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NUCLEAR POWER CORPORATION OF INDIA LTD.

(A Govt. Of India Enterprise)

SPECIFICATION NO.: PP-E-2509-R-0

TECHNICAL SPECIFICATION

ON

MODIFICATION IN EXISTING AUTOMATIC TOTAL FLOODING GASEOUS CARBON DIOXIDE FIRE EXTINGUISHING SYSTEM FOR EMERGENCY DG SETS FOR 220 & 540 MWE.

Ref. USI No.: 75220

Revision No. : 0

Date of revision (Month /Year)

: September- 2014

Total No. of Pages (including

cover sheet)

: 75

ORIGINAL

Prepared By :

H. W. PANDEY, ACE (LWS) PRADEEP GOLANI, Sr.EE

Checked By :

P. A. KOATNUR, ACE(LWS) T. JAYLAKHMI, ACE

Reviewed By :

S. K. DATIR, SO/H (LWS) H. S. RAJPUT, ACE (SQA-1)

H. R .VERMA, ACE

Approved By :

N. R. K .MURTHY CE (LWS & A&ESF)

(For Revisions see Revision Control Sheet)

File Name: PP-E-2509.doc

REVISION CONTROL SHEET

DOCUMENT TYPE: TECHNICAL SPECIFICATION

NO. : PP-E-2509

TITLE: TECHNICAL SPECIFICATION FOR

MODIFICATION IN EXISTING AUTOMATIC TOTAL FLOODING GASEOUS CARBON DIOXIDE FIRE EXTINGUISHING SYSTEM FOR EMERGENCY DG SETS FOR 220 & 540 MWe. REV. NO.

& DATE DESCRIPTION OF REVISION

PREPARED BY

CHECKED BY

REVIEWED BY

APPROVED BY

NPCIL PROPRIETARY

This document contains confidential and protected information and that the same are

the intellectual property of Nuclear Power Corporation of India Limited (NPCIL). No part

of this document including notably any editorial elements, verbal and figurative marks

and images included herein, shall be reproduced or transmitted or utilized or published

or stored in any form or by means now known or hereinafter invented, electronic, digital

or mechanical, including photocopying, scanning, recording or by any information

storage or retrieval system, without prior written permission from NPCIL, by any person

or entity. Unauthorized use, disclosure or copying is strictly prohibited and may

constitute unlawful act and can attract legal action.

1. SCOPE:

This specification covers the general technical requirements for carrying out modification in existing Carbon di-oxide fire extinguishing system for emergency diesel generator (EDG) set rooms of 220 MWe & 540 MWe. The general technical requirements include design, engineering, manufacture, fabrication at site (wherever specified), examination, inspection at manufacturer’s site, packing, transportation, safe delivery at site, installation, erection, commissioning, performance testing, quality surveillance, and guarantee of automatic total flooding gaseous carbon dioxide fire extinguishing system for EDG set rooms of 220 MWe & 540 MWe. Scope of supply: Supply shall consist of complete system including fire detectors, piping system consisting of pipes, pipe-fittings, valves, specialties including their supports, distribution nozzles, equipments like pilot cylinders, CO2 cylinders , equipment supports, local control panels with accessories, batteries, supports, all control and instrumentation including cabling, and other devices required as per specification. Power supply to local control panels shall be provided by PURCHASER.

2. OBJECTIVE:

The objective of issuing this specification is to provide design guidelines for up gradation in existing non-automatic / automatic CO2 total flooding system provided for EDGs in operating plants. The intent of up gradation is to incorporate following improved design features :-

(a) To make system operation automatic instead of manual or remote manual operation as per AERB guidelines.

(b) To make CO2 fire protection system independent for each EDG sets by providing independent detectors (not through fire alarm system) , control panels and control power supply

(c) To make system actuation based on multiple coincidence logic. (d) To make system available & poised for other EDG during maintenance on

one EDG. (e) To make the system feasible for online logic testability.

3 CONTENTs: The requirements of this specifications are covered under the following

headings. Description Page

No. Scope Objective Contents Applicable specifications, standards and codes System description Design Requirements Supply, Fabrication and Erection Inspection maintenance and testing History Docket requirements Document to be submitted along with bid Document to be submitted for approval after award of contract Documents to be submitted for records Preparation for shipment Guarantee Spares Erection and maintenance tools Annexure-1: Typical sketch for CO2 total flooding fire extinguishing

system

Data Sheet –A (Information provided by the purchaser) Data Sheet –B (Format for the data to be filled-in by the vendor)

4 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES All documents listed below and those referred to elsewhere in this specification issue in effect on the date of tender documents constitute a part of this specification to the extent defined herein. In the event of any conflict between the requirements of this specification and the publications and drawings listed below, this specification shall govern. The design, manufacture, testing and performance of automatic total flooding gaseous carbon dioxide fire extinguishing system shall conform to all currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed.

NFPA-12 : National Fire Protection Association (NFPA) - Standard for Carbon dioxide extinguishing systems.

IS : 6382 : Code of practice for design and installation of fixed carbon dioxide fire extinguishing system.

BS : 5446 - Part-5 : Components of automatic fire detection systems. ANSI.B 31.1 : Power Piping Code. Piping Material Specification

:

IS . 307 : Specification for carbon dioxide IS. 7285 : Specification for seamless manganese steel cylinders for

permanent and high pressure liquefiable gases.

BS : 5839-Part-1 : Fire Detection & Alarm Systems in buildings. (Codes of practice for installation & servicing)

NFPA-72 : National Fire alarm and signalling Code-2007 IS:9000-1994/ Part-III

: Basic environmental testing procedure for electrical and electronic items

ASME Section - IX : ASME Boiler & Pressure vessel code for Welding and brazing qualifications

ASME Section - V : ASME Boiler & Pressure vessel code for Non-destructive Examinations

AERB/NF/SS/FPS (R-1)

: AERB safety standard on Fire Protection Systems on Nuclear Facilities.

Applicable NPCIL Specifications:

PP-P-1819 : Technical specification on Seismic Qualification of Valves, Panels, Reciprocating & rotary equipment, Tanks, Vessels, Piping, Supports & structures

PC-E- 234 : Technical specification for EPR insulated LHLS sheathed un-armoured instrumentation cables.

PC-E- 730 : Technical specification for Local Control Panels/Racks. PC-E-709 : Engineering standard on Instrumentation & Control system

grounding. PC-E-710 : Engineering standard on electromagnetic compatibility

qualification of C&I equipment PC-E-188 : Technical specification for DC to DC Converter and SMPS PC-P-345 : Technical specification for cleaning methods of piping. PC-P-344 : Technical specification for piping fabrication and erection for

Nuclear Power Plants (PHWRs) PC-P-285 : Technical specification for field welding of piping for Nuclear

Power Plants (PHWRs) PC-P-599 : Technical specification for Carbon Steel pipes, pipe-fittings and

piping components for Light Water Systems. PC-P-345 : Technical specification for paints in Nuclear Power Plants

(PHWRs) PP-E-155 : Technical specification for Brass compression type(flareless)

tube fittings PP-M-107 : Technical specification for Seamless austenitic stainless steel

Tubing PC-E-274 : Technical specification for Stainless steel compression type

twin ferrule (flarelss) tube fittings PC-E-448 : Technical specification for Stainless Steel Bourdon Tube

Pressure Gauges PC-E-607 : Technical specification for Pressure and Differential Pressure

Switches PC-E-635 : Technical specification for Stainless Steel Instrument Isolation

Needle Valves PC-E- 234 : Technical specification for EPR insulated LHLS sheathed

Un-armoured instrumentation cables. PC-E-347 : Technical specification for Junction Box PC-E-298 : Technical specification for Electromagnetic Relays PP-E-2061 : NPC technical specification for requirements of components for

instrumentation items PP-E-1443 : NPC specification for manufacture of Single sided, Double

sided and Multilayered printed wiring boards. The Bidder shall indicate date of issue of the codes / standards he proposes to

use while making his quotation. Approvals : CO2 storage cylinders shall be approved by Chief Controller of Explosives, Nagpur (CCE). The CO2 fire extinguishers, other operating devices, fire detectors, etc. shall be approved by either of the following bodies :- a) Underwriter’s Laboratory (UL), USA. b) Underwriter’s Laboratory (UL), CANADA. c) Factory Mutual Corporation (FM), USA. d) Loss Prevention Council, UK. e) Any other equivalent body of international repute. VDS Germany (acceptable t o HQ)

5 SYSTEM DESCRIPTION Carbon dioxide is also used widely as a fire-extinguishing agent. It extinguishes fire by reducing the oxygen content of the air so that combustion cannot be supported. Around 34-50% concentration of CO2 lowers oxygen content below 14-10% and usual combustible materials can no longer burn. The automatic CO2 fire suppression system is provided for areas where water is unacceptable or ineffective. The extinguishing agent is carbon-dioxide gas stored under pressure in cylinders kept outside the fire area. Cylinder pressure release valves, a network of discharge piping, and nozzles at fixed locations direct the gas into the area which is to be flooded with CO2 thereby extinguishing fire quickly. It is ensured that an area where CO2 fire protection is provided doesn't contain sensitive electronic gadgets, which may get impaired due to the sudden temperature fall in the event of flooding by CO2. Also, care is taken during layout of discharge nozzles to guard against occurrence of any thermal shock due to sudden cooling on account of CO2. For CO2 System, optical type smoke detectors & heat detectors shall be strategically placed in the areas sense the fire. These shall be wired and arranged in a crossed zone configuration. Audible and visual alarms shall be annunciated in the local control panel near the area and potential free contacts shall be provided for wiring to the Fire protection system’s central alarm panel.

System of operation shall be of total flooding type. The system automatically detects and releases CO2 to extinguish fire in the areas to be protected. Audible and visible alarms shall be provided to annunciate operation of the system, as well as fire detection. Backup manual operation of system can be resorted to if automatic action fails to take place. The system shall be designed as per National Fire Protection Association, USA code NFPA-12. The flooding shall be achieved in about a minute after discharge. Sizing shall be done as per NFPA and 100% standby storage capacity shall also be provided. The cylinders shall be located away from the fire hazard. For all EDG rooms a common battery of CO2 cylinders with tripping and release mechanism shall be provided with directional valves. The cylinders shall be provided with pneumatically operated discharge valve with provision for manual operation. The directional valves ensure CO2 is directed to the fire affected DG room only. The discharge valves and directional valve shall be pneumatically operated by pilot Nitrogen gas. The pilot Nitrogen shall be released on fire signal by opening solenoid valve on the pilot cylinders. The directional valves shall be placed in piping circuit such that in case of maintenance on any one of directional valve in piping circuit, the CO2 fire protection system for other EDG should not be affected. The CO2 fire protection system of affected EDG shall be under shutdown during maintenance whereas for other EDG the CO2 fire protection system shall remain poised. Please refer schematic attached as per Annecure-1. The schematic is indicating two EDGs in one building. If there are three EDGs in single building, each EDG shall have its own CO2 gas piping distribution network, local control panel and detection independent of others. The local control panel along with its batteries and other accessories for each CO2 system shall be preferably located in DG control panel room. If not, they can be located in CO2 cylinder room adjacent to EDG room.

6 DESIGN REQUIREMENTS:- The design requirements for fixed condensed CO2 total flooding fire extinguishing system shall comply with NFPA-12. However, following requirements shall also be read and complied with in conjunction with above standard:-

6.1 The automatic total flooding gaseous carbon di-oxide fire extinguishing system for EDG set rooms shall be designed as per safety class-3 and seismic category-1.

6.2 The Design of CO2 extinguishing system shall be total flooding type as specified in Data Sheet A.

6.3 The discharge time required to achieve 95% of design concentration shall not exceed 60 seconds from the starting of the actuation.

6.4 The quantity of CO2 gas required shall be calculated to achieve desired design concentration as indicated in Data Sheet-A and the quantity so calculated shall be increased by adequate margin to take care of leakages through various openings as per as per NFPA-12A guidelines. The margin considered and its

basis shall be furnished by the CONTRACTOR. The concentration of CO2 shall be achieved within 3 minutes.

6.5 The CO2 gas concentration shall be maintained for specified period of time to prevent reignition of fire before effective emergency action can be taken by trained personnel.

6.6 Independent outlets from common headers formed by pilot cylinders and main cylinders should be used for each EDG set rooms. Operation of more then one solenoid valve (SV) should only initiate the flow of CO2 in one EDG room to extinguish fire. Spurious actuation of any one of SV should not cause operation of CO2 fire protection system in other EDG room. Vendor shall ensure that the system is designed to avoid spurious actuation due to single component failure. CO2 fire protection system for each EDG room should be able to be shutdown (during maintenance) without, in any way, affecting the other adjacent EDG set’s fire protection system. The directional valves shall be placed in piping circuit such that in case of maintenance on any one of directional valve in piping circuit , the CO2 fire protection system for other EDG should not be affected. The CO2 fire protection system of affected EDG shall be under shutdown during maintenance of relevant directional valve whereas for other EDG the CO2 fire protection system shall remain poised.

6.7 All devices shall be located, installed or suitable protected, so that they are not subject to mechanical, chemical or other type of damage which would render them inoperative.

6.8 Each DG room shall have independent fire extinguishing system.

6.9 The detectors shall be at least three in numbers for each EDG room and shall be based on diverse operating principal. The Detection System shall consist of smoke, heat. The no. of detectors shall be such that the complete area being protected is covered by the detection system.

6.10 Detection system shall be based on ‘Cross Zone’ Principle by providing two detector circuits to avoid spurious release of CO2 gas. If only one circuit is energized, audio / visual alarm alone should be sounded. The gas shall be released only when detector on each of the circuits goes into alarm condition.

6.11 A CO2 release manual push button station shall be provided for each protected area located at convenient and easily accessible place for manual release of CO2 . Manual inhibition switch shall also provided to prevent accidental discharge of CO2. Indicating lamps will be provided to give ‘Auto’ or ‘Manual’ mode release status of the system. CO2 shall be released after a preset time delay between 0 to 60 seconds, adjustable from the control panel.

6.12 To avoid spurious actuation of CO2 gas system each EDG room CO2 fire protection system shall have independent power supply, detection system, actuators and Local Control Panels (LCP) and battery backup.

6.13 CO2 extinguishing system for EDG sets shall be controlled from a relay based local control panel while the fire detection system shall be relay / solid state circuit based.

6.14 In case, if microprocessor based circuit is used for fire detection, the relevant IV&V procedures and documentation shall be provided by the vendor as per Annexure -2.

6.15 For each area “Fire detected”,” System Operated”, “Control power supply failure”, “Main cylinder pressure low”, etc parameters should be monitored and potential free contacts for each area for “Fire detected”,” System Operated”, “Control power supply failure” shall be provided for annunciation in MCR.

6.16 For opening / closing status of directional valves limit switches shall be provided on these valves.

6.17 The CO2 cylinders used in these systems shall be seamless and made of high strength alloy steel. The CO2 containers shall also have approval of Chief Controller of Explosives, Nagpur.

6.18 Each container shall have a pressure relief device which should automatically operate when internal pressure exceeds the maximum pressure as allowed by the statutory bodies.

6.19 The CO2 cylinders shall be secured within fabricated steel racks designed for the bank of cylinders.

6.20 The material for pipes shall be seamless steel conforming to ASTM.A106.GR.B & ANSI-B-36.10 . The fittings shall be as per ASTM-A-234.

6.21 Discharge nozzles used shall be suitable for the use in CO2 flooding system. It shall be of chrome plated brass or stainless steel.

6.22 Seismic Requirement All the equipments, piping including supports, devices, including Control & Instrumentation and supports shall be seismically qualified. For checking the stresses due to different load combinations ASME Sec. III NC shall be referred. It is essential that CO2 fire protection system piping, equipments, supports and its associated instruments & control panels, and CO2 cylinder’s storage rack shall withstand seismic shock loading along its three principal axes and remain in operating condition. The qualification of the system and its associated instruments & control panel shall be as per PURCHASER specification no PP-P-1819 titled ‘Technical Specification for Methods & Procedures for seismic qualification of valves, panels, devices, rotating equipments, tanks, vessels, piping and supports. The

specification is largely based on IEEE 382, IEEE 384 and ASME-QME-1. The specification shall be given to successful bidder. • Seismic qualification to be carried out by analytical method for piping, valves and piping supports, CO2 cylinder’s storage rack. • Shake table test to be performed for LCP, Main & standby batteries, pilot cylinders. The required response spectra for seismic qualification will be provided later to the successful bidder. The supplier shall submit design, analysis and test procedure to PURCHASER for approval.

6.23 CONTRACTOR shall provide engraved instruction plates detailing emergency procedures near each local control panel as well as at each manual push button station. Permanent name plates shall be used on the control panel to identify the control logic units, contacts and major circuits.

6.24 CONTRACTOR to carry out all functional test after complete installation & commissioning of the system. The functional test shall conform to the requirements of NFPA-12 standard.

6.25 Supports, base plates and other fixtures required for installation of piping, equipments , panels etc. shall be fabricated from structural steel sections conforming to IS:2062 , Quality-B, GR-E-250 (Fe-410-W). The welding of supports and other fixtures shall conform to the requirements of ASME Boiler & Pressure vessel code, Section –IX Welding and brazing qualifications. All support welds shall be visually inspected and root and final weld shall be subjected to 100 % DP test for acceptance of welds as per the requirements of ASME Boiler & Pressure vessel code, Section –V- Non-destructive Examination.

6.26 All supports shall be painted as follows :- Surface preparation - Blast clean to SA 2.5. If not practical, manual/mechanical cleaning to ST 2 / ST 3. Primer application - 2 coats (50 microns per coat) of polyamide cured high build epoxy zinc phosphate primer, 55% solids, colour: red oxide 1 coat (75 microns) of Polyamide cured, high build epoxy intermediate with laminar micaceous ion oxide pigment, 52% solids content. Final painting - 1 coat (40 microns per coat) of aliphatic isocyanate cured acrylic Polyurethane paint at shop and 1 coat (40 microns) of touch up paint (of same material) at site. Total thickness - 250 microns. Color code - Aircraft Grey (693) as per IS-5.

6.27 CONTROL & INSTRUMENTATION: (a) Fire Detection Alarm & Control System :

(i) Detection System:

The fire detection system shall comprise of fire detectors, and Control system (local control panels). Independent fire detection, alarm and control system shall be provided for each diesel generator set room. Detector Types: The following type of fire detectors, apart from thermal cord, shall be used depending upon the area of usage and type of fire fighting method applied. • Photoelectric/Optical Type smoke detectors • Thermal Detectors (Fixed temperature / rate of rise type) The detectors shall be of conventional type and shall be standard Class B wiring All the detectors and associated circuits and accessories shall be qualified for seismic conditions. If the CONTRACTOR offers addressable type detection system for Purchaser’s consideration, independent verification and validation (IV&V) and documentation requirements as specified in Annexure -2. For each area that is being protected, the detector scheme shall be as follows: The fire detectors shall be wired in cross zoning configuration. For each fire detection zone two redundant circuits of detectors (with different working principle) shall be provided. The redundant detector circuits shall be physically arranged in such a way that at least three detectors are provided in the same area. The actuation of CO2 discharge shall initiate only after confirmation of fire condition through automatic control logic. The contractor shall suggest the effective control logic for confirming the fire condition in the control philosophy for purchaser’s consideration. The design of fire detection scheme shall be done as per NFPA-72 standard and/or other relevant standard. Each redundant detector circuit shall meet the area per detector criteria as per NFPA-72 individually. The detailed scheme of fire detection showing the physical location of detectors, type of detector, redundancy, spacing between the detectors, no. Of detectors, and height of mounting along with the design calculations shall be submitted for Purchasers approval. The short circuit and/or ground fault at the detector shall be identified on the local control panel by lamp indication. The redundant circuits shall be designed in such a way that any fault in one detection circuit shall not affect the functioning of other redundant detection line. Short circuit and/or ground fault in the detection circuit shall not inhibit the detection capability of the detection

circuit. Wiring of the detectors shall be done with the 1.5 sq. mm. EPR insulated LHLS type cables as per purchaser’s specification no. PC-E-234.

General Requirements of Detectors:

i) The circuit used in the detectors shall be of solid state & of fail-safe design. The circuit shall be hermetically sealed to have resistance to humidity, corrosion, dust and dirt.

i) The circuit shall be protected against usual electrical transients, electromagnetic interference (EMI & RFI) and static electricity.

ii) Reverse polarity or fault in the field wiring shall not damage the detector.

iii) Moving parts, which may wear and tear, shall be avoided.

iv) The visual (alarm) response of a detector (by an LED) shall be clearly visible from the outside by a steady/flashing light of sufficient brightness

v) The detector shall be designed for fast and simple cleaning method in lab or on site without need of specialized tools.

vi) The fire detectors (smoke & heat type) shall be plug-in types. The detector base shall be mechanically and electrically identical for smoke & heat detectors and therefore interchangeable. Suitable locking devices shall be supplied along with each detector.

vii) The detector shall be suitable for wall/column/ceiling mounting.

viii) The detector shall conform to relevant national and international standards such as BIS, BS, UL, NFPA, En etc. Test certificates shall be supplied.

ix) Operating voltage for the detectors shall be 24 V DC nominal.

xi) Protection Category – as per relevant standards.

xii) It shall be possible to connect the detectors in any combination to the same detection line.

xiii) It shall be possible to install and un-install detectors mounted at a height of 7 meters from the floor with installation tool. Suitable installation tool shall be supplied.

xiv) The manufacturing date of fire detectors & other field modules shall be less than two years from the date of despatch to site. Shelf life shall be specified for each type of detector.

xv) Static / dynamic characteristics of the detectors shall be provided.

xvi) Signal conditioning requirements for detectors shall be provided, if any.

In case of addressable detectors, the detector address setting shall be by means of soft addressing, dip switches, decade switches, or suitable pre-punched cards. In case of hand addressing the address setting shall be preferably in the detector base, so that, address setting will not change with detector replacement.

Mounting & Anchoring Requirements: The control panel shall be capable of being anchored or welded on the EP’s provided on the floor.

4-Way GI Mounting Boxes for Bases of detectors: It shall be possible to mount fire detector base on the 4-way mounting box. It shall be of square type design of size 150x 150 x 60 mm for smoke, heat detectors, fault isolators, flame detectors. The 4-way mounting box shall be fabricated from cold rolled sheet steel of 16 SWG and shall be having powder coated in post office red colour. The 4-way mounting box shall have provision of knock out holes from four sides for cable termination. A stud for grounding of cable shield shall be provided on the mounting box.

Extension Fixtures for Detectors: If required, suitable extension fixtures shall be provided for detectors mounting from high ceiling level.

b) Seismic Requirement Field Instruments, detectors and panels along with the devices and components mounted on it and wired shall be qualified and tested for structural integrity / operability under seismic condition by shake table test (Type test). The items mounted on the panel shall be shown to be capable of performing all essential functions during and after seismic test with the following specifications: Type of motion: Sinusoidal Axis: Uniaxial test in each of the three axis separately (1 vertical and 2 horizontal) Period of test : 30 sec. at each of the test frequency The values of peak acceleration and test frequencies will be furnished to the successful bidder after award of contract. NPCIL specification no. PP-P-1819 shall be followed. Fire detectors, field instruments, relays, hand switches, pushbuttons, indicating lamps and all other devices one no from each lot shall be seismically tested by shake table test (Type Test). One Control Panel complete with wiring and

components mounted on it along-with support structure, and all other C&I devices and instruments shall be qualified for SSE condition by shake table test in energized condition and shall meet the functional and performance requirement during and after the test.

c) Control Power Supply and Batteries: One feeder of Class-I, 240 Volts AC Control Power Supply will be provided as control power supply to LCPs by Purchaser. All devices shall be rated for 24 VDC. The necessary AC to DC Convertor shall be provided by the Contractor. Any other type of power supply if required for the operation of any devices shall be derived by the contractor from the input 240 V AC supply. Contractor shall inform the requirement of control power supply (240 V AC) well in advance to the purchaser. Provision of terminal blocks shall be made in the control panel to terminate the power supply cable upto 6.0 sqmm conductor size. However, in case the purchaser, provides Class I, 24 or 48 V DC for system operation the circuit can be designed accordingly and submitted for purchaser’s approval. Local battery bank along with battery charging circuit for the control power supply backup with capacity sufficient to feed the control power supply requirement for at least 24 hours and for one system actuation after 24 hours and shall be provided by the contractor along with the necessary switch over circuit. The battery shall be lead acid tubular type of reputed make. The changeover circuit shall incorporate the necessary isolation devices and changeover shall take place whenever main power supply voltage drops to less than 80% of the rated voltage. The set point shall be settable over a range from 70 % to 90 %. There shall be inbuilt facility to check the health of batteries and give lamp indication for fault in batteries and/or battery charging circuit. The control power supply arrangement shall be such that, single failure of a component should not result in unavailability of the system.

d) Requirement of Instruments and Devices: The following are the minimum requirements for the system. However additional measurements / Indications, if required, for efficient system operation shall be provided by the CONTRACTOR.

Devices & Instruments in Field:

1. One hooter and a flasher in each D.G.Room. 2. Caution Boards:

i) Caution boards inside DG room for fire occurred “CO2 being released. Please evacuate”.

ii) Caution boards outside DG room for system operated “CO2 being released. Do not enter”.

3. Push buttons:

i) Manual Release Push Buttons for emergency system operation manually. [Manual Release Push Buttons shall override Abort PB.]

ii) Abort push button located out side the D.G.Room to facilitate aborting the CO2 discharge process. The abort PB shall be of deadman type that requires constant manual pressure to cause abort and the system shall not be in the aborted mode without personnel present.

4. Lamp indication:

i) System aborted lamp in each D.G.Room.

Devices on LCP:

1. Selector switch for Auto /Manual mode selection. 2. Control Power Hand Switch to isolate (both positive and negative supply)

240 V AC Control Power Supply located inside the Panel. 3. Push Buttons for:

1. Manual operation of discharge system during Manual mode selection through Auto/Manual Selector Switch.

2. Reset PB to reset the control circuit 3. Hooter silence PB to mute the hooters 4. Fire test for simulating fire conditions for testing the functioning of

LCP after isolating the CO2 cylinders. 5. Lamp test for checking healthiness of all indicating lamps. 6. Aborting CO2 system actuation.

4. Indicating Lamps for: i) Control power supply ‘ON’ ii) Fire detected iii) System aborted iv) System operated v) System on Manual vi) Fire detector circuit fault vii) Batteries Faulty viii) Charger circuit faulty.

5. One Hooter on LCP. 6. Meters to indicate the health of the batteries. 7. Each LCP shall be provided with 240 VAC space heater, illuminating

(LED) lamp with door switch, power receptacle and cooling fan. 240 VAC CL-III power supply for the same shall be provided by Purchaser.

Potential Free Contacts : The Contractor shall provide potential free contacts wired up to the terminal strips of LCP for wiring to Purchaser’s Fire Protection Panel (FPP) in Remote Control Room for the following parameters:

(1) Fire detected in DG Room. (2) CO2 System Actuated. (3) Control Power Supply trouble/ FD fault. (4) System Aborted / Operated manually. Supply and installation of cables between the Local Control Panels and FPP shall be in PURCHASER’s scope. The Contractor shall also provide potential free contacts one each for of ‘Fire Detected in DG Room” for tripping the respective DG and stopping the Ventilation Fans. Wiring between LCP and DG panel shall be in DG vendor’s scope.

7 SUPPLY, FABRICATION AND ERECTION Supply of all materials required for CO2 fire protection system shall include scope as mentioned in NFPA-12. Materials to be supplied at site along-with co-related materials test certificates showing mechanical properties and chemical analysis as per relevant material specifications, codes/standards. Materials shall be dispatched to site only after release of shipping release issued by the PURCHASER’s authorizes representatives. After supply of materials at site the materials shall be kept under proper storage as per the approved storage procedures. The structural steel sections required for fabrication of supports and embedded plates shall conform to IS-2062, Quality-B, Gr- E-250 (Fe-410-W). For fixing of embedded plated on floor, wall and roof, Hilti make anchors of suitable size shall be used. Other requirements for fabrication , erection and testing shall be as per NPCIL technical specifications mentioned in clause no. – 4 of this specification.

8 INSPECTION , MAINTENENCAE AND TESTING: The CONTRACTOR shall be responsible for and shall provide for and perform all the examination and testing specified herein, in the presence of purchaser’s authorized quality control representative. The product shall be carefully examined during manufacture and after completion to determine its conformance with this specification with respect to material, workmanship, finish, marking and dimensions and to assess its conformance with other requirements stated or reasonably implied and not covered by specific tests. Inspection and testing shall be conducted in a manner satisfactory and test reports shall be submitted by the CONTRACTOR to the PURCHASER. The PURCHASER or his authorized agency shall have access to the CONTRACTOR’s premises at all times to the extent necessary to ensure compliance with the provisions of this specification. The PURCHASER shall also have the right to conduct at his own expense any additional inspection or testing, he deems necessary.

The CONTRACTOR shall obtain permission from PURCHASER before repair and subsequent use of such equipment or part. If the repairs, including redesign, are likely to affect the result of tests or work previously completed, appropriate re-inspection and retesting shall be conducted.

8.1 After the installation is complete the system shall be inspected by PURCHASER’S representative and certified by representative of original manufacturer in accordance with the manufacturer’s recommended procedures.

8.2 All wiring shall be tested for proper connection, continuity and resistance to ground.

8.3 The VENDOR shall provide two inspections of the system during the one year warranty period. The first inspection shall take place after six months from the date of system acceptance and the second before the end of warranty period.

8.4 Inspection, shall include determination of container weight and pressure and that the system is in proper working order.

8.5 Inspection of enclosure protected by CO2 system shall be thoroughly inspected every 12 months to determine if penetrations or other changes have occurred that could adversely effect CO2 leakage or change volume of hazard or both.

8.6 The system shall be provided such that annual maintenance can be ensured and vendor shall provide the procedure for the same.

8.7 Where the amount of agent in the container is determined by special measuring device, these devices shall be listed. If the containers show a loss in the agent weight more then ten (10) % , agent shall be replaced.

8.8 Documents certifying satisfactory system conditions shall be submitted to PURCHASER upon completion of each inspection.

8.9 Tests of field mounted instruments as per NPCIL specifications. All C&I devices shall be tested as per relevant QAP enclosed in respective NPCIL Specifications (PC-E) on instruments. All Local Control Panels shall be subjected to the following tests. The following tests are the minimum required, any other additional test required to establish functional and performance requirement as per NPCIL specification shall be done by the CONTRACTOR.

a) Visual inspection including thread checking.

b) Material test certificates.

c) Tests on painting viz, (paint thickness check, scratch hardness, bend test(flexibility test) and pull off (adhesion) test.

d) High voltage test at 1.5 KVAC for 1 minute – for 240 V AC & 220 V DC Circuits.

e) High voltage test at 1 KVAC for 1 minute –for 24 V DC Circuits (High voltage test shall not be carried out on instrumentation items as they contain solid state components).

f) Megger test (500 V DC, 25°C, 50% RH); Insulation resistance shall be better than 100 Mega ohms,

g) Continuity checks for wiring.

h) Electrical and mechanical operation of all instruments/components.

i) Integrated Functional check with all instruments and detectors wired to the panel.

j) Electrical control and interlock test.

k) Seismic vibration test as per section 6.27(b).

l) Environmental Test (Dry Heat and Damp Heat): One number each of sub-units (card, detector, field module PSU etc) shall be subjected to standard environmental test as specified below: -Dry heat (as per part III of IS 9000-1977 or equivalent) 55oC + 2oC, not exceeding 50% R.H., duration 4 hrs. -Damp heat (as per part V of IS 9000-1977 or equivalent) 2 cycles of 24 hours (12 hrs + 12 hrs) each over the range of 40oC +2oC, 90% RH to 25+5oC 98% R.H.

m) EMI/RFI test as per NPCIL Specification PC-E-710 (Type Test)

n) System Integration Test

9 HISTORY DOCKET REQUIREMENTS As part of the Station’s Quality Assurance records requirement, a draft copy of History Docket shall be prepared and submitted to the Purchaser at the time of inspection for approval. Ten copies of the approved history docket shall be submitted after complete satisfactorily supply, delivery, erection, commissioning and testing of CO2 fire protection system for all emergency DG sets including its control and instrumentation. This docket shall consist of the minimum of the following records/documents.

a) Purchase order and sub-order copies, copies of approved QAP and procedures.

b) Copies of shipping release against sub-orders on sub-vendors.

c) Certified material test reports, test certificates including for bought out items.

d) NDE Reports and Dimensional Records.

e) Type test and routine test reports.

f) Guarantee certificate.

g) Component ordering information for future replacement, if required.

h) Basic design calculations for CO2 requirement and extinguisher capacity selection. To the extent of feasible, the CONTRACTOR shall also supply one set of above documents in magnetic media. All examination and test reports shall be signed by vendor, sub-vendor as Purchasers representative. The shipping release may not be issued if history docket is not ready in acceptable form. Delivery will be deemed incomplete till the history docket is supplied.

9.1 Prior to final acceptance, the CONTRACTOR shall submit for PURCHASER’S approval six (6) copies of operation and maintenance manual. All aspects of system operation and maintenance shall be detailed including electrical schematics of all circuits, a description of the system components, drawing illustrating control logic, technical bulletins describing each equipment used in the system, checklists procedures for emergency situation, trouble shooting techniques. After the instruction manual is approved, the CONTRACTOR shall submit twenty (20) copies of the approved manual for PURCHASER’S distribution and records.

9.2 Prior to the acceptance, the CONTRACTOR shall impart training to the PURCHASER’S personnel for operation and maintenance of the complete system.

10 DOCUMENTS TO BE SUBMITTED ALONG WITH BID The BIDDER shall furnish the following data along with data asked in Data sheet-B to enable evaluation of his BID.

10.1 A schematic showing complete integrated scheme of CO2 fire protection system.

10.2 Basic design calculations for CO2 requirement and cylinder capacity selection.

10.3 General arrangement drawing indicating the location of cylinders, pipe routing & nozzle location.

10.4 Original manufacturer’s catalogues giving dimensional outline drawing of container, nozzle, directional control valve and other system components.

10.5 CO2 nozzle discharge characteristics.

10.6 Approval certificates from various approving bodies as listed in clause 4.0.

10.7 List of at least three similar installations designed and installed by the TENDERER in the past.

10.8 Preliminary general arrangement drawings showing dimensions and indicating the location of CO2 cylinders, control panels, fire detectors and other instrumentation devices etc, Cable routing GA.

10.9 Experience in similar field with Purchaser and other industries along with the job references.

10.10 Proposed QAP.

10.11 Existing infrastructure available with the bidder and possible sub-vendor(s) for design, manufacture/fabrication of the components, equipments.

10.12 Existing facilities/infrastructure available with the bidder and possible sub vendor(s) for carrying out examination and testing. Capability for seismic analysis and method of the analysis.

10.13 Material of construction and size of various major components.

10.14 Scope of sub-contract, if any (names/address of possible sub-vendors, item and value of sub-contract).

10.15 Manufacturing and delivery schedule, from the date of placement of the Letter of Intent or Purchase Order – whichever is earlier, with break-up of major activities.

10.16 A detailed process and Instrumentation flow sheet.

10.17 Control Philosophy.

10.18 Bill of Materials of system components.

10.19 All information called for in data sheet B.

10.20 Data Sheet `B’ duly filled.

10.21 List of deviations (if any) section-wise from this specification no. PP-E-2509.

10.22 Other details required for the comparison and evaluation of the bids.

11 DRAWINGS AND DOCUMENTS TO BE SUBMITTED FOR APPROVAL AFTER AWARD OF CONTRACT:

11.1 Data Sheets a. Data sheets for CO2 cylinders, b. All design calculations for automatic CO2 fire extinguishing system.

11.2 Drawings Six copies of drawings showing :

a. Process and instrument schematic showing design parameters and control logic.

b. Control schematic and control panel drawing. c. Design calculations. d. General arrangement drawings ( plan, section and view) covering

outline dimensions, layout of CO2 fire extinguishers, control panels, fire detectors and other instrumentation devices etc. Structure foundation support arrangement, location and dimensions of local control panels and detectors and their types. Control logic and instrumentation. Weighing arrangement for CO2 fire extinguishers, Location of emergency push buttons, Hooter and caution boards etc. for each protected area. Arrangement of battery and battery charger etc.

e. Bill of materials with standards/codes of materials. f. As built drawing of CO2 extinguishers , supports, panels etc. g. Instrument Schedule, Instrument Erection Drawings, Engineering &

Wiring Diagrams, Panel General Arrangement Drawings, Interconnection Cable Schedule, Terminal Lists and Specification sheets for Instruments.

11.3 Documents

a. Design note including design calculation for CO2 quantity

requirements for flooding, sizing & capacity of CO2 cylinders, design basis , applicable codes and standards, system description, system operation, material of construction, postulated failures, precautions and maintenance, spare parts requirement.

b. Computerized calculations shall be furnished. c. Data sheets for all components as indicated in Process and

instrumentation schematic. d. Quality Assurance Plan. e. Material examination procedure. f. Visual and dimensional examination procedure. g. Liquid penetrant examination procedure. h. Seismic analysis report for structural integrity. i. Welding and weld repair procedure (s). j. General performance test procedure. k. Performance/functional test procedure. l. Cleaning procedure. m. Painting and rust preventive procedure. n. Packing procedure. o. Storage procedure. p. Material handling procedure. q. Approval certificates. r. Material test certificates. s. Manufacturer’s installation manual.

t. Instruction and maintenance manual. u. Control Philosophy v. IV&V Documents : The Contractor shall prepare IV&V documents as

specified in Annexure-2 for the system and offer one copy of the draft documents for purchaser’s review and comments which shall be taken care in the revised version of the documents.

12 DOCUMENTS TO BE SUBMITTED FOR RECORDS

12.1 One set of reproducible (dilar/tracing) for each as built drawing. One set of microfilm of each drawing.

12.2 Ten sets of all approved design reports.

12.3 Ten sets of approved history docket (Section 8.0 of this specification) and Seismic analysis reports. Radiographic films.

12.4 10 sets of approved Installation , Operation and Maintenance Manual.

12.5 Soft copies on Compact Discs for all the documents generated by Supplier.

13 PREPARATION FOR SHIPMENT Before shipment items shall be thoroughly cleaned and dried. To prevent ingress of dirt or dust during shipment and site storage, openings shall be shielded protected against damage by steel plates and gaskets securely bolted in place. All small loose pieces, including bolting tools, gasket, etc. shall be adequately crated or boxed for protection during shipment. All pieces shall be marked with the equipment piece number or mark number.

14 GUARANTEE The CO2 fire protection system shall be guaranteed for material, workmanship and performance as specified for minimum period of 12 months from commissioning or 48 months from the placement of order whichever ends earlier. If any equipment/major components fails and replaced during this guarantee period the components/equipment shall be further guaranteed for the performance for a minimum period of 12 months from the date of such replacement. On failure of part in the guarantee period, the cause of failure shall be determined. If the failure is primarily due to or precipitated by a fault in the design, the design shall be modified and redesigned replacement parts provided for all protected areas by the Manufacturer at no expense to the Purchaser. On failure of replacement parts, the Manufacturer shall redesign, repair and/or replace such parts which fail within one year of the replacement or before expiry of the original warranty period whichever is longest.

15 SPARES :

15.1 One Spare Control Panel for both the units shall be provided. The Contractor shall provide 20% spare field instruments (detectors, accessories, caution boards etc.) subject to a minimum 1 no. of each type per unit.

15.2 Recommended spares by suppliers : Vendor shall recommend spares for 3 years of trouble free service.

15.3 50% of CO2 cylinders of quantity required for one DG room for both units shall be supplied as spare quantities.

16 ERECTION AND MAINTENANCE TOOLS The supplier shall furnish a complete unused set of all special tools, wrenches etc., with necessary tools boxes as required for erection, maintenance, overhaul and complete replacement of any equipment being supplied under this specification for each Project. In addition, the following Detector Removal/Installation Tool shall also be provided i). Installation & removal of detector located at height of 7 meters shall be possible from a distance with the help of detector removal tool. ii) On line detector removal tool by the help of which detectors can be exchanged from the floor also shall be supplied. iii) The detector removal tool arm length shall be at least 6 meters and the length shall be achievable by three or four pieces or it shall be of collapsible type of concentric rods. Special Tool Kit: In addition all special tools required if any for installation and maintenance shall be offered.

Part-1

1. Mode of operation Automatic as well as manual.

2. Medium CO2

3. Application Total flooding (FDG-ROOMS)

4. Concentration For total flooding: 40-50 %

5. Discharge time 3 minutes

6. Equipment to be protected Emergency Diesel engine set

7. Material of construction (piping) A 106 Sch.80-NFPA 12 (fittings shall be as

recommended b NFPA 12)

7.1 Container Manganese, steel, seamless construction as

per IS:7285

7.2 Cylinder support frame Fabrication steel conforming to IS:2062,

quality-B, GR-E-250 (Fe-410-W)

7.3 Nozzle Chlorine plated brass- as per IS:318

7.4 Weighting scale to be provided

for weighting CO2 release

panel.

Yes

8. CO2 release panel

8.1 Supply voltage 240V AC

8.2 Power supply to be provided

by

Purchaser

8.3 Battery with charger to be

provided by

Vendor

8.4 Range of time for delayed

release of co2

Adjustable 0-60 seconds

9 Test and Inspection

9.1 Material test certificates

required

Yes

9.2 Approval of UL/FM/FOC/VDC/

other recognized body required

Yes

9.3 Approval from TAC required Yes

9.4 Approval from Chief Inspector

Explosives, Nagpur required

Yes

9.5 Discharge test, required No.

10 Inspection

10.1 Inspection after installation

required

Yes, refer para 6.1 of spec.

10.2 Inspection during warranty Yes, refer para 6.5 of spec. noted

10.3 Inspection required after

warranty period

Yes

10.4 Whether testing / certification

of containers will be

undertaken before refilling

Yes

10.5 Whether annual service

contract will be undertaken by

vendor (for regular periodic

inspection)

Yes

Part-2 (Data to be filled by operating station and to be attached with tender

specification)

Existing Drawing number of Process & Instrumentation Diagram/Flow sheet/ Process & Instrumentation Schematic for CO2 fire protection system of EDGs.

Rating of each EDGs (kW)

Existing piping GA drawing number

Existing wiring diagram number

Existing Control power supply details for detection and system actuation

EDG room layout drawing number

Number of EDGs per unit

Size of each DG room (mm x mm x mm)

Area to be protected

DATA SHEET-B

(Data to be filled and submitted by Vendor along with the bid) A GENERAL DATA

1 Name of reputed vendor :

2 List of supporting documents :

3 Make, model, approval of CO2 fire

extinguishers :

4 Make, model, approval of fire

detectors :

5 Make, model, approval of Battery

with charger :

6 Make, model, approval of local

control panels:

7 Probabilistic Safety Analysis (PSA)

Input Data:

Following data to be submitted for PSA to be carried out by the PURCHASER :-

a. Mean time between failures

(MTBF) :

b. Test Frequency :

c. Impact of ageing on performance :

d. No. of cycles of operation in life

time:

(B)

DESIGN DATA

1 Number of Containers :

2 Design application density (gm/M3)

:

3 Total flooding quantity (g) :

4 Discharge time required to achieve

95% of design application density

in EDG room

(sec):

5 Duration of effectiveness of CO2 in

DG room after its release:

6 Adverse effect level of CO2:

7 Toxicity testing certificate for

normally occupied spaces:

8 Post operation cleaning

requirements:

9 Can it be used for local flooding

applications also for EDG room

(provide support documents) :

10 Design codes & standards :

11 Approval from UL/TAC/FM :

12 Approval from other agencies as

per clause no. 4.0 :

(C) CONSTRUCTION FEATURES

1 Material of construction of :-

a. Support frame: b. Local control panel:

2 Provision of weighing and

measurement of CO2 fire

extinguishers:

3 Tests to be carried out at site :

(D) Control and Instrumentation :

1 Make, Model and range of all

instrumentation items individually .

2 Make, Model and Amp Hour

capacity of Battery Bank.

3 Material and Dimension of Control

Panel.

4 Power consumption of each control

panel.

5 Cable entry from the top.

6 Control note and schematic of the

system being proposed.

(E) Proof of Ability: The bidder shall submit with the bid a brief list of power stations / fertilizer plants / chemical plants, oil refineries, any other installations etc. where the manufacturer has carried out similar mature of work of complete design & engineering, supply , construction, erection, testing including control and instrumentation required for automatic CO2 total flooding fire extinguishing system preferably for Diesel generators (give rating also) and which are in operation. The supplier shall indicate the year of commissioning and guaranteed effluent quality on each case.

(F) Drawings, Literature and Other Information to be submitted with the Bid Following drawings, data and information for the equipment shall be submitted by the Bidder along with his proposal.

a Schematic of integrated control and instrumentation diagram of automatic CO2

total flooding fire extinguishing system with control panel, fire detectors etc.

b Preliminary general arrangement drawings showing location of fire detectors,

control panels, CO2 extinguishers, etc. and giving overall dimensions.

c Particulars of the performance tests to be conducted.

d Descriptive and illustrative drawings including cross-sectional drawings of CO2

cylinders with Bill of material of construction.

e Cleaning Procedure.

f Approvals form recognized body like FM/UL/TAC.

g Literature/Catalogues for all equipment/instruments offered.

(G) DRAWINGS, DATA, INSTRUCTION MANUAL, TEST REPORTS SCHEDULE OF SUBMISSION – DELIVERY

Description Submission of Drawing for Approval in weeks after the issue of Purchase Order

1 Final version of all the drawings, data etc., which includes P & I diagram.

_________________ weeks

2 Final layout drawings.

_________________ weeks

3 Load and foundation design data of all equipment.

_________________ weeks

4 Erection procedure

_________________ weeks

5 Detailed equipment drawings indicating dimensions and materials of construction

_________________ weeks

6 O & M instruction manuals

_________________ weeks

7 Reports on various test at site

_________________ weeks

8 End documents

_________________ weeks

9 Other drawings and data

_________________ weeks

10 Start of procurement / fabrication of equipment/component

_________________ weeks

11 Completion of procurement/fabrication of equipment

_________________ weeks

12 Start of dispatch of equipment to site

_________________ weeks

13 Completion of delivery of equipment to site

_________________ weeks

14 Completion of erection of equipment to site

_________________ weeks

15 Completion of testing & commissioning of automatic CO2 extinguishing system

_________________ weeks

(H) DRAWINGS AND INFORMATION TO BE SUBMITTED BY SUCCESSFUL BIDDER:

1 After finalisation of the contract, various drawings and data shall be submitted for review of PURCHASER and afterwards final distribution in quantities & procedures as indicated in the applicable Clauses elsewhere in this specification. The various drawings and data to be furnished shall include the following :

a Final version / as built drawings of piping and supports .

b Design Documents-Process & control description, Technical specification, data sheets.

c Erection manual.

d Operation and maintenance instruction manual as specified in relevant clauses.

e Instrument Schedule & Data-Sheets, Instrument Erection Drawings, Engineering & Wiring Diagrams, Panel General Arrangement Drawings, Interconnection Cable Schedule, Terminal Lists .

f Support schedule, bill of quantities, list of equipments/devices etc.

g Control Philosophy for CO2 fire protection system.

2 All data furnished during bidding stage including details furnished under Clause-F above shall be treated as final and binding on the Bidder. If, however, any change is essential during detail design stage for any improvement in the system, such changes shall be carried out only after obtaining PURCHASER’s approval.

3 Test reports, performance data and other particulars as required by the applicable clauses of this specification.

Annexure-1 CO2 GAS FLOODING SYSTEM FOR NAPS 1, DG-1 AND DG-2 Sr No

Item Description Unit NAPS 1 .DG-1 & DG-2 MOT TOT Total

Main Standby Total Only Main Bank

Only Main Bank

1 New Empty CO2 Cylinder (Water capacity will be similar to existing main bank cylinders ).

Existing 18 Nos of Cylinders will be used subject to passing Hydro test

18 18 1 1 20 Nos.

2 Hydro testing, refilling of CO2 Cylinders

18 18 36 1 1 38 Nos.

3 Electro/Pneumatic Operated Valve (Master)

2 2 4 1 1 6 Nos.

4 Pneumatic Operated Valve (Slave)

16 20 36 2 2 40 Nos.

5 Manifold Check Valve 18 22 40 3 3 46 Nos. 6 CO2 Discharge Hose 18 22 40 3 3 46 Nos. 7 CO2 Interconnection

Hose 16 20 36 2 2 40 Nos.

8 Online Hanging Type Cylinder Weighing Device

18 22 40 3 3 46 Nos.

9 CO2 Discharge Nozzle with Horn.

12 4 4 20 Nos.

10 CO2 Cylinder Manifold - for 18 Cylinders

1 1 2 0 0 2 Lot

11 CO2 Cylinder mounting frame for 18 cylinders

1 1 2 0 0 2 Lot


0 0 0 1 1 2 Lot


0 0 0 1 1 2 Lot

14 N2 Pilot Cylinder with electro pneumatic valve

1 1 2 1 1 4 Lot

15 Pneumatic Operated Directional valve with limit switch

1 1 2 0 0 2 Nos.

16 DV Manifold with end fittings

1 0 0 1 No.

17 Pneumatic Line vent 2 2 4 1 1 6 Nos. 18 Piping Pressure Switch 5 1 1 7 Nos. 19 Pneumatic testing of

Pipe and fittings 5 1 1 7 Nos.

20 Miscellaneous Mechanical Items like Structural Steel for Supports, Brackets Paint, Pneumatic Tubing, Nut Bolts,

1 1 1 3 Lot

CO2 GAS FLOODING SYSTEM FOR NAPS 1, DG-1 AND DG-2 Sr No



Only Main Bank

fastners etc 21 Conventional CO2 Gas

Release Fire Alarm CO2 Panel

1 1 1 3 Nos.

22 Conventional Multi Detector

20 0 0 20 Nos.

23 Probe type Heat Detector

0 2 2 4 Nos.

24 Hooter 4 1 1 6 Nos. 25 Manual Call Point 2 1 1 4 Nos. 26 Manual Release

Switch 2 1 1 4 Nos.

27 Abort Switch 2 1 1 4 Nos. 28 Cables.2C X 1.5 Sq

mm Armoured FRLS Cable on saddles

500 100 100 700 Lot

29 Miscellaneous Electrical Items like Cable Glands, Junction Box, Cable Marker, Tags ,etc

1 1 1 3 Lot

CO2 GAS FLOODING SYSTEM FOR NAPS 1, DG-1 AND DG-2 S. No.

Item Description Qty Unit rate (Rs.)

1.00 If the existing CO2 Cylinder fails in hydro tests , it will be disposed off as per PESO government guidelines and New CO2 Cylinders have to be provided .Rate of New Empty CO2 Cylinder (Water capacity will be similar to existing main bank cylinders ) without valve and without gas (Rates are to quoted)

1

2.00 CO2 Pipes. MOC Carbon steel .Seamless ASTMA106 2.10 2" Sch 80 (Rates are to be quoted) 1 2.20 1.5" Sch 80 (Rates are to be quoted) 1 2.30 1" Sch 80 (Rates are to be quoted) 1 2.40 3/4" Sch 40 (Rates are to be quoted) 1 2.50 1/2" Sch 40 (Rates are to be quoted) 1 Following items are quoted on unit rate basis as the routing can be decided during detailed engineering post purchase order . 3.00 FRLS Armoured Cable 3.1 2C X 1.5 Sq mm (Rates are to be quoted) 1 3.2 10C X 1.5 Sq mm (Rates are to be quoted) 1 CO2 GAS FLOODING SYSTEM FOR NAPS 2, DG-1 AND DG-2 Sr No



Only Main Bank

1 New Empty CO2 Cylinder (Water capacity will be similar to existing main bank cylinders ).

Existing 18 Nos of Cylinders will be used subject to passing Hydro test .

18 18 1 1 20 Nos.

2 Hydro testing ,refilling of CO2 Cylinders

18 18 36 1 1 38 Nos.


2 2 4 1 1 6 Nos.

4 Pneumatic Operated Valve (Slave)

16 20 36 2 2 40 Nos.

5 Manifold Check Valve 18 22 40 3 3 46 Nos. 6 CO2 Discharge Hose 18 22 40 3 3 46 Nos. 7 CO2 Interconnection

Hose 16 20 36 2 2 40 Nos.

8 Online Hanging Type Cylinder Weighing Device

18 22 40 3 3 46 Nos.

9 CO2 Discharge Nozzle with Horn.

12 4 4 20 Nos.


1 1 2 0 0 2 Lot


1 1 2 0 0 2 Lot


0 0 0 1 1 2 Lot

13 CO2 Cylinder 0 0 0 1 1 2 Lot

CO2 GAS FLOODING SYSTEM FOR NAPS 2, DG-1 AND DG-2 Sr No



Only Main Bank

mounting frame for 3 cylinders


1 1 2 1 1 4 Lot

15 Pneumatic Operated Directional valve with limit switch

1 1 2 0 0 2 Nos.

16 DV Manifold with end fittings

1 0 0 1 No.

17 Pneumatic Line vent 2 2 4 1 1 6 Nos. 18 Piping Pressure Switch 5 1 1 7 Nos. 19 Pneumatic testing of

Pipe and fittings 5 1 1 7 Nos.

20 Miscellaneous Mechanical Items like Structural Steel for Supports, Brackets Paint, Pneumatic Tubing, Nut Bolts, fastners etc

1 1 1 3 Lot

21 Conventional CO2 Gas Release Fire Alarm CO2 Panel

1 1 1 3 Nos.

22 Conventional Multi Detector

20 0 0 20 Nos.

23 Probe type Heat Detector

0 2 2 4 Nos.

24 Hooter 4 1 1 6 Nos. 25 Manual Call Point 2 1 1 4 Nos. 26 Manual Release

Switch 2 1 1 4 Nos.

27 Abort Switch 2 1 1 4 Nos. 28 Cables.2C X 1.5 Sq

mm Armoured FRLS Cable on saddles

500 100 100 700 Lot

29 Miscellaneous Electrical Items like Cable Glands, Junction Box, Cable Marker, Tags, etc

1 1 1 3 Lot

CO2 GAS FLOODING SYSTEM FOR NAPS 2, DG-1 AND DG-2 Following items are as optional and will be required if the existing components fails in hydro test/pneumatic test Sr No


1.00 If the existing CO2 Cylinder fails in hydro test , it will be disposed off as per PESO government guidelines and New CO2 Cylinders have to be provided .Rate of New Empty CO2 Cylinder (Water capacity will be similar to existing main bank cylinders ) without valve and without gas (Rates are to quoted)

1

2.00 CO2 Pipes. MOC Carbon steel .Seamless ASTMA106 2.10 2" Sch 80 (Rates are to quoted) 1 2.20 1.5" Sch 80 (Rates are to quoted) 1 2.30 1" Sch 80 (Rates are to quoted) 1 2.40 3/4" Sch 40 (Rates are to quoted) 1 2.50 1/2" Sch 40 (Rates are to quoted) 1 We have approximately estimated cables in above bill of materials , however ,cable routing will be decided during detailed engineering post purchase order .Hence any additional quantity will be billed as per unit rate below:

3.00 FRLS Armoured Cable 3.1 2C X 1.5 Sq mm (Rates are to quoted) 1 3.2 10C X 1.5 Sq mm (Rates are to quoted) 1 CO2 GAS FLOODING SYSTEM FOR NAPS-1 & 2, DG-3

Sr No

Item Description Quantity Unit NAPS-1 &2 .DG-3 Total

Main Standby Total 1 New Empty CO2 Cylinder (Water

capacity will be similar to existing main bank cylinders).

Existing 18 Nos of Cylinders will be used subject to passing Hydro test

18 18 18 Nos.

2 Hydro testing ,refilling of CO2 Cylinders

18 18 36 36 Nos.


2 2 4 4 Nos.

4 Pneumatic Operated Valve (Slave) 16 20 36 36 Nos. 5 Manifold Check Valve 18 22 40 40 Nos. 6 CO2 Discharge Hose 18 22 40 40 Nos. 7 CO2 Interconnection Hose 16 20 36 36 Nos. 8 Online Hanging Type Cylinder

Weighing Device 18 22 40 40 Nos.

9 CO2 Discharge Nozzle with Horn. 12 12 Nos. 10 CO2 Cylinder Manifold - for 18

Cylinders 1 1 2 2 Lot


1 1 2 2 Lot


0 0 0 0 Lot


0 0 0 0 Lot


1 1 2 2 Lot

15 Pneumatic Operated Directional valve 1 1 2 2 Nos.

CO2 GAS FLOODING SYSTEM FOR NAPS-1 & 2, DG-3 Sr No

Item Description Quantity Unit NAPS-1 &2 .DG-3 Total

Main Standby Total with limit switch

16 DV Manifold with end fittings 1 1 No. 17 Pneumatic Line vent 2 2 4 4 Nos. 18 Piping Pressure Switch 5 5 Nos. 19 Pneumatic testing of Pipe and fittings 5 5 Nos. 20 Miscellaneous Mechanical Items like

Structural Steel for Supports, Brackets Paint, Pneumatic Tubing, Nut Bolts, fastners etc

1 1 Lot

21 Conventional CO2 Gas Release Fire Alarm CO2 Panel

1 1 Nos.

22 Conventional Multi Detector 20 20 Nos. 23 Probe type Heat Detector 0 0 Nos. 24 Hooter 4 4 Nos. 25 Manual Call Point 2 2 Nos. 26 Manual Release Switch 2 2 Nos. 27 Abort Switch 2 2 Nos. 28 Cables.2C X 1.5 Sq mm Armoured

FRLS Cable on saddles 500 500 Lot

29 Miscellaneous Electrical Items like Cable Glands, Junction Box, Cable Marker, Tags ,etc

1 1 Lot

CO2 GAS FLOODING SYSTEM FOR NAPS-1 & 2, DG-3 Following items are as optional and will be required if the existing components fails in hydro test/pneumatic test Sr No


1.00 If the existing CO2 Cylinder fails in hydro tests , it will be disposed off as per PESO government guidelines and New CO2 Cylinders have to be provided .Rate of New Empty CO2 Cylinder (Water capacity will be similar to existing main bank cylinders ) without valve and without gas (Rates are to quoted)

1

2.00 CO2 Pipes. MOC Carbon steel .Seamless ASTMA106 GRB 2.10 2" Sch 80 (Rates are to quoted) 1 2.20 1.5" Sch 80 (Rates are to quoted) 1 2.30 1" Sch 80 (Rates are to quoted) 1 2.40 3/4" Sch 40 (Rates are to quoted) 1 2.50 1/2" Sch 40 (Rates are to quoted) 1 We have approximately estimated cables in above bill of materials , however ,cable routing will be decided during detailed engineering post purchase order .Hence any additional quantity will be billed as per unit rate below:

3.00 FRLS Armoured Cable 3.1 2C X 1.5 Sq mm (Rates are to quoted) 1 3.2 10C X 1.5 Sq mm (Rates are to quoted) 1

Annexure-II General Specifications:

A. CO2 fire fighting system for DG room. DG CO2 fire fighting system comprises three zones each zone should have independent fire sensor, manual call points local flasher Hooter, abort switch. All necessary valve pilot valve pneumatic cylinders, actuators, electronics component] relays internal wiring etc. will supplied by supplier to meet the requirements of all six nos. DGs sets. For all three zones, 2 nos. CO2 banks are to be provided. Each bank contains 18 nos. CO2 cylinders. In case of sensing fire by thermal detectors, manual call points or by pneumatic mode, audio visual alarm (by flasher Hooter) to be annunciated at respective zone as well as at local panel and after 30 seconds, CO2 gas to be flooded in respective zone. This time delay is meant for evacuation of affected zone. However in case of actuation emergency push button, CO2 to be flooded immediately (without time delay) it is preferable this time delay programmable. Mounting brackets for CO2 cylinders should be seismically qualified as per attached Specification No. PP-E-2509-R-0. The control panel of all the DGs should have mounting seismically qualified as per PPE. All new CO2 cylinders should have certified for hydro test qualified and, if existing cylinders are to be used should also have hydro test qualification. Supplier has to remove old existing detectors, Hooter, cables, conduit, control panel etc. and lay new FRLS cable, conduit pipe, detectors, manual call point, Hooter, control panel etc. All the cables, conduit, detectors, hooters, control panel etc. are to be supply, install and commission by supplier only. New nozzles are to be provided by supplier. All CO2 cylinders, their mounting bracket / frame removal, fabrication of CO2 cylinders mounting brackets, installation of mounting bracket, required piping & support, required pilot valve, pilot cylinders, required nuts and bolts etc. are in the scope of supplier. CO2 cylinder hydro test is also in the scope of supplier. Online hanging type weight monitoring device for each cylinders is to be provided by supplier.

B. CO2 fire fighting system for oil tanks (namely MOT & TOT) There are total 4 nos. CO2 fire protection system is required for NAPS-1 & 2 MOT & TOT. The control panel for MOT & TOT should be independent and their mounting should be seismically qualified as per enclosed PP-E-2509-R-0. Both MOT & TOT CO2 cylinders should have independent banks and interlocks. All necessary valve pilot valve, pneumatic cylinder. Actuator, electronic component, relays internal wiring etc. will be supplied by supplier to meet the requirement. Supplier has to remove old existing detectors, Hooter, cables, conduit, control panel etc. and lay new FRLS cable, conduit pipe, detectors, manual call point, Hooter, control panel etc. All the cables, conduit, detectors, hooters, control panel etc. are to be supply, install and commissioning by supplier only. All CO2 cylinders, their mounting bracket / frame removal, fabrication of CO2 cylinders mounting brackets, installation of mounting bracket, required piping, required

pilot valve, pilot cylinders, required nuts and bolts etc. are in the scope of supplier. CO2 cylinder hydro test is also in the scope of supplier. Online hanging type weight monitoring device for each cylinders is to be provided by supplier.

C. Party has to submit full schematic drawing for offered CO2 fire protection system with his offer. Party may require to visit NAPS site to understand the requirement before / after submitting their offer. Detailed circuit diagram, wiring diagram, general arrangement of system panel, interlocks, programming details of panel to be supplied as part of the system.

D. The specifications PP-E-2509-R-0 covers the general technical requirement for carrying out modification in existing CO2 fire extinguishing system for DGs of NAPS. Party has to send their offer as per enclosed PP-E-2509-R-0.

E. Actuation logic: System should actuate flooding of CO2 by the following 2 modes. 1. Electrical Mode :

(a) By sensing fire by any thermal detector in respective zone. (b) By braking glass of manual call point located at respective zone. (c) By actuation of emergency manual push button located at electronic panel supplied

by supplier.

2. Pneumatic mode: in absence electronic panel / power supply outage (non-availability of power battery supply) system should actuate with pneumatic cylinders located at remote.

F. Control and indication: 1. In any case fire is sensed either manually or automatically, potential free

contacts to be generated for remote indications (for control room indication / logic actuation). For this potential free contacts independent for each zone ( 3 CO, 24 V AC @ 5 Amp.).

2. Diagnostic alarm message power supply healthiness indications, logic actuation, system healthiness indication, status / indication of mode of actuation, detectors / loop / healthiness indications etc. are to be provided on electronic panel.

3. Alarm acknowledges, silence, reset and test facility to be provided for each zone independent.

G. Power supply: 1. System should operable by feeding 240 V AC. Necessary, power supply

modules to supplied as part of system in case requirement of the system. 2. In case of failure 240 V AC, Battery backup should be capable of system

concerned. 3. Normally battery should be on floating mode.

H. For pneumatic of operation 10 nos. (6 nos. of DGs for CO2 fire fighting system+4 nos. for MOT & TOT fire fighting system) of nitrogen cylinder along with valve / fitting are to be supplied by the supplier.

I. CO2 hose should be double wire braded rubber covered hose suitable to with stand minimum bursting pressure of 420 kgf/sqcm at 54 Deg. C as per clause no. 3.3.1.5 of IS:6382.

J. Thermal detector should have fixed temperature as well as rate of rise set point. K. For CO2 fire protection system optical type smoke detectors and heat detectors

shall be strategically placed in the areas sense the fire. These shall be wired and arranged in a crossed zone configuration.

L. Each DGs Room shall have independent fire extinguishing system. M. Required CO2 cylinders and pilot cylinder are to be supplied by the supplier

before supply actuators, which are to be mounted on cylinder, compatibility is to be confirmed and accordingly to be supplied.

N. Details manual containing operation, maintenance / trouble shooting guideline for electronic panel, pneumatic valves / actuator pilot valves etc. are to be supplied.

O. Cards, terminals, PCB, relay identification tagging / marking to be provided.

(V. Mehra) SO/F, CMS

SCHEMATIC DIAGRAM OF CO2 FIRE PROTECTION SYSTEM FOR NAPS-1 & 2 DGs.

SCHEMATIC DIAGRAM OF CO2 FIRE PROTECTION SYSTEM FOR NAPS-1 & 2 MOT & TOT