicable for switchgear with motor feeders. (e) Bus VT module-1 No. on each bus section

3.5.2 Two (2) nos. 100% 415/110V 1-ph transformers shall be provided in

each switchboard for deriving control supply .Rating of each transformer shall be adequate to cater both the bus sections. Normally each transformer feed one bus section each. A changeover switch shall be provided for selection.


VOL-III A



ISSUE R0


3.5.3 LT switchgear shall comply with the particulars indicated in section – D, TCE.M4-219-11 and associated data sheets and typical control schemes enclosed.

3.5.4 The incomer, bus coupler and outgoing breakers of LT

switchboards will be controlled from DCS. Manual live changeover facility shall be provided between the two incomers of LTMSB for ESP, any other MCC with ACB incomers. When planned outage of one of the normal incoming supplies is required, the respective incomers shall be tripped automatically after the bus coupler breaker is closed manually after checking the synchronism between the two bus voltages. For this purpose synchrocheck relay shall be provided in the switchgear. Syncronisinng breaker selection and intended breaker selection will be from DCS.

3.5.5 Thus depending on the selection, incomer-A/B will be tripped once

bus coupler is closed manually .A timer shall be provided for annunciation of running breaker failed to trip. i.e. two sources paralleled beyond preset time. Then the last closed breaker is tripped based on synchronising selection from DCS. When normal supply has to be brought back into operation, the incomer breaker will be closed and bus coupler shall be tripped automatically. All hardware required for meeting the functional requirements stated above shall be included in the scope of supply.

3.5.6 Motors rated 150KW and above shall be controlled by Air circuit

breakers and those below 150KW and above 50KW shall be controlled by MCCB, bi-metal relay and contactor and those rated 50KW and below shall be controlled by MPCB and contactor

3.6 Power supply distribution boards 3.6.1 Power supply distribution boards for different voltages as required

by the system are included in VENDOR’s scope.

3.6.2 The constructional features of these boards shall be as per enclosed specification TCE.M4-219-01, Section-D along with its Data Sheet – A.

3.6.3 PURCHASER will provide 100% duplicate feeders at one point for

distribution by VENDOR. Necessary changeover arrangement shall be provided between the two incomers to the distribution boards. Required number of outgoing feeders with minimum of one(1) spare feeder of each rating shall be provided.


VOL-III A



ISSUE R0


3.6.4 The BIDDER shall furnish the rating of all the power supplies

required by him from the list above. BIDDER shall also indicate the proposed location of the distribution boards to enable the PURCHASER to arrange for the power supplies.

3.6.5 The distribution panels are located in such a way that they are

nearer to load centre. In view of this, if the requirement of distribution boards of any type is more than one, the quantity, distribution arrangement and tentative location proposed shall be furnished by the BIDDER in the bid.

3.6.6 The distribution of power supplies shall include all the equipment

under the scope of this specification viz. thermocouples or cold junction compensation boxes, lube oil system local JB or control panels, equipment handling systems, fans and their motor temperature gauges, bearing temperature gauges, motor speed switches etc.

3.6.7 For the 110V AC, 1PH and 240V AC, 1 PH PURCHASER will

arrange only two nos. 100%, 400V or 415V, 3PH AC supplies for each distribution board. BIDDER shall provide suitable step down transformers to obtain the necessary supplies required.

3.6.8 Following details shall be furnished by the VENDOR during detailed

engineering for PURCHASER’s approval for all distribution panels.

(a) General arrangement, foundation / fixing layout

(b) Single line diagram (from both VENDOR and his SUB-VENDOR

3.7 Junction boxes (JBS) / Marshalling boxes(MBS)/Local push button stations( LPBs)

3.7.1 The constructional features of JBs/MBs/LPBs shall be as per the details indicated in the enclosed specification TCE.M4-219-01, Section - D.

3.7.2 The junction boxes are required for terminating the cables from field instruments, thermocouples etc., and for further cabling.

3.7.3 The Junction Boxes and Marshalling boxes shall be selected such that at least 20% spare terminals are available in each of these boxes after all the cabling is completed.


VOL-III A



ISSUE R0


3.7.4 The Local push button stations shall be two push button type with START and STOP push buttons. STOP PB (NC) contact shall be directly wired to MCC, while START PB (NO) and STOP PB (NO/NC) shall be taken to DCS. Since contacts are taken for different circuits, separation shall be provided between these two contacts in the terminal block.

3.8 Cables 3.8.1 LT Power cables pertaining to Boiler valves, ESP & soot blower

system shall be included in Bidder’s scope. Control and instrumentation cable scope shall be as per Vol-V

The cables shall be as per specification described below: 3.8.2 LT Cables

The LT cables shall be 1.1kV grade with single/multicore, stranded aluminium conductor, XLPE insulated, extruded PVC (type-ST-2) inner sheathed, aluminium round wire armourd for single core/galvanised steel round wire / strip armoured for multicore, extruded FRLS PVC (TYPE-ST-2) outer sheathed cables conforming to IS-7098 part-1.

3.8.3 Control Cables

The control cables shall be 1100v grade, multi core of 2.5/4 sq.mm cross section stranded (7 strands) copper conductor, PVC insulated, inner PVC sheathed (type ST-1), galvanised steel wire / strip armoured and with FRLS PVC outer sheath conforming to IS-1554 pt-1.

3.8.4 Instrumentation cables Instrumentation cable shall be suitable for the requirements of

instrumentation system. Cable in general will be stranded annealed, tinned copper conductor, PVC insulated, twisted pair/triplets with overall screening for RTDs and digital signals, shall conform to each pair screened and overall screened for analog signals inner PVC sheathed, steel wire/strip armoured and outer sheath of FRLS PVC conforming to clause 2.8.3 below. The cables shall conform to IEC – 189 Pt –1 & 2.


VOL-III A



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3.8.5 Outer sheath for FRLS cables shall meet the following test requirements related to flame retardance, low smoke emission, low acid and toxic gas emission. The BIDDERs shall have proper test apparatus to conduct all the relevant tests as per the applicable Standards mentioned herein.

3.8.5.1 Test for Flame Retardance (a) Oxygen Index

The critical oxygen index value shall be minimum 29 when tested at 27+2oC as per ASTM-D-2863 and the temperature index value shall be minimum 250oC at oxygen index of 21 when tested as per NES 715/ ASTM-D-2863

(b) Flammability

i. Cables shall pass test under fire conditions as per IS-10810- Part-53.

ii. Cables shall also pass tests as per IS-10810 Part- 61 &

Part-62. iii. Cables shall also pass tests as per IEC-332-1

iv. Fire survival cables in addition to tests (i) and (ii) above

shall pass tests as per IEC-331. 3.8.5.2 Test for Smoke Generation The cables shall satisfy the tests conducted to evaluate the

percentage obscuration by smoke in an optical system placed in the path of the smoke. The maximum smoke density rating shall not be more than 60% when tested as per ASTM-D-2843.

3.8.5.3 Tests for Acid Gas Generation The hydrochloric acid generation when tested as per IEC 754-1 shall

be less than 20% by weight. 3.8.5.4 Tests for Resistance to Ultra Violet Radiation


VOL-III A



ISSUE R0


This test shall be carried out as per DIN 53387. The retention values of tensile strength and ultimate elongation after the tests shall be minimum 60% of tensile strength and ultimate elongation before test.

3.9 Cable Sizing

The LT Power cables shall be selected on the basis of current carrying capacity, permissible voltage drop during running of motor and permissible voltage dip during motor starting. a) Minimum LT Power cable size (aluminium conductors) shall be

4 sq.mm except for valve actuators for which 2.5 sqmm copper cable can be used.

b) Minimum control cable size shall be 1.5 sq. mm copper. c) Power cables for motors controlled by switch fuse units and

contractors shall be based on the maximum load current, derating factors for temperatures, laying & grouping and voltage drop during running as well as starting. Voltage dip during starting of any individual motor shall not exceed 15% and minimum derating factor for temperature, laying and grouping shall be 0.7. Voltage drop during running shall not exceed 5%. Additionally for motors controlled by Air circuit breakers, short circuit withstand time shall also be considered.

d) The power cable sizes selected by the CONTRACTOR shall

be subject to approval by PURCHASER. For this purpose, CONTRACTOR shall furnish necessary calculations during detailed engineering. Any change in cable size as decided by PURCHASER shall be accommodated without commercial / delivery implications.

e) Space Heating

LT motors of rating 30 kW and above- 4 sq.mm Al or 2.5 sq.mm copper.

3.10 Cable Installation

Cables shall be laid in Purchaser’s cable trays in all areas except in Boiler platforms and ESP platforms, where Bidder shall supply & install cable trays along with supports. Vendor shall install, test and commission cables which are included in their scope. Bidder shall


VOL-III A



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submit Cable tray layouts in Boiler and ESP platforms for Purchaser’s review.

3.11 Cable glands and lugs Cable glands & lugs for all cables included in Bidder’s scope shall

be in Bidder’s scope. All cable glands shall be of double compression brass type. All lugs shall be of tinned copper crimping type.

3.12 Cable termination 3.12.1 All cable shall be terminated at both ends. Cables shall be

additionally supported near the entry point of equipment in order to avoid the whole weight of the cables coming on to the gland plate / cable box.

3.12.2 The scope of termination at each end shall include dressing and connecting all the cores of the cables. The following shall be included in the scope of work:

(a) Making the requisite holes on the gland plate of the panels, fixing glands, terminating the cables in the cable boxes, earthing the cable armour, crimping of cable lugs on each, neatly clamping the cables inside switchgear and distribution board. The cable and core identifying tags and core identifying ferrules respectively shall be supplied and installed by the VENDOR as a part of cable termination work.

3.12.3 The VENDOR shall tag / ferrule all control cable cores at all terminations as instructed by the PURCHASER. For panels where a large number of cables are to be terminated and cable identification may be difficult, each core ferrule shall include the complete cable number.

3.12.4 Spare cores shall be similarly tagged / ferruled / cross ferruled with a suffix letter “S” along with cable numbers and coiled up after end sealing.

3.13 Cable tags and markers

(a) Each cable shall be tagged with numbers. The scheme of numbering will be informed to successful BIDDER during detailed engineering.


VOL-III A



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(b) The tag shall be aluminium with the number punched on it and securely attached to the cable / conduit by not less than two turns of 20SWG GI wire confirming to IS: 280. Cable tags shall be a rectangular shape for cables.

(c) Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossings, on each duct / conduit entry and at every ten (10) metres.

3.14 Earthing and Lightning protection

The main earth grid will be provided by Purchaser Two(2) nos GS risers will be provided from the main grid for Boiler and ESP platforms. The earthing of all equipment in Boiler and ESP platforms is in vendor’s scope. The conductor sizes for the individual equipment earthing shall be in accordance with IS-3043 considering the appropriate ground fault current and the duration of the fault current. Calculation shall be submitted for Purchaser’s review. Lightning protection of ESP platforms and Boiler platforms is included in Bidder’s scope. The lightning protection shall be in accordance with IS-2309.The down conductors shall be connected to the main plant earth grid in the grade level through direct driven rods.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD 2 X 800MW TPP NEAR KRISHNAPATNAM STEAM GENERATORS & AUXILIARIES

SPEC NO.

TCE-5103A-C-510-01

DESIGN PARAMETERS OF SG AND AUXILIARIES

VOLUME IIIA

DATA SHEET – A1

SHEET 1 OF 5

REV.NO. RO PPD. BY : JOB NO. CLIENT : APPDCL DATE CKD. BY : TCE -5103A REV. BY DATE : PROJECT: 2 X 800MW TPP NEAR

KRISHNAPATNAM

ISSU

E N

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0

SL. NO.

PARTICULARS UNITS 60 % TGMCR

80% TG MCR

100% TGMCR

TOP HEATER OUT OF SERVICE (100% TGMCR)

100% SG MCR

1 2 3 4 5 6 7 8

STEAM AND FEED WATER

1. STEAM FLOW AT SH OUTLET

t/hr 1380*1 1880*1 2380*1 Later 2500

2. PRESSURE AT MAIN STEAM STOP VALVE OUTLET

bar (a) *2 *2 *2 *2 *2

3. PRESSURE AT TERMINAL POINT IN MAIN STEAM LINE

bar (a) 160*1 214*1 242 242 242

4. STEAM TEMPERATURE AT SH OUTLET

0C *2 *2 *2 *2 *2

5. STEAM TEMPERATURE AT TERMINAL POINT

0C 565 565 565 565 565

6. STEAM FLOW AT RH OUTLET

t/h Later Later 1982 Later 2075*1

7. RH INLET PRESSURE AT TERMINAL POINT

bar (a) Later 49 61 Later 62.5*1

8. RH INLET TEMPERATURE AT TERMINAL POINT

0C Later 350*1 350*1 Later 350*1

9. RH OUTLET PRESSURE AT TERMINAL POINT

bar (a) Later 45.6*1 57*1 Later 58.5*1


SPEC NO.

TCE-5103A-C-510-01


VOLUME IIIA

DATA SHEET – A1

SHEET 2 OF 5


KRISHNAPATNAM

ISSU

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SL. NO.


80% TG MCR

100% TGMCR


100% SG MCR

1 2 3 4 5 6 7 8

10. RH OUTLET TEMPERATURE AT TERMINAL POINT

0C 593 593 593 593 593

11. FEED WATER FLOW TO ECONOMISER

t/h 1394*1 1899*1 2404*1 Later 2575

12. FEED WATER TEMPERATURE AT ECONOMISER INLET

0C 263*1 280*1 293*1 Later 295*1

Note : *1: Tentative values. Exact values will be furnished after finalization of TG contract

*2: Bidder to indicate

HEAT RELEASE RATE

13. VOLUMETRIC BASIS kCal /m3/hr

≤ 100000

14..

EFFECTIVE PROJECTED RADIANT SURFACE (EPRS)

kCal/ m2/hr

15. NET HEAT INPUT TO PLAN AREA (NHI /PA)

kCal/ m2/hr

≤ 4.75X106

16. BURNER ZONE kCal/ m2/hr

≤1.55X106

17. GAS TEMP AT FURNACE OUTLET AT SGMCR FOR COAL

0C ≤1100


SPEC NO.

TCE-5103A-C-510-01


VOLUME IIIA

DATA SHEET – A1

SHEET 3 OF 5


KRISHNAPATNAM

ISSU

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0

SL. NO.


80% TG MCR

100% TGMCR


100% SG MCR

1 2 3 4 5 6 7 8

COMBUSTION AIR AND SITE DATA

18.. EXCESS AIR AT APH INLET

% 20

19. AIR PREHEATER OUTLET TEMP

0C ≤140

20. UNBURNT COMBUSTIBLES AT ECONOMISER OUTLET AS % OF FLY ASH

% ≤ 3

21. AMBIENT AIR TEMP. AND RELATIVE HUMIDITY

% As per section B

22. ELEVATION ABOVE SEA LEVEL

As per section B

23. NOX EMISSION LIMITS

< 200 gms/GJ of heat input

24. FEED WATER

24.1 pH < ------------------------------ 8 - 9 ------------------------------ >

24.2 DISSOLVED OXYGEN

PPM < ------------------------------0.007 ------------------------------ >

24.3 TOTAL DISSOLVED SOLIDS

PPM Normal 0.5, Maximum during start-up / condenser leak 2.0

25. FUEL FOR STARTUP AND LOW LOADS

Fuel oil as per section B


SPEC NO.

TCE-5103A-C-510-01


VOLUME IIIA

DATA SHEET – A1

SHEET 4 OF 5


KRISHNAPATNAM

ISSU

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26. MAIN FUEL Coal as per section B

27. CODES AND STANDARDS

27.1 INDIAN BOILER REGULATIONS

27.2 INTERNATIONAL ORGANISATION FOR STANDARDISATION

27.3 AMERICAN SOCIETY FOR MECHANICAL ENGINEERS

27.4 AMERICAN NATIONAL STANDARDS INSTITUTE

27.5 AMERICAN NATIONAL STANDARDS INSTITUE

27.6 AMERICAN WELDING SOCIETY

27.7 TUBULAR EXCHANGE MANUFACTURER’S ASSOCIATION

27.8 HEAT EXCHANGE INSTITUTE

27.9 HYDRAULIC INSTITUTE

27.10 ANSI / ASME – POWER TEST CODE

27.11 DEUTSCHE INDUSTRIE NORMEN

27.12 OTHER ESTABLISHED NATIONAL OR INTERNATIONAL STANDARDS EQUAL OR SUPERIOR TO THE ABOVE TESTED STANDARDS.

NOTES

1.0 FOLLOWING SHALL BE NOTED FOR CALCULATING HEAT RELEASE RATES

1.1 THE NET HEAT IS THE EFFECTIVE HEAT IN THE FURNACE. THIS SHALL BE CALCULATED ON THE BASIS OF THE GROSS HEATING VALUE (GHV) OF THE FUEL, CORRECTED BY SUBTRACTING RADIATION LOSS, UNBURNT COMBUSTIBLE LOSS, LATENT HEAT OF WATER IN THE FUEL AND ADDING THE SENSIBLE HEAT IN BOTH THE FUEL AND THE COMBUSTION AIR ABOVE SPECIFIED AMBIENT TEMPERATURE.


SPEC NO.

TCE-5103A-C-510-01


VOLUME IIIA

DATA SHEET – A1

SHEET 5 OF 5


KRISHNAPATNAM

ISSU

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1.2 FURNACE NET HEAT RELEASE ON EPRS BASIS SHALL BE OBTAINED BY DIVIDING NET HEAT BY EFFECTIVE PROJECTED RADIANT SURFACE (EPRS) OF THE FURNACE WHICH IS THE TOTAL ENVELOPE MULTIPLIED BY APPROPRIATE EFFECTIVENESS FACTOR FOR THE VARIOUS WALL SURFACES.

1.3 THE METHOD THAT VENDOR USES TO CALCULATE FURNACE EFFECTIVE RADIANT SURFACE AREA SHALL BE CLEARLY STATED.

1.4 PLAN AREA SHALL BE OBTAINED BY MULTIPLYING THE WIDTH WITH THE DEPTH OF THE FURNACE AS SHOWN IN SH. 1 OF 3 OF DATA SHEET B2 of Vol IIIA.

1.5 BURNER ZONE HEAT RELEASE RATE SHALL BE OBTAINED BY DIVIDING NET HEAT BY 2 X (FURNACE WIDTH + FURNACE DEPTH) X BURNER ZONE HEIGHT WHERE BURNER ZONE HEIGHT IS EQUAL TO (VERTICAL DISTANCE BETWEEN TOP AND BOTTOM ROW BURNERS + 3 METERS).

1.6 COLUMNS LEFT BLANK SHALL BE SHALL BE FILLED BY THE BIDDER

SPEC NO.

TCE-5103A-C-510-01

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD



VOLUME IIIA

DATA SHEET – A2

SHEET 1 OF 1

UTILITY REQUIREMENTS


KRISHNAPATNAM

SL. NO. DESCRIPTION UNIT VALUE

1.0 AUXILIARY STEAM

1.1 Pressure bar (a) 19

1.2 Temperature 0C 305

2.0 COMPRESSED AIR

2.1 Pressure Kg/cm2 (a) 7 - 8

3.0 CONDENSER COOLING WATER

3.1 Quality Sea water As per Section B

3.2 Temperature at condenser inlet for performance guarantee (average temperature)

0C 33

3.3 Minimum temperature at condenser inlet 0C 28

3.4 Maximum temperature at condenser inlet 0C 34

3.5 Temperature rise across condenser limited to 0C 10

4.0 AUX COOLING WATER

4.1 Quality Passivated DM water

4.2 Pressure (Design) Kg/cm2 (a) 10

4.3 Temperature (Max.) 0C 37

4.4 Maximum allowable pressure drop across VENDOR’S terminal point

Kg/cm2 1.5 *

NOTE : * vendor to arrange booster pumps (2 x 100%) to augment the inlet pressure in

case pressure drop is more than 1.5 bar

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET – A3

SHEET 1 OF 1

STEAM GENERATOR PRESSURE PARTS

SR.NO. ITEM UNITS VALUES


KRISHNAPATNAM

1.1 Type of Steam generator Once through reheat, radiant, dry bottom,

balanced draft, outdoor 1.8 Explosion force / Implosion Maximum of (± 650 mm WC or

Shut off head of the ID and FD fan at Test Block condition and ambient temperature)

1.10 Code IBR and ASME or other reputed international codes

1.17 Furnace tube arrangement Membrane

1.18 Type of furnace tubes and header for pressure parts

Seamless spiral plus vertical, or vertical rifle tubes

1.19 Flue gas velocity in SG convection/ second pass

m/s ≤ 10 (Average gas velocity). Bidder to indicate maximum expected flue gas velocity

1.20 MATERIALS OF CONSTRUCTION

1.20.1 Furnace wall/Economiser Medium carbon steel

1.20.3 Super heater /Reheater High temp. above 565 oC : Bidder to indicate.

High temp. above 400oC & up to & including 550 oC: Alloy steel to ASTM A 335/ASTM A 213, P-11/T-11, P-22/T-22, P-91/T-91,P-92/T-92 OR approved equivalent

Low temp. upto 400oC: Carbon steel to ASTM 106 Gr B/C or SA 210 C or approved equivalent.

Note: Bidder shall use proven materials for high temperature SH and RH Tubes.

1.20.1 Inspection /Access doors Heat resistant without water cooling

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET– A4

SHEET 1 OF 1

REGENERATIVE AIR PREHEATER


REV.NO. PO PPD. BY : JOB NO. CLIENT : IFFCO DATE CKD. BY : TCE -5103A REV. BY DATE : PROJECT : 2 X 800MW TPP NEAR

KRISHNAPATNAM

1.1 Type Trisector ( 2 X 50 %) / Bisector

1.2 On load cleaning medium Steam

1.3 Off load cleaning medium Water

1.3.1 Air preheater leakage Shall not exceed 10 % of total air requirement.

1.4 Accessories to be provided

1.4.1 Auxiliary air motor Yes

1.4.2 Hand operated barring device Yes

1.4.3 Seal plate adjustment Automatic and external

1.4.4 Air receiver Adequate for safe coasting down without external air supply

1.4.5 Air supply to air receiver From station service air system


1.5.1 Hot end elements Carbon steel or equivalent

1.5.2 Cold end elements Corten steel or equivalent

1.5.3 Rotor and intermediate elements Corrosion resistant low alloy steel

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET– A5

SHEET 1 OF 1

CENTRIFUGAL FANS



KRISHNAPATNAM

1.1 Designation Induced draft fan (ID fan) with VFD & IGV or Bidder can also offer blade pitch controlled axial fan with proven experience

1.2 Number Two(2)

1.3 Design parameters

a) Capacity With two fans operating, shall be able to meet 115% SGMCR flow

b) Head

30% over 100% SGMCR requirement

c) Temperature

150C above maximum flue gas temperature

1.4 Speed rpm ≤ 750

1.4.1 First critical speed rpm At least 15% above normal speed

1.5 Blade type Backward curved, aerofoil type

1.6 Flow control

Electric motor with variable frequency drive and inlet guide vane control.

1.7 Fan / motor bearings Self aligning


1.8.1 Fan scroll Lined with abrasion resistant material

1.8.2 Suction chamber IS 1079 / 73 SH. 34

1.8.3 Casing IS 2062

1.8.4 Shaft SAE 1045 forged normalised and tempered steel

1.8.5 Sleeves High grade Babbit

1.8.6 Regulating vane IS 1079/73

1.8.7 Diffusers and dampers IS 2062

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET– A6

SHEET 1OF 1

AXIAL FANS



KRISHNAPATNAM

1.1 Designation FD fan, PA fan 1.2 Number 2x50% for each type 1.3 Location Outdoor 1.4 Type Axial blade pitch controlled 1.5 Design parameters

a) Capacity With two fans operating, it shall be able to meet 115% SG MCR flow

b) Head 30 % over100% SGMCR requirement for FD fan & PA fan.

c) Temperature 50C above maximum ambient temperature

d) Fluid to be handled Clean air 1.6 Speed RPM ≤ 1500 1.6.1 First critical speed At least 15% above normal speed 1.5 Flow control Variable blade pitch 1.6 Blade pitch variation system Hydraulic 1.7 Fan / motor bearings Self aligning 1.8 MATERIALS OF CONSTRUCTION 1.8.1 Impeller blade Cast aluminium alloy 1.8.2 Impeller hub Forged steel or fabricated steel 1.8.3 Shaft SAE 1045 or equivalent forged

normalised and tempered steel

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET– A7

SHEET 1OF 1

SOOT BLOWING SYSTEM



KRISHNAPATNAM

1.1 Designation Wall blowers, Rotary blowers, long

retractable blowers, short retractable blowers and air preheater blowers.

1.2 Cleaning medium Superheated steam 1.3 Drive Dual electric drive for traverse and

rotary motion 1.4 Accessories Required 1.4.1 Emergency hand crank for every soot

blower Yes

1.4.2 Facility to adjust angular travel of short retractable soot blower

Yes

1.5 MATERIALS OF CONSTRUCTION 1.5.1 Lance / swivel tube

- in high temp. area

High temp. chrome steel - in intermediate temp area Steel with chromium surface coating - in low temp. area Carbon steel 1.5.2 Nozzle 2.5% chromium, 12% Ni stainless steel 1.5.3 Bearing (in high temp. area) Chrome alloy steel 1.5.4 Bearing (in intermediate temp. area) Chrome cast iron Alloy 1.5.5 Bearing (in low temp. area) Cast Iron or Steel 1.5.6 Blowing head Stainless steel 304 1.5.7 Feed Tube Stainless steel 304

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET– A8

SHEET 1OF 1

COAL BURNERS



KRISHNAPATNAM

1.0 GENERAL

1.1 Combustion air Secondary / primary

1.2 DESIGN DATA

1.2.1 Turn down ratio To match with coal mills

1.2.1 Coal fineness 70% through 200 mesh

1.2.3 Excess air 20% at APH inlet

1.2.4 Mode of adjustment of combustion air Air damper


1.3.1 Coal burner nozzle High chrome heat resistant

1.3.2 Guide plates High chrome heat resistant

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET– A9

SHEET 1OF 1

COAL MILLS

SR.NO. ITEM UNITS



KRISHNAPATNAM

1.1 Coal mills Medium speed vertical spindle; N +1 with worst coal and N + 2 with design coal [ N – number of mills in operation]

1.2 Mill inside condition Pressurised 1.3 Output fineness 70% through 200 mesh 1.4 Minimum stable load without oil

support Bidder to indicate

1.5 Coal sampling device for sampling coal from coal mill discharge with rigid accessible platform.

Required as per ISO / ASME. One working and one as standby.

1.6 Sampling connection & cock on coal pipe to each burner

Required

1.7 Coal mill inerting system Required 1.8 Coal mill system safety To meet NFPA requirement 1.9 Coal feeder Gravimetric 1.10 Reverse rotation facility for coal

feeder for bunker emptying Required

1.11 MATERIALS OF CONSTRUCTION 1.11.1 Lube oil system Integral 1.11.2 Grinding ring/race Segmental 1.11.3 Shaft Coupled / monoblock / mfg. Std. 1.11.4 Coupling Flexible gear 1.11.5 Drive transmission Gear 1.11.6 Coal feed pipe from bunker to feeder SS 1.11.7 Coal feed pipe from feeder to coal mill SS

SPEC NO.

TCE-5103A-C-510-01


VOLUME IIIA DATA

SHEET–A10 SHEET

1 OF 1

FUEL OIL BURNERS AND IGNITORS



KRISHNAPATNAM

1.1 Designation Start up / low load flame stabilisation

1.2 Fuel oil Light diesel oil for start-up, heavy fuel oil for flame stabilisation

1.3 Turndown ratio of fuel oil burners 4 : 1

1.4 Igniters HEA

1.5 Atomising medium Air for LDO, steam for HFO


1.6.1 Oil burner – spray plate mixing plate Alloy steel

1.6.2 Diffuser Alloy steel

1.6.3 Nozzle cap Alloy steel

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET–A11

SHEET 1 OF 1

FUEL OIL PUMP



KRISHNAPATNAM

1.1 Designation HFP Pump LDO Pump

1.2 Number required (common for 2 units) 3 x 100% 2 x 100 %

1.3 Type of bearing Antifriction heavy duty and external

1.4 Design motor size of the pumps Based on highest viscosity of oil plus 15% as margin

1.5 LIQUID DATA

1.5.1 Liquid pumped HFO LDO


1.6.1 Casing -------------Fabricated steel------------

1.6.2 Rotor -------BS 970 EN 9 or equivalent-------

1.6.3 Shaft -------BS 970 EN 9 or equivalent--------

1.6.4 Base plate --------------Fab. Steel / CI--------------

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET–A12

SHEET 1 OF 2

ELECTROSTATIC PRECIPITATOR



KRISHNAPATNAM

1.1 Number required per steam generator one 1.2 Duty Continuous 1.3 Location Between air-preheater and ID fan 1.4 Design & Construction Requirements 1.4.1 Number of Gas Streams By Bidder 1.4.4 Dust concentration at outlet of ESP with

design and worst coal range. - with worst coal and all fields in

service - with worst coal and one field out of

service

mg/Nm3

50 (max.) 75 (max)

1.4.5 Bulk ash density - For hopper capacity kg/m3 800 1.4.6 - For hopper strength kg/m3 1600 Casing design pressure Compatible with furnace design

pressure 1.4.7 Thickness of steel sheet mm Not less than 6 mm Storage capacity of dust hopper with

worst coal firing (To be measured 600 mm below electrodes)

8 hrs. (minimum)

Plate angle of dust hopper degrees Not less than 70 Thickness of collecting electrode plate Not less than 18 gauge 1.4.8 No. of ESPs per boiler 4 (Minimum) 1.4.9 Spacing between collecting electrodes mm 300 (Minimum) Specific collection area m2/m3/s > 200 1.4.10 Flue gas velocity within ESP m/s Not more than 1 Items to be Provided 1.4.11 Inlet and outlet gas isolation dampers/

gates Yes

Fly ash hoppers with panel type heaters, level indicators, outlet flange poke holes, access doors etc.

Yes

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET–A12

SHEET 2 OF 2

ELECTROSTATIC PRECIPITATOR



KRISHNAPATNAM

1.4.12 Thermal insulation aluminium cladding Yes Weather-proof enclosure for insulator

compartment with heaters, air blowers, filters, controls etc.

Yes

Provision of water washing system (off-load)

Yes

Test connections of std. size for measuring pressure, temperature, velocity, dust loading at inlet and outlet of precipitator

Yes

Interior access walkways minimum of 600 mm wide, exterior platforms, staircase on both sides , ladder, access doors and galvanised hand rails of 40 mm pipe etc.

Yes

Opacity monitor Yes 1.5.6 Elevation of hopper outlet flange M EL (+) 3.0

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET–A13

SHEET 1 OF 1

SPECIFIC TECH REQUIREMENT OF SG & AUX

DUCT & DAMPERS



KRISHNAPATNAM

1. Dampers

1.1 Numbers As per functional requirement

1.2 Application Isolation / Control 1.3 Duty Intermittent / Continuous

1.4 Installation Outdoor

1.5 Gas handled Flue gas / cold air / hot air mixed with particulate matter

1.6 DESIGN AND CONSTRUCTION REQUIREMENTS

1.6.1 Isolation damper Zero leakage guillotine type - ESP inlet and outlet - ID fan inlet - GR fan inlet and outlet (if

applicable) - RAPH inlet and outlet (flue gas

side)


1.7.1 Dampers frame Heavy structural steel channels or plates not less than 10 mm thick

1.7.2 Blades Not less than 10 mm thick made up of 2x 5 mm thick plates

1.7.3 Linkage bolts and pins Stainless steel

2. Duct

2.1 Flue gas velocity - Upstream of ESP - Downstream of ESP

m/s

Not to exceed 15 Not to exceed 20

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET–A14

SHEET 1 OF 2

CHAIN PULLEY BLOCK

(HAND OPERATED)



KRISHNAPATNAM

1.0 DESIGN CONDITIONS

1.1 Type Spur

1.2 Pulley block As per IS 3832

1.3 Frame made of Steel

1.4 Hook Forged alloy or carbon steel as per IS : 2758 / IS : 2759 / IS 3832

1.5 Load chain As per IS 3109 / BS 1663 / BS 3114 / IS 6216

1.6 Hand chain As per BS 590

1.7 Load chain wheel To suit load chain

1.8 Hand chain wheel To suit hand chain

1.9 Factor of safety Not less than 5

1.10 Gears Cut from cast or forged steel, Spur and helical as per BS 436 Worm as per BS 721

1.11 Brake Friction disc type to sustain load at any working position

1.12 Bearing Ball and / or roller

1.13 Trolley wheels Wrought iron / cast iron / low alloy steel

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET–A14

SHEET 2 OF 2

CHAIN PULLEY BLOCK

(HAND OPERATED)



KRISHNAPATNAM

1.14 Lubrication Centralised grease lubrication with hand pump

1.15 Material test certificates To be submitted for hook, chain, pulley block, etc.

1.16 Overload test with 150% of specified load

At works – Yes At site – Yes

1.17 Visual inspection and dimensional check

Yes

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET–A15

SHEET 1 OF 2

ELECTRICALLY OPERATED HOISTS



KRISHNAPATNAM

1.0 DESIGN CONDITIONS

1.1 Class of hoist Class II, as per IS:807

1.2 Hoist speed 2-3 m/min

1.3 Method of operation Pendant push button

1.4 Speed control (hoist) Single speed


1.5.1 Drums & sheave Cast iron / cast steel / mild steel drum, grooving construction as per IS 3938

1.5.2 Hook Forged alloy / carbon steel, as per IS 2758 / IS 2759 single hook provided with standard depress safety latch lock to prevent hook from swivelling

1.5.3 Bearing Ball and / or roller

1.5.4 Shaft Steel

1.5.5 Wire rope Construction 6 x 36 minimum ultimate strength 1.6 x 206 kN/m2 as per IS 2365 factor of safety as per IS 3938

1.5.6 Gear Cut from cast / forged steel as per IS 436

1.5.7 Brake Electro hydraulic type to hold 125% of the load torque

SPEC NO.

TCE-5103A-C-510-01




VOLUME IIIA

DATA SHEET–A15

SHEET 2 OF 2




KRISHNAPATNAM

1.5.8 Trolley Gears and brakes same as for hoist

1.5.9 Lubrication Centralised grease lubrication with hand pump

1.5.10 Trolley wheels Heat treated carbon steel / low alloy steel / graded CI single flanged

1.6 Material test certificates To be submitted for critical components such as hook, wire rope, drum, trolley, etc.

1.7 Overload test with 150% of specified load

At works : Yes At site : Yes

1.8 Visual inspection and dimensional check

Yes

1.9 Hoist motor shall be suitable for inching operation

SPEC NO.

TCE-5103A




VOLUME IIIA

DATA SHEET–A16

SHEET 1 OF 9

POWER PLANT PIPING AND VALVES


KRISHNAPATNAM

SPECIFIC REQUIREMENTS FOR PIPING SL. NO.

SERVICE SIZE PIPES FITTINGS FLANGES GASKETS LINE JOINT

STEAM TEMP. 550°C AND ABOVE UPTO 600OC

NB 65MM & ABOVE

ASTM A335 - P91

ASTM A234 – WP91

ASTM A182 – F91

SPIRAL WOUND SS 316

BUTT WELDED

1.1

NB 50MM & BELOW

ASTM A335 - P91

ASTM A182 – F91

ASTM A182 – F91

SPIRAL WOUND SS 316

SOCKET WELDED

1.2

STEAM TEMP. ABOVE 510°C AND UPTO 549°C

NB 65MM & ABOVE

ASTM A335 - P22

ASTM A234 – WP22

ASTM A182 – F22

SPIRAL WOUND SS 316

BUTT WELDED

NB 50MM & BELOW

ASTM A335 - P22

ASTM A182 – F22

ASTM A182 – F22

SPIRAL WOUND SS 316

SOCKET WELDED

1.3

STEAM TEMP. 400°C TO 510°C

NB 65MM & ABOVE

ASTM A335 - P11

ASTM A234 - WP11

ASTM A182 - F11

SPIRAL WOUND SS 316

BUTT WELDED

NB 50MM & BELOW

ASTM A335 - P11

ASTM A182 - F11

ASTM A182 - F11

SPIRAL WOUND SS 316

SOCKET WELDED

1.4

STEAM BELOW 400°C

NB 65MM & ABOVE

ASTM A106 Gr.B

ASTM A234 – WPB

ASTM A105

SPIRAL WOUND SS 316

BUTT WELDED

NB 50MM & BELOW

ASTM A106 Gr. B

ASTM A105 ASTM A105 SPIRAL WOUND SS 316

SOCKET WELDED

1.5

FEED WATER / CONDENSATE

NB 65MM & ABOVE

ASTM A106 Gr. C/B

ASTM A234 – WPC / WPB

ASTM A105

SPIRAL WOUND SS 316

BUTT WELDED

NB 50MM & BELOW

ASTM A106 Gr. C/B

ASTM A105

ASTM A105

SPIRAL WOUND SS 316

SOCKET WELDED

1.6

LUBE OIL AND CONTROL / HYDRAULIC OIL (UPSTREAM OF FILTER)

NB 65MM & ABOVE

ASTM A106 Gr. B

ASTM A234 - WPB

ASTM A105

GRAFOIL

BUTT WELDED

SPEC NO.

TCE-5103A




VOLUME IIIA

DATA SHEET–A16

SHEET 2 OF 9



KRISHNAPATNAM

NB 50MM & BELOW

ASTM A106 Gr.B

ASTM A105

ASTM A105

GRAFOIL

SOCKET WELDED

1.7

LUBE OIL & CONTROL / HYDRAULIC OIL (BEYOND FILTER)

NB 65MM & ABOVE

ASTM A 312 TP 316 (SEAM LESS)

ASTM A 403 GR. WP316

ASTM A182 F316

GRAFOIL

BUTT WELDED

NB50MM & BELOW

ASTM A 312 TP 316 (SEAM LESS)

ASTM A 403 GR. WP316

ASTM A182 F316

GRAFOIL

SOCKET WELDED

1.8

DEMINERALI-SED WATER

NB 65MM TO 150 200 T0 350

ERW, BLACK, IS 1239 (PT-1) Heavy class Rubber lined IS 1978 ERW OR API 5L GR.B Rubber lined

ASTM A 234 GR. WPB RUBBER LINED

ASTM A 105 RUBBER LINED

GRAFOIL

FLANGED

NB 50MM & BELOW

ASTM A312 TP 304(ERW)

A 182-F304

ASTM A 182 F304

GRAFOIL

SOCKET WELDED

1.9

AUXILIARY COOLING WATER (PASSIVATED DM WATER), SERVICE WATER SYSTEM (FRESH WATER APPLICATION), SERVICE AIR SYSTEM

NB 65 TO 150 200 TO 450

ERW, BLACK IS 1239 Heavy class (PT-1) ERW, IS 1978 (OR) API 5L GR. B (OR) IS 3589 FABRICATED FROM IS 2062

ASTM A234 Gr.WPB

ASTM A105 (A283GR-C FOR ABOVE NB 200 MM)

GRAFOIL

BUTT WELDED

SPEC NO.

TCE-5103A




VOLUME IIIA

DATA SHEET–A16

SHEET 3 OF 9



KRISHNAPATNAM

SL. NO.

SERVICE

SIZE

PIPES

FITTINGS

FLANGES

GASKETS

LINE JOINT

500 & ABOVE

IS 3589 FABRICATED FROM IS 2062 PLATES

NB 50 MM & BELOW

ERW, BLACK, IS 1239 (PT-1)

ASTM A105

ASTM A105

GRAFOIL

SOCKET WELDED

1.10

SEA WATER CONDENSER COOLING WATER, AUXILIARY COOLING WATER (SECONDARY CIRCUIT)

NB 65 TO 150 NB 200 TO 800

ERW, BLACK IS 1239 Heavy class (PT-1) Rubber Lined (5 mm thk) ERW, IS 1978 (OR) API 5L GR. B (OR) IS 3589 FABRICATED FROM IS 2062 – Rubber Lined (5 mm thk)

ASTM A234 Gr.WPB – Rubber Lined (5 mm thk)

ASTM A105 (A283GR-C FOR ABOVE NB 200 MM) – Rubber Lined (5 mm thk)

GRAFOIL

FLANGED

NB 900 & ABOVE

IS 3589 FABRICATED FROM IS 2062 PLATES Gunited with cement mortar

NB 50MM & BELOW

ASTM A312 TP 304 (ERW)

A 182-F304

ASTM A 182 F304

GRAFOIL

SOCKET WELDED

SPEC NO.

TCE-5103A




VOLUME IIIA

DATA SHEET–A16

SHEET 4 OF 9



KRISHNAPATNAM

SL. NO.

SERVICE

SIZE

PIPES

FITTINGS

FLANGES

GASKETS

LINE JOINT

1.11

POTABLE WATER SYSTEM/ INSTRUMENT AIR SERVICE

NB 65 TO 150

ERW, BLACK, IS 1239 Heavy class (PT-1), GALVANISED

ASTM A234 Gr.WPB GALVANI-SED

ASTM A105 GALVANI- SED

GRAFOIL

FLANGED

200 NB TO 450

IS 1978, ERW(OR) API 5L GR.B (OR) IS 3589 FABRICATED FROM IS 2062 PLATES (A LL GALVANISED)

NB 50 MM & BELOW

ERW, BLACK, IS 1239 (PT-1), GALVANISED

ASTM A105 GALVANI-SED

ASTM A105 GALVANI- SED

GRAFOIL

SCREWED

1.12

LIGHT DIESEL OIL (LDO) / HEAVY FURNACE OIL (HFO) / HIGH SPEED DIESEL (HSD)

NB 65MM & ABOVE (SEAM LESS)

ASTM A 106 Gr. ‘B’

ASTM A 234 WPB

ASTM A105

TEFLON

BUTT WELDED

NB50MM & BELOW (SEAM LESS)

ASTM A 106 Gr. ‘B’

ASTM A 105

ASTM A105

TEFLON

SOCKET WELDED

SPEC NO.

TCE-5103A




VOLUME IIIA

DATA SHEET–A16

SHEET 5 OF 9



KRISHNAPATNAM

1. All mandatory tests shall be carried out as per ASME Boiler & Pressure Vessel Code ASME Section-II,

2. Each length of pipe shall be hydro-tested at shop as per the Codes/Standards.

3. Blind flanges on SS Pipe lines shall be to ASTM A 240-TP 316. Stub ends shall be used at flanged connections.

4. All branch connections shall be wrought (seamless) or forged steel based on the size and availability based on ASTM Standards.

5. Piping System under Sl. No.1.1, 1.2 ,1.3 & 1.4 shall have IBR Approval. Boiler feed discharge under item no.1.5 shall also be under IBR Approval.

6. All painting with primer coats (2 coats each) shall be provided for the piping and all hangers.

7. IS 1239, pipes

SPEC NO.

TCE-5103A




VOLUME IIIA

DATA SHEET–A16

SHEET 6 OF 9



KRISHNAPATNAM

SPECIFIC REQUIREMENT FOR VALVES

SL. NO.

SERVICE SIZE BODY/ BONNET

DISC STEM HAND WHEEL

VALVE ENDS

1 STEAM LINES (TEMP >550OC AND <600OC)

>65NB < 50 NB

ASTM A217 C-12 ASTM A182 Gr.F-91

ASTM A217 C-12 ASTM A182 Gr F91

ASTM A182 Gr. F6a ASTM A182 Gr.F6a

ASTM A47 G Gr. 32510 ASTM A97 Gr.32510

BUTT WELDED. SOCKET WELDED

2 STEAM LINES (TEMP >510OC AND <550 OC)

>65NB < 50 NB

ASTM A217 WC-9 ASTM A182 Gr.F-22

ASTM A217 WC-9 ASTM A182 Gr F22




3 STEAM LINES (TEMP>400OC AND <510 OC)

>65NB < 50 NB

ASTM A217 WC-6 ASTM A182 Gr.F-11

ASTM A217 WC-6 ASTM A182 Gr F11




4 STEAM LINES (TEMP<400OC), CONDENSATE BLOW DOWN, BOILER FEED SUCTION LINE

>65NB < 50 NB

ASTM A216 Gr WCB ASTM A105

ASTM A216 Gr WCB ASTM A182 Gr F6a

ASTM A182 Gr F6a ASTM A182 Gr F6a

ASTM A47 Gr 32510 ASTM A47 Gr 32510

BUTT WELDED SOCKET WELDED

SPEC NO.

TCE-5103A




VOLUME IIIA

DATA SHEET–A16

SHEET 7 OF 9



KRISHNAPATNAM

5 BOILER FEED DISCHARGE & RECIRCULATION SYSTEMS

> 65 < 50

ASTM A 216 Gr. WCB/C ASTM A 105

ASTM A 216 Gr. WCB/C ASTM A 182 Gr. F6a

ASTM A 182 Gr. F6a ASTM A 182 Gr. F6a

ASTM A 47 Gr. 32510 ASTM A 47 Gr. 32510


6. LUBE OIL, SLUDGE, OILY WATER DRAINS (UPTO FILTER)

>65NB < 50 NB

ASTM A216 Gr WCB ASTM A105

ASTM A216 Gr WCB ASTM A479 Type 410-2

ASTM A479 Type 410-2 ASTM A479 Type 410-2



7. LUBE OIL & CONTROL OIL / HYDRAULIC OIL (BEYOND FILTER)

>65NB <50NB

SS 410 SS410

SS 410 SS 410

SS 410 SS 410

ASTM A47 GR. 32510 ASTM A47 GR. 32510


8. >65 A126

CLASS B

A126 CLASS B

ASTM B 124 C 37700

ASTM A47 GR. 32510

FLANGED FLAT FACE

CONDENSER COOLING WATER, AUXILIARY COOLING WATER, POTABLE WATER

< 50 ASTM B62 ASTM B62 ASTM B 312 GR.A

ASTM A47 GR. 32510

SCREWED TYPE

SPEC NO.

TCE-5103A-C-500-01




VOLUME IIIA

DATA SHEET–A16

SHEET 8 OF 9



KRISHNAPATNAM

9 INSTRUMENT AIR

>65NB < 50 NB

ASTM A 216 GR.WCB ASTM A 105

ASTM A 216 GR. WCB 13% Cr Steel (Ball)



FLANGED RAISED FACE SCREWED TYPE

10 DM WATER >65NB < 50 NB

ASTM A 126 CLASS B RUBBER LINED ASTM A 182 F316L

ASTM A 126 CLASS B RUBBER LINED ASTM A479 Type 410-2



FLANGED RAISED FACE SCREWED TYPE

SPEC NO.

TCE-5103A-C-500-01




VOLUME IIIA

DATA SHEET–A16

SHEET 9 OF 9



KRISHNAPATNAM

NOTES: 1. Testing of body, seat and back seat shall be as per ANSI B16.34

2. For water system covered under sl.no.8 for sizes 150NB and above and sl.no.10 for sizes 65NB and above, butterfly valves shall be used and shall conform to AWWA C-504.

3. Ball valves or plug valves shall be provided for oil systems.

4. All shut off valves on oil system shall have leakage ANSI B 16.104 class VI.

5. Ball valves shall be used for instrument air system up to 50NB size.

6. IBR approval for valves shall be included wherever applicable

SPEC NO ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

2X 800 MW TPP NEAR KRISHNAPATNAM

VOLUME III A

SPECIFIC TECH REQUIREMENT OF SG & AUX DATA SHEET – A17 TCE.5103A-C-500-01

STRAINERS SHEET 1 OF 2

REV. NO. PPD. BY JOB NO. CLIENT : APPDCL. DATE CKD. BY REV. BY 5103A PROJECT : 2x800MW TPP, KRISHNAPATNAM

TCE FORM 330 R1

ISSU

E N

O R

O

1.0 Tag Number Lube Oil & Fuel oil

2.0 Quantity Required *

3.0 Location * 4.0 Type Duplex 5.0 Fluid Lube oil 6.0 Flow rate, kg/hr * 7.0 Operating pressure – Kg/cm2 (g) * 8.0 Operating temperature – 0C * 9.0 Design pressure – Kg/cm2 (g) * 10.0 Design temperature – 0C * 11.0 Fluid viscosity cP at Op. temp * 12.0 Fluid Sp. gravity at Op. temp. * 13.0 Max. permissible Pr. Drop at 50% clogging * 14.0 Screen / basket data (i) CA of perforations * (ii) Min. Thickness – mm 1.5 (iii) Free straining area 4 times pipe cross sectional area. 15.0 Steam jacket No (a) Inlet pr. Kg/cm2(g) Op. / Desn. (b) Inlet temp. 0C Op. / Desn. 16.0 End connections (a) Size NB mm * (b) Type Welded (c) Details / Standards ANSI B 16.25

DE

SIG

N D

ATA

17.0 Cover Quick opng./ Bolted 18.0 (a) Body Cast carbon steel ASTM A 216 Gr. B (b) Cover - do - (c) Screen basket Stainless steel (d) Bolts / Studs ASTM A 193 Gr. B7 (e) Nuts ASTM A 194 Gr 2H M

ATE

RIA

L

(f) Gaskets Red rubber – Full face wire inserted

19.0 ACCESSORIES BY VENDOR

(a) For Bolts Yes

(b) Diff. Pressure gauge Yes

(c) Drain / Vent cock (Forged Steel) Yes

20.0 Hydro static test Pr. – Kg/cm2 (a) Shell side * (b) Jacket side 21.0 Vacuum test required No

22.0 Press. drop test required clean/50% clogged Yes

SPEC NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD


VOLUME IV A

TCE.5103A-C-500-01

SPECIFIC TECH REQUIREMENT OF STG & AUX DATA SHEET – A17

STRAINER SHEET 2 OF 2


TCE FORM 330 R1

1. Duplex Filter shall be provided with Valves with a single handle or interlink so as to

operate simultaneously. 2. External valve position indicator shall be provided to indicate strainer housing in use. 3. Strainer parts shall be replaceable without removing strainer housing from the line. 4. Strainer housing covers shall be provided with Davit arm. 5. Provision for equalising the pressure in standby housing before switching over should be

provided. 6. Acceptable leakage rates : NIL 7. Strainers shall be skid mounted.

VENDOR to furnish information in blank spaces

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD SPEC. NO.


VOLUME IV A

SPECIFIC TECH REQUIREMENT OF SG & AUX DATA SHEET – A 18 TCE.5103A-C-500-01 SHELL & TUBE HEAT EXCHANGER SHEET 1 OF 2


TCE FORM 330 R1

SL. NO. ITEMS UNITS VALUES

1.0 Designation By Bidder

2.0 Capacity 2 X 100% FOR EACH EQUIPMENT


COMPONENT MATERIAL

3.1 Shell IS-2002 GR. 2A/SA-285 GR. C/OR EQUAL

3.2 Shell Flanges IS-2002 GR. 2A/SA-285 GR. C/OR EQUAL, SA 181 GR 1/OR EQ.

3.3 Shell Cover IS-2002 GR. 2A/SA-285 GR. C/OR EQUAL.

3.4 Shell Cover Flange IS-2002 GR. 2A/SA-285 GR. C/ IS 1875 CL. B/ SA 181 GR 1/OR EQ.

3.5 Shell Nozzles IS-1978 ST 25/SA-53 GR. B/OR EQUAL.

3.6 Shell Nozzles Flanges IS-2002 GR. 2A/IS-1875 CL. B/SA 285 GR C/SA 181 GR 1/OR EQUAL

3.7 Channels IS-2002 GR. 2A/SA-285 GR. C/ OR EQUAL

3.8 Channel / Flanges IS-2002 GR. 2A/IS 1875 GR B/ SA 285 GR C/SA 181 GR 1 OR EQUAL

3.9 Channel Cover Flange IS-2002 GR. 2A/IS-1875 GR B/ SA 285 GR. C/SA 181 GR. 1/OR EQUAL

3.10 Channel Nozzles IS-1978 ST 25/SA-53 GR B/OR EQUAL

3.11 Channel Nozzle Flanges IS-2002 GR 2A/IS 1875 GR B/SA 285 GR C/SA 181 GR 1/OR EQUAL

3.12 Tubes SA-179/BS-3059 CDS 33/OR EQUAL

3.13 Tube Sheets : i) Stationary

ii) Floating

IS-2002 GR 2A/IS-1875 GR B/SA 285 GR C/SA 181 GR 1/OR EQUAL.

3.14 Baffles : i) Longitudinal COMMERCIAL QUALITY STEEL

ii) Cross COMMERCIAL QUALITY STEEL

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD SPEC. NO.


VOLUME IV A

SPECIFIC TECH REQUIREMENT OF SG & AUX DATA SHEET – A 18 TCE.5103A-C-500-01 SHELL & TUBE HEAT EXCHANGER SHEET 2 OF 2


TCE FORM 330 R1

3.15 Support Plates COMMERCIAL QUALITY STEEL

3.16 Pass Partition COMMERCIAL QUALITY STEEL


3.17 Impingement Plate COMMERCIAL QUALITY STEEL

3.18 Tie Rods COMMERCIAL QUALITY STEEL

3.19 Spacers COMMERCIAL QUALITY STEEL

3.20 Floating Tube Sheet Joint IS-1367-8.8, EN 24 T : SA 193-B-7-STUDS

3.21 All Other Shell Side Joints IS-1367-B, EN 8 : SA 194-2H NUTS

3.22 Gaskets

3.22.1 Shell Cover ANNEALED STEEL JACKETTED COMP ASI

3.22.2 Channel Cover ANNEALED STEEL JACKETTED COMP ASI

3.22.3 Fixed Tube Sheets Shell Side COMP ASB

3.22.4 Fixed Tube Sheets Channel Side ANNEALED STEEL JACKETTED COMP. ASB

3.22.5 Floating Tube Sheet Shell Side ANNEALED STEEL JACKETTED COMP. ASB

3.22.6 Floating Tube Sheet Channel Side ANNEALED STEEL JACKETTED COMP. ASB

3.23 Saddle Supports / Brackets COMMERCIAL QUALITY STEEL

3.24 Jack Screws MILD STEEL SA 193 B7 : IS-1367-B, 8.8 : EN 24 T OR EQUAL

SPEC.NO ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 2X 800 MW TPP NEAR KRISHNAPATNAM

VOLUME IIIA

TCE.5103A-C-500-001 SPEC TECH REQUIREMENTS FOR SG & AUX DATA SHEET A19

THERMAL INSULATION FOR HOT SURFACES SHEET 1 OF 2

TCE FORM 329 R4

ISSUE R0

ISSU

E N

O R

0


1.0 Insulation Material for Lightly bonded mineral wool / pre-formed calcium silicate

1.2 Equipment All equipment as applicable except

steam turbine 2.0 Finishing Cement No 3.0 Sheathing Material Aluminium as per IS737 – 31000, Gr.H3 3.1 For pipes i) Insulation outside dia above 450mm

– Sheet thickness – 20 SWG. ii) Insulation outside dia 150 to 450mm

– Sheet thickness – 22 SWG. iii) Insulation outside dia below 150mm

– Sheet thickness – 24 SWG. 3.2 For Equipment i) Flues & ducts – Sheet thickness

1.0mm ii) SG casing & rear wall enclosure –

Sheet thickness 1.6mm. 4.0 Design thicknes is / should be based on : a) Station ambient temperature Deg.C 30 b) Outer surface temperature on surface

of sheathing Deg.C 60 under still air condition

5.0 Recommended thickness furnished

(Applicable for calcium silicate also) Yes / (Refer sheet 2 of 2)

7.0 Codes & Standards IS 8183

IS 14164 BS 5970 IS-8154, BS 3958

8.0 Notes : 1. For insulation thickness calculation maximum thermal conductivity indicated in relevant BIS

shall be considered

SPEC.NO ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 2X 800 MW TPP NEAR KRISHNAPATNAM

VOLUME IIIA

TCE.5103A DATA SHEET A19 THERMAL INSULATION FOR HOT SURFACES SHEET 2 OF 2

TCE FORM 329 R3

ISSUE R0

Temp (0C) 51 – 100

101-150

151-200

201-250

251-300

301-350

351-400

401-450

451-500

501-550

551-575

Pipe Dia INSULATION THICKNESS IN mm. 15 mm (1/2”) 25 25 40 40 50 65 80 90 100 115 125 20 mm (3/4”) 25 25 40 50 50 65 80 90 100 125 125 25 mm (1”) 25 40 40 50 65 80 90 100 115 125 140 32 mm (1-1/4”) 25 40 40 50 65 80 90 100 115 140 140 40mm (1-1/2”) 25 40 40 50 65 80 90 115 125 140 150 50mm (2”) 25 40 40 50 65 80 100 115 125 150 165 80mm (3”) 25 40 50 50 80 90 100 125 140 165 170 100mm (4”) 40 50 50 65 80 90 115 125 150 165 190 150mm (6”) 40 50 50 65 80 100 115 140 165 190 200 200mm (8”) 40 50 50 65 80 100 125 140 165 190 215 250mm (10”) 40 50 50 65 90 115 125 150 175 200 215 300mm (12”) 40 50 65 75 90 115 140 150 190 215 225 350mm (14”) 50 65 75 75 90 115 140 165 190 215 225 400mm (16”) 50 65 75 75 90 115 140 165 190 215 240 450mm (18”) 50 65 75 75 90 115 140 165 190 225 240 500mm (20”) 50 65 75 100 115 115 140 165 200 225 240 600mm (24”) 50 65 75 100 115 115 140 175 200 240 250 625mm (25”) 50 65 75 100 115 115 140 175 200 240 250 650mm (26”) 50 65 75 100 115 115 150 175 200 240 250 700mm (28”) 50 65 75 100 115 115 150 175 215 240 300 800mm (32”) 50 65 75 100 115 125 150 175 215 240 300 900mm (36”) 50 65 75 100 115 125 150 175 215 240 300 950mm (38”) 50 65 75 100 115 125 150 175 215 240 300 1000mm (40”) & above flat Surfaces

50 65 75 100 115 140 170 215 250 300 350

Insulation thicknesses are calculated considering aluminium sheathing for the ambient temperature of 300C. The above values hold good for mineral wool insulating material only having the following densities. (a) Temperature upto and including 4000C - 100 Kg/m3 (b) Temperature above 4000C - 150 Kg/m3

SPEC NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME III A


SPECIFIC TECH REQUIREMENT OF SG & AUX

DATA SHEET–A20

TCE.5103A-C-510-01 FLASH TANKS SHEET 1 OF 1

REV. NO. PPD. BY JOB NO. CLIENT : APPDCL DATE CKD. BY REV. BY DATE 5103A PROJECT: 2x800MW TPP,

KRISHNAPATNAM

FORM 330 R1

SL.NO. ITEMS UNITS VALUES

1.0 GENERAL FLASH TANK

1.1 Number 1 1.2 Location Outdoor 2.0 DESIGN DATA

2.1 Operating pressure Kg/cm2(a) Bidder to indicate 2.2 Design pressure Kg/cm2(a) * 2.3 Operating temperature oC * 2.4 Design temperature oC * 2.5 Corrosion allowances mm --------------- 3 (min.) -------------- 3.0 MATERIALS OF

CONSTRUCTION

3.1 Shell and head --------------Carbon steel--------------- 3.2 Internal piping ----------ASTM-A106-Gr.B------------

- 3.3 Nozzle --------------ASTM-A106-Gr.B--------

---- Note : * BIDDER to indicate

SPECIFICATION No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED SECTION IIIA 2X 800 MW TPP NEAR KRISHNAPATNAM DATASHEET A21 TCE. M4-203-01 INDUCTION MOTORS SHEET 1 OF 5

REV. NO. PPD. BY JOB NO. CLIENT : APPDCL DATE CKD. BY TCE.5103A PROJECT : 2X800 MW TPP

REV. BY DATE TCE.FORM NO.330R1

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SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS 1.0 GENERAL 1.1 APPLICATION 1.2 NUMBER OF UNITS 1.3 TYPE OF MOTOR SQUIRREL CAGE/ WOUND ROTOR 1.4 SUPPLY SYSTEM FAULT LEVEL MVA 1.5 SUPPLY NEUTRAL TYPE OF EARTHING 1.6 COMPLIANCE WITH TCE.M4- 203-02 IS REQUIRED YES/NO 1.7 IF YES CLAUSES OF TCE.M4-203-02 WHICH ARE NOT APPLICABLE: 2.0 RATING 2.1 RATED OUTPUT: kW 2.2 RATED VOLTAGE: V 2.3 NUMBER OF PHASES & FREQUENCY 2.4 SUPPLY CONDITION (REF. CL.NO.4.1 OF TCE.M4- 203-01) I/II 2.5 SYNCHRONOUS SPEED RPM 3.0 DUTY 3.1 TYPE OF DUTY (CLAUSE 9.2 OF IS:325 OR EQUIVALENT) 3.2 POWER REQUIRED BY LOAD kW

SPECIFICATION No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED SECTION IIIA 2X 800 MW TPP NEAR KRISHNAPATNAM DATASHEET A21

E. M4-203-01 INDUCTION MOTORS SHEET 2 OF 5



TC

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SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS 4.0 METHOD OF STARTING D.O.L./STAR DELTA/ OTHER 5.0 INSULATION 5.1 CLASS OF INSULATION 5.2 REF. AMBIENT TEMPERATURE deg. C 5.3 TEMPERATURE RISE OF WINDING 5.3.1 BY THERMOMETER METHOD deg. C 5.3.2 BY WDG RESISTANCE METHOD deg. C 6.0 INSTALLATION 6.1 LOCATION Indoor/Outdoor 6.2 HAZARDOUS AREA DIVISION (IS: 5572 OR EQUIVALENT) 6.3 ATMOSPHERE CHEMICAL/DUSTY/SALT LADEN 7.0 ENCLOSURE 7.1 TYPE OF COOLING (IS 6362) 7.2 DESIGNATION FOR DEGREE OF PROTECTION (IS 4691) 8.0 MAIN TERMINAL BOX 8.1 LOCATION AS SEEN FROM NON- DRIVE END: RIGHT/LEFT 8.2 RATINGS (a) SHORT TIME i. CURRENT : kA (RMS) ii. DURATION: SECS. 0.25 (b) DYNAMIC : kA (PEAK)




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SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS 8.3 EXTERNAL CABLE DETAILS 8.3.1 TYPE 8.3. 2 SIZE & NO OF CORES 8.4 EARTHING CONDUCTORS 8.4.1 MATERIAL 8.4.2 SIZE 9.0 MISCELLANEOUS REQUIREMENTS TO BE FILLED IF MOTORS ARE BOUGHT

SEPERATELY 9.1 SHAFT ORIENTATION HORIZONTAL/VERTICAL/ HOLLOW VERTICAL 9.2 MOUNTING SYMBOL (IS: 2253 OR EQUIVALENT) 9.5 ROTATION AS SEEN FROM CLOCKWISE/ANTI-CLOCKWISE NON-DRIVE END 9.6 TYPE OF BEARING 9.6.1 DRIVE END 9.6.2 NON DRIVE END 9.7 WHETHER BED PLATE REQUIRED YES/NO 9.9 COLOUR SHADES OF PAINT 9.10 WHETHER CTs FOR DIFFEREN- TIAL PROTECTION REQUIRED FOR MOTORS >1000 kW YES/NO




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SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS 9.10.1 C.T. PARTICULARS: a) 3 CTs, ONE IN THE NEUTRAL LEAD OF EACH PHASE b) RATIO c) CLASS PS d) KNEE POINT VOLTAGE KPV e) MAX. R.C.T. SECONDARY WINDING RESISTANCE OHMS f) MAX. EXCITING CURRENT AT 1/2 KPV g) CLASS OF INSULATION 9.11 WHETHER VIBRATION PADS REQUIRED YES/NO 9.12 TEMPERATURE DETECTORS/ INDICATORS 9.12.1 EMBEDDED TEMPERATURE DETECTORS FOR WINDING REQUIRED YES/NO 9.12.2 EMBEDDED TEMPERATURE DETECTORS FOR BEARINGS REQUIRED YES/NO 9.12.3 BEARING THERMOMETERS FOR DRIVING END & NON DRIVING ENDS REQUIRED YES/NO 9.13 SPACE HEATERS FOR YES/NO MOTORS REQUIRED




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NOTES DRAWINGS SHOULD BE SUBMITTED FOR REVIEW AS FOLLOWS: 1) GENERAL ARRANGEMENT WITHIN ___ WEEKS AFTER AWARD OF CONTRACT 2) DETAILS MARKED THUS (*) WILL BE DECIDED AND INTIMATED BY THE BIDDER BASED ON DRIVEN EQUIPMENT CHARACTERISTICS.

SPEC. No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED SECTION IIIA TCE. M4-203-01 DATA SHEET-A21 INDUCTION MOTORS SHEET 1 OF 2



SL.NO. BRIEF TITLE REFERENCE NUMBER OF STANDARDS 1. THREE PHASE INDUCTION MOTORS IS-325 BS-4999 IEC-34 2. ROTATING ELECTRICAL MACHINES IS-4722 BS IEC 3. SINGLE PHASE INDUCTION MOTORS IS-996 BS IEC 4. CODE OF PRACTICE FOR CLIMATE IS BS-6751 IEC PROOFING 5. DESIGNATIONS FOR TYPES OF IS-2253 BS IEC-34-7 CONSTRUCTION AND MOUNTING ARRANGEMENT OF ROTATING ELECTRICAL MACHINES 6. TERMINAL MARKING & DIRECTION IS-4728 BS-4999 IEC-34-8 OF ROTATION FOR ROTATING -108 ELECTRICAL MACHINERY 7. DESIGNATION OF METHODS OF IS-6362 BSEN 60034 IEC-34-6 COOLING FOR ROTATING -6-1994 ELECTRICAL MACHINES 8. DEGREES OF PROTECTION PROVI- IS-4691 BS-4999 IEC-34-5 DED BY ENCLOSURE FOR ROTATING -105 ELECTRICAL MACHINERY 9. GUIDE FOR TESTING THREE PHASE IS-4029 BS IEC-34 INDUCTION MOTORS 10. MEASUREMENT AND EVALUATION OF IS-12075 BS-4999 IEC-34-14 VIBRATION OF ROTATING 142 ELECTRICAL MACHINES 11. CLASSIFICATION OF HAZARDOUS IS-5572 BS IEC-79 AREAS FOR ELECTRICAL INSTALLATION 12. DIMENSIONS OF SLIDE RAILS FOR IS-2968 BS-4999 IEC ELECTRIC MOTORS -141 13. PERMISSIBLE LIMITS OF NOISE IS-12065 BSEN 60034 IEC LEVEL FOR ROTATING ELECTRICAL -9-1994 MACHINES 14. GUIDE FOR TESTING INSULATION IS-7816 BS IEC RESISTANCE OF ROTATING MACHINES

SPEC. No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED SECTION IIIA TCE. M4-203-01 DATA SHEET-A21 INDUCTION MOTORS SHEET 2 OF 2



SL.NO. BRIEF TITLE REFERENCE NUMBER OF STANDARDS 15. TANGENT DELTA & DELTA TANGENT IS-13508 BS IEC DELTA TEST 16. IMPULSE VOLTAGE WITHSTAND TEST IS BS IEC-34-15 17. TEMPERATURE RISE MEASUREMENT IS-12802 BS IEC OF ROTATING ELECTRICAL MACHINES 18. TYPE OF DUTY AND CLASSES OF RATING ASSIGNED TO ROTATING ELECTRICAL MACHINES IS 12824 BS IEC 19. CBIP RECOMMENDATION FOR MOTORS NOTES 1. EQUIPMENT, ASSOCIATED ACCESSORIES, COMPONENTS/PARTS, RAW MATERIAL AND TESTS SHALL IN GENERAL CONFORM TO IS BS IEC 2. OFFERS CONFORMING TO OTHER AUTHORITATIVE STANDARDS MAY ALSO BE CONSIDERED/ MAY NOT BE CONSIDERED.

SPEC. No. TCE CONSULTING ENGINEERS LIMITED SECTION D TCE. M4-203-01 DATA SHEET-A2 INDUCTION MOTORS SHEET 1 OF 2



SPEC. No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED VOLUME IIIA

TCE. M4-203-02 2X 800 MW TPP NEAR KRISHNAPATNAM DATA SH A22 INDUCTION MOTORS - HT SHEET 1 OF 5

REV. NO. PPD. BY JOB NO. CLIENT : APPDCL

DATE CKD. BY TCE. PROJECT : 2x800 MW THERMAL

REV. BY DATE 5103A POWER PLANT

TCE.FORM NO.330R1

ISSU

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SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS 1.0 GENERAL 1.1 APPLICATION SG AUXILIARIES 1.2 NUMBER OF UNITS 1.3 TYPE OF MOTOR SQUIRREL CAGE 1.4 SUPPLY SYSTEM FAULT LEVEL MVA BY PURCHASER 1.5 SUPPLY NEUTRAL TYPE OF EARTHING MEDIUM RESISTANCE EARTHED WITH CURRENT LIMITED TO 400AMPS 2.0 RATING 2.1 RATED OUTPUT : kW BY BIDDER 2.2 RATED VOLTAGE : V 11000 2.3 NUMBER OF PHASES & FREQUENCY 3PH,50 HZ 2.4 SUPPLY CONDITION (REF. VOLTAGE VARIATION:+/- 10%, FREQUENCY VARIAITON:+/- 5% COMBINED VARIATION:10% 2.5 SYNCHRONOUS SPEED RPM * 3.0 DUTY 3.1 TYPE OF DUTY (CLAUSE 9.2 OF IS: 325 OR EQUIVALENT) S1 3.2 POWER REQUIRED BY LOAD kW *






TCE.FORM NO.330R1

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SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS 4.0 METHOD OF STARTING D.O.L 5.0 INSULATION 5.1 CLASS OF INSULATION CLASS-F 5.2 REF. AMBIENT TEMPERATURE deg. C 50 5.3 TEMPERATURE RISE OF WINDING 5.3.1 BY THERMOMETER METHOD deg. C N.A 5.3.2 BY WDG RESISTANCE METHOD deg. C 70 6.0 INSTALLATION 6.1 LOCATION INDOOR 6.2 HAZARDOUS AREA DIVISION (IS:5572 OR EQUIVALENT) NON HAZARDOUS 6.3 ATMOSPHERE DUSTY 7.0 ENCLOSURE 7.1 TYPE OF COOLING (IS 6362) TETV/CACW /CACA 7.2 DESIGNATION FOR DEGREE OF PROTECTION (IS 4691) IP-54 8.0 MAIN TERMINAL BOX 8.1 LOCATION AS SEEN FROM NON- DRIVE END: LEFT 8.2 RATINGS (a) SHORT TIME i. CURRENT : kA(RMS) 40 ii. DURATION: SECS. 0.25 (b) DYNAMIC : kA(PEAK) 100






TCE.FORM NO.330R1

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SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS 8.3 EXTERNAL CABLE DETAILS 8.3.1 TYPE ALUMINUM COND.,XLPE INSULATED 8.3. 2 SIZE & NO OF CORES LATER 8.4 EARTHING CONDUCTORS 8.4.1 MATERIAL GS 8.4.2 SIZE BY BIDDER 9.0 MISCELLANEOUS REQUIREMENTS 9.1 SHAFT ORIENTATION TO MATCH WITH THE PUMP 9.2 MOUNTING SYMBOL (IS:2253 * OR EQUIVALENT) 9.5 ROTATION AS SEEN FROM TO MATCH WITH THE PUMP NON-DRIVE END 9.6 TYPE OF BEARING 9.6.1 DRIVE END * 9.6.2 NON DRIVE END * 9.7 WHETHER BED PLATE REQUIRED * 9.9 COLOUR SHADES OF PAINT SHADE 631 OF IS-5 9.10 WHETHER CTs FOR DIFFEREN- TIAL PROTECTION REQUIRED FOR MOTORS >1000 kW BY SWITCHGEAR VENDOR






TCE.FORM NO.330R1

ISSU

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SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS 9.10.1 C.T. PARTICULARS: a) 3 CTs, ONE IN THE NEUTRAL LEAD OF LATER EACH PHASE b) RATIO c) CLASS PS d) KNEE POINT VOLTAGE KPV e) MAX. R.C.T. SECONDARY WINDING RESISTANCE OHMS f) MAX. EXCITING CURRENT AT 1/2 KPV g) CLASS OF INSULATION 9.11 WHETHER VIBRATION PADS REQUIRED YES 9.12 TEMPERATURE DETECTORS/ INDICATORS 9.12.1 EMBEDDED TEMPERATURE DETECTORS FOR WINDING REQUIRED YES –6 NOS. DUPLEX/12 NOS. SIMPLEX (PRT-100) 9.12.2 EMBEDDED TEMPERATURE DETECTORS FOR BEARINGS REQUIRED ONE NO.DUPLEX RTD (PRT-100) FOR EACH BEARING 9.12.3 BEARING THERMOMETERS FOR DRIVING END & NON DRIVING ENDS REQUIRED YES 9.13 SPACE HEATERS FOR YES MOTORS REQUIRED






TCE.FORM NO.330R1

ISSU

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NOTES DRAWINGS SHOULD BE SUBMITTED FOR REVIEW AS FOLLOWS: 1) DETAILS MARKED THUS (*) WILL BE DECIDED AND INTIMATED BY THE BIDDER BASED ON DRIVEN EQUIPMENT CHARACTERISTICS. 2) THE MAXIMUM NOISE LEVEL MEASURED AT A DISTANCE OF 1 M FROM THE OUTER SURFACE

OF THE MOTOR SHALL NOT EXCEED 85 dB(A) 3) VIBRATION PICKUP AND MONITOR SHALL BE PROVIDED AT BOTH DE AND NDE OF MOTOR AT

BOTH X AND Y DIRECTION.

SPEC. No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY VOLUME IIIA

TCE. M4-203-02 LIMITED DATA SH A 22 INDUCTION MOTORS - HT SHEET 1 OF 2




TCE.FORM NO.330R1

SL.NO. BRIEF TITLE REFERENCE NUMBER OF STANDARDS 1. THREE PHASE INDUCTION MOTORS √ IS-325 BS-4999 IEC-34 2. ROTATING ELECTRICAL MACHINES √ IS-4722 BS IEC 3. SINGLE PHASE INDUCTION MOTORS √ IS-996 BS IEC 4. CODE OF PRACTICE FOR CLIMATE IS √ BS-6751 IEC PROOFING 5. DESIGNATIONS FOR TYPES OF √ IS-2253 BS IEC-34-7 CONSTRUCTION AND MOUNTING ARRANGEMENT OF ROTATING ELECTRICAL MACHINES 6. TERMINAL MARKING & DIRECTION √ IS-4728 BS-4999 IEC-34-8 OF ROTATION FOR ROTATING -108 ELECTRICAL MACHINERY 7. DESIGNATION OF METHODS OF √ IS-6362 BSEN 60034 IEC-34-6 COOLING FOR ROTATING -6-1994 ELECTRICAL MACHINES 8. DEGREES OF PROTECTION PROVI- √ IS-4691 BS-4999 IEC-34-5 DED BY ENCLOSURE FOR ROTATING -105 ELECTRICAL MACHINERY 9. GUIDE FOR TESTING THREE PHASE √ IS-4029 BS IEC-34 INDUCTION MOTORS 10. MEASUREMENT AND EVALUATION OF √ IS-12075 BS-4999 IEC-34-14 VIBRATION OF ROTATING 142 ELECTRICAL MACHINES 11. CLASSIFICATION OF HAZARDOUS √ IS-5572 BS IEC-79 AREAS FOR ELECTRICAL INSTALLATION 12. DIMENSIONS OF SLIDE RAILS FOR √ IS-2968 BS-4999 IEC ELECTRIC MOTORS -141 13. PERMISSIBLE LIMITS OF NOISE √ IS-12065 BSEN 60034 IEC LEVEL FOR ROTATING ELECTRICAL -9-1994 MACHINES 14. GUIDE FOR TESTING INSULATION √ IS-7816 BS IEC RESISTANCE OF ROTATING MACHINES

SPEC. No. ANDHRA PRADESH POWER DEVELOPMENT COMPANY VOLUME IIIA

TCE. M4-203-02 LIMITED DATA SH A 22 INDUCTION MOTORS - HT SHEET 2 OF 2




TCE.FORM NO.330R1

SL.NO. BRIEF TITLE REFERENCE NUMBER OF STANDARDS 15. TANGENT DELTA & DELTA TANGENT √ IS-13508 BS IEC DELTA TEST 16. IMPULSE VOLTAGE WITHSTAND TEST IS BS √ IEC-34-15 17. TEMPERATURE RISE MEASUREMENT √ IS-12802 BS IEC OF ROTATING ELECTRICAL MACHINES 18. TYPE OF DUTY AND CLASSES OF RATING ASSIGNED TO ROTATING ELECTRICAL MACHINES √ IS 12824 BS IEC 19. CBIP RECOMMENDATION FOR MOTORS NOTES 1. EQUIPMENT, ASSOCIATED ACCESSORIES, COMPONENTS/PARTS, RAW MATERIAL AND TESTS SHALL IN GENERAL CONFORM TO √ IS BS IEC 2. OFFERS CONFORMING TO OTHER AUTHORITATIVE STANDARDS MAY ALSO BE CONSIDERED

SPECIFICATION NO.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED


VOLUME IIIA

DATA SH A23 TCE-M4-203-11 D.C. MOTORS SHEET 1 OF 2

REV. NO. PPD. BY : JOB NO. CLIENT : APPDCL DATE CKD. BY : TCE. REV. BY DATE : 5103A PROJECT : 2x800 MW THERMAL

POWER PLANT

TCE FORM 330 R1

ISSU

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1.0 GENERAL

1.1 Application SG AUXILIARIES

1.2 Supply System Fault Level kA 20 ( However will be confirmed during Detailed engineering) 1.3 Type of Supply Earthing UNEARTHED 1.4 Supply Voltage Variation % of +10%/-15% Rated Voltage 2.0 RATING 2.1 Rated Voltage V 220 3.0 DUTY 3.1 Type of Duty CONTINUOUS 4.0 STARTING 4.1 Method of Starting Reduced Voltage 4.2 Starting Current Not greater than 2.5 times full load current

5.0 INSULATION

5.1 Class of Insulation CLASS-F

6.0 TERMINATIONS

6.1 Terminal Box Rotation 360 deg. in steps of 90 deg.

6.2 External Cable Details

a) Armature AL conductor,XLPE b) Field insulated,Armoured c) Others

6.3 Earthing Conductor

a) Material GS b) Size mm By bidder

7.0 INSTALLATION

7.1 Location Indoor

SPECIFICATION NO.



VOLUME IIIA

DATA SH A23 TCE-M4-203-11 D.C. MOTORS SHEET 2 OF 2


POWER PLANT

TCE FORM 330 R1

ISSU

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7.2 Hazardous Area Classification N.A

a) Division / Zone b) Gas Group IIA/IIB/IIC c) Temp. Classification T1 to T6

7.3 Atmosphere Dusty

7.4 Treatment Against Corrosion Required No 8.0 ENCLOSURE

8.1 Type of Enclosure TEFC 8.2 Designation for Degree of Protection IP-54 9.0 OTHERS

9.1 Thermometer and Temperature Relay Required

for Alarm

9.2 Space Heaters Suitable for 1 ph, Required 240V, 50 Hz supply

9.3 Paint Finish Grey Enamel Paint-shade 631 as per IS-5

9.4 a) Starter Panel Required

b) Starter Control Wiring Diagram No Enclosed (If Yes, mention drawing No.)

9.5 Field Rheostat as per Cl.11.0 of Sec.D Required 10.0 TESTS

10.1 Routine Tests All tests as per Applicable

Standards 10.2 Type Tests Not Reqd. Copy of Test certificates shall

Be furnished

SPECIFICATION NO.

IFFCO CHHATTISGARH POWER LIMITED (ICPL)

2X500/600 MW TPP NEAR PREMNAGAR, SARGUJA DIST

VOLUME IIIA

DATA SH A22/2 TCE-M4-203-11 D.C. MOTORS SHEET 1 OF 1


POWER PLANT

TCE FORM 330 R1

ISSU

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1.0 APPLICABLE STANDARDS

1.1 Rotating Electrical Machines � IS 4722 � BS-4999, � IEC-60034

BSEN-60034-1

1.2 Vibrations � IS 12075 � BS 4999-142 � IEC-60034-14

1.3 Climate Proofing � IS � BS

1.4 Tests � IS 4722 � BS 4999 � IEC-60034

1.5 Degree of Protection � IS 4691 � BS 4999-105 � IEC-60034-5

1.6 Hazardous Area Classification � IS 5572 � BSEN 60079 -10 � IEC-60079-10

1.7 Mounting of Motors � IS 2253 � BSEN-60034-7 � IEC-60034-7

1.8 Terminal Markings � IS 4728 � BS 4999-108 � IEC-60034-8

1.9 Methods of Cooling � IS 4362 � BSEN 60034 -6 � IEC-60034-6

1.10 Flame Proof Enclosure � IS 2148 � IEC-60079-1

1.11 Guide for selection of � IS 5591 � BSEN 60079 � IEC-60079

Electrical Equipment for

Hazardous Areas

2.0 NOTES

2.1 Equipment, accessories, components/parts, raw

materials and tests in general shall conform to � IS � BS � IEC

SPECIFICATION NO.



VOLUME IIIA

DATA SH A24 TCE-M4-203-06 MOTOR OPERATED VALVE ACTUATORS SHEET 1 OF 4

REV. NO. PPD. BY: JOB NO. CLIENT: APPDCL DATE CKD. BY: TCE REV. BY DATE: 5103A PROJECT: 2x 800 MW THERMAL

POWER PLANT

TCE FORM 330 R1

ISSU

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R4

1.0 Application

2.0 Degree of Protection & Sealing (for motor

actuators and starter enclosure) IP IP 67, ‘O’ ring sealed

3.0 Explosion proof As applicable 4.0 Type of Actuator (As per IS 9334) Type 1 A 5.0 Direct temperature sensing thermostats to be

provided in motor winding (2 Nos.) Required

5.1 Switching capacity of contacts 5A, 230 V AC 6.0 Motor duty As per IS 9334 7.0 Motor starting DOL 8.0 Power Supplies 8.1 Main Power Supply 400V or 415V, 3 - phase, 3 – wire 50 Hz

Effectively Earthed 8.2 Control supply 110 V,1 – Phase, 50 Hz 8.3 Variation in supply voltage and frequency from

rated values

8.3.1 Supply voltage o/o ± 10 8.3.2 Supply frequency o/o ± 5 8.3.3 Combined voltage and frequency variation o/o 10 9.0 Integral motor starter to be provided Yes 10.0 Remote position transducer Required 10.1 Potentiometric type / Others Non contact type 24 VDC 10.2 Position Transmitter giving signal output of 4 –

20 mA dc Yes

10.3 If transducer indicated in 10.2 provided, it shall have 2 – wire output / 4 wire output to match the remote indicator / controller

2 wire output

10.4 Auxiliary supply for transducer V, AC/DC Loop powered

SPECIFICATION NO.



VOLUME IIIA



POWER PLANT

TCE FORM 330 R1

ISSU

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11.0 Supply monitoring device with contact output

for remote annunciation, required. Yes

12.0 Torque switch 12.1 Number Close direction (min) Nos. 1 Open direction (min) Nos. 1 12.2 Additional switch Close Nos. 1 Open Nos. 1 12.3 Switching capacity As per IS 9334 13.0 Limit switch 13.1 Number & contact development As per following table (Sh 4) showing limit

switch contact requirement. 13.2 Switching capacity Amp. As per IS 9334 14.0 Blinker relay & lamp required Yes 15.0 Two (2) interposing relays required for

receiving remote command signal Yes ( 24V DC relay suitable to accept 24V

DC logic level remote command signal) 15.1 Coil voltage rating Volts 24 V DC 15.2 Burden VA 16.0 Additional contact of local / remote switch

required for remote switch indication. Yes

17.0 Remote commands shall comprise Open Yes Stop No Close Yes 18.0 Drawings TCE.M2-EL-CW-S-2625 & 2626

enclosed with specification. (Required only for valve Actuators with integral starters)

Yes

19.0 Terminal box Separate terminal box shall be provided for

power and control wiring. 19.1 Terminals for motor Stud type with plain washers, spring washers

and check nuts 19.2 Gaskets Neoprene 19.3 Cable glands / lugs Required

SPECIFICATION NO.



VOLUME IIIA



POWER PLANT

TCE FORM 330 R1

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19.4 If yes to 19.3 a) Glands Brass b) Lugs Tinned copper c) Cable size Sq.mm i) Power

ii)Control 3CX 2.5 sq.mm

0.5 sq.mm screened cable 20.0 Paint and Finish 20.1 Primer One coat 20.2 Finish 2 coats of grey enamel paint (Shade 631 as

per IS.5)

SPECIFICATION NO.



VOLUME IIIA


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TORQUE AND LIMIT SWITCH CONTACT REQUIREMENT FOR PURCHASER’S USE

Switch Designation

Full Open Intermediate Full Close

Non- Integral Starter

Integral Starter Requirement

Not applicable

Torque switch open

2 NO + 1 NC YES

Torque switch close

2 NO + 1 NC YES

Limit switch Open

2 NO + 1 NC YES

Limit Switch close

2 NO + 1 NC YES

(Adjustable type from 0 to 50 % position)

2 NO + 1 NC YES

(Adjustable type from 50 to 100% position)

2 NO + 1 NC YES

SPECIFICATION NO.


VOLUME IIIA


REV. NO. PPD. BY: JOB NO. CLIENT: APPDCL DATE CKD. BY: TCE. REV. BY DATE: 5103A PROJECT:2X800 MW THERMAL POWER

PLANT

TCE FORM 330 R1

ISSU

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1. Factory built assemblies of switchgear and control gear for voltages upto and including 1000 V AC and 1200 V DC.

� IS:8623 � BS-EN-60439 � IEC:60439

2. Air break switches � IS:13947-3 � BS-EN-60947-3 � IEC-60947-3

3. H. R. C Cartridge fuses � IS:9224 � BS-88 � IEC-60269

4. Contactors � IS:13947-4 � BS-E-N-60947-4 � IEC-947-4

5. Starters � IS:13947-4 � BS-EN-60947-4-1 � IEC-947-4-1

6. Control switches / push buttons � IS:6875 � BS: � IEC :

7. Relays � IS:3231 � BS- � IEC : 60255

8. Degree of Protection � IS:2147 � BS- � IEC :60529

9. Code of practice for installation and maintenance of switchgear

� IS: � BS: � IEC :

10. Climate proofing of electrical equipment � IS: � BS- � IEC:

11. Electrical motor operated actuators � IS:9334 � BS- � IEC:

12. Flame proof enclosure � IS:2148 � BS- � IEC:

Note :

Equipment, accessories, component parts, raw materials and tests shall in general conform to :

� IS � BS � IEC

SPECIFICATION NO.



VOLUME IIIA

DATA SH A 25 TCE-M4-219-01 CONTROL CABINET SHEET 1 OF 1

REV. NO. PPD. BY: JOB NO. CLIENT:APPDCL DATE CKD. BY: 5103A REV. BY DATE: PROJECT: 2x800 MW THERMAL POWER

PLANT

TCE FORM 330 R1

ISSU

E N

O R

7

1.0 GENERAL PATICULARS

1.1 DESIGNATION LOCAL CONTROL PANELS/DC MOTOR STARTERS

1.2 LOCATION INDOOR / OUTDOOR

1.3 DESIGN AMBIENT TEMPERATURE 0 C 50

1.4 TYPE OF MOUNTING FLOOR/COLUMN/WALL MOUNTED

1.5 CABLE ENTRY

A) TOP / BOTTOM AS REQUIRED

B) GLANDS / CONDUITS -SIZE GLANDS(BY VENDOR) – DOUBLE COMPRESSION BRASS

C) GLANDS IF REQUIRED YES

1.6 EARTHING CONDUCTOR – BY VENDOR

A) MATERIAL GS

B) TYPE STRIPS

C) SIZE BY BIDDER

1.7 PAINTING:

A) COLOUR FINISH

OUTSIDE SHADE 631 OF IS-5

INSIDE GLOSSY WHITE

B) EPOXY PAINT REQUIRED Yes/No NO

1.8 CONTROL SCHEME & BILL OF MATERIAL, ENCLOSED

YES, Ref .No

TO BE FURNISHED BY BIDDER

If NO, TO BE FURNISHED BY VENDOR

2.0 VOLTAGE 400Vor 415V AC, 3-PHASE, 4-WIRE

2.1 POWER DEVICES, MOTOR DRIVES, ETC.

A) SUPPLY VOLTAGE 400Vor 415V, 3PH, 50Hz

B) DUPLICATE FEED REF. SEC-C

2.2 CONTROL VOLTAGE V, AC/DC 110V AC

2.3 CONTROL TRANSFORMER REQD/ NOT REQD.

REQUIRED FOR DERIVING 110V AC

2.4 SPACE HEATER/LIGHTING SUPPLY VOLTAGE

230V AC , 1-Ph, 50 Hz (TO BE DERIVED BY VENDOR FROM 415V ,3PH,4 WIRE SUPPLY BY SUITABLY RATED TRANSFORMER)

3.0 OTHER PARTICULARS WHEN APPLICABLE

3.1 STARTERS TYPE DOL/REVY

DOL

3.2 CONTACTOR RATED DUTY (AS PER IS:2459 & 8544)

AC3-NON REVERSIBLE DRIVES, AC4-FOR REVERSIBLE DRIVES

SPECIFICATION NO.


VOLUME IIIA

DATA SH A 25 TCE-M4-219-01 CONTROL CABINET SHEET 1 OF 1

REV. NO. PPD. BY: JOB NO. CLIENT:APPDCL DATE CKD. BY: 5103A REV. BY DATE: PROJECT: 2x800 MW THERMAL POWER

PLANT

TCE FORM 330 R1

ISSU

E N

O R

7

1.0 APPLICABLE STANDARDS

1.1 SWITCHGEAR GENERAL REQUIREMENTS

♦ IS-4237 � BSEN-60947 � IEC-

1.2 FACTORY BUILT ASSEMBLIES OF SWITCHGEAR AND CONTROL GEAR FOR VOLTAGES UPTO AND INCLUDING 1000V. A.C. & 1200 V. D.C.

♦ IS-8623 � BS-5486 � IEC-60439-1

1.3 AIR BREAK SWITCHES � IS-13947 � BSEN 60947-3 � IEC-60405

1.4 MINIATURE CIRCUIT BREAKERS � IS-8828 � BS-3871 � IEC- (PI)

1.5 H.R.C. CARTRIDGE FUSES � IS-13703 � BS-88 � IEC-60269-1 & IEC 60269-2 & IEC-60269-4

1.6 D TYPE FUSES � IS-8187 � BS- � IEC

1.7 CONTACTORS � IS-13947 � BS-775 �IEC-947-4-1

1.8 STARTERS � IS-13947 � BSEN-60947 � IEC-947-4-2

1.9 CONTROL SWITCHES/PUSH BUTTONS � IS-13947 � BS- � IEC-

1.10 CURRENT TRANSFORMERS � IS-2705 � BS-60044-1 � IEC-60185

1.11 POTENTIAL (VOLTAGE) TRANSFORMERS

� IS-3156 � BS-7625 � IEC-60186

1.12 RELAYS � IS-3231 � BS-142 � IEC-60255

1.13 INDICATING INSTRUMENTS � IS-1248 � BS-89 � IEC-60051

1.14 ARRANGEMENT FOR BUS BARS, MAIN CONNECTIONS AND ACCESSORIES

� IS-5578 & IS11353 � BS-159 � IEC-

1.15 A.C. ELECTRICITY METERS � IS-722 � BS-5685 � IEC-

1.16 DEGREE OF PROTECTION � IS-13947 � BS- � IEC-60947-1

1.17 THE PERFORMANCE OF A.C. CONTROL GEAR EQUIPMENT RATED UP TO 660V FOR USE ON HIGH PROSPECTIVE FAULT CURRENT SYSTEM

� IS- � BS- � IEC-

1.18 CODE OF PRACTICE FOR INSTALLATION AND MAINTENANCE SWITCHGEAR

� IS-10118 � BS- � IEC-

1.19 CLIMATE PROOFING OF ELECTRICAL EQUIPMENT

� IS-3202 � BS- � IEC-

1.20 CODE OF PRACTICE FOR PHOSPHATING IRON & STEEL

� IS-6005 � BS-3189 � IEC-

1.21 WROUGHT ALUMINIUM & ALUMINIUM ALLOYS FOR ELECTRICAL PURPOSES

� IS-5082 � BS-2898 � IEC-114

2.0 NOTES

2.1 EQUIPMENT, ACCESSORIES, COMPONENT PARTS, RAW MATERIALS AND TESTS SHALL IN GENERAL CONFORM TO

� IS- � BS- � IEC-

SPECIFICATION NO.



VOLUME IIIA

DATA SH A 26 TCE-M4-219-11 LOW VOLTAGE SWITCHGEAR SHEET 1 OF 6

REV. NO. PPD. BY : JOB NO. CLIENT : APPDCL DATE CKD. BY : TCE. REV. BY DATE: 5103A PROJECT : 2x800 MW THERMAL POWER

PLANT

TCE FORM 330 R1

ISSU

E N

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6

1.0 SWITCHGEAR & BUSBAR RATING

1.1 RATED VOLTAGE, PHASES & FREQUENCY

400V OR 415V, 3 ph, 50 Hz.

1.2

SYSTEM NEUTRAL EARTHING : (EFFECTIVELY/NON EFFECTIVELY)

Effectively

1.3 MAXIMUM SYSTEM VOLTAGE

440 V

1.4 ONE MINUTE POWER FREQUENCY VOLTAGE

A) POWER CIRCUITS B) CONTROL CIRCUITS C) AUX. CIRCUITS CONNECTED TO SEC. OF CTS

VOLTS VOLTS VOLTS

2500 1500 2000

1.5 CONTINUOUS CURRENT RATING OF BUSBARS UNDER SITE REFERENCE AMBIENT TEMPERATURE

REFERE ITEM-2 BELOW AND DATA SHEET-A3

1.6 REFERENCE AMBIENT TEMPERATURE

°C 50

1.7 MAXIMUM TEMPERATURE OF BUSBARS, DROPPERS AND CONTACTS AT CONTINUOUS CURRENT RATING UNDER SITE REFERENCE AMBIENT TEMPERATURE

°C 85

1.8 SHORT CIRCUIT WITHSTAND FOR BUSBARS AND DROPPERS A) SHORT TIME (1 SEC.) AT 415V B) DYNAMIC RATING

KA(RMS) KA (PEAK)

50 105

1.9 STANDARD APPLICABLE AS PER DATA SHEET-A2

2.0 SWITCHGEAR PARTICULARS: DESIGNATION BUSBAR DETAILS SINGLE/

DOUBLE/ FULLY /SEMI DRAWOUT/

CABLE ENTRY TOP (T) BOTTOM (B)

AMP CU/ AL

TP/ TPN

(SF/DF) FIXED (FD/SD/F)

POWER CONTROL

1.Refer sec-C2 2. 3. 4. 5. 6.

NOTE: FEEDER DESIGNATION, RATINGS & MODULE TYPES REFER DATA SHEET A3 & ENCLOSED DRAWINGS.

SPECIFICATION NO.



VOLUME IIIA



PLANT

TCE FORM 330 R1

ISSU

E N

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6

3.0 SWITCH GEAR CONSTRUCTIONAL

REQUIREMENTS

3.1 THICKNESS OF SHEET STEEL COLD ROLLED HOT ROLLED

MM MM

AS PER SECTION D 2.0 FRAME, 1.6 DOORS, 1.6 COVERS 2.5 FRAME, 2.0 DOORS, 2.0 COVERS

3.2 DEGREE OF PROTECTION AS PER IS:13947

IP-52 FOR SWGR. RATING UPTO 1600A. IP-42 FOR SWGR. RATED ABOVE 1600 A

3.3 COLOUR FINISH SHADE AS PER IS:5 INTERIOR EXTERIOR

GLOSSY WHITE LIGHT SEMI GLOSSY SHADE : 631

3.4 EARTHING BUS MATERIAL SIZE

MM

GS BY BIDDER

3.5 PURCHASER'S EARTHING CONDUCTOR

MATL. SIZE

BY BIDDER

3.6 CLEARANCES IN AIR OF LIVE PARTS

PHASE TO PHASE : 25.4 MM PHASE TO EARTH : 19.4 MM

3.7 METAL ENCLOSED BUSDUCT/BUS TRUNKING ENTRY TO CUBICLES IF REQUIRED

A) TOP B) INDOOR/OUTDOOR

4.0 STARTERS

4.1 TYPE DOL/REV/Y-∆ / ANY OTHER

4.2 CONTACTOR RATED DUTY AS PER IS:13947

AC3

4.3 UTILISATION CATEGORY AS PER IS:13947

4.4 CONTROL SCHEME & BILL OF MATERIAL ENCLOSED

YES/NO IF YES, REF.NO. SEE ENCLOSED DWG LIST IN SECTION-C

4.5 CONTROL TRANSFORMER : A) SEPARATE FOR EACH MODULE B) COMMON FOR EACH SWITCHGEAR SECTION WITH 100% STANDBY

YES/NO YES/NO

YES NO

4.6 SINGLE PHASING PREVENTOR REQUIRED

YES/NO YES AS A PART OF BIMETAL RELAY

4.7 STANDARD APPLICABLE AS PER DATA SHEET-A2 4.8 THERMAL OVER LOAD RELAY RESET AUTO

SPECIFICATION NO.



VOLUME IIIA



PLANT

TCE FORM 330 R1

ISSU

E N

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6

5.0

BREAKERS

5.1 CIRCUIT BREAKER TYPE

5.2 VOLTAGE, FREQUENCY & NO. OF PHASES

400V or 415V, 50 HZ, 3PH, 3 WIRE

5.3 RATED BREAKING DUTY B-3 MIN-MB3 MIN-MB 5.4 RATED BREAKING CAPACITY

A) MVA B) KA(RMS) AT 415V 0-25 P.F.

36 50

5.5 SHORT CIRCUIT WITH STAND CURRENT FOR 1 SEC. DURATION

KA 50

5.6 RATED MAKING CURRENT KA (PEAK)

100

5.7 RATED CURRENT AT SITE REFERENCE AMBIENT TEMPERATURE

A SEE DATA SHEET-A3

5.8 TYPE OF OPERATING MECHANISM

MOTOR WOUND SPRING CHARGED

5.9 KEY INTERLOCKING REQUIRED YES/NO

NO

5.10 SHUNT TRIP REQUIRED YES/NO

YES

5..11 PROTECTION REQUIRED : A) RELAYS/SERIES RELEASES B) RELAY TYPE & SETTINGS C) UNDER VOLTAGE RELEASE REQUIRED

YES/NO SETTING

NO NO NO

5.12 MINIMUM NO. OF AUXILIARY CONTACTS

6 NO+6 NC

5.13 CONTROL VOLTAGE A) FOR SPRING CHARGING MOTOR B) FOR CLOSING/TRIPPING

V, AC/DC

230 V AC 220V DC

5.14 EMERGENCY MANUAL OPERATION REQUIRED IN ADDITION TO ELECTRICAL OPERATING DEVICES: A) FOR SPRING CHARGING & CLOSING B) FOR TRIPPING

YES/NO YES./NO

YES YES

5.15 ANNUNCIATOR REQUIRED YES/NO

NO

5.16 STANDARDS APPLICABLE

AS PER DATA SHEET-A2

SPECIFICATION NO.



VOLUME IIIA



PLANT

TCE FORM 330 R1

ISSU

E N

O. R

6

6.0 MCCBS

6.1 MOULDED CASE CIRCUIT BREAKERS TO BE PROVIDED A) FOR MOTOR CONTROL CIRCUITS B) FOR OTHER CIRCUITS

YES/NO YES/NO

YES YES

6.2 VOLTAGE, FREQUENCY & NO. OF PHASES

400V or 415V, 50 HZ, 3PH, 3 WIRE

6.3 RATED OPERATING DUTY

6.4 RATED BREAKING CAPACITY (AT 415V 0.25 P.F.)

KA (RMS)

50KA

6.5 RATED MAKING CURRENT KA (PEAK)

100KA

6.6 RATED CURRENT AT SITE REFERENCE AMBIENT TEMPERATURE

TO SUIT MOTOR CONTROL CIRCUITS SEE DATA SHEET – A3

6.7 ON/OFF OPERATION : MANUAL REMOTE POWER OPERATED

YES/NO YES/NO

MANUAL

6.8 RELEASES REQUIRED : OVERLOAD INVERSE TIME UNDER VOLTAGE

YES/NO YES/NO

YES YES

6.9 STANDARD APPLICABLE AS PER DATA SHEET – A2 7.0 ESSENTIAL SPARES

DESCRIPTION ESSENTIAL SPARES TO BE FURNISHED

A) COMPLETE BREAKER WITH OPERATING MECHANISM AND RELEASES WHERE SPECIFIED

1 NO. OF EACH RATING

B) COMPLETE POLE OF BREAKER

SPECIFICATION NO.



VOLUME IIIA



PLANT

TCE FORM 330 R1

ISSU

E N

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6

2 NOS OF EACH RATING

C) CLOSING & TRIPPING COILS 2 SETS OF EACH RATING

D) SPRING, CHARGING MOTORS,

ALONG WITH CLOSING & TRIPPING SPRINGS IN CASE OF SPRING OPERATED BREAKERS

2 NOS

E) FIXED MOVING CONTACT ASSEMBLIES OF EACH BREAKER

2 SETS OF EACH RATING

F) BREAKER CONTROL SWITCHES, AUX. SWITCH ASSEMBLY, LIMIT SWITCHES, LOCAL / REMOTE SELECTOR SWITCH, OTHER SWITCHES

5 NOS. EACH

G) BUS BAR SUPPORT INSULATORS

10 NOS.

H) PROTECTIVE RELAYS i)51 ii)51N

1 NO 1 NO.

I) CLUSTERED LED INDICATING LAMPS 10 NOS. OF EACH COLOUR

J) CURRENT TRANSFORMERS i) ii) iii) iv) v) vi) vii)

2 NOS. OF EACH RATIO & TYPE

K) VOLTAGE TRANSFORMERS i) ii) iii) iv) v)

2 NOS. OF EACH RATIO & TYPE

M) INSTRUMENTS : i) AMMETER FOR 1A OPERATION ii) VOLTMETER FOR 110V OPERATION iii) KW METER

1 NO. OF EACH TYPE EACH RATING 1 NO. 1 NO.

SPECIFICATION NO.



VOLUME IIIA



PLANT

TCE FORM 330 R1

ISSU

E N

O. R

6

N) CONTACTORS, RATING :

POWER & AUXILIARY i) CONTACTOR ii) iii) iv)

5 NOS. OF EACH RATING

O) BI-METALLIC THERMAL ELEMENTS TO SUIT MOTORS OF FOLLOWING RATINGS :

1 NO. OF EACH RATING

P) POWER FUSES TO SUIT CIRCUITS OF FOLLOWING RATINGS :

10 NOS. OF EACH RATING

Q) CONTROL CIRCUIT FUSES 10 NOS. OF EACH RATING R) TRANDUCERS OF EACH TYPE & RATING 2 NOS.

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED

Volume IIIA

TCE-M4-219-11 LOW VOLTAGE SWITCHGEAR

DATA SH A 26 SHEET 1OF 2

TCE FORM 329 R3

ISSUE R6

TITLE

APPLICABLE STANDARDS: 1.

SWITCHGEAR GENERAL

� IS : 13947 � BSEN: 60947 � IEC

2.

AC CIRCUIT BREAKERS

� IS:13118 � BSEN 60947-2 � IEC 947-2 � BS:3871(PI) MCCB

3.

FACTORY BUILT ASSEMBLIES OF SWITCHGEAR AND CONTROL GEAR FOR VOLTAGES UPTO AND INCLUDING 1000V A.C. & 1200 V D.C

� IS:8623 � BS:5486 � IEC:439

4.

AIR BREAK SWITCHES

� IS:13947 � BSEN:60947-3 � IEC-947-3

5.

MINIATURE CIRCUIT BREAKERS

� IS:8828 � BS:3871 � IEC:

6.

HRC CARTRIDGE FUSES

� IS:13703(P2) � BS:88 � IEC-769

7.

D TYPE FUSES

� IS:8187 � BS: � IEC:

8.

CONTACTORS

� IS:13947 � BSEN-60947-1 � IEC:9474-1

9.

STARTERS

� IS:13947 � BSEN-60947-4-1 � IEC:947-4-1

10.

CONTROL SWITCHES/PUSH BUTTONS

� IS:13947 � BS: � IEC:

11.

CURRENT TRANSFORMERS

� IS:2705 � BS:7626 � IEC:185

12.

VOLTAGE TRANSFORMERS

� IS:3156 � BS:7625 � IEC:186

13.

RELAYS

� IS:3231 � BS:142 � IEC:255

14

INDICATING INSTRUMENTS

� IS:1248 � BS:89 � IEC:51

15.

ARRANGEMENT FOR BUSBARS MAIN CONNECTIONS AND ACCESSORIES

� IS:5578 � BS:159 � IEC: � IS:11353

16.

AC ELECTRICITY METERS

� IS:8530 � BS:37 � IEC:

17.

DEGREE OF PROTECTION

� IS:13947(PI) � BS: � IEC:947-1

18.

THE PERFORMANCE OF AC CONTROL GEAR EQUIPMENT RATED UPTO 600 V FOR USE ON HIGH PROSPECTIVE FAULT CURRENT SYSTEM

� IS: � BS: � IEC:

19.

CODE OF PRACTICE FOR INSTALLATION AND MAINTENANCE OF SWITCHGEAR

� IS:10118 � BS: � IEC:

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED

Volume IIIA

TCE-M4-219-11 LOW VOLTAGE SWITCHGEAR

DATA SH A 26 SHEET 2OF 2

TCE FORM 329 R3

ISSUE R6

TITLE

20. CLIMATE PROOFING OF ELECTRICAL EQUIPMENT

� IS: � BS: � IEC:

21.

CODE OF PRACTICE FOR PHOSPHATING IRON AND STEEL

� IS: 6005 � BS: 3169 � IEC:

22. WROUGHT ALUMINIUM AND ALUMINIUM ALLOYS FOR ELECTRICAL PURPOSES

� IS:5082 � BS:2898 � IEC:

23. CONTROL TRANSFORMER FOR SWITCHGEAR AND CONTROL GEAR FOR VOLTAGE NOT EXCEEDING 110V AC

� IS:12021 � BS: � IEC:

NOTE : EQUIPMENT, ACCESSORIES, COMPONENT PARTS, RAW MATERIALS AND TESTS SHALL IN GENERAL CONFORM TO :

SPECIFICATION NO.



VOLUME IIIA

DATA SH A 27 TCE-M4-203-71 VARIABLE SPEED DC/AC DRIVES SHEET 1 OF 2

REV. NO. PPD. BY: JOB NO. CLIENT:APPDCL DATE CKD. BY: TCE. REV. BY DATE: 5103A PROJECT: 2x 800 MW THERMAL

POWER PLANT

TCE FORM 330 R1

ISSU

E N

O. R

1

(General Requirements) 1.0 Type of Drive Inverter controlled AC drives. 1.1 Rating of the drive 1.2 Type of duty (cl. 3.5) Class I 1.3 Quadrants of operation I 2.0 Quantity 3.0 Power supply 11 kV, 3ph, 50 Hz 4.0 Variation voltage + 10 % 5.0 Variation in Frequency 50 Hz + 5% 6.0 Combined voltage and

frequency variation + 10%

7.0 Environmental Conditions 8.0 Location Indoor a) Whether in air conditioned room Yes. However Bidder to indicate their

recommendation b) If NO, Average ambient temperature 0 C Design ambient temperature 0 C Relative humidity % Vibration 9.0 Type of cooling for drive panel Natural cooling

If water cooled, is DM water

required

If yes, quantity of DM water ------ litres/minute 10.0 Cable a) Size and type later b) Entry Bottom

SPECIFICATION NO.



VOLUME IIIA

DATA SH A 27 TCE-M4-203-71 VARIABLE SPEED DC/AC DRIVES SHEET 2 OF 2

REV. NO. PPD. BY: JOB NO. CLIENT:APPDCL DATE CKD. BY: TCE. REV. BY DATE: 5103A PROJECT: 2x 800 MW THERMAL

POWER PLANT

TCE FORM 330 R1

ISSU

E N

O. R

1

11.0 Dimensions By Bidder 12.0 Types of Protection 12.1 Instantaneous over current required 12.2 Motor overload protection required 12.3 Over voltage / under voltage Ride through with adjustable under voltage

and time setting 12.4 Momentary power loss required 12.5 Stall prevention required 13.0 Control characteristics for

both AC/DC

a) Control Method Automatic with feedback b) Freq. control range To suit fan requirement c) Accelerate/decelerate time To suit fan requirement 14.0 Harmonics Limitations a) Load side for AC drives Maximum within 5% b) Source side(with DC/AC drives) 5th ……. 7th THD <= 5% Current harmonics 11th …….. 13th THD <= 5% 15.0 Controls on Drive Panel a) Start / Stop Required b) Speed Raiser / Lower Required c) Auto / Manual Required d) Local / Remote Required e) DOL by-pass Required f) Emergency Stop Required g) Any other As recommended by Bidder

SPECIFICATION NO.



VOLUME IIIA

DATA SH A 27

TCE-M4-203-71 VARIABLE SPEED DC/AC DRIVES SHEET 1 OF 3

REV. NO. PPD. BY: JOB NO. CLIENT APPDCL DATE CKD. BY: TCE. REV. BY DATE: 5103A PROJECT 2x800 MW THERMAL POWER

PLANT H

TCE FORM 330 R1

ISSU

E N

O. R

1

Inverter Controlled A.C. Drives 1.0 Application fans 2.0 Quantity 2 3.0 a) Starting/rated torque

By Bidder

b) Type of converters PWM

c) Inverter capacity at specified pf By Bidder d) Rated Current By Bidder e) Load power factor By Bidder f) Max. continuous current By Bidder g) Rated voltage with number of

phases By Bidder

h) Rated frequency 50 Hz i) Converter Bridge 6/12 pulse-By Bidder to limit THD to <=

5% j) Single Quadrant/Two quadrant/

Four Quadrant Single

4.0 Control Characteristics i) Speed Control a) Rated speed By Bidder b) Speed ratio By Bidder c) Constant torque/constant power By Bidder d) Speed accuracy 0.5% e) Closed loop/open loop Closed loop

SPECIFICATION NO.



VOLUME IIIA

DATA SH A 27



PLANT H

TCE FORM 330 R1

ISSU

E N

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1

f) If tacho-generator used (for

closed loop) Yes

g) Accel./Deccel. time By Bidder h) Type of tacho-generator Digital - If analogue, then reference signal mA/mV j) Is remote operation required Yes - If yes, is it through DCS k) Type of control Digital ii) Braking a) Type of braking By Bidder b) Braking Torque By Bidder 5.0 Miscellaneous Soft-start Yes Flying restart Yes Auto restart Yes Kinetic Buffering Yes 6.0 Indication on Drive Panel

(minimum) Required

a) Motor running b) Motor stopped / trip c) AC mains ‘ON’ d) System Ready to start e) VSD system fault 7.0 Metering Required

SPECIFICATION NO.



VOLUME IIIA

DATA SH A 27



PLANT H

TCE FORM 330 R1

ISSU

E N

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1

Digital Display of the following

Minimum parameters on the Drive Panels:-

a) Input AC Voltage b) Input AC Frequency c) Input AC Current d) Output Voltage e) Output Current VSD/Bypass f) Output Frequency g) Motor speed Necessary transducers shall be

Provided with 4-20mA output for indicating motor speed & current in DCS.

SPECIFICATION NO.



VOLUME III A

DATA SH A27 TCE-M4-203-71 VARIABLE SPEED DC/AC DRIVES SHEET 1 OF 3


PLANT H

TCE FORM 330 R1

ISSU

E N

O. R

1

Specification for metal clad base

materials for printed circuits for use in electronic and telecommunication equipment

√IS:5921

Specification of Transformers and

Inductors (Power, Audio, Pulse and Switching) for Electronic Equipment

√IS:6297

Semiconductor rectifier equipment safety code for

√IS 6619

Specification for printed wiring Board

√IS:7405

Recommended practice for emerg-

ency and standby power systems for industrial and commercial applic.

IS : IEC : √ IEEE :446

Semiconductor devices √IS: 3700 IEC:146 Essential rating & characteristics Basic climate for mechanical

durability tests for electronic components

√IS:9000

Specification for metal-clad base

materials for printed circuits for use in electronic and communication equipment

√IS:5921

Specification for transformers and

inductors (Power audio pulse and switching) for electronic equipment

√IS:6297

Specification for printed wiring board √IS: 7405 Degree of protection provided by

enclosures for low voltage switchgears and control gears

√IS:2147

SPECIFICATION NO.



VOLUME III A



PLANT H

TCE FORM 330 R1

ISSU

E N

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1

Environmental requirements of

semiconductor devices and integrated circuits

√IS:6553

Ambient temp. of electronic

equipment √IS:9676

Environmental tests for electronic

equipment √IS:9000

Terminal for electronic equipment √IS:4007 Equipment accessories, component parts, raw materials and test shall in general conform to

√IS IEC Factory built assemblies of low

Voltage √IS: 4237 BS: IEC:439

Semiconductor rectifier assemblies

And thyristor converters √IS:3695 BS:4417 IEC:148 √IS:4560

Busbars and Busbar connections √IS:5082 BS:159 IEC: Code of practice for earthing √IS:3043 BS:CP:1013 IEC: Control cabinet √IS:4237 BS: IEC: Current transformers √IS:2705 BS:3938 IEC:185 Potential transformers √IS:3156 BS:3941 IEC:185 Power transformers √IS:2024 BS:171 IEC:75 Indicating meters √IS:1248 BS:89 IEC:51 Wiring rectifiers √IS:2274 BS: IEC: Pulse transformer √IS:6297 BS: IEC: Semiconductor Converters √IEC:146

SPECIFICATION NO.



VOLUME III A



PLANT H

TCE FORM 330 R1

ISSU

E N

O. R

1

Basic climate and Mechanical

Durability Tests for Electronic Components

√IS:589

Environmental tests for electronic

and electrical equipment √IS:9000 Parts 1 to 18

Low-voltage

switchgear & control gear – General Rules

√IS:13947

SPECIFICATION NO.



VOLUME IIIA

SPECIFIC TECH REQUIREMENT OF SG & AUX DATA SHEET – B1

TCE-5103A-C-500-01 EQUIPMENT PERFORMANCE DATA SHEET 1 OF 11

ENQUIRY /SPECIFICATION NO. SR.NO. ITEM BIDDER →

NOTE TO BIDDER 1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE MARKED SIGNATURE WITHIN ASTERISK(*) (DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS) OF BIDDER 2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

DATE

1.1.0 GENERAL 1.1.1 Manufacturer 1.1.2 No. of units 1.1.3 Type of units 1.1.4 Fuels 1.1.4.1 Fuel for initial warm up 1.1.4.2 Fuel for start up/flame stabilisation 1.1.4.3 Fuel for performance guarantee 1.1.4.4 Fuel for load carrying 1.1.4.5 Fuel for ignitors 1.2.0 UNIT CAPABILITY DATA 1.2.1 SG MCR 1.2.1.1 Superheater flow kg/s 1.2.1.2 Steam conditions at super heater header outlet a) Pressure bar(a) b) Temperature deg.C 1.2.1.3 Reheater flow kg/s 1.2.1.4 Steam conditions at reheater inlet a) Pressure bar (a) b) Temperature deg.C 1.2.1.5 Steam conditions at reheater outlet a) Pressure bar (a)

SPECIFICATION NO.



VOLUME IIIA





DATE

b) Temperature deg.C 1.2.1.6 Maximum allowable working pressure for - Superheater bar(a) - Reheater bar(a) 1.2.1.7 Feed water inlet temperature deg.C 1.2.1.8 Fuel consumption kg/s 1.2.1.9 Efficiency based on fuel GCV % 1.2.1.10 Excess air at furnace exit % 1.2.1.11 Excess air at outlet of air heater % 1.2.1.12 a) Flue gas temperature at APH outlet deg.C - Considering leakage in APH - Without considering leakage in APH b) Flue gas temperature at ID fan outlet deg.C 1.2.1.13 SG Water Volume - Furnace including economiser m3 - superheater m3 - reheater m3

1.3.0 ANTICIPATED PERFORMANCE FOR 40% 60% 80% 100% 100% SLIDING PRESSURE OPERATION SGMCR TGMCR TGMCR TGMCR SGMCR 1.3.1 Steam flow : 1.3.1.1 Steam quantity leaving final superheater outlet kg/s 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR

SPECIFICATION NO.



VOLUME IIIA





DATE

1.3.1.2 Steam quantity leaving final reheater outlet kg/s 1.3.2 Steam generator efficiency based on the GCV of the fuel % 1.3.3 GCV of fuel as fired Kcal/kg. 1.3.4 NCV of fuel as fired Kcal/Kg. 1.3.5 Fuel, air and gas flow : 1.3.5.1 Fuel firing rate kg/s 1.3.5.2 Combustion air requirement kg/s (without leakage) - Burner - Overfire air 1.3.5.3 Excess air % 1.3.5.4 Air handled by both FD fans kg/s 1.3.5.5 Air leakage in RAPH kg/s 1.3.5.6 Gas flow at economiser outlet kg/s 1.3.5.7 Gas flow at air heater outlet (including air leakage if any) kg/s 1.3.5.8 Feed water pressure at economiser inlet bar(a) 1.3.5.9 Fuel oil/gas pressure at burner inlet bar(a) 1.3.6 Temperatures: 1.3.6.1 Gas - 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR a) Leaving furnace deg.C

SPECIFICATION NO.



VOLUME IIIA





DATE

b) Entering high temperature superheater deg.C c) Leaving high temperature superheater deg.C d) Entering reheater deg.C e) Leaving reheater deg.C f) Entering low temperature superheater deg.C g) Leaving low temperature superheater deg.C h) Entering economiser deg.C i) Entering air heater deg.C j) Leaving air heater deg.C k) At stack entrance deg.C 1.3.6.2 Air - a) Entering steam coil air pre heater deg.C b) Leaving steam coil air pre heater deg.C c) Entering air heater deg.C d) Leaving air heater deg.C e) Entering burner windbox deg.C f) Entering coal mills deg.C 1.3.6.3 Feed Water - a) Entering economiser deg.C b) Leaving economiser deg.C 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR 1.3.6.4 Flue gas velocity at furnace exit m/s

SPECIFICATION NO.



VOLUME IIIA





DATE

1.3.7 Pressure drops : 1.3.7.1 Steam path: a) Superheater bar b) Superheater desuperheater bar c) Reheater bar d) Reheater desuperheater bar 1.3.7.2 Air pressure Lossess : a) Ducts mmwc b) Air preheater mmwc c) Across flow elements mmwc d) Burner registers mmwc e) Total loss through the system mmwc 1.3.7.3 Draft Losses a) Furnace suction mmwc b) Superheater mmwc c) Economiser mmwc d) Air preheater mmwc e) Flue gas duct upto stack mmwc 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR f) Electrostatic precipitator including transition pieces mmwc

SPECIFICATION NO.



VOLUME IIIA





DATE

g) Total loss through the system mmwc 1.3.8 Heat balance (based on GCV of fuel as fired): 1.3.8.1 Heat to steam and water % 1.3.8.2 Heat loss in dry flue gases % 1.3.8.3 Heat loss due to moisture % 1.3.8.4 Heat loss due to hydrogen in fuel % 1.3.8.5 Heat loss due to moisture in air % 1.3.8.6 Unburnt fuel loss % 1.3.8.7 Manufacturer’s margin % 1.3.8.8 Radiation and unaccounted losses (radiation losses with a temperature differential of 28 deg.C between steam generator surfaces and ambient air) % 1.3.8.9 Gross efficiency based on GCV of fuel % 1.3.8.10 Total heat loss % 1.3.9 Desuperheater 1.3.9.1 Superheater desuperheaters 1.3.9.1.1 Spray water pressure at inlet bar 1.3.9.1.2 Spray water quantity kg/s 1.3.9.1.3 Spray water system design capacity kg/s 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR 1.3.9.2 Reheater desuperheater (If the spray is for emergency condition, indicate the maximum spray water expected under abnormal condition)

SPECIFICATION NO.



VOLUME IIIA





DATE

1.3.9.2.1 Spray water pressure at inlet bar 1.3.9.2.2 Spray water Quantity kg/s 1.3.9.2.3 Spray water system design capacity kg/s 1.3.10 Induced draft Fans: 1.3.10.1 Volume of gas handled by each fan Nm3/sec 1.3.10.2 Temperature of gas at fan inlet deg.C 1.3.10.3 Total draft loss mmwc 1.3.10.4 Speed of Fan rpm 1.3.10.5 Fan efficiency % 1.3.10.6 Variable speed hydraulic coupling efficiency (if applicable) % 1.3.10.7 Driving motor efficiency % 1.3.10.8 Electrical power input to each motor kW 1.3.11 Forced Draft Fans: 1.3.11.1 Volume of air handled by each fan Nm3/sec 1.3.11.2 Temperature of air at fan inlet deg.C 1.3.11.3 Total air pressure loss mmwc 1.3.11.4 Speed of fan rpm 1.3.11.5 Fan efficiency % 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR 1.3.11.6 Driving motor efficiency % 1.3.11.7 Electrical power input to each motor kW

SPECIFICATION NO.



VOLUME IIIA





DATE

1.3.12 Primary Air Fans: 1.3.12.1 Volume of air handled by each fan Nm3/sec 1.3.12.2 Temperature of air at fan inlet deg.C 1.3.12.3 Total air pressure loss mmwc 1.3.12.4 Speed of fan rpm 1.3.12.5 Fan efficiency % 1.3.12.6 Driving motor efficiency % 1.3.12.7 Electrical power input to each motor kW 1.3.13 Gas Recirculation Fans: 1.3.13.1 Volume of gas handled by each fan Nm3/sec. 1.3.13.2 Temperature of gas at fan inlet deg.C 1.3.13.3 Total gas pressure loss mmwc 1.3.13.4 Speed of fan rpm 1.3.13.5 Fan efficiency % 1.3.13.6 Driving motor efficiency % 1.3.13.7 Electrical power input to each motor kW 1.3.14 Coal Mills: 1.3.14.1 No. of mills in operation with design coal No. 40% 60% 80% 100% 100% SGMCR TGMCR TGMCR TGMCR SGMCR 1.3.14.2 Load on each mill kg/s 1.3.14.3 Output size % thru 200 mesh 1.3.14.4 Driving motor efficiency %

SPECIFICATION NO.



VOLUME IIIA





DATE

1.3.14.5 Electrical power input to each motor kW 1.13.14.6Minimum stable load of SGMCR when required no. of coal mills are in operation with design coal without oil support 1.13.14.7Minimum stable load of SGMCR when required no. of coal mills are in operation with worst coal without oil support 1.4.0 MILL PERFORMANCE DATA Load on each mill Load on SG (% mill MCR) (%SGMCR) 1.4.1 Three coal mills in operation - Minimum stable load on each coal mill below which stopping of one mill is to be initiated % 1.4.2 Two coal mills in operation - Minimum load on each mill at which oil stabilisation is necessary before taking out a mill % 14.3 One coal mill in operation - Minimum load on the mill with stabilising oil burners 1.5.0 Mode of operation SH outlet pressure SH outlet temp. deviation deviation 1.5.1 Steady state 1.5.2 Load change between 40% TGMCR to 100% TGMCR 1.5.2.1 Between 50% TGMCR to

SPECIFICATION NO.



VOLUME IIIA





DATE

60% TGMCR at 3% per minute of sliding pressure operation a) For sliding pressure operation 1.5.2.2 Between 60% TGMCR to 90% TGMCR at 5% per minute for sliding pressure operation 1.5.2.3 Between 90% TGMCR to 100% TGMCR at 3% per minute for constant pressure operation 1.5.3 Step load change between 100% SG MCR and 60% TG MCR in case of run back due to loss of one FD/ID/PA fan or BFP or any other emergency 1.6.0 Time required to shut down the unit from full load condition 1.7.0 Restart capability of the unit immediately

after full load rejection 1.8.0 Maximum permissible rate of temperature change oC Start up Load change Shut down 1.8.2 Superheater 1.8.3 Reheater 1.9.0 COLD AND HOT START PROGRAMMES 1.9.1 Recommended periods to bring steam generator on load with HP-LP bypass (60% bypass) 1.9.1.1 After cold start hrs 1.9.1.2 After thirty six hours shut down hrs 1.9.1.3 After twenty four hours shut down hrs 1.9.1.4 After twelve hours shut down hrs

SPECIFICATION NO.



VOLUME IIIA





DATE

1.9.1.5 After eight hours shut down hrs 1.9.1.6 After four hours shut down hrs 1.9.1.7 Hot restart after trip out (less than 1 hr hrs shut down) 1.10 Auxiliary steam consumption 1.10.1 Steam conditions (a) Pressure kg/cm2 (a) (b) Temperature 0C 1.10.2 Fuel oil heating units kg/s 1.10.3 Fuel oil atomizing kg/s

SPECIFICATION NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED


VOLUME IIIA


TCE-5103A-C-500-01 HEAT RELEASE AND OTHER DATA SHEET 1 OF 3

ENQUIRY /SPECIFICATION NO.

SR.NO. ITEM BIDDER →


DATE



VOLUME IIIA






DATE

1.1 Maxim furnace exit gas temperature at furnace outlet deg. C 1.2 Clearance between pendant platen surface and furnace arch (nose) - B m 1.3 Clearance between centre line of top

coal burners (nozzles) and work point of furnace arch (nose) - C 1.4 Clearance between centre line of bottom coal burners (nozzles) and work point of hopper - D m

a) For front and / or rear wall firing m

b) For tangential firing m

1.5 Angle ( alpha ) deg 1.6 a) Height - H m b) Width - W m c) Depth - G m d) Platen Height - H1 m 1.7 Volumetric heat release rate (Net heat kcal/m3/hr input at SG MCR / WxGxH) 1.8 Furnace plan area heat release rate x106

(Net heat input at SGMCR / furnace kcal / hr/m2 width x depth)

1.9 Burner zone heat release = Net heat input at SGMCR / burner zone surface x106

kcal /hr/m2 Burner zone surface = (2 x (furnace

width + furnace depth) x burner zone height Burner zone height = distance F + 3 m



VOLUME IIIA






DATE

1.10 Effective projected radiant surface release rate (Net heat input at SG MCR / kCal/m2 effective radiant surface) 1.11 Detail calculations for the net heat Input value, utilised in arriving at Various heat release rate mentioned above. 1.12 Maximum flue gas velocity through tube banks at design excess air at SG MCR m/s 1.13 Economiser tube banks arrangement BARE / FINNED;

INLINE / TAGGERED 1.14 Clearance centerline of burner to side wall 1.15 Maximum width of furnace hopper opening - E



VOLUME IIIA


TCE-5103A-C-500-01 STEAM GENERATOR PRESSURE PARTS SHEET 1 OF 5




DATE

1.1.0 GENERAL Economiser Evaporator SH RH 1.1.1 Design capacity kg/s 1.1.2 Design pressure bar(a) 1.1.1 Design temperature - Economiser - Furnace wall deg.C - Superheater - Reheater 1.1.1 Maximum safety valve set pressure for SH bar (a) 1.1.4 Maximum safety valve set pressure for RH bar (a) 1.2.0 FURNACE WALLS 1.2.1 Furnace 1.2.1.2 Outside diameter mm 1.2.1.3 Pitch mm 1.2.1.4 Thickness mm 1.2.1.6 Design standard 1.2.1.7 Material 1.2.1.8 Total projected surface area of tubes m2 1.2.2 Side Walls, Rear Walls & Roof Side Rear Roof Walls Walls 1.2.2.1 Number 1.2.2.2 Outside diameter mm 1.2.2.1 Pitch mm 1.2.2.4 Thickness mm 1.2.2.6 Design standard



VOLUME IIIA






DATE

1.2.2.7 Material 1.2.2.8 Total projected surface area of tubes m2 1.2.1 Water Wall Headers 1.2.1.1 Number of headers 1.2.1.2 Outside diameter mm 1.2.1.1 Thickness mm 1.2.1.4 Length of each header mm 1.2.4 Erosion/corrosion allowance for all water wall tubes 1.1.0 SUPERHEATER AND REHEATER TUBES AND HEADERS 1.1.1 Superheater Tubes Radiant Convective Section Section (FSH) (LTSH) 1.1.1.1 Material 1.1.1.2 Heating surface (effective) m2 1.1.1.1 Total circumferential heating surface m2 1.1.1.4 Gas flow path area m2 1.1.1.5 Maximum metal temperature deg.C 1.1.1.6 Outside diameter mm 1.1.1.7 Tube thickness mm 1.1.1.8 Effective length (per one tube) mm 1.1.1.9 Gross length (per one tube) mm 1.1.1.10 Number of elements/section



VOLUME IIIA






DATE

1.1.1.11 Tube pitch (Indicate for each type of superheater ) a) Parallel to gas flow mm (Longitudinal) b) Across gas flow mm (Transverse 1.1.1.12 Erosion/corrosion allowance mm 1.1.1.11 Type of flow Parallel / Cross 1.1.2 Superheater Headers 1.1.2.1 Max. operating pressure bar(a) 1.1.2.2 Design pressure bar(a) 1.1.2.1 Construction 1.1.2.4 Outside diameter mm 1.1.2.5 Thickness mm 1.1.2.6 Material 1.1.2.7 Number of steam passes 1.1.2.8 Erosion/corrosion allowance mm 1.1.1 Reheater Tubes 1. 1.1.1 Material 1.1.1..2 Heating surface (effective) m2 1.1.1.1 Total circumferential heating surface m2 1.1.1.4 Gas flow path area m2



VOLUME IIIA






DATE

1.1.1.5 Maximum operating pressure bar(a) 1.1.1.6 Maximum metal temperature deg.C 1.1.1.7 Design pressure bar(a) 1.1.1.8 Outside diameter mm 1.1.1.9 Tube thickness mm 1.1.1.10 Effective length (per one tube) mm 1.1.1.11 Gross length (per one tube) mm 1.1.1.12 Tube pitch (Indicate for each type

of reheater) a) Parallel to gas flow mm (Longitudinal) b) Across gas flow mm (Transverse) 1.1.1.11 Type of flow Parallel / Cross 1.1.4 Headers 1.1.4.1 Construction 1.1.4.2 Outside diameter mm 1.1.4.1 Thickness mm 1.1.4.4 Material 1.1.4.5 Number of steam passes 1.1.4.6 Erosion/corrosion allowance mm 1.4.0 ECONOMISER 1.4.1 Effective heating surface (water side) m2



VOLUME IIIA






DATE

1.4.2 Effective heating surface (gas side) m2 1.4.1 Gas flow path area m2 1.4.4 Gas velocity at SG MCR m/s 1.4.5 Tubes 1.4.5.1 Material 1.4.5.2 Outside diameter mm 1.4.5.1 Thickness mm 1.4.5.1 Length mm 1.4.5.4 Pitch a) Parallel to gas flow mm (Longitudinal) b) Across gas flow (transverse) mm 1.4.6 Headers 1.4.6.1 Material 1.4.6.2 Outside diameter mm 1.4.6.1 Thickness mm 1.4.6.4 Length mm



VOLUME IIIA


TCE-5103A-C-500-01 REGENERATION AIR PREHEATER SHEET 1 OF 3




DATE

1.1.0 GENERAL Primary Air Secondary Air 1.1.1 No. of air preheaters (APH) per steam generator 1.1.2 Type 1.1.3 Make 1.1.4 Speed rpm 1.2.0 HEATER ELEMENTS No. of Height of Material

baskets elements (mm)

1.2.1 Cold/middle/upper hot elements 1.2.1.1 Cold end elements 1.2.1.2 Middle elements 1.2.1.3 Upper hot elements 1.2.2 Casing thickness mm 1.2.3 Total effective heating surface m2 1.2.1 Pressure drop at SG MCR 1.2.1.1 Air side mmWc 1.2.1.2 Gas side mmWc 1.3.0 SEALING 1.3.1 Type of radial seals 1.3.1.1 Hot end 1.3.1.2 Cold end 1.3.2 Type of circumferential seal



VOLUME IIIA






DATE

1.3.3 Type of axial seal 1.3.4 Air leakage across seals (expressed as % of air flow at 100% SG MCR) 1.4.0 AIR AND GAS DATA 1.4.1 Gas velocity at 100% SG MCR m/s 1.4.2 Air velocity at 100% SG MCR m/s 1.4.3 Net free areas for air and gas flow m2 1.4.4 Air flow rate cu.m/s 1.4.5 Gas flow rate cu.m/s 1.5.0 AIR HEATER DRIVES 1.5.1 Electric motor drive 1.5.1.1 Motor speed rpm 1.5.1.2 Motor rating kW 1.5.2 Speed reducer 1.5.2.1 Type 1.5.2.2 Speed ratio 1.5.2.3 Shaft power kW 1.5.3 Emergency drive (Air motor drive) 1.5.3.1 Type 1.5.3.2 Shaft power kW 1.5.3.3 Speed rpm 1.5.3.4 Air requirements a) Pressure bar(a)



VOLUME IIIA






DATE

b) Flow rate m3/s 1.6.0 ROTOR AND BEARINGS 1.6.1 Rotor material 1.6.2 Bearings 1.6.2.1 Type 1.6.2.2 Type of lubrication



VOLUME IIIA


TCE-5103A-C-500-01 STEAM COIL AIR PREHEATER SHEET 1 OF 2




DATE

1.1.0 GENERAL 1.1.1 No. of steam coil air preheaters (SCAPH) per SG unit 1.1.2 Type 1.1.3 Manufacturer 1.2.0 DESIGN CONDITIONS (Each SCAPH) 1.2.1 Total air flow m3/h 1.2.2 Temperature of air entering heater deg.C 1.2.3 Temperature of air leaving heater deg. C 1.2.4 Air velocity m/s 1.2.5 Air pressure drop across heater mmWc 1.2.6 Corrosion allowance mm 1.2.7 Heating steam requirement: 1.2.7.1 Quantity kg/s 1.2.7.2 Inlet pressure bar(a) 1.2.7.3 Inlet temperature deg.C 1.2.8 Drain: 1.2.8.1 Drain temperature deg.C 1.2.8.2 Drain enthalpy Kcal/Kg 1.2.9 Total surface area m2 1.2.10 Heat transfer coefficient Kcal/hr m2deg.C 1.3.0 CONSTRUCTION FEATURES 1.3.1 No. of sections per heater



VOLUME IIIA


TCE-5103A-C-500-01 STEAM COIL AIR PREHEATER SHEET 2 OF 2




DATE

1.3.2 No. of tubes in each section 1.3.3 Materials of Construction 1.3.3.1 Tubes 1.3.3.2 Fins 1.3.3.3 Nozzles 1.3.3.4 Casing 1.3.3.5 Supporting plate 1.3.3.6 Gasket 1.3.4 Surface area of each section m2 1.3.1 Tube diameter mm 1.3.6 Tube thickness mm



VOLUME IIIA

SPECIFIC TECH REQUIREMENT OF SG & AUX DATA SHEET– B6

TCE-5103A-C-500-01 CENTRIFUGAL FANS SHEET 1 OF 2




DATE

1.0 GENERAL 1.1 No. of fans per steam generator 1.2 Type 1.3 Manufacturer 2.0 DESIGN PERFORMANCE 2.1 Capacity m3/s 2.2 Head mmWC 2.3 Design margins over BMCR- DC 2.3.1 Capacity % 2.3.2 Head % 2.4 Design temperature 0C 2.5 Flue gas density kg/m3 2.6 Draught loss at 100% SG MCR-DC mmWC 2.7 Fan speed rpm 2.8 Fan critical speeds 2.8.1 First critical speed rpm 2.8.2 Second critical speed rpm 2.9 Fan efficiency at MCR (DC) % 2.10 Motor efficiency at MCR(DC) % 2.11 Motor rating kW 3.0 CONSTRUCTION FEATURES 3.1 Casing 3.1.1 Material



VOLUME IIIA


TCE-5103A-C-500-01 CENTRIFUGAL FANS SHEET 2 OF 2




DATE

3.1.2 Thickness mm 3.2 Coupling 3.2.1 Type 3.2.2 Make 3.3 Impeller 3.3.1 Diameter mm 3.3.2 Material 3.4 Shaft 3.4.1 Diameter mm 3.4.2 Material 3.5 Bearings 3.5.1 No., make and type 3.5.2 Bearing liner material 3.5.3 Type of cooling 3.5.4 Bearing lubrication type 3.6 Shaft sealing arrangement



VOLUME IIIA


TCE-5103A-C-500-01 AXIAL FANS SHEET 1 OF 2




DATE

1.0 GENERAL 1.1 Number of fans per steam generator 1.2 Type 1.3 Manufacturer 2.0 DESIGN PERFORMANCE 2.1 Capacity m3/s 2.2 Total head mmWC 2.3 Design margin 2.3.1 Capacity – BMCR (DC) % 2.3.2 Head - BMCR (DC) % 2.4 Design temperature 0C 2.5 Air density Kg/m3 2.6 Draft loss at 100% SG MCR mmWC 2.7 Fan speed rpm 2.8 Fan critical speeds 2.8.1 First critical speed rpm 2.8.2 Second critical speed rpm 2.9 Fan efficiency at MCR % 2.10 Motor efficiency at MCR % 2.11 Motor rating kW 3.0 CONSTRUCTION FEATURES 3.1 Casing 3.1.1 Material



VOLUME IIIA


TCE-5103A-C-500-01 AXIAL FANS SHEET 2 OF 2




DATE

3.1.2 Thickness mm 3.2 Coupling 3.2.1 Type 3.2.2 Make 3.3 Impeller 3.3.1 Diameter mm 3.3.2 Blade material 3.3.3 Hub material 3.4 Shaft 3.4.1 Diameter mm 3.4.2 Material 3.5 Bearings 3.5.1 No., make and type 3.5.2 Bearing liner material 3.6 Shaft sealing arrangement 3.7 Hydraulic serve drive 3.7.1 No., make and type 3.8 Lube oil system 3.8.1 No. and type of pumps 3.8.2 No. and type of oil coolers



VOLUME IIIA


TCE-5103A-C-500-01 SOOT BLOWING SYSTEM SHEET 1 OF 3


SR.NO . ITEM BIDDER →


DATE

1.1.0 GENERAL 1.1.1 Source of steam 1.1.2 Steam pressure bar(a) 1.1.3 Steam temperature deg.C 1.2.0 SOOT-BLOWERS 1.2.1 Furnace, Radiant, Convective Sections Furnace Superheater Reheater 1.2.1.1 Type and make 1.2.1.2 Number of soot blowers - Radiant section - Convective section 1.2.1.3 Material of construction - Lance / swivel tube - Nozzle - Blower head - Feed tube - Bearing (in high temp. area) - Compression hangers 1.2.1.4 Total time required for one complete cycle hr of soot blowing operation 1.2.1.5 Duration of operation min. 1.2.1.6 Operating pressure bar(a) 1.2.1.7 Steam consumption rate per cycle Kg/hr 1.2.1.8 Rate of steam consumption per blower Kg/h 1.2.2 Economiser & Air preheater: Economiser Air preheater 1.2.2.1 Type and make 1.2.2.2 Number of soot blowers



VOLUME IIIA






DATE

1.2.2.3 Material of construction - Lance / Swivel tube - Nozzle - Blower head - Feed tube - Swivel joint 1.2.2.4 Duration of operation min. 1.2.2.5 Operating pressure bar(a) 1.2.2.6 Steam consumption rate per cycle Kg/h 1.2.2.7 Rate of steam consumption per blower Kg/h 1.2.2.8 Total time required for one complete cycle of soot blowing operation h 1.3.0 PRESSURE REDUCING VALVES (Furnish data for all valves) 1.3.1 Type and make 1.3.2 Inlet pressure bar(a) 1.3.3 Outlet pressure bar(a) 1.3.4 Outlet temperature deg.C 7.3.5 Material : 1.3.5.1 Valve seat 1.3.5.2 Body 1.3.5.3 Stem 1.4.0 SAFETY VALVES (Furnish data for all valves) 1.4.1 Type and make 1.4.2 Blowing pressure bar(a)



VOLUME IIIA






DATE

1.4.3 Blowing capacity t/h



VOLUME IIIA


TCE-5103A-C-500-01 FUEL OIL BURNER AND IGNITOR SHEET 1 OF 2




DATE

1.1.0 FUEL OIL BURNERS 1.1.1 Designation LDO HFO/LSHS/HPS 1.1.2 Number of burners per steam generator 1.1.3 Type 1.1.4 Make 1.1.5 Capacity of each burner Kg/h 1.1.6 Turn-down ratio of burner 1.1.7 Heavy oil pressure : 1.1.7.1 Maximum bar(a) 1.1.7.2 Normal bar(a) 1.1.7.3 Minimum bar(a) 1.1.8 Atomising medium 1.1.8.1 Atomising steam/air requirement of each burner i) Flow rate Kg/h ii) Pressure bar(a) 1.1.9 Scavenging steam requirement of each burner 1.1.9.1 Flow rate Kg/h 1.1.9.2 Duration of cleaning min 1.1.9.3 Pressure bar(a) 1.1.10 Viscosity of oil at burner tip for good atomisation Cst 1.1.11 Air requirement of auto retract mechanism



VOLUME IIIA


TCE-5103A-C-500-01 FUEL OIL BURNER AND IGNITOR SHEET 2 OF 2




DATE

Service / instrument air 1.1.11.1 a) Quality b) Quantity/operation Nm3 c) Pressure bar(a) 1.1.12 Material of construction: 1.1.12.1 Oil burner 1.1.12.2 Diffuser 1.1.12.3 Nozzle cap 1.2.0 IGNITORS 1.2.1 Type 1.2.2 Number 1.2.3 Fuel 1.2.4 Capacity of each ignitors Kg/h 1.2.5 Ignition gas pressure bar(a) 1.2.5.1 Maximum 1.2.5.2 Normal 1.2.5.3 Minimum



VOLUME IIIA


TCE-5103A-C-500-01 COAL BURNERS SHEET 1 OF 2




DATE

1.1.0 Number of burners 1.2.0 Type (Low Nox burner) Yes/No 1.3.0 Make 1.4.0 Capacity of each burner Kg/h 1.5.0 Turndown ratio without oil support 1.6.0 Coal/air mixture pressure before burner mmwc 1.7.0 Velocity of the mixture at entry to burner m/s 1.8.0 Velocity of secondary air at entry to burner m/s 1.9.0 Material 1.9.1 Coal burner nozzle 1.9.2 Guide plate 1.9.3 Support bearing inside wind box 1.9.4 Drive mechanism for tilting (linkages etc. if provided) 1.10 COAL FEEDER 1.10.1 Type 1.10.2 Manufacturer 1.10.3 Capacity T/hr

1.10.4 Speed rpm 1.10.5 Distance between centre line

of inlet and outlet

1.10.6 Inlet Diameter mm



VOLUME IIIA


TCE-5103A-C-500-01 COAL BURNERS SHEET 2 OF 2




DATE

1.10.7 Belt width mm 1.10.8 Motor rating kW 1.10.9 Type of controls



VOLUME IIIA


TCE-5103A-C-500-01 COAL MILLS SHEET 1 OF 3


SR.NO. ITEM

BIDDER →


DATE

1.1.0 GENERAL 1.1.1 Make 1.1.2 Type 1.1.3 No of mills 1.1.4 Manufacturer 1.1.5 Capacity (Indicate for worst and design coal) t/h 1.1.6 Method of feeding 1.1.7 Input lump size max. mm 1.1.8 Speed of rotation rpm 1.1.9 Guaranteed output at specified input size and moisture t/h 1.1.10 Output fineness 1.1.11 Mode of adjustment of ball / roller 1.1.12 Mode of adjustment of classifier vanes 1.1.13 Material 1.1.13.1 a) Grinding ring/race/cylinder b) Liner, if applicable 1.1.13.2 a) Rolls/balls b) Liner, if applicable 1.1.13.3 a) Housing grinding zone b) Liner, if applicable 1.1.13.4 a) Reject collection zone



VOLUME IIIA




SR.NO. ITEM

BIDDER →


DATE

b) Linear, if applicable 1.1.13.5 Gear drive make 1.1.13.6 Main drive shaft 1.1.13.7 Worm shaft 1.1.13.8 Classifier type 1.1.13.9 Pressure springs 1.1.14 Type of bearings and seals 1.1.15 Method of lubrication of rotating parts 1.1.16 Type of flexible coupling 1.1.17 Power consumption per mill at 10% SG MCR Kw - For design coal - For worst coal 1.1.18 Mill drive motor rating Kw 1.1.19 Wear parts life 1.1.20 Grinding ring/race life 1.1.21 Rolls / Balls life 1.2.0 Expected no. of operating hours between major over-hauls of the coal mill 1.3.0 Rate of coal mill rejects - When the mills are relatively new (Just started operation) - Considering worn out condition of



VOLUME IIIA




SR.NO. ITEM

BIDDER →


DATE

grinding parts 1.4.0 Any other Data - List items



VOLUME IIIA


TCE-5103A-C-500-01 GEAR/SCREW PUMPS SHEET 1 OF 2




DATE

1.1.1 Designation LDO HFO/LSHS/HPS 1.1.2 Manufacturer 1.1.3 Type 1.1.4 No. of pumps 1.1.5 Capacity m3/h 1.1.6 Total dynamic head mlc 1.1.7 Suction head mlc 1.1.8 Efficiency % 1.1.9 Speed rpm 1.1.10 Type of coupling 1.1.11 Packing type 1.1.12 Materials of construction: 1.1.12.1 Casing 1.1.12.2 Rotor 1.1.12.3 Shaft 1.1.12.4 Shaft sleeves 1.1.12.5 Base plate 1.1.12.6 Wearing rings (if required) 1.1.13 Type of bearing used Internal/external 1.1.14 Connections 1.1.14.1 Suction size mm 1.1.14.2 Discharge size mm



VOLUME IIIA


TCE-5103A-C-500-01 GEAR/SCREW PUMPS SHEET 2 OF 2




DATE

1.1.15 Relief valve set pressure bar(a) 1.1.16 Motor 1.1.16.1 Motor rating and speed kW/rpm 1.1.17 Maximum allowable suction lift mlc 1.1.18 Any other Data - List items



VOLUME IIIA


TCE-5103A-C-500-01 FUEL OIL HEATERS SHEET 1 OF 2




DATE

1.0 Number provided 2.0 Design Data for each heater Shell Side Tube Side 2.1 Fluid circulated 2.2 Flow rate (max) kg/hr 2.3 Operating temperature (a) Inlet 0C (b) Outlet 0C 2.4 Pressure drop across heater kg/cm2 2.5 Hydrotest pressure kg/cm2(a) 2.6 Corrosion allowance mm 2.7 Fouling resistance Hr.m2

0C/kcal

2.8 No. of passes 3.0 Total heat transfer area m2 4.0 Tube details (a) No. (b) Outside dia mm/BWG (c) Pitch mm (d) Length mm 5.0 Materials of construction (a) Shell (b) Tubes



VOLUME IIIA


TCE-5103A-C-500-01 FUEL OIL HEATERS SHEET 2 OF 2




DATE

(c) Tube sheets (d) Baffles (e) Gaskets 6.0 Empty weight of heater tonnes 7.0 Flooded weight of heater tonnes 8.0 Assembled dimension of heater m x m x m



VOLUME IIIA


TCE-5103A-C-500-01 AIR AND GAS DUCTS AND DAMPERS SHEET 1 OF 2




DATE

1.1.0 AIR DUCTS 1.1.1 FD fan cold air intake mm x mm duct size 1.1.2 FD fan cold air discharge mm x mm duct size 1.1.3 PA fan cold air intake duct mm x mm size 1.1.4 PA fan hot air duct size mm x mm 1.1.5 Thickness of plate : 1.1.5.1 Cold air mm 1.1.5.2 Hot air mm 1.1.6 Material 1.1.7 Air velocity in : 1.1.7.1 Cold air duct FD fan m/s 1.1.7.2 Cold air duct PA fan m/s 1.1.7.3 Hot air duct PA fan m/s 1.2.0 GAS DUCTS ID Fan GR Fan (If produced) 1.2.1 Size of ID fan discharge mm x mm duct 1.2.2 Size of common flue gas mm x mm duct (after headering) 1.2.3 Duct plate thickness mm 1.2.4 Material 1.2.5 Gas velocities : 1.2.5.1 Suction side m/s



VOLUME IIIA


TCE-5103A-C-500-01 AIR AND GAS DUCTS AND DAMPERS SHEET 2 OF 2




DATE

1.2.5.2 Discharge m/s 1.3.0 DAMPERS Isolation Control Guillotine 1.3.1 Type and make 1.3.2 Location 1.3.3 Service 1.3.4 Type of drive 1.3.5 Sealing efficiency % 1.4.0 Materials of construction 1.4.1 Dampers frame 1.4.2 Blades 1.4.3 Linkage bolts and pins



VOLUME IIIA


TCE-5103A-C-500-01 ELECTROSTATIC PRECIPITATOR SHEET 1 OF 7




DATE

1.1.0 GENERAL INFORMATION 1.1.1 Manufacturer 1.1.2 Number of ESP / Steam generator 1.1.3 Number of gas stream / ESP 1.1.4 Number of electrical fields in series in gas path / stream 1.1.5 Total active treatment length per stream m 1.1.6 Treatment time secs. 1.1.7 Corona power per ESP stream watts per 1000 m3 per min. 1.1.8 No. of hours ESP can run at specified gas flow and dust loading without emptying any hopper 1.1.8.1 With worst coal 1.1.8.2 With design coal 1.1.9 Dust conc. at the ESP outlet 1.1.9.1 Worst coal firing All fields in service mg/Nm3 One TR set out of service mg/Nm3 1.1.9.2 Guarantee coal firing All fields in service mg/Nm3 One TR set out of service mg/Nm3 1.1.10 Total power input to the ESP per steam generator



VOLUME IIIA






DATE

1.2.0 ELECTRODES & BUS SECTIONS 1.2.1 Collecting Electrodes 1.2.1.1 Type 1.2.1.2 Material 1.2.1.3 Electrode thickness mm 1.2.1.4 Clear distance between collecting electrode plates mm 1.2.1.5 Number of gas passages / stream 1.2.1.6 Active length per electrode m 1.2.1.7 Cross sectional area of each passage m2 1.2.1.8 Active height per electrode m2 1.2.1.9 Specific collection plate area m2/m3/sec 1.2.1.10 Total number of electrodes per SG 1.2.1.11 Aspect ratio length / height 1.2.1.12 Average gas velocity in the electrical field m/s 1.2.2 Bus Section 1.2.2.1 Total numbers 1.2.2.2 Number of bus sections in parallel in gas path 1.2.2.3 Number of sections in parallel in gas path 1.2.2.4 HT Voltage kV (peak) 1.2.2.5 Total power on HT electrode kW



VOLUME IIIA






DATE

1.2.2.6 Ratio of collecting electrode area to bus sections 1.2.2.7 Number of sections lost if one transformer is out of service 1.2.3 Discharge Electrode 1.2.3.1 Type 1.2.3.2 Material 1.2.3.3 Number of electrodes per gas path 15.2.3.4 Distance between effective distance electrodes in direction of gas flow m 1.2.3.5 Total number of electrodes / SG 1.2.3.6 Electrode dimension height m 1.2.3.7 Effective length of electrode m 1.2.4 High Voltage Conductor 1.2.4.1 Manufacturer 1.2.4.2 Type 1.2.4.3 Size 1.3.0 RAPPING SYSTEM 1.3.1 Collecting Electrodes 1.3.1.1 Type 1.3.1.2 Total number of rappers per SG 1.3.1.3 Maximum number of electrodes rapped by a rapper at any one time



VOLUME IIIA






DATE

1.3.1.4 Percentage of plates rapped at one time 1.3.1.5 Rapping acceleration force minimum / plate g 1.3.1.6 Average input rapping power to rapping system kW 1.3.1.7 Rapper controller type 1.3.2 Discharge Electrode 1.3.2.1 Type 1.3.2.2 Total number of rappers 1.3.2.3 Percentage of electrodes rapped at

any time % 1.3.2.4 Rapping energy of each rapper kgs. 1.3.2.5 Average input power to rapping system kW 1.3.2.6 Rapper controller type 1.4.0 SUPPORTS 1.4.1 High Tension Support Insulators 1.4.1.1 Type 1.4.1.2 Material 1.4.1.3 Leakage distance mm 1.4.1.4 Minimum flash over kV 1.4.1.5 Location 1.4.2 High Tension Conductor Support 1.4.2.1 Type 1.4.2.2 Material



VOLUME IIIA






DATE

1.4.2.3 Insulator 1.5.0 TRANSFORMER RECTIFIER UNIT 1.5.1 Total numbers 1.5.2 Capacity - each kVA 1.5.3 Transformer 1.5.3.1 Type of transformer 1.5.3.2 Class of insulation 1.5.3.3 Temperature rise of oil over ambient 0C 1.5.3.4 Class of bushing 1.5.3.5 Rating of each set a) Input power kVA b) Output power kW c) Output voltage kV (peak) d) Output current mA 1.5.3.6 Volume of oil Litres 1.5.4 Rectifier 1.5.4.1 Type 1.5.4.2 Half-wave / full wave 1.5.4.3 Guaranteed life hours 1.5.4.4 Rating-each 1.5.5 Transformer Rectifier Control Unit 1.5.5.1 Number offered



VOLUME IIIA






DATE

1.5.5.2 Type of cabinet 1.5.5.3 Voltage control 1.5.5.4 Arc suppression 1.5.5.5 Protection 1.5.5.6 Instrumentation provided as required 1.6.0 POWER CONSUMPTION OF ESP PER SG 1.6.1 Input power kVA 1.6.2 Output power from TR sets kW 1.6.3 Output voltage kV 1.6.4 Output current mA 1.6.5 Total connected load kW 1.6.6 Maximum power requirement kW 1.6.7 Corona power available Watts / m2 1.6.8 Auxiliary power kW 1.6.8.1 Rapping system kW 1.6.8.2 Seal air fan kW 1.6.8.3 Seal air heaters (during start up) kW 1.6.8.4 Seal air heaters (normal operation) kW 1.6.8.5 Hopper heaters kW 1.7.0 HOUSING 1.7.1 Plate thickness mm 1.7.2 Design pressure mmwg



VOLUME IIIA






DATE

1.8.0 DUST HOPPERS PER SG 1.8.1 Total numbers 1.8.2 Plate thickness mm 1.8.3 Material 1.8.4 Hopper valley angle degrees 1.8.5 Electric heater a) Rating b) Number per hopper 1.9.0 PERFORATED GAS DISTRIBUTION PLATE 1.9.1 Type 1.9.2 Material 1.9.3 Location



VOLUME IIIA


TCE-5103A-C-500-01 INSULATION / REFRACTORY SHEET 1 OF 2




DATE

1.1 Insulation

1.1.1 Area of application (separately furnish for SG, flue gas duct, hot air duct, ESP etc)

1.1.2 Type of insulation 1.1.3 Manufacturer 1.1.4 Composition 1.1.5 Thickness of insulation mm 1.1.6 Density of insulation (for pourable / castable

refractory indicate for dry condition) Kg /m3

1.1.7 Thermal conductivity mW/cm0C 1.1.8 Maximum continuous withstanding temperature 0C 1.1.9 Code to which insulation / refractory is offered ?

(Name, number and year of code)

1.1.10 Finishing cement provided? 1.1.11 If yes, (a) Thickness of finishing cement mm (b) Density of finishing cement Kg/m3 1.1.12 Sheathing material, type wherever applicable 1.1.13 Thickness of sheathing material mm 1.1.14 Is the insulating material corrosive to surface on

which it is applied ?

1.2

Refractory

Value

1.2.1 Area of application ( furnish separately for each area of application )

1.2.2 Type



VOLUME IIIA


TCE-5103A-C-500-01 INSULATION / REFRACTORY SHEET 2 OF 2




DATE

1.2.3 Manufacturer

1.2.4 Composition

1.2.5 Density

Kg/cm3

1.2.6 Thermal conductivity

W/ m2 C

1.2.7 Maximum continuous Withstanding Temperature Deg C 1.2.8 Code to which refractory material is offered



VOLUME IIIA


TCE-5103A-C-500-01 SEPERATOR DRAIN RECIRCULATION PUMPS SHEET 1 OF 1




DATE

1.1.1 Manufacturer 1.1.2 Type 1.1.3 No. of pumps provided 1.1.4 No. of pumps in operation during start up 1.1.5 Capacity of each pump m3/h 1.1.6 Total dynamic head mlc 1.1.7 Suction head mlc 1.1.8 Efficiency % 1.1.9 Speed rpm 1.1.10 Materials of Construction 1.1.10.1 Casing 1.1.10.2 Impeller 1.1.10.3 Shaft 1.1.10.4 Bearings 1.1.11 Motor housing INTERNAL / EXTERNAL 1.1.17 Motor rating / speed kW / rpm



VOLUME IIIA


TCE-5103A-C-500-01 ATMOSPHERIC DRAIN TRANSFER PUMPS SHEET 1 OF 1




DATE

14.1.1 Manufacturer 14.1.2 Type 14.1.3 No. of pumps provided 14.1.4 No. of pumps in operation during start up 14.1.5 Capacity of each pump m3/h 14.1.6 Total dynamic head mlc 14.1.7 Suction head mlc 14.1.8 Efficiency % 14.1.9 Speed rpm 14.1.1 Materials of Construction 14.1.10.1 Casing 14.1.10.2 Impeller 14.1.10.3 Shaft 14.1.10.4 Bearings 14.1.11 Motor housing INTERNAL / EXTERNAL 14.1.17 Motor rating / speed kW / rpm



VOLUME IIIA


TCE-5103A-C-500-01 HORIZONTAL CENTRIFUGAL PUMPS SHEET 1 OF 1




DATE

19.1 Service

19.2 Number Offered

19.3 Pump Make And Model Number

19.4 Design Capacity M3/Hr

19.5 TDH Mlc

19.6 Shut-Off Head Mlc

19.7 Number Of Stages

19.8 Pump Efficiency At Duty Point %

19.9 Pump Speed Rpm

19.10 Drive Motor Rating Kw

19.11 Method Of Lubrication

19.12 Npsh Required Mlc

19.13 Type And Make Of Mechanical Seal

19.14 Type Of Coupling

19.15 Minimum Capacity For Continuous M3/Hr



VOLUME IIIA


TCE-5103A-C-500-01 DRAWING AND DETAILS SHEET 1 OF 3




DATE

1.0 The dimensioned drawings / details and data listed below shall be submitted with the bid. The BIDDER shall note that these drawings are minimum requirement only and he must include sufficient drawings to give a clear and comprehensive indication of the plant offered.

1.1 General Arrangement 1.1.1 Steam generator area plan upto stack for both 1st and

2nd unit.

1.1.2 Front elevation, side elevation, and cross-section of the

steam generating unit showing location of headers and drums.

1.1.3 Layout of interconnecting platforms and platforms

meant for connecting the steam generator floors to the turbine operating floor.

1.2 Flow Diagrams, Control Schemes And Performance

Curves

1.2.1 Scheme of steam and water showing instrument tap-off

points

1.2.2 Scheme of air and gas path with instrument tap off

points

1.2.3 Scheme of pulveriser system with instrumentation 1.2.4 Scheme of fuel oil supply and burning system with

instrumentation

1.2.5 Cold start up, warm start up (Overnight shutdown) and

hot start-up curves.

1.2.6 Correction curves 1.3 Draft Plant



VOLUME IIIA






DATE

1.3.1 FD / SA and PA fans blade angle lines, stall line, equal efficiency line, system resistance line with all fans in service and with one SA and one PA fan out both at 50 Hz and 47.5 Hz respectively showing SGMCR & test block points, for both one fan and two fan operation as applicable.

1.3.2 ID fan inlet vane angle / speed lines, stall line, equal

efficiency line, system resistance line for normally fouled condition with both ID fans and electrostatic precipitator sections in service and also with one ID fan and one electrostatic precipitator section out both at 50 Hz and 47.5 Hz respectively showing SG MCR and test block points, for both one fan and two fans operations as applicable.

1.4 Coal Burning System 1.4.1 General arrangement of feeders, etc.. 1.4.2 General arrangement of mill, etc. 1.4.3 Description of coal feeders 1.4.4 Description of coal mills 1.5 Fuel Oil Burning System 1.5.1 Description of supply and firing system with

associated equipment drawings

1.6 Ignition System 1.6.1 Description of supply and firing system including

associated equipment and drawings

1.7 Soot Blowing System 1.7.1 Scheme of soot blowing system 1.7.2 Write-up on operation of soot blowing system



VOLUME IIIA






DATE

1.8 Description of flame scanners used on ignitors and fuel oil guns and installation list covering the latest three year period of in-service experience

SPECIFICATION NO.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED 2X800 MW TPP NEAR KRISHNAPATNAM

VOLUME IIIA

TCE.M4-113-54 DATA SHEET B21

ELECTRICALLY OPERATED HOISTS SHEET : 1 OF 3

ENQUIRY/ SPECIFICATION NO. TCE.

SL. NO.

BIDDER ITEM

1. DESIGNATION ELECTRICALLY OPERATED HOIST

FOR

2. NUMBER OFFERED

3. TAG NUMBERS

4. CAPACITY T 5. MANUFACTURER

6. MAKE

7. MODEL NUMBER

8.

9. 10. MANUFACTURER

11. MAKE

12. MODEL NUMBER

13. 14. HOIST MOTOR : MAIN CREEP

14.1 MAKE

14.2 TYPE

14.3 RATING KW

14.4 SPEED RPM

15. TROLLEY MOTOR : MAIN CREEP

15.1 MAKE

15.2 TYPE

15.3 RATING KW

15.4 SPEED RPM

16. LIMIT SWITCHES FOR :

16.1 HOISTING : MAKE, TYPE AND NUMBERS

PROVIDED

16.2 TRAVELLING: MAKE, TYPE AND NUMBERS

PROVIDED

NOTES TO BIDDER

1. DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN REPRODUCED IN DATA SHEET-B. IN CASE OF DEPARTURE FROM DATA SHEET-A, BIDDER SHALL BRING OUT THE SAME IN SCHEDULE OF DEVIATIONS, FAILING WHICH IT SHALL BE CONSTRUED THAT BIDDER COMPLIES WITH THE REQUIREMENTS STIPULATED IN DATA SHEET-A.

2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER

DATE

TCE FORM NO. 294 R1 FILE NAME: DB11354R5.DOC

GE

NE

RA

L

HO

IST

T

RO

LL

EY

E

LE

CT

RIC

AL

RE

QU

IRE

ME

NT

S

ISSU

E N

O. R

5

SPECIFICATION NO.



VOLUME IIIA

TCE.M4-113-54 DATA SHEET B22

ELECTRICALLY OPERATED HOISTS SHEET : 2 OF 3


SL. NO.

BIDDER ITEM

17. TYPE OF DOWN SHOP LEAD

17.1 MAKE

17.2 SIZE

17.3 LENGTH M

17.4 SUPPORTING ARRANGEMENT

17.5 IF CURVED MONORAIL, NUMBER OF CABLE NO./

TROLLEYS PROVIDED AND WIDTH OF EACH mm

TROLLEY

18.

19.

20.

21. 22. MONORAIL IF PROVIDED BY VENDOR :

INDICATE BEAM SIZE MINIMUM/ MAXIMUM mm ISMB / ISMB

SUITABLE FOR TROLLEY MOVEMENT

23. MONORAIL IF PROVIDED BY PURCHASER : YES/ NO

IS SIZE SPECIFIED IN DATA SHEET A SUITABLE

IF NO, INDICATE SUITABLE

FOR TROLLEY MOVEMENT SIZE ISMB

24. DISTANCE BETWEEN HIGHEST HOOK POSITION

TO BOTTOM OF MONORAIL mm

25. IF MONORAIL IS CURVED, MINIMUM RADIUS

TROLLEY CAN NEGOTIATE mm

26.

27. IF HOIST IS IN HAZARDOUS AREA :

27.1 TROLLEY WHEELS

27.2 ROPE DRUM AND SHEAVES

27.3 GEARS AND PINIONS

28.

29.

NOTES TO BIDDER



SIGNATURE OF BIDDER

DATE

EL

EC

TR

ICA

L R

EQ

UIR

EM

EN

TS

(CO

NT

D.)

DIM

EN

SIO

NS

MA

TE

RIA

LS

OF

CO

NST

RU

CT

ION

ISSU

E N

O. R

5

SPECIFICATION NO.



VOLUME IIIA

TCE.M4-113-54 DATA SHEET B22 ELECTRICALLY OPERATED HOISTS SHEET : 3 OF 3


SL. NO.

BIDDER ITEM

30. WIRE ROPE DIAMETER mm

31. WIRE ROPE BREAKING LOAD KN

32. WEIGHT OF COMPLETE HOIST AND TROLLEY

ASSEMBLY Kg

33. WEIGHT OF HOIST Kg

34. WHEEL LOAD WITH IMPACT AND WITHOUT Kg

IMPACT /

35. PRELIMINARY DIMENSIONED GENERAL

ARRANGEMENT DRAWING OF ELECTRICALLY WHETHER FURNISHED

OPERATED HOIST ALONG WITH WHEEL STOP YES/ NO

DETAILS TO BE FURNISHED

36.

37.

38.

39.

NOTES TO BIDDER



SIGNATURE OF BIDDER

DATE

TCE FORM NO. 294 R1

TCE FORM NO.294 R1

FILE NAME:

FILE NAME: DB11354R5.DOC

ISSU

E N

O. R

5

SPEC. NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED

2X800 MW TPP NEAR KRISHNAPATNAM VOLUME IIIA

TCE.5103A-C-500-01

DATA SHEET B22

FOUNDATION LOADING AT COLUMN BASE SHEET 1 OF 1



NOTE TO BIDDER 1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE MARKED

SIGNATURE

WITHIN ASTERISK(*) (DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS) OF BIDDER 2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

DATE

TCE FORM 294 R1

W T

BM XX TM

BM YY TM

SF XX T

SF YY T

W T

BM XX TM

BM YY TM

SF XX T

SF YY T

W T

BM YY TM

SF YY T

W T

BM XX TM

SF XX T

W T

BM YY TM

SF YY T

W T

BM XX TM

SF XX T

BM XX - B M ABOUT LONG AXIS, BM YY - B M ABOUT TRANS AXIS, W - VERTICAL AXIAL LOAD

SF XY - HORIZONTAL SHER ALONG AXIS, SF XX - HORIZONTAL SHEAR ALONG TRANS AXIS

TM - TONNE METRES, T - TONNE

UN

DE

R

MIN

IMU

M

LOA

DIN

G

CO

ND

ITIO

NS

LOA

DS

DU

E T

O B

OIL

ER

PA

RTS

A

ND

SE

LF W

EIG

HT

OF

STR

UC

TUR

E E

TC.

SE

ISM

IC F

OR

CE

S

AC

TIN

G A

LON

G

LON

G A

XIS

SE

ISM

IC F

OR

CE

S

AC

TIN

G A

LON

G

TRA

NS

AX

IS

3

AD

DIT

ION

AL

LOA

DIN

G D

UE

TO

S

EIS

MIC

1

WIN

D A

CTI

NG

A

LON

G L

ON

G

AX

IS

KIND OF LOAD COLUMN DESIGNATION

UN

DE

R

MA

XIM

UM

LO

AD

ING

C

ON

DIT

ION

S

SL. NO UNIT

2

AD

DIT

ION

AL

LOA

DIN

G D

UE

TO

WIN

D

WIN

D A

CTI

NG

A

LON

G T

RA

NS

A

XIS

2

2

LONG AXISOF BOILER C

S YY

S XX

C TRANS AXIS

11

BM YYBM XX

PLAN

SECTION .1 - 1 SECTION -2 - 2

SPECIFICATION NO.



DATA SHEET B23 TCE-M4-219-11 LOW VOLTAGE SWITCHGEAR SHEET 1 OF 8




SIGNATURE


DATE

TCE FORM 294 R1

ISSU

E N

O.R

6

1.0 SPECIFIC PARTICULARS

1.1 Switchgear designations

1.2 Single front or double front SF/DF

1.3 Applicable Standard

1.4 Fully drawout/semi drawout/Fixed

FD/SD/F

1.5 Total dimensions of each complete switchgear L x W x D

mm L W D

1.6.1 1.6.2

Width of each vertical section with cable alley Width of cable alley only

mm mm

1.7

Minimum clear space required a) In front b) Back

mm mm

1.8 Max. cubicle weight with components kg 1.9 Have all the feeders and

components specified in enclosed Drawings and Data Sheets A - 3 been provided ?

YES/NO

SPECIFICATION NO.







SIGNATURE


DATE

TCE FORM 294 R1

ISSU

E N

O.R

6

2.0 GENERAL PARTICULARS

2.1 Sheet steel a) Cold rolled/Hot rolled b) Thickness : i) Frames ii) Door iii) Rear cover iv) Side and top covers v) Panel partitions

mm mm mm mm mm

2.2 Degree of protections provided by the enclosure (As per IS : 13947)

2.3 Earth busbar size Sq.mm GI/AL/CU 2.4 BUSBAR

a) Material of busbars b) Section c) Continuous current rating under site conditions d) Whether busbars have been insulated e) Type of insulation f) Temperature rise over the reference ambient when carrying rated

Sq.mm A °C

AL/CU PH : N: YES/NO

SPECIFICATION NO.







SIGNATURE


DATE

TCE FORM 294 R1

ISSU

E N

O.R

6

current g) Material of busbar supports h) Clearance in air : i) Between phases ii) Between phases earth i) Short time rating (One Sec.) j) Momentary rating (peak)

mm mm kA kA

3.0 CIRCUIT BREAKERS 3.1 Maker’s name 3.2 Maker’s type designation 3.3 Applicable standards 3.4 Circuit breakers type

(air break and or MCCB)

3.5 Rated voltage V 3.6 Rated operating duty 3.7 Rated current A 3.8 Derating factor for

operation under site conditions

3.9 Rated symmetrical breaking current at rated voltage. (Indicate power factor)

kA P.F.

3.10 Rated peak making current

kA

3.11 Rated short time withstand rating (for 1 sec.) (For MCCB, BIDDER to indicate the time)

3.12 Operating mechanism type 3.13 Limits of voltage for satisfactory

operation of the following devices as a % of normal voltage

SPECIFICATION NO.







SIGNATURE


DATE

TCE FORM 294 R1

ISSU

E N

O.R

6

i) Operating mechanism ii) Closing at normal voltage iv) Trip coil

% % %

3.14 Power required for closing at normal voltage

W

3.15 Power required for tripping at normal voltage

W

3.16 Spring charging motor details : i) Rating ii) Rated voltage iii) Spring charging

kW V, AC/DC Sec.

3.17 Overload release provided YES/NO 3.18 Short circuit release settings and time

delay features

3.19 Undervoltage release setting 3.20 Have electrical and mechanical anti-

pumping features been provided YES/NO

3.21 Have type test certificates been enclosed ?

YES/NO

4.0 AIR BREAK SWITCHES 4.1 Make 4.2 Type 4.3 Rated Voltage 4.4 Applicable standards 4.5 Maximum prospective fault current

withstand of composite unit of switch and fuse

kA (peak)

5.0

FUSES

5.1 Make 5.2 Type 5.3 Applicable standards 5.4 Rated voltage V

5.5 Rated current for individual circuits to be provided as per requirements of protection coordination

YES/NO

6.0 CONTACTORS

SPECIFICATION NO.







SIGNATURE


DATE

TCE FORM 294 R1

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6.1 Make

6.2 Rated duty

6.3 Rated Utilisation Category

6.4 Applicable standards

6.5 Rated (thermal) current provided as per specification

YES/NO

6.6 Rated voltage of auxiliary contacts V

6.7 Rated voltage of coil V

6.8 Rated breaking capacity Factor of rated current

6.9 Rated making capacity Factor of rated current

6.10 Limits of operation i) Supply voltage variation ii) Supply frequency variation for closing iii) Drop out voltage

+ % + % %

6.11 No of auxiliary contacts : I) Normally open ii) Normally closed

7.0 SINGLE PHASING PREVENTERS

7.1 Is it in built-in bimetal thermal overload relay

YES/NO

8.0 CURRENT TRANSFORMERS

8.1 Make


8.3 All other parameters of CT as per enclosed SLD/list and Section-D

YES/NO

9.0 VOLTAGE TRANSFORMERS

9.1 Make


9.3 Ratio V/V

9.4 Output per phase VA

9.5 Accuracy class

9.6 Over voltage factor

SPECIFICATION NO.







SIGNATURE


DATE

TCE FORM 294 R1

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6

9.7 Class of insulation

10.0 CONTROL TRANSFORMERS

10.1 Make

10.2 Type


10.4 Ratio

10.5 Class of insulation

10.6 Rated output VA

11.0 INSTANTANEOUS OVERCURRENT RELAY

11.1 Application (phase fault or earth fault)

11.2 Make

11.3 Type designation

11.4 Setting range

12.0 INVERSE TIME AND THERMAL OVERCURRENT RELAY

12.1 Application

12.2 Make

12.3 Type

12.4 Current setting range

12.5 Time setting range at 10 times the current setting

Sec.

13.0 UNDERVOLTAGE RELAY

13.1 Make

13.2 Type

13.3 Voltage rating V

13.4 Setting range V

14.0 AUXILIARY RELAYS AND TIMERS

14.1 Make

14.2 Type

14.3 Coil voltage V

15.0 CONTROL/SELECTOR SWITCH

15.1 Make

15.2 Type designation

16.0 VOLTMETER

16.1 Make

16.2 Type 16.3 Applicable standards 16.4 Accuracy class 17.0 AMMETER

SPECIFICATION NO.







SIGNATURE


DATE

TCE FORM 294 R1

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6

17.1 Make 17.2 Type 17.3 Applicable standards 17.4 Accuracy class 18.0 WATTMETER 18.1 Make 18.2 Type 18.3 Applicable standard 18.4 Accuracy class 19.0 INDICATING LAMPS 19.1 Make 19.2 Type 19.3 Voltage V 19.4 Series resistor Ohms 19.5 Wattage of lamp W 20.0 PUSH BUTTONS 20.1 Make 20.2 Type designation 20.3 No of contacts:

i) Normally open ii) Normally closed

20.4 Contact rating A 21.0 SPACE HEATER 21.1 Make 21.2 Type 21.3 Rated voltage V 21.4 Heater output for each vertical panel W 21.5 Thermostat at setting °C 22.0 WIRING AND TERMINAL BLOCKS 22.1 Voltage grade 22.2 Insulation 22.3 Minimum size of conductor for :

i) Power wiring ii) Control wiring

Sq.mm Sq.mm

22.4 Type of terminal blocks :

SPECIFICATION NO.







SIGNATURE


DATE

TCE FORM 294 R1

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i) For withdrawable Type ii) For Fixed type

22.5 Minimum current rating of terminal blocks

A

22.6 Whether terminals for CT’s have been provided with short circuiting facilities

YES/NO

23.0 PUSH BUTTON STATION 23.1 Metal Enclosure :

i) Die-cast aluminium/sheet metal of

2mm thickness ii) Degree of protection iii) Painting, inscription earthing terminals as specified

YES/NO

23.2 Gland plate and cable glands provided YES/NO 22.3 Facility for fixing on wall/structure

provided YES/NO

23.4 No. of Contacts : i) Normally open ii) Normally closed

23.5 Contact rating : I) At 415 V AC ii) At 110 V AC iii) At 220 V DC

A A A

23.6 Terminal blocks with identification nos. provided for external connections.

YES/NO

SPECIFICATION NO.






ISSU

E N

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6

TCE FORM 329 R3

SPECIFICATION NO.



DATA SHEET B24 TCE-M4-203-06 MOTOR OPERATED VALVES ACTUATORS SHEET 1 OF 2




SIGNATURE


DATE

TCE FORM 294 R1

ISSU

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R4

1.0 Manufacturer’s Name & Address 2.0 Type / Model No. 3.0 Motor Rating KW 4.0 Operating time of actuator Secs. 5.0 Integral Motor Starter provided (please furnish

detailed wiring diagram) Yes / No.

5.1 Contactor 5.1.1 Make and type 5.1.2 Rated Duty 5.1.3 Rated utilisation category 5.1.4 Rated voltage and current V,A 5.1.5 Rated voltage of coil V 5.1.6 Thermal overload relay range % of motor

current rating

6.0 Interposing relay 6.1 Make of relay 6.2 Type of relay 6.3 Coil voltage rating V 6.4 Relay Burden VA 6.5 Contact rating V, A 7.0 Space heating supply derived from control

transformer (Applicable for 3 phase, 3 wire system)

Yes / No.

8.0 Space heater rating V, Watts 9.0 Actuator catalog furnished Yes / No 10.0 Typical test certificates furnished Yes / No

SPECIFICATION NO.



DATA SHEET B24 TCE-M4-203-06 MOTOR OPERATED VALVES ACTUATORS SHEET 2 OF 2




SIGNATURE


DATE

TCE FORM 294 R1

ISSU

E N

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R4

11.0 Technical requirements 11.1 Whether technical requirements as per section

– D (write – up), data sheet – A1 and the standards as per data sheet – A3 are met fully.

Yes / No

11.2 If ‘No’ to Cl. 11.1 whether all deviations are

brought out in schedule of deviations in section – F

Yes / No

1

ISSUE R4

TCE FORM 329 R3

SPECIFICATION NO.



DATA SHEET B 25 TCE-M4-203-11 D.C. MOTORS SHEET 1 OF 2




SIGNATURE


DATE

TCE FORM 294 R1

ISSU

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1.0 Application / Designation 2.0 Manufacturer 3.0 Applicable Standards 4.0 Type of Motor 5.0 Rating a) Output kW b) Speed RPM 6.0 Duty 6.1 Type of Duty 6.2 Duty Designation 7.0 Current a) Full Load (FL) i) Armature Amps ii) Field Amps b) Starting i) Max. starting % FL ii) Min. starting % FL 8.0 Full Load Efficiency % 9.0 Method of Starting – D.O.L./ Reduced Voltage

Starting

10.0 Torque a) Full Load (FLT) Kg-m b) Starting % FLT c) Maximum % FLT 11. Resistance 11.1. Armature Wdg. Ohms 11.2 Field Wdg. Ohms

SPECIFICATION NO.



DATA SHEET B 25 TCE-M4-203-11 D.C. MOTORS SHEET 2 OF 2




SIGNATURE


DATE

TCE FORM 294 R1

ISSU

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12.0 Inductance 12.1 Armature Wdg. mH 12.2 Field Wdg. mH 13.0 Dimensional Dwg. Enclosed Yes/No 14.0 Starter in Vendors’ Scope of Supply Yes/No 15.0 Technical Requirements 15.1 Technical requirements, as per Section-D, Data

Sheet-A1 and the standards as per Data Sheet-A2 Yes/No

15.2 If ‘NO’ to CL. 15.1, deviations are brought out in

Schedule of Deviations in Section-F Yes/No

SPECIFICATION NO.



DATA SHEET B26 TCE-M4-203-71 VARIABLE SPEED DC/AC DRIVES SHEET 1 OF 4

ENQUIRY / SPECIFICATION NO.


SIGNATURE


DATE

TCE FORM 294 R1

ISSU

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1


1.0 Converter Designation 2.0 Overload capacity & duration % , Mins 2.1 Minimum duration required for two

successive overloads as specified above Min/Hrs

2.2 Switching frequency (specify if derating

required for any switching frequency) kHz

3.0 Transient change in the nominal output

voltage for 100% charge in motor load --- % with recovery to steady state

within ------ sec. 4.0 Size of largest motor which can be started

direct on line kW

4.1 Maximum length of power supply cable

without output filter m

5.0 Max distortion factor of input current at

I/P of drive

6.0 CONTROL SYSTEM 6.1 Nature of system Analog/Digital 6.2 Detailed technical information enclosed Yes/No 6.3 Auxiliary Voltage Supply 6.3.1 Analog Inputs No. of Inputs Input Range 6.3.2 Digital Inputs No. of Inputs 6.3.3 Analog Output No. of Output Range

SPECIFICATION NO.






SIGNATURE


DATE

TCE FORM 294 R1

ISSU

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1


6.3.4 Digital Outputs 6.3.5 Serial Communication for panel (specify port and protocol) 6.3.6 Serial Communication for external control (specify port and protocol) 7.0 MONITORING AIDS 7.1 Power Semi-conductors 7.1.1 Are temperature sensing elements

provided? Yes/No

7.1.2 Technical write up enclosed Yes/No 7.2 Cooling system 7.2.1 Nature of cooling of converters Natural/Forced 8.0 Tentative Dimensions & weight 9.0 Type of Mounting 10.0 GA drawing of Drive Panel enclosed Yes/No

SPECIFICATION NO.






SIGNATURE


DATE

TCE FORM 294 R1

ISSU

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1

SR.NO. ITEM DC DRIVE BIDDER →

1.0 Pulse Number 6/12 2.0 No. of parallel six pulse bridge arms 2.1 Current rating per bridge arm 2.2 Total current rating of converter 3.0 No. of power semi-conductors in series per

bridge arm

4.0 Whether Converter connected to source

directly Yes/No

4.1 If no rating of the converter transformer kVA 5.0 If Armature Control used the field is

connected

5.1 Directly to the sources Yes/No 5.2 Through converter transformer of the

armature voltage control Yes/No

5.3 Through separate converter transformer of

rating kVA

SPECIFICATION NO.






SIGNATURE


DATE

TCE FORM 294 R1

ISSU

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1

SR.NO. ITEM AC DRIVE BIDDER →

1.0 Rated Output Voltage V 1.1 Accuracy of output voltage to maintain

constant V/f

2.0 Output Frequency Hz 2.1 Setting range Hz 2.2 Accuracy % 3.0 Output rating kVA at power factor

specified in data sheet A

4.0 Output transformer rating & details, if

provided kVA, V, % Z

5.0 Maximum Distortion factor of output

Voltage

1

TCE FORM 329 R3

SPECIFICATION NO.



DATA SHEET B27 TCE-M4-219-01 CONTROL CABINETS SHEET 1 OF 1




SIGNATURE


DATE

TCE FORM 294 R1

ISSU

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1.0 Manufacturer's name

2.0 Indoor/Outdoor application

3.0 Thickness of sheet steel mm

4.0 Degree of protection provided (as per IS:2147 or equivalent)

5.0 Bill of Material for the various equipment giving make, type, ratings etc. enclosed

Yes/No

6.0 Colour of finish paint

a) Outside

b) Inside

7.0 Busbars for power devices (when applicable)

a) Material (PVC Insulated/Bare)

b) Continuous current rating A

8.0 Control Wiring/Power Wiring

a) Material of conductor and size Cu/Al mm2

b) Conductor – solid/Stranded -

TCE FORM NO.329R3

1

R7

MAIN PLANT & AUXILIARIES SPECIFICATION


VOLUME – IIIB

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD VOLUME IIIB

TCE-5103A-C-510-01 2 X 800MW TPP NEAR KRISHNAPATNAM


CONTENTS SHEET 1 OF 3

VOL IIIB - CONTENTS

ISSUE R0


SECTION

CONTRACT NO

ISSUE NO.

TITLE

NO OF SHEETS

D1 TCE-M4-203-01

R8 INDUCTION MOTORS 5

R8 DATA SHEET-C 3

D2 TCE-M4-219-01 R7 CONTROL CABINETS

6

R7 DATA SHEET-C 1

D3 TCE-M4-219-11 R7 LOW VOLTAGE SWITCHGEAR

18

R7 DATA SHEET-C 4

D4 TCE-M4-203-71 R1 VARIABLE SPEED DC/AC DRIVES 19

R1 DATA SHEET-C 1

D5 TCE-M4-203-02

R8 INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS

4

R8 DATA SHEET-C 4

D6 TCE-M4-203-06 R4 MOTOR OPERATED VALVE ACTUATORS

4

R4 DATA SHEET-C 1

D7 TCE-M4-203-11 R8 D.C. MOTORS 4

R8 DATA SHEET-C 1

D8 TCE M4-101-01-01 R3 SHELL AND TUBE HEAT EXCHANGER

10

R3 DATA SHEET-C 1

D9 TCE.M4-102-01-01 R3 WELDED UNFIRED PRESSURE VESSEL

9

R3 DATA SHEET-C 1

D10 TCE.M4.102-34 R1 GUSSETS FOR NOZZLE 40 NB AND BELOW

1

D11 TCE.M4-102-43 R1 EARTHING CLEAT

1

D12 TCE.M4-102-51 R3 FABRICATION TOLERANCE FOR PRESSURE VESSELS

2





VOL IIIB - CONTENTS

ISSUE R0


SECTION

CONTRACT NO

ISSUE NO.

TITLE

NO OF SHEETS

D13 TCE.M4.102-30-01 R3 SUPPORTING SADDLE VESSEL

OUTSIDE DIAMETER 219.1 TO 508

1

D14 TCE M4 102-30-02 R3 SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 600 TO 900

1

D15 TCE.M4 102-30-03 R3 SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 1000 TO 1200

1

D16 TCE.M4-102-30-04 R3 SUPPORTING SADDLE VESSEL OUTSIDE DIAMETER 1300 TO 1900

1


1


1

D19 TCE M4 102-30-07 R3 SUPPORTING SADDLE GENERAL NOTES

1

D20 TCE M4 103-99 R3

VALVES AND SPECIALITIES 4

R3 DATA SHEET-C

1

D21 TCE M4-103-54 R3

CAST STEEL VALVES

6

R3 DATA SHEET-C

1

D22 TCE M4-103-55 R3

FORGED STEEL VALVES

4

R3 DATA SHEET-C

1

D23 TCE. M4- 104-50 R3 WEATHERHOODS FOR PIPES THROUGH ROOF SLAB AND EXTERNAL

1

D24 TCE. M4- 104-51 R3 TYPICAL INSULATION DETAILS FOR FLANGED VALVES AND FLANGES

2

D25 TCE. M4- 104-52 R3 TYPICAL INSULATION FOR BENDS

1

D26 TCE. M4- 104-53 R4 TYPICAL INSULATIONS FOR HANGERS

1





VOL IIIB - CONTENTS

ISSUE R0


SECTION

CONTRACT NO

ISSUE NO.

TITLE

NO OF SHEETS

D27 TCE. M4- 134-103 R7 DESIGN OF POWER PLANT PIPING

14

R5 DATA SHEET-C

2

D28 TCE. M4- 134-02 R2 SUPPLY, SHOP FABRICATION AND TESTING OF POWER PLANT PIPING

13

D29 TCE. M4-105-01 R10 HORIZONTAL CENTRIFUGAL PUMPS

3

R10 DATA SHEET –C

1

D30 TCE.M4-113-54 R5 ELECTRICAL OPERATED HOISTS AND TROLLEYS

4

R5 DATA SHEET-C

1

D31 TCE. M4- 113-50 R3 CHAIN PULLEY BLOCKS

2

R3 DATA SHEET-C

1

D32 TCE.M4-405-03 R3 SUPPLY, DESIGN, FABRICA-TION ,TESTING AND ERECTION OF STRUCTURAL STEEL FOR STEAM GENERATOR

6

D33 TCE.M4-104-02 R9 THERMAL INSULATION FOR HOT SURFACES

12

R9 DATA SHEET-C

2

D34 TCE.M4-134-03 R4 ERECTION AND TESTING OF POWER PLANT PIPING

11

R4 DATA SHEET-C

1

D35 TCE.M4-134-04 R5 WELDING SPECIFICATION FOR PIPING SYSTEM

15

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIIB

TCE-M4-203-01


INDUCTION MOTORS SHEET 1 OF 5

ISSUE R8

TITLE


TCE FORM NO. 329 R4

1.0 SCOPE 1.1 The specification covers the design, material, constructional features,

manufacture, inspection and testing at the VENDOR'S/his SUB-VENDOR'S works, delivery to site and performance testing of induction motors.

1.2 For motors of rated above 500 V, a separate specification (TCE.M4-203-02 -

Additional requirements for HV motors) covers the additional requirements, any or all of which shall be complied with for motors rated 415V if specified in Data Sheet-A.

2.0 CODES AND STANDARDS 2.1 The design, material, construction, manufacture, inspection, testing and

performance of induction motors shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the applicable standards specified in data sheet A1 latest revision as on the date of offer Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. In case of conflict between the standards and this specification, this specification shall govern.

3.0 DRIVEN EQUIPMENT 3.1 When this specification forms part of the driven equipment specification,

information not given in the Data Sheet-A will be governed by the driven equipment specification.

3.2 Motors shall be capable of satisfactory operation for the application and duty as

specified in the motor Data Sheet-A and as specified for the driven equipment. 4.0 PERFORMANCE AND CHARACTERISTICS 4.1 Motors shall be capable of giving rated output without reduction in the expected

life span when operated continuously under either of the following supply conditions as


TCE-M4-203-01



ISSUE R8

TITLE


TCE FORM NO. 329 R4

specified in Data Sheet-A. Supply Condition I II (a) Variation in supply voltage from rated voltage +6% +10% (b) Variation in supply frequency from rated frequency +3% +5% (c) Combined voltage and frequency variation 9% 10% 4.2 Motors shall be suitable for the method of starting specified in the Data Sheet-A. 4.3 The minimum permissible voltage shall be 85% of the rated voltage during motor

starting 4.3.1 Motors shall be capable of starting and accelerating the load with the applicable

method of starting, without winding temperatures reaching injurious levels, when the supply voltage is in the range of 85% of the rated motor voltage to maximum permissible voltage specified in Data Sheet-A.

4.4 The locked rotor current of the motor shall not exceed 600% of full load current

(subject to tolerances as per the applicable standard) unless otherwise specified. 4.5 Motors shall be capable of developing the rated full load torque even if the

supply voltage drops to 70% of the rated voltage. If such operation is envisaged for a period of one second, the pull out torque of the motor shall be atleast 205% of full load torque.

4.6 Motors when started with the driven equipment coupled shall be capable of

withstanding atleast two successive starts from cold conditions & one start from hot condition without injurious heating of windings. The motors shall also be suitable for three equally spread starts per hour under the above referred supply conditions.

5.0 INSULATION 5.1 The insulation shall be given tropical and fungicidal treatment for successful

operation of the motor in hot, humid and tropical climate.

6.0 TEMPERATURE RISE


TCE-M4-203-01



ISSUE R8

TITLE


TCE FORM NO. 329 R4

6.1 The temperature rises shall not exceed the values given in IS 12802. Under

extremes of supply condition (clause 4.1 above), the temperature rise shall not exceed the value indicated in IS by 10oC.

6.2 For motors specified for outdoor installation heating due to direct exposure to

solar radiation shall be considered. 7.0 CONSTRUCTIONAL FEATURES 7.1 Motors weighing more than 25 kg. shall be provided with eyebolts, lugs or other

means to facilitate safe lifting. 8.0 BEARINGS 8.1 Unless otherwise specified in data sheet-A, motor bearings shall not be

subjected to any external thrust load. 8.2 Unless otherwise specified, motor bearings shall have an estimated life of atleast

40,000 hrs. 8.3 The bearings shall permit running of the motor in either direction of rotation. 8.4 When forced oil lubrication or water cooling is required, prior approval from

the purchaser shall be obtained. 8.5 When forced oil lubrication or water cooling is required, the machine shall be

suitable for starting & continuous operation for atleast 10 minutes, without the availability of lubrication or cooling system

8.6 If the bearings are oil lubricated, a drain plug shall be provided for draining

residual oil & an oil level sight gauge shall be provided to show the precise oil level required for stand still and running conditions.

8.7 It shall be possible to lubricate the bearings without dismantling any part of the

motor. 9.0 TERMINAL BOX 9.1 Terminal boxes shall have a degree of protection of atleast IP 55 for out door

applicable 9.2 Unless otherwise approved, the terminal box shall be capable of being turned

through 360o in steps of 90o. 9.3 Terminals shall be of stud type & the terminal box shall be complete with necessary

lugs, nuts, washers.


TCE-M4-203-01



ISSUE R8

TITLE


TCE FORM NO. 329 R4

9.4 When single core cables are to be used the gland plates shall be of non magnetic

material. 9.5 Sizes of terminal boxes and lugs shall be as given in Table-I, unless specified

otherwise in data sheet A or Section C.

TABLE-I

415 V MOTORS - SIZES OF CABLES, STUDS, TERMINAL LUGS & TERMINAL BOXES

(TO BE PROVIDED ON MOTORS BY VENDOR)

------------------------------------------------------------------------------------------------------------------------- SL. MOTOR RATING 1100V Al Conductor Stud Terminal lug size Minimum

Terminal NO. kW armoured PVC Cable Size of DOWELL MAKE Box Size Cores x mm2 equivalent to H x W x

D DOWELL'S CAT NO. mm x mm

x mm ------------------------------------------------------------------------------------------------------------------------- 1. Upto 3 3x4 M6 CUS/06 100 x 100 x 60 2. 3.1 - 7.5 3x6 M6 CUS/07 100 x 100 x 60 3. 7.6 - 15 3x16 M6 CUS/09 100 x 100 x 60 4. 16 - 25 3x35 M8 CUS/12 150 x 150 x 75 5. 26 - 40 3x70 M10 CUS/17 200 x 200 x 100 6. 41 - 55 3x120 M12 CUS/22 400 x 400 x 125 7. 56 - 70 3x185 M16 CUS/28 450 x 450 x 150 8. 71 - 85 3x240 M20 CUS/30 500 x 500 x 200 9. 86 - 110 3x400 M20 CUS/33 600 x 600 x 200 10. 111 - 175 3x1Cx500 M20 CUS/34 600 x 200 x

200 (3 separate cable boxes for the 3 single core cables)

----------------------------------------------------------------------------------------------------------------------


TCE-M4-203-01



ISSUE R8

TITLE


TCE FORM NO. 329 R4

10.0 PAINT AND FINISH 10.1 All motor parts exposed directly to atmosphere shall be finished and painted to

produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with one coat of primer and finished with two coats of grey enamel paint.

11.0 HEATING DURING IDLE PERIODS 11.1 For motors rated 30 kW and below, during idle periods, the stator winding will be

connected to a 24 V single phase, 50 Hz, AC supply for heating and elimination of moisture. The supply will be connected between any two terminals.

11.2 Motors rated above 30 kW shall have space heaters suitable for 240V, single

phase, 50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal temperature above dew point to prevent moisture condensation during idle period. The space heaters shall be placed in easily accessible positions in the lowest part of the motor frame.

12.0 ACCESSORIES 12.1 Two independent earthing points shall be provided on opposite sides of the

motor, for bolted connection of the PURCHASER'S earthing conductors as specified in data sheet-A. These earthing points shall be in addition to earthing stud provided in the terminal box.

12.2 Except when otherwise specified, the motors shall be provided with a bare shaft

extension having a key slot and a key at the driving end. 13.0 TESTS 13.1 Motor shall be subjected to all the routine tests as per applicable standard in the

presence of the PURCHASER'S representative. Copies of test certificates of type and routine tests, shall be furnished as specified in the distribution schedule, for the PURCHASER'S approval. The VENDOR shall ensure to use calibrated test equipment/instruments having valid calibration test certificates from standard laboratories traceable to national/international standards.

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIIB TCE-M4-203-01


DATA SHEET-C

INDUCTION MOTORS

SHEET 1 OF 3

ISSUE R8

TITLE

INFORMATION TO BE SUBMITTED BY THE VENDOR

AFTER AWARD OF CONTRACT

1.0 Technical particulars as per data sheet B of tender specification. (Based on motor

manufacturer) 2.0 Type and frame size : 3.0 Starting time (Secs) 3.1 With 100% voltage at terminals 3.2 With minimum voltage at terminals (at ____ % Rated voltage) 3.3 With 110% voltage at terminals 4.0 Safe stall time at 100/110% rated voltage under hot/cold condition. 5.0 Type and size of cable for which gland is provided in the terminal box : 6.0 Type of bearings and expected life. 7.0 Total weight of motor (kg) 7.1 Weight of Stator (kg) 7.2 Weight of Rotor (kg) 8.0 Motor GD2 : 9.0 Efficiency (%) 9.1 Full Load Efficiency 9.2 75% Load Efficiency 9.3 50% Load Efficiency 9.4 25% Load Efficiency



DATA SHEET-C

INDUCTION MOTORS

SHEET 2 OF 3

ISSUE R8

TITLE

10.0 Power Factor 10.1 Full Load Power Factor 10.2 75% Load Power Factor 10.3 50% Load Power Factor 10.4 25% Load Power Factor 11.0 Torque (% FLT) 11.1 Starting 11.2 Maximum (Pullout torque) 11.3 Pull up torque 12.0 Type of Enclosure 13.0 Cooling designation 14.0 Space heaters 14.1 Rated voltage/number 14.2 Rating total 14.3 Separate terminal box provided 15.0 Motor reactances (Pu) 15.1 Subtransient reactance 15.2 Transient reactance 15.3 Steady state reactance 16.0 Guaranteed losses (kW) 16.1 Iron loss 16.2 Copper loss 16.3 Friction, Windage & Stray losses.



DATA SHEET-C

INDUCTION MOTORS

SHEET 3 OF 3

ISSUE R8

TITLE

17.0 Motor outline dimension drawing (Number of copies as per distribution schedule) 18.0 Type test certificates (Number of copies as per distribution schedule) 19.0 Speed torque curve at rated & minimum starting voltage. 20.0 Current - speed curve. 21.0 Current - time curve. 22.0 Efficiency, power factor, slip, current against output curve. 23.0 Thermal withstand characteristic for motors of 100 kW & above - Hot & Cold. 24.0 Negative sequence current Vs time curve for motor of 100 kW & above. 25.0 Rotor voltage/Rotor current (for wound motors).

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIB TCE-M4-219-01 2X 800 MW TPP NEAR KRISHNAPATNAM

CONTROL CABINETS

SHEET 1 OF 6

ISSUE R7

TCE FORM NO. 329 R4CONSULTANTS: TCE Consulting Engineers Limited

1.0 SCOPE

1.1 This specification covers the design, material, construction features, manufacture, inspection and testing at the VENDOR'S / his SUB-VENDOR'S works, delivery to site and performance testing of Control cabinets upto 415V.

2.0 CODES AND STANDARDS

2.1 This design, material, construction, manufacture, inspection, testing and performance of control cabinets shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the latest applicable standards mentioned in Data Sheet A2. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

2.2 Supply items which are bought out by the VENDOR shall be procured from approved manufacturers acceptable to the PURCHASER/ENGINEER.

3.0 CONSTRUCTIONAL FEATURES

3.1 Control cabinets shall be sheet steel enclosed and shall be dust, weather and vermin proof providing a degree of protection of IP 52 for indoor use and IP 54 for outdoor use. Sheet Steel used shall be cold rolled and at least 2.0mm thick and properly braced to prevent wobbling.

3.2 Control cabinets shall be provided with hinged door(s) with padlocking arrangement and suitable brackets/channels shall be provided for the type of mounting specified in Data Sheet A1.

3.3 All doors, removable covers and plates shall be gasketed all around with neoprene gaskets. All accessible live connections shall be shrouded and it shall be possible to change individual fuses, switches, MCBs without danger of contact with live metal.

3.4 All live parts shall be provided with atleast phase to phase and phase to earth clearances in air of 25 mm and 20mm respectively.

3.5 Adequate interior cabling space and suitable removable cable glands shall be provided if specified in Data Sheet 1 Sr No.1.5 (C). Necessary number of cable glands shall be supplied and fitted screwed-on type and made of brass.


CONTROL CABINETS

SHEET 2 OF 6

ISSUE R7


3.6 Two earthing terminals shall be provided to suit the PURCHASER'S earthing conductor.

3.7 All sheet steel work shall be degreased, pickled, phosphated and then applied two coats of zinc chromate primer and two coats of finishing synthetic enamel paint, both inside and outside, of colour as specified in Data Sheet A1. For chemical/corrosive areas epoxy paint shall be used whenever specified in Data Sheet A1.

4.0 MAIN BUSBARS

4.1 Busbars shall be insulated and of aluminium alloy of E91E grade and shall have adequate cross-section to carry the required continuous currents such that the operating temperature of the busbars does not exceed 850C.

5.0 MOTOR FEEDERS

5.1 Each motor to be controlled from the cabinet shall be provided with 3 pole/2 pole isolating switch, HRC fuses, contractors with thermal overload relays and other equipment required for satisfactory control of motors. When schematic drawings/bill of material is enclosed, all equipment shown shall be supplied by the VENDOR. The isolating switch and contactor shall be rated at least 20% more than the connected motor full load current.

5.2 Unless otherwise specified motors rated 0.5KW and above being controlled from the control cabinet will be rated for 415V, 3 phase, 50 Hz and motors rated below 0.5 KW will be 240V, 1 phase, 50 Hz.

6.0 SWITCHES/MCBS

6.1 Switches / MCBs / MPCBs /MCCBs shall be hand operated, air break, heavy duty, quick make, quick break type conforming to applicable standards mentioned in Data Sheet A2.

6.2 The rating of switch shall be so chosen as to get complete protection by associated O/L relay or fuse under all normal/abnormal conditions such as full load, overload, locked rotor, short circuit etc. MCBs / MPCBs /MCCBs shall be provided with overload/short-circuit protective device.

6.3 It shall be the responsibility of the VENDOR to fully coordinate the overload and short circuit tripping of the MCBs / MPCBs /MCCBs with


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the downstream MCBs/fuses/motor starters, to provide satisfactory discrimination.

6.4 Switch handle shall have provision for locking in both fully open and fully closed positions. MCBs / MPCBs /MCCBs shall be provided with locking facility when called for in Data Sheet A1.

7.0 CONTACTORS

7.1 Contactor type motor starters shall be of the full voltage, direct-on-line, air break, single throw, electro-magnetic type unless otherwise specified. Automatic star-delta type starters shall be provided when specified.

7.2 Contactors shall be provided with at least 2 'NO' and 2 'NC' auxiliary contacts.

7.3 Contactor shall be provided with a three element, positive acting, ambient temperature compensated time lagged, hand reset type thermal overload relay with adjustable settings to suit the rated motor current.

8.0 FUSES

8.1 Fuses generally shall be of the HRC cartridge link type, mounted on plug-in type of fuse bases having a rupturing capacity of 80 kA. Fuses upto 63A may be of HRC cartridge screw-cap, D-type, having a rupturing capacity of not less than 46 kA at 440V A.C. and 16 kA at 250V D.C.

8.2 Fuses shall be provided with visible operation indicators to show that they have operated.

8.3 All accessible live connections shall be adequately shrouded, and it shall be possible to change fuses with the circuit alive, without danger of contact with live metal.

9.0 INSTRUMENT TRANSFORMERS

9.1 Current and voltage transformers shall be dry type. Unless otherwise specified it shall be the responsibility of the VENDOR to ensure that the class and VA burdens of the instrument transformers provided are adequate for the relays and meters connected to these. Facilities shall be provided for short circuiting and grounding the CT secondary at the terminal blocks. Test links shall be provided in the CT secondary leads to carryout current and phase angle measurement tests with CTs in


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service. Voltage transformers shall be provided with suitably rated primary and secondary rated fuses. The details of the instrument transformer are subject to the PURCHASER's approval.

10.0 CONTROL AND AUXILIARY POWER SUPPLY

10.1 All AC control equipment shall be suitable for operation on 240V AC, 1 phase, 50 Hz system. This supply may be obtained from phase and neutral when 4 wire 415V main supply is available. Otherwise, or when control voltage, other than 240V is specified, a suitable transformer shall be provided. The control transformer shall be complete with isolation facilities and primary and secondary HRC fuses.

10.2 Separate circuits with switches, fuses etc. of adequate rating shall be provided for control of space heater, through thermoster and panel illumination etc.

11.0 RELAYS

11.1 Necessary auxiliary release for alarm, time-delay relays, voltage relays as required for control and protection shall be mounted inside the cabinet. Relays shall be equipped with externally reset, positive action operation indicator. Voltage relays shall have sufficient thermal capacity for continuous energization, using external resistors if necessary.

11.2 Auxiliary relays shall be rated to operate satisfactorily between 80% and 110%of the rated voltage.

11.3 Each relay shall be provided with at least two potential free contacts (1NO+1NC) for the PURCHASER's use.

11.4 Make and type of relay shall be subject to the PURCHASER's approval.

12.0 CONTROL AND SELECTOR SWITCHES

12.1 Control and selector switches shall be of the rotary type provided with properly designated escutcheon plates clearly marked to show the operating positions. Control switches shall have momentary contacts, spring return to centre, with pistol grip handle. Selector switches shall have stay put contacts with oval handles. The number of contacts and their operation in each switch shall be as indicated in control schematic (when enclosed) or shall be as per the requirements of the connected


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circuit. The switches shall be rated for minimum 10A at 240V A.C. and 1A inductive break at 220V D.C.

13.0 PUSH BUTTONS

13.1 All pushbuttons shall be of push to actuate type having 2 'NO' and 2 'NC' self reset contacts. They shall be provided with integral escutcheon plates, engraved with their functions. Pushbuttons contacts shall be rated for 10 Amps at 240V A.C. and 1 Amp inductive breaking at 220V D.C.

14.0 INDICATING LAMPS

14.1 Indicating lamps of the Clustered Coloured LED type with coloured Lens engraved “ON”,”OFF”,”TRIP”.

15.0 SPACE HEATER

15.1 Strip type space heaters of adequate capacity shall be provided inside each cabinet. Heaters shall be complete with rotary type 'ON-OFF' switch, HRC fuse on phase or a single-pole MCB with overload and short circuit protection, link on the neutral and a thermostat to cut off the heaters at 45 Degree Celsius and shall have continuously settable range from 30 to 90 degree Celsius.

16.0 INTERIOR LIGHTING AND RECEPTACLE

16.1 Control cabinet shall be provided with a 240V, 1 phase, 50 Hz, 40W preferably fluorescent lighting fixture for interior illumination controlled by a 'ON-OFF' switch / MCBs and 240V, 1 phase, 5/15 Amp., 3 pin receptacle with Plug and Switch/MCB for Switching ON & OFF.

16.2 Power source for interior lighting and receptacles shall be completely independent of control power source.

17.0 CABINET INTERNAL WIRING

17.1 Control cabinet shall be supplied completely wired, ready for the PURCHASER'S external connections at the terminal blocks. All wiring shall be carried out with 650/1100V grade, PVC insulated, stranded conductors. Power circuits shall be wired with standard aluminium conductors of adequate sizes to suit the rated circuit current; the minimum size shall be 4 sq.mm. Control, alarm and indication circuits shall be wired with stranded copper conductors of sizes not smaller than 1.5 sq.mm. C.T. circuits shall be colored wired for R Y B phases with stranded copper conductor of size, not smaller than 2.5 sq.mm.


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17.2 Engraved identification ferrules, marked to correspond with the wiring diagram shall be fitted at both ends of each wire. All wiring shall be adequately rated for the circuit current, the minimum rating shall be 20A.

18.0 LABELS AND DIAGRAM PLATE

18.1 Every equipment mounted in the cabinet shall be provided with individual labels with equipment designation/rating. Also, the cabinet shall be provided on the front & Rear side with a non-rusting label engraved with the designation of the cabinet as furnished by the PURCHASER.

18.2 Inside the door a circuit diagram engraved on non-rusting metal / PVC shall be fixed for reference.

19.0 DRAWINGS AND DATA

19.1 As part of the proposal, the BIDDER shall furnish the following drawings and data for scrutiny.

a) Control cabinet general arrangement drawing showing dimensioned views, cable entry location and mounting details.

b) Schematic wiring diagram of the control cabinet.

c) Bill of material listing equipment designation, make, type, rating etc. of the various equipment mounted on the control cabinet.

20.0 TESTS & TEST REPORTS

20.1 Acceptance and routine tests for all supply equipments/component parts shall be carried out as per the relevant standards for the respective equipment. These test reports and available type test reports shall be submitted to the PURCHASER before despatch of the equipment.

20.2 Control cabinet shall be subjected to following tests: a) High voltage test (2000 volts for 1 minute)

b) Megger test

c) Electrical control, interlock and sequential operation tests.

20.3 Calibration certificates. Instruments used for testing and inspection shall have valid calibration and accuracy traceable to National Standards.

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIIB TCE-M4-219-01 2X 800 MW TPP NEAR KRISHNAPATNAM

CONTROL CABINETS

DATA SHEET -C

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DATA TO BE FURNISHED BY THE VENDOR

AFTER AWARD OF CONTRACT

1.0 Following data shall be submitted within 3 months after placing the order.

1.1 Schematic diagram indicating terminal numbers for external connections and with a Bill of Material for all the equipment.

1.2 Control cabinet drawing showing outline dimensions, cable entry openings, floor / wall / pedestal fixing arrangements, padlocking arrangement, weights.

1.3 MANUFACTURER'S technical literature on various equipment mounted on control cabinet.

2.0 Cabinet internal wiring diagram (This drawing shall be submitted only for information and records and shall be based on a approved schematic drawing. The correctness of this drawing shall be the responsibility of the VENDOR).

3.0 Test certificates for the control cabinet and the various equipment mounted therein shall be submitted atleast 2 weeks before despatch of equipment.

Note The VENDOR should allow atleast 4 weeks time in his manufacturing schedule for approval of the drawing by the PURCHASER.


LOW VOLTAGE SWITCHGEAR

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TCE FORM NO. 329 R4 CONSULTANTS: TCE Consulting Engineers Limited

1.0 SCOPE This specification covers the requirements of design, materials,

manufacturing, testing and inspection at Vendor's works of Low Voltage switchgear for voltage not exceeding 1000 V A C.

2.0 CODES AND STANDARDS The design, manufacture and performance of equipment shall comply with

latest applicable Codes of Standards specified in Data Sheet-A2. In case of conflict between standards and this specification, this specification shall govern.

3.0 CONSTRUCTIONAL FEATURES 3.1 The major parameters of the switchgear and other required features are given

in data sheet - A1, A2 and A3. The bidder shall in his offer specifically conform compliance of these data in full. Deviation if any should be specifically brought out in the schedule of Technical Deviation.

3.2 The switchgear shall be indoor, metal enclosed, floor mounted of uniform

height not more than 2450 mm, made up of the requisite vertical sections, dust and vermin proof construction with IP - 52 degree of protection, unless otherwise stated.

3.3 Adjacent switchgear cubicles shall be provided with side sheets on either side

to ensure complete isolation. The switchgear shall be easily extendable on both sides by the addition of vertical sections.

3.4 The bottom of the switchgear shall be fully covered by sheet steel. 3.5 Removable gland plates shall be provided for power and control cables. The

gland plates shall be 3mm thick for panel with breaker cubicles and 2mm thick for other cubicles. The gland plates for single core cables shall be of non-magnetic material.

3.6 All sheet steel work shall be thoroughly cleaned of rust, scale, oil, grease, dirt

and swarf by pickling, emulsion cleaning etc. The sheet steel shall be phosphated and then painted with two coats of zinc rich primer paints. After application of the primer, two coats of finished synthetic enamel ovenbaked/stoved, paint shall be applied or powder coated.

3.7 Each switchgear cubicle shall be fitted with a label in the front and back of the

cubicle. Each switchgear shall also be fitted with label indicating the



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switchgear designation, rating and duty. Each relay, instrument, switch, fuse and other devices shall be provided with separate labels.

3.8 Operating devices shall be incorporated only in the front of the switchgear. No

equipment needing manual operation shall be located less than 250 mm above ground level.

3.9 The switchgear shall be divided into distinct vertical sections comprising of

a) Individual feeder module which shall be integral multiples of basic module, containing all associated equipment, enclosed in sheet steel enclosure on all sides and the rear except cable alley side and provided with hinged door on the front.

b) A completely metal enclosed, busbar compartment running

horizontally, and a vertical busbar compartment serving all modules in vertical section.

c) A vertical cable alley covering the entire height, except horizontal

busbar compartment with minimum 250 mm width for MCC modules at right hand side and minimum 200 mm for circuit breaker controlled modules, with adequate number of slotted cable support arms.

d) A horizontal separate enclosure or enclosures separated by

hylum/FRP sheets for power and control buses with tap off connections to each vertical section.

3.10 The circuit breakers shall be fully draw out type. The circuit breakers shall

have distinct service, test, isolated and maintainance positions. In the test position the circuit breakers shall be capable of being tested for operation without energising the power circuits. Four normally open auxiliary contacts shall be provided for each of the services and test limit positions switches.

The test position should preferably be obtained without the need to

disconnect normal control connections and use extension cords for testing. 3.11 The current transformers shall be mounted on the fixed portion of the

switchgear but not directly on buses or the breaker truck. 3.12 The withdrawable chassis housing feeder for motor control equipment except

circuit breakers/common control transformers of big size, shall be of the fully drawout, semi-drawout, or fixed type as specified in the Data Sheet-A1.



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3.12.1 Fully Drawout Type Withdrawable Chassis In this type of construction it shall be possible to drawout the withdrawable

chassis without having to unscrew or unbolt any connections to the equipment mounted on the withdrawable chassis. The power and control drawout type connections shall be of the stab-in or sliding type. All drawout contacts, including for auxiliary and control wiring shall be of self aligning type.

3.12.2 Semi-Drawout Type Withdrawable Chassis In this type of construction, it shall be possible to drawout the withdrawable

chassis after manually unplugging at the terminal blocks the control circuit connections of the equipment mounted on the withdrawable chassis, without having to unbolt any power connections of the equipment. The power connections shall be of the stab-in or sliding type and shall be disconnected when the chassis is withdrawn.

3.12.3 Fixed Type Withdrawable Chassis In this type of construction all power connections to the equipment mounted

on the withdrawable chassis shall be of the bolted type. All control circuit connections to equipment mounted on the withdrawable chassis shall be carried out through conventional terminal blocks mounted in the respective chassis. It shall be possible to drawout the chassis after unbolting/ unscrewing all the power and control circuit connections to the equipment mounted on the withdrawable chassis.

3.13 All identical equipment and corresponding parts including chassis of drawout

modules of the same size shall be fully interchangeable, without having to carry out modifications.

3.14 The draw-out contacts shall be made of copper/ copper alloy/aluminium

faces, which shall be silver or tinplated. 3.15 If ventilating louvers are provided they shall be provided with fine-screened

brass or GI meshes from inside to prevent entry of vermin and dust. 3.16 Module Types 3.16.1 The various types of modules indicating the control requirements of each

type, together with the list of component equipment required for each type are detailed in the enclosed drawings. These are as follows :

A - Incoming circuit - Isolating switch & fuse.



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B - Incoming circuit - Circuit Breakers. C - Incoming circuit - Isolating switch. D - Voltage transformer circuit. E - Outgoing feeder - Circuit breaker. F - Outgoing feeder - Switch-fuse unit controlled. G - Bus coupler H - Auxiliary services - Common equipment for annunciation scheme. J - Auxiliary services - Common equipment for space heater supply. K - Motor control - Direct-on-line-non essential motors L - Motor control - Direct-on-line essential motors M - Motor control - Automatic Star-Delta motor (open-transition) P - Motor control - Automatic Star-Delta motor (close-transition) R - Motor control - Reversing control 3.16.2 Motor control modules are further differentiated by suffixes as described

below, unless otherwise stated in Data Sheets-A3. Suffix in Denotion Suffix in Denotion First (Control second (Motor kW Digit location) digit rating range) 1 Controlled 1 Upto 30 kW from MCC 2 31 - 49 kW 3 50 -125kW 4 above 125 kW 2. Controlled 1 Upto 30 kW remote from 2 31-49 kW MCC 3 50-125 kW 4 above 125 kW 3.17 Main And Auxiliary Buses 3.17.1 Busbars shall be of uniform cross section throughout the length of the

switchgear, and upto the incoming terminals of the incoming feeder circuit breaker/ switch.



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3.17.2 All busbars, shall be insulated with close fitting sleeve, all bus taps, joints shall be insulated with moulded caps. If insulating sleeve is not coloured busbars shall be colour coded with coloured bands at suitable intervals.

3.17.3 Busbars shall be adequately supported on insulators. These shall withstand

dynamic stresses due to short circuit currents specified. 3.17.4 Auxiliary Buses Auxiliary buses for control power supply, space heater power supply or any

other specified service shall be provided. These buses shall be insulated, adequately supported and sized to suit specific requirements. The material of control power supply buses shall be electrolytic copper. The material for space heater power supply buses shall be same as that for the main power buses. Supply transformer(s), auxiliary busbars and necessary connections to the supply transformers and associated circuits shall be in the VENDOR'S scope.

3.18 SAFETY INTERLOCKS AND FEATURES 3.18.1 Withdrawal or engagement of circuit breakers or switch (isolator) shall not be

possible unless it is in the open position. 3.18.2 Operation of circuit breaker shall not be possible unless it is fully in service

positions or in test position or is fully drawn out. 3.18.3 Circuit breaker cubicles shall be provided with safety shutters operated

automatically by the movement of the circuit breaker carriage, to cover the exposed live parts when the breaker is withdrawn.

3.18.4 Caution name plate with inscription "Caution - Live Terminals" shall be

provided at all points where the terminals are likely to remain live and isolation is possible only at remote end, e.g. incoming terminals.

3.18.5 A breaker of given rating shall be prevented from engaging with a stationery

element of higher rating. 4.0 CIRCUIT BREAKERS 4.1 Circuit breakers shall be provided with following accessories. 4.1.1 Accessories as asked in Data sheet - A1



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4.1.2 Mechanically operated targets to show 'Open', 'Closed', 'Service' and 'Test' positions of the circuit breaker.

4.1.3 Mechanically operated, red 'trip' push button, shrouded to prevent accidental

operation. 4.1.4 Locking facilities in the 'Service', 'Test', and 'Isolated', positions. In test

position the breaker will be tested without energising the power circuits. The breaker shall remain fully housed inside the compartment in the test position.

4.1.5 Minimum 6 NO and 6 NC potential free auxiliary contacts, rated 10 A at 240V

A.C. and 1A (inductive breaking at 220 V D.C.) 4.1.6 'Red', 'green' and 'amber' indicating lamps to show 'Closed' 'Open', and 'Auto-

trip' conditions of the circuit breaker when breaker operation is controlled by a control switch.

4.1.7 Closing and trip coil shall operate satisfactorily under the following conditions

of supply voltage variation : Closing coils - 85% to 110% of rated voltage. Trip coils - 70% to 110% of rated voltage. 4.1.8 When series trip circuit breakers are specified the following releases with

adjustable settings shall be provided : (Oil dash-pot type release is not acceptable):

a) Overload b) Short circuit c) Undervoltage 4.1.9 In addition to the adjustable current setting range specified in the Data Sheet-

A1 short circuit releases shall be provided with at least four adjustable time delay settings, If it is not possible to provide the specified adjustable current setting range for the short circuit releases, shunt trip circuit breakers together with necessary protective relays shall be offered and shall be indicated in Data Sheet-B by the VENDOR.

4.1.10 Facilities shall be provided for blocking the under-voltage release, if so

required at Site. 4.1.11 Each of the foregoing releases shall be provided with a single pole, double

throw, potential free alarm contact rated for 0.5A, 220V D.C.



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4.1.12 The breakers controlling motors shall operate satisfactorily under following conditions :

a) Direct-on-line starting of the specified motor. b) Breaking no load current of the specified motor. 4.2 SPRING OPERATED MECHANISM The operating mechanism shall be manually operated spring charging stored

energy type or with motor, opening and closing springs, limit switches for automatic charging and all necessary accessories. Facility for manual charging of the closing spring shall be provided. The operating mechanism shall be trip-free and non-pumping electrically. An antipumping relay to achieve electrical anti-pumping feature even if the breaker has provision for anti-pumping by mechanical arrangement.

Power operated mechanism shall be :

a) Provided with facilities for remote panel closing and opening operations whenever specified in Data Sheet-A3 as per breaker module designation and respective enclosed control scheme drawing.

The control scheme will be as follows for remote control : Breaker Position Service Test Selector Switch Local Remote Local Remote 1. Switchgear Protection Yes Yes Yes Yes Tripping 2. Remote Interlock Yes Yes - - Tripping 3. Switchgear Manual - - Yes - Closing 4. Remote and - Yes - Yes Auto Closing through Interlocks 5. Switchgear Manual Yes - Yes - Tripping



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6. Remote Manual Yes Yes - Yes Tripping 7. Local P.B. Station of Motor (For breaker operated motors): a) Closing for trial Yes - - - run b) Tripping Yes Yes Yes Yes Power operating mechanisms shall be provided with the following additional

features: b) Closing of the circuit breaker shall automatically initiate recharging of

the spring ready for the next closing stroke. c) The motor shall be mechanically decoupled as soon as the emergency

manual charging handle is coupled.

5.0 PROTECTION COORDINATION It shall be the responsibility of the Vendor to fully coordinate the overload and

short circuit tripping of the circuit breakers with the upstream and downstream circuit breakers/fuses/motor starters, to provide satisfactory discrimination.

6.0 AIR BREAK SWITCHES 6.1 Air break switches shall be of the heavy duty, group operated load-break,

fault-make type, complying with the requirements of applicable standards mentioned in Data Sheet-A2.

6.2 Continuous current rating of switches shall be as specified in Data Sheet-A3

or single line diagam enclosed with specification. 6.3 Whenever solid link are used for the connections between switches and

fuses, such links shall be fitted with insulated sleeves. Whenever the links are of less than 100 mm length where sleeves cannot be fitted, taping is acceptable.

6.4 All live parts of the switch shall be shrouded. 6.5 Switch operating handle shall be suitable for padlocking in 'OFF' position.



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6.6 It shall be possible to open the door only when the switch is in the 'off'

position. 6.7 Suitable means shall be provided to intentionally release the interlocks

specified in the preceeding clause 6.6 for making trip setting adjustments and operation tests.

7.0 FUSES 7.1 Fuses generally shall be of the HRC cartridge fuse-link type having a certified

rupturing capacity of not less than 80 kA at 440V. 7.2 Fuses shall be provided with visible indication to show that they have

operated. 7.3 Fuse ratings chosen by the VENDOR for application in various circuits shall

be subject to the PURCHASER'S approval. 7.4 Fuses shall preferably be mounted in moulded plastic carriers and shall be

complete with fuse bases. 7.5 Wherever it is not possible to mount fuses on carriers, fuses shall be directly

mounted on plug-in type of bases. In such cases an insulated fuse pulling handle shall be provided for each size of fuse for each switchboard.

7.6 Current time characteristics of fuses shall be furnished along with bid. 8.0 MOTOR STARTERS 8.1 CONTACTORS 8.1.1 Motor starter contactor shall be of the electromagnetic type rated for

uninterrupted duty as defined in applicable standards unless otherwise specified in Data Sheet-A1.

8.1.2 Operating coils of contactors shall be suitable for operation from the control

supply system specified in Section-B or as per enclosed control schemes. 8.1.3 Class of coordination for starter module shall be class '2' as per IS-13947. 8.2 DIRECT-ON-LINE STARTERS



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8.2.1 Direct-on-line starters shall be suitable for Class AC 3 utilisation category as specified in applicable standards, unless otherwise mentioned in Data Sheet-A1.

8.3 AUTOMATIC STAR-DELTA STARTERS 8.3.1 Automatic star-delta starters shall comprise three sets of contactors one for

the line, one for the star point and one for the delta, and a timer to automatically change the connections from star to delta.

8.3.2 Star-delta contactors shall be electrically interlocked to permit starting of the

motor in the proper sequence, namely star contactor closing, line contactor closing, timer energised after time delay, timer contact de-energising the star contactor, and delta contactor closing.

8.3.3 Star-delta starters shall be suitable for AC 3 utilisation category as specified

in applicable standards, unless otherwise mentioned in Data Sheet-A1. 8.4 REVERSING STARTERS 8.4.1 Reversing starters shall comprise forward and reverse contactors, electrically

interlocked with each other. 8.4.2 Reversing starters shall be suitable for Class AC 4 duty as specified in

applicable standards, unless otherwise mentioned in Data Sheet-A1. 8.5 THERMAL OVERLOAD RELAYS 8.5.1 Starters shall be complete with a three element, positive acting, ambient

temperature compensated, time lagged thermal overload relay with adjustable settings and built in single phasing preventer. The setting range shall be properly selected in accordance with the rating of the motor.

8.5.2 Thermal overload relays shall be hand reset type, unless otherwise specified

in Data Sheet-A1. 8.5.3 'Stop' push button of the starter and hand reset device shall be separate from

each other. 8.5.4 Overload relay hand reset push button shall be brought out on the front of the

compartment door. 8.6 SWITCH AND CONTACTOR RATINGS



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8.6.1 Switch and contactor rating for various motor starter modules shall be selected by the bidder and indicated in the bid. BIDDER shall also select appropriate ratings for HRC fuses and ranges for thermal overload relays and indicate the same in the bid. These details shall be subject to the PURCHASER'S approval.

8.7 Moulded Case Circuit Breakers 8.7.1 Moulded case circuit breakers (MCCBs) shall be provided when called for in

Data Sheet-A1, for use in lieu of switchfuse for the motor controls. The MCCBs shall conform to the latest applicable standards.

8.7.2 MCCBs in AC circuits shall be of triple/four pole construction arranged for

simultaneous three/four pole manual closing and opening. If indicated in Data Sheet-A1, power closing device for remote operation shall be provided. Operating mechanism shall be quick-make, quick-break and trip-free type. The ON, OFF and TRIP positions of the MCCB shall be clearly indicated and visible to the operator. Operating handle for operating MCCBs from door of board shall be provided.

8.7.3 The instantaneous short circuit release shall be so chosen by the VENDOR

as to operate at a current in excess of the peak motor inrush current and a range of settings shall be provided for the PURCHASER'S selection.

8.7.4 MCCB terminals shall be shrouded and designed to receive cable lugs for

cable sizes relevant to circuit ratings. 8.8 MINIATURE CIRCUIT BREAKERS 8.8.1 Miniature circuit breakers for use on motor space heater control circuits shall

comply with the requirements of applicable standards, unless otherwise mentioned in Data Sheet-A1.

9.0 EARTHING 9.1 An earthing bus shall be provided at the bottom and extended throughout the

length of the switchgear. It shall be bolted/welded to the frame work of each unit and each breaker earthing bar.

9.2 All non-current carrying metal work of the switchgear shall be effectively

bonded to the earth bus. Hinged doors shall be earthed through flexible earthing braid.

9.3 Positive earthing of the circuit breaker frame shall be maintained both in

service and test position.



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10.0 INSTRUMENT TRANSFORMERS 10.1 The ratings of instrument transformers specified in Data Sheet - A1 and A3

are approximate. The BIDDER shall ensure that the specified ratings are adequate for the relays and meters furnished by him. If specified ratings are not adequate the BIDDER shall offer instrument transformers of required rating.

10.2 The CTs and VTs shall be dry type and withstand momentary and short time

current ratings of the associated switchgear. For feeders with fuse, CTs shall have withstand capacity equal to let-through current of associated fuse.

10.3 Unless otherwise specified minimum performance requirements of CT's &

VTs shall be as follows. 10.3.1 CURRENT TRANSFORMERS Measuring CTs - 10VA, accuracy Class 1.0 and ISF of 5 Protective CTs - 10

VA, accuracy class of 5P-10. CTs shall be provided with test links in both secondary leads for carrying out

current and phase angle measurement. 10.3.2 VOLTAGE TRANSFORMER Measuring VT's - 50 VA per phase with accuracy class of 1.0. Protective VT - 50 VA per phase with accuracy class of 3.0. Dual purpose VT - 100 VA per phase and dual accuracy of 1.0/3.0 for

metering and protection respectively. Voltage transformer shall have continuous over voltage factor of 1.2 and

short time over voltage factor of 1.5 for 30 seconds for effectively earthed system and 1.9 for 8 hours for non-effectively earthed system.

Voltage transformers shall be complete with suitable rated primary,

secondary and tertiary fuses. Primary fuses shall have a rupturing capacity equal to the rupturing capacity rating of the associated switchgear. Fuses shall be provided on each sub circuit.

It shall be possible to replace voltage transformers without having to de-

energise the main bus bars.



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The terminals of V.T. secondary and tertiary windings which are required to be connected to earth shall be earthed by an isolating link without a fuse.

11.0 SWITCHGEAR ACCESSORIES AND WIRING 11.1 Switchgear shall be supplied completely wired internally upto terminal blocks

ready for the PURCHASER's external cable connections at the terminal blocks. Inter panel wiring between cubicles of same switchgear shall be routed inside by the VENDOR.

11.2 All auxiliary wiring shall be carried out with 1100 volts grade, single core,

stranded copper conductor with PVC insulation. The sizes of wire shall be not less than 2.5 mm² per lead of CT circuits and 1.5 mm² per lead of other circuits.

11.3 Terminal blocks shall be of stud type, 1100 volts grade, 10 amps. rated

complete with insulated barriers. Terminal blocks for CTs and VTs shall be provided with test links and isolating facilities and CT terminals shall have short circuiting and earthing facility.

11.4 All spare contacts and terminals of cubicle mounted equipment and devices

shall be wired to terminal blocks. 11.5 Accuracy class for indicating instruments shall be 2.0 or better. Instruments

shall be 96 mm square 90° scale for semi-flush mounting with only flanges projecting.

11.6 Relays shall be suitable for semi-flush mounting with only flanges projecting. 11.7 All protective relays shall be in draw-out cases with built-in test facilities.

Necessary test plugs shall be supplied loose and shall be included in the VENDOR'S scope of supply. All auxiliary relays and timers shall be supplied in non-draw-out cases. All relays shall be of self reset type except lockout relay unless otherwise specified. Externally operated hand reset flag indicators shall be provided on all relays and timers. Timers shall be of electromagnetic or electronic type only.

11.8 Control and instrument switches shall be rotary type provided with

escutcheon plates clearly marked to show operating position and suitable for semiflush mounting with only switch front plate and operating handle projecting out.

11.9 Breaker control switches shall be pistol grip black and selector switches shall

be oval or knob, black. Breaker control switches shall be 3 position spring return to neutral. Instruments selector switches shall be of the maintained



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stay-put type. Contacts of the switches shall be spring assisted and contact faces shall be with rivets of pure silver. The contact ratings shall be adequate to meet the requirements of circuit capacity in which they are used. If specified in data sheets, control switches with builtin flashing type discrepancy lamp shall be provided to control circuit breaker.

11.10 Push buttons shall be provided wherever specified. They shall be provided

with inscription plates engraved with their functions. Push buttons shall be rated for 10A at 240 AC and 1A at 220 VDC, with 2 No and 2NC contacts. Start PB shall be green in colour and stop PB shall be red coloured stay put type.

11.11 Indicating lamps shall be Cluster type LEDS. 11.12 Space heaters of adequate capacity shall be provided inside each panel.

They shall be suitable for 240 V, 1 ph, 50 cycles supply. They shall be complete with MCB or HRC fuses, isolating switches and adjustable thermostat.

11.13 Each switchgear panel shall be provided with 240 Volts, 1 phase. 50 cycles,

5 amps. 3 pin receptacle with switch located in a convenient position. 11.14 The single phasing preventer relay shall be provided when called for in data

sheet-A1 and shall have following characteristics.

- Operate for supply voltage unbalance of more than + 5% and when relay internal wiring is open circuited.

- Not operate for 3 ph supply failure. - Instantenous hand reset type - Visual indication for operation - Suitable for reversible and non-reversible motors 11.15 Transformers For Control, Space Heating And Annunciator Supplies 11.15.1 Adequately rated single phase, two winding, dry type transformers shall be

provided for providing supply to the switchgear control and alarm circuits, space heaters provided in plant equipment and space heaters in the switchgear and motor winding heating circuits.

11.15.2 As specified in the enclosed module control wiring drawing/bill of material

either duplicate common transformer with one as stand by shall be provided



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in each switchgear or a separate control transformer shall be provided in each module to cater for that particular module. Common control transformer rating shall be adequate to cater for all the control equipment connected across it. For control transformers in each module, the minimum rating shall be as follows :-

Motor rating Control Control transformer kW type rating VA ------------------- ------------- -------------------------- Upto and K-11 or 75 including 30 K-21 or R21 L-11 or L-21 100 Above 31 All types 300 11.15.3 All transformers of 500 VA and above shall be controlled by MCBs/

switches and fuses on the primary and secondary side. 11.15.4 Common control transformer shall have fuses on all line leads of each

winding and control transformer in individual module shall have fuse in the line lead of only secondary winding. The fuses shall be of proper rating to protect the control transformers against over loads and short circuits. the neutral or the earth lead shall have earth link instead of fuses.

11.16 Window Type Alarm Annunciator 11.16.1 The alarm annunciator if called for in Data Sheet-A shall consist of flush

mounted facia and shall have following features:- - Fault indication by steady lit window - Audiable alarm on fault occurrence - Acknowledgement, resetting and test - Suitable for NC/NO initiating contacts - Facility for separate audio visual alarm on control supply failure 11.16.2 The alarm annunciator scheme operation shall be as follows : Visual Audible alarm alarm ----------- ------------



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Normal OFF OFF On occurrence of fault - First fault Flashing ON Subsequent faults Flashing ON Accept fault - First faults Steady OFF Subsequent faults Steady OFF Reset - Faults cleared OFF OFF Faults not cleared Steady OFF Lamp test Steady OFF 12.0 CABLE TERMINATION 12.1 If asked for in Data Sheet-A1 necessary number of cable glands and lugs

shall be supplied for terminating power and control cables. Glands shall be of heavy duty brass castings, machine finished and complete with check nut. washers, neoprene compression ring etc. The lugs shall be tinned copper/aluminium depending on cable conductor and of solderless crimping type.

13.0 LOCAL PUSH BUTTON STATIONS 13.1 The local P.B. stations shall be metal enclosed, provided with IP-55

protection, made up of diecast aluminium or 2 mm thick sheet metal. 13.2 The P.B. station shall be suitable for wall or structure mounting, provided with

lables, earthing terminals, suitable lugs glands. 13.3 Push buttons shall be fitted with 2 No and 2NC contacts (1A at 220V DC and

10A at 240V AC) with stop PB of stay put type and red in colour. Other PB's shall be green in colour.

13.4 PB station shall be of one of the following types



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Type A -Three PB's forward-reverse-Stop for reversible motors Type B -Two PB's start-stop for non-reversible motors Type C -One PB STOP for emergency 14.0 SPARE PARTS The BIDDER shall furnish a list of recommended spare parts for five years

operation along with unit prices. 15.0 TESTS AND REPORTS 15.1 Type test reports for the switchgear and circuit breakers shall be furnished

along with the tender and subsequently. 15.2 The switchgear, circuit breakers and all associated equipment shall be tested

in accordance with relevant standards. All routine tests shall be carried out. Type tests shall also be carried out if not tested previously.

15.3 Type and routine test report shall be submitted for the PURCHASER's

approval before the equipment is despatched. Bound copies of test reports shall be furnished along with the switchgear.

15.4 All meters and other reference devices used for testing shall have valid

calibration from reputed national laboratories/institutes. Inspection by Purchaser/ Engineer will not be carried out unless the vendor confirms that calibrated equipment are ready for proceeding with the tests.

15.5 Equipment shall not be despatched unless the test certificates are duly

approved by the PURCHASER/ ENGINEER. DRAWINGS AND DATA The following shall be furnished as part of the tender: a) General arrangement showing plan, elevation and typical sectional

views. b) Foundation plan showing location of fixing channels, floor openings

etc. c) Schematic wiring drawings for each cubicle. d) Technical literature on the equipment offered.



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e) All drawings and data sheets shall be annotated in English. f) Quality Assurance Plan.


LOW VOLTAGE SWITCHGEAR SHEET 1 OF 4


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DATA SHEET-C

DATA TO BE FURNISHED BY THE VENDOR AFTER AWARD OF THE CONTRACT

Time periods indicated below are for project with equipment delivery period of

12 months these will be proportionately revised as per agreed delivery period. 1.0 OVERLOAD RELEASE (a) Characteristics (b) Settings 2.0 SINGLE PHASING PREVENTERS 2.1 Make 2.2 Type designation 2.3 Rated voltage 3.0 AUXILIARY RELAYS AND TIMERS 3.1 Time delay range (for timers) Sec. 3.2 Resetting features 3.3 No. of contacts 3.3.1 Normally open/Normally closed 3.3.2 Contact rating A 3.4 Whether operation indicator YES/NO is provided 4.0 CONTROL/SELECTOR SWITCH 4.1 Whether contact arrangement YES/NO as given in control scheme




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5.0 LIST OF DRAWINGS The VENDOR shall furnish the following drawings for each panel and

switchgear within the time indicated after placing the order. If a large number of switchgears are involved, the PURCHASER will indicate the priorities.

5.1 Overall outline dimensions and general 2 months arrangement including plan, front elevation, rear & side elevations, clearances required in front and back, details of busduct connections, if any. 5.2 Switchgear layout plan including 2 months floor openings, fixing arrangements and loading details. 5.3 Schematic control diagrams to cover 3 months controls, protection, interlocks, instruments, space heaters, etc. for each type of module 5.4 (a) Detailed internal wiring diagram 4 months of each type of module, including terminal block numbers, ferrule numbers and the PURCHASER's external cable connection designations (b) Itemised bill of material for each 4 months module, listing all devices mounted and also otherwise furnished like cable glands, indicating the MANUFACTURER's type, rating, quantity & special notes, if any. 5.5 Interpanel interconnection wiring 6 months diagram including terminal numbers and ferrule numbers 5.6 Switch development diagrams 6 months




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5.7 Each type of protection relay and cir- 6 months cuit breaker release characteristics 5.8 Fuse characteristic curves for each 6 months type and rating of fuse 5.9 Space heater ratings and numbers 6 months provided per cubicle and the internal distribution scheme for the same, for each switchgear NOTES: (a) The VENDOR shall be entirely responsible for the correctness of the internal

wiring diagrams mentioned against Item 5.4. (b) The VENDOR shall ensure that the characteristics of the CTs, fuses,

protection relays, VTs and all other devices offered by him are such as to be suitable for the purpose for which they are intended.

(c) The VENDOR shall plan his manufacturing schedule so as to allow atleast 4

weeks time for approval of the drawings after their receipt by the PURCHASER.

6.0 TEST CERTIFICATES 6.1 Type test certificates of all standard component parts, e.g. contactors,

breakers, switches, fuses, relays, CTs, VTs, and for the standard factory built assembly shall be submitted by the VENDOR within 3 months from receipt of order.

7.0 INSTRUCTION MANUALS The VENDOR shall furnish specified number of copies of the instruction

manual which would contain detailed instructions for all operational & maintenance requirement. The manual shall be furnished at the time of despatch of the equipment and shall include the following aspects :

a) Outline dimension drawings showing relevant cross-sectional views,

earthing details and constructional features. b) Rated voltages, current, duty-cycle and all other technical information

which may be necessary for correct operation of the switchgear.




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c) Catalogue numbers of all components liable to be replaced during the

life of the switchgear.

d) Storage for prolonged duration. e) Unpacking. f) Handling at site. g) Erection. h) Precommissioning tests. i) Operating procedures. j) Maintenance procedures. k) Precautions to be taken during operation and maintenance work.

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIIIB

TCE-M4-203-71 2X 800 MW TPP NEAR KRISHNAPATNAM

VARIABLE SPEED DC/AC DRIVES

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1.0 SCOPE 1.1 This specification covers requirements for the design, manufacture, testing and

supply of semiconductor (Thyristor/ Transistor) controlled variable speed DC/AC drives, both analog & digital type.

1.2 The motors and Converter Transformer when forming part of Bidder’s scope,

shall meet the requirements given in following standard specifications: a) Squirrel Cage Induction Motor : TCE-M4-203-01 (General Purpose) b) Squirrel Cage Induction Motor : TCE-M4-203-02 (Special Purpose) c) DC Motor : TCE-M4-203-11 d) Converter Transformer : TCE-M4-200-21 e) Induction motors for hazardous : TCE-M4-203-51 area (General purpose) 2.0 CODES AND STANDARDS 2.1 The design, material, construction, manufacture, inspection, testing and

performance of AC/DC Drives shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

2.2 Unless otherwise specified, the equipment / system shall conform to the latest

applicable standards as mentioned in enclosed Data Sheet-A.4 3.0 DESIGN BASIS FOR POWER SEMICONDUCTORS 3.1 Power semiconductors of reputed make either in stud mounting form or

disc/flat pack type can be offered based on the duty requirements specified in Data Sheet A1 and to meet the technical and functional requirments.

3.2 The peak reverse voltage rating of each power semiconductor shall be as

follows:




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3.2.1 Power Semiconductors Protected by RC Snubber The following factors of safety shall be observed: a) For converters operating in : 2.0 times peak of the No rectifying mode only load source voltage. b) For converters operating : 2.5 times peak of the no both in rectifying and load source voltage inverting modes 3.2.2 Power Semiconductors Protected by Avalanche Diodes The BIDDER shall choose and recommend the factor of safety which

however, shall not be less than 1.5. 3.3 The current rating of the power semiconductor shall be estimated for the

specified duty class in Data Sheet A. In sizing the power semiconductor both the forward voltage drop and the forward resistance shall be considered.

3.3.1 A derating of approximately 20% shall be made to take into account series operation of devices.

3.4 The class of overload shall be one of the following: - - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Duty Class Rated current values for converter (in percent of rated direct current - - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I 100 % Continuous II 100 % Continuous 150 % overload for 1 minute once in period of 24 hours III 100% continuous 150 % overload for 2 minute once in period of 24 hours 200 % overload for 10 seconds once in period of 24

hours - - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.5 For the cases where the power semiconductor chosen is of inadequate current

or voltage capacity the BIDDER shall conform to the following guidelines:




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3.5.1 Inadequate Current Capacity

a) If the power semiconductor is of stud mounting type, then current sharing reactors shall be provided to prevent current missharing between the power semiconductors connected in parallel.

b) If the power semiconductors in parallel are of capsule type, then, one

of the following options may be exercised:

i) Power semiconductors with adequate derating and the layout configured so that current missharing between various power semiconductors in parallel is minimised.

ii) Selection of power semiconductors so that their forward

voltages are within a tolerance band of 100 mV to 250 mV.

3.5.2 Inadequate Voltage Capacity In this case the power semiconductors shall be connected in series with

adequate protection to prevent irregular voltage grading across each power semiconductor during turn-on.

3.6 The converter shall be provided with adequate surge suppression circuitry at

the AC input, DC output and across the devices to limit the main voltage surges, transformer switching surges, reverse recovery transients to less than twice the peak value of line working voltage.

4.0 QUADRANTS OF OPERATION The drive should be according to the no. of Quadrants specified in Data Sheet

A. The Quadrant Operation of the Drive will be according to the following criteria.

a) One Quadrant Operation -> (I) : One Quadrant of operation means only

Motoring is required & the drive should operate in the Ist Quad. b) Two Quadrant Operation -> (II) :- Two Quadrant Operation means the

drive should be able to control the motoring & Braking of the motor. It can be of two types.

i) Voltage Positive & Current can charge Polarity i.e. Operating

in First & Second Quad.




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ii) Current Positive & Voltage can charge Polarity i.e. operating in

first & fourth Quad.

c) Four Quad Operation -> (IV) :- The drive should be able to operate in all four Quadrant i.e. the motor requires forward motoring, forward braking, Reverse motoring & Reverse braking.

5.0 CONTROL FOR DC MOTORS 5.1 Armature Voltage Control Converter 5.1.1 This converter shall consist of, unless otherwise stated in Data Sheet-A, a

three phase full wave bridge circuit. 5.1.2 Each arm of the bridge can have a number of power semiconductors both in

series and/or in parallel. The design basis for such cases shall be in conformity with Clause 3.0 of this specification.

5.1.3 If the drive operates in the first quadrant only, a free wheeling diode may be

provided for the purpose of allowing decay of energy during the condition of braking of the drive. This diode may be housed within the same cubicle as the bridge converter.

5.1.4 Redundancy shall be provided as follows:

a) For power semiconductors in parallel one additional parallel three phase full wave bridge arm shall be provided as redundant element.

b) For power semiconductors in series, at least 2% of the total thyristors

in series for each parallel arm shall be provided.

The factors of safety to be observed in such designs shall be in conformity to Clause 3.0 of this specification.

5.2 Field Excitation Control Converter 5.2.1 Unless otherwise stated in Data Sheet A, this converter shall be powered from

a single phase line-to-line source tapped at the three-phase incomer to the armature voltage control converter with adequate isolation.

5.2.2 Unless otherwise stated in Data Sheet-A, this converter shall be a bridge of

diodes of adequate capacity.




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5.3 Transducers 5.3.1 Armature Circuit

a) For drives where accuracy of speed control is better than 0.5%, the actual speed of the drive shall be measured by a tacho-generator of suitable rating, and type (Digital pulse tacho or analog tacho).

b) For drives where accuracy of speed control required can exceed 2% or

more, measuring the current by a current transformer on the AC side of the converter can be accepted.

c) For drives whose accuracy of speed should not exceed 2% it is

necessary that a suitable DC shunt of 75 mV and adequate current capacity shall be provided.

5.3.2 Field Circuit For Drives where there is a possibility of field circuit failing, then in such

cases transducers should be provided. 6.0 FREQUENCY CONVERTERS FOR SQUIRREL CAGE INDUCTION

MOTORS 6.1 Configuration Frequency converters shall have one of the two configurations given below: a) Current source inverter. b) Voltage source inverter. 6.2 DC Link 6.2.1 Current Source Inverter

a) The smoothing reactor shall be sized to avoid conditions of discontinuous current operation of the frequency converter at its lowest frequency of operation, which shall not be less than 5 Hz.

b) The smoothing reactor shall be uniformly insulated and shall be

protected for voltage surges occurring during sudden load throw-off.




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c) The smoothing reactor shall be made from electrolytic grade copper/aluminium and shall be epoxy encapsulated with suitable class of resin decided from techno-economic considerations and performance requirements in conformity with IEC-146.

6.2.2 Voltage Source Inverter

a) The smoothing reactor shall conform to requirements specified in Clause 6.2.1

b) The DC capacitor shall be shunt connected at the input to the inverter.

It shall be sized so that the reactive power requirements of the motor during its total range of operation is met. Further, the following aspects shall be observed:

i) As per standards, the nominal value of capacitance referred to

the temperature of 250C shall be within tolerance range of 10%. At the design ambient temperature, the value of capacitance and the tolerance range shall be such as to meet the normal operation/performance requirements of the frequency converter.

ii) As per standards, the dissipation factor of each unit of the

capacitor shall be less than 1% at 250C. However, the design ambient shall be such as to meet the normal operational/performance requirements of the frequency converter.

iii) The impregnant used for the capacitor shall be non-

inflammable, non PCB dielectric liquid. iv) The voltage rating of each capacitor shall be selected based on

considerations of life expectancy, overvoltage during regeneration of energy, design ambient temperature, ripple voltage etc.

6.3 Inverter 6.3.1 The inverter system suitable for three phase output shall consist of the

following subsystems:

a) The basic inverter circuit consisting of the switching device say Thyristors/Transistors/IGBT/MOSFET, connected so as to supply three phase power.




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b) The logic network to enable rapid transition of the main inverter

switching devices from on-state to off-state. c) Suitable feedback system to allow balance of reactive power flow

during load power factor fluctuation as well as regeneration. d) The filter system of the inverter output to supress 5th, 7th, 11th, 13th

harmonics at the output of the inverter to less than 5% of the fundamental amplitude.

e) The ripple control system to limit current ripple to 4% at the input

terminals of the inverter caused by distorted current output.

6.3.2 The output frequency of inverter shall be controlled to within the limits specified in Data Sheet-A.

6.4 Inverter for AC drive 6.4.1 Current Source Inverter

a) Constant Torque Operation The current output by the DC link shall be accurately monitored so that

the ratio of the terminal voltage of the motor and the corresponding frequency remains constant and the duty cycle requirements indicated in Data Sheet A are met. Necessary protective features for tripping the frequency converter, alarm/annunciation and fault diagnostics shall be provided.

b) Constant Horsepower Operation In this type of operation, the motor’s internal voltage shall be

maintained within + 1% while the frequency of the inverter is varied to meet the duty cycle requirements indicated in Data Sheet A. Necessary protective features for tripping the frequency converter, alarm/annunciation and fault diagnostics shall be provided.

6.4.2 Voltage source Inverter a) Constant Torque Operation

The DC voltage input to the inverter shall be accurately monitored to maintain the ratio the terminal voltage of the motor to frequency at the




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rated/design value so that the duty cycle requirements indicated in Data Sheet A are met. The DC voltage input shall be maintained within + 1% of the required value. Should this fall for any reason, necessary action for tripping the frequency converter, and initiation of annunciation/alarm and fault diagnostic shall be provided.

b) Constant Horsepower Operation In this type of operation, the voltage at the terminals of the motor shall

be maintained within +1% of the rated value while the frequency of the inverter is varied to meet the duty cycle requirements indicated in Data Sheet A. Necessary protective features for tripping the frequency converter , initiation of alarm/annunciation and fault diagnostic shall be provided.

6.5 Output Overcurrent Limit Unless otherwise stated, the inverter shall be capable of being temporarily

overloaded to 150% of its full load ampere capacity for sixty (60) seconds beyond which a current limit action shall be initiated and an alarm contact initiated for annunciation.

6.6 Control Modules 6.6.1 All elements of the control system shall be mounted on epoxy laminate boards

and each board shall be a plug in module mounted on a standard nineteen inch rack which shall be accessible from the front. Each card shall have LED indication on its front plate to indicate normal condition of the card. Readily accessible and clearly marked test pins shall be provided at the important points on the cards to enable signal analysis. The BIDDER shall furnish the signal input to the card.

6.6.2 The epoxy laminates shall be free from manufacturing errors and shall be

designed to prevent incorrect insertion in the card rack. The copper side of the card shall be suitably lacquered to prevent oxidation. The gap between two cards shall be sufficient to permit adequate ventilation.

6.6.3 Adjustments susceptible to change by accidental contact shall be lockable. 7.0 CONTROL REQUIREMENTS 7.1 Short time voltage dips upto 80% of nominal (e.g. in case of large motor start-

up connected to same bus) shall not cause the control system to stop functioning and shall not trip the drive system.




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7.2 The drive motor shall be speed regulated corresponding to 4-20mA or 0-10V reference input signal. Upon complete loss of users speed reference signal, the drive shall automatically run at constant speed as determined by the last speed reference available prior to loss of the signal.

7.3 The required provision for interfacing with PLC/DCS, including details of

communication module and data transfer facility, I/O details shall be furnished by the Bidder.

8.0 DRIVES WITH WOBBULATION CONTROL Drives used in application like synthetic fibre projects should have the main

feature of Wobbulation control as specified in the data sheet. The Wobbulation control should consist of a generation of a modulated

frequency, in converters feeding traversing drives. The drive should produce a triangular voltage of variable frequency and amplitude, which is superimposed on the frequency set-points voltage in the analog frequency generator.

9.0 PROTECTION 9.1 Protection of Power Semiconductor

a) Each power semiconductor shall be protected against short circuit. The fuse shall be sized so that its I2t does not exceed the I2t characteristic of the power semiconductor itself. The voltage and current rating of the fuse shall match the duty on the power semiconductor. The arc voltage, due to melting of the fuse shall not exceed the repetitive peak reverse voltage of the power semiconductor.

b) All fuses shall have a trip indicator to operate a suitable microswitch

with at least 1 NO + 1 NC potential free contacts for annunciation and/or tripping.

c) A fast tripping feeder circuit breaker shall be used in case fuses for

short circuit protection of thyristors are not used.

9.2 Protection of Converter System for DC Drive 9.2.1 Armature Circuit




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The basic protection to be provided are as follows: a) Earth fault relay b) Thermal overload relay Other optional protections that are required shall be considered in scope of

supply as listed in Data Sheet A. 9.2.2 Field Circuit The basic protection to be provided are as follows: a) Minimum excitation limit relay b) Thermal overload relay c) Earth Fault Relay Other optional protections that are required shall be considered in scope of

supply as listed in Data Sheet A. 9.3 Protective Systems for AC Inverter Drive

a) Fuses for all power semiconductors and/or other devices like commutation chokes, capacitors etc. which are not adequately protected against flow of abnormal currents.

b) Under voltage and over voltage protection on the input side. Loss of

input voltage to inverter shall entail tripping of the inverter. c) Protection for all control cards, power supply stabilisers, filter circuits

etc. Protection shall be provided such that failure of a part does not cause damage elsewhere in the system.

d) Polarising relay to prevent reversal of polarity on the input side of the

inverter. e) Protection of inverter thyristor, commutating circuits and other inverter

elements during regenerative operation of the inverter and also during sudden load throw-off.

f) Besides the above, the following protective systems shall be supplied if

called for in Data Sheet A.




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i) Current limit fuses at the output of the inverter. ii) Commutation circuit undervoltage iii) Inverter overfrequency iv) Programmable overcurrent v) Phase sequence/loss of phase protection vi) Earth fault protection

vii) DC link overvoltage protection viii) Specific motor protection

ix) Incoming line surge protection

x) Ventilation Loss

xi) Over temperature

9.4 All controls, indication, Metering, Annunciation on the Drive Panel, will be as

specified in Data Sheet-A.

10.0 COOLING OF POWER CONVERTERS 10.1 Power semiconductors shall be mounted on heatsink which can be individual

or common to a number of devices. Adequate provision for clamping and mounting the power semiconductors shall be available.

10.2 Cooling of power semiconductors can either be natural air cooled or forced air

cooled. The BIDDER shall recommend the type of cooling. However, for power converters which exceed capacities of 2 kA continuous load, alternative cooling methods as oil or water cooling shall be considered. The power semiconductors shall preferably be double side cooled.

10.3 Auxiliary power supply for the forced cooling system shall be drawn from the

alternatives specified in Section-B. All equipment required for safe and correct operation as drive motor, blower/pump, cooling water/oil header, water/oil distribution piping, daioniser system, flow monitors etc. as applicable shall be considered in the BIDDER’s scope of supply.

11.0 SWITCHING DEVICES




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11.1 Switching devices as circuit breakers, isolators, contactors; switch-fuse units

etc. shall be considered in the scope of supply as specified in Section-C of this specification and Data Sheet A-3.

11.2 The switching devices shall be enclosed in a separate enclosure forming the

set of panels for the power converters. They shall have adequate clearance both with adjacent devices and metalwork at earth potential. Connection between devices shall be by adequate size of electrolytic grade of copper/aluminium strips. These connections shall be adequately braced and insulated.

12.0 CONSTRUCTIONAL FEATURES

The controller should have modular construction to facilitate maintenance. 12.1 Busbars 12.1.1 Power connections shall be of the bolted type and mating surfaces shall be

tinned. 12.1.2 The bus bars running to various converters shall be suitably designed to ensure

equal sharing between the parallel strings and prevent mechanical stress on the fuse.

12.1.3 All bus bars shall be adequately insulated for full circuit voltage by insulating

tapes and similar insulating material. 12.1.4 In case aluminium bus bars are specified, care shall be taken to ensure that

bimetallic connections are provided wherever necessary. 12.1.5 All cubicles shall have copper earth buses of adequate size running the entire

cubicle height along the sides. 12.2 Cubicle 12.2.1 Cubicles housing the power semiconductors and drive level control system

shall conform to IP 42 degree of protection to enclosures. 12.2.2 Panels shall be free standing, floor mounting type and shall comprise rigid

welded structural frames enclosed completely with cold rolled sheet steel of thickness no less than 2.5 mm for front and rear portions and 2.0 mm for sides, top and bottom portions. There shall be sufficient re-inforcement to provide




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level surfaces, resistance to vibrations and rigidity during transportation and installation.

12.2.3 All doors, removable covers and panels shall be gasketed all round with

neoprene gaskets. Ventilating louvers shall have screens and filters. The screens shall be made of either brass or GI wire mesh.

12.2.4 Design, material selection and workmanship shall be such as to result in a neat

appearance inside and outside with no welds, rivets or belt heads apparent from outside, with all exterior surfaces true and smooth.

12.3 Painting 12.3.1 All sheet steel work shall be phosphated in accordance with the following

procedure and in accordance with IS:6005 “Code of Practice for Phosphating Iron and Steel”.

12.3.2 Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning. 12.3.3 Rust and scale shall be removed by pickling with dilute acid followed by

washing with running water, rinsing with slightly alkaline hot water and drying.

12.3.4 After phosphating, thorough rinsing shall be carried out with clean water

followed by final rinsing with dilute dichromate solution and even drying. 12.3.5 The phosphate coating shall be followed by the application of two coats of

ready mixed stoving type zinc chromate primer. The first coat may be “flash dried” while the second coat shall be stoved.

12.3.6 After application of the two coats of primer finishing synthetic enamel paint

shall be applied, each coat followed by stoving. The second finishing coat shall be applied after completion of tests.

12.3.7 The final finished thickness of paint film on steel shall not be less than 100

microns and shall not be more than 150 microns. 12.3.8 Finished painted surface of panels shall present an aesthetically pleasing

appearance free from dents and uneven surface. 12.3.9 A small quantity of finishing paint shall be supplied for minor touching up

required at site after the installation of the panels. 12.4 Bins and Printed Circuit Cards




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12.4.1 Individual bins shall be mounted on a swingable frame so that the connections

at the rear are also accessible. 12.4.2 Self retaining thumb head screws shall be needed for holding the bins in

position. 12.4.3 Adequate number of card/bin extenders for testing of PCBs shall be provided,

each with flexible cables at least two metres long. These extenders shall be of a universal type suitable for use with any card / bin as the case may be.

12.4.4 All adjustments which are to be made while changing a card shall be outside

in a separate module preferably plugged into the regulator bin. 12.4.5 Locking of individual cards in a bin shall preferably be through self retaining

thumb-head screws. 12.4.6 Control modules shall be in the form of plug in packages, plugged into a

module bin. Each plug in unit shall consist of a strong frame on which a printed circuit board would be permanently screwed. The plug connections shall only be of the pin type.

12.4.7 The printed circuit board (P.C.B.) shall be made of glass fibre filled with

epoxy laminates. The plug in unit shall be screwed to the basic socket in the module bin with long through bolts and knurled heads.

12.4.8 The front plates of the plug in unit shall have the switches, the potentiometers,

miniature monitoring meters, test points etc. Each plug in unit shall have its own identification legend.

12.4.9 All plug in units shall be polarised to prevent incorrect insertions into the

module bin. 12.4.10 The gap between two plug in units inside a bin shall be sufficient to permit

adequate ventilation. 12.4.11 The copper side of the printed circuit board shall be lacquered to prevent

oxidation. 12.4.12 Each side of the printed circuit board shall have a shield cover to prevent inter

circuit and external interference. 12.4.13 The P.C.B. shall be mounted on P.C.B. guides fixed on standard racks and the

shield properly grounded.




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12.4.14 Control circuit test points shall be easily accessible for monitoring and

maintenance. 12.5 Annunciation 12.5.1 The annunciator shall work on DC power supply as specified in Data Sheet-A. 12.5.2 Each annunciator window shall have two lamps connected in parallel which

operate at not more than 75% of their rated voltage. 12.5.3 Window shall be arranged in a logical group. 12.5.4 The annunciator shall have a module construction with glass epoxy plug in

cards. 12.5.5 Alarm bell/siren shall be continuously rated and shall have a series resistance. 12.5.6 The annunciator shall have the following facilities. a) First in sequence, memory reset. b) Fleeting faults shall be memorised. c) Test Feature. 12.5.7 There shall be a three tier system of protection and annunciation: a) Alarm both audible and visual.

b) Warning with delayed shut down –time delay through a timer of range 0-60 sec.

c) Disturbance associated with failures of systems elsewhere.

12.6 Meters 12.6.1 Individual meters shall be provided for speed reference, speed feed back,

current reference, current feedback, pulse output, and regulated power supply voltages.

12.6.2 All meters shall be identical and fed through individual buffer I.C. amplifiers.




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12.6.3 All meters shall be the circular scale type having a full scale deflection of 2700.

12.6.4 All meters shall conform to at least accuracy class 1.0 12.6.5 All meters with their individual buffer amplifier cards shall be housed in

separate bin. It is recommended that the buffer amplifiers all be housed on a single/two card/s and this card/s be itself/themselves housed in the regulator bin.

Sensitive signal leads in that case will not have to traverse from one bin to

another, only noise insensitive buffer amplifier output leads will need to go to the meter bin.

12.6.6 Selector switches if used with any meters shall have pistol grip handles. 12.7 Wiring 12.7.1 Stranded, flexible copper cable of 2.5 sq.mm shall be used for C.T. circuits

and 1.5 sq.mm for other control circuits. However for PCB terminals 0.75 sq.mm may be accepted.

12.7.2 Ultra flexible cables shall be used for all connections from a fixed part to a

movable member. In addition, a hanging loop of sufficient length shall be provided to avoid any cable stressing.

12.7.3 All terminal boards for outgoing connections shall be at a height of at least

250 mm from the cubicle floor, and preferably tilted at an angle of 450 to the horizontal for ease of connections. Similarly, connection of the incoming power cables to the bus bars shall be done at a height of at least 250 mm from the cubicle floor.

12.7.4 Item designation and location marking shall be in line with IEC

recommendations. 12.7.5 Device labeling shall be on its fixed mounting and not on the device itself such

that labeling remains even when the device is replaced. Metallic labels/paper labels or sticker shall be accepted.

13.0 TESTING

All routine tests shall be carried out on various devices / assemblies in line with codes & standards indicated in data sheet-A4. Type Tests shall be carried out wherever indicated in Data sheet-A1 to A3 and / or in Section ‘C’




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13.1 Tests on Power Semiconductors All power semiconductors selected shall be subject to quality assurance tests

to check on the characteristics submitted by the successful BIDDER on samples. The BIDDER and/or his sub-vendor shall allow PURCHASER’S authorised representative to witness the tests. Details of the test are to be agreed between the PURCHASER and the BIDDER. The broad outlines of the tests to be conducted are as follows:

a) Off state voltage and reverse voltage b) Critical rate of rise of off state voltage c) On state voltage d) Thermal resistance e) Surge on-state current f) Triggering data g) Recovery charge and recovery time h) Critical rate of rise of on-state current i) Switching losses j) Environmental Tests 13.2 Tests on Converters Converter with its enclosure and cooling system shall be connected to a

dummy load. A variable voltage source on the source side shall be adjusted so that the specified current rating of the converter at no-delay of the firing angle (in case thyristors) shall be passed. At the end of stipulated period of test a timer shall cut-off the source. The load side and source side current shall be measured/recorded during the testing phase. The temperature of the case and the heat sink and wound components like chokes shall be suitably recorded. The temperature decay measurement/recording shall continue for the off-duty cycle at agreed intervals. During the course of test the cooling system shall be operative.

The following tests shall be conducted: (IEC 61800-2)




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a) Checking of the setting of the protection devices and their functioning. b) Checking of the auxiliary devices and their functioning. c) Speed regulation of the drive shall be observed at different output

voltage and frequency settings (for AC drives). d) Determination of the power losses at specified loads (By

Calculation).(Type Test) e) Load test or rated current test for large converters (above 1 MW). f) Insulation test g) Temperature rise (Type Test).

h) Light load & Functional Test. i) Observation of various wave forms i.e. current and voltage.

13.3 Other Composite Test at No-load

a) Environmental tests on printed circuit boards, pulse transformers etc. b) Other tests as may be agreed on various converter subsystems.

13.4 Acceptance Test These shall be conducted at the works of the VENDOR’S and/or his sub-

vendor to ascertain that performance stipulated in this specification has been honoured (e.g. overcurrent capability, measurement of ripple voltage & current, P.F. measurement, Audible noise, etc). Dummy loads as required for the purpose of simulating the operation conditions at the VENDOR’s works shall be considered in scope of this specification. However, should this not be possible, testing at site with the actual load shall be conducted to prove the performance of the power converters.

13.5 All the meter, instruments, devices used for the testing purpose shall be

properly calibrated by standard authorised agencies which shall be traceable to National Standards. For each such instrument proper validity of calibration shall be documented by Vendor.




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14.0 HARMONICS LIMITATIONS When specified in Data Sheet A, the harmonics generated on source (Input)

side (Both AC/DC drive) and output side (For AC drive only) shall be restricted to the following limits: (IEEE-519 for source side and IEC-61800 for load side)

a) Voltage Harmonics Source side Load side Maximum 5% Maximum 5%(THD) b) Current Harmonics Source side 5th Maximum 30% 7th Maximum 20% 11th Maximum 10% Bidder shall indicate clearly the method of achieving above requirement.


VOLUME IIIB


VARIABLE SPEED DC/AC DRIVES SHEET 1 OF 1

ISSUE R1

TITLE


DATA SHEET – C

DATA TO BE SUBMITTED BY VENDOR 1.0 Following data shall be submitted within the period specified in Section C,

after placing the order, for the PURCHASER’S approval. 1.1 General arrangement drawings showing outline dimensions, cable entry

openings, fixing/foundation details, weights and door openings. 1.2 Front & cross section views showing arrangement details of equipment and

terminals and with a Bill of Material for all equipment. 1.3 Schematic diagram indicating terminal number for external connections &

block diagram of control system. 1.4 MANUFACTURER’S technical literature on various equipments supplied. 2.0 Wiring diagram of complete inverter. This shall be based on approved

schematic drawing. The correctness of this drawing shall be the responsibility of the VENDOR.

3.0 Test certificates for the cabinet and all individual equipments and performance

load tests shall be submitted atleast 2 weeks before dispatch of equipment. 4.0 Operation and maintenance manuals shall be furnished with the equipment. 5.0 Detailed drawing of converter showing layout of power semiconductors, fuses,

heat sinks, cooling system etc. 6.0 Details of testing procedures for power semiconductors and power converters

as per Standards/Code of Practice for approval. 7.0 Shipping details of the equipment.


TCE-M4-203-02


INDUCTION MOTORS ADDITIONAL REQUIREMENT FOR HV MOTORS

SHEET 1 OF 4

ISSUE R8

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TCE FORM NO. 329 R4

1.0 SCOPE 1.1 This specification covers requirements of HV induction motors. These are in

addition to the requirements of specification No.TCE.M4-203-01. Clauses of this specification which are not applicable for any motor are mentioned in Data Sheet-A1 of TCE.M4-203-01.

1.2 In case of conflict between TCE.M4-203-01 or applicable standard and this

specification, this specification shall govern. 2.0 PERFORMANCE AND CHARACTERISTICS 2.1 Motors shall be capable of starting and accelerating the load with the applicable

method of starting, without exceeding acceptable winding temperatures, when the supply voltage is 80% of the rated voltage.

2.2 Motors shall be capable of satisfactory operation at full load at a supply

voltage of 80% of the rated voltage for 5 minutes, commencing from hot condition.

2.3 Motors shall withstand the voltage and torque stresses developed due to the

vector difference between the motor residual voltage and the incoming supply voltage equal to 150% of the rated voltage, during fast change over of buses. The duration of this condition is envisaged for a period of one second.

2.4 The locked rotor current of the motors shall not exceed the following values

which are inclusive of 20% tolerance. 2.4.1 600% of full load current for motors upto and including 1500 kW. 2.4.2 450% of full load current for motors above 1500 kW. 2.5 The locked rotor withstand time under hot conditions at 110% rated voltage shall

be more than the starting time at minimum permissible voltage (clause 2.1 above) by atleast three seconds or 15% of the accelerating time whichever is greater. Provision of speed switch shall be avoided to the extent possible. In case the speed switch is required, it shall be indicated out by the bidder in his offer.

When a speed switch is mounted on the motor shaft , the same shall remain

closed for speeds lower than 20% and open for speeds above 20% of the rated speed. The speed switch shall be capable of withstanding 120% over speed in either direction of rotation. If the speed switch requires any auxiliary voltage, it shall be suitable for the auxiliary voltage specified in Section-B - Project Information of the specification


TCE-M4-203-02



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TCE FORM NO. 329 R4

3.0 INSULATION TREATMENT 3.1 Motors shall be given power house treatment. Additional treatments to withstand

heavily salt polluted or similar atmospheric conditions shall be given based on the location indicated in Data Sheet-A

4.0 ACCESSORIES 4.1 EMBEDDED TEMPERATURE DETECTORS (ETD'S) Atleast six resistance type temperature detectors for the stator winding each

having D.C. resistance of 100 ohms at 0oC, embedded in the stator winding at locations where highest temperatures may be expected, shall be provided. The material of the ETD's shall be platinum. One ETD shall be provided for each of the motor bearing & shall be wired upto the terminal box. The temperature detectors shall be of 3 wire , duplex type.

4.2 BEARING THERMOMETERS 4.2.1 Each bearing shall be provided with a dial type thermometer. Each

thermometer shall consist of 2 potential free contacts. They shall be designed to close independently at two different temperatures - one for 'Alarm' and another for 'Trip'.

4.2.2 The contact rating of the potential free contacts shall be 1A at 240V AC & 0.1A at

220V DC.Any auxiliary supply ,if required shall be indicated by the bidder. 4.2.3 The thermometers shall be located at a convenient height for easy reading

and handling. 4.2.4 One bearing shall be insulated to prevent shaft currents. 4.3 DRAIN PLUGS Motors shall be provided with drain plugs, so located to drain water, resulting

from condensation or due to other causes ,from all pockets in the motor casing. 4.4 FLOW SWITCHES Flow switches shall be provided for monitoring cooling water flow if CACW

motors are specified. 4.5 VIBRATION PADS Vibration pads shall be provided when called for in the specification.


TCE-M4-203-02



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TCE FORM NO. 329 R4

5.0 TERMINAL BOX 5.1 Separate terminal boxes shall be provided for each of the following : 5.1.1 Stator Leads 5.1.2 Rotor leads (wound motors) 5.1.3 Space Heaters 5.1.4 Temperature Detectors 5.2 The three phases shall be segregated by barriers of metal or fibre glass. 5.3 The cable box design shall be suitable for any type of cable termination kits

available. 6.0 EARTHING PAD The earthing pads shall be of non-corrodible metal welded or brazed at two

locations on opposite sides complete with suitable bolt and washers for connecting the PURCHASER'S earthing flat.

7.0 RATING PLATE 7.1 The following details, in addition to those specified in applicable standards shall

be included on the rating plate. 7.1.1 Temperature rise of windings in degree centigrade at rated load, rated voltage,

frequency and ambient conditions and the method of measuring temperature rise. (Thermometer/ Winding resistance).

7.1.2 Type of bearings, recommended lubricant, lubricating interval & re-lubricating

quantity. 8.0 TESTS 8.1 Type test certificates for similar motors shall be furnished with the Bid. 8.2 Extra price for performing type tests on the motor as per applicable standard

shall be quoted. 8.3 If specified in data sheet-A, for motors rated 3.3 kV and above, the induced

shaft voltage shall be measured at the manufacturer's works during shop testing. The maximum value of induced voltage in the motor shaft shall not exceed 250mV.


TCE-M4-203-02



SHEET 4 OF 4

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TCE FORM NO. 329 R4

8.4 The polarisation index test shall be carried out on all motors rated at 3.3 kV and

above. The minimum value of the polarisation index shall be 2 when determined as per IS-7816.

8.5 Coils of HV motors shall be tested as per IEC-34-15. 8.6 Loss tangent measurement of coils for motors rated 6.6 kV & above shall be

done as per IS-13508. 8.7 All other routine tests shall be carried out as per applicable standards.




DATA SHEET-C

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1

ISSUE R8

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TCE FORM NO. 329 R4

INFORMATION TO BE SUBMITTED BY THE VENDOR

AFTER AWARD OF CONTRACT A .DOCUMENTS TO BE SUBMITTED FOR PURCHASER'S APPROVAL. 1.0 Technical particulars as per data sheet-B of TCE.M4.203-01 & 02 2.0 Bearing temperature indicator 2.1 Type and make 2.2 Number 2.3. Number of contacts in each indicator 2.4 Contact rating at 220V DC at 240V AC 3.0 A separate dimensioned outline and general arrangement drawing of motor shall be furnished indicating the following: Name of Manufacturer, Wight of motor (kg.) Centre line of motor Foundation details, Openings ,embedment details in foundation for entry of all cables such as power,space heater,etd etc. Connection details of motor i.e, start/delta , terminal markings, clearance between phase, disconnecting facilities and direction of cable entry and cable glands (if provided). 3.1 Dimensions of terminal boxes for main power leads, space heater leads and ETD leads. 3.2 Size, type and overall diameter of cable for which terminal boxes are suitable. 3.3 Openings and embedments in foundation for cable entry for power leads, space heater leads, ETD leads and earthing conductor, etc. with relative locating dimensions and sizes in all views of motor.




DATA SHEET-C

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2

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TCE FORM NO. 329 R4

3.4 Location of bearing thermometers and pockets for the same. 3.5 No. & type (NO/NC) of contacts provided on bearing thermometers. 3.6 Location and size of earthing terminals/holes in earthing pads. 3.7 Coupling type, diameter of shaft extension, dimensions of key slot and details of half coupling (if specified). 3.8 The following additional data/details should be shown on the motor drawing, when applicable. 3.9 Cooling water requirement for water cooled bearing (Lts/min). 3.10 Cooling water requirement for water cooled windings (Lts/min). 3.11 Required pressure of cooling water (kg/cm2). 3.12 Required maximum temperature of cooling water (oC). 3.13 Weight of cooler if removable (kg). 3.14 Oil level sight gauges for oil lubricated bearings B. DOCUMENTS TO BE SUBMITTED FOR INFORMATION. 1.0 Insulation 1.1 Material and treatment of insulation 2.0 Winding 2.1 Stator winding (a) Connection (b) Resistance/phase 2.2 Rotor winding




DATA SHEET-C

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3

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TCE FORM NO. 329 R4

(a) Connection (b) Resistance/phase 3.0 Bearing 3.1 DE Bearing 3.1.1 Type, No. & make 3.1.2 Lubricant 3.1.3 Initial quantity 3.1.4 Relubricating interval 3.1.5 Relubricating quantity 3.1.6 Anticipated life 3.2 NDE Bearing 3.2.1 Type, No. & make 3.2.2 Lubricant 3.2.3 Initial quantity 3.2.4 Relubricating interval 3.2.5 Relubricating quantity 3.2.6 Anticipated life 4.0 Motor bearing lubrication system - Self lubrication/Forced oil lubrication 4.1 Forced oil lubrication system (if provided) a) Whether this is compatible with forced oil lubrication system of driven equipment. If NO, furnish the following details for motor bearing i) Type, make and specification of oil ii) Flow rate (Ltrs/Sec)




DATA SHEET-C

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4

ISSUE R8

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TCE FORM NO. 329 R4

iii) Pressure (Kg/cm2) iv) Quantity of lube oil pump sets provided for each motor v) Local control panel provided for forced oil lubrication system of each motor vi) Make, type and name plate particulars of lube oil pumps & 415V, 3 phase, 50Hz motors. vii) Filters - Make & type 5.0 Air temperature detector (Internal) (CACA/CACW motor) 5.1 Type & make 5.2 Number 5.3 Number of contacts in each indicator 5.4 Contact rating at - 220V DC - 240V AC 6.0 Terminal box 6.1 Location of main terminal box viewed from non drive end (Right/Left) 7.0 No load current of motor at rated voltage & frequency (for each type of motor) 8.0 Limiting rotor temperature for determining safe stall time 10.0 Instruction Manual (Number of copies as per distribution schedule)



MOTOR OPERATED VALVE ACTUATORS

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1.0 SCOPE This specification covers the requirements of motor operated valve

actuators with and without integral starters. 2.0 CODES AND STANDARDS 2.1 The design, manufacture and performance of the valve actuator and its

accessories shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

2.2 All codes and standards referred to in the specification shall be

understood to be the latest version on the date of offer made by the BIDDER unless otherwise indicated.

3.0 MOTOR OPERATED VALVE ACTUATOR 3.1 Each valve actuator motor operating mechanism shall essentially

consist of the following components: (a) AC electric motor (b) Reduction gear unit (with thrust bearing if required) (c) Torque switch mechanism (d) Limit switch mechanism (e) Hand wheel, for manual operation (f) Valve position indicator (g) Manual-Auto lever with suitable locking arrangement (h) Valve position transmitter (To be provided only if called for in

data sheet-A1) (i) Space heater for enclosure

(j) Thermostat if called for in data sheet A1 3.2 For valve actuator with integral starter The following components in

addition to those indicated in clause 3.1 shall be provided (a) Integral reversing contactor starter complete with overload

relays of suitable range and adequately rated control fuses (b) Local / Remote selector switch (c) Local control switch / push buttons




SHEET 2 OF 4

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(d) 415V / 110 V - 240V AC control & space heating transformer or if space heater is rated for 110V AC, space heating supply shall be derived from 415V / 110V control transformer (Control transformer required for 415V, 3 phase, 3-wire system only). For 3-phase, 4-wire system control supply and space heating supply shall be 240 V AC derived between phase-neutral

(e) A white lamp for supervision of main supply. To be provided

locally. (f) A potential free contact shall be provided to annunciate over

load trip / main supply failure on remote panel. (g) A blinker relay and lamp shall be provided such that the lamp

shall blink as long as the actuator is running ; either to close or to open position.

(h) Two (2) DC interposing relays for matching the low voltage of

remote commands with the control voltage. The command signal voltage and the control voltages will be, as indicated in Data Sheet-A1.

4.0 CONSTRUCTIONAL AND TECHNICAL REQUIREMENTS 4.1 The constructional and technical requirements of actuators including

motor shall be as per IS 9334, except as noted in this specification. 4.2 Reversing Contactor Starters For Valve Actuators 4.2.1 Forward and reverse contactors shall be mechanically and electrically

interlocked with each other. 4.2.2 The contactors shall have a minimum thermal rating of 9A and shall be

suitable for class AC4 duty as specified in applicable standards. The contactor shall have 20% margin over the rated current of the motor.

4.2.3 The thermal overload relays provided with the reversing starters shall

be three element, positive acting, hand reset type, ambient temperature compensated, time lagged, thermal overload relay with adjustable settings and built in single phasing preventer. The setting range shall be properly selected in accordance with the rating of the motor.




SHEET 3 OF 4

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4.2.4 ‘Stop’ push button of the starter and hand reset push button for the thermal overload relay shall be separate from each other.

4.2.5 Overload relay hand reset push button shall be brought out to the front

and made easily accessible. 4.2.6 Overload relay shall be provided with at least one ‘NO’ and one ‘NC’ or

one change-over contact. 5.0 TESTS 5.1 The routine and acceptance tests specified in IS 9334 shall be

conducted on each valve actuator. In addition to the above tests the following shall also be conducted as part of routine tests.

5.1.1 Visual checks of workmanship, dimensions, component assembly,

number of torque and limit switches, cable entry and valve position transmitter.

5.1.2 Mechanical checks of gear ratio and torque clutch operation. 5.1.3 Wiring check as per approved VENDOR drawing. 5.1.4 Resistance values of potentiometric type position transmitter and 4-

20mA dc signal of transducer type position transmitter shall be measured at various positions of the valves.

5.1.5 Insulation resistance test ( Meggering) using 1000V megger for power

terminals and 500V megger for control terminals. 5.1.6 High voltage test at 1.5 kV AC for 1 sec. 5.1.7 Performance test (at no load) to check the operation of the actuator

limit switches and torque switches. Measurement of torque and motor currents shall be done and the values at which the torque switch operates, noted.




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5.1.8 For actuator with integral starters, all the above tests shall be performed in addition to the following :-

(a) The wiring of the starter shall be checked as per the approved

VENDOR drawing (b) The operation of the starter shall be checked. (c) Tests as per standards indicated in data sheet - A3. 5.2 Type test certificates for type tests carried out as per IS 9334 on

similar actuators shall be furnished for PURCHASER’S review. If type test has not been carried out on similar actuators, then VENDOR shall carry out the tests.

5.3 All instruments used for testing shall have valid calibration certificates,

which shall be produced at the time of inspection. 5.4 All test reports shall be submitted for PURCHASER’s approval.


DATA SHEET - C MOTOR OPERATED VALVE ACTUATORS

SHEET 1 OF 1

ISSUE R4

TITLE


DATA TO BE FURNISHED BY THE VENDOR AFTER AWARD OF THE CONTRACT

1.0 The VENDOR shall furnish the following drawings / documents / data for each type of valve actuator in his scope of supply :

1.1 Drawings for Approval (a) Drawing indicating overall dimensions and mounting details of

valve actuator on the valve (b) Detailed internal wiring diagram of the actuator and limit switch

development diagram

(c) Detailed Bill of Materials of all electrical items indicating clearly make, type, ratings, etc.

(d) Terminal box details.

1.2 Drawings / Data for Information (a) Type test certificates of similar valve actuators and also for all

individual electrical components used. (b) Valve Actuator catalogues and operating and maintenance

manual (c) Gear ratio, motor shaft speed and output shaft speed. (d) Full load current and starting current of the valve actuator

motors 1.3 Final Test Certificates for Approval (a) Routine and acceptance test certificates of the valve actuators

(b) Equipment shall not be despatched unless the test certificates are duly approved by the PURCHASER.



D.C. MOTORS

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ISSUE R7

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1.0 SCOPE This specification covers the design, material, construction features,

manufacture, inspection and testing at the VENDOR's/his SUB-VENDOR's works, delivery to site and performance testing of D C Motors for general purpose.

2.0 CODES AND STANDARDS 2.1 The design, material, construction, manufacture, inspection, testing and

performance of D C Motors shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the latest applicable standards. Nothing in this specification shall be construed to relieve the VENDOR from this responsibility.

2.2 All codes and standards referred to in the specification shall be

understood to be the latest version on the date of offer made by the BIDDER unless otherwise indicated.

3.0 DRIVEN EQUIPMENT 3.1 When this specification forms part of the driven equipment specification,

information not given in Data Sheet-A1 will be governed by the driven equipment specification.

3.2 Motors shall be capable of satisfactory operation for the application and

duty as specified in the Data Sheet-A1 and as required by the driven equipment.

4.0 PERFORMANCE AND CHARACTERISTICS 4.1 Motors shall be capable of giving rated output without reduction in the

expected life span when operated continuously at a supply voltage within +10 to –15 % from the motor rated voltage or as specified in Data Sheet-A1.

4.2 Motors shall be capable of starting and accelerating the load with the

applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is in the range 85% of the rated motor voltage to maximum permissible voltage specified in Data Sheet-A1.



D.C. MOTORS

SHEET 2 OF 4

ISSUE R7

TITLE


5.0 TEMPERATURE RISE 5.1 The temperature rise shall be in accordance with the relevant standards. 5.2 For motors specified for outdoor installation, account shall be taken of

heating due to direct exposure to solar radiation. 5.3 The field windings for the motors shall be continuously rated without

forced ventilation. 6.0 CONSTRUCTIONAL FEATURES Motors weighing more than 25 Kg shall be provided with eyebolts, lugs

or other means to facilitate safe lifting. 7.0 BRUSHES AND BRUSH GEAR 7.1 Brush materials with large brush contact area for good commutation

under high acceleration and overload conditions should be provided. 7.2 The brushes shall be of electric graphite of high quality. The pressure on

the brush shall be adjustable, if necessary. 7.3 The brush holder to which the brushes are fixed should be so

constructed that the brushes touch the commutator face evenly. Individual brush holders shall be with drawable without disturbing any other part of the machine.

7.4 There shall be provision for holding off each brush from commutator to

facilitate maintenance. 7.5 The brush rocker should be split to facilitate easy erection and

dismantling which will enable the brush rocker to be adjusted to its correct position.

7.6 When specified in Data Sheet-A1, motors located in acid fume area shall

be specifically treated against corrosion from acid fumes and shall be provided with sealed bearings.



D.C. MOTORS

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TITLE


8.0 TERMINAL BOX 8.1 Terminal box shall be weather proof construction designed for outdoor

service to eliminate entry of dust and water. Gaskets of neoprene or approved equivalent shall be provided at cover joints and between box and motor frame.

8.2 All terminals should be brought out to the terminal box. The terminals

shall be stud type with necessary plain washers, spring washers and check nuts. The construction of terminal box shall be such that the terminals are easily accessible. The terminals themselves shall be such as to facilitate easy change of connections in the box without disturbing any internal connections in the machine.

9.0 ACCESSORIES 9.1 Two independent earthing points shall be provided on opposite sides of

the motor for bolted connection of the PURCHASER's earthing conductors, as specified in the Data Sheet-A1. These earthing points shall be in addition to the earthing stud provided in the terminal box.

9.2 Except when otherwise specified, the motors shall be provided with a

bare shaft extension having a key slot and a key at the driving end. 9.3 When the motor half coupling is supplied by the PURCHASER or driven

equipment VENDOR, the motor VENDOR shall strictly adhere to the dimensional requirements and other instructions related to accessory.

10.0 STARTER PANEL 10.1 Starter panel when included in motor VENDOR's scope shall meet the

following requirements. 10.2 The constructional features of these panels shall comply with the

requirements of specification TCE.M4-219-01, Section-D. 10.3 The starter for motor feeders shall preferably be housed within the main

panel. If starting resistors are provided in the power circuits, the same can be located in a separate box which will be placed near the main panel.



D.C. MOTORS

SHEET 4 OF 4

ISSUE R7

TITLE


10.4 The motor Starter shall be provided with the following. a) Switch, fuses, air break contactors. b) Thermal overload relays (for alarm only) c) Starting resistors with associated timers. d) ON, OFF and fault indicating lamps. e) Necessary auxiliary contactors for fault alarm circuit. f) 240V space heating circuit (240V supply to be arranged by

VENDOR). g) ON, OFF PBs for testing purposes. h) One shunt, ammeter and one shunt for providing remote ammeter. i) Suitable circuitry to receive ON, OFF commands from remote

panel, interlocks, off command from local Push button station etc. j) MCB for space heating circuit.

11.0 FIELD RHEOSTAT

Field rheostat for adjusting the motor speed at site, to match the requirement of the driven equipment, shall be provided by the motor VENDOR and it shall be mounted in the starter panel. If starter panel is not in motor VENDOR’s scope, the field rheostat shall be supplied as a loose item.



DATA SHEET-C

D.C. MOTORS

SHEET 1 OF 1

ISSUE R7

TITLE


DATA TO BE FURNISHED BY THE VENDOR

AFTER AWARD OF CONTRACT For approval: 1. Motor GD² (Kg.m²). 2. Motor outline dimension drawing (Number of copies as per distribution

schedule). 3. Type and routine test certificates (Number of copies as per distribution

schedule). 4. Electrical time constant in seconds (te). 5. Mechanical time constant in seconds (tm). 6. Field time constant in seconds (tf). 7. Starter data / drawings. 7.1 Detailed design calculations for starting current and selection of starting

resistance values. 7.2 Schematic drawing. 7.3 General arrangement / foundation drawings. 8. Field rheostat details For information:

10. Type and frame size 11. Starting time in seconds. 12. Safe stall time at 100% rated voltage and under hot condition. 13. Make and type of bearings and expected life. 14. Total weight of motor (kg).


TCE.M4-101-01


SHELL AND TUBE HEAT EXCHANGERS

SHEET 1 OF 10

ISSUE R3

TITLE


1.0 SCOPE This specification covers the general design, preparation of detailed

fabrication drawings for review and approval, supply of materials, fabrication, stage-wise inspection, final inspection, testing, packing, forwarding, transportation and delivery at site of unfired shell and tube heat exchangers.

2.0 CODES AND STANDARDS 2.1 The design, materials, fabrication, inspection, testing and performance of shell

and tube heat exchangers shall comply with all currently applicable design codes and standards, statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal, or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

2.2 This specification covers shell and tube heat exchangers designed as per the

standards of the Tubular Exchanger Manufacturers Association (TEMA). 2.3 If statutory approvals are specified in data sheet A, the VENDOR shall be

responsible for obtaining all approvals on design, materials, stage-wise inspection, final inspection and testing of the heat exchanger.

3.0 MATERIALS 3.1 All materials used in the fabrication of heat exchangers shall be as specified in

the data sheets. Equivalent materials are acceptable only when approved by the PURCHASER in writing.

3.2 All plates shall be ultrasonically tested as follows :

(a) For nominal thickness 20 mm and higher when used for fabrication of dished ends

(b) For nominal thickness 40 mm and higher when used for fabrication of

shells

(c) For nominal thickness 50 mm and higher when used for blind flanges

(d) All thicknesses, when used for body flanges and tube sheets 3.3 The VENDOR shall ensure that code mandatory requirements of impact

testing are met in accordance with the minimum design temperatures specified in the data sheets.

3.4 Any non-pressure parts such as cleats, pads at support lugs or legs, wear

plates at saddles and pads at pipe supports etc., welded directly on to the pressure parts, shall be of the same material as the pressure parts.


TCE.M4-101-01



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TITLE


3.5 Reinforcement pads at nozzles and other load bearing locations shall be of the same material and nominal thickness as the pressure part.

3.6 ALLOY STEEL PROTECTIVE LINING AND CLADDING 3.6.1 Lining is defined as loose strip lining and bush lining. Cladding may be by

weld deposit overlay or explosion bonding or roll bonding. 3.6.2 Clad plate or lining shall conform to the following requirements :

(a) Clad plate thickness shall be minimum 3 mm, exclusive of pass-partition groove depth. Wherever pass-partitions are specified cladding or lining shall be minimum 8 mm thick.

(b) Clad plate made either by the explosion bonding process or reduction

roll bonding process is acceptable. (c) Clad plate shall meet the ASME code requirements of SA 263,SA

264, SA 265 including bond test or AD - Merkblatter W-8.The shear bond test shall be executed as per SA 264, Figure 1.Ultrasonic inspection shall be carried out in accordance with SA 578, acceptance level S-6.

(d) For the purpose of ensuring that cladding thickness of reduction

roll-bonded clad plates is not less than 3 mm, each plate shall be inspected at the mill using a "coating gauge".Plates shall be scanned on at least three edges and one across the width of the plate. Thickness shall be plotted at points not more than 600 mm apart. The VENDOR shall furnish a mill certificate, showing an outline of the plate and the points at which readings were taken together with the results.

(e) Instead of lining, weld deposit overlay may also be considered.

(f) At weld deposit overlay or clad-restoring welds, at least the same

chemical composition shall be present at 3 mm depth, to be analysed by the welding procedure qualification in advance.

(g) Weld deposit overlay and clad-restoring welds shall be dye penetrant

tested and crack-free.

(h) Weld deposit overlay and clad-restoring welds as a minimum, shall be qualified as per ASME section IX.

3.6.3 Alloy steel lining shall not be used when cladding is specified. Alloy steel

lining, when specified, shall be so designed that the distance between attachments does not exceed 150 mm.

3.6.4 The minimum required thickness of pressure parts shall exclude cladding or

lining. 3.6.5 Cladding or lining requirements discussed in this specification are using low

and high alloy steels only. For cladding or lining using non-ferrous and other


TCE.M4-101-01



SHEET 3 OF 10

ISSUE R3

TITLE


materials, when specified, the VENDOR shall furnish on his drawings all details, including Welding Procedure Specification (WPS), for review and approval.

4.0 MINIMUM THICKNESS 4.1 The thicknesses of pressure parts as shown in the data sheets or drawings

are the minimum acceptable thicknesses after manufacture, even though the code may permit a lesser thickness. The minimum acceptable thickness includes specified corrosion allowance.

4.2 The VENDOR shall be responsible for proper selection of plate thickness

considering the fabrication and forming allowances, mill under-tolerances etc., to meet the minimum thickness requirements as specified.

5.0 SHELLS Shell courses shall be of the largest possible dimensions to minimise the

number of weld seams. 6.0 HEADS AND REDUCING SECTIONS 6.1 Heads shall be of 2:1 ellipsoidal or equivalent ellipsoidal type (crown radius

R = 0.9 D, knuckle radius r = 0.17 D), unless specified otherwise, where D is the inside diameter of the shell.

6.2 Reducing sections or conical bottoms shall have a knuckle radius of r =

0.06D, unless specified otherwise. However, knuckle radius shall not be less than 50 mm.

6.3 Dished ends shall be seamless or 100 % radiographed when made from more

than one piece. 7.0 NOZZLES AND MANHOLES 4.3 Nozzles fabricated from plates are acceptable for sizes larger than 250 mm

NB in case of carbon and low alloy steels and 150 mm NB in case of high alloy steels. However, this is to be done with prior approval and subject to all welds being 100% radiographed.

7.2 All nozzle sizes and quantities indicated in the data sheets are tentative and

for bid purpose only. Final sizes and quantities are subject to confirmation during review of drawings. The BIDDER shall include and confirm in his BID, that changes, to the extent of one size lower or higher for each nozzle and quantities plus or minus one number for each size, are acceptable at no extra cost to the PURCHASER.

7.3 All nozzles with butt-welding end connections shall have edge preparation as

per ANSI B 16.25 suitable for connected piping inside diameter. Such nozzles shall have 100 mm extra stub length with pipe caps for hydrotest purpose.

7.4 All nozzles of sizes 40 mm NB and below shall be gusseted as per the

companion specification TCE.M4-102-34.


TCE.M4-101-01



SHEET 4 OF 10

ISSUE R3

TITLE


7.5 All openings in pressure parts shall be compensated for the area of opening

as per code. Minimum width of pad shall be 50 mm. 7.6 All load bearing areas in pressure parts shall be verified for buckling and local

stresses. Adequate reinforcement shall be provided. 7.7 Nozzle and manhole necks shall be flush with the inside surface unless

specified otherwise. Inside edges of manholes shall be smooth and rounded-off with a radius of 3 mm.

8.0 FLANGES 8.1 Unless specified otherwise, all nozzles shall be provided with rated flanges

only, from considerations of interchangeability, as per the dimensional standards indicated in the data sheets.

8.2 Bolt holes shall straddle the main exchanger axes, unless specified

otherwise. 8.3 All flanges on nozzles shall be of forged construction with integral hubs. Plate

or plate type forged flanges are not acceptable in place of forged flanges with integral hubs.

8.4 All slip-on type flanges of sizes larger than 50 mm NB and girth flanges shall

be provided with adequate venting arrangement during welding. 8.5 Girth flanges, if made out of multiple plates, shall be a maximum of three

segments. All welds shall be 100 % radiographed. Pre-heating and postweld heat treatment shall be carried out as per code.

8.6 Companion flanges specified with alloy steel liner shall be supplied with 100

mm long alloy steel stub ends with butt-welding edge preparation to suit connected pipe thickness.

8.7 When companion flanges are of welding neck type, the same shall be to suit

bore of connected pipe. However, this information shall be provided by the PURCHASER, during review of drawings.

8.8 Blind flanges and covers intended for inspection or access openings shall be

provided with adequate arrangement to facilitate opening and closing without undue effort .

8.9 Unless specified otherwise, seating surfaces for non-metallic gaskets shall

have stock or serrated finish. For other types of gaskets, the type of finish shall be furnished by the VENDOR on the drawings for review and approval.

8.10 When flanges specified are of tongue and groove or male and female type,

groove or female face shall be on the nozzle flanges and tongue or male face on the companion flanges.


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9.0 TUBES 9.1 All tubes shall be seamless, unless specified otherwise. 9.2 When welded tubes are specified, the same shall be tested with eddy current

method besides other test requirements. 9.3 All tubes shall be formed from a single length without circumferential welds. 9.4 The VENDOR shall check the adequacy of tube gauge for external

pressure. 10.0 TUBE BUNDLES 10.1 The tube bundle, after taking out the floating head cover and the

backing device, shall be removable through the inlet channel end. 10.2 The tube bundle shall be capable of being rotated, through 180 degrees

about the longitudinal axis without bending. 10.3 When straight tube channel type construction is used, all tubes shall be

accessible for inside cleaning, rolling and replacement from both ends of the exchanger.

10.4 On vertical removable bundle units with channel down, stationary tube sheet

shall be provided with at least four collar bolts or other means approved by the PURCHASER, to hold the tube bundle with channel removed.

10.5 Guide devices to ensure alignment and to facilitate assembly shall be

provided for floating head covers, internal bellows, flanges, channel covers and stationary tube sheets having grooved partitions.

10.6 Sliding bars or rails shall be provided to facilitate pulling the removable tube

bundles. 10.7 Vertical exchangers shall be provided with four sliding bars or rails

equally spaced around the circumference of the bundle. 10.8 When mechanical cleaning is required on shell side (tube layout of square

pitch patterns), the sliding bars or rails shall not obstruct the tube lanes. 10.9 Kettle-type exchangers (TEMA - type K) shall be provided with sliding rails

continuously welded to the shell.Bundles shall be provided with suitable means to be secured in place during shipment and erection.

10.10 Annular clearances between tubes and shell shall be kept to minimise

by-passing for efficient heat transfer. If the clearance exceeds 20 mm, suitable longitudinal sealing strips shall be provided.

10.11 U-TUBES 10.11.1 All tubes shall be seamless, unless specified otherwise.


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10.11.2 Tubes shall be cold bent. 10.11.3 Each U tube shall be formed from a single length. Thinning shall meet the

stipulations as per TEMA. 11.0 EXPANSION BELLOWS 11.1 Expansion bellow shall preferably be made from a single piece. 11.2 When made from more than one piece, all seams shall be 100%

radiographed. 11.3 When carbon steel is specified as the expansion bellow material, the outer

diameter of cylindrical portion of bellow shall be flush with outer diameter of the shell.

11.4 All exchangers fitted with expansion bellows shall be provided with restraining

bars to protect the bellows assembly during handling and transportation. These bars shall be painted yellow.

11.5 Expansion bellows without internal sleeve shall be installed between two

transverse baffles. 11.6 Only a single ply construction shall be provided for expansion bellows, unless

specified otherwise. 11.7 Expansion bellows shall preferably be located near the supports. 12.0 GASKETS 12.1 All gaskets with or without internal web segments shall be made in one

piece. 12.2 All spiral-wound gaskets shall be provided with outer centering ring and inner

ring, unless specified otherwise. 13.0 PASS PARTITION PLATES 13.1 Pass partition plates shall be tightly welded in place. 13.2 Adequate weep holes shall be provided in the pass partition plates. 14.0 BAFFLES AND SUPPORT PLATES 14.1 Baffles shall be provided with adequate bottom notches for shell draining. 14.2 All removable tube bundles shall be provided with a full baffle or support plate

for support at the free end. Also, a central opening, of area equal to percentage cut in the baffle, shall be provided in the full baffle. However, this opening requirement is not applicable for kettle-type of exchangers.


TCE.M4-101-01



SHEET 7 OF 10

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TITLE


15.0 WEIR PLATES Weir plates for kettle-type exchangers shall have a minimum thickness of 10

mm and 6 mm for carbon steel and stainless steel materials respectively. In no case shall the thickness be less than two times the specified corrosion allowance on shell side.

16.0 IMPINGEMENT PLATES 16.1 The impingement plate shall be square or rectangle in shape having double

the area of the inlet nozzle. It shall have a minimum thickness of 10 mm and 6 mm for carbon steel and stainless steel materials respectively and shall be located on the tube bundle and not in the nozzle.

16.2 Perforated impingement plates are not acceptable. 17.0 VENT AND DRAIN CONNECTIONS All high and low points on shell side and tube side of an exchanger shall be

provided with 20 mm NB flanged connections covered with blind flange, unless specified otherwise.

18.0 PRESSURE GAUGE CONNECTIONS All flanged nozzles 50 mm NB or larger shall be provided with 20 mm NB

flanged connection covered with blind flange, unless specified otherwise. 19.0 THERMOMETER CONNECTIONS All flanged nozzles 100 mm NB or larger shall be provided with one 25 mm

NB flanged connection covered with blind flange, unless specified otherwise. 20.0 JACK SCREWS 20.1 Jack screws of proper size and number shall be provided for breaking the

channel cover joint, shell cover joint and floating head cover joint. 20.2 The jack screws shall be of the same material as the bolting. 21.0 HOLDING LUGS AND EYE BOLTS Suitable holding lugs and forged steel eye bolts shall be provided for channel

and shell cover, tube sheets and floating head cover for assembly and dismantling the unit.

22.0 DOWEL PINS Dowel pins shall be provided to prevent misassembly of floating head cover,

channel, channel cover having grooved partitions and stationary tube sheet to shell flange.

23.0 TEST RIG / TEST FLANGE


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23.1 At least one set of test rigs and/or test flanges shall be supplied in case of

heat exchangers with removable tube bundle for each size and each type. 23.2 In the case of stacked units, number of sets to be supplied shall be equal to

number of shells in a stack. 24.0 STACKED UNITS 24.1 For stacked units, the VENDOR shall develop and furnish the required details

for accommodating expansion. 24.2 The VENDOR shall check and ensure that the local stresses at support and

intermediate nozzles (assuming exchanger in corroded condition) are within the allowable limits.

24.3 Intermediate nozzles between units shall have raised face flanges for ease of

assembly. 24.4 Bolting in flanges of mating connections between stacked exchangers shall be

removable without moving the exchangers. 24.5 Intermediate supports shall be installed during fabrication and the entire stack

shall be erected at the manufacturer's works and checked for accuracy of nozzle location and alignment.

24.6 A set of shim plates with a total thickness of 15 mm shall be provided for final

adjustments at site. 25.0 MISCELLANEOUS 25.1 The BIDDER shall include two (2) numbers stainless steel name plates in his

scope. This requirement is exclusive of manufacturer's name plate. The details on name plate shall be furnished during review of drawings.

25.2 Lifting lugs shall be provided for all heat exchangers. Details are subject to re-

view and approval. 25.3 Earthing cleats as per companion specification TCE.M4-102-43 shall be

provided at the approved locations. 25.4 All pads at nozzles, supports etc. shall be provided with a tell-tale hole at the

bottom-most location, which shall be tested with air at 1.0 kg/cm2 (g) and checked with soap solution for leakage. Such tell-tale holes shall be plugged after satisfactory testing.

25.5 For insulated or fire proofed heat exchangers, the insulation or fire proofing

supports as per enclosed companion specification shall be provided by the VENDOR.

25.6 Where materials are “free issue” as indicated in the enquiry specification or

data sheet, the BIDDER shall furnish along with the technical BID, a firm Bill


TCE.M4-101-01



SHEET 9 OF 10

ISSUE R3

TITLE


of Materials (BOM) of all “free issue” items and also indicate cutting and wastage allowances both accountable and unaccountable.

26.0 ANCHOR BOLTS Anchor bolts are not included in the scope of supply of the VENDOR, unless

specified otherwise in the data sheets. 27.0 FABRICATION 27.1 All welders, WPS and Procedure Qualification Records (PQR) shall meet the

requirements of the specified code irrespective of pressure service or non-pressure service.

27.2 Before welding , edges shall be checked in order to ascertain the absence of

flaking, irregularities or serious defects. 27.3 Stainless steel and high alloy steel fabrication shall have independent set of

tools, grinding wheels and wire brushes etc. 27.4 Welding shall be executed by qualified welders. 27.5 Butt-welds shall have full penetration. Single sided welds shall be chipped

back to sound metal and rewelded from the other side. Wherever chipping is not possible, root run shall be by TIG. Backing strip shall not be used without prior approval.

27.6 Openings, reinforcing pads and attachments shall clear longitudinal and

circumferential weld seams. 27.7 Circumferential welds shall be situated 100 mm above or below the support

rings and packing support rings meant for supporting internals, if specified. 27.8 Circumferential and longitudinal weld seams shall clear saddles and support

lugs. Longitudinal seams, in case of horizontal heat exchangers, shall be at least 150 mm above saddle wear plate.

27.9 Nozzle and reinforcement pads, where applicable, shall be set-in type and

attached to the heat exchanger by full penetration welds. 27.10 All welds shall be deburred, free from undercuts, overlap ridges and

valleys. 27.11 No welding shall be carried out after stress relieving and/or postweld heat

treatment. All flange faces shall be suitably protected against oxidation during heat treatment.

28.0 PAINTING All carbon steel exteriors shall be descaled, edges deburred and wire

brushed. Subsquently, all such surfaces shall be painted with two coats of red oxide primer.


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29.0 ESSENTIAL AND RECOMMENDED SPARES 29.1 The BIDDER shall include following essential spares in his scope of supply : (a) Two (2) gaskets as spares for each nozzle (b) Three (3) gaskets as spares for body flanges

(c) 10% spare fasteners of each size and length. However, the minimum quantity shall be four (4) for each size and length.

29.2 In addition to essential spares as indicated in para 29.1, the BIDDER may

recommend additional spares considered necessary by him, for three (3) year trouble-free operation.

29.3 The BIDDER shall include essential spares as indicated in para 29.1 and

recommended spares as considered necessary by him, in TCE.M4-993-01 “Schedule of Essential and Recommended Spares”. Total value of such spares shall not be included in the quoted price for supply of equipment. This value shall be considered for the purpose of BID evaluation.


TCE.M4-101-01


SHEET 1 OF 1

ISSUE R1

TITLE

TCE FORM NO. 329R3 FILE NAME : M410101R3.DOC

DATA SHEET C

DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE ORDER

1. Schedule of complete design calculations, drawings and documents to be

submitted along with submission dates 2. Quality Assurance Plan (QAP) 3. Complete design calculations 4. General arrangement drawing indicating overall dimensions, complete design

data, general notes, BOM, specifications of each of the pressure and non-pressure parts, tube bundle assembly, tube sheet details, tube layouts and related details, nozzle schedule with nozzle tag number, service, size, nozzle wall thickness, complete end connection details, nozzle elevations, locations, and orientation, support details, locations and orientation etc. Drawing shall also include removal space for tube bundle, wherever applicable. Tube bundle weight, operating weight, erection weight and weight filled with water shall also be indicated.

5. Detailed fabrication drawing for each part and welding details 6. Welding procedure


TCE.M4-102-01


WELDED UNFIRED PRESSURE VESSELS

SHEET 1 OF 9

TITLE

ISSUE R3


1.0 SCOPE This specification covers the general design, preparation of detailed

fabrication drawings for review and approval, supply of materials, fabrication, stage-wise inspection, final inspection, testing, packing, forwarding, transportation and delivery at site of welded unfired pressure vessels.

2.0 CODES AND STANDARDS 2.1 The design, materials, fabrication, inspection, testing and performance of

welded unfired pressure vessels shall comply with all currently applicable design codes and standards, statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal, or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

2.2 If statutory approvals are specified in data sheet A, the VENDOR shall be

responsible for obtaining all approvals on design, materials, stage-wise inspection, final inspection and testing of the vessel.

3.0 MATERIALS 3.1 All materials used in the fabrication of pressure vessels shall be as specified

in the data sheets. Equivalent materials are acceptable only when approved by the PURCHASER in writing.

3.2 All plates shall be ultrasonically tested as follows :

(a) For nominal thickness 20 mm and higher when used for fabrication of dished ends

(b) For nominal thickness 40 mm and higher when used for fabrication of

shells

(c) For nominal thickness 50 mm and higher when used for blind flanges

(d) All thicknesses, when used for body flanges 3.3 The VENDOR shall ensure that code mandatory requirements of impact

testing are met in accordance with the minimum design temperatures specified in the data sheets.

3.4 Any non-pressure parts such as cleats, pads at support lugs or legs, wear

plates at saddles and pads at pipe supports etc., welded directly on to the pressure parts, shall be of the same material as the pressure parts.


TCE.M4-102-01



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3.5 Reinforcement pads at nozzles and other load bearing locations shall be of

the same material and nominal thickness as the pressure part. 3.6 Material for skirt in case of alloy steel vessels and columns shall be the same

as that of pressure part at least for a minimum length of 500 mm from bottom tan-line.

3.7 ALLOY STEEL PROTECTIVE LINING AND CLADDING 3.7.1 Lining is defined as loose strip lining and bush lining. Cladding may be by

weld deposit overlay or explosion bonding or roll bonding. 3.7.2 Clad plate or lining shall conform to the following requirements :

(a) Clad plate thickness shall be minimum 3 mm, unless specified otherwise.

(b) Clad plate made either by the explosion bonding process or reduction

roll bonding process is acceptable. (c) Clad plate shall meet the ASME code requirements of SA263, SA264,

SA265 including bond test or AD-Merkblatter W-8.The shear bond test shall be executed as per SA264, Figure 1.Ultrasonic inspection shall be carried out in accordance with SA 578, acceptance level S-6.

(d) For the purpose of ensuring that cladding thickness of reduction

roll-bonded clad plates is not less than 3 mm, each plate shall be inspected at the mill using a "coating gauge". Plates shall be scanned on at least three edges and one across the width of the plate. Thickness shall be plotted at points not more than 600 mm apart. The VENDOR shall furnish a mill certificate, showing an outline of the plate and the points at which readings were taken together with the results.

(e) Instead of lining, weld deposit overlay may also be considered.

(f) At weld deposit overlay or clad-restoring welds, at least the same

chemical composition shall be present at 3 mm depth, to be analysed by the welding procedure qualification in advance.

(g) Weld deposit overlay and clad-restoring welds shall be dye penetrant

tested and crack-free.

(h) Weld deposit overlay and clad-restoring welds as a minimum, shall be qualified as per ASME Section IX.

3.7.3 Alloy steel lining shall not be used when cladding is specified. Alloy steel

lining, when specified, shall be so designed that the distance between attachments does not exceed 150 mm.


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3.7.4 The minimum required thickness of pressure parts shall exclude cladding or

lining. 3.7.5 Cladding or lining requirements discussed in this specification are using low

and high alloy steels only. For cladding or lining using non-ferrous and other materials, when specified, the VENDOR shall furnish on his drawings all details, including Welding Procedure Specification (WPS), for review and approval.

4.0 MINIMUM THICKNESS 4.1 The thicknesses of the pressure parts as shown in the data sheets or

drawings are the minimum acceptable thicknesses after manufacture, even though the code may permit a lesser thickness. The minimum acceptable thickness includes specified corrosion allowance.

4.2 The VENDOR shall be responsible for proper selection of plate thickness

considering the fabrication and forming allowances, mill under-tolerances etc., to meet the minimum thickness requirements as specified.

5.0 SHELLS Shell courses shall be of the largest possible dimensions to minimise the

number of weld seams. 6.0 HEADS AND REDUCING SECTIONS 6.1 Heads shall be of 2:1 ellipsoidal or equivalent ellipsodial type (crown radius

R = 0.9D, knuckle radius r = 0.17D), unless specified otherwise, where D is the inside diameter of the shell.

6.2 Reducing sections or conical bottoms shall have a knuckle radius of r =

0.06D, unless specified otherwise. However, knuckle radius shall not be less than 50 mm.

6.3 Dished ends shall be seamless or 100% radiographed when made from more

than one piece. 7.0 AGITATOR ASSEMBLY 7.1 Agitator assembly shall be complete with drive motor, mechanical seal with

seal housing, bearings, gear box, agitator shaft with impellers, foot-step bearing with support, rigid coupling between agitator shaft and gear box output shaft with spool piece, flexible couplings between gear box and drive motor, suitable base plate and supporting structure for agitator drive


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arrangement and necessary fasteners etc. so as to make it complete in all respects.

7.2 Drive motor and gear box shall be mounted on a common base frame and

duly coupled and aligned through flexible couplings. 7.3 Agitator shaft and gear box output shaft shall be coupled through a rigid

coupling with split ring locking arrangement in order to ensure that agitator shaft does not fall into the vessel during operation.

7.4 Agitator, shaft and impeller assembly shall be statically and dynamically

balanced. 7.5 The VENDOR shall obtain necessary approvals from the seal manufacturer

regarding arrangement of assembly and application of API cooling plan etc. for the mechanical seal.

7.6 The gear box shall be rated for heavy duty agitator service, continuously

working for 24 hours a day and shall be suitable to withstand static and dynamic loads and bending moment on the gear box due to agitator shaft.

7.7 Drive motor and gear box unit shall be provided with a suitable lifting eye

hook. 7.8 There shall be no oil spillage from gear box on to the vessel. 7.9 Base frame shall be provided with suitable lifting lugs suitably designed for

lifting complete agitator assembly. 8.0 NOZZLES AND MANHOLES 8.1 Nozzles fabricated from plates are acceptable for sizes larger than 250 mm

NB in case of carbon and low alloy steels and 150 mm NB in case of high alloy steels. However, this is to be done with prior approval and subject to all welds being 100% radiographed.

8.2 All nozzle sizes and quantities indicated in the data sheets are tentative and

for bid purpose only.Final sizes and quantities are subject to confirmation during review of drawings.The BIDDER shall include and confirm in his BID, that changes, to the extent of one size lower or higher for each nozzle and quantities plus or minus one number for each size, are acceptable at no extra cost to the PURCHASER.

8.3 All nozzles with butt-welding end connections shall have edge preparation as

per ANSI B16.25 suitable for connected piping inside diameter. Such nozzles shall have 100 mm extra stub length with pipe caps for hydrotest purpose.


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8.4 All nozzles of sizes 40 mm NB and below shall be gusseted as per the companion specification TCE.M4-102-34.

8.5 All openings in pressure parts shall be compensated for the area of opening

as per code. Minimum width of pad shall be 50 mm. 8.6 All load bearing areas in pressure parts shall be verified for buckling

and local stresses.Adequate reinforcement shall be provided. 8.7 Nozzle and manhole necks shall be flush with the inside surface of vessel,

unless specified otherwise. Inside edges of manholes shall be smooth and rounded-off with a radius of 3 mm.

9.0 FLANGES 9.1 Unless specified otherwise, all nozzles shall be provided with rated flanges

only, from consideration of interchangeability, as per the dimensional standards indicated in the data sheets.

9.2 Bolt holes shall straddle the main vessel axes, unless specified otherwise. 9.3 All flanges on nozzles shall be of forged construction with integral hubs. Plate

or plate type forged flanges are not acceptable in place of forged flanges with integral hubs.

9.4 All slip-on type flanges of sizes larger than 50 mm NB and girth flanges shall

be provided with adequate venting arrangement during welding. 9.5 Girth flanges, if made out of multiple plates, shall be a maximum of three

segments. All welds shall be 100% radiographed. Pre-heating and postweld heat treatment shall be carried out as per code.

9.6 Companion flanges specified with alloy steel liner shall be supplied with 100

mm long alloy steel stub ends with butt-welding edge preparation to suit connected pipe thickness.

9.7 When companion flanges are of welding neck type, the same shall be to suit

bore of connected pipe.However,this information shall be provided by the PURCHASER, during review of drawings.

9.8 Blind flanges and covers intended for inspection or access openings shall be

provided with adequate arrangement to facilitate opening and closing without undue effort.

9.9 Unless specified otherwise, seating surfaces for non-metallic gaskets shall

have stock or serrated finish. For other types of gaskets, the type of finish shall be furnished by the VENDOR on the drawings for review and approval.


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9.10 When flanges specified are of tongue and groove or male and female type, groove or female face shall be on the nozzle flanges and tongue or male face on the companion flanges.

10.0 SUPPORTS 10.1 All skirt supports shall have at least one access opening and adequate vent

holes at the top of skirt. 10.2 Skirt shall be provided with adequate holding and climbing rungs inside,

above and below the skirt opening. Details shall be furnished by the VENDOR on the drawings for review and approval.

11.0 MISCELLANEOUS 11.1 The sizing of vessel internals shall be such that all removable parts can be

removed through manholes. 11.2 Wherever applicable and unless specified otherwise in data sheets all

support rings, bolting bar for internals such as trays, tower packings, downcomers etc. shall be in the scope of the VENDOR.

11.3 Internal baffles, tray support beams of other internals spanning a chord or

diameter of the vessel shall be provided with a means for allowing differential expansion between the part and the vessel shell.

11.4 Unless specified otherwise, baffles or weir plates shall not be welded directly

to the shell or dished end of the vessel. These shall be bolted to the support attachments which are welded to the shell or dished end.

11.5 The BIDDER shall include two (2) numbers stainless steel name plates in his

scope.This requirement is exclusive of manufacturer's name plate. The details on name plate shall be furnished during review of drawings.

11.6 Lifting lugs shall be provided for all vessels. Details are subject to review and

approval. 11.7 Earthing cleats as per companion specification TCE.M4-102-43 shall be

provided at the approved locations. 11.8 All pads at nozzles, supports etc. shall be provided with a tell-tale hole at the

bottom-most location, which shall be tested with air at 1.0 kg/cm²(g) and checked with soap solution for leakage. Such tall-tale holes shall be plugged after satisfactory testing.

11.9 For insulated or fire proofed vessels, insulation or fire proofing supports as

per enclosed companion specification shall be provided by the VENDOR.


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11.10 Wherever platforms and ladders are specified in the data sheets, necessary supports shall be provided by the VENDOR as per details which shall be made available during review of drawings.

11.11 Where materials are “free issue” as indicated in the enquiry specification or

data sheet, the BIDDER shall furnish along with the technical BID, a firm Bill of Materials (BOM) of all “free issue” items and also indicate cutting and wastage allowances both accountable and unaccountable.

12.0 ANCHOR BOLTS Anchor bolts are not included in the scope of supply of the VENDOR, unless

specified otherwise in the data sheets. 13.0 FABRICATION 13.1 All welders, WPS and Procedure Qualification Records (PQR) shall meet the

requirements of the specified code irrespective of pressure service or non-pressure service.

13.2 Before welding, edges shall be checked in order to ascertain the absence of

flaking, irregularities or serious defects. 13.3 Stainless steel and high alloy steel fabrication shall have independent set of

tools, grinding wheels and wire brushes etc. 13.4 Welding shall be executed by qualified welders. 13.5 Butt-welds shall have full penetration. Single sided welds shall be chipped

back to sound metal and rewelded from the other side. Wherever chipping is not possible, root run shall be by TIG. Backing strip shall not be used without prior approval.

13.6 Openings, reinforcing pads and attachments shall clear longitudinal and

circumferential weld seams. 13.7 Circumferential welds shall be situated 100 mm above or below the support

rings and packing support rings meant for supporting internals, if specified. 13.8 Circumferential and longitudinal weld seams shall clear saddles and support

lugs. Longitudinal seams, in case of horizontal vessels, shall be at least 150 mm above saddle wear plate.

13.9 Nozzle and reinforcement pads, where applicable, shall be set-in type and

attached to the vessel by full penetration welds.


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13.10 Skirt to vessel heads joints shall have continuous flat-faced weld matching with outer diameter of the vessel. The width of the weld shall be equal to skirt thickness and height of weld shall be twice the width.

13.11 All welds shall be deburred, free from under cuts, overlap ridges and valleys. 13.12 No welding shall be carried out after stress relieving and/or postweld heat

treatment. All flange faces shall be suitably protected against oxidation during heat treatment.

14.0 FIELD ERECTION 14.1 Where size or shape of vessel makes it impossible to ship it in one piece for

erection by others, the VENDOR shall ship largest shop fabricated sections suitable for shipment and ease of handling for field erection and assembly. Fabrication and erection shall be completed at the site by the VENDOR.

14.2 All pieces shall be shop fit-up into sections and each sections shall be fit to

adjacent section and all pieces shall be match marked. 14.3 The width of permissible gap during fit-up shall be in accordance with

approved drawings and welding procedures and shall generally be 3 mm maximum with a tolerance of plus 0.8 mm to minus 0.0 mm.

14.4 Flame cut edges shall be ground by the VENDOR as required to remove

slag, detrimental discoloration and non-uniformity of edges. 14.4 All radiographic requirements for welds completed in shop shall be made by

the VENDOR before the parts of section leave the shop. 15.0 PAINTING All carbon steel exteriors shall be descaled, edges deburred and wire

brushed. Subsequently, all such surfaces shall be painted with two coats of red oxide primer.

16.0 ESSENTIAL AND RECOMMENDED SPARES 16.1 The BIDDER shall include following essential spares in his scope of supply : (a) Two (2) gaskets as spares for each nozzle (b) Three (3) gaskets as spares for body flanges

(c) 10% spare fasteners of each size and length. However, the minimum quantity shall be four (4) for each size and length.


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16.2 In addition to essential spares as indicated in para 16.1, the BIDDER may recommend additional spares considered necessary by him, for three (3) year trouble-free operation.

16.3 The BIDDER shall include essential spares as indicated in para 16.1 and

recommended spares as considered necessary by him, in TCE.M4-993-01 “Schedule of Essential and Recommended Spares”. Total value of such spares shall not be included in the quoted price for supply of equipment. This value shall be considered for the purpose of BID evaluation.

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIIB TCE.M4-102-01



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1. Schedule of complete design calculations, drawings and documents to be

submitted along with submission dates 2. Quality Assurance Plan (QAP) 3. Complete design calculations 4. General arrangement drawing indicating overall dimensions, complete design

data, general notes, BOM, specifications of each of the pressure and non-pressure parts, nozzle schedule with nozzle tag number, service, size, nozzle wall thickness, complete end connection details, nozzle elevations, locations, and orientation, support details, locations and orientation etc. Operating weight, erection weight and weight filled with water shall be indicated.

5. Detailed fabrication drawing for each part and welding details 6. Details of internals 7. Details of external cleats and structurals 8. Welding procedure


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1.0 SCOPE The following paragraphs describe general requirements for valves and specialities.

Only the applicable paragraphs for the type of valve or speciality are to be considered along with data sheet-A. These apply unless specified otherwise in data sheet-A.

2.0 CODES AND STANDARDS Valves and specialities shall be generally as per the following standards: 2.1 ANSI B16.1 : Cast Iron Valve Ratings 2.2 ASME B16.34 : Ratings of Valves-Flanged, Threaded and Welding Ends 2.3 API 594 : Wafer and Wafer - Lug Check Valves 2.4 API 600 : Steel Flanged and Butt Welding End Gate Valves 2.5 API 602 : Steel Gate Valves, Threaded and Socket Welding Ends 2.6 API 609 : Butterfly Valves 2.7 BS 1414 : Steel Gate Valves, Flanged and Butt Welding Ends 2.8 BS 1868 : Steel Check Valves, Flanged and Butt Welding Ends 2.9 BS 1873 : Steel Globe Valves, Flanged and Butt Welding Ends 2.10 BS 5156 : Diaphragm Valves 2.11 BS 5351 : Steel Ball Valves 2.12 BS 5352 : Steel Gate, Globe and Check Valves, 50 mm and Smaller 2.13 IS 778 : Bronze Valves 2.14 MSS-SP 67 : Butterfly Valves 3.0 GEAR OPERATORS Gear operators shall be provided on the following basis: 3.1 GATE AND GLOBE VALVES Up to and including ANSI 300 class - 350 mm and larger 600 class and higher - 200 mm and larger 3.2 OTHER VALVES Plug and ball - 150 mm and larger


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Butterfly - 200 mm and larger 3.3 Gear operators shall be suitable for a differential pressure corresponding to the

maximum valve rating at room temperature. 3.4 All gear operators shall be of the enclosed type. 4.0 INTEGRAL BYPASS 4.1 Gate valves shall be provided with integral bypass valve, as per MSS-SP 45, as

follows: Classes 150 and 300 - 350 mm and larger Class 600 and higher - 200 mm and larger 4.2 Type of bypass valve shall generally be the same as the main valve. Bypass pipe

shall be at least schedule 80 and material of construction of bypass valve and pipe shall be compatible with the main valve.

5.0 VALVE STEMS Valve stems shall be of wrought materials. Castings are not acceptable. 6.0 BACKSEAT All gate, globe and piston valves shall be provided with back seating arrangement to

facilitate replacement of gland packing with the valve in service. 7.0 CHECK VALVES Check valves of sizes 350 mm and larger shall be provided with features to prevent

slamming and hammering. These can be in the form of springs or external dash pot. 8.0 HARDNESS 13% chromium steel seat surfaces shall have a minimum hardness of 250 BHN and

a differential hardness of 50 BHN. 9.0 NAME PLATES The details on name plates shall be as per MSS-SP 25. 10.0 TAG PLATES Tag plates shall be of stainless steel type 304 or aluminium.


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11.0 TESTING Strength and leak tests shall be as per any of the standards MSS-SP-61, API 598 or

BS EN 12266-1 and 2 at the test pressures indicated in data sheet-A. Stainless steel valves shall be tested using potable water.

12.0 NDT REQUIREMENTS 12.1 All cast steel valves shall be subject to radiography in all accessible areas, as

defined in ASME B16.34, on the following basis: (a) Class 600 and higher - All sizes (b) Class 300 - Sizes 450 mm and larger (c) Class 150 - Sizes 600 mm and larger 12.2 All cast steel valves of class 600 and higher shall also be subject to magnetic

particle or liquid penetrant examination as per ASME B16.34. 12.3 All cast steel valves of class 300 shall have radiography quality castings irrespective

of size. 12.4 Acceptable levels of defects shall be as per ASME B16.34. 13.0 FACE-TO-FACE OR END-TO-END DIMENSIONS 13.1 Face-to-face dimensions of flanged-end valves and end-to-end dimensions of butt

welding-end valves shall be as per ASME B16.10. 13.2 For valves not covered by ASME B16.10, the dimensions shall be as per applicable

valve standards. 14.0 PREPARATION FOR DESPATCH 14.1 COATING All carbon steel and cast iron exposed surfaces shall be given one coat of primer

and two coats of aluminium finish paint after release has been given for painting and before despatch. Machined surfaces shall be coated with an easily removable rust protective except that this is not applicable for austenitic stainless steel components.

14.2 END PROTECTION After completion of the requirements of para 14.1, body end ports, flange faces and

welding ends shall be covered with suitable close fitting protectors to protect the machined ends and prevent ingress of dirt and moisture.


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14.3 DISC The disc shall be closed before despatch except in the case of soft-seated valves

where the disc shall be backed off to relieve the pressure on the seal. 14.4 PACKING

Valves and specialities shall be so packed as to minimise the possibility of damage during storage or transit. The packing shall be suitable for tropical conditions.


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DATA TO BE FURNISHED BY THE VENDOR AFTER THE

ISSUE OF PURCHASE ORDER

1.0 List of drawings and documents to be submitted for review, approval or

information with scheduled submission dates. 2.0 Quality Assurance Plan (QAP) 3.0 Drawings showing outline dimensions, clearance dimensions for disassembly,

weight, part numbers, materials of construction, test pressures, statutory and any special requirements, sizes, tag numbers and quantities. All information covered in data sheets A and B shall be incorporated in this drawing. The PURCHASER'S identifying tag numbers shall be shown on each drawing or on a sheet attached to the drawing with proper cross-references.

4.0 Operation and maintenance manuals


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manufacture, inspection and testing at the VENDOR's/his SUB-VENDOR's Works and delivery to Site of cast steel gate, globe including angle and Y-type and check valves generally for sizes NB65 and larger.

2.0 CODES AND STANDARDS 2.1 The design, material, construction, manufacture, inspection, testing

and performance of valves shall comply with all currently applicable statutes, regulations and safety codes in the locality where the valves will be installed. Valves shall also conform to the latest editions of applicable codes and standards as specified in various clauses of this specification. Nothing in this specification shall be construed to relieve the VENDOR from this responsibility.

2.2 Various codes and standards referred in this specification shall form an

integral part of this specification. In the event of conflict between this specification and the codes and standards, the same shall be brought to the attention of the CONSULTANT for resolution.

3.0 DESIGN AND CONSTRUCTION FEATURES 3.1 The following design and construction features of valves shall be minimum

acceptable unless otherwise specified in Data Sheet-A and/or Section-C. 3.1.1 All gate and globe valves shall be of rising stem, outside screw and yoke

type. The design of valves shall ensure a streamlined passage and gate valves shall have low pressure drop. The seats and discs shall be easily renewable and/or shall be suitable for easy refacing and grinding. Valve discs shall be of such design as to keep the seats tight when the valve body is subjected to pressure, temperature variations and piping stresses. Gate valves shall close in both flow directions.

3.1.2 All globe valves shall be capable of being closed against pressure. 3.1.3 All valves end details shall be as specified in Data Sheet-A. In the case of all

end-welded valves, the stub ends of the valves shall project from the valve body a sufficient amount to ensure that the welding process will not distort the valve body and internal parts.

3.1.4 Valves for regulating duties shall be of the globe type with tapered plug type

disc. 3.1.5 Hardness of seating surfaces shall be a minimum of 350 BHN and a

minimum differential hardness of 50 BHN shall be provided between seats to prevent galling. This is not applicable for stellited seats.


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3.1.6 Check valves of sizes 400 mm NB and larger shall have dash pot

arrangement. 3.1.7 All gate and globe valves shall have back-seating arrangement to

facilitate easy replacement of packing with the valve in service. 3.1.8 All valves shall be so designed that the hand-wheel moves in a clockwise

direction to close the valve. The face of the hand-wheel shall be clearly marked with the words 'OPEN' and 'CLOSE' and an arrow to indicate the direction for opening. All hand-wheels shall be fitted with name plate.

3.1.9 Piston lift check valves shall have accurately guided pistons so that the

pistons are cushioned in their cylinders as they move up. 3.2 All gate, globe, Y-type and angle valves intended for manual operation

and falling under the following categories shall be equipped with a gear operator for ease of operation and to ensure fast and tight closure:

ANSI PRESSURE RATING VALVE SIZES FOR WHICH GEAR OPERATOR IS REQUIRED ----------------------------------- ---------------------------------------------- Class 300 and below 350 mm and larger Class 600 and above 200 mm and larger 3.3 All gate valves falling in the following categories shall be provided with

integral bypass valve. Bypass size shall conform to MSS-SP-45 as a minimum standard unless otherwise specified in Data Sheet-A. The bypass valve shall be hand operated unless otherwise specified in Data Sheet-A. Pipe for bypass shall be at least Schedule 80 seamless and of a material of the same nominal chemical composition and physical properties as that used for the main line. Orientation of bypass arrangement shall be subject to the approval of PURCHASER/ENGINEER.

ANSI PRESSURE RATING VALVE SIZES FOR WHICH BYPASS IS REQUIRED ------------------------------------ ------------------------------------------------- Class 600 and over 200 mm and larger Class 300 & 150 350 mm and larger 3.4 All gate valves of ANSI pressure rating class 150 and 300 shall have solid

or flexible wedge and ANSI pressure rating class 600 and above shall have flexible or parallel slide type of wedge.


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3.5 Valves with flexible wedge shall have provision for relieving the pressure in the neck of the valve when the valve is in the closed position.

3.6 All valves of ANSI pressure rating upto class 600 shall have bolted bonnet

construction and class 900 and above shall have bonnet construction of the pressure seal type. Pressure seal valves shall have stainless steel inlay in the gasket area and silver-plated gaskets or other acceptable proven features.

3.7 All carbon steel valves of ANSI pressure rating upto class 150 and 300

shall have stainless steel trim (13% Cr) unless otherwise specified in Data Sheet-A and ANSI pressure rating class 600 and above shall have stellited trim.

3.8 All alloy steel valves shall have stellited seats. 3.9 All valves of ANSI pressure rating upto class 900 and higher shall have

yoke with anti-friction bearing arrangement. 3.10 Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be

provided with a non-detachable locking arrangement. The locking arrangement provided shall be subject to approval by the PURCHASER.

3.11 As specified in Data Sheet-A, valves operating under vacuum conditions

shall have glands with water sealing. The inlet and outlet connections shall be NB 15mm. The VENDOR shall indicate the maximum and minimum sealing water pressure and the required flow rate.

3.12 Motor operators shall be designed to close the valve within the time shown

in Data Sheet-A. For details of motor operator, refer companion specifications TCE.M4-203-01 and TCE.M4-203-06.

3.13 Y-globe valves shall have flow area designed for minimum turbulence and

pressure drop. 3.14 Stop check valves shall have full floating and accurately guided discs. 3.15 When chain wheels are specified for valves, they shall be constructed to

give good traction for the chain. Roller guides shall be provided to hold the chain to a greater part of the circumference of the wheel, to increase traction and to prevent the chain from jumping off the wheel.

3.16 Extension stems where specified, shall be of extra strong pipe with

suitable coupling, fastened by locknuts and set screws. Floor stands shall be of sturdy construction and shall be at least one metre high from the floor. They shall be provided with chromium-plated scales and valve movement indicators. Where lateral and/ or vertical movements of valve are indicated in Data Sheet-A, the floor stand and extension spindle shall be


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designed to permit these movements. Adequate greasing facilities shall be provided for all pedestals and extended operating spindle attachments.

3.17 Flow direction shall be clearly embossed on the valve body for globe and

check valves. 3.18 Wherever special class valves as per ANSI B16.34 "Steel Valves" are

specified in Data Sheet-A, all requirements of ANSI B16.34 for this class of valves shall be met in addition to the requirements given in this specification.

4.0 WELDING REQUIREMENTS All welding procedure qualifications and welder performance

qualifications shall be in accordance with Section-IX of the ASME Boiler and Pressure Vessel Code. Hard facing operations require procedure qualification.

5.0 CLEANING Prior to factory inspection, all manufacturing waste, such as metal chips

and filings, welding rods and stubs, rags, debris and all other foreign matter shall be removed from the interior of each valve. All mill scale, rust, oil, grease, chalk, crayon, paint marks and other deleterious material shall be removed from the interior and exterior surfaces. At the time of shipment, valves shall be clean inside and outside.

6.0 INSPECTION AND TESTS 6.1 Inspection & tests shall be as per TCE.M4-185-17 and TCE.M4-185-01. 6.2 Defect Removal and Repair in Castings 6.2.1 Defects in excess of acceptance standards shall be removed by suitable

means. If removal of surface defects does not result in reduction in wall thickness below 5% of intended thickness of metal at that location, the area shall be blended smoothly into the surrounding surface. Where defect removal results in a wall thickness below the above, resultant cavity may be repaired by welding. The procedure and operator shall be qualified as per applicable standards. Major weld repairs shall be stress relieved or heat treated in accordance with ASME Section VIII Division I-UCS 56.

6.2.2 The required area shall be re-examined and the acceptance standards

shall be as in the original examination. 6.2.3 Weld repairs made as a result of radiographic examination shall be

radiographed after welding. Repairing a particular area more than 2 times is not permitted and the component shall be rejected. The acceptance


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standards for welds shall be as per ASME Boiler and Pressure Vessel Code, Section VIII, Division I, UW - 51.

6.2.4 Prior approval shall be obtained from the PURCHASER/ ENGINEER before

taking up major weld repairs (major weld repair - when depth of repair exceeds 20% of thickness or 1 inch whichever is smaller). Mapping of major weld repairs is also required.

6.3 All valves shall be tested hydrostatically for strength, tightness of seats and

tightness of backseating at the pressures indicated in Data Sheet-A, in accordance with MSS-SP 61, "Hydrostatic Testing of Steel Valves". Water used for hydrostatic testing of valves with stainless steel components shall not have chloride content exceeding 20 ppm. Clean potable water may be used for testing of all other valves.

6.4 All valves except check valves shall be tested for seat tightness by air at a

pressure of 6 bar (g) on both sides of seat. 6.5 All check valves shall also be hydrotested at 25% of the seat hydro test

pressure. 6.6 All valves shall be checked for correctness in respect of specified end details

as per applicable standards. 7.0 PAINTING AND CORROSION PROTECTION Unless otherwise specified in Data Sheet-A/Section-C, two coats of primer

of thickness 35 microns for each coat shall be applied to all steel and cast iron exposed surfaces as required to prevent corrosion, after release has been given for painting and before despatch. The use of grease or oil, other than light grade mineral oil, for corrosion protection is prohibited. Bores of all valves shall be covered, immediately after testing, draining and drying with suitable plastic end covers to avoid ingress of foreign materials.

8.0 DRAWINGS The BIDDER shall furnish, along with his Bid, drawings giving outline

dimensions, clearance dimensions for disassembly and weight of valve with actuator.

9.0 NAME PLATES All valves shall have permanent stainless steel name plates indicating

details as per MSS SP-25 "Standard Marking Systems for Valves, Fittings, Flanges and Unions". Also for all carbon steel valves of ANSI pressure rating class 600 and above, the pressure containing castings shall be marked with melt identification number. In addition, they shall


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have a permanent stainless steel tag fixed on the valve body indicating the PURCHASER's valve tag number and service.

10.0 DATA SHEETS As specified in Data Sheet-A/Section-C, the BIDDER shall submit details

about valves. 11.0 INFORMATION TO BE FURNISHED AFTER THE AWARD OF CONTRACT The VENDOR shall furnish all the information as called for in Data Sheet-C.



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DATA SHEET - C

DATA TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF CONTRACT

The VENDOR shall submit, in the manner and within the time set forth in

the Purchase Order/Letter of Intent the following : 1.0 Drawings showing Purchase Order number, outline dimensions,

clearance dimensions for disassembly and weight (valve and actuator). The VENDOR's drawings identified by character, number and date, when reviewed by the PURCHASER, will be considered a part of this specification. The PURCHASER's identifying tag numbers shall be shown on each drawing or on a sheet attached and referenced to the drawing.

2.0 Quality plans as per the format enclosed in TCE.M4-185-01, covering also

the inspection requirements as indicated in this specification, as minimum. 3.0 Operation and maintenance instruction manuals. 4.0 Test Certificates/reports for :

a) Physical and chemical analysis and metallurgical tests for all components of valves.

b) Hydrostatic and pneumatic tests. c) Non-destructive tests.

5.0 Test certificates as required by statutory regulations. 6.0 If specified in Data Sheet-A/Section-C, the details of all valves and valve list

as per enclosed formats.


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manufacture, inspection and testing at the VENDOR's/his SUB-VENDOR's Works and delivery to Site of forged steel valves comprising gate, globe including angle and Y-type, needle and check valves generally for sizes NB 50 and smaller.

2.0 CODES AND STANDARDS 2.1 The design, material, construction, manufacture, inspection, testing

and performance of valves shall comply with all currently applicable statutes, regulations and safety codes in the locality where the valves will be installed. The Valves shall also conform to the latest editions of applicable codes and standards as specified in various clauses of this specification. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

2.2 Various codes & standards referred in this specification shall form an

integral part of this specification. In the event of conflict between this specification and the codes and standards, the same shall be brought to the attention of the CONSULTANT for resolution.

3.0 DESIGN AND CONSTRUCTION FEATURES 3.1 The following design and construction features of valves shall be minimum

acceptable unless otherwise specified in Data Sheet-A and/or Section-C. 3.1.1 All gate and globe valves shall be of rising stem, outside screw and yoke

type. The design of valves shall ensure a streamlined passage and low pressure drop. The seats and discs shall be easily renewable and/or shall be suitable for easy refacing and grinding. Valve discs shall be of such design as to keep the seats tight when the valve body is subjected to pressure, temperature variations and piping stresses. Gate valves shall close in both directions.

3.1.2 In the case of all end-welded valves, the stub ends of the valves shall

project from the valve body a sufficient amount to ensure that the welding process will not distort the valve body and internal parts.

3.1.3 Valves for regulating duties shall be of the globe type with tapered plug type

disc. 3.1.4 Hardness of seating surfaces shall be a minimum of 350 BHN and a

minimum differential hardness of 50 BHN shall be provided between seats to prevent galling. This is not applicable for stellited seats.


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3.1.5 All gate and globe valves shall have back-seating arrangement to facilitate easy replacement of packing with the valve in service.

3.1.6 All valves shall be so designed that the hand-wheel moves in a clockwise

direction to close the valve. The face of the hand-wheel shall be clearly marked with the words 'OPEN' and 'CLOSE' and an arrow to indicate the direction for opening. All hand-wheels shall be fitted with name plate.

3.1.7 Forged steel needle and Y-type valves shall have extra long thread

chambers and a plug type disc which shall be resistant to wear and foreign matter. The stuffing box shall be adequately deep and shall be fitted with a high grade packing. Stems shall have fine pitch threads to permit fine adjustment. The discs and seats shall be cone shaped.

3.2 All valves of ANSI pressure rating upto class 600 shall have bolted bonnet

construction and class 900 and above shall have bonnet construction of integral or welded type.

3.3 All carbon steel valves of ANSI pressure rating class 600 and 800 shall

have stainless steel trim (13% Cr.) unless otherwise specified in Data Sheet-A and ANSI pressure rating exceeding class 800 shall have stellited trim.

3.4 All alloy steel valves shall have stellited seats. 3.5 Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be

provided with a non-detachable locking arrangement. The locking arrangement provided shall be as per standard practice and shall be subject to approval by the PURCHASER/ENGINEER.

3.6 As specified in Data Sheet-A, valves operating under vacuum conditions

shall have special glands designed for such conditions. 3.7 Motor operators shall be designed to close the valve within the time shown

in Data Sheet-A. For details of motor operator, refer companion specifications TCE.M4-203-01 and TCE.M4-203-06.

3.8 Wherever extension stems are specified , these shall be of extra strong

pipe with suitable coupling, fastened by locknuts and set screws. Floor stands shall be of sturdy construction and shall be at least one metre high from the floor. They shall be provided with chromium-plated scales and valve movement indicators. Where lateral and/ or vertical movements of valve are indicated in Data Sheet-A, the floor stand and extension spindle shall be designed to permit these movements. Adequate greasing facilities shall be provided for all pedestals and extended operating spindle attachments.


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3.9 Flow direction shall be clearly embossed on the valve body for globe and check valves.

4.0 WELDING REQUIREMENTS All welding procedure qualifications and welder performance

qualifications shall be in accordance with Section-IX of the ASME Boiler and Pressure Vessel Code. Hard facing operations require procedure qualification.

5.0 CLEANING Prior to factory inspection, all manufacturing waste, such as metal chips

and filings, rags, debris, welding rod stubs, and all other foreign matter shall be removed from the interior of each valve. All mill scale, rust, oil, grease, chalk, crayon, paint marks and other deleterious material shall be removed from the interior and exterior surfaces. At the time of shipment, valves shall be clean inside and outside.

6.0 INSPECTION AND TESTS 6.1 Inspection & tests shall be as per TCE.M4-185-18 and TCE.M4-185-01. 6.2 All valves shall be checked for correctness in respect of socket dimensions

as per standard. 6.3 All valves shall be tested hydrostatically for strength, tightness of seats and

tightness of backseating at the pressures indicated in Data Sheet-A . Water used for hydrostatic testing of valves with stainless steel components shall not have chloride content exceeding 20 ppm. Clean potable water may be used for testing of all other valves.

6.4 All valves shall be tested for seat tightness by air at a pressure of 6 bar (g)

except for check valves. 6.5 All check valves shall also be hydrotested at 25% of the seat hydro test

pressure. 7.0 PAINTING AND CORROSION PROTECTION Unless otherwise specified in Data Sheet-A/Section-C, two coats of

primer of thickness 35 microns for each coat shall be applied to all steel and cast iron exposed surfaces as required to prevent corrosion, after release has been given for painting and before despatch. All parts shall be adequately protected for rust prevention. The use of grease or oil, other than light grade mineral oil, for corrosion protection is prohibited. Bores of


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all valves shall be covered, immediately after testing, draining and drying with suitable plastic end covers to avoid ingress of foreign materials.

8.0 DRAWINGS The BIDDER shall furnish, along with his Bid, dimensioned outline and

cross sectional drawings. 9.0 NAME PLATES All valves shall have permanent stainless steel name plates indicating

details as per MSS SP-25 "Standard Marking Systems for Valves, Fittings, Flanges and Unions". In addition, they shall have a permanent stainless steel tag fixed on the valve body indicating the PURCHASER's valve tag number .

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIIB TCE.M4-103-55

FORGED STEEL VALVES

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DATA SHEET C

DATA TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF CONTRACT

The VENDOR shall submit, in the manner and within the time set forth in

the Purchase Order/Letter of Intent the following : 1.0 Drawings showing Purchase Order number, outline dimensions,

clearance dimensions for disassembly and weight (valve and actuator). The VENDOR's drawings identified by character, number and date, when reviewed by the PURCHASER, will be considered a part of this specification. The PURCHASER's identifying tag numbers shall be shown on each drawing or on a sheet attached and referenced to the drawing.

2.0 Quality plans as per the format enclosed in TCE.M4-185-01, covering also

the inspection requirements as indicated in this specification, as minimum. 3.0 Operation and maintenance instruction manuals. 4.0 If specified in Data Sheet-A/Section-C, the details of all valves and valve list

as per Purchaser’s formats.



DESIGN OF POWER PLANT PIPING

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1.0 SCOPE This specification covers the minimum technical requirements and essential

particulars for the design of the piping systems included in the VENDOR’s scope as identified in the drawings and documents forming a part of this specification. The VENDOR/CONTRACTOR shall demonstrate that the piping meets the specification and the applicable codes.

2.0 CODES AND STANDARDS 2.1 The design of pipes, pipe assemblies, pipe fittings, flanges and components,

valves and specialities and any other pressure retaining part in a piping system shall be carried out in accordance with the applicable power piping code.

2.2 The design of the piping systems shall also meet the statutory requirements of the

countries of manufacture and installation of the piping systems. In case the piping systems are manufactured and / or installed in India, the design shall meet the requirements of the Indian Boiler Regulations (IBR) for system under the purview of IBR.

2.3 Notwithstanding the recommendations and stipulations of the codes and

standards mentioned above, the requirement of this specification and associated Data sheets shall be deemed minimum and shall be complied with fully.

2.4 All codes and standards referred shall be the latest version on the date of offer

made by the Bidder unless otherwise indicated. 2.5 Nothing in this specification shall be construed to relieve the Vendor/Contractor of

his responsibilities as above. 3.0 BASIC DESIGN CRITERIA 3.1 Piping shall be designed adequately to meet the system requirements of flow,

pressure drop, etc., under all operating modes of the plant, both normal and abnormal. Planned and forced outages of equipment or systems shall be taken into account and it shall be ensured that realisation of maximum feasible plant performance in terms of output and efficiency is not hampered by inadequacies in piping design.

3.2 It shall also be ensured that, under no circumstances, including mal-operation or

failure of an equipment or system, the safety of the plant, equipment or personnel is endangered by inadequate design of piping.

3.3 Piping systems shall also be designed and conceived in such a manner as to

maximise plant or equipment availability. Provision of ring headers, sectionalising valves, isolating valves, block valves, bypass, etc., are examples illustrating this concept and it is the responsibility of VENDOR/CONTRACTOR to ensure provision of such facilities, at no extra cost to the PURCHASER, as deemed




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necessary regardless of whether the same have been identified in contract documents and drawings or not.

4.0 LINE SIZING 4.1 Sizes of piping shall be selected such that the velocity of fluid in pipes does not

exceed the following limits under conditions of maximum possible volumetric flow. STEAM Superheated steam 75 m/s Saturated steam / Exhaust steam 40 m/s. Wet steam 30 m/s. WATER Pump suction 1.5 m/s. Pump delivery 3.0 m/s Boiler feed pump discharge 6.0 m/s. City water 1.5 m/s. OIL Heavy oil (Heated) 2 m/s. Light oil 2 m/s. GASES Compressed air 15 m/s. Natural gas 30 m/s. 4.2 Lower values of velocities than those stated above shall be used to determine line

size if dictated by considerations of pressure drop, NPSH, surges, water hammer, etc.

4.3 The design flows considered in line sizing shall not be less than the rated

capacities of equipment to which the piping is connected such as pumps, blowers, compressors turbines, boilers, etc., rated capacity of control valve, flow limiting orifices, etc., or, the system heat and / or mass balance diagrams.

4.4 The selection of line size shall take into account likely increase in pressure drop

with the ageing of the pipe due to increase in pipe roughness, encrustation of pipe




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with scale, dirt, foreign matter, etc. A suitable allowance shall be made towards this expected increase in pressure drop and the same shall be subject to the approval of PURCHASER/ENGINEER.

4.5 While sizing pump suction lines, NPSH requirements of pumps shall be fully met

under all conditions of operation including trip-out of an operating pump and failure of the standby pump to come on line.

4.6 Wherever strainer pressure drops are considered, the same shall be for the 50%

clogged condition of the strainers. Pressure drops across equipment shall correspond to unclean condition of the equipment.

4.7 Sizes of boiler feed pump suction piping shall be selected to meet the NPSH

requirements of the pumps under transient conditions prevailing on turbine trip out and simultaneous loss of steam supply to feed water tank.

4.8 Cascade drain piping systems of feed water heaters shall also be designed to

handle the additional flows that are likely to occur due to tube rupture in the heaters besides other operating conditions stipulated elsewhere. The minimum additional flow to be considered shall be either 10 percent of tube side flow at Maximum Continuous Rating (MCR) conditions or the flow that can result from the complete rupture of one tube with two open ends, whichever is greater.

4.9 All overflows shall be designed for a capacity not less than the maximum possible

difference between inlet and outlet flows under all operating conditions normal and abnormal, including mal-operation.

5.0 MATERIALS 5.1 The material specifications of piping of various systems shall be as specified in

Data sheet – A. 5.2 Bidders may offer, if they so desire, alternate materials equal or superior to those

specified. However, no credit would be given to offers containing materials superior to those specified. The responsibility for establishing equality or superiority of the alternate materials offered to those specified rests entirely with the Bidder, the PURCHASER/ENGINEER reserves the right to reject such alternate materials and insist upon those specified.

5.3 Bidders shall note that equality or superiority of the materials offered by them vis-

à-vis those specified would be judged not only based on a comparison of the material standards but also on the ease of fabrication, shop and field welding, heat treatment, service record and any other characteristics considered important by the ENGINEER.

5.4 Bidders shall indicate, in their offer, reasons for their wishing to deviate from the

materials specified.




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6.0 DESIGN PRESSURES 6.1 The minimum design pressures of piping systems shall be as indicated in Data

Sheet – A attached to this specification. In the event of this information not being available in the Data sheets, the following shall be construed to be the minimum requirements for design pressures.

6.2 MAIN STEAM LINE 6.2.1 The main steam line beyond the steam stop valve shall be designed for the design

pressure of boiler, i.e. not less than the highest pressure at which any safety valve is to be set to lift, except that, for piping which are operating under thermal creep and the total capacity of the safety valve on the superheater is not less than 20% of the evaporative capacity of the boiler, the lowest pressure at which any superheater safety valve is set to lift.

6.2.2 When there is no superheater, the design pressure of the piping shall be the

design pressure of the boiler. 6.2.3 In case of a forced flow steam generator, the design pressure shall be as indicated

in data sheet – A. 6.3 REHEAT STEAM LINES 6.3.1 In reheat systems which are not operating under thermal creep, the design

pressure shall be the highest pressure at which any safety valve on the reheat system is set to lift. When no safety valves are mounted at the reheater inlet, the design pressure of the reheater inlet piping shall be the highest pressure at which any reheater outlet safety valve is set to lift, increased to take account of the pressure drop through the reheater corresponding to the most severe condition of operation.

6.3.2 In reheat systems which are operating under creep, the design pressure shall be

the lowest pressure to which any safety valve on the reheat system is set to lift. 6.4 EXHAUST STEAM LINES All uncontrolled extraction steam lines of turbine shall be designed for 1.1 times

the maximum possible working pressure on the lines. 6.5 FEED WATER PIPELINE 6.5.1 The feed water piping beyond the discharge nozzles of the feed water pumps,

shall be designed for the pump discharge pressure under no-flow condition for a fluid temperature of 15 deg. C.

6.5.2 In the event of there being a likelihood of the speed of the prime mover exceeding

the rated speed by more than 10%, the design pressure shall be increased by the effect of the excess in overspeed over 10%.




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6.5.3 Feed water booster pump suction line. The design pressure shall be not less than the sum of the highest set pressure of

safety valves on the deaerator / feed water tank and the pressure due to static head of the water in the suction line calculated for a fluid temperature of 15oC.

6.5.4 Feed water booster pump discharge line. The design pressure shall not be less than the sum of the design pressure as

calculated for the suction line of the booster pump and the differential head of the booster pump for the no-flow condition with a fluid temperature of 15 deg. C.

6.6 PROVISION OF SAFETY AND RELIEF VALVES 6.6.1 Piping downstream of pressure reducing devices such as control valves, orifices,

etc., shall be designed for the same pressures as applicable for piping upstream of the devices unless the downstream piping systems are adequately protected by safety or relief valves as under :

6.6.2 In order to take cognisance of the provision of safety or relief valves, the combined

relieving capacity of all safety or relief valves provided to protect a system shall equal or exceed the maximum possible mass flow that the system may be expected to handle under all normal or abnormal conditions of operation. In the case of safety valves located downstream of a control valve for example, the combined relieving capacity of the safety valves shall equal or exceed the estimated flow through the control valve when the valve is wide open with maximum upstream pressure and all downstream valves closed.

6.6.3 When safety and / or relief valves have been provided as above, the design

pressure of the piping system protected by the safety valves shall not be less than 1.1 times the highest set pressure of any safety valve. The lowest set pressure of any safety valve shall not be less than 1.1 times the maximum expected working pressure of the system.

6.7 PUMP DISCHARGE LINES The discharge piping of all pumps other than the boiler feed pumps and boiler feed

booster pumps shall be designed for a pressure not less than 1.1 times the pump discharge pressure under no-flow conditions for a working fluid temperature of 150C.

6.8 The design pressure of all branch piping including drain, vent and instrument

impulse piping up to the last roof valve shall be the same as that of the main line. 6.9 In general, piping shall be designed for the maximum possible pressure attainable

under the most arduous operating condition including pressure surges. However, the design pressure of any piping system shall not be less than 10 kg/cm2g.




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7.0 DESIGN TEMPERATURES 7.1 The design temperatures shall be as indicated in the Data Sheets – A. 7.2 Where no value is indicated in the Data sheets, the same shall be as per the

recommendations of applicable codes. 8.0 WALL THICKNESS 8.1 The calculation of wall thickness required for piping subject to internal and / or

external pressure shall be based on the formulae and recommendations given in the applicable codes. Adequate allowances shall be made towards thinning due to bending, weakening at branch connections, threading, commercial tolerances on pipe wall thickness, corrosion and erosion, etc., and the same shall be subject to approval by the ENGINEER.

8.2 A minimum corrosion / erosion allowance of 1 mm, shall be considered while

selecting wall thickness of pipes for all systems. Additional allowances would be required in the case of piping handling corrosive and / or erosive media and in case of piping located in a corrosive environment.

8.3 Pipe handling flashing liquids, as in case of feed heater drain lines, shall be

selected with extra wall thickness to combat erosion. 8.4 Much greater wall thickness than called for by strength calculations would be

required in order to minimise noise and vibration at certain locations such as downstream sections of high pressure reducing valves. The thickness and lengths of such sections shall be as specified by the ENGINEER.

8.5 Unless otherwise indicated in Data sheets – A, piping shall be designed for a maximum equivalent full temperature cycles of 7000 occurring over the design life of the piping system.

8.6 In case of carbon steel materials, (primarily for water & air services) the nominal

wall thickness of no piping shall be less than the minimum acceptable values given below. For rolled and welded pipes thickness shall be 8 mm from NB 500 to NB 800, 10 mm from NB 850 to NB 1000, 12 mm from NB 1050 to NB 1200.

NB mm (in) 15

(1/2) 20 (3/4)

25 (1)

32 (1-¼)

40 (1-½)

50 (2)

65 (2-½)

80 (3)

100 (4)

125 (5)

Min. Nominal Thickness mm

3.25 3.25 4.05 4.05 4.05 4.5 4.5 4.85 5.4 5.4

Nb mm (in) 150

(6) 200 (8)

250 (10)

300 (12)

350 (14)

400 (16)

450 (18)

Min. Nominal Thickness mm

5.4 6.35 6.35 6.35 7.1 7.1 7.1




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Minimum thickness for other services (steam, feed water, condensate, fuel oil system etc.,) shall be as per standard schedule of ASME B 36.10.

9.0 FLEXIBILITY ANALYSIS 9.1 Formal flexibility analysis calculations shall be carried out in case of piping subject

to restrained thermal expansions or contractions. The following piping systems shall be analysed.

9.1.1 Pipelines with a maximum operating temperature equal to or greater than 150 deg.

C. 9.1.2 Regardless of the operating temperatures, all piping connected to sensitive

rotating equipment such as turbines, feed pumps etc., for which limiting values of pipe reaction have been specified by the equipment manufacturer.

9.1.3 Any other pipeline which in the opinion of the ENGINEER requires a formal

analysis even for the lines less than 150 deg.C 9.2 OBJECTIVES OF FLEXIBILITY ANALYSIS The flexibility analysis calculation carried out shall meet the following basic

objectives. 9.2.1 To ensure that the stresses in the piping system are within the permissible values

as given in the applicable codes under operating conditions, hot or cold. 9.2.2 To ensure that the forces and moments exerted by the piping on connected

equipment are within the maximum allowable values stipulated by the supplier of equipment under any operating condition, either hot or cold.

9.2.3 To ensure that the forces and moments at the various restraints and anchors in

the piping system are within limits acceptable to the ENGINEER under any operating conditions either hot or cold.

9.2.4 To calculate the deflections and rotations of the piping at various salient points

and to ensure availability of adequate space for the same. 9.2.5 To arrive at a rational basis for the selection and design of hanger and support

system for the piping. 9.3 METHOD OF ANALYSIS Wherever formal analysis is called for, comprehensive analytical methods

employing the use of modern electronic computers shall be adopted and these methods shall be comparable to the state of the art. The software used for analysis shall be validated with bench mark problems. In particular, the following requirements shall be met.




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9.3.1 Piping systems shall be treated as a whole between anchor points. 9.3.2 Linear and rotational behaviour of connecting equipment and intermediate

attachments shall be taken into account. 9.3.3 All linear and rotational restraints shall be taken into account. 9.3.4 The restraining effect of hangers and supports shall be taken into account. Thus,

the CONTRACTOR shall include, in his flexibility analysis calculations, all piping beyond his terminal points upto the next available anchor in each branch in order to treat the system as a whole for purposes of flexibility analysis.

9.3.5 Flexibility characteristics and stress intensification factors for bends, and other

items branches shall be utilised. Flange correction factor and bend stress intensification shall be used where applicable.

9.3.6 All components in a piping system which have heavy wall section and do not

contribute to the flexibility of the piping system shall be considered as rigid elements (for example, valves).

9.3.7 The effect of the dead weight of the piping system shall be taken into account. 9.3.8 Piping systems shall be analysed for all possible temperature distributions arising

from various modes of operation, normal and abnormal, including possible mal-operation and the objectives of the analysis shall be met for each mode of operation.

9.4 In the case of equipment to which several pipelines are connected each of which

is analysed independently, it would be necessary to ensure that the combined values of the forces and moments exerted by each pipeline on the equipment for all possible modes of operation are also within acceptable limits as specified by the equipment manufacturer. The method of combining the values of forces and moments shall be as specified by the equipment manufacturer.

9.5 COLD SPRINGING 9.5.1 Cold springing of piping may be carried out when the operating temperatures are

high and the net thermal expansions are large, provided that the same is acceptable to the equipment manufacturer. Cold springing of piping systems with relatively small thermal expansions as in case of boiler feed pump suction and discharge piping, is not permitted. CONTRACTOR shall obtain specific approval from ENGINEER in the event he proposes to carry out cold springing of any piping system.

9.5.2 If the cold springing is carried out, it is recommended that the cold spring factor

lies between 0.5 and 0.85.




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10.0 SURGE ANALYSIS 10.1 If it is deemed necessary by the PURCHASER / ENGINEER, a surge analysis

shall be carried out by the CONTRACTOR to evaluate the effect of sudden closure of valves that are hydraulically or pneumatically actuated. The pressure rise in the piping, additional thrusts and moments created at the terminal ends and intermediate restraints, additional stresses to which the piping is subjected and the deflection and rotation that the piping is subjected to due to the impact and / or surge shall be computed.

10.2 The additional stresses, forces and moments created shall be studied in

conjunction with the corresponding values computed by the flexibility analysis and the combined values shall be held within permissible limits specified by the equipment manufacturer and / or codes.

10.3 The deflection and rotations of the pipe at the locations of the power actuated

valves causing the impact and surge shall be within the limits specified by the valve manufacturer. In the event of these limits being exceeded, the CONTRACTOR shall introduce shock absorbers at suitable locations to hold the deflection and rotations within permissible limits. These shock absorbers shall not offer any resistance to the movements and rotations of the piping caused by the thermal expansion as computed by flexibility analysis studies.

10.4 The details of the shock absorbers, mode of their connection to piping and

structures and the loads transferred to the structures shall be furnished to PURCHASER/ENGINEER for review and approval.

10.5 The CONTRACTOR shall also submit to the PURCHASER/ENGINEER, a write-up

outlining the procedure adopted by him for carrying out the surge analysis to the PURCHASER / ENGINEER for prior approval.

11.0 LAYOUT AND DETAILING 11.1 Contractor shall prepare composite drawings floor/elevation - wise on AUTOCAD

which shall cover the following details :

(a) Piping layout (NB 65 and above). (b) Hanger location (c) Valve spindle Orientation. (d) Equipment with maintenance details (e) Cable tray and ventilation ducts. (f) All main and internal columns, vertical bracings and other civil details.




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(g) Individual drawings shall be prepared only after approval of the composite drawings. Composite drawings shall be drawn to scale 1:50 scale. The CONTRACTOR shall also furnish floppy of the composite drawings.

11.2 All pipes of sizes greater than NB 50 mm are considered as shop fabricated piping

and detailed piping layout drawings shall be to scale and shall be prepared as plan and sections and shall contain the following minimum details.

11.2.1 Fully dimensional layout with locating dimensions referred to plant axes and co-

ordinates. 11.2.2 Details of all stub connections and other welded attachments as required for

anchors, restraints, hangers, supports, etc., and all details to meet IBR requirements.

11.2.3 Slope, drains and vents. 11.2.4 Edge preparation details of weld ends. 11.2.5 Mounting and orientation of valves and specialities and maintenance space

requirements. 11.2.6 Location and tag nos., of hangers, supports, restraints, anchors, etc. 11.2.7 Locations and magnitudes of cold cuts, if any. 11.2.8 Pipe sizes, materials, design parameters, shop and field test requirements. 11.2.9 Insulation details. 11.2.10 Tolerances if any. 11.2.11 Any specific requirements on shop fabrication and / or field erection. 11.2.12 Any other details considered necessary by the ENGINEER. 11.3 Pipes of sizes of NB 50 mm and smaller are regarded as field -routed. The

CONTRACTOR shall however indicate any specific requirements he may have in regard to the routing of these pipes.

11.4 Detailed bills of material shall be prepared for all piping systems. In case of shop -

fabricated piping, the bill of materials shall correspond to the layout drawing prepared. In the case of field - run piping, these shall be estimated quantities, with adequate surplus materials for wastage and contingencies.

11.5 While routing piping, the following requirements shall be taken into account : 11.5.1 All piping shall be routed so as to avoid interference with other pipes and their

hangers and supports, electrical cable trays, ventilation ducting, structural




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members, equipment, etc. Adequate clearances shall be ensured with respect to the above to accommodate insulation and pipe movements.

After the award of the contract, adequate number of prints of the PURCHASER’s /

ENGINEER’s structural, general arrangement and such other drawings as may be required to finalise the piping layout will be furnished to the VENDOR / CONTRACTOR for his reference and use.

11.5.2 All piping shall be grouped where practicable and shall be routed to present a neat

appearance. 11.5.3 The piping shall be arranged to provide clearance for the removal of equipment

requiring maintenance and for easy access to valves and other piping accessories.

11.5.4 Piping shall be generally be routed above ground but where specifically indicated /

approved by the ENGINEER, the pipes may be arranged in trenches or buried. Pipes at working temperatures above the ambient shall however not be buried. Buried piping shall be coated and wrapped as per TCE.M4-134-102

11.5.5 Overhead piping shall have a minimum vertical clearance of 2.3 metres above

walkways and working areas and 6 metres above roadways unless otherwise approved by the ENGINEER.

11.5.6 Drains shall be provided at all low points and vents at all high points as per actual

layout regardless of whether the same have been shown in the flow diagrams or not. Pipes shall be sloped towards the drain points.

Besides at low points, tell-tale drains shall be provided at all other locations as

necessary to remove on-line valves & specialities from piping for repair or replacement (e.g on either side of control valves).

Where spray water is introduced into steam piping, at a suitable location

downstream, drain pots shall be envisaged along with motor - operated drain valves and high and low level switches. The drain valves shall be interlocked with the level switches for automatic operation.

All start-up drains on main steam, cold reheat, hot reheat and HP-LP bypass

piping shall be furnished with motor-operated regulating valves. All other drains on steam piping systems shall be trapped and all trap stations

shall be provided with isolating, bypass and free-blow valves. When drains are headered, each drain shall be provided with a non-return valve. Only drains from lines at identical operating pressures may be headered.

Drains from all steam and hot water lines and equipment other than tell-tale drains

shall be led into suitable flash tanks which in turn shall be drained and vented to condenser and/or atmosphere as directed by the PURCHASER/ENGINEER. All cold water drains shall be led down to the nearest floor drain. All vents shall be




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led into conveniently located anti-flash funnels which shall be drained into the nearest floor drain.

11.5.7 Provision shall be made while preparing piping layout to accept control valves,

flow measuring elements and any other online speciality or equipment supplied by others. Sufficient upstream and downstream lengths shall be provided for flow measuring devices, control valves, desuperheaters and other specialities as required by the suppliers.

11.5.8 At all the screwed valves and screwed connections on equipment, unions or

flanges shall be provided to facilitate disassembly. Likewise, unions/flanges shall also be provided at suitable points on straight length of screwed piping.

11.5.9 All local instruments shall be so located on piping as to render them observable from the nearest available platforms/floors.

11.5.10 At all points where pipes pass through concrete floors or brick or other walls,

suitable floor collars or wall boxes shall be provided by OTHERS. The VENDORS / CONTRACTOR shall design and furnish the details of the floor collars to the ENGINEER / PURCHASER.

11.5.11 In the case of flanged piping, boxes shall be large enough to permit the passage

of the flange. 11.6 HANGERS AND SUPPORTS 11.6.1 All piping supports, guides, anchors, turnbuckles, and hangers, spring hangers,

rollers, with incidental structural subframing shall be designed, by the VENDOR/CONTRACTOR.

11.6.2 The VENDOR/CONTRACTOR’s supports, spring hangers, guides, anchors and

rollers shall utilise the PURCHASER’s existing steel in so far as this can be done. Where additional steel is required for the attachment of hangers, it shall be designed by the VENDOR/CONTRACTOR.

11.6.3 The hangers and supports shall be spaced in accordance with standard

engineering practice as outlined in applicable codes and standards. Their locations shall also be so chosen as to avoid unduly heavy loads being transferred to the PURCHASER’s structures. The location of hangers and supports is be subjected to approval by the PURCHASER/ENGINEER.

11.6.4 If severe vibration of piping is encountered in systems over which the

VENDOR/CONTRACTOR has control, or if the piping system is to be subjected to shock loading, hangers shall be supplemented by vibration control equipment and/or snubbers of an approved design.

11.6.5 At locations where lateral or axial movement is expected, the hangers shall be

provided with suitable linkages to permit swing. All hangers shall be designed to be vertical in the cold position unless otherwise stipulated by the ENGINEER.




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11.6.6 In order to minimise any horizontal force components of the dead weight or any binding of the pin or rocker joints used on the hangers, hanger rods should be as long as possible. In critical piping systems, the length of the hanger assembly capable of swinging shall not be less than 20 times the maximum expected pipe movement in the horizontal plane at the hanger location.

11.6.7 The CONTRACTOR shall furnish embedded part details covering type, size,

location, design load, material specification and detailed drawings of the part (If necessary). He shall furnish the embedded part list and details to the PURCHASER when called for.

11.6.8 When medium or heavy brackets are bolted to walls, back plates of adequate size

and thickness shall be furnished to distribute the load against the wall. Where the use of a back plate is not practical, the brackets shall be fastened to the wall in an approved manner. However, the attachment of support brackets to brick walls shall be avoided as far as possible and where this is not possible, details of the attachment shall be furnished to the ENGINEER for his approval.

11.6.9 In case the PURCHASER is carrying out the building structural steel design, the

CONTRACTOR shall furnish the following details :

(a) Intensity of piping load to be considered in all areas. (b) Location of the hanger with load. (To mark this PURCHASER/ENGINEER

would furnish floor framing drawing or floppy. CONTRACTOR shall indicate location of these on floor framing drawings and return the floppy to PURCHASER/ENGINEER).

11.7 FITTINGS AND FLANGES 11.7.1 Branch connections in piping shall as far as practicable be made by the use of

wrought or forged seamless fittings such as tees, laterals and crosses. Small stubs as may be required for instrument, drain and vent connection may be provided in the form of weldolet fittings or forged couplings. Pipe to pipe branch connections are acceptable only in the event of non-availability of fittings. Such connections shall be reinforced as required.

11.7.2 Mitred bends may be adopted for piping systems upto a design pressure of 10

kg/cm2g only. Mitre angle shall not exceed 22.5 degrees. 11.7.3 Slip-on type of flanges shall be used only upto a maximum pressure rating of ANSI

class 300 in the case of non-steam systems and 150 class in the case of steam systems. In case of higher pressure ratings, welding neck type of flanges shall be employed.

11.8 DIMENSIONAL STANDARDS 11.8.1 Uniform dimensional standards for all piping components shall be employed to

ensure compatibility with one another.




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11.8.2 Nominal pipe sizes and pipe outside diameters shall generally be as per ASME

B36.10. In case of deviation, the CONTRACTOR shall bring it to the specific attention of the ENGINEER for prior approval stating reasons for the deviation.

11.9 INSTRUMENT CONNECTIONS 11.9.1 Unless otherwise called for by the PURCHASER, all thermowell stubs shall have

an internal threading to M33 x 2. 11.9.2 All stubs for pressure or flow measurement for piping with a maximum working

pressure equal to or above 62 barg or with a maximum working temperature equal to or above 4250 C shall be NB 25 mm and double root valves shall be used.

11.9.3 Stubs for pressure or flow measurement on pipelines with a maximum working

pressure less than 62 bar(g) or with a maximum working temperature less than 4250C shall be NB 15 mm size and single root valves shall be used.

11.9.4 Pressure measurement stubs on fuel oil lines shall be of NB 25 mm size. 11.10 DRAIN AND VENT CONNECTIONS 11.10.1 Vent and drain connections on pipelines shall be atleast of NB 25 mm size. 11.10.2 For pressure as defined in clause 11.9.2, double isolating valves shall be used on

drain and vent lines. For pressure and temperature conditions as defined in clause 11.9.3, single isolating valves are considered adequate.

12.0 For drawings and documents to be submitted by the CONTRACTOR after the

award of the CONTRACT, refer Data sheet – C attached to this specification.

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION : D


DESIGN OF POWER PLANT PIPING SHEET 1 OF 2

DATA SHEET-C

FILENAME: M4134103R7.DOC TCE FORM NO. 329 R3

ISSUE R7

TITLE

INFORMATION TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF

CONTRACT The VENDOR shall submit, in the manner and within the time set forth in

the purchase order/letter of intent, the following: 1.0 DESIGN CALCULATIONS FOR THE FOLLOWING:

(a) Line sizes (b) Pipe wall thickness calculations (c) Branch reinforcement calculations (d) Results of the flexibility analysis. (e) Hanger loads, selection and related details. (f) Results of surge analysis (Where applicable). (g) Code compliance calculations.

2.0 Necessary piping layout and/or isometric drawings for submission to

statutory authorities/IBR. 3.0 Composite piping layout drawings. This shall indicate the piping layout

engineered by the VENDOR as well as other piping layouts which are used by him to check for interferences. This shall also indicate the hanger locations.

4.0 Floppy of Purchaser’s drawing (where applicable) with locations of

hangers and supports marked therein. The VENDOR/CONTRACTOR shall be responsible for maintaining arrangement, dimensions etc., in accordance with the ENGINEER’s approved drawings.

5.0 Results of the flexibility analysis: The results shall indicate for each

system and each mode of operation on the following: 5.1 Ranges of hot and cold values of forces and moments exerted by the

piping on each nozzle of connected equipment. 5.2 Summation of above values at all nozzles of a particular equipment as

per the procedure to be outlined by the PURCHASER/ENGINEER. 5.3 Ranges of hot and cold values of forces and / or moments at all other

anchors, restraints, etc..

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION : D


DESIGN OF POWER PLANT PIPING SHEET 2 OF 2

DATA SHEET-C

FILENAME: M4134103R7.DOC TCE FORM NO. 329 R3

ISSUE R7

TITLE

5.4 Ranges of hot and cold values of stresses as computed at all salient

points of the piping system. 5.5 Permissible values of stress range and hot and cold working stresses as

per the governing code. 5.6 Ranges and if applicable, design to hot and design to cold values of

rotations and movements of the piping systems at all junction points and at all hanger locations.

5.7 An isometric plot of the layout indicating dimensions, temperature

distributions considered, pipe materials and properties, locations of anchors, restraints, etc.

5.8 Magnitudes and locations of cold pulls where applicable. 6.0 Detailed procedure and write-up for cold springing if adopted. 7.0 Detailed valve list with tag numbers, service, pressure rating, VENDOR

details etc., (as per format agreed between PURCHASER/ENGINEER). 8.0 Bill of materials for all piping system in the VENDOR’s scope. 9.0 Complete hanger details. 10.0 Line designation schedule (as per format agreed between

PURCHASER/ENGINEER).

SPEC. NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIIB

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1.0 SCOPE This specification covers the technical requirements and essential particulars for

the design (as applicable), supply, shop fabrication, inspection, testing, cleaning, commissioning assistance and protection of the piping systems as covered in the tender specification documents and drawings. The CONTRACTOR shall demonstrate that the piping satisfies the requirements of the specification and applicable codes. To the extent design and engineering of piping systems are specified to be in the CONTRACTOR scope in Section C of the tender documents and hereunder, all references to the PURCHASER drawings and documents in the subsequent clauses of this section shall be understood to imply the CONTRACTOR's drawings and documents.

2.0 CODES AND STANDARDS 2.1 All piping systems including subcontracted items shall comply with all currently

applicable statutes, regulations and safety codes in the locality where the system will be installed. The piping shall also conform to the latest editions of the codes and standards listed under Clause 2.2 below. Nothing in this specification shall be constructed to relieve the CONTRACTOR of this responsibility.

2.2 The system and work under this contract shall conform to the following

standards/codes: (a) Indian Boiler Regulations (b) Indian Regulations of Inspector of Explosives (c) ASME Code ‘Power Piping’ - ASME B 31.1 and all other associated

ANSI/ASME standards. (d) Manufacturer's Standardisation Society (MSS), USA, Standard Practices.

(e) American Society for Testing and Materials (ASTM) Specifications. (f) Pipe Fabrication Institute (PFI), USA, Standards 2.3 In case of conflict between the codes and standards referred to herein and the

requirements of this specification, the more stringent requirement shall govern. 3.0 SCOPE OF WORK 3.1 The scope of supply of the CONTRACTOR under this contract shall be as

defined in Section C of this specification. For all the piping systems included in this scope of supply, the CONTRACTOR shall supply all materials except those items specifically excluded from his scope in Section C, and render the piping systems complete as applicable. The CONTRACTOR's scope of supply shall include but not be limited to the following:

(a) Pipes, tubes, headers, manifolds, etc.


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(b) Bends, elbows, returns, tees, laterals, crosses, reducers, caps and

closures, full and half couplings, plugs, sleeves and saddles, stubs and bosses, unions and other similar fittings.

(c) Flanges (d) Gaskets and fasteners (e) Complete assemblies of hangers, supports, anchors, guides, restraints,

snubbers, shock absorbers, etc., including welded attachments, springs and spring gauges, beam clamps, clips, shoes, rollers, trapezes, trunnions, etc.

(f) Auxiliary steel, concrete foundations, pedestals, etc., as required for

hangers, supports, guides, restraints, anchors, snubbers, shock absorbers, etc.

(g) All materials as required for providing anti-corrosive treatment to buried

pipes (h) All paints, varnishes, primers, thinners and other painting materials.

(i) Weather hoods for bare pipes crossing ceilings and walls. 3.2 Unless otherwise specified in Section C, the CONTRACTOR’s scope of supply

includes all instrument impulse piping and fittings upto the last root valve. In the case of temperature measurement points, the CONTRACTOR’s scope includes supply of thermowell stubs.

3.3 The CONTRACTOR shall supply all necessary drains and vents including anti

flash funnels as required for the safe and effective draining/venting of the piping systems. It must be noted that the flow diagrams may not indicate all the drains and vents that would be required. As stated elsewhere, it is the CONTRACTOR's responsibility to identify the requirements of drains and vents whether the same have been shown in the flow diagrams or not and supply the necessary pipe work, fittings, hangers, supports, etc. The drains and vents indicated on the flow diagrams shall however be regarded as minimum requirements. The drains and vents shall be led upto the nearest floor drain in case of cold water systems and upto the flash tank in case of steam and hot water systems, as directed by the PURCHASER.

3.4 In the case of pipes laid in trenches or on pipe racks, the CONTRACTOR shall

supply necessary steel members, cross beams and other supporting accessories such as stools, saddles, base plates, clamps, U-bolts, angles, clips, etc.

3.5 All concrete pedestals and foundations other then those specifically indicated as

excluded from the CONTRACTOR’s scope in Section C shall be supplied by the CONTRACTOR.


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3.6 Wherever uninsulated pipes cross walls or roofs, the necessary weather hoods

shall be designed, fabricated and supplied by the CONTRACTOR as directed by the PURCHASER.

3.7 The CONTRACTOR shall design, fabricate and supply all hangers and supports,

anchors, guides, restraints, etc., including necessary welded attachments and auxiliary steel based on data furnished by the PURCHASER/ENGINEER. The data to be furnished by the PURCHASER / ENGINEER would be from the systems point of view and would typically include the overall configuration of the support system, operating and design loads, cold to hot movements of pipe, desired hanger/support spring constant, type of spring support, viz., constant load type or variable load type, etc. It is the CONTRACTOR’s responsibility to design, engineer and select the individual components of the hangers, supports, restraints, guides or anchors based on the PURCHASER’s data and in accordance with the requirements of this specification.

3.8 The loads indicated in the PURCHASER’s hanger/support sketches do not

include the weights of hanger components such as clamps, turnbuckles, trapezes, spring cage assemblies, etc. The weights of these components shall be considered by the CONTRACTOR in the design and settings of hangers and supports under advice to the PURCHASER/ENGINEER.

3.9 The CONTRACTOR shall perform necessary internal machining of pipes for

installing orifices, flow nozzles, straightening vanes, etc. 3.10 At all intersection joints, it is the CONTRACTOR’s responsibility to design and

provide suitable reinforcements as per the applicable codes and standards taking into account the pressure, temperature and dead weight loads.

3.11 Welding, nondestructive examination of welded joints and repair of weld defect

areas shall conform to TCE specification no. TCE.M4-134-04. 3.12 The CONTRACTOR shall prepare fabrication isometric drawings and bills of

material for piping NB 65 mm and larger based on the PURCHASER’s piping drawings except for Low Pressure (LP) piping systems such as water and air. The PURCHASER/ ENGINEER will review, prior to release for fabrication, all piping isometric drawings. The PURCHASER/ENGINEER may request changes, if the PURCHASER/ENGINEER’s stress analysis or other considerations require it. As the CONTRACTOR is responsible for the design and adequacy of hanger components, no comments or approval may be given by the PURCHASER/ENGINEER except in those instances where it may appear that the CONTRACTOR’s work does not meet the standard desired by the PURCHASER/ ENGINEER. In such cases, the CONTRACTOR shall be guided by the PURCHASER / ENGINEER's comments and the CONTRACTOR shall comply to the requirements at no extra cost.

3.13 The CONTRACTOR's fabrication drawings shall take into account the

requirements of this specification as also all applicable codes and standards including statutory regulations such as the Indian Boiler Regulations. The


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CONTRACTOR’s fabrication drawings shall carry all details of fabrication, welding, etc., as may be required for obtaining necessary statutory clearances. It is the CONTRACTOR's responsibility to obtain all such clearances, and fabrication shall commence only after the necessary clearances have been obtained from the appropriate authorities. All expenses incurred in obtaining these clearances shall be to the CONTRACTOR’s account.

4.0 MATERIALS AND WALL THICKNESS 4.1 All piping materials to be supplied by the CONTRACTOR shall be in accordance

with the PURCHASER’s piping material specification and/or piping bill of materials.

4.2 The BIDDERs may offer if they so desire, alternate materials equal or superior to

those specified. However, no credit would be given to offers containing materials superior to those specified. The responsibility for establishing equality or superiority of the alternate materials offered to those specified rests entirely with the BIDDER. The PURCHASER / ENGINEER reserves the right to reject such alternate materials and insist upon only those specified.

4.3 The BIDDERs shall note that equality or superiority of the materials offered by

them vis-a-vis those specified would be judged not only based on a comparison of the material standards but also on the ease of fabrication, shop and field welding, heat treatment, service record and any other characteristic considered important by the ENGINEER.

4.4 BIDDERs shall indicate in their offer, reasons and justification for their wishing to

deviate from the materials specified. 4.5 Materials inferior to those specified will not be acceptable. 4.6 Where bending and forming allowances are excluded from the wall thicknesses

specified in the specification documents, the specified wall thicknesses shall be increased in accordance with the CONTRACTOR's standards to allow for the manufacturing process for bends and fittings. In no case shall the wall thicknesses of fittings be less than those specified for straight pipes.

4.7 For steam piping systems, all materials shall be procured directly from the

manufacturers. Materials procured from traders and stockists are not acceptable. For LP piping systems, these can be procured from reputed and approved traders or stockists.

4.8 All materials procured shall be new and specifically for the subject contract. 4.9 All materials shall be certified by proper material test certificates. All material test

certificates shall carry proper identification number or other acceptable references to enable identification of the certificate with the material it purports to certify. The heat number shall also be indicated on the material certified.


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5.0 FABRICATION 5.1 Unless otherwise specified in Section C, all steam piping systems of size NB 65

mm and larger shall be supplied fully prefabricated at works as per the piping drawings. All piping, NB 50 mm size and smaller, shall be supplied in straight lengths, with the pipe ends cut square to the axis.

5.2 Unless otherwise specified in piping drawings or piping materials specification

data sheets, all pipeline joints shall have welded construction. Butt-welded joints shall be used for pipes NB 65 mm and larger. Socket welded joints shall be used for pipes NB 50 mm and smaller. The use of companion flanges to connect two pieces of pipe or the use of odd or short pieces of pipes in making up long runs is prohibited, except as noted on the PURCHASER's piping drawings.

5.3 Where welded pipes or fittings are used, longitudinal welds in adjoining sections

shall be staggered by minimum of 90o during fabrication. All piping shall be fabricated true to lines and elevations as indicated in the piping drawings.

5.4 Neither butt nor branch joints shall be closer than twice the pipe diameter to any

other joint in the same pipeline except where 'weldolet' type fittings are used, in which case the branch weld will be made to the 'weldolet'.

5.5 The number of joints for field welding shall be kept as a minimum as practicable

and limited to accessible circumferential butt welds. 5.6 All pipe bends shall have a bend radius of five nominal pipe diameters unless

otherwise specified in the PURCHASER’s piping drawings. The pipe bends shall be true to angle and radius and shall maintain a true circular cross section of pipe without deformity or undue stretching. Crimping of pipes to form bends is not acceptable.

5.7 All pipe flanges and contact surfaces shall be concentric with the axis of the

piping. All flanges and fittings shall be accurately machined and drilled true to template.

5.8 All threads on piping components shall be taper pipe threads as per applicable

standards. Threaded connections for insertion type fluid temperature sensing and sampling devices shall be seal welded when the service temperature exceeds 495oC or the service pressure exceeds 103.5 bar (g). The threads shall be entirely covered by the seal weld and only qualified welders shall carry out such seal welding.

5.9 The CONTRACTOR shall cut the pipe short for cold spring for all hot lines in

accordance with the data furnished by the PURCHASER. In addition to the cut for cold spring, a length of pipe must be cut to attain slope when the line is in the cold or hot position. The additional cut must not add to the cold spring in the system. In order not to add to the cold spring, the pipe must be detailed and fabricated so that the affected horizontal runs will be sloped to the proper angle when installed in the field before the final weld is made. At the point of closure,


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the two pipe ends should be separated by the required amount of cold spring only.

5.10 All welded attachments such as lugs, shoes, trunnions, etc., as required for

supporting, restraining or anchoring a pipe shall be welded to the pipe at works and stress relieved as required. All welded attachments and thermocouple pads shall be of the same material as the parent pipeline and shall be subjected to the same fabrication and welding procedures as the associated piping.

5.11 All welds between dissimilar materials shall be carried out at works. Field

welding of joints involving dissimilar materials shall be avoided. 5.12 The first circumferential weld joint after a pipe bend shall as far as possible be

after a minimum straight length of two times the pipe diameter or 500 mm whichever is less.

5.13 All pipelines shall be pitched to low point(s) where drainage is indicated on the

PURCHASER's drawings. The pitch shall be sufficient to prevent pockets of moisture collecting at low points between supports.

5.14 The CONTRACTOR shall fabricate the pipe assemblies in such a way as to

avoid any difficulty during field erection. 5.15 All branch connections shall be realised through the use of tees, crosses and

laterals to the extent such standards fittings are available as per ANSI standards. Where intersection welds are employed due to non-availability of a standard fitting, they shall be of suitable structural adequacy by virtue of intrinsic weld connection, reinforcing pads or rings or materials inherent in the branch. It is the CONTRACTOR's responsibility to provide reinforcement, wherever necessary for branch connections.

5.16 The CONTRACTOR shall machine welding ends of all pipes, bends and fittings,

to make sound welds. The welding rod shall be compatible with the parent material.

5.17 The CONTRACTOR shall be responsible for determining the proper bending

procedure, including bending temperature, as well as the heat treatment or stress relieving procedures to produce the desired end product.

5.18 Cold bending may be performed on carbon steel, carbon molybdenum and

chromium molybdenum steel pipes with chromium content less than 1 % in a stress relieved, normalised and tempered or fully annealed condition. Bending performed at temperatures below 900oC shall be considered "cold bending".

5.19 Only hot bending at 900oC to 1200oC shall be performed on chromium -

molybdenum steel regardless of its heat treatment by full annealing. The pipes shall be filled with free running, sulphur free silica sand or other dry solid inert material, firmly tapped for the hot bending operations. Optical pyrometry or other approved methods shall be used for temperature control of these operations.


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5.20 Oxyacetylene torches shall not be used for heating purposes during bending operations.

5.21 Carbon steel, carbon molybdenum and chromium molybdenum piping shall be

bent hot if cold bends, free of cracks or buckles, cannot be made. 5.22 Bends in seam welded pipes shall be oriented so that the seam is positioned

along the neutral axis. 5.23 All materials that have been bent, forged or formed shall be subsequently heat

treated in a furnace as described below:

(a) Hot bent, forged or formed carbon steel piping require no subsequent heat treatment.

(b) Hot bent, forged or formed ferritic alloy steel piping shall receive a stress

relieving treatment, a full anneal or a normalise and temper treatment. (c) Cold bent, forged or formed carbon steel and ferritic alloy piping shall be

stress relieved after bending when: i. Carbon steel pipe wall thickness equals or exceeds 19 mm. ii. Ferritic alloy steel pipe wall thickness equals or exceeds 13mm or

when the nominal pipe size is 100 mm or larger. 5.24 Cold bending of carbon and ferritic alloy steel pipe in sizes and wall thicknesses

less than specified in para 5.23(c) may be used without a postheat treatment, if it is demonstrated that the mechanical and metallurgical properties are not impaired by omission of such post heat treatment.

5.25 Ferritic piping materials upto and including 2.25 Cr - 1 Mo that have been bent,

forged, formed or welded may have the final heat treatment delayed until a full furnace charge is available.

5.26 The preferred method of heat treatment is full annealing for the low chromium

molybdenum steels. The full annealing heat treatment shall be carried out in a temperature-controlled furnace capable of accommodating the assembly with adequate supports and contact thermocouples. The PURCHASER/ENGINEER shall reserve the right to select the alternative heat treatment, viz., normalising and tempering.

5.27 Liquid quenching for heat treatment is not permitted. The preferred method of

heat treatment for the chromium molybdenum steel is full annealing. Following are the recommended heat treatments in the order of preference:

(a) Full annealing chromium molybdenum steels, 1 Cr 1/2 Mo to 3 Cr 1 Mo

inclusive. Full annealing shall be accomplished by heating in a heat treatment furnace to a metal temperature of 900oC+14oC and holding at that temperature for a period equal to one hour per 25 mm of wall


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thickness of the thickest section but in any case not less than one hour. The material shall then be allowed to cool in the furnace at a rate of 30oC per hour to a metal temperature of 600oC. The material shall then be removed from the furnace and cooled in still air in a building having a room temperature of not less than 10oC.

(b) Normalising and tempering chromium molybdenum steels, 1 Cr 1/2 Mo to

3 Cr 1 Mo inclusive. Normalising shall be accomplished by heating in a heat treatment furnace to a metal temperature of 900oC to 960oC and holding at that temperature for a period equal to one hour per 25 mm of wall thickness of the thickest section but in any case not less than one hour. The material shall then be allowed to cool in still air to a metal temperature of 315oC or below. The air temperature shall not be lower than 10oC. Tempering shall be accomplished by reheating in a heat treatment furnace to a metal temperature of 630oC to 750oC depending on the alloy range and holding at that temperature for a period equal to one hour per 25 mm of wall thickness of the thickest section but in any case not less than one hour. The material shall then be cooled to 315oC in the furnace at a controlled rate not to exceed 110oC per hour. At 315oC, the material may be removed from the furnace.

5.28 Stress relieving treatment for carbon steel shall be accomplished by heating in a

heat-treatment furnace to a metal temperature of 635oC to 675oC and holding at that temperature for a period equal to one hour per 25 mm of wall thickness of the thickest section but in any case not less than one hour. The material shall then be cooled in the furnace until the metal temperature drops to 315oC. or below, and then air cooled in a draft free area where the air temperature is not below 10oC.

5.29 Stress relieving treatment for C - 1/2 Mo and 1/2 Cr 1/2 Mo steels shall be

accomplished by heating in a heat treatment furnace to a metal temperature as follows:

Carbon 1/2 Molybdenum steel 650oC 675oC 1/2 Chromium1/2 Molybdenum steel 690oC 729oC The temperature shall be held for a period equal to one hour per 25 mm of wall

thickness of the thickest section but in any case not less than one hour. The material shall then be cooled in the furnace until the metal temperature drops to 315oC or below, then air cooled in a draft free area where the air temperature is not below 10oC.

5.30 When pipe must be threaded before bending, forging or heat treating, all

exposed thread surfaces should be protected during heat treatment with high temperature silicone paint.


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6.0 CLEANING OF PIPING 6.1 All hot bent, forge formed, fabricated and straight sections of piping shall be

chemically cleaned, pickled or wire brushed and purged with an air blast or shot / grit blast to remove all sand and scale from the inner surface. The inside and outside of all pipes shall be free of sand, loosely adhering scale, dirt and other foreign matter. The method of cleaning shall not leave any material on the inner or outer surfaces that will affect the serviceability of the pipe.

6.2 During manufacturing and fabrication of carbon and alloy steel piping, surfaces

shall be descaled by any one of the following methods: (a) Completely grit blast inner and outer surfaces with angular silicon carbide

or steel grit (Sand blasting is prohibited). Grit shall be removed completely by an air blast or other convenient means such as rotary brushing.

(b) Pickle in commercial hot inhibited sulphuric acid. Wash in cold water

followed by wash in hot water. (c) Clean by power driven wire brushes. The brushes shall be of the same

or similar material as the metal being cleaned. 6.3 Cleaning technique and tests shall follow the guidelines of Structural Steel

Painting Council Surface Preparation Specifications. 7.0 CORROSION PROTECTION 7.1 The outside of carbon steel and low alloy steel piping, with exception of

machined surfaces (e.g., weld ends) shall be coated with enamel or other protective paint. All weld end preparations shall be coated with deoxaluminate paint. Use of grease or oil, other than light grade mineral oil, is prohibited.

7.2 After cleaning carbon or low alloy steel piping by any method producing

continuous white metal on the inside of the pipe and prior to shipment, the surface shall be coated with a readily water soluble corrosion inhibitor such as a solution of 1/2 % sodium nitrite, 1/4 % monosodium phosphate and 1/4 % disodium phosphate.

7.3 Following the application of corrosion protection systems, all components shall

be covered, boxed, capped, plugged or otherwise shielded from further contamination of corrosion.

8.0 MARKING 8.1 All pipe and fittings supplied by the CONTRACTOR shall be legibly marked with

its identifying pipeline description and piece number, as per the relevant component or spool piece drawing.


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8.2 Materials may be marked with any method, provided the method does not result in sharp discontinuities and does not loose its identity until the piping system is erected. Materials 6 mm or thicker may be marked by stamping, which when adopted, shall be done with round nose or interrupted hot die stamps having a minimum radius of 0.8 mm. Any item too small to be legibly marked shall have a metal tag containing the necessary information securely attached to each bundle or container of such items, so that it does not lose its identity during shipping and storage.

8.3 Marking paint, ink and tape shall be certified to be free of chloride, sulphur, lead,

tin, or mercury. 9.0 HANGERS AND SUPPORTS 9.1 The design loads indicated on the PURCHASER’s hanger sketches include the

weight of pipe, the weight of insulation and the weight of medium transported or the medium used for testing, whichever is heavier. All components of hanger or support assembly shall be designed for the above design load and the self-weight of hanger/support assembly. Each rod of a double rod hanger shall be designed for the full design load specified for the hanger.

9.2 All hanger components including springs shall generally conform to MSS SP58

'Pipe Hangers and Supports-Material and Design'. 9.3 The design shall take full advantage of commercially available, load rated and

tested hanger components to the maximum extent possible. Uniformity and simplicity in design shall be maintained. All hangers shall be functional and shall be easily installable using conventional field erection techniques.

9.4 The materials used in the construction of hangers, supports and accessories

shall be the most suitable for the service intended. 9.5 Lugs or other means of welded attachments to pipes shall be welded on in the

shop and shall be of the same materials as the parent pipe. Wherever possible, pipe attachments for horizontal piping shall be a pipe clamp.

9.6 The hangers shall be designed, fabricated and assembled in such a manner that

any movement of the supported pipe does not disengage them. 9.7 The hangers shall be provided with suitable linkages to permit swing. 9.8 The diameter of hanger rods for piping, NB 50 mm and smaller, shall be

minimum of 9.5 mm. 9.9 The diameter of hanger rods for piping, NB 65 mm and larger, shall be minimum

of 12.5 mm. 9.10 Bolted pipe clamps, used with rod hangers, shall have a minimum thickness of 5

mm for weather-protected locations and 6 mm for places exposed to weather.


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9.11 Springs, for spring hangers, shall be of helical compression type and shall be provided with means to prevent misalignment, buckling and eccentric loading and with stops to prevent excessive travel. The construction shall also be such that complete release of piping load will be impossible in case of spring failure or misalignment. Suitable stops shall be provided for field hydrostatic test of piping. Springs shall be enclosed in spring cages. Load/travel indicators shall be provided on the spring cages.

9.12 Constant support hangers shall have a field load adjustment range of ±20% of

the operating load specified and shall be provided with stops for field hydrostatic test of piping and also with suitable distant visible travel scales and indicators clearly showing cold and hot settings. The total travel of the unit selected shall be the calculated travel plus 20% (minimum 25 mm) to take care of possible discrepancy between calculated and actual thermal movements. Constant support hangers shall have support variation of not more than 2.5% throughout the total travel range.

9.13 Where variable spring hangers are specified, the units selected shall have

support variation of not more than 25% through its total travel range. 9.14 All rigid hangers shall have a means for vertical adjustment after erection. 9.15 Pipe springs shall be fitted with an adequate malleable iron adjusting nut of the

locking type, threaded to a rod that will allow adjustment after erection while supporting the load.

9.16 All spring hangers shall be furnished with forged steel turnbuckles to permit

adjustment and setting of pipe elevation at site. All rigid hangers for loads 250 kg and above shall have forged steel turnbuckles. All rigid hangers, for loads less than 250 kg, shall have the hanger rods threaded to permit adjustment and setting of pipe elevation at site.

9.17 Beam clamps shall be of forged steel, each equipped with a rod to fix a nut. 9.18 All supports for carbon steel piping shall be provided with carbon steel machine

bolts and nuts in accordance with applicable codes. Bolt heads shall be regular square and unfinished. Nuts shall be cold punched, semi finished, heavy hexagonal type. For supporting alloy steel piping, bolts and nuts, as per applicable codes shall be provided.

9.19 All threaded members shall have a true and complete depth of thread. The

turnbuckles or adjusting nut shall have its full length of thread in service while in use and the amount of adjustment plainly visible. All similar adjustable arrangements shall have provision for locking.

9.20 The threads on threaded parts such as hanger rods, nuts and turnbuckles shall

conform to applicable codes for the coarse thread series with a 'medium' class fit or equivalent.


TCE.M4-134-02



SHEET 12 OF 13

ISSUE R4

TITLE


9.21 All hangers shall be furnished with beam clamps, rods, pipe stubs and all other materials required to make the hanger complete.

9.22 All hangers shall be designed for rigid fastening to the structure either directly or

through a bracket. Anchors and guides shall be capable of withstanding the moments and forces imposed by thermal expansion.

9.23 The parts of hangers which move relative to the pipe during expansion shall be

connected to the pipe clamps or lugs in such a way that these parts lie entirely outside the insulation.

9.24 All components of hangers and supports and anchors shall be given one shop

primer coat of red oxide paint. 10.0 INSPECTION AND TESTING 10.1 All items covered by this specification shall be subject to inspection by the

PURCHASER/ENGINEER at no additional cost to the PURCHASER and the CONTRACTOR shall advise the PURCHASER / ENGINEER promptly when items are ready for inspection.

10.2 All materials shall be subjected to source inspection by the CONTRACTOR to

ensure compliance with material specifications mentioned herein or any other approved material specifications.

10.3 The CONTRACTOR shall permit the PURCHASER to maintain one or more of

his representatives in the CONTRACTORS’s shops and the shops of his SUB-CONTRACTORSs, for the purpose of inspecting various steps in the shop fabrication of the materials specified herein. The PURCHASER’s representative shall at all reasonable times have free access to the VENDOR's shops and be able to witness the CONTRACTOR’s heat treatment records and magnetic particle, fluroscent particle or dye penetrant or ultrasonic or radiographic inspection records, reports of repairs, etc.

10.4 The works shall also be subject to inspection in the CONTRACTOR’s / his SUB-

CONTRACTOR’s shop by an inspector of a selected inspection or insurance company, where required, depending upon local manufacturing, construction and safety codes. The inspection shall be as frequent as required to ensure progress of work and quality of workmanship.

10.5 Any workmanship or material inspected in the field and found not to comply with

this specification, the same shall be replaced or repaired at the VENDOR’s expense, if the noncompliance is the fault of the VENDOR.

10.6 All inspection shall meet the requirements of TCE standard nos. TCE.M4-185-28

and TCE.M4-185-38. 10.7 For radiography procedure, ASTM E94 and ASTM E142 shall be followed.


TCE.M4-134-02



SHEET 13 OF 13

ISSUE R4

TITLE


10.8 Radiographic Acceptance Criteria for weld ends, the examination techniques, requirements and repairs for weld ends shall meet the mandatory requirement of ASME Section VIII Division 1 Appendix 7 in all respects.

10.9 Defect Removal and Repair in Castings (a) Defects in excess of acceptance standards shall be removed by suitable

means. If removal of surface defect does not result in reduction in wall thickness below acceptable minimum, the area shall be blended smoothly into the surrounding surface. Where defect removal results in a wall thickness below the acceptable minimum, resultant cavity may be repaired by welding. The procedure and the operation shall be qualified as per applicable standards. Major weld repairs shall be stress relieved or heat treated in accordance with the material specification.

(b) The repaired area shall be reexamined and the acceptance standards

shall be as followed in the original examination. (c) Major weld repairs made as a result of radiographic examination shall be

re-radiographed after welding. The acceptance standards for porosity and slag inclusions in welds shall be as per ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.

10.10 On completion of forging and subsequent heat treatment operations on

chromium molybdenum fittings, the forged material shall be machined / ground and blasted to clean metal on the interior and exterior surfaces.

10.11 Unacceptable defects disclosed by visual, magnetic particle, radiographic or

ultrasonic inspection, shall be repaired by removing the defects completely and re-welding. The repaired spots shall be re-examined in a way similar to the one followed for the main weld. Only qualified welders shall be employed for repair welding and shall be carried out as per approved welding procedure.

10.12 All pipes, fittings, etc., shall be tested hydrostatically at the shops,

where manufactured, at test pressures which are given in the applicable codes, material specification sheets and/or Section C. After completion of test, the piping shall be completely drained prior to shipment to insure against damage from freezing. When such drainage requires removal of plugs, valves, drain cover, caps, etc., the CONTRACTOR shall ensure that these parts are reinserted or reassembled prior to shipment.

10.13 Where the pipe work is composed of pipe and standards fittings, the test

pressure to be applied shall be the standard test pressure for the lowest rated standard component in the assembly.


TCE.M4-105-01


HORIZONTAL CENTRIFUGAL PUMPS

SHEET 1 OF 3

ISSUE R10

TITLE


1.0 SCOPE

This specification covers the general design, materials, construction features, manufacture, shop inspection and testing at manufacturer’s works and delivery at site of Horizontal Centrifugal Pumps.


The design, materials, construction, manufacture, inspection, testing and performance of horizontal centrifugal pumps shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

3.0 DESIGN REQUIREMENTS 3.1 Pumps of a particular category shall be identical and shall be suitable for parallel

operation with equal load division. Components of identical pumps shall be inter-changeable.

3.2 Flow rate versus head curve shall have a stable and continuously rising characteristics towards the shut-off head. In case of unstable (drooping) characteristics the duty point shall be well away from the unstable region. Besides the actual flow rate versus head curve, curves for minimum and maximum impeller diameters shall also be shown.

3.3 The shut-off head shall be at least 110% of the differential head.

3.4 The required NPSH at duty point shall be at least one (1) metre less than the available NPSH.

3.5 The rating of the pump driver shall be the larger of the following :

(a) The maximum power required by the pump from zero discharge to run-out discharge at site climatic conditions.

(b) 110% of the power required at the duty point at site climatic conditions.

3.6 The corrosion allowance for pressure parts shall be 3 mm.

3.7 Pumps shall run smooth without undue noise and vibration. Noise level produced individually or collectively shall not exceed 85 dB(A) measured at a distance of 1.86 metres from the source in any direction. The overall vibration level shall be as per zones A and B of ISO 10816-1.

3.8 In case of fire water pumps, pumps and drivers with all the accessories shall meet

the requirements of Tariff Advisory Committee (TAC) or any other standard as called for in data sheet A. Pump type shall be as approved by TAC.


TCE.M4-105-01



SHEET 2 OF 3

ISSUE R10

TITLE


4.0 CONSTRUCTION FEATURES 4.1 In addition to static balancing, impeller and balancing drum shall be balanced

dynamically at or near the operating speed. 4.2 Pump shall be provided with renewable type casing ring. Pump having capacity

1,000 M3/Hr and above shall be provided with impeller ring in addition to casing ring. The hardness of impeller ring shall be 50 BHN higher than that of casing ring.

4.3 Pump casing shall be provided with drain and vent connection with plugged or

valve connection. 4.4 Bearing shall be oil-lubricated or grease-lubricated and shall have a life of 40,000

hours of working. In case of oil-lubricated bearing, constant oil leveller with magnetic drain plug shall be provided.

4.5 Replaceable shaft sleeves shall be provided to protect the shaft where it passes

through stuffing box. 4.6 Stuffing box shall be of such design that it can be repacked without removing any

part other than the gland and lantern ring. 4.7 Mechanical seals shall be provided if called for in data sheet - A. If required, a

flushing line shall be furnished, complete with strainer and orifice, from the pump discharge to the sealing face. When pumping liquid is not suitable for this purpose, a flushing connection shall be provided so that it can be connected to an external source. Auxiliary piping and plan shall be in accordance with appendix - D of API 610.

4.8 The allowable loads on the pump nozzles shall be at least twice the values listed

in the relevant tables of API 610 without reference to any other criterion. The base plate shall be designed to cater to the above increased loads.

4.9 All pumps, except for back-pull out type, shall be provided with flexible coupling.

Back-pull out type pumps shall be provided with spacer type coupling. 4.10 Coupling guard made of expanded metal and bolted to the base plate shall be

furnished for all coupled pumps. 4.11 In addition to accessories listed in data sheet A, any other accessories required

for safe and efficient operation of pump shall be provided. 4.12 All incidental piping and valves required for sealing, lubrication and cooling for

stuffing box packing and/or bearing of pump shall be furnished by the VENDOR. 4.13 Leakage from the pump shall be led to the nearest surface drain by OTHERS.

Pump VENDOR shall provide necessary arrangement like drip tray, base plate drain connection etc.


TCE.M4-105-01



SHEET 3 OF 3

ISSUE R10

TITLE


5.0 TESTS AND INSPECTION 5.1 Hydrotest pressure on casing shall be 1.5 times maximum discharge head or

twice differential head whichever is higher. ( Maximum discharge head = shut-off head + maximum suction head). Unless otherwise stated in data sheet A, the hydrostatic tests on the casing shall be conducted for a minimum duration of 30 minutes.

5.2 The pumps shall be tested as per IS 5120, at rated speed at MANUFACTURER's

works to measure capacity, total head, efficiency and power. The negative tolerance on efficiency shall be limited to 2.5% and not 5% as indicated in IS 5120. These tests shall form the basis for acceptance of pumps except for vibration and noise. The pumps shall be tested over the range covering from shut-off head to the maximum flow. The duration of the test shall be minimum one (1) hour. Minimum five (5) readings approximately equidistant shall be taken for plotting the performance curves.

5.3 After installation, the pumps shall be subjected to testing at site also. If the site

performance is found not to meet the requirements regarding vibration and noise as specified, the equipment shall be rectified or replaced by the VENDOR, at no extra cost to the PURCHASER.

6.0 PERFORMANCE GUARANTEE

Performance parameters to be guaranteed by the VENDOR and tolerances permitted shall be as indicated in section C and/or data sheet A. BIDDER shall confirm acceptance of these by indicating values in data sheet B. Pump or any portion thereof is liable for rejection, if it fails to give any of the guaranteed performance parameters.


TCE.M4-105-01 2X 800 MW TPP NEAR KRISHNAPATNAM


SHEET 1 OF 1


ISSUE R10

TITLE

DATA SHEET C


1. List of drawings and documents to be submitted for review, approval and

information with scheduled submission dates 2. Quality Assurance Plan (QAP) 3. Detailed dimensioned general arrangement drawing of pump and driver. This

drawing shall indicate all the design data and information furnished in data sheets A and B.

4. Foundation drawing of pump and driver with static and dynamic loads, details of

fixing, grouting and all relevant data required for design of foundation 5. Cross-section drawing of the pump with complete part list, materials of

construction and relevant standards for each part 6. Pump performance curves flow rate Vs head, BKW, efficiency, NPSHR from zero

flow to maximum flow and torque-speed curve 7. Scheme for pump sealing, lubrication and cooling 8. Driver dimensional drawing 9. Surface preparation and painting procedures 10. Catalogues, data sheets and drawings for instruments 11. Installation, operation and maintenance manual along with lubrication schedule


TCE.M4-113-54



SHEET 1 OF 4

ISSUE R5


TITLE

1.0 SCOPE This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at the manufacturer’s works, delivery at site and performance testing at site of Electrically Operated Hoists.

2.0 CODES AND STANDARDS The design, materials, construction, manufacture, inspection, testing and

performance of electrically operated hoist shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

3.0 CONSTRUCTION FEATURES Electrically operated hoist shall be a complete unit with travelling trolley, hoisting

motor, travel motor (if travelling trolley is motor operated), rope drum, wire rope, necessary gearing, sheaves, brakes, hook, pendent push button station, contactor panel, all wiring, conductor for travel motion (if travelling trolley is motor operated), limit switches, end stops, buffers, earthing terminals and other accessories to make the equipment complete in all respects. Electrically operated hoist shall have minimum factor of safety as five (5).

3.1 TRAVELLING TROLLEY The travelling trolley shall be motor driven or push pull or manual geared type

as specified in data sheet A. Trolley frames shall be fabricated from rolled structural steel sections. The side plates of the trolley shall extend beyond wheel flanges, thus providing bumper protection for the wheels. The two side plates shall be connected by means of an equalising pin. The wheels shall be machined on their treads to match the profile of the monorail.

3.2 ROPE DRUM Rope drum shall be as per IS 3938. Rope drum shall be either cast or welded to

sustain concentrated loads resulting from rope pull. Drum shall be machine grooved right and left with grooves of a proper shape for the rope used. Grooving shall be of proper length to handle entire rope required to make the specified lift plus the two dead laps at each anchor point, without overlapping.


TCE.M4-113-54



SHEET 2 OF 4

ISSUE R5


TITLE

3.3 WIRE ROPES Wire ropes shall be extra flexible with well lubricated hemp core having six (6)

strands of thirty-seven (37) or thirty-six (36) wires per strand with ultimate tensile strength of 1.6 × 106 KN/M². Wire ropes shall be of Right Hand Ordinary (RHO) lay construction. The rope shall be fastened to the drum with an attachment having strength equal to that of the rope. The rope fastening at the swinging end shall be aligned so as to prevent rope coming off its reeving. Rope shall be of sufficient length so that two (2) full laps shall remain on the drum at extreme low position of the hook. Reverse bends or cross bends and bird caging shall be avoided. The breaking loads for the hoist ropes shall not be less than the factor specified in IS 3938. The load shall include rated load on hooks, weight of the bottom block and the weight of rope.

3.4 LOAD CHAIN AND LOAD CHAIN WHEEL In case chain is employed for lifting the load instead of wire rope, it shall be heat

treated to give required ductility and toughness so that it stretches before breaking. The total length of the load chain shall exceed the minimum length required to give the specified range of lift by not less than three (3) links per fall to ensure that the slack end anchorage is not loaded. The load chain wheel shall be of adequate strength and shall be suitably designed to ensure effective operation of the chain and shall be properly secured with shaft, preferably with splines

3.5 SHEAVES Sheaves shall be as per IS 3938. These shall be equipped with anti-friction

bearings and shall be fully guarded to prevent the rope coming off. Equalising sheaves, if provided, shall also be as per IS 3938. Grooves shall be machined to proper shape for the rope used.

3.6 GEARS Gears shall be cut from solid cast or forged steel blanks or shall be of stress-

relieved welded steel construction or built-up from steel billets and welded together to form a one piece gear section. Pinions shall be of forged carbon or heat treated alloy steel. All gears and pinions shall be totally enclosed type upto last stage of reduction in all motions and shall be carried in fabricated steel gear boxes which shall be dust proof and firmly sealed to prevent oil leakages. For travel motion, creep speed if specified shall be achieved by one of the following methods :

(a) Planetary gear box integral with main gear box (b) Planetary gear box independent with motor (c) Worm reducer with clutch

However, for hoisting motion, creep speed shall be achieved only by methods (a) or (b) indicated above. Creep speed shall be generally 10 % of main speed.


TCE.M4-113-54



SHEET 3 OF 4

ISSUE R5


TITLE

3.7 BEARINGS Bearings may be ball or roller type. All anti-friction bearings shall be of approved

make, which are interchangeable with corresponding size bearings of other make. Bearing housings shall be of split type or so designed to permit easy removal of the shaft. The design shall be such that there is no ingress of dust and oil or grease does not leak out. Bearings shall have a minimum life expectancy of 20 years based on equivalent running time as per specified class.

3.8 SHAFTS AND AXLES Shafts and axles shall be of forged steel and shall have ample strength, rigidity

and adequate bearing surface for intended duties. Shafts and axles shall be accurately machined and properly supported. Shafts shall, as far as possible, be furnished straight. If shouldered, these shall be provided with fillets of ample radius or shall be tapered to avoid loss of strength and stress concentration. These shall be designed considering allowances for keys and splines.

3.9 BRAKES All brakes shall be of ‘fail-safe’ design and shall operate automatically in case of

power failure. Each of the trolley and hoisting motors shall be equipped with electrically released, spring set, friction shoe type brakes. Hoisting brake shall be designed to hold 1.5 times full load torque while trolley travel brake shall be designed to hold 1.25 times full load torque. Separate brakes shall be provided for creep motions. All brakes shall have weather-proof enclosures. Coupling halves shall not be used as brake drums.

3.10 LIFTING HOOK The lifting hook shall be single hook type, solid, forged, heat treated, of rugged

construction and provided with a standard depress type safety latch. Lifting hook shall have swivels and operate on ball or roller thrust bearings with hardened races. Lock to prevent hook from swivelling shall be provided.

3.11 BUFFERS, STOPS AND SWEEPS 3.11.1 Spring or rubber buffers shall be provided on the trolley. Suitable end stops

shall be provided which shall be welded on the ends of monorail to contact the buffers mounted on the trolley.

3.11.2 Trolley wheel stops shall be provided before the end stops. These shall match

to wheel radius. Stops to prevent trolley from running off the monorail shall be abutted against ends of monorail. Stops shall be welded to the monorail.

3.11.3 Sweeps shall be attached to the trolley to remove foreign material from the rails. 3.12 GUARDS


TCE.M4-113-54



SHEET 4 OF 4

ISSUE R5


TITLE

3.12.1 All exposed couplings, shafts, gear wheels, pinions, drives etc. shall be safely encased and guarded.

3.12.2 The sheaves of hook blocks shall be guarded to prevent trapping of hand

between a sheave and the in-running rope. 4.0 ELECTRICAL EQUIPMENT 4.1 MOTORS Drive motors shall be as per IS 325 and companion specification TCE.M4-203-

01. Motor shall be suitable for frequent reversal, braking and acceleration. Pull-out torque shall be 2.15 times the rated torque.

4.2 PENDENT PUSH BUTTON STATION The pendent push button station shall be supported independently, earthed

separately independent of suspension and shall comprise the following push buttons and indicating lamps :

(a) ‘Start’ and ‘Stop’ (b) Trolley travel - ‘To’ and ‘Fro’ (c) Hook - ‘Hoist’ and ‘Lower’ Red lamp shall indicate supply ‘ON’ 4.3 MISCELLANEOUS Controllers and resistors, controls, electrical protective devices, cables and

conductors, earthing guards etc. shall be as per IS 3938. Limit switches shall be provided for overhoisting and overlowering and for two extreme ends of trolley travel.

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: IIIB

TCE.M4-113-54



SHEET 1 OF 1

ISSUE R4

TITLE


DATA SHEET C DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE

ORDER

1. List of drawings and documents to be submitted for review, approval and information with scheduled submission dates

2. Quality Assurance Plan (QAP) 3. Motor power calculations 4. Brake selection calculations 5. Detailed to-scale dimensioned general arrangement drawing showing all the

components. Drawing shall also indicate all design data and information furnished in data sheets A and B

6. Part list of all the components with materials and codes of construction 7. Flexible trailing cable arrangement drawing 8. Detailed explanatory functional write-up of control scheme, wiring diagrams

and control cabinet drawings 9. Dimensional drawing for the hook 10. Installation, operation and maintenance manual with lubrication schedule



CHAIN PULLEY BLOCKS SHEET 1 OF 2

ISSUE R2


1.0 SCOPE This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at the manufacturer’s works, delivery at site and performance testing at site of Chain Pulley Blocks.

2.0 CODES AND STANDARDS The design, materials, construction, manufacture, inspection, testing and

performance of the chain pulley blocks shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or equivalent standards. Other international standards are also acceptable, if these are established to be equal or superior to the listed standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

3.0 CONSTRUCTION FEATURES The chain pulley block shall be a complete unit with travelling trolley, load chain,

load chain wheel, hand chain, hand chain wheel, necessary gearing, brakes for hoisting, hook and other accessories to make the equipment complete in all respects. Chain pulley block shall be of worm or spur gear type and shall have minimum factor of safety as five (5).

3.1 TRAVELLING TROLLEY The travelling trolley shall be of push pull or manual geared type as specified in

data sheet A. Trolley frames shall be fabricated from rolled structural steel sections. The side plates of the trolley shall extend beyond wheel flanges, thus providing bumper protection for the wheels. The two side plates shall be connected by means of an equalising pin. The wheels shall be machined on their treads to match the profile of the monorail.

3.2 LOAD CHAIN AND LOAD CHAIN WHEEL The load chain shall be heat treated to give required ductility and toughness so

that it stretches before breaking. The total length of the load chain shall exceed the minimum length required to give the specified range of lift by not less than three (3) links per fall to ensure that the slack end anchorage is not loaded. The load chain wheel shall be of adequate strength and shall be suitably designed to ensure effective operation of the chain and shall be properly secured with shaft, preferably with splines.

3.3 HAND CHAIN AND HAND CHAIN WHEEL The hand chain for the hoisting and traverse mechanism shall hang well clear of

the hook and both the chains shall be on the same side. The length of the hand chain shall be such that the lowest point of the suspended loop shall hang 400 mm above the operating floor level. The hand chain wheels shall be provided with flanges and designed to ensure effective operation. The hand chain wheels




ISSUE R2


shall be provided with roller type guarding to prevent snagging and fouling of the chain.

3.4 GEARS Gears shall be cut from solid cast or forged steel blanks or shall be of stress-

relieved welded steel construction or built-up from steel billets and welded together to form a one-piece gear section. Gears shall have proper lubrication arrangement and shall preferably be of totally enclosed type.

3.5 SHAFTS AND AXLES Shafts and axles shall be of forged steel and shall have ample strength, rigidity

and adequate bearing surface for intended duties. Shafts and axles shall be accurately machined and properly supported. Shafts shall, as far as possible, be furnished straight. If shouldered, these shall be provided with fillets of ample radius or shall be tapered to avoid loss of strength and stress concentration. These shall be designed considering allowances for keys and splines.

3.6 BRAKES Brakes shall be of automatic type that shall stop and hold the load when hand-

chain pull is released and shall permit controlled lowering of the load when hand-chain pull is applied for lowering the load.

3.7 RATCHET AND PAWL Ratchet and Pawl mechanism shall be provided to arrest the full load from

lowering due to gravity. The ratchet and pawl shall be of steel, hardened and tempered so as to attain required wear resistance and toughness.

3.8 LIFTING HOOK The lifting hook shall be single hook type, solid, forged, heat treated, of rugged

construction and provided with a standard depress type safety latch. Lifting hook shall have swivels and operate on ball or roller thrust bearings with hardened races. Lock to prevent the hook from swivelling shall be provided.

SPEC. NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: IIIB



ISSUE R2


DATA SHEET C DATA TO BE FURNISHED BY THE VENDOR AFTER THE ISSUE OF PURCHASE

ORDER


2. Quality Assurance Plan (QAP) 3. Calculations for manual effort required to lift the load and for cross travel 4. Detailed to-scale dimensioned general arrangement drawing showing all the

components. Drawing shall also indicate all design data and information furnished in data sheets A and B.

5. Part list of all the components with materials and codes of construction 6. Dimensional drawing for the hook 7. Installation, operation and maintenance manual with lubrication schedule

SPEC NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME IIIB

TCE. M4-405-03


SUPPLY,DESIGN, FABRICATION,TESTING & ERECTION OF STRUCTURAL STEEL FOR STEAM GENERATOR

SUPPORTING STRUCTURES

SHEET 1 of 6

ISSUE R0


TITLE

1.0 SCOPE 1.1 This specification covers the general requirements for the supply, design, fabrication,

testing and erection of structural steel for steam generator supporting structures. 1.2 Structural framing shall be provided as required, including but not limited to the

following : Buckstays for pressure parts, top supporting girders, main and auxiliary columns,

bracings, base plates, anchor bolts, ladders, platforms, stairways and hand railing, gratings, pipe and other supports, curb plates and angles, chequered floor plates, hangers and hanger supports, miscellaneous steel such as frames, sill plates, struts, ties, lifting hooks, eye bolts, etc. and steel for enclosures and other items as may be required for satisfactory completion of the work.

2.0 APPLICABLE CODES AND SPECIFICATIONS The following standard specifications and codes of practice are made a part of this

specification. All standards and codes referred to herein shall be the latest editions including all applicable official amendments and revisions.

i) IS:456 Code of practice for plain and reinforced concrete. ii) IS:800 Code of practice for General construction in steel. iii) IS:875 Code of practice for design loads (other than earthquake) for

buildings and structures. iv) IS:1893 Criteria for earthquake resistant design of structures. v) AWSD 1.1 Structural welding code - steel. 3.0 SUPPLY, DESIGN, FABRICATION & TESTING OF STRUCTURAL STEEL 3.1 Design and fabrication of structural steel shall be in accordance with TCE

specification no. TCE.M4-405-01 and as further specified herein below. In case of any conflict, requirements of this specification shall govern.

3.2 Steam generator supporting structure and necessary auxiliary steel shall be

adequate to support loads of the steam generator and all piping and accessory equipment furnished by the VENDOR/CONTRACTOR. In addition such loads, both vertical and horizontal, as may be imposed by the PURCHASER's piping, connecting steel, maintenance monorails, miscellaneous platforms, stairs and elevator connections with the boiler shall also be considered. Hangers as are required for piping furnished by the VENDOR/CONTRACTOR shall also be provided.


TCE. M4-405-03




SHEET 2 of 6

ISSUE R0


TITLE

3.3 Design Parameters 3.3.1 All structures and equipment, including ducts shall be designed for wind loads as

specified in Indian Standard "Code of Practice for Design loads ( other than earthquake) for buildings and structures - IS:875 - Part III."

3.3.2 All structures and equipment, including ducts shall be designed for seismic loads as

applicable as per "Criteria for Earthquake Resistant Design of Structures" IS:1893. For seismic design, platform live load shall not be considered for calculation of lumped mass.

3.3.3 Wind and earthquake shall not be considered as acting simultaneously. The

VENDOR/CONTRACTOR shall submit the foundation design loading accordingly. 3.3.4 Insulation of steam generating unit shall be so arranged that the temperature of the

steel is kept below 93°C. 3.3.5 Base plates shall be designed according to IS:800 for an allowable bearing pressure

on the PURCHASER'S concrete foundation as per IS:456 for M20 grade concrete, with 33-1/3% increase for wind/seismic loading. All horizontal shears shall be transferred from column base plates to the foundation through adequate shear plates welded to underside of base plates. Anchor bolts shall not be designed to transfer any shear load.

3.3.6 Level of the bottom of base plate of all columns shall be fixed such that only the

column shaft projects above the boiler area grade slab and the entire base plate assembly is embedded below the grade slab.

3.3.7 The VENDOR/CONTRACTOR shall design anchor bolts for uplift using a basic

allowable unit tensile stress as per IS:800 on nominal area at root of thread with 25% increase allowed for wind/seismic loading. Anchor bolts shall be provided with pipe sleeves of adequate size and length. The anchorage length of foundation bolts beyond the pipe sleeves shall be designed in accordance with IS:456 or alternatively sufficient mechanical anchorage shall be provided.

3.3.8 Platforms shall be designed for a live load of 500 kg/m2 except areas where

dismantled equipment has to be placed or conveyed, which shall be designed for appropriate loading. Deflection of grating shall be limited to 1/325 of span.

3.4 Design Requirements 3.4.1 Vertical bracings shall be so arranged that the entire wind/seismic horizontal loading

is distributed over as many number of foundations as possible.


TCE. M4-405-03




SHEET 3 of 6

ISSUE R0


TITLE

3.4.2 Vertical bracings shall be so arranged that the entire width of all walkway areas shall have a minimum clear head room of 2.2 metres.

3.4.3 Column ends and contact area of base plates shall be milled to transmit full vertical

load by direct bearing at base plates and splices. 3.4.4 Projecting lengths of all foundation anchor bolts, nuts, locknuts and washers shall be

galvanised. 3.5 Platforms & Stairs 3.5.1 Platforms and stairways needed for access to all parts of steam generator and for

operation, inspection and maintenance shall include but not be limited to the following :

a) Air heater access platform b) Superheater platform, each side c) Main steam drum platform, each side d) Intermediate platforms, each side, as required and particularly at access doors, soot blowing equipment and damper control units. e) Safety valve platforms f) Elevator access platforms g) Burner access platforms h) Access platforms vertical around the ends of retractable soot blowers when

the soot blowers are in the retracted or withdrawn position. i) Dust and soot hopper access platforms. j) Electrostatic precipitator access platform. k) Access platform for access to fan bearings, coupling motor etc. l) All major access platforms shall completely circumscribe the unit and a

stairway shall be furnished on each side. Ladders shall not be used unless unavoidable and approved by the PURCHASER.

3.5.2 Arrangement of platforms shall be subjected to PURCHASER'S approval. 3.5.3 Platform walkways shall not have clear width less than 1000 mm. Those areas

requiring maintenance shall have adequate platform or work space and shall also be


TCE. M4-405-03




SHEET 4 of 6

ISSUE R0


TITLE

designed for maximum anticipated loads that could be encountered during maintenance.

3.5.4 Stairs shall be not less than 900 mm clear width except where interference of

equipment makes this impracticable. The PURCHASER'S approval for all exceptions shall be taken. Stairs shall have a slope of not more than 42 degrees to the horizontal and, preferably be limited to 38 degrees. Stairway head room shall not be less than 2.2 M.

3.5.5 Stairway risers shall be limited to 200 mm maximum. 3.5.6 Stair treads shall be galvanised rectangular welded grating with minimum 25 mm x 6

mm bearing bars at 25mm centres. All treads and landings shall have cast aluminium (or other approved material) abrasive nosings. Treads shall be fastened to steel stringers with galvanised bolts.

3.5.7 Ladders shall be provided only where access is seldom required or where congestion

makes it impossible to provide stairs and the location in each case shall be subject to the PURCHASER'S approval. Ladder side rails shall be spaced 400 mm apart and rungs shall be 20 mm dia. spaced 300 mm apart. Where the height of ladder exceeds 3 M, safety cage shall be provided.

3.5.8 Unless otherwise specified, all gratings shall be rectangular, welded, hot dip

galvanised with bearing bars of 6 mm minimum thickness suitably fastened at all supporting members. The span of gratings shall not generally exceed 1.5 metres. The maximum width of openings in gratings shall not exceed 40 mm.

3.5.9 Grating and chequered plate shall be neatly shop cut to fit around columns, major

equipment and pipes requiring openings 200 mm or more in diameter. Pipe openings shall clear insulations by 25 mm beyond extreme movement. The PURCHASER will indicate locations and sizes of openings required for his piping. Grating cut to within 25 mm of columns and equipment shall be banded with a flush top bar. Pipe openings 300 mm or larger shall be provided with curb plates.

3.5.10 All platforms and stair landings shall have two rows of galvanised pipe hand railing,

the top rail 1.0 M above platform/landing level and pipe posts spaced not more than 2.0 M apart. They shall have screwed ends with necessary accessories of bends, tees, junctions, sockets etc. Pipes used for hand rail shall be 32 NB type 'medium' as per IS 1239. Where the platforms and stair landings are located 30m above grade level, height of the handrail shall be 1.35m above platform/landing level with 3 rows of pipes.

3.5.11 Toe guards shall be provided at the edges of all platforms and stair landings, they

shall be of 8 mm minimum thickness and shall extend 75 mm above platform/ landing level. Curb plates and curb angles shall be neatly finished at corners and shall be shop assembled and attached to supporting steel members wherever practicable. All


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curb plates and curb angles for chequered plate platforms shall be seal welded to supporting steel.

3.5.12 Staircases shall have hand railing as specified for platforms and stair landings, the

top rail being at 1.0M above nosing line for stairs upto 30M elevation and 1.35m for higher elevations. Hand rail posts shall be placed opposite each other on stringers.

3.6 Fabrication 3.6.1 All steel shall be fabricated for field bolting with high strength friction grip bolts or

welding. M.S. bolts shall be permitted for field connections of girts, stairs and hand railing only. The fabrication of structural members shall be planned to keep the field fabrication work to minimum.

3.6.2 All welding of structural steel shall conform to the specific requirements as per the

standard AWSD 1.1. 3.6.3 Before commencement of shop welding, the VENDOR/ CONTRACTOR shall furnish

complete details of welding procedures he proposes to adopt, for the PURCHASER'S approval.

3.6.4 The VENDOR/CONTRACTOR shall furnish anchor bolt assemblies in time to enable

the PURCHASER to place them in position for taking up the execution of the boiler foundations.

4.0 STRUCTURAL ERECTION 4.1 Erection of structural steel shall be in accordance with TCE specification No.

TCE.M4-405-02 and as further specified herein below. In case of any conflict, requirements of this specification shall govern.

4.2 Columns which support main boiler supporting girders shall be extended, as

required, above top of roof steel to facilitate erection of girders. These column extensions shall be removed by the VENDOR/CONTRACTOR after erection of girders.

4.3 All structural components shall have erection marks to permit identification. The final

elevation of the component shall be designated by a letter (A, B and C etc.); area location by a number (1,2,3 etc); shipping sequence by a circled number (1), (2), (3), etc.

4.4 The VENDOR/CONTRACTOR shall supply all high strength friction grip bolts for all

field connections including that of the PURCHASER'S steel to the VENDOR/CONTRACTOR'S steel.


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4.5 The VENDOR/CONTRACTOR shall furnish temporary or fitting up bolts, shims, wedges, guys, etc. for erection of the structural steel.

5.0 PAINTING 5.1 Surface preparation and painting of steel surfaces shall be in accordance with TCE

specification M4-405-04.


TCE.M4-104-02


THERMAL INSULATION FOR HOT SURFACES

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1.0 SCOPE

This specification covers the technical requirements and essential particulars for the supply, application and finishing of the complete thermal insulation for hot equipment, piping systems, flues, ducts, steam generator casing, fixture casing, steam turbine etc. up to an operating temperature of 5650C. This specification is not applicable where the insulation is to be used for dual temperature (both hot and cold) service. Unless specified otherwise in section C and/or data sheet A, the scope of supply of the CONTRACTOR shall include, but not be limited to, the following items :

(a) Insulation materials of all types as specified and required

(b) Finishing materials of all types as specified and required

(c) Auxiliary materials such as binding and lacing wires, wire netting, bands, screws etc., as specified and required

(d) Angles, clamps, lugs etc. for supporting insulation

(e) Weather hoods

(f) Any other material as may be required for making the insulation complete


2.1 The supply and application of thermal insulation and finishing covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where it is to be applied. The materials and application shall also conform to the latest editions of the codes and standards listed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility.

2.2 The following are some of the codes and standards relevant to this specification :

IS 277 Galvanised Steel Sheets (Plain and Corrugated)

IS 737 Wrought Aluminium and Aluminium Alloy Sheet and Strip for General Engineering Purposes

IS 3144 Mineral Wool Thermal Insulation Materials - Method of Test

IS 3677 Unbonded Rock and Slag Wool for Thermal Insulation

IS 3690 Unbonded Glass Wool for Thermal Insulation

IS 8154 Preformed Calcium Silicate Insulation for Temperatures up to 650°C.


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IS 8183 Bonded Mineral Wool

IS 9842 Preformed Fibrous Pipe Insulation

IS 14164 Industrial Application and Finishing of Thermal Insulation Materials at Temperatures above (-) 800C and up to (+) 7500C

BS 5970 Thermal Insulation of Pipework and Equipment (in the Temperature Range (-) 1000C to (+) 8700C)

3.0 GENERAL DESIGN REQUIREMENTS

3.1 All exposed portions of the plant which operate at temperatures of 650C and above during normal operation shall be thermally insulated so that the temperature on the outer surface of the finish does not exceed 600C based on an ambient temperature of 300C in still air conditions, unless specified otherwise in data sheet A.

3.2 Insulation thickness for rock wool and glass wool materials have been indicated in data sheet A. These insulation thickness do not include thickness of finishing materials such as cement sand plaster, aluminium or Galvanised Steel (GS) sheet, binding and lacing wires, wire netting and bands etc.

3.3 Insulation thickness indicated in data sheet A shall be regarded as the minimum requirement. BIDDER may provide higher thickness in order to meet the design criteria indicated at para 3.1.

3.4 Equipment and piping which are not insulated from heat conservation considerations but have a surface temperature exceeding 650C shall be insulated for personnel protection when :

(a) The bottom of the equipment or pipe is less than 2 metres from the ground or working floor or platform or walkway, or

(b) The equipment or pipe, or parts thereof, are within 600 mm from a working floor or platform or walkway

Equipment and piping to be insulated for personnel protection, shall be insulated to the extent that the temperature on the outer surface of the finish does not exceed 600C.

3.5 Equipment in horizontal position, which are to be insulated for personnel protection, shall be fully insulated when the equipment outside diameter is less than 1250 mm and to a height of 2 metres from the working floor or platform for larger sizes.


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4.0 MATERIALS

4.1 GENERAL

4.1.1 All materials shall be new and fresh, incombustible, fire retardant, rot-proof, non-hygroscopic, vermin proof, fungus proof, non-injurious to health, chemically inert, non-corrosive to steel and aluminium (even if soaked in water for extended periods) and shall be guaranteed to withstand continuously and without deterioration the maximum temperature to which these shall be subjected to under the specified applications.

4.1.2 The insulation materials and any component of the finished insulation job shall not react chemically, singly or in combination, with water or moisture to form substances that are more actively corrosive to applied surface than water or moisture alone.

4.1.3 In order to protect the workers from the hazards of insulation materials, suitable protective gadgets shall be provided. Required safety precautions shall be taken during handling and application of insulation.

4.1.4 The insulation material shall be kept dry at all times during transport, storage and installation. Decking and covering tarpaulins alone are not adequate for any length of time and shall not be allowed except in extreme emergencies and only for short period. Stacking of insulation materials directly on ground shall not be done. No wet insulation shall be installed. If wet insulation is present, it shall be removed and replaced with new dry insulation. The insulation may be protected with plastic film but shall be vented to prevent sweating.

4.2 INSULATION MATERIALS

The insulation material shall be one or more of the following types as specified in data sheet A.

Material Description Material Code

4.2.1 Unbonded rock wool mattress as per IS 3677 Type 2 at an application density of 150 Kg/M3 for temperatures 65 to 3990C

U150

4.2.2 Unbonded rock wool mattress as per IS 3677 Type 2 at an application density of 200 Kg/M3 for temperatures 400 to 5650C

U200

4.2.3 Unbonded glass wool mattress as per IS 3690 Type 2 at an application density of 80 Kg/M3 for temperatures 65 to 5500C

U80

4.2.4 Lightly resin-bonded rock wool mattress as per IS 8183 at an application density of 100 Kg/M3 for temperatures 65 to 3990C

L100


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4.2.5 Lightly resin-bonded rock wool mattress as per IS 8183 at an application density of 150 Kg/M3 for temperatures 400 to 5650C

L150

4.2.6 Bonded rock wool pipe sections as per IS 9842 at an application density of 144 Kg/M3 for temperatures 65 to 5650C

PS1

4.2.7 Calcium silicate preformed blocks, slabs and pipe sections as per IS 8154 at an application density of 200 Kg/M3 for temperatures 65 to 5650C

CS1

4.3 FINISHING MATERIALS

The finishing material shall be one or more of the following types as specified in data sheet A.


4.3.1 Portland cement and inorganic fibre with water proofing compound at an application density of 1050 to 1100 Kg/M3

FC

4.3.2 Aluminium sheet as per IS 737, designation 31000, condition H3 for insulation material codes U150, U 200 and U 80

AL1

(a) Insulation outside diameter above 450 mm - sheet thickness 18 SWG

(b) Insulation outside diameter 150 to 450 mm - sheet thickness 20 SWG

(c) Insulation outside diameter below 150 mm - sheet thickness 22 SWG

(d) Flues and ducts - sheet thickness 1.0 mm

(e) Steam generator casing and rear wall enclosure - sheet thickness 1.6 mm

4.3.3 Aluminium sheet as per IS 737, designation 31000, condition H3 for insulation material codes L100, L150, PS1 and CS1

AL2



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4.3.4 GS sheet as per IS 277, designation GP, for insulation material codes U150, U200 and U80

GS1

(a) Insulation outside diameter above 450 mm -sheet thickness 20 SWG





4.3.5 GS sheet as per IS 277, designation GP, for insulation material codes L100, L150, PS1 and CS1

GS2





(e) Steam generator casing and rear wall enclosure-sheet thickness 1.2 mm

4.4 AUXILIARY MATERIALS

4.4.1 Binding and Lacing Wires


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(a) For temperatures up to 3990C : Annealed GS 20 SWG

(b) For temperatures from 400 to 5650C : Annealed SS 304 20 SWG

4.4.2 Wire Netting

(a) For temperatures up to 3990C : 20 SWG GS wire with 20 mm hexagonal opening

(b) For temperatures from 400 to 5650C : 20 SWG SS 304 wire with 20 mm hexagonal opening

4.4.3 Bands

(a) For securing insulation material : 20 SWG GS, 20 mm wide

(b) For securing aluminium and GS sheets

: 24 SWG anodised aluminium or SS 304, 20 mm wide

(c) For securing aluminium foil on SS surface

: 24 SWG aluminium, 20 mm wide

4.4.4 Screws

Screws shall be of self-tapping type and shall be of aluminium or stainless steel for aluminium sheets and GS for GS sheets.

5.0 INSULATION OF EQUIPMENT AND PIPING (EXCEPT STEAM TURBINE)

5.1 GENERAL

5.1.1 The application of insulation shall be made in a professional manner. The insulation shall be applied to all surfaces when these are at ambient temperature. Ample provision shall be made for the maximum possible thermal movement and the insulation shall be applied in a manner which shall avoid breaking or telescoping due to alternate periods of expansion and contraction. A single layer of insulation shall not be more than 75 mm thick.

5.1.2 Insulation shall be applied after all leak tests on equipment and piping are over and the section of the plant has been specifically released by the PURCHASER for such work. If insulation has to be applied before the leak test, all welded and flanged joints shall be left exposed and insulated after satisfactory completion of the leak test.

5.1.3 All surfaces to be insulated shall be clean and dry before the insulation is applied. The surfaces shall be cleaned of all foreign material such as scale,


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dirt, rust and paint, by the use of steel wire brushes and steel scrapers, where necessary. Where a surface is not free of paint the CONTRACTOR shall notify the PURCHASER of the condition for remedial action. The insulation shall be applied after remedial action, suggested by the PURCHASER, has been taken by the CONTRACTOR.

5.1.4 Carbon steel and low alloy steel surfaces to be insulated shall be thoroughly cleaned by wire brushing. For operating temperatures below 125°C, the surface shall be given one coat of heat-resistant aluminium paint of coating thickness not less than 20 microns.

5.1.5 All stainless steel surfaces to be insulated shall be protected against chloride attack as follows :

(a) For operating temperatures up to 500°C, the stainless steel surfaces shall be mechanically separated from insulation surface by wrapping with 0.1 mm (42 SWG) thick aluminium foil. Application and other details shall be same as those described for steam traced piping in para 5.2.6.

(b) Above 500°C, the metal surface shall be given one coat of heat-resistant aluminium paint of coating thickness not less than 20 microns.

5.1.6 All sheet metal joints shall be sealed with bitumastic paint and made effectively weather and water-proof. All flat surfaces shall be adequately sloped to prevent pools of water collecting. The sheet shall be protected internally with 2 coats of bitumastic paint.

5.1.7 All actions shall be taken to complete the application of finishing on exposed surfaces covered with insulation before closing the day’s work. If this is not practicable, adequate precautions shall be taken to protect the insulation from weather, for example by wrapping it with polythene sheet, roofing felt or other approved material.

5.2 INSULATION ON PIPING

5.2.1 All vertical pipes shall be provided with suitable insulation supports to prevent the insulation from collapsing due to its own weight. Suggested method is indicated in TCE.M4-104-54. Any welding required, shall be carried out by the CONTRACTOR with the prior permission of the PURCHASER and only under his direct supervision. Where welding is not permitted, suitable clamped supports shall be used. The insulation shall be applied starting from bottom up. Mattress type insulation materials shall be clamped from top.

5.2.2 If rock wool preformed pipe section insulation material is used, the sections shall be fitted closely to the pipe. Where there is more than one layer of insulation material, all joints shall be staggered. Each section shall be held in place by circumferential bands or wires at spacing not greater than 450 mm. If mattress is used, the insulation shall be formed to fit the pipe and applied with edges pulled together tightly at the longitudinal joint and secured by lacing wire. The insulation shall be turned to bring this joint to the lower side. Adjacent


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length shall be butted closely and laced together with lacing wire. Mattress insulation shall be backed-up by wire-netting on one side. For insulation thickness of more than 75 mm, where application shall be in two or more layers, each layer of mattress shall be backed up with wire netting.

5.2.3 When calcium silicate is the insulation material, all pipes up to and including 300 mm nominal diameter shall be covered with preformed rigid sections to form a robust pipe covering. Larger sizes shall be covered with segmental blocks moulded to a diameter to fit the curved surfaces. All sectional and segmental insulation shall be carefully fitted to the pipes with side and end joints butted tightly and securely wired in place at spacing not greater than 400 mm.

5.2.4 The ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully pressed into the surface of the insulation. All calcium silicate insulation joints shall be fully staggered and any cavities between joints and cracks if any in both inner and outer layers shall be filled with insulating cement.

5.2.5 When preformed insulation material is used, the number of segments shall be minimum and all joints shall be filled with the same basic insulation material in loose form.

5.2.6 The thickness of insulation for steam traced lines shall be the higher value as determined by the size and temperature of the steam tracer and the service line. The tracer shall be tightly wired to the main pipe at intervals of 500 mm. Aluminium foil not less than 0.1 mm thick (42 SWG) shall then be wrapped around both the pipe and tracer with an overlap of at least 25 mm and wired or banded in place. This is to prevent insulation from separating the pipe and tracer and to provide a hot air enclosure and also to provide a barrier to radiant energy leaving the pipe. The insulation proper shall then be fitted and finished in the normal way. Cross-section of preformed insulation shall be suitable for accommodating tracers.

5.2.7 All insulation shall be protected by a finishing material as specified in data sheet A. The sheets shall be installed with the longitudinal lap joints at 45° below the horizontal for horizontal pipes and the joints sealed with bitumastic paint. On vertical pipes the sheets shall be applied working from bottom up. Each section of sheets shall have a minimum overlap of 50 mm longitudinally and circumferentially. Each circumferential joint shall be made weather-proof by securing with a band of sheet material and sealing with bitumastic paint. Longitudinal lap joints shall be fixed with screws at approximately 150 mm centres.

5.2.8 Weather hoods shall be provided for insulated piping passing through roof, and external walls as per TCE.M4-104-50.

5.3 INSULATION ON PIPE FITTINGS, VALVES AND SPECIALITIES

5.3.1 All pipe fittings, valves and specialities shall be covered with the same type and thickness of insulation as specified for the adjoining pipe, with the special


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provisions and/or exceptions as listed below. On pipe fittings, insulation outside diameter shall be same as the outside diameter of adjacent pipe insulation.

5.3.2 Unless specified otherwise in section C or data sheet A, all valves and specialities, shall also be insulated to the same extent as the adjacent piping.

5.3.3 Unless specified otherwise in section C, valves and specialities of sizes 100 mm NB and larger shall be provided with removable box type insulation. Box shall be fabricated from sheet material specified for adjoining pipes. Pipe insulation on adjoining flanges shall be stopped at one bolt length plus 25 mm before flange to permit removal of the bolts and nuts. The insulation shall be applied after the finish has been applied over insulation on the adjacent piping. A typical arrangement is shown in TCE.M4-104-51.

5.3.4 Flanged joints shall be insulated. Arrangement shall be similar to that for valves shown in TCE.M4-104-51. Unions shall not be insulated.

5.3.5 Non-metallic expansion joints shall not be insulated. Metallic expansion joints identified in bill of materials shall be insulated.

5.3.6 Traps shall not be insulated. However, trap discharge lines and safety valve discharge lines shall be insulated for personnel protection only.

5.3.7 Pipe hanger clamps shall be covered with insulation along with the pipe. Upper bolts of three-bolt hanger clamps shall not be insulated. A typical arrangement is shown in TCE.M4-104-53. On piping outdoors, a weather hood packed with waterproof sealing material shall be supplied and installed.

5.4 INSULATION ON EQUIPMENT

5.4.1 Where the insulation material is in the mattress form, cleats in the form of wire nails or nuts or angles and flats for supporting the insulation material, shall be welded to the equipment by others. If wire nails are to be used as insulation cleats, these shall be bent and secured with the metal fabric of the mattress, after the insulation has been applied. Where insulation cleats are in the form of M6 and M10 nuts, the CONTRACTOR shall supply and install bolts of suitable length for fixing the insulation. The insulation applied to equipment shall be reinforced with wire netting. One course of wire netting shall be applied to the surface of the equipment and each layer of insulation shall be backed up with wire netting. All irregularities of the surface shall be filled and levelled over with insulating cement. All mattress joints shall be butted tightly and the mattresses shall be secured with 20 mm wide 24 SWG GS bands at 450 mm centres. After banding, all mattress edges shall be laced tightly.

5.4.2 When calcium silicate is the insulation material, segmental blocks moulded to fit the curved surfaces shall be used for cylindrical portions of the equipment. Flat blocks shall be used for equipment of diameter greater than 2500 mm and for flat surfaces.


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5.4.3 For equipment up to 2500 mm in diameter and temperatures up to 200°C, the blocks shall be cut and fitted so that the inner diameter of insulation is 13 mm greater than the equipment outside diameter to take care of equipment circumferential expansion. The blocks shall be applied tightly butted and sealed with insulating cement. The insulation shall be secured by circumferential bands in such a way that tension of the bands produces compression on the butt edges rather than on the surface towards the equipment.

5.4.4 For equipment either above 2500 mm in diameter or at temperatures above 200°C, a 25 mm thick rock wool fibre mattress insulation shall be applied around the equipment prior to the application of calcium silicate. Calcium silicate blocks must be cut and fitted to the outside radius of the equipment plus the thickness of the rock wool spacer insulation. The insulation, when installed, shall not compress the fibrous mattress.

5.4.5 All equipment, unless specified otherwise, shall have a smooth aluminium or GS sheet finish as specified in data sheet A, applied in a manner similar to that specified for piping. For fixing of aluminium or GS sheets, spacer rings at 1000 mm centres shall be welded to the equipment by the CONTRACTOR. If welding is not permitted, spacer rings shall be suitably clamped. Spacer ring material shall be the same as that of the surface to be insulated. All vertical and horizontal sheets shall be overlapped a minimum of 75 mm. The lapped joints of adjoining sections of sheets shall be secured with screws. On all equipment above 2500 mm diameter and flat surfaces the sheet shall be further secured by circumferential bands at approximately 1000 mm centres. Each sheet joint shall be sealed with bitumastic paint. The roof sections shall overlap the side walls to prevent water seepage between insulation and the equipment wall. Side wall sheets shall be securely banded at intersections of the side wall and roof sections.

5.4.6 All equipment manholes, hatches, bolted or screwed cover plates, flanged ends etc. shall have removable box type insulation, with same thickness of insulation as for adjacent surfaces. Insulation adjoining such equipment openings shall be tapered towards these openings to permit removal of bolts, screws, heads, covers or plates with no damage to adjacent surface insulation or cover. A typical detail of manhole insulation is shown in TCE. M4-104-56.

5.4.7 Nozzles and other connections on tanks, heaters and other equipment shall be insulated in the same manner as the pipes.

5.4.8 Pump casing shall be completely insulated with removable type of boxes fabricated from the specified sheet material.

5.4.9 Name plates on equipment shall not be insulated.

5.5 CEMENT SAND PLASTER FINISH

5.5.1 On piping and equipment, where cement sand plaster finishing is specified in data sheet A, a barrier of polythene bonded hessian with the hessian layer outwards or bituminised Kraft paper shall be provided over the insulation. A


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total of 15 mm thick cement sand (1:4) plaster shall be applied in two layers after a GS wire netting is stretched over the entire surface of the barrier and securely fastened down. The plaster shall be hand-trowelled over the wire netting to a smooth finish. Curing shall be carried out by wrapping damp hessian cloth around the plaster. The application of finishing plaster shall be terminated, at the end of day's work, at an expansion joint.

5.5.2 The cement sand plaster finish shall have the following properties :

(a) A light shower of rain, falling immediately after application shall not wash off the plaster.

(b) At any time, one week or more after application, it shall not shatter if struck a sharp blow with a 0.7 Kg hammer. Such a blow may damage the finishing locally but shall not cause large pieces to break away.

(c) When set, it shall withstand prolonged exposure to the weather without additional protection.

5.5.3 Outdoors, the finishing plaster shall be applied immediately after application of insulation. If this is not practicable, the CONTRACTOR shall take adequate precautions to protect the insulation from weather, e.g. by wrapping it with polythene sheet, roofing felt or other approved material.

6.0 INSULATION EXPANSION JOINTS

Necessary insulation expansion joints shall be provided to prevent cracking of rigid insulation and hardsetting finishing cement layer. Insulation expansion joints shall be provided at intervals as shown in TCE.M4-104-54. These shall also be fitted on both sides and within 1000 mm of each bend and branch connections. At the insulation expansion joint, there shall be complete cut through the insulation and the sheet metal covering shall be provided with sliding joints.

7.0 STEAM TURBINE INSULATION

7.1 Steam turbine and its integral piping shall be lagged with calcium silicate plastic composition in multiple layers.

7.2 Before applying the insulation, the surface to be insulated shall be thoroughly cleaned with wire brush to remove all dirt, rust and scale. After cleaning, the insulation shall be applied in successive layers to the required thickness. Each individual layer shall be properly dried before the next layer is applied.

7.3 The heating of the steam turbine cylinder before the application and drying of the individual layers shall be by infra-red lamps. The CONTRACTOR shall provide all equipment and make all necessary arrangements.


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7.4 The insulation shall be reinforced with GS wire netting and lacing. Where layer interface temperature is 4000C and above, SS 304 wire netting and lacing shall be used. Reinforcing wire netting shall be provided over each successive layer of insulation.

7.5 The insulation shall be secured to the steam turbine cylinder and steam chests. For securing the insulation properly, nuts shall be provided on the outer steam turbine casing and steam chest. Studs of suitable length shall be screwed on to the nuts and the insulation shall be held rigidly by the studs.

7.6 The studs shall be wrapped with asbestos mill board paper or rope to avoid direct contact of the wire-mesh with the studs. The studs shall be of stainless steel material.

7.7 The insulation shall be finished with a layer of hard setting insulating cement, trowelled to a smooth finish, to prevent damage.

7.8 The steam turbine shall then be covered with 1.2 mm thick aluminium appearance cladding.

8.0 MEASUREMENT

Measurement of insulation over equipment and piping shall be as per IS 14164.

9.0 GUARANTEES

9.1 The CONTRACTOR shall demonstrate to the PURCHASER that the temperature of the outer surface of the finish has not exceeded 60°C. Temperature shall be measured at the middle of a segment of piping run to be mutually agreed. Two measurements, one at the top and other at the bottom, shall be taken at the measuring points. These temperatures shall be taken as the representative temperature for that length of piping.

9.2 The CONTRACTOR shall guarantee that, if the temperature on the outer surface of the finish exceeds 60°C, the CONTRACTOR shall either replace the insulation with a superior material or provide additional insulation thickness at the PURCHASER'S discretion at no extra cost to the PURCHASER.

10.0 MISCELLANEOUS

Approval of the PURCHASER shall be obtained of samples of all materials and necessary test certificates of approved national laboratories, before despatching these to site. Insulation shall not be applied until specific release is given by the PURCHASER.


TCE.M4-104-02


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ISSUE R1

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DATA SHEET C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF CONTRACT


2. Quality Assurance Plan (QAP)

3. List of insulation materials with specifications and properties like density, thermal conductivity etc.

4. Values for thermal conductivity at various mean temperatures for all insulation materials

5. List of finishing materials with specifications

6. List of auxiliary materials with specifications

7. Test certificates for insulation and other materials

8. Detailed insulation application and finishing procedure


TCE.M4-134-03


ERECTION AND TESTING OF POWER PLANT PIPING

SHEET 1 OF 11

ISSUE R4

TITLE


1.0 SCOPE This specification covers the minimum technical requirements and essential

particulars for erection, inspection, testing and cleaning of power plant piping systems included in the CONTRACTOR's scope of work. The CONTRACTOR shall demonstrate that the piping meets the requirements of the specification and applicable codes. In the event supply and shop fabrication of piping systems are also included in the CONTRACTOR's scope of work in Section C, all references to the PURCHASER's drawings in the subsequent clauses of this section shall be understood to imply the CONTRACTOR's drawings.

2.0 CODES AND STANDARDS The CONTRACTOR shall comply with the latest editions of applicable Codes

and Standards. The CONTRACTOR shall also comply with all applicable statutes, regulations and safety codes in the locality where the piping will be erected. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility.

3.0 GENERAL REQUIREMENTS 3.1 The CONTRACTOR shall erect all piping, online instruments, control valves,

block valves, specialities, etc., as per the PURCHASER's piping drawings for piping systems of NB 65 mm size and larger.

3.2 Unless otherwise specified in Section C, piping systems of size NB 65 mm

and larger are deemed shop-fabricated and would be delivered to site in prefabricated condition. The extent of fabrication to be carried out on these pipelines at site by the CONTRACTOR is indicated in the piping layout drawings and also specified in Clauses 3.3, 3.4, 3.5, and 3.6 of this specification.

3.3 If adequate dimensional data is not available sufficiently in advance from the

suppliers of control valves, flow nozzles, orifice plate assemblies, desuperheaters and such other specialities, pipe spools on either side of these specialities may be sent to site in unfabricated or semi-fabricated condition. The CONTRACTOR shall cut these spools to the required lengths, prepare their ends for purposes of welding, weld bosses for drains, vents, instruments, etc., as required, weld support lugs or shoes, if required and carry out any other fabrication work on these spools as might be required to render these system complete in all respects and compatible with the final piping drawings.

3.4 Flow nozzles, flow orifices and control valves on pipelines which are steam

blown shall be installed after steam blowing. These pipelines would therefore be sent to site without being cut short for the flow nozzles/orifices/control valves. After completion of blow out operation, CONTRACTOR shall cut spool pieces of appropriate lengths, prepare the weld ends and install the flow nozzle / orifice assemblies / control valves.


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3.5 All other fabrication work as required on prefabricated pipe work for connecting temporary piping for purposes of mass flush, chemical cleaning, steam blow out, hydraulic testing, vacuum testing, etc., dismantling the temporary pipe work and restoring the permanent pipe work to their design condition shall be carried out by the CONTRACTOR.

3.6 Where required for hydrotesting, chemical cleaning or steam blowing of

piping, the CONTRACTOR shall provide necessary vents and drains, whether these are shown on piping drawings or not.

3.7 The CONTRACTOR shall install all hangers and supports, guides, restraints,

anchors, vibration dampeners, shock absorbers, etc., as per the approved hanger sketches. Any field fabrication such as cutting and threading of hanger rod, etc., required for the installation of such hangers and supports shall be carried out by the CONTRACTOR.

3.8 Pipelines of size NB 50 and below are regarded as field-run piping. It is the

CONTRACTOR's responsibility to plan suitable layouts for these systems at site as per the requirements of this specification and in consultation with the PURCHASER and/or the ENGINEER. The CONTRACTOR shall prepare isometric drawings indicating the layout of field-run pipe work based on the PURCHASER's flow diagrams and general arrangement drawings. The isometric drawings shall be approved by the PURCHASER/ENGINEER prior to the installation of the field run pipe work. Any layout for field-run pipe work that may be indicated on PURCHASER's layout drawings may be used for guidance.

3.9 While routing field run piping, the following requirements shall be taken into

account by the CONTRACTOR. 3.9.1 All piping shall be routed so as to avoid interference with other pipes and

their hangers and supports, electrical cable trays, ventilation ducting, structural members, equipment, etc. Adequate clearances shall be ensured with respect to the above to accommodate insulation and pipe movements.

3.9.2 All piping shall be grouped where practicable and shall be routed to present a

neat appearance. 3.9.3 The piping shall be arranged to provide clearance for the removal of

equipment requiring maintenance and for easy access to valves, instruments and other piping accessories required for operation and maintenance.

3.9.4 Piping shall generally be routed above ground but where specifically

indicated / approved by the ENGINEER, the pipes may be arranged in pipe trenches or laid buried. Insulated pipes shall not be buried.

3.9.5 Overhead piping shall have a minimum vertical clearance of 2.3 meters

above walkways and working areas and 6.0 meters above roadways unless otherwise specified by the ENGINEER.


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3.9.6 Drains shall be provided at all low points and vents at all high points as per actual layout regardless of whether the same have been shown in the flow diagrams or not. Pipelines shall preferably be sloped towards the drain points.

3.9.7 Provision shall be made while preparing piping layout to install control valves,

flow measuring elements and any other on line speciality or equipment supplied by OTHERS. Sufficient upstream and downstream lengths shall be provided for flow measuring devices, control valves, desuperheaters and other specialities as required, in consultation with the ENGINEER.

3.9.8 At all screwed valves and screwed connections on equipment, unions shall

be provided to facilitate disassembly. Likewise, unions shall also be provided at suitable locations on straight lengths of screwed pipelines.

3.9.9 All local instruments shall be located on pipelines so as to render them easily

observable from the nearest available platforms 3.9.10 Piping with operating temperatures above or below the ambient shall be

routed so as to provide adequate flexibility for the pipeline. The CONTRACTOR shall be responsible for the design and provision of suitable expansion loops, guides, restraints and anchors so as to keep the pipe stresses within the limits imposed by the governing codes.

3.9.11 Tap offs on main lines for field routed pipe work, if not indicated on

PURCHASER's layout drawings, shall be suitably located by the CONTRACTOR to suit the layout evolved by him.

3.10 For field run piping, the CONTRACTOR shall plan, locate, design, fabricate

and install all hangers and supports as required with due regard to general arrangement, layout of other pipeline, hangers, cable trays, ducting, structural members, etc., and in consultation with and to the approval of the PURCHASER/ENGINEER.

3.11 The CONTRACTOR shall utilise the PURCHASER's existing structural

members for supporting field run piping after ascertaining that the existing member can safely bear this extra load. Any auxiliary structural steel, if necessary to be provided, shall be designed, fabricated and erected by the CONTRACTOR. Welding to structural members for hangers and supports shall be made only under the supervision of the PURCHASER/ENGINEER and in no case, shall welding be permitted across flanges of main structural members. Unless otherwise specified in Section-C, the supply of the necessary auxiliary steel is also included in the CONTRACTOR's scope.

3.12 Erection of field-run piping shall be started only after completion of erection of

other piping, structures, equipment, etc., in the vicinity, unless otherwise directed by the PURCHASER / ENGINEER.

3.13 The CONTRACTOR shall install all thermowell stubs and all instrument trim

piping and fittings upto the last root valve(s) and reducer(s) including the root valves and reducers as shown on the relevant flow diagrams.


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3.14 When stubs required for vents, drains and instrumentation or welded

attachments required for hangers and supports are not provided on prefabricated piping, the CONTRACTOR shall install these stubs or attachments as per the PURCHASER's piping drawings, flow diagrams or hanger sketches.

3.15 Where the CONTRACTOR's scope ends adjacent to equipment or piping

installed by OTHERS, the final joint shall be the made by the CONTRACTOR. If at his terminal connections or at connections to online specialities, the supply of counter flanges is by OTHERS, the same shall be erected by the CONTRACTOR. Necessary gaskets and fasteners are included in the CONTRACTOR's scope of supply.

3.16 The CONTRACTOR shall also install small accessory piping and any

specialities furnished with equipment such as relief valves, built-in bypasses, etc.

3.17 The CONTRACTOR shall install thermowells supplied by the PURCHASER

prior to hydrotesting of the piping systems. In the event of non-availability of thermowell in time, the CONTRACTOR shall provide necessary plugs to carry out the hydro testing of the piping systems.

3.18 The CONTRACTOR shall cold pull pipes wherever cold cuts are indicated on

the PURCHASER's drawings / documents. The CONTRACTOR shall submit his cold pulling procedure for review and approval by the PURCHASER/ENGINEER, prior to starting of the operation.

3.19 Setting and logging of all spring hangers, supports, restraints, etc., is the

responsibility of the CONTRACTOR. Initial setting of all such supporting systems shall correspond to the cold values indicated on the PURCHASER's drawings. The CONTRACTOR shall check all hangers / support loads after completion of all weld joints in the piping systems and after cold pulling of pipes wherever required. In case of any significant differences between the load readings and the cold loads indicated on the PURCHASER's drawings, the CONTRACTOR shall take necessary steps to adjust the settings in such a manner as to eliminate these differences. He shall however consult the PURCHASER/ENGINEER before adjusting the hanger settings. After satisfactory completion of the settings, all load values shall be properly logged by the CONTRACTOR as per the format to be furnished by the PURCHASER. The CONTRACTOR shall monitor the behavior of the hangers, supports, restraints, snubbers, etc., during initial stages of the plant startup. Upon the unit reaching its rated load and the individual piping systems obtaining their rated temperatures, the CONTRACTOR shall log all the load readings of the hangers, supports, etc., in their hot condition and compare the same with the desired hot settings indicated in the PURCHASER's drawings. In case of any significant differences, the CONTRACTOR shall take necessary steps to minimise/eliminate the differences as directed by the PURCHASER. Final hot load values of the hangers, supports, etc., shall be recorded by the CONTRACTOR as per the


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PURCHASER's format. All logs of hot and cold loads shall be submitted by the CONTRACTOR to the PURCHASER.

3.20 In case of critical piping, in addition to the procedure outlined in clause 3.19,

additional adjustments to settings might be required for certain hangers in order to render the final weld joints at the turbine valve nozzles stress free. CONTRACTOR shall carry out all such adjustments as directed by the PURCHASER as part of his scope of work.

3.21 The CONTRACTOR shall carry out hydrostatic/pneumatic testing of all piping

erected by him. All necessary equipment including temporary pipes, fittings and supporting arrangement for carrying out such tests shall be provided by the CONTRACTOR. The CONTRACTOR shall ensure that the arrangement made by him for hydrostatic/ pneumatic testing will not transfer forces and moments to permanent piping in an unacceptable manner. After the successful completion of hydro tests, the piping shall be drained and thoroughly dried. The CONTRACTOR shall restore the permanent piping to its original condition after the testing is completed.

3.22 The CONTRACTOR shall erect all temporary pipes, fittings, valves and

hangers and supports required for steam blowing of main steam, cold reheat and hot reheat piping in accordance with the PURCHASER's drawings. The PURCHASER / ENGINEER will carry out the steam blowing operations. If severe vibrations are encountered during steam blowing, the CONTRACTOR shall modify the supporting arrangement and provide additional supports, if necessary, to eliminate/minimise vibrations, as directed by the PURCHASER/ENGINEER. In addition to the above, as part of the erection scope of contract, the CONTRACTOR shall supply and install all required temporary pipes, fittings, valves and specialities and hangers and supports for cleaning operations to be carried out by him as described in Clause 5.0. The CONTRACTOR shall ensure that the arrangement made by him will withstand the conditions during cleaning operations and that it will not transfer forces and moments to permanent piping in an unacceptable manner. After completion of cleaning operations, the CONTRACTOR shall dismantle temporary piping and hangers and supports and restore permanent piping to its final position.

3.23 Welding, nondestructive examination of welded joints and repair of weld

defect areas shall conform to TCE specification no. TCE.M4-134-04, `welding specification for power plant piping systems'.

4.0 FABRICATION 4.1 Unless otherwise specified on piping drawings or piping material specification

Data Sheets, all pipeline joints shall be of welded construction. Butt-welded joints shall be used for pipe sizes NB 65 mm and larger and socket welded joints for pipe sizes NB 50 and smaller. The use of companion flanges to connect two pieces of pipe and the use of odd or short pieces of pipe in making up long runs is prohibited except as noted in the PURCHASER's piping drawings.


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4.2 Where welded pipes or pipe fittings are used, longitudinal welds in adjoining sections shall be staggered by a minimum of 90º during erection.

4.3 Neither butt nor branch joints shall be closer than twice the pipe diameter to

any other joint in the same pipe except where `Weldolet' type fittings are used, in which case the branch weld will be made to the `Weldolet'.

4.4 All pipe flanges and contact surfaces shall be concentric with the axis of the

piping. 4.5 All threads on piping components shall be taper pipe threads as per

applicable standards. Threaded connections for insertion type fluid temperature determination and sampling devices shall be seal welded when the service pressure exceeds 103.5 bar (g) or when the temperature exceeds 495o C. The threads shall be entirely covered by the seal weld and such seal welding shall be done by qualified welders only.

4.6 The CONTRACTOR shall machine all welding ends to make sound welds

including those to valves, fittings or equipment. The welding rod used shall be compatible with the parent material.

4.7 When pipe must be threaded before hot bending or heat treatment, all

exposed thread surfaces shall be protected with high temperature silicone paint

4.8 Before commencement of fabrication or erection, the CONTRACTOR shall

ensure that the drawings available with him are the latest issues on date. 4.9 Welding of joints shall be undertaken only after ensuring that the pipeline

alignment is correct and conforms to the construction drawings and after obtaining the PURCHASER's clearance for the same.

4.10 At equipment terminal points, welding shall be carried out after taking into

account specific requirements and/or recommendations of equipment suppliers.

5.0 CLEANING OF PIPING 5.1 All piping including valves and specialities shall be cleaned by the

CONTRACTOR before and during erection to remove grease, dirt, scale and welding slag.

5.2 The CONTRACTOR should carry out the following cleaning operations after

hydrostatic tests:

(a) All piping will be mass flushed, in addition to the specific cleaning operations as described below, as required

(b) Main steam, cold and hot reheat piping and HP & LP bypass piping

shall be steam blown. Necessary target plates, for steam blowing, shall be supplied by the CONTRACTOR.


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(c) Extraction steam, condensate, boiler feed suction and discharge and

heater drains and vents piping shall be alkaline flushed (d) Auxiliary steam piping, steam piping to turbine drives; pressure

reducing stations and other users shall be steam blown. (e) Fuel oil, fuel gas and light oil piping shall be mass flushed. (f) Compressed air piping shall be blown by air at compressor discharge

pressure. (g) Turbine lubricating oil piping shall be pickled and passivated and

flushed with DM water. 6.0 HANGERS AND SUPPORTS 6.1 For field run piping, the CONTRACTOR shall space hangers and supports in

accordance with standard engineering practice as outlined in applicable codes. In selecting the position and type of pipe hangers, the CONTRACTOR shall endeavor to layout the work in such a manner that:

(a) Pipe load stresses imposed on the supporting steel are kept to a

minimum (b) The forces and moments on connecting equipment are kept within

allowable values, and (c) Field work is made simple and inexpensive

6.2 Unless design loads are specified by the PURCHASER / ENGINEER, the

strength of all supporting components shall be based on the weight of the pipe, the weight of medium transported or the medium used for testing, whichever is higher, and the weight of insulation covering.

6.3 If vibration is encountered after a piping system is in operation, appropriate

vibration control equipment shall be installed by the CONTRACTOR at the direction of the PURCHASER /ENGINEER.

7.0 FLOOR COLLARS AND WEATHERHOODS 7.1 At locations where pipes pass through concrete floors or brick or other walls,

suitable carbon steel floor collars or wall boxes will be supplied and installed by the PURCHASER. The CONTRACTOR should indicate requirements. For all bare pipes, which pass through roofs and external walls, a suitable sheet metal hood shall be designed, fabricated, supplied and installed by the CONTRACTOR as a protection against the weather.


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8.0 ERECTION TOOLS AND PERSONNEL 8.1 The CONTRACTOR shall deploy qualified and experienced personnel and

provide all necessary erection tools and tests equipment needed for the complete erection and testing of all piping. Shipment of such tools and equipment shall be made at the CONTRACTOR's expense and liability. The PURCHASER assumes neither responsibility nor liability for tools and equipment care and their storage.

8.2 All site fabrication machinery, erection tools, rigging, scaffolding, bending,

flaring, cutting, welding and stress relieving and all other equipment, thermocouples, asbestos blanket, cables, temperature recorders, X-ray and Gamma ray equipment isotopes radiographic films, penetrameters, magnetic particle test equipment and consumables for checking the M.P testing dyes for D.P. tests, etc., required for complete erection and field testing of all the piping specified, shall be furnished by the CONTRACTOR.

8.3 All transport and material handling equipment shall be provided by the

CONTRACTOR. 8.4 The CONTRACTOR shall furnish all welding electrodes required for the

complete erection of all piping systems including those required for welder and procedure qualification tests.

8.5 As a part of scope of erection contract, the CONTRACTOR shall furnish

gaskets and fasteners (bolts, studs, nuts, washers, etc.) required for all flanged joints. These shall be as per the job specification.

8.6 The CONTRACTOR shall furnish all erection consumables such as oxygen,

acetylene, argon, carbon dioxide and any other gases that may be required, filler rods temperature sensing crayons, chalks, charts for temperature recorders, etc.

8.7 The CONTRACTOR shall furnish all equipment and materials as required for

cleaning, flushing, blowing out and testing of the piping systems. These shall include but not be limited to pumps, blowers and compressors with prime movers, instruments, pipe work with supports, valves, strainers and other specialities, blanks, plugs, spool pieces, dummy plates, electrical accessories, etc. (All to be taken back by the CONTRACTOR after completion of work). Where systems for which alkaline flushing is required, necessary tanks, pumps and chemicals shall be provided by the CONTRACTOR.

8.8 The CONTRACTOR shall provide services of erection superintendent,

managers, engineers, supervisors, foreman, fitters and riggers, welders, transport and crane operators, clerical and administrative staff, skilled and unskilled labour.


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9.0 INSPECTION AND TESTING 9.1 All fabrication/erection work covered by this specification shall be subject to

inspection by the PURCHASER / ENGINEER at no additional cost to the PURCHASER and the CONTRACTOR shall advise the PURCHASER/ ENGINEER promptly at various stages of erection for inspection.

9.2 The PURCHASER/ENGINEER shall have free access to the

CONTRACTOR's /his SUB-CONTRACTOR's works at the site or elsewhere at all times when any fabrication testing work is being carried out and the CONTRACTOR shall provide all necessary facilities/cooperation to the PURCHASER/ ENGINEER in this regard.

9.3 The PURCHASER's representatives shall, at all times, have facility to

witness the CONTRACTOR's operator's qualification tests conducted by the CONTRACTOR. They shall also have access to the CONTRACTOR's heat treatment records and magnetic particle, fluorescent particle or dye penetrant, ultrasonic and radiographic records, reports and repairs, etc.

9.4 Any workmanship by the CONTRACTOR/his SUB-CONTRACTOR inspected

in the field and found not to comply with this specification the same shall be repaired at the CONTRACTOR's expense, if the noncompliance is the fault of the CONTRACTOR.

9.5 Only approved welders shall be permitted to correct any defect with the prior

approval of the CONTRACTOR's welding supervisor. 9.6 On completion of erection, the inside of all pipes, valves, fittings, etc., shall

be clean and free from loose scale and foreign matter before subjecting the line to any test/inspection.

9.7 Prior to erection, the CONTRACTOR shall examine and ensure that all

prefabricated spools and components received by him either from his works or from the PURCHASER conform in respect of overall dimensions to the certified drawings available with him. Necessary steps shall be taken by the CONTRACTOR to rectify any inaccuracies exceeding the limits of manufacturing tolerances on materials supplied by him. No dislocation in the pipe work or cold pull of pipe work arising from improper fitup would be acceptable to the PURCHASER.

9.8 All piping systems shall be tested hydrostatically / pneumatically by the

CONTRACTOR, after erection, at pressures given in the applicable codes listed in Data Sheet A or Section C or as given in the Line Designation Schedule. The test pressures shall be maintained until all welded/flanged joints are inspected for leakage or at least for thirty minutes.

9.9 Wherever possible, underground lines should be tested before backfilling.

Where it is essential to backfill any section of a line before testing, such a section should be subjected to test pressure for a period of at least two hours and checked for pressure drop.


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9.10 Mechanical equipment and pressure relieving devices should be blanked off or removed from the line during pressure testing and control valves should be set in open position for the duration of the test.

9.11 Orifice plates should not be erected untill hydrostatic testing and cleaning

operations are completed. 9.12 Lines having check valves should have the source of test pressure located

on the upstream side. 9.13 Expansion joints, instruments, filters and similar equipment for which the

maximum permissible cold test pressure is lower than the hydrostatic test pressure applied to the system, shall be removed or blanked off from the line before testing. The CONTRACTOR shall consult the PURCHASER/ENGINEER for specific guidance

9.14 Test pressure readings may be taken at the lowest point of the system being

tested provided the effect of static head is taken into account. 9.15 When conditions require a test pressure to be maintained for a period of time

during which the testing medium in the system might be subjected to thermal expansion, provision may be made for the relief of excess pressure.

9.16 After hydrostatic test, leaky joints, if any, shall be cut and repaired or

completely replaced, and test repeated until the test has satisfactorily passed.

9.17 After completion of hydrostatic test, safety valves, orifice plates, etc., withheld

for the hydrostatic tests, shall be installed in an approved manner. Orifice plates shall however be installed after completion of cleaning operations.

9.18 Clean water at a temperature not less than dew point or 10oC which ever is

higher, nor exceeding 50oC shall be used for hydrostatic test. 9.19 The rate of pressure increase must not exceed 7 bars per minute. 9.20 No personnel shall be allowed near piping/equipment under test when the

hoop stress induced by the test pressure is near the yield strength or when test pressures over 35 bar being applied. The pressure should be lowered by 10% before inspecting for the leaks.

9.21 When draining the test liquid, the pipeline vent shall be opened to avoid

vacuum. 9.22 A block valve shall be installed on the pipeline from the test pump to the pipe

line/equipment under test. 9.23 All bolted joints for pipes, valves and fittings which are subject to high

pressure or high temperature conditions are to be tightened up after the initial heating and before any thermal insulation is applied. The CONTRACTOR shall notify the PURCHASER before this operation is carried out.


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10.0 UNDERGROUND PROTECTION Underground protection for buried pipes shall be as per TCE specification

No.TCE.M4-134-102, `underground protection for piping'. The CONTRACTOR shall supply and apply all the necessary materials in this regard. All equipment necessary for application and testing of protection such as kettles, thermometers, recorders, holiday detectors, etc., shall be supplied by the CONTRACTOR.

11.0 INFORMATION TO BE FURNISHED AFTER THE AWARD OF CONTRACT The CONTRACTOR shall furnish all the information as called for in Data

Sheet C.


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DATA SHEET C

INFORMATION TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF CONTRACT

1.0 Prior to erection, the CONTRACTOR shall submit the following:

(a) Erection sequence sufficiently detailed to describe and identify the type of operations, inspection and/or test at each point in the stage of erection to enable the PURCHASER to keep in readiness the corresponding equipment or facilities to perform his duties and to select inspection points for witnessing.

(b) Cold pulling procedures. (c) Welding procedure and performance qualification reports. (d) NDT procedures. (e) Weld repair procedures. (f) Heat treatment and/or stress relieving procedures. (g) Hydrostatic / pneumatic test procedures.

2.0 Site Weld Data:

(a) Identification of the weld procedure specification, procedure qualification record & performance of the welder, preheating, postweld heat treatment data, results of nondestructive examinations along with the name of the INSPECTOR and the date of inspection.

(b) Certification of ASNT-TC-1A qualification. (c) Weld procedure specification & performance qualification records and its

test reports. (d) Weld filler material test reports.

3.0 Hydrostatic or Pneumatic test records hold time and the results of the tests

(after the testing of the piping system is completed). 4.0 Test certificates and reports as required by statutory regulations.


TCE.M4-134-04


WELDING SPECIFICATION FOR

POWER PLANT PIPING SYSTEMS

SHEET 1 OF 15

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TITLE

1.0 SCOPE 1.1 This specification shall apply to all welded pipe joints of carbon and alloy steels

including stainless steels for power plant piping systems. This specification is applicable to shop fabrication, site fabrication and field erection. The welded joints are hereby defined as including:

1.1.1 All the line joints of the longitudinal and circumferential butt welded and socket

welded type. 1.1.2 The attachment of castings, forgings and flanges to pipe. 1.1.3 Welded manifold headers and all other sub-assemblies. 1.1.4 Welded branch connections with or without saddles and reinforcement rings. 1.1.5 Fabrication of built-up fittings. 1.1.6 The attachment of smaller connections for drips, drains instruments, branch

lines, weldolets, sockolets, thermowells, couplings, etc. 1.1.7 Any other similar joints not specified above but encountered during fabrication

and/or erection stage. It is imperative that the CONTRACTOR makes every effort to secure the same high degree of competent supervision and workmanship during field erection as is intended for shop fabrication in view of the adverse field conditions of weather, piping location etc.

1.2 Material specifications generally covered are as follows : 1.2.1 Alloy Steel Piping Ferritic alloy steel pipes to SA 335 grades P11, P12, P22, P-91 or equivalent:

austentic alloy steel pipes to SA 312 Grade TP 304, 316, etc. or equivalent and corresponding materials for fittings, flanges valves etc.

1.2.2 Carbon Steel Piping Carbon steel pipes to SA106 grade A,B,C or SA 53 Grade A,B; SA 672 Gr

B60 C1.12, IS-1239, IS-1978, API-5L grade B, etc. or equivalent and corresponding materials for fittings, flanges, valves, etc.

2.0 CODES AND STANDARDS The welding of fusion welded system shall comply with all currently applicable

statutes, regulations and safety codes in the locality where it will be installed.It shall also conform to the latest applicable standards. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. In particular, the welding and fabrication shall conform to the latest editions of the following codes and standards.

2.1 ASME code for power piping (ASME B31.1)


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2.2 Indian Boiler Regulations (IBR) 2.3 ASME Boiler and Pressure Vessel Codes:

Section II, Part A “Ferrous Material Specifications”

Section II, Part C “Specifications for Welding Rods, Electrodes and Fillter Metals”

Section V “Non Destructive Examination”

Section VIII “Rules for Construction of Pressure Vessels”

Section IX “Welding and Brazing Qualifications”.

2.4 Standards of Pipe Fabrication Institute, USA. 2.5 BS 2633 “Specification for Class 1 Arc Welding of Ferritic Steel Pipe Work for

Carrying Fluids”. 2.6 Any other codes/ standards specified in Section C 2.7 The above mentioned codes and standards form an integral part of this

specification. In the event of conflict between this specification and the codes and standards listed above, the stricter requirement of the two shall govern.

3.0 WELDING PROCESSES 3.1 The welding processes that are used in the fabrication and welding are

restricted to shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW) or a combination of the two.

3.2 GTAW root pass shall be employed for all alloy steel piping and carbon steel

piping. Subsequent welding after root pass can be carried out by SMAW with coated electrodes. Exceptions are as follows :

(a) For pipes of thickness less than 6mm, the entire welding shall be carried

out by GTAW only. When using GTAW welding process, welding without the addition of filler metal shall not be done.

(b) For LP piping systems such as water and air piping systems entire

welding including root pass may be carried out by SMAW. 3.3 Where special welding techniques are recommended by equipment

manufacturer for piping connecting to equipment, appropriate qualification tests and welding techniques shall be followed. The specific and detailed instructions of equipment manufacturer regarding welding, preheating, stress relieving etc. shall be strictly adhered to by the CONTRACTOR at no extra cost to the Purchaser.


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4.0 PROCEDURE AND PERFORMANCE QUALIFICATIONS 4.1 No production welding shall be undertaken until the procedure qualification

tests which are to be used have been established as per ASME Boiler and Pressure Vessel Code- Section IX and/or IBR. Test results and specimens from qualification tests of the welding process and welding operators-shall be made available to the PURCHASER/ ENGINEER, for approval, where results of existing procedure qualifications and of welders, performance tests are acceptable to the PURCHASER/ ENGINEER, such results shall be kept on file and be subject to review regularly. Where doubt exists regarding the acceptability of any qualification test, a retest shall be made. All such qualifications tests and specimen testing shall be conducted in the presence of the PURCHASER/ENGINEER.

4.2 The costs of all procedure qualification and tests shall be borne by the

CONTRACTOR. 4.3 The CONTRACTOR shall prepare a written specification containing the

information detailed in section IX of ASME Boiler and Pressure Vessel Code. Form QW-482, - “Welding Procedure Specification” (WPS) and the qualification test data and other information detailed in Form QW-483.- “Procedure Qualification Record” (PQR). These documents shall be provided to the PURCHASER/ENGINEER for review and approval. The CONTRACTOR shall prepare certificate of Welder/Welding operator Performance Qualification Test (WPQ) containing the information detailed in Form QW-484 : “Manufacturer’s Record of Welding or Welding Operator Qualification Test” of ASME Section IX . These shall be kept on field and made available to the PURCHASER/ ENGINEER upon request.

5.0 WELDERS AND SUPERVISORS 5.1 Unless otherwise agreed, the CONTRACTOR shall advise the

PURCHASER/ENGINEER, in writing at least three (3) weeks before any welder is employed on the work, the names and qualifications of the proposed welders and welding supervisors. It shall be the CONTRACTOR’s responsibility to ensure that all welders employed by him or his SUB-CONTRACTORS on any part of the Contract either in the CONTRACTOR’S /his SUB-CONTRACTOR’s works or at site are fully qualified as required by the code. Each welder shall qualify for all types of welds and materials he may be called upon to weld.

5.2 Should the PURCHASER/ENGINEER require test or retest of any welder,

the CONTRACTOR shall arrange for the same at no extra cost to The PURCHASER/ENGINEER.

5.3 Welding supervisors shall have qualifications such as Engineering

Degree/Diploma in welding technology with adequate knowledge of non-destructive testing and a minimum of 5 years experience in supervising welding of pipe joints.


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5.4 All welding including tack welding shall be carried out by approved welders only. Any weld made by other than an approved welder shall be cut out and rewelded.

5.5 For purposes of identification and to enable tracing full history of each

joint, each welder employed on the work shall be given a designation. The welder’s designation and the date on which the joint was made shall be stamped on the relevant piping and marked on the relevant drawings also. Copies of the drawings so marked shall be furnished to the PURCHASER/ENGINEER for record purposes. Alternatively, record charts may be used.

5.6 For each welder, a record shall be maintained showing the procedures for

which he is qualified. The details of production welds, the date of welding the type of defects occurred and their frequency. The record shall be available for review by the PURCHASER/ENGINEER and those welders whose work required a disproportionate amount of repair shall be disqualified from welding. Requalification of welders disqualified shall be entirely at the discretion of the PURCHASER/ENGINEER.

6.0 PREPARATION OF WELD ENDS 6.1 Surfaces to be welded shall be smooth, uniform and free from fins, tears

and other defects which would adversely affect the quality of the weld. All welding faces and adjoining surfaces, for a distance of atleast 150 mm from the edge of the welding groove or 12mm from the toe of the fillet in the case of socket welded or fillet welded joints shall be thoroughly cleaned of rust, scale, paint, oil or grease both inside and outside prior to welding.

6.2 Unless otherwise specified, joints for pipes 50mm NB and smaller, shall be

socket welding type and for pipes 65mm NB and larger, shall be of the butt-welding type. All butt welds shall be full penetration welds.

6.3 BUTT JOINTS 6.3.1 Butt joints shall be prepared as per ASME B 16.25 and/or IBR unless

otherwise specified. 6.3.2 While meeting the alignment requirements of piping joints as per Cl.

127.3.1 C of ASME B31.1, care shall be exercised that the trimming depth in case of excess mis-alignment does not interfere with Radiography/Ultrasonic Test (RT/UT) interpretations. In such cases the trimming width from the tip of the edge preparation along the pipe shall be large enough that it is well away from the weld face.

6.3.3 Unless noted otherwise, all butt welds shall be made without using backing

rings. 6.4 T, CORNER AND LAP JOINTS These shall be prepared as follows :


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a) Fillet welds shall have a throat dimension equal to the nominal

thickness of either of the joint members.

b) Weld edges of full penetration groove welds for T joints shall be prepared with a minimum included angle of 45 deg.

6.5 The ends shall be prepared by machining , grinding or flame cutting. Where

flame cutting is used, the effect on the mechanical and metallurgical properties of the base metal shall be taken into consideration. Flame cutting of alloy steel pipes is not allowed. However, flame cutting of carbon steel pipes is permitted. Wherever practicable, flame cutting shall be carried out by machine. Machine flame cut edges shall be substantially as smooth and regular as those produced by edge planing and shall be cleaned free of slag. Manual flame cutting shall be permitted only where machine flame cutting is not practicable and with the approval of the PURCHASER/ENGINEER, and such surfaces shall be ground or dressed to a smooth finish as required by the specification and to the satisfaction of the PURCHASER/ENGINEER. Slag, scale or oxides shall be removed by grinding to bright metal atleast 2mm beyond the burnt area.

6.6 Thermal cutting of carbon steel piping shall be performed under the same

conditions of preheat and post heat as for the welding of carbon steel material. However, post weld heat treatment is not required when :

a) The heat affected zone produced by thermal cutting is removed by

mechanical means immediately after cutting However, in any case, all remaining slag scale or oxides shall be removed by grinding to bright metal at least 2mm beyond the burnt area, or

b) Thermal cutting is part of fabrication, manufacturing or erection sequence leading to a weld end preparation where welding immediately follows.

6.7 For the piping systems that are supplied by the PURCHASER/ ENGINEER

but being erected by the CONTRACTOR, bevelling of pipes for butt welds shall be carried out as indicated on the respective piping fabrication drawings, where required. For systems which the CONTRACTOR supplies and erects, the pipe ends shall be bevelled to conform to applicable codes/standards. At connections to equipment, the bevelling of piping shall conform to the requirements of the equipment connections.

6.8 Any change in the joint configuration shall be done after the approval from

the PURCHASER/ENGINEER. 6.9 All weld joint fit-up shall comply with the tolerances specified on the design

drawings or applicable codes and standards. 6.10 If the CONTRACTOR uses a header arrangement with central location of

oxygen and acetylene for cutting and edge preparation operations, the arrangement shall be in accordance with best safety practices and standards and shall be approved by the PURCHASER/ENGINEER.


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6.11 Before fitting up the weld joint, the profile and dimensions of the weld end

preparation shall be checked by the PURCHASER/ENGI-NEER. If the specified tolerances are exceeded, this shall be corrected (with prior approval) by grinding, machining or any other method acceptable to the PURCHASER/ ENGINEER.

6.12 All fit-ups shall be examined by the PURCHASER/ENGINEER prior to

welding the root pass. 7.0 WELDING OF PIPES 7.1 All vertical welding shall be carried out in the uphill direction unless

otherwise approved by the PURCHASER/ ENGINEER. 7.2 No single run in SMAW shall exceed 8 mm in size. 7.3 Each leg of the fillet weld shall have a length of atleast 1.25 times the

nominal wall thickness of the pipe. Socket and fillet welds shall have a minimum of two weld layers.

7.4 All tack welds shall be made using a qualified procedure and qualified

welders. Any preheat requirements specified on the welding procedure shall also apply to tack welds.

7.5 All tack welds shall be examined visually for defects, and if found

defective shall be completely removed. 7.6 As the welding proceeds, tack welds shall be either removed completely or

shall be properly prepared by grinding or filling their stopping and starting ends so that they may be satisfactorily incorporated in the final weld.

7.7 The maximum weaving of any SMAW or GTAW run shall be of 3 times the

electrode dia. 7.8 Welded-on branches for all piping systems shall be full penetration type

connection. 7.9 Preheating prior to tack welding and welding as called for in clause 8.0

shall be employed as a means of crack prevention and improving general weld reliability. At no time during welding shall the temperature of the joint be allowed to fall below the minimum preheat temperature. Excessive preheating shall be avoided.

7.10 Irrespective of the class of steel, root runs shall be made without

interruption except for changing the electrodes or to allow the welder to reposition himself. Root runs made in the shop may afterwards be allowed to cool by taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry asbestos blanket. Welds made at site shall not be allowed to cool until the thickness of weld metal deposited exceeds one third of the final weld thickness or 10 mm, whichever is greater.


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7.11 When welding alloy steels, it is strongly recommended that interruption of

welding shall be avoided. Where such interruption is unavoidable, either the preheat shall be maintained during interruption or the joint shall be wrapped in dry asbestos blankets to ensure slow cooling . Before recommencing welding preheat shall be applied again.

7.12 No welding shall be done if there is impingement of rain, snow, sleet or

high wind on the weld area. 7.13 Welded-on bridge pieces and temporary attachments should prefer-ably be

avoided. Where approved by the PURCHASER/ ENGINEER. they may be used .Material of these shall be compatible with parent material. All these pieces shall be removed carefully without damaging the parent material after welding of pipe joints and the weld area ground flush and subjected to magnetic particle examination before applying any postweld heat treatment, which shall embrace the area occupied by the bridge pieces also. These pieces shall be welded by qualified welders and with electrodes compatible with the parent material. The preheating requirements shall be applied and maintained during the welding of pieces.

7.14 The arc shall be struck only on those parts of parent metal where weld

metal is to be deposited. In the event of any inadvertent arc strikes the defects shall be removed by grinding and the area examined by liquid penetration or magnetic particle testing method.

7.15 (a) Oxides shall not be permitted to form during welding or heat

treatment or both, on the internal surfaces of pipes which will not be subsequently cleaned. Inert gas purging will be an acceptable method to prevent such oxidation. All joints in materials which contain greater or equal to 5% chromium shall be purged to assure that less than 1% of oxygen is present on the joint underside before initiation of the welding. The purging operation shall be maintained for two passes. Refer Cl. 7.15 (b) for flow rate during purging .The CONTRACTOR may submit examples of any other procedures for consideration of the PURCHASER/ENGINEER.

(b) Argon gas used in GTAW process for shielding and purging shall be

of minimum 99.95%. purity. Purging shall be carried out at a flow rate depending on diameter of pipe until 6 times the volume between dams is displaced. In no case shall the initial purging period be less than 10 minutes. After initial purging, the flow of the backing gas shall be reduced to a point where only a slight positive pressure prevails. Any dams used in purging shall be fully identified and removed after welding and accounted for in order to avoid leaving them in the system.

7.16 Thorough check shall be exercised to ensure that the required inter pass

temperature is maintained. 7.17 All equipment necessary to carry out the welding for supporting of the work,

for the preheating and post weld heating including thermal insulation for


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retaining the heat and for the protection of the welder shall be provided by the CONTRACTOR.

7.18 After deposition, each layer of weld metal shall be cleaned with a wire

brush to remove all slag, scale and defects, to prepare for the proper deposition of the next layer. The material of the wire brush shall be compatible with pipe material. Special care shall be taken to secure complete and thorough penetration of the fusion zone into the bottom of the weld. It is recommended that the root run be checked by liquid penetrant or magnetic particle procedures.

7.19 The cleaning of the root from the second side of butt welds is to be carried out

wherever feasible by gouging, grinding, chipping, machining or other approved methods. The gouged surface must be cleaned to remove any carbon or oxidised metal before commencing the welding. The welding grove shall be examined by dye penetrant or magnetic particle method to ensure that the root is free from defects.

7.20 Repair of weld metal defects shall meet CL 127 .4.11 of ASME B31.1. 7.21 Upon completion of welding , the joints shall be wrapped in dry asbestos

blankets to ensure slow cooling, unless post-weld heat treatment is applied immediately.

7.22 No welding or welded parts shall be painted, plated, galvanised or heat

treated until inspected and approved by the PURCHASER/ ENGINEER. Welds shall be prepared/ground in such a way that weld surfaces merge smoothly into the base metal surface.

7.23 Except where necessary to grind flush for non-destructive examination

purpose, the centre of reinforcement for butt welds shall be as indicated below:

Component Thickness (mm) Max Reinforcement (mm) Upto 12 1.6 Over 12 to 25 2.4 Over 25 to 50 3.2 Over 50 4.0 The reinforcement shall be crowned at the centre and tapered on each side

of the joined members. The exposed surface of the weld shall be ground where required to present a workman like appearance and shall be free from depressions below the surface of the joined members. The exposed surface of the butt welds shall be free from undercuts greater than 0.8 mm in depth, overlaps or abrupt ridges or valleys and shall merge smoothly into the pipe surface at the weld toe. However, undercuts shall not encroach on the minimum section thickness.

7.24 Any weld repair shall be subject to the approval of the

PURCHASER/ENGINEER.


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7.25 The same area on the weld shall not be repaired more than twice. The joint shall be remade in case of more than 2 repairs.

7.26 Postweld heat treatment shall be carried out as per Cl. 132 of ASME B31.1. 7.27 IDENTIFICATION OF WELDS Wherever code symbol stamps are required on carbon steel and ferritic

alloy steel piping they shall be applied directly to the pipe with low stress dotted design metal die stamps or to a small stainless steel plate especially provided for such marks. These plates shall be lightly tack welded to the pipe using electrodes (of diameter 3 mm or less ) of the type specified for the material. Before making the required tack weld, the pipe material in the immediate surrounding area shall be preheated, as required, by electric means or propane or natural gas burners. Cooling shall take place under asbestos insulation in a draft free area. Stress relieving of these welds is not required. Steel stamping directly on the surface of alloy steel piping with other than low stress die stamps shall not be permitted. Use of oxy acetylene gas for pre-heating is not allowed.

7.28 SEAL WELDS 7.28.1 Seal welding shall be done by qualified welders and in accordance with

approved drawings 7.28.2 Threaded joints that are to be seal welded shall be made without the use

of thread lubricating compound. 8.0 PREHEATING Preheating prior to cutting, tack welding and welding shall be employed as

a means of crack prevention and improving general weld reliability. The general requirements listed in para 9.0 '‘Stress Relieving’ shall be applied for preheating. Preheating when performed shall be in accordance with Cl. 131 of ASME B31.1 Preheating requirement for thermal cutting shall be the same as applicable to welding.

8.1 CARBON STEEL /ALLOY STEEL 8.1.1 At no time during the welding operation shall the temperature of the weld

area be allowed to fall below the specified temperatures. Before performing any tack welding which may be required in preparing alloy/carbon steel pipe for welding or other fabrication, or before attaching thermocouples, the pipe area to which the tack weld is to be made shall be evenly heated to these temperatures preferably by resistance heating or induction coils. Propane or natural gas torches or preferably burner rings shall be employed where it is impossible to use electric heating. The use of oxy-acetylene is prohibited. The metal temperatures in this procedure shall be determined by the use of thermocouples and potentiometers except that temperature sensitive crayons may be used as temperature indicators in tack welding thermocouples.


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8.1.2 Welded joints for piping NB 100mm and larger shall be heated by means

of induction coil or resistance heating . Welded joints in smaller pipe shall be heated by means of electrical resistance coils or suitable propane or natural gas torches.

8.2 AUSTENITIC STAINLESS STEEL Welded joints in austenitic stainless steel piping need not be preheated

except where the ambient temperature is below 0oC. For this condition , the joint shall be heated to 40oC by propane, natural gas or electrical means before any welding is performed.

9.0 POSTWELD HEAT TREATMENT

Postweld heat treatment of piping welds is required when so specified in code clause 132 of ASME B31.1 and shall be performed as described below. However for carbon limitation on carbon steel material of all piping refer Cl. 9.2.1.

9.1 GENERAL REQUIREMENTS 9.1.1 A complete automatic temperature recording shall be used during

preheating and stress relieving operations. Where propane gas burners or electrical resistance coils are employed, a complete temperature record of the preheating and stress relieving operation shall be made by means of a box type potentiometer. Other means of recording temperatures are permissible subject to the PURCHASER/ENGINEER’S approval.

9.1.2 Stress relief may be local or full furnace. Local stress relief shall be

performed with electric induction or electric resistance coils. Suitable gas burning equipment using natural gas or propane may be employed.

9.1.3 During stress relieving / preheating cycle, no water or liquid cooling medium

shall be employed. 9.1.4 Where members being joined are unequal in thickness, the dimension of

the heavier section shall govern the selection of width of the heated band and the duration of the holding period.

9.1.5 When local stress relief is performed, the area of the welded joint and the

adjacent material to be postweld heat treated, shall be as called for in para 132.7 of ASME B31.1

9.1.6 For local stress relief using electrical methods, a minimum of two

thermocouples tack-welded to the surface and potentiometers, shall be used on the pipe under at least 4 layers of asbestos paper. The hot junctions of the thermocouples shall be located on either side of the joint atleast 12mm from the edge of the joint, but no farther away than 100mm. When employing induction heating , at least six turns of induction cable shall be wrapped on top of the asbestos paper protecting the


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thermocouples with the first turn approximately 150mm from the centre of the weld.

9.1.7 Local stress relief using natural gas torches or ring burners may be

employed. However, the procedure shall be limited to pipes below 100mm NB and must be approved by the PURCHASER/ENGINEER.

9.1.8 The stress relieving temperature shall be maintained for a period of time

proportioned on the basis of one hour per 25 mm of wall thickness of the thickest section at the joint, but in no case less than one hour.

9.1.9 For tubing joints and socket welded joints, pads, bosses and couplings,

one thermocouple shall be positioned at a minimum distance of two pipe wall thickness from the weld.

9.1.10 For welds used for attachment of base brackets, two thermocouples shall

be used for determinations of preheating and stress relieving temperatures. They shall be tack welded directly to the header and located 180 deg apart on the circumference of the header and midway between adjacent legs.

9.1.11 Piping on both sides of any joint shall be adequately supported throughout

the preheating, welding and stress relieving operations to prevent distortion. When a butt welded joint is to be post-weld heat treated and the piping is cold sprung, the forces required to position the pipes shall be maintained by external means until the completion of the heat treatment procedure.

9.1.12 All heating and cooling must be performed in still air 9.2 CARBON STEEL 9.2.1 Welded joints of carbon steel piping where the nominal pipe wall

thickness of the heaviest material being joined is greater than 19mm or the carbon content more than 0.25% for piping system under IBR and 0.3% for non-IBR piping systems shall be stress relieved upon completion of welding operation.

9.2.2 When the height of a boss above the OD of the pipe is 19 mm or greater

the weld shall be stress relieved 9.2.3 When the wall thickness of a coupling or a pad is greater than 19 mm the

weld shall be stress relieved 9.2.4 When local stress relief is employed, the welded joint shall be heated to a

temperature of not less than 600oC. This temperature level shall be maintained within the limits of 600 oC to 650 oC for one hour per 25mm of wall thickness, but in no case less than 1 hour. The weld area shall then be allowed to cool undisturbed in still air to a temperature not exceeding 315

oC.


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All welded joints which are locally stress relieved in pipes 100mm NB and larger shall be heated by means of electric induction coils or resistance heating. Welded joints in pipes smaller than 100mm NB shall be stress relieved by means electric resistance coils or suitable propane or natural gas torches only.

9.2.5 Heating and Cooling Carbon steels after having reached their specific stress relief temperatures,

may be cooled in the furnace or under wraps i.e leaving the induction coils or resistance heaters and insulation in place. This means that at the stress relief temperatures, the power to the furnace or heating coils may be shut off and cooling is allowed to take place in the furnace or with all insulation and coils remaining on the pipe. For furnace stress relief, the doors of the furnace may be opened after the power is shut off, at 315 deg C The thermocouples controlling the temperatures shall remain during the cooling cycle so that excessive cooling, if it occurs, can be observed and immediately corrected. The rate of heating and cooling shall conform to Cl.132.5 of ASME/B31.1. The stress relieving coils and insulation shall be removed only after the piping has cooled to below 315 deg C, or if stress relieved in a furnace, the pipe may be removed from the furnace and permitted to cool in still air, when this pipe has cooled below 315 oC.

9.3 ALLOY STEEL 9.3.1 All welds in alloy steel piping shall be stress relieved after the welding

operation in accordance with C1.132 of ASME B31.1. Immediately after welding the material shall be wrapped in asbestos and allowed to cool.

9.3.2 Local Stress Relief All welded joints in pipes 100 mm NB size and larger shall be locally stress

relieved by means of electric induction coils or resistance heating. Welded joints in smaller pipe sizes shall be stress relieved by means of electric resistance coils or propane or natural gas torches only.

9.3.3 For full furnace stress relief of a welded assembly the entire fabricated

section shall be heated uniformly to the temperature specified. The temperature shall be maintained for a period of time proportioned on the basis of one hour per 25 mm wall thickness of the piece having the greatest wall thickness in the furnace charge, but in no case less than one hour.

9.3.4 Heating and Cooling The rate of heating and cooling shall conform to CI. 132.5 ASME of B31.1 9.4 AUSTENITIC STAINLESS STEEL Joints in austenitic stainless steel piping need not be stress relieved after

welding.


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10.0 ELECTRODES 10.1 (a) The specification and size of the electrodes, voltages and

amperages, thickness of beads and number of passes shall be as specified in the approved welding procedure or otherwise agreed in writing Only basic coated electrodes shall be used, which will deposit weld metal having the same or higher physical properties and similar chemical composition to the members being joined. For each batch of approved brand, certificate showing compliance with the specification shall be secured and shall be submitted to PURCHASER/ENGINEER for review before being released for use on project piping. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. All low hydrogen electrodes shall be baked at 350 deg. C for 1 hour and stored in ovens kept at 80-100 deg C before being used. Recommendations of the electrode manufacturer shall be followed.

(b) For welding of all grades of steel and alloys by the GTAW process, a

2% thoriated tungsten electrode conforming to SFA-5 .12 EWTH-2 (AWS-A5.12, EWTH-2 ) classification shall be used.

10.2 CARBON & ALLOY STEEL All electrodes to be used on alloy and carbon steel shall conform to ASME

Boiler and Pressure Vessel Code Sec 2 Part C or any other equivalent code.

10.3 As welding electrodes deteriorate under adverse conditions of storage

leading to dampness in the electrode coating, they should normally be stored in air conditioned rooms or in hot boxes or ovens in their original sealed containers whose temperatures shall be maintained within specific limits. The condition of electrodes shall be frequently inspected. Electrodes with damage to coating shall not be used. Electrodes shall remain identified until consumed.

10.4 The type of electrodes used should be only those recommended by the

manufacturer for the use in the position in which the welds are to be made. Electrodes which have the areas of flux covering broken away or damaged shall not be used.

11.0 INSPECTION AND TESTING 11.1 The PURCHASER/ENGINEER shall have accessibility to inspect the

welding or any other related operations at any time and at any stage of fabrication.

11.2 The PURCHASER/ENGINEER may require non-destructive testing of any

weld for reasons other than those given in the specification. The responsibility for the cost of such testing shall be mutually decided between the PURCHASER/ENGINEER and the CONTRACTOR.


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11.3 The CONTRACTOR shall inform the PURCHASER/ENGINEER when the

weld preparation and setting up for welding of various members selected by the PURCHASER/ENGINEER is in progress so that the PURCHASER/ENGINEER can inspect the assembly before welding starts.

11.4 The responsibilities of the PURCHASER/ENGINEER’s representative shall

in no way reduce the CONTRACTOR’s responsibilities to ensure that the work is carried out in accordance with the specification.

11.5 Non-Destructive Test (NDT) shall be carried out at appropriate time as

below. Radiographic Testing (RT) on welds shall be carried out after final heat treatment except for welds on PI Group material for which (Refer ASME Sec. IX ) RT can be performed either before or after final heat treatment.

11.6 All requirements specified in TCE.M4-185-28 and TCE.M4-185-38 shall be

strictly followed. 11.7 EXAMINATION METHODS OF WELDS 11.7.1 Non destructive examinations of welds shall be carried out in accordance

with TCE. M4-185-28 and TCE.M4-185-38. 11.7.2 Penalty Clause Where radiography specified is less than 100%, the penalty shall be as

follows:

(a) For every weld found defective two additional penalty joints on either side of the joint shall be marked for RT.

(b) If any of the penalty joints is found defective, entire weld joints represented

by the defective joint shall be radiographed.

(c) If the penalty joints referred under point (a) above are found acceptable, the original defective weld shall be repaired to the required standard and re-radiographed.

11.7.3 In addition, at the discretion of the PURCHASER/ENGINEER and the

INSPECTORS, and where requested by them, the CONTRACTOR shall perform radiography and other tests of the joints of any other piping. Refer 11.2 on cost of such testing.

11.7.4 (a) Where access holes for radiography have been provided in the piping,

the CONTRACTOR shall employ single wall thickness radiography. The access holes shall be plugged and seal welded only after the radiograph is found acceptable


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(b) Where no access holes for radiography are provided in the piping, the CONTRACTOR shall employ double wall radiography, with elliptical projection technique.

(c) The CONTRACTOR shall ensure that isotopes of sufficient strength and

quality are used in order that the radiographs taken are of proper density, contrast and visibility.

(d) Access hole plug welding shall be examined by magnetic particle or

liquid penetrant methods. 12.0 QUALIFICATIONS AND CERTIFICATION OF NON- DESTRUCTIVE

EXAMINATION PERSONNEL Organisations performing code required, non-destructive examinations shall

use personnel competent and knowledgeable to the degree specified by ASME.

13.0 ACCEPTANCE STANDARDS The acceptance standards for radiographic, ultrasonic, magnetic particle,

liquid penetrant and visual examinations etc. shall conform to ASME B31.1. 14.0 REPAIR WELDING 14.1 All defects in welds requiring repair shall be removed by flame or arc

gouging, grinding, chipping or machining. The major repairs may involve.

(a) Cutting through the weld

(b) Cutting out a length of pipe containing the weld, or (c) Removing the weld metal down to the root depending upon the

magnitude of the defects. 14.2 After removing the defect, the welds shall be examined by the same non-

destructive testing methods as specified for the original weld and the same acceptance criteria shall hold good.

14.3 All the repair welds shall be made using same or other specified welding

procedures as those used in making the original welds including preheating and stress relieving as originally required.

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