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ICHAKLKARANJI POWERLOOM MEGA CLUSTER LTD

PIPING

I. Material selection

Sr. No.

Service Pipe Material

1. Steam piping of Metal temperatures ≥ 510˚C

21/4% chromium, 1%molybdenum ferritic alloy steel seamless pipe (ASTM A-335 P-22)

2. Steam piping of Metal temperatures ≥ 400 & < 510˚C

11/4% Chromium, ½% 1%molybdenum ferritic alloy steel seamless pipe (ASTM P11/P22)

3. Steam piping of Metal temperatures < 400˚C

ASTM A -106 Grade B

4. For large diameter thin wall thickness pipes

Electric fusion welded pipes to ASTM specification A 672 and ASTM A 691

5. HP and LP dosing system and DM water system

Stainless steel

6. Circulating water, auxiliary cooling water, raw water, service water and portable water piping.

IS 1239 Part-I Heavy Class ≤ 150 NB IS 3589 > 150 NB

7. Service & Instrument air applications

IS 1239 Part -I GI pipes of heavy grade

8. Other piping ASTM A-106 Grade B or ASTM A-53 Grade B Seamless pipe.

II. Velocity considered

Nominal Pipe size in mm

Average velocity in Meter / Second

Below 50 mm 50 to 150 mm 200 mm & above

Saturated steam at sub-atmospheric Pressure

- 10-15 15-20 Saturated steam at 0-1 kg/sq. cm(g) 15-20 17-30 20-23 Saturated steam at 1-1 -7 kg/sq. cm (g)

15-22 20-33 25-43 Saturated steam over 7 kg/sq. cm (g) 15-25 20-35 30-50 Superheated steam at 0-7 kg/sq. cm(g)

20-30 25-40 30-50 Superheated steam at 7.1 – 35 kg/sq. cm (g)

20-33 28-43 35-55 Superheated steam at 35.1-70 kg/sq. cm(g)

22-33 30-50 40-61 Superheated steam at 70 kg/sq. cm(g)

22-35 35-61 5.-76 Compressed air 7-10 10-15 18 Pump suction, condensate 04.06 0.6-0.7 Pump suction, boiler feed 06.09 0.6-0.9 Pump suction, general service 0.6-0.9 0.7-1.3 0.9-1.5 Pump suction, viscous liquid 0.3 0.3-0.4 0.4-0.5 Pump discharge, condensate 0.9-1.2 1.2-2.1 1.5-2.2 Pump discharge, boiler feed 1.0-1.2 1.5-2.1 1.8-2.4 Pump discharge, general service 0.9-1.0 1.52.4 1.5-2.4 Pump discharge, viscous liquid 1.0 1.0 1.2-1.4 Header, general service under 2.0 kg/sq.cm (g)

1.3-2.0 1.8-2.4 Header, general service 2.0 kg/sq. cm (g) & up

1.5-2.4 2.1-2.4


…2…

- 2 - Civil & Structure

The contour survey (separately available) of the earmarked land for the proposed power

plant Project and the soil investigation report from the textile plant thereof, will form the

basis of designing of civil work & structural. The major items of civil works will include

foundations for boiler and auxiliary equipment, turbine / generator and auxiliary

equipment, fuel / ash handling and auxiliary equipment, substation equipment, water

treatment plant equipment, etc. Apart from foundations, TG building, WTP building &

laboratory, security and administration offices, colony form other major items of civil

work. Cable trenches, pipe structural and supports, internal roads, storm drains and

culverts, etc. will also form the part of civil works. The reinforced concrete structures

shall be designed in accordance with the latest version of IS 456, „Code of practice for

plain and reinforced concrete‟. The structural steel design shall be as per IS 800. The

design wind speed and seismicity shall be in accordance with IS 875 and IS 1893

respectively. The structures shall be designed to withstand the calculated Dead loads,

Live loads, along with the wind and seismic loads in appropriate combinations

recommended by the Codes. The minimum dead and live loads for the design of the

platforms and walkways shall be 500 kg/sq.m as per IS 800. Structural steel shapes,

plates and other structural materials shall conform to IS 800, with minimum yield

strength of 25 kg/sq. mm. The connection bolts shall conform to IS 1367. Welding

electrodes shall be as per AWS. HYSD reinforcement steel bars shall conform to

IS:1786. All structural steel (IS:2062) and MS members will be painted with two coats of

red oxide zinc chromate paint and two coats of synthetic enamel paint. All foundations

shall be of the spread footing or mat type. Soil bearing capacity shall be identified as per

the soil investigation report. The soil bearing capacity shall be verified again by soil

investigation before final design. The proposed site is relatively flat, requiring minimal

grading and leveling (leveling & grading up to 0.5 m). No major grading / leveling work is

envisaged. All excavation work shall be done by conventional manual methods or by

mechanical equipment method (wherever required). For substructures and

superstructures Ordinary Portland Cement (grade 43) will be used. Grade of Concrete

for steam turbo-generator foundations and chimney shall be M-25 and all other

foundations / pedestals / buildings etc. shall be of M-20.


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VENDORS FOR MAJOR EQUIPMENT :

Sr. No.

Particulars Details

1 Turbine

1 Turbine Siemens / Triveni / Man

2 Gear Box Triveni

3 Alternator TDPS / BHEL

4 Main & Aux. oil Pump Tushaco / Rotodel

5 Lubrication & control oil system Enpro Industries Pvt. Ltd.

6 Governing system 505E woodward

7 Vibration analysis system Bently nevada

8 Air cooled condenser Paharpur

9 ACC cleaning system JNW Cleaning Solutions

10 Condensate extraction pumps KSB Pumps Ltd

11 Oil centrifuge machine Alfa lawal

12 All IBR Isolation Valves KSB Valves Ltd.

13 Safety Valves Tyco Sanmar

14 Steam Trap Pennant

15 EOT Crane Extract

2 Boiler

1 Boiler Thermax / Isgec

2 Boiler Feed Water Pumps / Transfer Pump

KSB Pumps ltd / Grundfos

3 Dosing Pumps Positive meter Pumps / Milton Roy

4 Draft Fans Batliboi Environmental Engineering Ltd / Flaktwoods

5 ESP BHEL / Thermax

6 Safety Valves Tyco sanmar

7 Control Valves MIL / Forbes Marshal

8 IBR valves KSB Valves

9 Non IBR Valves Kirloskar

10 Butter fly valves Delval / Aira / Crane

11 Ash handling system Mecgale

12 Ash Handling Compressor Atlas Copco

3 ESP Components

1. Transformer Rectifiers Kraft powercon make

2 Cables CCI / Finolex.

3 Switch-gear components inside MCC

SIEMENS

4 Insulator Heaters VISHWESH

5 Insulators IEC / Power Mat.

6 Thermal Insulation GOENKA / APPROVED VENDOR

7 PLC for rapper Controller / Ash handling system.

Siemens

8 Level Switch EIP

9 Thermostat SWITZER


10 MCC UESL APPROVED VENDOR

11 TR sets controller Kraft powercon make

12 PA Fan Motor CGL / SIEMENS

…4… - 4 -

Sr. No.

Particulars Details

13 Auxiliary Control Panel vendor Approved vendor

14 Rapper control panel Auto data

4 Fuel handling System

1 Conveyer belt NRC / Hindustan / MRF / Phoenix

2 Gear box Bonfiglioli Transmission Pvt. Ltd. / Top Gear

3 Crusher Sayaji Engineering ltd

4 Vibro Feeder & Vibro-Screen International Combustion (India) Lt

5 Online Coal Weighing machine IPA prt. Ltd. banglore

5 WTP

1 DM Plant Thermax / Ion Exchange

2 UF / RO Membrane Filmtech

3 Chemical Dosing pumps Milton Roy only

4 Transfer Pump KSB Pumps Ltd / Kirloskar


CODES AND STANDARDS 1] Codes and Standards for Boiler

The design, manufacture, testing and performance of the Boiler and Accessories shall comply with the requirements of applicable Indian/British/American / DIN Standards, such as the following, and those standards, specified therein , in so far as they apply.

a. Indian Boiler Regulations (IBR)

b. IIS 800 - Code of practice for Constructions in steel

c. IS 875 - Code of practice for design loads for buildings structures.

d. IS 1893 - Criteria for Earthquake Resistant – Design of Structures.

e. IS 2825 - Code for unfired pressure vessels

f. ASME Section I - Rules for construction of power boilers

g. ASME Section IX - Welding and Brazing Qualifications

h. ASME PTC 4 - Steam Generating Units

i. ASME PTC 4.3 - Air Heaters

j. ASME PTC 19.11 - Water and Steam in the Power Cycle (Purity and Quality, Leak detection and Measurement).

k ASME 25.3 - Safety and Relief Valves

l ASME B 31.1 - Code for Power piping

2] Codes and Standards for Structural Works.

The following Indian Codes and Standards shall be generally used for design of tructural works. In all cases, the latest revisions with amendments/corrigenda, if any, at the time of execution shall be followed. For work not covered by Indian Standards, other International Standards, as applicable shall be followed.

a. General

IS 875 Code of practice for design loads building and structures, IS 1893 Criteria for earthquake resistant design of structures.

b. Steel Structure

IS 800 Code of practice for use of structural steel in general building construction.

IS 806 Code of practice for use of steel tubes in general building construction.

BS 4592 Industrial type metal floors, walkways an stair trades

BS 5395 Stairs, ladders and walkways

3] Codes and Standards for Turbo generator


a. All equipment, Systems, hardware, 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. The equipment and systems, if required by virtue of their country of origin, shall also conform to the latest applicable INDIAN / BRITISH / AMERICAN / GERMAN / FRENCH / CSN standards, The following specific standards are applicable for the major equipment and system in the turbine package.

…2…

- 2 -

Turbine :

EC Recommendation Publication No : 45

CSN 080030

DIN1943

Condenser :

H.E.I. standards for steam surface Condensers

TEM

ASME : Section VIII piping :

ASME B31.1

Any other established national and international standards equal to or superior to the above may also be used.

b. The EPC contractor shall furnish English translation of all standards for which his equipment and systems offered are conforming to.

c. In the event of any conflict between the codes and standards, referred to, and the requirements to these specifications, the more stringent of the two shall govern.

4] Codes and Standards for Piping and its Accessories

a. The welding of fusion welded piping system shall comply with currently applicable regulations, codes 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 constructed to relieve the EPC Contractor of this responsibility. In particular, the pipe welding shall conform to the latest edition of the following codes and standards.

b. ASME codes for power piping – ASME B 31.1

c. Indian Boiler Regulation – IBR

d. ASME Boiler and pressure Vessel Codes

Section I : Rules for construction of Power Boilers

Section II Part A : Ferrous material specifications,

Section II Part C : Specifications for welding rods Electrodes and fillet metals

Section V : Non destructive examination

Section VIII : Rules for construction of pressure Vessels

Section IX : Welding & Brazing qualification


e. Specification of the American Welding Society.

f. Standards, of Pipe fabrication Institute.

g. BS 2633 Specification for Class I arc welding of ferritic steel pipe Work for carrying fluids.

h. Any other codes and standards which are required to perform the Specified welding.

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- 3 -

i. The above mentioned code and standards form an integral part of this specification. In the event of conflict between this specification and the codes and standards listed above, this specification shall govern.

17.5 Codes and Standards, for refractory and insulation.

The supply and application of thermal insulation to piping systems and equipment covered under this Specification shall comply with all currently applicable regulations and safety codes in the locality where the thermal insulation will be applied. The insulating materials shall as also conform to the latest editions of the codes and standards listed below :

Nothing in this specification shall be constructed to relieve the EPC Contractor of this responsibility.

IS:6 : Moderate heat duty fire clay refractories Group-A

IS:8 : High heat duty fire clay refractories

IS 737 : “Specification for wrought aluminum and aluminum alloys sheet and strip (For General Engineering Purpose)

IS : 2042 : Insulating bricks

IS3346 : Method of determination of thermal conductivity of thermal insulation material

IS10556 : Code of practice for storage and handling of insulating materials.

IS14164 : Industrial application and finishing of thermal insulting materials at temperatures above 80 deg C and up to 700 Deg. C American Society for Testing and Materials

IS: 8183 : “Specification for Bonded Mineral Wool”

IS 2150 : “Hexagonal wire netting for general purpose”

IS3144 : “Methods of test for mineral Wool Thermal Insulation Material. 17.6 Codes and standards for Dense phase ash handling system

The design, manufacture, testing and performance of the system shall comply with the requirement s of applicable Indian/other recognized stands, such as the following, in so far as they apply :

IS: 800 : Code of practice for general construction in steel

IS : 1893 : Criteria for earthquake resistance, Design of structures.

IS : 7403 : Code of practice for selection of standard worm and Helical gear box


IS : 325 : Three phase induction motors

IS: 1554 : PVC insulated (heavy duty) electric cables

IS: 2309 : Practice for the protection of the buildings and allied Structures against lighting-code of practice

IS: 2705 : Current transformers

IS: 6043 : Code of practice of earthling

…4…

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IS: 5082 : Wrought aluminum and aluminum alloy bars rods, tubes And selections for electrical purpose.

IS 6206 : Guide for selection installation and maintenance of air Compressor up to 10 bars.

IS 5456 : Code of practice for testing of positive air displacement type Compressors and exhausters

IS: 5727 : Glossary of terms relating to compressor and exhausters

IS: 2825 : Code for unfired pressure vessels ASME Design code for pressure vessels Sec - VIII

IS: 7938 : Air receivers for compressed air installation

IS: 1239 : MS tubes, tubular and other wrought steel fittings

IS: 3589 : Seamless or electrically welded steel pipes for water gas and Sewage

IS: 4771 : A brasion resistant iron castings TEMA Code for design of heat exchangers

17.7 Codes and Standards for Material Handling System

The design, manufacture, testing and performance of the conveyors shall comply with the requirement of applicable Indian / other recognized standards such as the following, in so far as they apply :

IS: 800 : Code of Practice for General Construction in steel

IS: 1893 : Criteria for Earthquake Resistance, Design of structures

IS: 1891 : Specification for troughed belt conveyors

IS: 4776 : Code of practice for conveyor safety

IS: 7155 : Code of practice for selection of standard worm and helical gear Box

IS: 7403 : Specification for pulleys for belt conveyors

IS: 8531 : Specification for idlers for belt conveyors On site non-mechanical jointing of plied Textile reinforced IS8598 Specification for idlers for belt conveyors

IS: 14206 : rubber conveyor belting code of practice Part-1 : Hot vulcanising

IS: 11592 : Code of practice for selection and design of

IS: 325 : Three phase induction motors


IS 1554 : PVC insulated (heavy duty) electric cables

IS: 2306 : Practice for the protection of the buildings and allied structures Against lighting – code of practice

IS: 3043 : Code of practice of earthling.

IS: 5082 : Wrought aluminum and aluminum alloy bars, rods, tubes and Selections for electrical purpose.

…5…

- 5 - 17.8 Codes and Standards for RCC Cooling Tower

The design, material, construed, manufacture, inspection, testing and performance of Induced Draft Cooling tower 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 EPC Contractor of this responsibility. The equipment shall also conform to the latest applicable Indian and / or British Standards and publications of the cooling Tower institute and the Hydraulic Institute. Other National Standards are acceptable, if they are established to be equal or superior. Codes and Standards for Air cooled Condenser

Air cooled condenser design : HEI / ASME Sec-Viii Div-1

ACC Performance test : PTC-30

Steam / Duct piping : ASME Sec-Viii Div-1

Structural steel design : IS 800 17.9 Codes and Standard for EOT crane.

The crane in its entirety shall comply with all currently applicable statutes, regulations and safety codes relating to the design, construction and operation of cranes in the locality where the crane will be installed. Nothing in the specification shall be construed to relieve the Supplier of this responsibility. The cranes supplied shall comply with the latest applicable Indian and /or British Standards. Other National standards are acceptable if they are established to be equal or superior to the listed standards. 17.10 Codes and standards for Centrifugal pumps.

a) Only nationally accredited codes and standards, such as BS, DIN, ASTM, ASME, IS shall be used for design engineering, manufacturing and performance items as quoted and guaranteed. The standards specifically followed by the EPC contractor shall be indicated in the offer separately. The latest revision of the standards effective on the date of order is applicable.

b) Applicable requirements in the latest edition of the following process

c) Industries Practices and industries Standards shall be considered as an integral part of this specification:

d) American Gear Manufacturers Association (AGMA)


i. AGMA 9002 – Bars and Keyways for Flexible couplings (Inch Series)

e) American society of mechanical Engineers (ASME)

I. ASME B1.20.1 – Pipe Threads, General Purpose (Inch)

II. ASME B16.1 – Cast Iron Pipe Flanges and Flanged Fittings

III. ASME B1642 – Ductile Iron Pipe Flanges Flanged Fittings, Class 150 and Class 300

IV. ASME B16.47 – Large Diameter steel Flanges

V. ASME B 16.5 – Pipe flanges and flanged fittings

VI. ASME B31.3 – Chemical Plant and petroleum Refinery Piping …6…

- 6 -

VII. ASME Std 9 – Roller Bearings –Dynamic Load Ratings and Rating Life – Part 1 : Calculation Methods.

VIII. ASME Boiler and pressure Vessel Code (ASME Code ) Section V – Nondestructive Examination Section VIII, Division 1 – Pressure Vessels Section IX – Welding and Brazing Qualifications.

f) American Society for Testing and Materials (ASTM)

I. ASTM A105 – Specification for Forgings, Carbon steel, for Piping Components

II. ASTM A106 – Specification for Seamless Carbon Steel Pipe for High Temperature Service.

III. ASTM E125 – Reference Photographs for Magnetic Particle

IV. Indications on Ferrous Castings

V. ASTM E709 – Practice for Magnetic Particle Examination

g. Hydraulic Institute

I. Hydraulic Institute Standard

h. Process Industries Practices

I. PIP REEP001 – Seal Flush and Lubrication Guidelines for Centrifugal Pumps

II. PIP RECP001 – Design of Pumping Systems that use Centrifugal Pumps

III. PIP RESP002 – Design of ASME B73.1 and General Purpose pump Base plates

IV. PIP RESP73H – Application of ASME B73.1 M – 1991, specification for Horizontal End Suction Centrifugal Pumps for chemical Process.

i. Manufacturers Standardization Society (MSS)

I. MSS SP-55 – Quality standard for Steel Casings for Valves, Flanges and Other Piping Components – Visual Method


17.11 Codes and standards for Heat Exchangers.

The design, manufacture, procurements, inspection, testing and performance testing of high pressure fed water heater shall comply with Indian Boiler regulations (IBR) and all statues, regulations and safety codes currently applicable in the locality where the unit will be installed. The equipments shall also conform to the latest editions of the Codes and Standards specified below. Nothing in this technical specification shall be construed to relieve the Supplier of this responsibility.

Heat Exchange Institute (HEI) Hydraulic

Institute Standards (HIS) Indian Boiler

Regulations (IBR)

American Society of Mechanical Engineers (ASME) American Society for Testing …7…

- 7 -

Materials (ASTM) Power Test code for feed water Heater (ASME) ASME: Sec VIII Unfired Pressure Vessel Code

TEMA-C

Standards of Feed Water Heater Manufacturers Association

ASME Sec. IX

American Society of Non-Destructive Testing (ANST)

Steam Tables, Indian Standard Institution. 17.12 Codes and standards for Storage Tanks :

a. The storage tanks and accessories shall be designed, fabricated and tested in accordance with latest issue (including latest amendments ) of IS 8017

b. IS 2825 Code for Unfired Pressure Vessels

c. ASME B & PV : Section IX welding and brazing qualification

d. ASME B 16.11 Forged steel fittings _Socket welding and threaded

e. ASME B 16.25 Butt welding ends

f. ASME ; B 16.5 –Flanged ends

g. The storage tanks shall be calibrated in accordance with API standard 2550 “Method of Measurement and calibration of Upright Cylindrical Tanks Including all amendments.

h. IS 1893-1975” Criteria for Earthquake resistant Design f Structures

i. IS 4682 – Part –I-Code of practice for lining of vessels and equipment for Chemical Processes (Rubber lining)

17.13 Codes and standards for welding.

a. The welding of fusion welded system shall comply with currently applicable regulations, codes 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 EPC CONTRACTOR of this responsibility. In particular, the welding shall conform to the latest edition of the following codes and standards.

• ASME Boiler & Pressure vessel section IX for welding and welders procedures and qualifications.

• Indian Boiler regulation –IBR

• Specification of the American Welding Society-AWS

• The static and mobile pressure vessels (unfired) rules SMPV where applicable.

• Any other codes and Indian standards which are required to perform the specified welding.

b. 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, this specification shall govern.

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