spec_fuel gas conditioning system

2400 MW CCPP SAMALKOT

Expansion

Technical Specifications for

Fuel Gas Conditioning System

RELIANCE INFRASTRUCTURE LIMITED EPC Division, D-220, Sector-63, Noida

Document No. REL-SKCCP- NEM-161-P-00001 (Rev.00)


Fuel Gas Conditioning System 2400 MW SAMALKOT CCPP

EXPANSION

DOCUMENT CONTROL SHEET

0 10.12.10 Spec PT AKS KVH CS SSB KS AD NKG KBB SLK AS

Mech. Lead

Civil Lead

Elec.Lead

C&I Lead

Functional

specialist

Engg. Mgr

Deptt. Head / Func. Head

HOD

(Engg)

Project Director Prep.

By Pkg. Engr.

Reviewed By Approved By

Rev No. Date Descri

ption

R INFRA

(This document is a property of Reliance Infrastructure Limited. This is not transferable and

shall not be used for any purpose other than for which it is issued.)

Technical Specifications for Fuel Gas Conditioning System

2400 MW SAMALKOT CCPP EXPANSION

REL-SKCCP- NEM-161-P-00001 (Rev.00) INDEX Page2 of 3

PART-I SECTION 1 INFORMATION TO BIDDERS (ITB) SPECIAL CONDITIONS OF CONTRACT (SCC) COMMERCIAL EVALUATION FORMAT SECTION 2 GENERAL CONDITIONS OF CONTRACT (GCC) PART – II TECHNICAL SPECIFICATION SECTION-A GENERAL TECHNICAL INFORMATION

1. Intent of Specification

2. Project Information

a. Project Information Data

b. Clarified Water Analysis

3. Qualifying Requirements for Bidders

4. System Description & Layout

5. Scope of Supply & Services

6. Terminal Points & Exclusions

7. Liquidated Damages for Shortfall in Performance

8. Bid Evaluation Criteria

9. Tender Drawings

SECTION-B COMMON TECHNICAL SPECIFICATION

1. System Design Basis & Operating Capability

2. Codes & Standards

3. Performance Guarantees

4. System Trial Operations

5. Performance Guarantee Test Procedure



REL-SKCCP- NEM-161-P-00001 (Rev.00) INDEX Page3 of 3

6. Spare Parts

7. Type Test & Type Test Charges

SECTION-C DETAILED TECHNICAL SPECIFICATION MECHANICAL

ELECTRICAL INSTRUMENTATION & CONTROL

PART-III SECTION 1 GENERAL TECHNICAL REQUIREMENT (GTR) SECTION 2 ERECTION CONDITIONS OF CONTRACT (ECC)

PART-IV DATA TO BE SUBMITTED BY THE BIDDERS

SECTION 1 TECHNICAL DATA SHEETS

SECTION 2 SCHEDULES



REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION A Page 1 of 13

PART II

SECTION -A

GENERAL TECHNICAL INFORMATION




1.00.00 INTENT OF SPECIFICATION

1.01.00 This Bid document is intended to cover the design, engineering, manufacture, supply, assembly/re-assembly, tests at manufacturer's works, forwarding, (duly packed for transportation), transportation, delivery to the site, receiving at site, unloading, handling, storage, and in-plant transportation at site, complete services of erection, testing at site, successful commissioning, trial run, final painting and handing over the plant in a flawless operating condition to the Owner of the fuel gas conditioning system and as required for safe and trouble free smooth & efficient operation for Samalkot Project. Samalkot CCPP shall be of 03 (three) modules with each module having 2 Gas Turbine (GT) + 2 Heat Recovery Steam Generator (HRSG) + 1 Steam Turbine (ST). Heat Balance Diagram (HBD) No.s REL-SKCCP-NEG-E24-T-00001, REL-SKCCP-NEG-E24-T-00002, REL-SKCCP-NEG-E24-T-00003 are attached for reference.

1.02.00 Any additional item, material, services which are not specifically mentioned here, but are required to make the system complete in every respect in accordance with the technical specification and for safe, trouble free & efficient operation and guaranteed performance, shall be covered under the scope of this specification.

1.03.00 The equipment and services to be furnished and erected as required in Technical Specification shall also meet all the requirements as stated in “General Conditions of Contract” (GCC), “Special conditions of Contract”, and other schedules. “Erection Conditions of Contract” (ECC) and “Technical Data Sheets” shall be considered as a part of this technical specification.

1.04.00 It is not the intent to specify completely herein all aspects of design and construction of equipment. Nevertheless, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation.

1.05.00 Bidder is requested to carefully examine and understand the specifications and seek clarifications, if required. Such clarifications shall reach Owner at least 15 days before the scheduled date of the opening of the bid documents. The Bidder’s offer should not carry any sections like clarifications, interpretations and / or assumptions

1.06.00 Any deviation or variation from the scope, requirement and / or intent of this specification shall be clearly defined under Deviation Schedules of Bid Proposal sheets’ irrespective of the fact that such deviations / variations may be standard practice or a possible interpretation of the specification by the Bidder. Except for those deviations / variations covered under Deviation Schedules which are accepted by the Owner before the award of the contract, it will be the responsibility of the bidder to fully meet the intent and the requirements of the specification within the quoted price. No other deviation whatsoever from this specification, except for the declared deviations submitted by the bidder with his proposal under “schedule of deviations” shall be considered. Bids not complying with this requirement shall be treated as non responsive and hence liable for rejection. The interpretation of the Owner in respect of the scope, details and services to be performed by the bidder, shall be binding, unless specifically clarified otherwise by the Owner in writing before the award of the Contract.




2.00.0 PROJECT INFORMATION

2.01.0 PROJECT INORMATION DATA

1 Power Evacuation Generating Units shall be connected through generator transformer to 400 kV buses, which in-turn shall be connected with grid. Generating units shall be capable of operating in parallel with the other generating units of the plant and the grid.

2 Location Vetlapalam , East Godavari District, Andhra Pradesh. Latitude: 17°2’25”N Longitude: 82°8’10”E

3 Approach Road The proposed site is approachable from Samalkot town, which is about 1 Km from the existing ADB Road between Kakinada port and National Highway No. 5.

4 Railway Approach The Site is 3 Km from the Samalkot Railway Station on Vishakhapatnam - Vijayawada broad gauge line..

5 Nearest Air Port The nearest airport is Vishakhapatnam Air port, 155 km & Rajahmundry Air port, 50 km

Nearest Port Kakinada Port

6 Land Availability The land area available for expansion is approx. 130 acres.

7 Fuel Availability Natural Gas with expected composition as per Clause 2.2

8 Make-up Water The make up water requirement for the project would be made available by Owner at Plant Raw water reservoir. Raw Water Analysis is as per Clause 2.3

9 Meteorological Data

9.1 Finished Ground Level (FGL) of plant area 22-33 M above mean sea level

9.2 Max. Ambient DBT 470C with 20% RH

9.3 Min. Ambient DBT 140C with 90% RH

9.4 Relative Humidity (Min & Max) 20%-90%

9.5 Design Ambient DBT/ Design Cooling water

29°C/32°C/70%




temp/ Design RH

9.6 Annual Average WBT 27.40C

9.7 Basic Wind Velocity 50 m/s

9.8 Design Wind Velocity As per IS:875 Part-3(2003) & IS 15498 (2004)

9.9 Cyclonic effect 1.15 times basic wind speed

9.10 Annual average rain fall 1172 mm

9.11 Max. Rain fall intensity 501 mm per day

9.12 Normal Period of rain fall June – September

9.13 Earthquake Design Criteria

Zone-III as per IS:1893 -Part-I (2002) & Part –IV (2005) (Importance factor-1.75)

9.14 Wind Design Criteria Maximum wind pressure including winds of short duration shall be as per IS:875 Latest Issue.

9.15 General environment of site

Tropical Conditions with frequent cyclonic Condition

9.16

Soil Investigation and foundation consideration

The existing geotechnical investigation undertaken during Phase-I project ,indicates that the site consists of surficial soil which is laterite in nature(residual soils) to about 3 to 6m underlain by very severely weathered shale and sandstone. Before the commencement of civil / structural design, detailed geo-technical investigation for the expansion project should be carried out by the Bidder.

9.17 Site Topography and Grading.

As per the existing contour survey drawing from Phase-I the existing ground level gradually slopes up from south-west towards north-east. Finished grade level of site shall be decided based on site topography and local HFL.

Note:

a. Design ambient temp for electrical equipments shall be 500C.

b. Bidders are advised to visit project site and collect data on local conditions to

enable them make a fully compliant bid and successful execution of the Contract

2.02.0 SPECIFICATION OF NATURAL GAS

Gas analysis Property Unit Composition Range Design C1 Methane CH4 % Molar 80-100 99.55 C2 Ethane C2H6 % Molar 0-10 0.13 C3 Propane C3H8 % Molar 0-5 0.06




C4 IsoButane C4H10 % Molar 0-3 - C4 N Butane C4H10 % Molar - - C5 IsoPentane C5H12 % Molar 0-2 - C5 N Pentane % Molar - - C6 Hexanes % Molar - 0.03 C7 Tolune/Heptane % Molar - 0.04 C8 Octane - C9 Nonane - C10 Decane - - N2 Nitrogen % Molar 1 0.12 CO2 % Molar - 0.07 C2H2 (Acetylene) % Molar 0.1 - H2 (Hydrogen ) % Molar 0.1 - O2 - - Total % 100

Net heating value (volume based) Kcal/scm 8010-10680 8149

NHV KJ/Kg 49812 Ref temp for LHV Deg C 15.56 Density 0.685 Supply pressure, * Bar (g) 40-60 Supply temperature, Deg C < 55 Compressibility factor 'Z' Maximum variation in Wobbe index (WI) Contaminants : Trace Metals Pb+Zn ppm (wt) 0.5 (max) Na+K ppm (wt) 0.3 (max) Vanadium ppm (wt) 0.5 (max) Calcium ppm (wt) 2.0 (max) Magnesium ppm (wt) 2.0 (max) Sum of heavy metals (Hg +V+Pb+Zn+Ni +Others) ppm (wt) 1.0 (max) Liquid contents % wt Later

Moisture Kg/million

SCM 112 (max) H2S (Hydrogen Sulphide) ppm (wt) 5 (max) Total Sulphur (Including H2S ppm (wt) 10 (max)

* Exact pressure will be re-affirmed by Owner during detail engineering. However, Bidder shall indicate the minimum pressure required at gas terminal point.




2.03.0 RAW WATER ANALYSIS (Canal water)

Sr. No. Description Unit Min Max Avg

1 pH Value 7.1 7.8 7.47

2 Conductivity ppm 130 430 192.3

3 Turbidity ppm 10 702 127

4 Residual Chlorine as Cl2 ppm 0 0 0

5 Iron as Fe ppm 0.1 0.35 0.13

6 Total Dissolved Solids ppm 80 270 125

7 Total Hardness as CaCO3 ppm 48 112 69

8 Calcium ppm 28 72 43

9 Magnesium ppm 20 40 26

10 P-Alkanity ppm 0 0 0

11 Total Alkanity ppm 52 114 77

12 Chloride ppm 19.8 89 31

13 Sulphate ppm 2.0 10 4

14 Dissolved Silica ppm 11.4 17.2 14

2.04.0 Godavari River-Dowlaiswaram Barrage water analysis

Sample collection dt:08.09.10 PARAMETER (Tentative) UNITS VALUE pH - 7.65 Conductivity µS 146

Turbidity NTU 419 Total Hardness as CaCO3 mg/l 58.0

Calcium Hardness as CaCO3 mg/l 40.0 Magnesium Hardness as CaCO3 mg/l 18.0 Chlorides as Cl- mg/l 20.0 Iron as Fe +2 mg/l 0.21

Silica as SiO2 mg/l 15.3 P-Alkalinity as CaCO3 mg/l Nil Total Alkalinity as CaCO3 mg/l 58




3.00.00 QUALIFYING REQUIREMENTS FOR BIDDER

Bidders shall have designed, manufactured, supplied, erected, and commissioned minimum two nos. of Fuel gas conditioning system for similar capacity Combined Cycle Power Plant (CCPP). Such systems shall be in successful operation for a minimum period of two (2) years on the date set for opening of bid.

As an evidence of the qualification requirement, the bidder shall submit in his bid the relevant information such as following.

a) Name of the project/ Purchaser

b) Order Value and Date of commissioning

c) Major supply of equipment involved in the system along with its capacity.

d) Documentary evidence that Scope included “Design, supply, erection and commissioning” of Fuel gas conditioning system

e) Completion & Performance Certificate from purchaser stating that plant is in operation for atleast two (2) years.

f) Period for which it is in successful operation.

4.00.00 SYSTEM DESCRIPTION

R-Infra intends to construct a Combined Cycle Power plant of total 2200MW at Samalkot, Andhra Pradesh. The scheme envisaged Multi Shaft unit where one (1) block consists of 2 Gas Turbines, 2 Heat Recovery Steam Generator, 1 Steam Turbine. Selection of components of fuel gas conditioning system shall be based on the maximum flow and pressure of fuel gas corresponding to maximum capability of Gas Turbine at specified site ambient conditions. Bidder shall design, manufacture, and supply the fuel gas conditioning system as per scope specified under clause 5.00.00 for three (03) modules with all associated auxiliaries. Erection, Commissioning and testing at site shall be in the Bidder scope. All supporting structures as required for the work shall be in bidder scope. Fuel gas conditioning system shall be designed for the gas composition specified in clause 2.02.0 above. The Fuel gas parameters at plant boundary are considered as below

Pressure* 60 Bar(g) Temperature* 22° C

* These parameters shall be confirmed after finalization of contract with the Gas supply pipe line vendor.




The parameters required at the Accessory module gas compartment inlet are as below Pressure 28.3 to 34.5 Bar(g)

Temperature 10° C super heat or 70 which ever is higher to 185° C

Gas Quality As per GE document “GEI41040k” 5.00.00 SCOPE OF SUPPLY AND SERVICES

Scope of work in respect of equipment and systems shall be in accordance with the provisions of various sections of the specifications and to deliver a fully operational fuel gas conditioning system which meets the intent of the specification. The work shall be consistent with modern engineering and construction practices and shall be in compliance with all applicable code, standards, guidelines and safety requirements in force on the date of award of contract.

5.01.00 FUEL GAS CONDITIONING SYSTEM

5.01.01 Gas Conditioning system consisting of:

i) Emergency Stop Valve at the inlet to the gas system (one common for station)

ii) Knock Out Drum (1x100% for station)

iii) Gas flow metering devices- (1x100% for station)

iv) Filter separator (3x50% for station)

iv) Fuel Gas Startup Heater (2x50% for station)

v) Gas Pressure Reducing Station (3x50% for station)

vi) Absolute Filter units (2x100% for each GT-Total 12)

vi) Fuel Gas Efficiency Heater with temperature control valve on heating line and cold

leg bypass line to hot and cold mixing point (1x100% for each gas turbine-Total 6

Nos.)

vii) Scrubber (1x100 % for each Gas Turbine-Total 6)

viii) Gas condensate collection tank and disposal system complete with all piping and

fittings (one at Gas regulating Station area and one per GT for filters and scrubbers

- Total 7 )

ix) Nitrogen purging system for piping and equipments along with nitrogen cylinder.

x) All Electrical and C&I items for fuel gas conditioning plant.

xi) Complete piping, valves, safety valves, filters, and specialties in Fuel gas handling

system as specified and as required for safe and reliable operation. Necessary welding




neck counter flanges, gaskets & nuts and bolts at terminal connection to be provided.

The piping down stream of fine filter and by pass to efficiency heater shall be of

Stainless steal.

xii) Pipeline for LMS 100

xiii) Installation of Gas Chromatograph ( It will be supplied loose by owner)

xiv) Installation of Wobbe index meter ( It will be supplied loose by owner)

5.01.02 Heat insulation and cladding

5.01.03 Lifting lugs, eyebolts, access platform, etc.

5.01.04 Complete set of foundations bolts, nuts, shimming plates for horizontal; leveling,

connection bolt for protective earth grounding, etc. and embedded parts if

necessary.

5.01.05 Special Tools and tackles.

5.01.06 Surface preparation and painting at shop. Loose paint for touch up at site.

5.01.07 Erection, Commissioning, Performance guarantee test, reliability test.

5.01.08 Mandatory Spares and unit assemblies as applicable.

5.01.09 Start-up and commissioning spares.

5.01.10 Recommended spares for three (3) years normal operation and maintenance of

the plant at the option of the Owner.

5.01.11 Any other equipment/ system not specifically mentioned in the specification.

5.01.12 Control and Instrumentation

A. Scope of supply

The Bidder shall be responsible for providing all materials, equipment, field instruments/ devices as per the process requirement and services specified or otherwise which are required to fulfil the intent and ensuring operability, maintainability and reliability of total work covered under the specification. Complete Instrumentation & Control System required for safe and efficient operation of the Fuel Gas Supply System shall be in the scope of the Bidder. The scope of supply for C&I systems shall comprise the following as a minimum: 1. All required Measuring Instruments alongwith requisite process connection &

piping, viz. Pressure & Differential Pressure Transmitters/ Switches, Temperature Indicators/ Elements, Mass Flow Meter, Level Switches etc. required for safe & efficient operation of the system.

2. A complete Programmable Logic Controller (PLC) system, for control and

monitoring of complete Fuel Gas System, supplied by the Bidder.

The PLC shall be complete with the following as a minimum:




Redundant processors in hot standby configuration All required Input/ output (I/O) modules, including Remote I/O modules/

panels One PC based Operator cum Engineering Workstation including 21” TFT

monitor, mouse, Keyboard All required software Control desk/ furniture OPC connectivity to Owner procured BOP PLC network system All required cabinets

3. One complete adequately sized UPS system with 2x100% chargers/ inverters,

1x100% VRLA batteries for 1 hour backup, 1x100% solid state based standby AC source, 2 x 100% ACDBs, interconnect cabling etc.

4. Control valves on the heating line for the Efficiency heaters, complete with

microprocessor based positioner, actuator and other accessories as specified. 5. All required Instrumentation & Control Cables, including fibre-optic cables with

sub-trays for signal transmission from field/ MCC-Switchgear/ other system panels to PLC system/ Remote I/O cabinet, along with necessary laying, termination, accessories and erection hardware viz. conduits, lugs, glands, ferrules etc.

B. Scope of services The C&I system offered by the Bidder shall be complete in all aspects and any item or accessories not specifically mentioned in this specification, but essential for the proper operation and maintenance of the system, meeting all the requirements and intent of the specification, shall be supplied within the lump sum quoted price. The following services shall be included under Bidder’s scope

1 Erection and commissioning of all C&I Instruments and Control equipments

supplied under this package including Cable laying, termination, continuity check etc.. Bidder’s scope shall also include erection & commissioning (including the cabling of the same) of on-line Gas Chromatograph, procured by Owner under a separate package. Bidder shall provide an environment controlled enclosure for mounting the same.

2 Complete Documentation including O&M manuals. 3 Training of Owner’s personnel for PLC system and UPS

6.00.00 TERMINAL POINTS & EXCLUSIONS 6.01.00 TERMINAL POINTS

• Fuel gas supply at plant boundry

• Hot water inlet and condensate outlet nozzles at Fuel Gas Efficiency Heater

• Inlet to Gas Turbine Accessory module gas compartment for six ,9FA Gas

Turbines and at inlet to two, LMS 100 Gas Turbines

• DM water make up at inlet nozzle to Water bath heater

• Condensate pump discharge line at down stream of discharge valve




• Power Supply:

Owner shall provide three nos. 415 V three phase 50 Hz. Feeders at one point

from the switchgear/ Power Distribution Board. Further cabling including

distribution to Bidder’s loads shall be in Bidder’s scope.

• Hardwired Signal exchange with other systems viz. GTG control system, Fire

Fighting system, Chromatograph etc.

Terminals of other systems’ panels. Cabling from other systems’ panels to

Bidder’s system shall be in Bidder’s scope.

• OPC connectivity to BOP PLC network system

Ports of Switches of Bidder’s PLC system. Onward cabling to Owner’s BOP

PLC network system is excluded from Bidder’s scope

6.02.00 EXCLUSIONS

Following items of work are excluded from the scope of the present package:

- Civil Works - Construction water and power beyond the terminal point. These will be supplied

at one point for further distribution by the bidder as required.

- All utilities (service air, instrument air, de-mineralized water etc.) beyond terminal points.

- BOP PLC network system and cabling upto the same However, all required hardware/ software required at Bidder’s PLC end to enable bi-directional OPC connectivity to Owner’s BOP PLC network system shall be in Bidder’s scope.

- On-line Gas Chromatograph and Wobbe index meter

However, erection & commissioning of the same shall be in Bidder’s scope. 7.00.00 LIQUIDATED DAMAGES APPLICABLE FOR SHORTFALL IN PERFORMANCE 7.01.00 The Bidder shall guarantee that complete system specified in scope and detailed

specification, including all the Equipments offered individually shall meet the ratings and performance requirement stipulated in this specification.

7.02.00 The performance shall meet the requirements stipulated in the Section B. 7.03.00 The noise from the condensing plant and ancillary equipment shall be guaranteed to

meet the Ministry of Environment and Forest (MoEF) stipulations set out in the clearance letter i.e. 85 dB(A).

7.04.00 The design life for the condensing plant shall be guaranteed to be minimum of 25

years.




7.05.00 In case system fails to meet the contractual requirements as determined from the PG test evaluation, RInfra reserves the right to reject / accept the above mentioned equipments after levying the liquidated damages (LD). The liquidated damages shall be pro-rated for the fractional parts of the deficiencies. The amount of Liquidated damages shall be as per Part I, General Conditions of Contract.

7.06.00 Should the results of the performance test show that the equipments have

failed to meet the guarantees with respect to power consumption, the Contractor shall carry out the modification, at his own cost, if considered necessary to meet the guaranteed values. In such a case, the performance & guarantee test shall be repeated by the Contractor within one (1) month from the date the equipment is ready for retest. If the specified guarantees are not established within 90 days of notification by the Owner, the owner may at his discretion reject the equipment and recover the payments already made or accept the equipment after levying Liquidated Damages as specified above.

7.07.00 For the following parameters Liquidated damages shall be applicable:

Gas quality Gas Turbine Accessory module gas compartment. Pressure at Gas Turbine Accessory module gas compartment. Temperature at Gas Turbine Accessory module gas compartment

8.00.00 BID EVALUATION CRITERIA CONSIDERING GUARANTEED PARAMETERS 8.01.00 Functional Guarantees

Following data’s shall be demonstrated by the bidder Gas quality Gas Turbine Accessory module gas compartment. Pressure at Gas Turbine Accessory module gas compartment. Temperature at Gas Turbine Accessory module gas compartment

9.00.00 Tender Drawings

SL.NO DRAWING NO. TITLE

1. REL-SKCCP-NEM-161-P-00001 Flow Sheet- Fuel Gas conditioning System

2 REL-SKCCP-NEM-E15-B-00001 General plant layout

3 REL-SKCCP-NEG-E24-T-00001 Heat balance diagram: Base Load Operation Evaporative Cooler OFF

4 REL-SKCCP-NEG-E24-T-00002 Heat balance diagram: Base Load Operation Evaporative Cooler ON

5. REL-SKCCP-NEG-E24-T-00003 Heat balance diagram: 80% Net Equipment Load Evaporative Cooler OFF

6. GEI41040k FuelGasSpec from GT supplier

7. ----- White paper on fuel gas heating




8. ----- Fuel Gas efficiency heater specification from GE (Later)

9. 207D3883 schematic diagram Fuel gas system by GE

10. 143E2781 GE’s accessory module

11. 146E4069 Fuel gas Wobbe meter- GE drawing

12. 146E3454 Fuel gas chromatograph- GE drawing

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g GEI 41040k

Revised, January 2009

GE Energy

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Specification for Fuel Gases for Combustion in Heavy-Duty Gas

Turbines

GEI 41040k Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines

2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

TABLE OF CONTENTS

I. INTRODUCTION ...................................................................................................................................... 4 II. FUEL GAS CLASSIFICATION............................................................................................................... 9

A. Natural Gas, Liquefied Natural Gas (LNG) and Liquefied Petroleum Gas (LPG)................................ 9 B. Gasification Fuels ................................................................................................................................ 10 C. Process Gases....................................................................................................................................... 11

III. FUEL PROPERTIES............................................................................................................................... 11 A. Heating Values..................................................................................................................................... 11 B. Modified Wobbe Index (MWI)............................................................................................................ 12 C. Superheat Requirement........................................................................................................................ 13 D. Hydrocarbon Dew Point ...................................................................................................................... 15 E. Moisture Dew Point ............................................................................................................................. 15 F. Flammability Ratio .............................................................................................................................. 16 G. Gas Constituent Limits ........................................................................................................................ 16 H. Gas Fuel Supply Pressure .................................................................................................................... 16

IV. CONTAMINANTS................................................................................................................................... 17 A. Particulates........................................................................................................................................... 17 B. Liquids ................................................................................................................................................. 17 C. Sulfur ................................................................................................................................................... 17 D. Trace Metals ........................................................................................................................................ 19

V. SOURCES OF CONTAMINANTS ........................................................................................................ 19 A. Particulates........................................................................................................................................... 19 B. Liquids ................................................................................................................................................. 19 C. Sulfur ................................................................................................................................................... 19 D. Trace Metals ........................................................................................................................................ 19 E. Air ........................................................................................................................................................ 20 F. Steam ................................................................................................................................................... 20 G. Water.................................................................................................................................................... 21 H. Fuel ...................................................................................................................................................... 21

LIST OF FIGURES

Figure 1. Hydrocarbon and Moisture Superheat Requirements ........................................................................... 15 Figure 2. Moisture Dew Point as a Function of Concentration and Gas Pressure for a

Typical Natural Gas Fuel...................................................................................................................... 16

LIST OF TABLES

Table 1a. Fuel Gas Classification........................................................................................................................... 5 Table 1b. Representative GE Fuels Experience ..................................................................................................... 5 Table 2a. Fuel Gas Specification (see Note 1 and 2) ............................................................................................. 6 Table 2b. Allowable Gas Fuel Contaminant Levels............................................................................................... 7 Table 3. Test Methods for Gaseous Fuels............................................................................................................ 9

Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040k

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

APPENDIX

APPENDIX 1. DEFINITIONS.......................................................................................................................... 22 APPENDIX 2. PARTICLE SIZE LIMITATIONS ......................................................................................... 23 APPENDIX 3. EQUIVALENT CONTAMINANT RELATIONSHIPS (ALL MACHINES EXCEPT FB, H-CLASS) ................................................................................................. 24 APPENDIX 4. MINIMUM GAS TEMPERATURE REQUIREMENT CALCULATIONS ...................... 25 APPENDIX 5. REQUESTED FUEL ANALYSIS DATA FOR GE EVALUATION .................................. 26 APPENDIX 6. RELATED SPECIFICATION DOCUMENTS ..................................................................... 27



I. INTRODUCTION

General Electric heavy-duty gas turbines have the ability to burn a wide variety of gaseous fuels as classified in Table 1a. The properties of these gases can vary significantly due to the relative concentrations of the reactant and inert constituents. Because of GE’s long history and large installed base, GE’s experience with various fuel gases is broad and extensive. Table 1b summarizes this experience by frame size (B/E-class or F-class) and combustion system type (Dry Low NOx or Diffusion).

The fundamental combustor operability criteria must be satisfied regardless of the fuel that is being utilized by the turbine:

Robustness to auto-ignition Robustness to flashback Emissions compliance (NOx, CO, UHC, Smoke) Acceptable combustion dynamic pressures Robustness to lean blowout

The composition, reactivity, heating value, and contaminant levels of the fuel lead to selection of combustor design features to optimize these operability requirements. Prior to the mid-1970’s, diffusion combustors were the standard choice for gas turbines because of their simplicity and relative fuel flexibility. As emissions regulations became more stringent, water or steam injection systems were added to these diffusion combustors to reduce flame temperatures and lower NOx emissions. Further tightening of emissions requirements coupled with the desire for water-free low-emissions solutions led to the introduction of lean-premixed combustors in the late 1980’s such as GE’s Dry Low NOx (DLN) combustors. These lean-premixed combustion technologies were typically optimized for low-emissions operation on natural gas fuels and had characteristically lower fuel-flexibility than diffusion combustors.

As technology advances to achieve higher efficiency and lower emissions, some models and combustion systems impose restrictions on the physical and chemical properties of the fuel gases that can be utilized in order to protect the gas turbine and to burn these fuels in an efficient and robust manner. These restrictions are continually being updated as technology improves. Tables 2a and 2b provide a screen for fuels that are acceptable across most frame sizes and combustor types. Table 2a specifies the allowable fuel properties and constituents, and Table 2b lists the limitations on contaminants.

Fuels that fall outside of these limits are frequently acceptable for many specific applications; for example, a high hydrogen fuel can be used with diffusion flame combustors in most cases. The relationship between technologies can also be seen in the fuels experience shown in Table 1b. Additional approaches such as fuel heating and transfer fuels can extend the range of usable fuels. Because GE is continuously improving its products and increasing fuel flexibility, strict limits are not specified here by combustion system. Consultation with GE will allow a determination of the options available for specific fuel choices. Appendix 5 describes the information GE needs to evaluate potential fuel gases.

Table 3 identifies the acceptable test methods to be used for determining fuel gas properties shown in Tables 2a and 2b and discussed in the balance of this fuel specification.

The balance of this fuel specification provides more detailed description of the factors used in evaluating potential fuels as well as descriptions of the pretreatment that is sometimes required to ensure robust gas turbine operation.



Table 1a. Fuel Gas Classification

FUEL LHV Btu/scf

MAJOR COMPONENTS

Natural Gas and Liquefied Natural Gas 800-1200 Methane

Liquefied Petroleum Gas 2300-3200 Propane, Butane

Gasification Gases

- Air Blown 100-150 Carbon Monoxide, Hydrogen, Nitrogen, Water Vapor

- Oxygen Blown 200-400 Carbon Monoxide, Hydrogen, Water Vapor

Process Gases 300-3000 Methane, Hydrogen, Carbon Monoxide, Ethane, Ethene, Propane, Propene, Carbon Dioxide, Nitrogen

Table 1b. Representative GE Fuels Experience*

Constituent Limit, mole % Min Max Min Max Min Max Min Max NotesMethane 0 100 74 100 0 100 85 100 % of reactant speciesEthane 0 58 0 26 0 15 0 15 % of reactant speciesPropane 0 90 0 16 0 15 0 15 % of reactant speciesButane + higher paraffins (C4+) 0 100 0 7 0 5 0 5 % of reactant speciesHydrogen 0 95 0 18 0 47 0 3 % of reactant speciesCarbon Monoxide 0 76 0 15 0 60 0 5 % of reactant speciesTotal Inerts (N2 + CO2 + Ar) 0 68 0 42 0 24 0 28 % of total (reactants + inerts)

B/E-Class Experience F-Class ExperienceDiffusion DLN Diffusion DLN

*This experience is given as reference only and in no way guarantees robust operation on all combinations of fuels within this experience. For Fuel Gas Specification, see Table 2a.



Table 2a. Fuel Gas Specification (see Note 1 and 2)

FUEL PROPERTIES MAX MIN NOTES

Gas Fuel Pressure Varies with unit and combustor type

Varies with unit and combustor type

See Note 3

Gas Fuel Temperature, °F see note 4 Varies With gaspressure

see Note 4

Lower Heating Value, Btu/scf 1160 775 See Note 5

Modified Wobbe Index (MWI) See Note 6

- Absolute Limits 54 40 See Note 7

- Range Within Limits +5% -5% See Note 8

Flammability Ratio See Note 9 2.2:1 Rich: Lean Fuel/Air Ratio volume basis. See Note 10

Constituent Limits, mole %

Methane 100 85 % of reactant species

Ethane 15 0 % of reactant species

Propane 15 0 % of reactant species

Butane + higher paraffins (C4+) 5 0 % of reactant species

Hydrogen Trace 0 % of reactant species

Carbon Monoxide Trace 0 % of reactant species

Oxygen Trace 0 % of reactant species

Total Inerts (N2+CO2+Ar) 15 0 % of total (reactants + inerts).

Aromatics (Benzene, Toluene etc.)

Report 0 See Note 11

Sulfur Report 0 See Note 12



Table 2b. Allowable Gas Fuel Contaminant Levels

Turbine Inlet Limit, Xe ppbw

Fuel Equivalent Limit, XFe (see Note 13) ppmw

Machine Model Machine Model

MS3000,MS5000 B, E and F- Class

6C, FB, H-Class

Turbine inlet flow/fuelflow (B, E, F)

Turbine inlet flow/fuel (6C, FB, H)

Trace Metals

MS3000 MS5000 B, E and F- Class

6C, FB, H- CLASS

50 12 4 50 12 4

Lead (Pb) 20 20 1.00 0.240 0.080 1.00 0.240 0.080

Vanadium (V) 10 10 0.5 0.120 0.040 0.5 0.120 0.040

Calcium (Ca) 40 40 2.0 0.480 0.160 2.0 0.480 0.160

Magnesium (Mg) 40 40 2.0 0.480 0.160 2.0 0.480 0.160

Sodium + Potassium (see Note 14)

(Na/K)=28 20 1.00 0.24 0.080

(Na/K)=3 10 0.50 0.12 0.040

(Na/K)=<1 6

See GEK 107230 (1)

0.30 0.072 0.024

See GEK 107230 (1)

Particulates (see Note 15)

Total 600 600 30 7.2 2.4 30 7.2 2.4

Above 10 microns

6 6 0.3 0.072 0.024 0.3 0.072 0.024

Liquids: No Liquids allowed, gas must be superheated. (see Note 16)

Fuel Property and Contaminant Notes:

1. All fuel properties must meet the requirements from ignition to base load unless otherwise stated.

2. Values and limits apply at the inlet of the gas fuel control module, typically the purchaser’s connection, FG1.

3. Minimum and maximum gas fuel supply pressure requirements are furnished by GE as part of the unit proposal.

4. The minimum fuel gas temperature must meet the required superheat as described in section III–C. Separate requirements are included for hydrocarbon and moisture superheat. The maximum allowable fuel temperature is defined in GER 4189 (2).

5. Heating value ranges shown are provided as guidelines. Specific fuel analysis must be furnished to GE for thorough analysis. (See section III–A).

6. See section III–B for definition of Modified Wobbe Index (MWI).

7. The upper and lower limits for MWI shown are what can be accommodated within the standard dry low NOx fuel system designs. Fuels outside of this range can often be utilized and may need



additional design and development effort. Performance fuel heating may be restricted on fuel with high inert content to stay above the minimum MWI limit.

8. Variations of MWI greater than + 5% or –5% may be acceptable for some applications, (i.e., on units that incorporate gas fuel heating). GE must analyze and approve all conditions where the 5% variation is to be exceeded. See also Section III-B for applications where the MWI varies between the +-5% limits.

9. There is no defined maximum flammability ratio limit. Fuels with flammability ratio significantly larger than those of natural gas may require a start–up fuel. Further discussion and documentation on measurement and calculation of flammability limits are covered in references 5 and 6, Bureau of Mines Bulletins.

10. Candidate fuels, which do not meet these limits, should be referred to GE for further review. All fuels will be reviewed by GE on a case-by-case basis. (see section III–G).

11. When fuel heating for thermal efficiency improvements is utilized (e.g. Tgas > 300°F) there is a possibility of gum formation if excess aromatics are present. Contact GE for further information.

12. The quantity of sulfur in gas fuels is not limited by this specification. Experience has shown that fuel sulfur levels up to 1% by volume do not significantly affect oxidation/corrosion rates. Hot corrosion of hot gas path parts is controlled by the specified trace metal limits. Sulfur levels shall be considered when addressing HRSG Corrosion, Selective Catalytic Reduction (SCR) Deposition, Exhaust Emissions, System Material Requirements, Elemental Sulfur Deposition and Iron Sulfide. (refer to Section IV–C).

13. The contamination limits identified represent the total allowable limit at the inlet to the turbine section. These limits will be reduced if comparable contaminants are present in the compressor inlet air and combustion steam/water injection. Consult with GE for limits for specific applications.

14. Sodium and potassium, from salt water, are the only corrosive trace metal contaminants normally found in natural gases. Na/K =28 is nominal sea salt ratio. Other trace metal contaminants may be found in Gasification and Process Gases. GE will review these on a case-by-case basis.

15. The fuel gas delivery system shall be designed to prevent the generation or the admittance of solid particulate to the gas turbine gas fuel system. This shall include but not be limited to particulate filtration and non-corrosive (i.e. stainless steel) piping from the particulate filtration to the inlet of the gas turbine equipment. Fuel gas piping systems shall be properly cleaned/flushed and maintained prior to gas turbine operation. (See section IV–A).

16. The fuel gas supply shall be 100% free of liquids. Admission of liquids can result in combustion and/or hot gas path component damage. (See section III–C) GE will require an input signal from the conditioning system liquid level indication closest to the GE Speed Ratio Valve or Gas Control Valve. This liquid level indication will be brought into the turbine controller and used as a signal to stop Gas Turbine operation when the liquid level reaches a fault level. It is highly recommended that this device have redundancy. The supplier of the gas conditioning system should provide this signal.



Table 3. Test Methods for Gaseous Fuels

PROPERTY METHOD

Gas Sampling Procedure GPA 2166(3)

Gas Composition to C6 + (gas chromatography)

ASTM D 1945

Extended Gas Composition to C14

GPA 2286(4)

Heating Value ASTM D 3588

Specific Gravity ASTM D 3588

Compressibility Factor ASTM D 3588

Dew Point (see Test Method note 1)

ASTM D 1142

Sulfur (see Test method note 2) ASTM D 3246

Test Method Notes:

1. Hydrocarbon and water dew points shall be determined by direct dew point measurement (Chilled Mirror Device). If dew point cannot be measured, an extended gas analysis, which identifies hydrocarbon components from C1 through C14, shall be performed. This analysis must provide an accuracy of greater than 10 ppmv. A standard gas analysis to C6+ is normally not acceptable for dew point calculation unless it is known that heavier hydrocarbons are not present, as is most often the case with liquefied natural gases.

2. This test method will not detect the presence of condensable sulfur vapor. Specialized filtration equipment is required to measure sulfur at concentrations present in vapor form. Contact GE for more information.

II. FUEL GAS CLASSIFICATION

A. Natural Gas, Liquefied Natural Gas (LNG) and Liquefied Petroleum Gas (LPG)

Natural gases are predominantly methane with much smaller quantities of the slightly heavier hydrocarbons such as ethane, propane and butane. Liquefied petroleum gas is propane and/or butane with traces of heavier hydrocarbons.

1. Natural Gas

Natural gases normally fall within the calorific heating value range of 800 to 1200 Btu per standard cubic foot. Actual calorific heating values are dependent on the percentages of hydrocarbons and inert gases contained in the gas. Natural gases are found in and extracted from underground reservoirs. These “raw gases” may contain varying degrees of nitrogen, carbon dioxide, hydrogen sulfide, and contaminants such as salt water, sand and dirt. Processing by the gas supplier normally reduces and/or removes these constituents and contaminants prior to distribution. A gas analysis must be performed to ensure that the fuel supply to the gas turbine meets the requirements of this specification.



2. Liquefied Natural Gas (LNG)

Liquefied natural gas is produced by drying, compressing, cooling and expanding natural gas to approximately -260° F at 14.7 psia. The product is transported as a liquid and delivered as a gas after pressurizing and heating to ambient temperature. The composition is free of inerts and moisture and can be treated as a high quality natural gas. LNG can pick up moisture that is present in the pipeline but it is not a source of the moisture.

The hydrocarbon dew point is typically less than -10° F at 500 psia but, depending on the processing steps and tank size, the dew point may increase if the boil–off is continuously extracted between deliveries. Cooling and recompression of the boil–off will avoid this potential problem. The expected range in component concentrations should be obtained from the gas supplier to determine the potential change in dew point.

3. Liquefied Petroleum Gases

The heating values of Liquefied Petroleum Gases (LPGs) normally fall between 2300 and 3200 Btu/ scf (LHV). Based on their high commercial value, these fuels are normally utilized as a back-up fuel to the primary gas fuel for gas turbines. Since LPGs are normally stored in a liquid state, it is critical that the vaporization process and gas supply system maintains the fuel at a temperature above the minimum required superheat value. Fuel heating and heat tracing are required to meet these requirements.

B. Gasification Fuels

Gasification fuels are produced by either an oxygen blown or air blown gasification process and are formed using coal, petroleum coke or heavy liquids as a feedstock. In general, the heating values of gasification fuel are substantially lower than other fuel gases. The reduced heating value of gasification fuels result in the effective areas of the fuel nozzles being larger than those utilized for natural gas fuels.

1. Oxygen Blown Gasification

The heating values of gases produced by oxygen blown gasification fall in the range of 200 to 400 Btu/scf. These fuels normally have a hydrogen (H2) content above 30% by volume and a H2/CO mole ratio between 0.5 and 0.8. Oxygen blown gasification fuels are often mixed with steam for thermal NOx control, cycle efficiency improvement and/or power augmentation. When utilized, the steam is injected into the combustor by an independent passage. Due to the high hydrogen content of these fuels, oxygen blown gasification fuels are normally not suitable for Dry Low NOx (DLN) applications (see Table 2a). The high flame speeds resulting from high hydrogen fuels can result in flashback or primary zone re-ignition on DLN pre-mixed combustion systems. Utilization of these fuels requires evaluation by GE.

2. Air Blown Gasification

Gases produced by air blown gasification normally have heating values between 100 and 150 Btu/ scf. The H2 content of these fuels can range from 8% to 20% by volume and they can have a H2 /CO mole ratio 0.3 to 3:1. The use and treatment of these fuels is similar to that identified for oxygen blown gasification.

Gasification fuels provide a significant fraction of the total turbine mass flow rate. With oxygen blown fuels the diluents addition (typically nitrogen) also assists with NOx control. Careful



integration of the gas turbine with the gasification plant is required to assure an operable system. Due to the low volumetric heating value of both oxygen and air blown gases, a special fuel system and fuel nozzles are required.

C. Process Gases

Many chemical processes generate surplus gases that may be utilized as fuel for gas turbines. (e.g. tail or refinery gases). These gases often consist of methane, hydrogen, carbon monoxide, ethane, ethene, propane, propene, and carbon dioxide that are normally byproducts of petrochemical processes. The hydrogen and carbon monoxide contents of these fuels result in a high rich-to-lean flammability limit. These types of fuels often require inerting and purging of the gas turbine gas fuel system upon unit shutdown or a transfer to a more conventional fuel. When process gas fuels have extreme flammability limits such that the fuel will auto ignite at turbine exhaust conditions, a more “conventional” start-up fuel is required. Additional process gases that are utilized as gas turbine fuels are byproducts of steel production. These are:

1. Blast Furnace Gases

Blast Furnace Gases (BFGs), alone, have heating values below the minimal allowable limits. These gases must be blended with other fuels such as coke oven gas, natural gas or hydrocarbons such as propane or butane to raise the heating value above the required lower limit.

2. Coke Oven Gases

Coke oven gases are high in hydrogen and methane and may be used as fuel for non-DLN combustion systems. These fuels often contain trace amounts of heavy hydrocarbons, which may lead to carbon buildup on the fuel nozzles. The heavy hydrocarbons must be “scrubbed” or removed from the fuel prior to delivery to the gas turbine.

3. COREX Gases

COREX gases are similar to oxygen blown gasification fuels and may be treated as such. They are usually lower in H2 content and have heating values lower than oxygen blown gasification fuels.

III. FUEL PROPERTIES

A. Heating Values

The heat of combustion, heating value or calorific value of a fuel is the amount of energy generated by the complete combustion of a unit mass of fuel. The US system of measurement uses British thermal units (Btu) per pound or Btu per standard cubic foot when expressed on a volume basis. The heating value of a gas fuel may be determined experimentally using a calorimeter in which fuel is burned in the presence of air at constant pressure. The products are allowed to cool to the initial temperature, and a measurement is made of the energy released during complete combustion. All fuels that contain hydrogen release water vapor as a product of combustion, which is subsequently condensed in the calorimeter. The resulting measurement of the heat released is the higher heating value (HHV), also known as the gross heating value, and includes the heat of vaporization of water. The lower heating value (LHV), also known as the net heating value, is calculated by subtracting the heat of vaporization of water from the measured HHV and assumes that all products of combustion including water remain in the gaseous phase. Both the HHV and LHV may also be calculated from the gas compositional analysis using the procedure described in ASTM D 3588. For most gas fuels, a standard gas analysis to C6+ is adequate for determination of heating value, but an extended C14



analysis (4) may also be used if available. Gas turbines do not operate with condensing exhaust systems and it is common gas turbine industry practice to utilize the LHV when calculating the overall cycle thermal efficiency.

B. Modified Wobbe Index (MWI)

Gas turbines can operate with fuel gases having a very wide range of heating values, but the amount of variation that a specific fuel system design can accommodate is limited. The fuel nozzles are designed to operate within a fixed range of pressure ratios, and changes in heating value can be accommodated by increasing or decreasing the fuel nozzle area or gas temperature. A measure of the interchangeability of gas fuels for a given system design is the modified Wobbe index, or MWI . This term is used as a relative measure of the energy injected to the combustor at a fixed pressure ratio and is calculated using the fuel lower heating value, the specific gravity with respect to air and the fuel temperature. The mathematical definition is as follows:

(1)TgasxSGgas

LHV Index Wobbe Modified =

For an ideal gas this is equivalent to:

)2(Tgasx

96.28MWgas

LHV Index Wobbe Modified =

LHV = Lower Heating Value of the Gas Fuel (Btu/scf)

SGgas = Specific Gravity of the Gas Fuel relative to Air

MWgas = Molecular Weight of the Gas Fuel

Tgas= Absolute Temperature of the Gas Fuel (ºRankine)

28.96 = Molecular Weight of Dry Air

The allowable MWI range is established to ensure that required fuel nozzle pressure ratios are maintained during all combustion/turbine modes of operation. When multiple gas fuels are supplied and/or if variable fuel temperatures result in a MWI that exceed the 5% limitation, independent fuel gas trains, which could include control valves, manifolds and fuel nozzles, may be required for standard (diffusion flame) combustion systems. For DLN systems, an alternate control method may be required to ensure that the required fuel nozzle pressure ratios are met. An accurate analysis of all gas fuels, along with fuel gas temperature-time profiles shall be submitted to GE for proper evaluation.

MWI Variability Within the +/-5% Range

This gas fuel specification is written to provide customers with the allowable limits of gas fuel properties that can be tolerated with a specific set of hardware and permit the turbine to operate within the normal limits for emissions and combustor dynamics. It was not written with the intent of addressing fuel variability within the stated limits. The gas turbine can operate successfully within the stated limits without the need for outages or for combustion system hardware modification such as



fuel nozzle changes. It is expected that as the fuel properties vary from one extreme limit to the next, some controls adjustments to change combustor operation may be required to operate the combustion system with optimum dynamics and emissions performance. Currently, these controls changes are performed manually, on-line and without the need for an outage. Accordingly, if the variability described above is encountered on a frequent (daily, weekly) basis, then an automatic compensation system may be preferable to constant monitoring with manual intervention.

Exceptions to the fuel specification must be evaluated on a case-by-case basis.

C. Superheat Requirement

The superheat requirement is establish to ensure that the fuel gas supply to the gas turbine is 100% free of liquids. Superheat is the temperature difference between the gas temperature and the respective dew point. The requirement is independent of the hydrocarbon and moisture concentration.

Dependent upon their constituents, gas entrained liquids could cause degradation of gas fuel nozzles, and, for DLN applications, premixed flame flashbacks or re-ignitions. Condensation of moisture must be avoided to prevent the formation of gas hydrates and collection of water in low points of the gas fuel system. The superheat requirement is specified to provide enough margin to compensate for the temperature reduction as the gas expands across the gas fuel control valves. The requirements are applicable at all operating conditions and apply to all units including those installed with either standard or DLN combustion systems. Exceptions are units burning coal derived low Btu fuels, the requirements for which must be determined on a case-by-case basis. The superheat requirements take into account the gas temperature drop and the relationship of the moisture and hydrocarbon dew point lines to the gas fuel pressure. Because of differences between the dew point line characteristics in the region of interest (less than 700 psia), the opportunity for moisture condensation as the gas expands is less than that for hydrocarbons. Advantage has been taken of this physical property to provide users with two separate requirements in order to minimize the cost of superheating. In addition, the superheat requirements depend on the expansion ratio across the control valves and can therefore be expressed as a function of the incoming gas pressure at the inlet to the gas fuel control system.

To avoid hydrocarbon condensation the superheat requirement is:

( ) ( ) ( )3100Pgas

100Pgas 2

sh x2.8 - x 2.33T =

where:

Tsh is the hydrocarbon superheat requirement in °F (incremental temperature above the hydrocarbon dew point)

Pgas is the gas fuel delivery pressure at the inlet to the gas turbine control system, psia

To avoid moisture and hydrate formation the superheat requirement is:

( ) ( )47100Pgas15.5 sm - x T =

where:

Tsm is the moisture superheat requirement in °F (incremental temperature above the moisture dew point)



The superheat requirements are shown graphically on Figure 1 for moisture and hydrocarbons. Both should be determined and added to the respective dew points (moisture and hydrocarbon) at the gas turbine fuel delivery pressure. The higher of the two values, superheat plus dew point, will determine the preliminary minimum gas fuel temperature that is required in order to meet the superheat requirements. In some cases, the hydrocarbon dew point may be low enough that the requirement for meeting the moisture superheat will dominate. However, if the hydrocarbon dew point is close to the moisture dew point, and the hydrocarbon dew point varies sufficiently, the moisture and hydrocarbon superheat requirements may reverse on which one dominates. In order to avoid this situation, GE has developed a breakpoint strategy. The breakpoints that will be used are based on gas supply pressure, as seen in the table below:

Gas Supply Pressure Hydrocarbon Dew Point Breakpoint

500 psia or less -25°F

501 psia to 600 psia -35°F

601 psia to 700 psia -50°F

Maximum Hydrocarbon Dew Point less than Breakpoint

If the maximum hydrocarbon dew point, calculated during the Order to Requisition process, is below the breakpoint level, then GE will assume that the hydrocarbon superheat requirements are less than the moisture superheat requirements. Therefore, the minimum gas temperature will be determined by the moisture dew point plus the moisture superheat.

Maximum Hydrocarbon Dew Point greater than Breakpoint

However, if the maximum hydrocarbon dew point, calculated during the Order to Requisition process, is above a breakpoint, then GE will assume the unconditioned gas is saturated. This will require the full hydrocarbon superheat to be applied to the unconditioned gas. The resulting gas temperature may be higher than just adding the hydrocarbon dew point and hydrocarbon superheat. See Appendix 4 for a sample calculation.

Continuous Hydrocarbon Dew Point Measurement

An alternate approach to the use of a breakpoint is to provide instrumentation to measure the hydrocarbon dew point continuously, and then to provide that signal to GE through the gas turbine controller. The turbine controller will then use the hydrocarbon dew point, along with the moisture dew point, provided during the Order to Requisition process, to determine if sufficient superheat has been provided.

Non-superheated Gas Temperature Signal

GE will require an input signal, into the turbine controller, of the gas fuel temperature upstream of any performance or superheating system. The turbine controller will take action if sufficient superheat is not supplied.



Figure 1. Hydrocarbon and Moisture Superheat Requirements

D. Hydrocarbon Dew Point

The hydrocarbon dew point is the temperature at which the first droplet of hydrocarbon forms as the gas temperature is reduced at a given pressure and is analogous to the moisture dew point. The hydrocarbon dew point is very sensitive to small concentrations of heavy hydrocarbons (C6+) and contamination of the gas sample during sampling can be an issue. The use of a sample probe and following the sampling procedure described in GPA 2166(3), particularly with respect to sample cylinder purging, can avoid these problems. For this reason the recommended method for hydrocarbon dew point determination is by direct measurement using a chilled mirror instrument (ASTM D 1142). If a direct measurement cannot be performed, the dew point may be calculated from the extended C14 gas fuel analysis (4). Use of a C6+ analysis for dew point determination may result in an under-estimation of 30°F to 40°F or more. Exceptions are fuels that do not contain heavy hydrocarbons such as liquefied natural gas.

E. Moisture Dew Point

The gas fuel moisture dew point is dependent upon the moisture concentration and the gas fuel pressure. When expressed in units of lbs/mmscft (pounds per million standard cubic feet), the resulting dew point is practically independent of the gas fuel composition (other than moisture). Typically, many pipeline tariffs limit the maximum allowable moisture content to 7 lbs/mmscft while the actual value may be significantly less. It is the maximum allowable value, however, that determines the design requirements for superheat. Figure 2 is included to provide a guide for determining the expected moisture dew point from the moisture concentration and gas fuel pressure of a typical natural gas. The actual dew point will vary slightly with gas composition changes.



Figure 2. Moisture Dew Point as a Function of Concentration and Gas Pressure for a Typical Natural

Gas Fuel

F. Flammability Ratio

Fuel gases containing hydrogen and/or carbon monoxide will have a ratio of rich-to-lean flammability limits that is significantly greater than that of natural gas. Typically, gases with greater than 5% hydrogen by volume fall into this range and require a separate startup fuel. GE will evaluate the gas analysis to determine the requirement for a start-up fuel. Fuel gases with large percentages of an inert gas such as nitrogen or carbon dioxide will have a ratio of rich-to-lean flammability limits less than that of natural gas. Flammability ratios of less than 2.2 to 1 based on volume at ISO conditions (14.696 psia and 59° F), may experience problems maintaining stable combustion over the full operating range of the turbine.

G. Gas Constituent Limits

Gas constituent limits are specified to assure stable combustion through all gas turbine loads and modes of operation. A detailed gas analysis must be furnished to GE for proper evaluation. See reference (3) for the recommended sampling procedure and ASTM D1945 for a C6+ analysis procedure.

H. Gas Fuel Supply Pressure

Gas fuel supply pressure requirements are dependent on the gas turbine model, the combustion system design, the fuel gas analysis and unit specific site conditions. As part of the unit proposal, GE will furnish minimum and maximum gas fuel supply pressure requirements.



IV. CONTAMINANTS

Dependent on the type of fuel gas, the geographical location and the forwarding means, there is the potential for the “raw” gas supply to contain one or more of the following contaminants:

1. Tar, lamp black, coke

2. Water, salt water

3. Sand, clay

4. Rust

5. Iron sulfide

6. Scrubber oil or liquid

7. Compressor Lube oil

8. Naphthalene

9. Gas Hydrates

It is critical that the fuel gas is properly conditioned prior to being utilized as gas turbine fuel. This conditioning can be performed by a variety of methods. These include, but are not limited to: media filtration, inertial separation, coalescing and fuel heating. Table 2b identifies the trace metal, particulate and liquid contamination limits. It is critical that fuel gas conditioning equipment be designed and sized so that these limits are not exceeded. For further information on gas fuel conditioning, see publication GER 3942 (8).

A. Particulates

Contamination limits for particulates are established to prevent fouling and excessive erosion of hot gas path parts, erosion and plugging of combustion fuel nozzles and erosion of the gas fuel system control valves. The utilization of gas filtration or inertial separation is instrumental in ensuring that the particulate requirements as defined in Table 2b are met. GE recommends the use of stainless steel piping downstream of this last level of filtration to prevent the generation of corrosion-derived particulates.

B. Liquids

As identified in Table 2b, zero liquids are allowed in the gas turbine fuel gas supply. Refer to Note 16 of table 2b for current input requirements and turbine controller actions. The introduction of liquids with gas fuel can result in nuisance and/or hardware damaging conditions. These include rapid excursions in firing temperature and gas turbine load, primary zone re-ignition and flashback of pre-mixed flames. In severe conditions, liquid carryover to the first stage turbine nozzle may result in damage to downstream hot gas path components. When liquids are identified in the gas fuel supply, phase separation and heating must be employed to achieve the required superheat level.

C. Sulfur

There are several concerns relative to the levels of sulfur contained in the fuel gas supply. Many of these are not directly related to the gas turbine but to associated equipment and emissions requirements. These concerns include but not limited to:



1. Hot Gas Path Corrosion

Typically, use of sulfur bearing fuels will not be limited by concerns for corrosion in the turbine hot gas path. Experience has shown that fuel sulfur levels up to about 1% sulfur do not significantly affect oxidation/corrosion rates. Specifying the fuel alkali levels to values shown in Table 2b controls hot corrosion of hot gas path parts resulting from alkali sulfate formation. Unless sulfur levels are extremely low, alkali levels are usually limiting in determining hot corrosion of hot gas path materials. For low Btu gases, the fuel mass flow rate at the turbine inlet is increased over that for natural gas, and the alkali limit in the fuel is therefore decreased.

2. HRSG Corrosion

If heat recovery equipment is used, the gas fuel sulfur concentration must be known so that the appropriate design for the equipment can be specified. Severe corrosion from condensed sulfurous acid results if a heat recovery steam generator (HRSG) has metal temperatures below the acid dew point.

3. Selective Catalytic Reduction (SCR) Deposition

Units utilizing ammonia injection downstream of the gas turbine for NOx control can experience the formation of deposits containing ammonium sulfate and bisulfate on low temperature evaporator and economizer tubes. Such deposits are quite acidic and therefore corrosive. These deposits and the corrosion that they cause may also decrease HRSG performance and increase backpressure on the gas turbine. Deposition rates of ammonium sulfate and bisulfate are determined by the sulfur content of the fuel, ammonia content in the exhaust gas, tube temperature and boiler design. Fuels having sulfur levels above those used as odorants for natural gas should be reported to GE. In addition, the presence of minute quantities of chlorides in the compressor inlet air may result in cracking of ANSI 300 series stainless steels in the hot gas path.

4. Exhaust Emissions

Sulfur burns mostly to sulfur dioxide, but 5%-10% oxidizes to sulfur trioxide. The latter can result in sulfate formation, and may be counted as particulate matter in some jurisdictions. The remainder will be discharged as sulfur dioxide. To limit the discharge of acid gas, some localities may restrict the allowable concentration of sulfur in the fuel.

5. System Material Requirements

When considering fuel gases containing sulfur (sour gas fuels) material selection for system piping and components shall comply with NACE Standard, MR0175 (9).

6. Elemental Sulfur Deposition

Solid elemental sulfur deposits can occur in gas fuel systems downstream of pressure reducing stations or gas control valves under certain conditions. These conditions may be present if the gas fuel contains elemental sulfur vapor, even when the concentration of the vapor is a few parts per billion by weight. Concentrations of this magnitude cannot be measured by commercially available instrumentation and deposition cannot therefore be anticipated based on a standard gas analysis. Should deposition take place, fuel heating will be required to maintain the sulfur in vapor phase and avoid deposition. A gas temperature of 130°F or higher may be required at the



inlet to the gas control valves to avoid deposition, depending on the sulfur vapor concentration. The sulfur vapor concentration can be measured by specialized filtering equipment. Contact GE for further information on this subject.

7. Iron Sulfide

The presence of sulfur in the gas may promote the formation of iron sulfides. Under certain conditions, iron sulfide is a pyrophoric material that can auto ignite at atmospheric pressure and temperature when exposed to air. Extreme care must be taken when servicing gas fuel cleanup equipment to avoid accidental exposure to oxygen and subsequent combustion of filter material.

D. Trace Metals

Sodium is the only trace metal contaminant normally found in natural gas. The source of sodium in natural gas is salt water. Limits on trace metals are established to prevent the formation of corrosive deposits on hot gas path components. These deposits can be detrimental to gas turbine parts life. In addition to sodium, additionally harmful trace metal contaminants can be found in gasification and process gases. GE will determine limits on these contaminants on a case-by-case basis.

V. SOURCES OF CONTAMINANTS

A. Particulates

The major source of particulates is from corrosion products in the pipeline. These products are continuously formed over the life of the pipeline at rates that are determined by the corrosive components and water content of the gas. For this reason most gas suppliers control moisture content to avoid the possibility of water condensing and forming acid with CO2 or H2S.

B. Liquids

Gas at the wellhead is typically produced in a wet saturated condition and is treated to remove water and heavy hydrocarbon liquids. Depending on the degree of treatment and the supply pressure, the gas may be delivered in a dry condition. After pressure reduction it is possible for condensates to form as the gas cools during expansion. The condensates may be either water or hydrocarbons or both. Carry over of lubricating oil from compressor stations is another source of liquids.

C. Sulfur

Sulfur is usually combined with either hydrogen as H2S or carbon as COS. It is produced with the natural gas. Typically the gas supplier will limit H2S to a concentration of less than approximately 20 ppmv by removing sulfur in a treatment system. Sulfur may also be present in very low concentrations (< 100 ppbv) in the form of elemental sulfur vapor.

D. Trace Metals

The details of various sources of alkali contaminants in the following text apply to MS 3000, MS 5000, B, E and F class machines. The sources of contaminants for 6C, FB and H-class machines are discussed in GEK 107230 (1).

Contributions to the alkali content of the combustion gases can come from any of the material streams supplied to the combustor; fuel, air, water or steam. The basic parameter which can be used to define the allowable alkali metal content admitted to the turbine is Xt, the combined sodium and potassium content of the combustion gas at the entry to the first stage nozzle. This concentration must not exceed the values stated in Table 2b. Since there is no simple test method for measuring Xt in an



operating turbine, it must be calculated from the alkali metal contents of the fuel, air, water and steam flows.

T(Xt) = A(Xa) + F(Xf ) + S(Xs) + W(Xw)

Where T = total flow to turbine (= A + F + S + W):

Xt = alkali contaminant concentration in total flow as Na.

A = Air flow,

Xa = contaminant concentration in air.

F = Fuel flow,

Xf = contaminant concentration in fuel

S = Steam flow,

Xs = contaminant concentration in steam.

W = water flow

Xw = contaminant concentration in water.

The allowable levels of alkali contamination in the different flows entering the gas turbine are discussed below.

E. Air

There are four sources of alkaline metal contained in the compressor discharge air, (a) Inlet filter carryover of sodium chloride in ambient air (b) carryover of sodium dissolved in water used for evaporative cooling (c) carryover of sodium dissolved in water used for inlet fogging and (d) carryover of sodium from water used for on-line water washing.

When concentrations of trace metals in fuel, water or steam are not precisely known, a value of 0.005 ppmw, GER 3419 (10), can be used for systems with or without evaporative coolers. This value, based on experience, would cause an insignificant contribution to the overall contamination level and have a minor impact on parts lives.

For systems with inlet foggers, the water carry over is 100% compared with approximately 0.003% for evaporative coolers and the potential sodium carry over is therefore proportionally higher. The maximum inlet fogging water flow rate is approximately 1/3 of the natural gas flow rate and, depending on the sodium concentration, could use up a significant portion of the total allowed at the turbine inlet. Refer to GEK 101944 (11) for information on water purity requirements. If it is anticipated that the specification could be exceeded, General Electric should be consulted for recommendations on the selection of the water source and use of proper air filtration equipment.

F. Steam

Steam for gas turbine injection is typically taken from a suitable extraction point on a steam turbine or HRSG. The limiting purity requirements for this steam are those for the steam turbine. These limits are defined in GEK 72281 (12).



G. Water

The maximum alkaline metal (sodium plus potassium) content of water to be used for injection is discussed in GEK 101944 (11). The maximum water injection rate is approximately equal to the fuel injection rate. If the alkali content approaches the maximum allowable value stated in GEK 101944 (11), it may use all of the allowable margin at the turbine inlet, leaving none available for the fuel. If it is anticipated that the specification could be exceeded, General Electric should be consulted for recommendations on the selection of the water source.

Note that the concentration of sodium in steam and water, at the levels specified, can be measured directly using an on-line sodium analyzer or, in the laboratory, with an ion or pH meter fitted with a “sodium specific” electrode or by an atomic absorption spectrometer fitted with a graphite furnace.

H. Fuel

The final source of contamination to be considered is the fuel. Most cases of alkaline metal contamination and corrosion of hot gas path components are related to liquid fuel contamination. It is rare that natural gas will contain trace metals, but gasification fuels may contain alkalis carried over from the gas clean up system. The issues and requirements with gas fuels are discussed separately in the prior sections.



APPENDIX 1 I. DEFINITIONS

A. Dew Point This is the temperature at which the first liquid droplet will form as the gas temperature is reduced. Common liquids found in gas fuel are hydrocarbons, water and glycol. Each has a separate and measurable dew point. The dew point varies considerably with pressure, and both temperature and pressure must be stated to define properly the gas property. Typically, the hydrocarbon dew point will peak in the 300 to 600 psia range.

B. Dry Saturated Conditions The gas temperature is at, but not below or above, the dew point temperature. No free liquids are present.

C. Gas Hydrates Gas hydrates are semi-solid materials that can cause deposits that plug instrumentation lines, control valves and filters. They are formed when free water combines with one or more of the C1 through C4 hydrocarbons. Typically the formation will take place downstream of a pressure reducing station where the temperature drop is sufficient to cause moisture condensation in a region of high turbulence. Because hydrates can cause major problems in the gas distribution network, the moisture content is usually controlled upstream at a dehydration process station.

D. Gas Hydrate Formation Line This is similar to the dew point line. A potential for hydrate formation exists if free water is present. Calculations performed using the commercial software HYSYS (15) show that the hydrate formation line is approximately 10°F above the moisture dew point line. Maintaining the required degree of superheat above the moisture dew point will eliminate hydrate formation problems. (see section III–C Superheat Requirement).

E. Glycol

Glycol is not a natural constituent of natural gas but is introduced during the dehydration process. Various forms of glycol are used, di-ethylene and tri-ethylene glycol being two most common. In some cases glycol is injected into the pipeline as a preservative. In most cases, glycol may only be a problem during commissioning of a new pipeline or if an upset has taken place at an upstream dehydration station.

F. Odorant

Odorants are injected into natural and LP gas to make leaks readily detectable. The odorant commonly used for natural gas is tertiary butyl mercaptan, while ethyl mercaptan is used for LP gas.

G. Superheat

This is defined as the difference, gas temperature minus liquid dew point. The difference is always positive or zero. A negative value implies that the value is being measured at two differing states of pressure and temperature and is not valid. A measured gas temperature below the theoretical dew point means that the gas is in a wet saturated state with free liquids present.

H. Saturation Line

This is the same as the dew point line.

I. Wet (Saturated) Conditions

A mixture consisting of both vapor and liquids.



APPENDIX 2

I. PARTICLE SIZE LIMITATIONS

The effective particle size for erosion considerations is determined by a particle’s terminal settling velocity. The size and density distribution of the solid particles must be such that not more than 1.0 percent by weight of the particles shall have a terminal settling velocity in air (70°F and 30 inches Hg, absolute) greater than 14 inches per minute, and not more than 0.1 percent shall have a terminal settling velocity in excess of 23 inches per minute. For a solid spherical particle, Stoke’s Law of settling permits calculating the terminal settling velocity if the particle size and shape and particle specific gravity are known. The following tabulation gives the spherical particle diameters equivalent to the limiting terminal settling velocities for particles of specific gravity 2.0 and 4.

Settling Velocity (inches/min)

Specific Gravity (relative to water)

Equivalent Spherical Particle Diameter (microns)

14 2 10

23 2 13

14 4 7

23 4 9



APPENDIX 3

I. EQUIVALENT CONTAMINANT RELATIONSHIPS (ALL MACHINES EXCEPT FB, H-CLASS)

The following relationships can be used to determine turbine inlet contaminant and fuel equivalent contaminant concentrations to compare to limits given in Table 2b. In general, for mass balances on the flows and on the contaminants from fuel, air and steam/water at the turbine inlet.

E = F + A + S (5)

(XE) x E = (XF) x F + (XA) x A + (XS) x S (6)

where:

A, F, S and E are the mass flows of air, fuel, injected steam/water and combustion gases at the turbine inlet, respectively

XA, XF, XS, and XE are the contaminant concentrations (ppm by weight) in the inlet air, in the fuel, in the injected steam/water, and in the combustion gases at the turbine inlet, respectively.

The fuel equivalent concentration of contaminants (XFe ) is (dividing (5) and (6) by F)

XFe = XE x (1+ A/F + S/F) = XF + XA x (A/F) + XS x (S/F) (7)

For example for a natural gas contaminated with salt at a sodium concentration of 0.1 ppm, an air sodium contamination of 5 ppb, and a steam contamination of 5 ppb, the equivalent sodium in the fuel for A/F =50 and S/F=1 is from equation (7)

XFe = 0.1 + 0.005(50) + 0.005(1) = 0.355ppm (8)

This is the amount of sodium considered to come from a fuel source only, which gives the same sodium concentration at the turbine inlet as from the combined three sources.

The turbine inlet concentration, XE, is found by rearranging (7)

XE = XFe /(1 + A/F + S/F) = 0.355/(1 + 50 + 1) = 0.006827 ppm = 6.827 ppb (9)

These values are well within the sodium specification values of 1 ppm on a fuel basis (XFe), and 20 ppb for the turbine inlet concentration (XE). XE and XFe values for all contaminants are given in Table 2b.

For equivalent contaminant relationships in 6C, FB, and H-Class machines, refer to GEK 107230 (1).



APPENDIX 4

I. MINIMUM GAS FUEL TEMPERATURE REQUIREMENT CALCULATIONS

The gas fuel pressure at the purchaser’s connection FG1 should first be determined. The hydrocarbon and moisture superheat can then be calculated from the equations depicted in Figure 1. For example, at a gas fuel pressure of 490 psia, the moisture and hydrocarbon superheat requirements are 18°F and 42°F respectively.

For a typical pipeline gas the maximum allowable moisture content is 7 lbs/mmscft. At 490 psia the moisture dew point can be determined from Figure 2 and is equal to 23ºF. The minimum gas temperature to avoid moisture condensation is equal to the moisture dew point plus the required superheat, or 23º+ 18º = 41ºF.

For hydrocarbons, the maximum expected hydrocarbon dew point should be determined by consultation with the gas supplier and a review of historical data if available. The hydrocarbon dew point will be dependent on the source of the gas, the degree of gas processing and may vary seasonally with overall gas demand and the economics associated with liquids removal and recovery. For a fuel with a maximum hydrocarbon dew point of, for example, 35ºF at 490 psia, the theoretical minimum gas fuel temperature is 42º+ 35º= 77º F. The temperature, in this example, is higher than the minimum required to avoid moisture condensation, therefore it establishes the minimum gas temperature to avoid both hydrocarbon and moisture condensation. However, the actual minimum gas fuel temperature will be based on the hydrocarbon dew point breakpoint. (see section III-C) In the example above, the assumed hydrocarbon dew point was 35°F. (at 490 psia) The hydrocarbon dew point for this case is higher than the breakpoint. (-25°F) Therefore, GE will assume that the gas entering the superheating system is saturated, and will require the full hydrocarbon superheat be applied. For example, if the gas entering the superheating system is at a temperature of 55°F, then the minimum gas temperature would be 97°F. (55°F + 42°F) The 97°F temperature is what the turbine controller will begin to take protective action on. The use of the 97°F temperature, instead of the 77°F temperature is based on GE’s experience of gas fuel dew point variation on sites.

For another example, if the hydrocarbon dew point is calculated as –30°F, (at 490 psia) then the hydrocarbon dew point would be less than the breakpoint. (-25°F). Therefore, the minimum gas fuel temperature would be based on the moisture dew point and superheat. Assuming a 7 lbs/mmscft, the dew point is 23°F and superheat required is 18°F, resulting in a theoretical and actual minimum gas temperature of 41°F. (23 °F + 18°F).



APPENDIX 5: REQUESTED FUEL ANALYSIS DATA FOR GE EVALUATION Values

Property ASTM Method Nominal Min Max Lower Heating Value, Btu/scf ASTM D 3588 _______ _______ _______ Wobbe Index (Gross/Higher or Net/Lower) _______ _______ _______ Gas Fuel Temperature, ˚F _______ _______ _______ Gas Fuel Pressure _______ _______ _______ Constituents, mole % ASTM D 1945 & GPA 2286

Oxygen (O2) _______ _______ _______ Nitrogen (N2) _______ _______ _______ Carbon Dioxide (CO2) _______ _______ _______ Water Vapor (H2O) _______ _______ _______ Argon (Ar) _______ _______ _______ Helium (He) _______ _______ _______ Methane (CH4) _______ _______ _______ Ethane (C2H6) _______ _______ _______ Propane (C3H8) _______ _______ _______ Isobutane (C4H10) _______ _______ _______ Butane (n-butane) (C4H10) _______ _______ _______ Pentane (C5H12) _______ _______ _______ Isopentane (C5H12) _______ _______ _______ Neopentane (C5H12) _______ _______ _______ N-Hexane (C6H14) _______ _______ _______ Ethene (C2H4) _______ _______ _______ Propylene (C3H6) _______ _______ _______ Butene (C4H8) _______ _______ _______ Pentene (C5H10) _______ _______ _______ Benzene (C6H6) _______ _______ _______ Toluene (C7H8) _______ _______ _______ Carbon Monoxide (CO) _______ _______ _______ Hydrogen (H2) _______ _______ _______ Acetylene (C2H2) _______ _______ _______ Propyne (C3H4) _______ _______ _______ Butyne (C4H6) _______ _______ _______ Pentyne (C5H8) _______ _______ _______ Other (Please specify) _______ _______ _______

Other Constituents & Contaminants, ppm Hydrogen Sulfide (H2S) _______ _______ _______ Carbonyl Sulfide (COS) _______ _______ _______ Lead (Pb) _______ _______ _______ Vanadium (V) _______ _______ _______ Calcium (Ca) _______ _______ _______ Magnesium (Mg) _______ _______ _______ Sodium (Na) _______ _______ _______ Potassium (K) _______ _______ _______ Particulates _______ _______ _______ Siloxanes _______ _______ _______ Other (Please specify) _______ _______ _______



APPENDIX 6

I. RELATED SPECIFICATION DOCUMENTS

GER 3419 (10)- Includes specifications for compressor inlet air quality

GER 4189 (2)- Includes heated gas fuel temperature limits

GER 72281 (12)- Includes steam purity requirements in steam turbines

GER 101944 (11)- Includes water and steam purity requirements in gas turbines

GEK 106669 (13)- Includes cooling steam purity requirements for H class gas turbines

GEK 107230 (1)- Includes allowable alkali metal concentrations for 6C, FB and H class gas fuels

REFERENCES

1. GEK 107230 Specification for Alkali Metal Contamination in Fuels for the 6C, FB and H Model Gas Turbines

2. GER 4189 Design Considerations for Heated Gas Fuel

3. Obtaining Natural Gas Samples for Analysis by Gas Chromatography, GPA Standard 2166, Gas Producers Association, 6526 East 60th Street, Tulsa, Oklahoma

4. Tentative Method of Extended Analysis for Natural Gas and Similar Gaseous Mixtures by Temperature Programmed Gas Chromatography, GPA Standard 2286, Gas Producers Association, 6526 East 60th Street, Tulsa, Oklahoma 74145

5. Bureau of Mines Bulletin 503, Limits of Flammability of Gases and Vapors, 1952

6. Bureau of Mines Bulletin 622, Flammability Characteristics of Combustible Gases and Vapors, 1965

7. Wiley Critical Content - Petroleum Technology, Volumes 1-2. Hoboken: John Wiley & Sons, Inc., 2007. 363

8. GER 3942 Gas Fuel Clean-up System Design Considerations for GE Heavy-Duty Gas Turbines

9. MR0175, NACE Standard, Sulfide Stress Cracking Resistant Metallic Material for Oilfield Equipment

10. GER 3419 Gas Turbine Inlet Air Treatment

11. GEK 101944 Requirements for Water/Steam Purity in Gas Turbines

12. GEK 72281 Steam Purity Recommendations for Utility Steam Turbines

13. GEK 106669 Specification for Cooling Steam Purity for Closed Circuit Steam Cooled Gas Turbine



14. ASME Handbook “Water Technology for Thermal Power Systems”, chapter 12

15. Aspen HYSYS, a process modeling tool for conceptual design and performance improvement of petroleum and oil & gas processes. Aspen Technology, Inc., 200 Wheeler Road., Burlington MA 01803, +1-781-221-6400

g GE Energy General Electric Company

www.gepower.com

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LIST OF COMPLEMENTARY DOCUMENTS

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SPEC, SCHEMATICS AND DIAGRAMSNOMENCLATURE

372A3671IDENT

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SIZE DWG. NO. SH. REV.

D

DIAG - SCHEMATIC, FUEL GASSYSTEM

0482

1 of 1

DT1N

FIRST MADE FOR: ML-9K1WFA141-1T6

CLAUDIA LINAN 10-10-26

SEE PLM 10-10-26

SEE PLM 10-10-26

SEE PLM 10-10-26

1 -

NOTES:

GAS TURBINE

MAXCASE: 0482, 71EA, REV.= 21

1. FOR DETAILS SEE SPECIFIC MLI’S REFERENCED IN THE BLOCK DIAGRAM.

3. ALL INTERCONNECTION PIPING IS BY OTHERS.

FUEL GAS CHROMATOGRAPH

MLI-G023 SYSTEM-4035

2. THE TERM "OTHERS" USED ON THIS DRAWING IS DEFINED AS THE PLANT DESIGNER AND/OR PLANT INSTALLER.

4. PIPING DOWNSTREAM OF FINAL FILTER MUST BE STAINLESS STEEL.

FUEL GAS COALESCINGFILTRATION (BY OTHERS)

TO MLI 0422,FUEL GAS SYSTEM, "FG988"

FROM GASSUPPLY

FUEL GAS HEATING(BY OTHERS)

5. THE ARRANGEMENT SHOWN DOWNSTREAM OF POINT A IS TYPICAL FOR ONE GAS TURBINE.

SEE NOTE 5

A

SEE NOTE 6

6. PIPING BETWEEN FUEL GAS COALESCING FILTER AND FUEL GAS HEATER MUST BE STAINLESS STEEL.7. BYPASS LINE PIPING MUST BE STAINLESS STEEL.

FUEL GAS WOBBE METER

MLI-G028 SYSTEM-4072

GAS FUEL FLOWMEASUREMENT SYSTEM

MLI-0639 SYSTEM-0422

FUEL GAS SCRUBBER (IF REQUIRED BY OTHERS)

TO MLI 0422,FUEL GAS SYSTEM, "FG992"

SEE NOTE 7

WILLIAPA

GR1039/EDWARDSPORT

DIAG,SCHEM PP-FUEL GASWOBBE METER

4072

1 of 1

146E4069

FIRST MADE FOR: ML-9K1WFA141-1


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THIS DOCUMENT SHALL BE

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SHEETS OF THIS DOCUMENT

ARE THE SAME REVISION

LEVEL AS INDICATED.

8 7 6 5 4 3 2 1

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TOLERANCES ON

2 PL DECIMALS ±

3 PL DECIMALS ±

ANGLES ±

FRACTIONS ±

SIGNATURES DATE

ENONE

DRAWN

CHECKED

ENGRG

ISSUED

QUALITY

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SPEC, SCHEMATICS AND DIAGRAMS

NOMENCLATURE

372A3671

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ALL RIGHTS RESERVED. THE INFORMATION CONTAINED HEREIN IS GE

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146E4069 1 -

NOTES:

GAS TURBINE

1. SEE DEVICE SUMMARY MLI 0414 FOR DEVICE SETTINGS AND RATINGS.

2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION

INCLUDED IN MLI 0438 APPLY.

3. THE TERM "OTHERS" USED ON THIS DRAWING IS DEFINED AS THE PLANT

DESIGNER AND/OR PLANT INSTALLER.

5. FOR UPSTREAM AND DOWNSTREAM EQUIPMENT, SEE MLI 0482.

6. INITIAL HIGH AND LOW CALIBRATION GAS BOTTLES TO BE PROVIDED BY

WOBBE METER SUPPLIER. REPLACEMENT BOTTLES MUST BE SUPPLIED

BY OTHERS.

9. ACTIVE AND SPARE SAMPLE STREAM TUBING SHALL BE SUPPLIED BY WOBBE

METER SUPPLIER AND INSTALLED BY OTHERS. TUBING SHALL HAVE A

MAXIMUM LENGTH OF LESS THAN 100 FT [30.48 M].

7. N/A.

8. TUBING AND HEAT TRACE FROM CONNECTION POINTS [FG1000 & FG1001] TO

CONNECTION POINTS [FG1002 & FG1003] MUST BE PREINSULATED,

SELF-REGULATING HEAT TRACE TUBING. TUBING MUST BE FULLY ANNEALED,

HIGH QUALITY [TYPE 304 OR 316, SEAMLESS] ASTM A269 OR EQUIVALENT.

HEAT TRACE IS REQUIRED TO HOLD SAMPLE LINE TEMPERATURE AT

100°F [38°C].

4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND

ASSOCIATED NOTES. CONNECTIONS MARKED WITH ”PC” INDICATE

CONNECTION BY OTHERS. CONNECTIONS NOT MARKED WITH “PC” ARE

GEE-GEE CONNECTIONS, REQUIRE NO INTERFACE BY OTHERS, AND ARE NOT

SHOWN ON MLI 4063.

GAS SUPPLY

GAS SUPPLY

G028FUEL GAS WOBBE METER

WOBBE METER

[WMA]

FG998

FG999

FG1000

FG1001

ACTIVE SAMPLE STREAM

SEE NOTES 8 & 9

SEE NOTE 7

SPARE SAMPLE STREAM

SEE NOTES 8 & 9

VTA

SPARE SAMPLE PROBE

NO

VTA

ACTIVE SAMPLE PROBE

WOBBE METER

[WMB]

PI

PI-WM-1

PI

PI-WM-2

G028

G028

SEE NOTE 7

SEE NOTE 5

SEE NOTE 5

PC

PC

10. FG1002 AND FG1003 ARE 2.0 [50.6 MM] THRU HOLES WITH HEAT SHRINK

JACKET WHICH WILL ALLOW THE PRE-INSULATED SELF-REGULATING HEAT

TRACE TUBING TO BE FED THROUGH THE CABINET WALL AND TERMINATED

IN THE SAMPLE CONDITIONING OVEN.

FG1003

FG1002

SEE NOTE 10

SEE NOTE 10

SAMPLE CONDITIONING OVEN G028

NO

NC

PI

PI-WM-3

TI

TI-WM-1

2

13

PI

PI-WM-4

VTA

VTA

PS

63WM-2

PS

63WM-1

VPR83-1

VPR83-2

NO

NO

VPR82-1

VPR82-2

SEE NOTE 6

SEE NOTE 6

FG1004VTA

PC

NO NO

INSTRUMENT AIR

(BY OTHERS)

FG1006

PC

DRAINFG1005

PC

NO

G028-WM-1

96WM-10

30WM-1

30WM-3

G028-WM-2

96WM-11

30WM-2

30WM-4

NO

G028-WM-3

SEE NOTE 11

11. VENT TO ATMOSPHERE ONLY, THE USE OF FLARES OR OTHER BACK

PRESSURE DEVICES ARE NOT ALLOWED.

NO

NO

THIS DRAWING TO BE REVISED

IN VISIO 2002 ONLY

THE SOURCE FILE IS STORED IN A

SECURE DATABASE.

NO

NC

GE CLASS II

(INTERNAL NON-CRITICAL)

WILLIAPA

GR1039/EDWARDSPORT

7 I 3 146E3454 1

H

G

D

C

NOTES:

1. 2.

3.

4.

SEE DEVICE SUMMARY ML! 0414 FOR DEVICE SETTINGS AND RATINGS. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION INCLUDED IN MLI 0438 APPLY. THE TERM "OTHERS" USED ON THIS DRAWING IS DEFINED AS THE PLANT DESIGNER AND/OR PLANT INSTALLER. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND ASSOCIATED NOTES. CONNECTIONS MARKED WITH "PC" INDICATE CONNECTION BY OTHERS. CONNECTIONS NOT MARKED WITH "PC" ARE GEE-GEE CONNECTIONS, REQUIRE NO INTERFACE BY OTHERS, AND ARE NOT SHOWN ON MLI 4063. FOR UPSTREAM AND DOWNSTREAM EQUIPMENT, SEE MLI 0482.

INITIAL CARRIER GAS BOTTLES TO BE PROVIDED BY CHROMATOGRAPH SUPPLIER. CARRIER GAS MUST BE 99.999% ULTRA HIGH PURITY HELIUM. REPLACEMENT BOTTLES MUST BE SUPPLIED BY OTHERS.

THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS DOCUMENT ARE THE SAME REVISION LEVEL AS INDICATED.

REVISIONS


THIS DRAWING TO BE REVISED IN MICROSOFT VISIO ONLY THE SOURCE FILE IS STORED IN A SECURE DATABASE

7.

8.

9.

INITIAL CALIBRATION GAS BOTTLE TO BE PROVIDED BY CHROMATOGRAPH SUPPLIER. FOR CALIBRATION GAS CONSTITUENTS SEE MLI G023/EG26 OUTLINE DRAWING. REPLACEMENT BOTTLES MUST BE SUPPLIED BY OTHERS. REGULATOR IS BOTTLE TYPE TO BE MOUNTED DIRECTLY ON GAS BOTTLE.

N/A

10. TUBING AND HEAT TRACE FROM CONNECTION POINTS [FG264 & FG265] TO CONNECTION POINTS [FG259 & FG260] MUST BE PREINSULATED, SELF-REGULATING HEAT TRACE TUBING. TUBING MUST BE FULLY ANNEALED, HIGH QUALITY [TYPE 304 OR 316, SEAMLESS] ASTM A269 OR EQUIVALENT. HEAT TRACE IS REQUIRED TO HOLD SAMPLE LINE TEMPERATURE AT 100°F[38DC].

11. ACTIVE AND SPARE SAMPLE STREAM TUBING MUST BE INSTALLED BY OTHERS AND SHALL HAVE A MAXIMUM LENGTH OF LESS THAN 100 FT [30.48 M].

12. O SYMBOL DENOTES GAS CYLINDER CHANGEOVER REGULATOR.

13. FG259 AND FG260 ARE 2.0 [50.6 MM] THRU HOLES WITH HEAT SHRINK JACKET WHICH WILL ALLOW THE PRE-INSULATED SELF-REGULATING HEAT TRACE TUBING TO BE FED THROUGH THE CABINET WALL AND TERMINATED ON THE SAMPLE CONDITIONING OVEN.

GAS SUPPLY

SEE NOTE 5

SEE NOTE 5

(CJ COPYRIGHT 2010 GENERAL ELECTRIC COMPANY

PROPRIETARY INFORMATION - THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF GENERAL ELECTRIC COMPANY AND MAY NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE WRITTEN PERMISSION OF GENERAL ELECTRIC COMPANY.

I

UNLESS OTHERWISE SPECIFIED


TOLERANCES ON 2 PL DECIMALS ± 3 PL DECIMALS ± ANGLES ± FRACTIONS ±

SIGNATURES

.S.SUDHAKAR CHECKED

BRIAN GALLAGHER

JASON LONG

.S.SUDHAKAR

DATE

10-02-26

10-02-26

10-02-26

10-02-26

SIM TO: 143E2320


NOMENCLATURE

372A3671

IDENT


GE Energy GENERAL ELECTRIC COMPANY

GAS TURBINE

DIAG,SCHEM PP- HIGH TEMP FUEL GAS CHROMATOGRAPH FIRST MADE FOR: STANDARD 4035

CAGE CODE

1 SHEET 1 Of 1

G

C

B

DT1N 7 5 2

WILLIAPA

GR1039/EDWARDSPORT

0422

1 of 4

143E2781

DT1N

FIRST MADE FOR: ML-9K1WFA141-1T6


SEE PLM 10-10-26

SEE PLM 10-10-26

SEE PLM 10-10-26

THIS DOCUMENT SHALL BE

REVISED IN ITS ENTIRETY. ALL

SHEETS OF THIS DOCUMENT

ARE THE SAME REVISION

LEVEL AS INDICATED.

8 7 6 5 4 3 2 1

H

G

F

E

D

C

B

A

8 7 6 5 4 3 2 1

H

G

F

E

D

C

B

A

SIM TO:


SCALE SHEET




TOLERANCES ON

2 PL DECIMALS ±

3 PL DECIMALS ±

ANGLES ±

FRACTIONS ±

SIGNATURES DATE

ENONE

DRAWN

CHECKED

ENGRG

ISSUED

QUALITY

DISTR

TO


E

THIRD ANGLE PROJECTION PROPRIETARY INFORMATION - THIS DOCUMENT CONTAINS

PROPRIETARY INFORMATION OF GENERAL ELECTRICCOMPANY AND MAY NOT BE USED OR DISCLOSED TO

OTHERS, EXCEPT WITH THE WRITTEN PERMISSION OF

GENERAL ELECTRIC COMPANY.

© COPYRIGHT 2010 GENERAL ELECTRIC COMPANY


1

IT.


NOMENCLATURE

372A3671

IDENT

2 STRAINER MAINTENANCE RECOMMENDATIONS GEK 111154

REVISIONS


143E2781 1 -

NOTES:

GAS TURBINE

DIAG, SCHEM PP-FUEL GAS

MAXCASE: 0422, 91FA, REV.= 156

1. SEE DEVICE SUMMARY MLI 0414 FOR DEVICE SETTINGS AND RATINGS.

7. A TEMPORARY CONICAL STRAINER SUPPLIED BY G.E. IS TO BE INSTALLED (SEE

MLI A179).

9. CONNECTIONS BETWEEN COMBUSTOR END COVERS AND THE FUEL GAS

SUPPLY MANIFOLDS MUST BE PITCHED SO THAT THERE ARE NO LOW POINTS.

ALL LIQUIDS WILL DRAIN TO EITHER THE FUEL MANIFOLD FOR ALL LOWER

HALF COMBUSTION END COVERS AND/OR TO THE COMBUSTION CAN FOR ALL

UPPER HALF COMBUSTION END COVERS. LIQUID MUST NOT BE PERMITTED TO DRAIN TO THE LOWER CANS.

10. LOW POINT DRAIN BLANKED FLANGE CONNECTION.

11. SLOPED LINE FROM GAS COMPARTMENT AND MANIFOLD TO LOW

POINT CONNECTION.

8. REFER TO GAS FUEL STRAINER INSPECTION, CLEANING AND MAINTENANCE

RECOMMENDATIONS INCLUDED ON MLI 0438.

13. OTHERS MUST PROVIDE AN ANSI CLASS VI ISOLATION VALVE UPSTREAM OF

G.E. SUPPLIED EQUIPMENT IN ORDER TO ALLOW THIS EQUIPMENT TO BE

ISOLATED FOR MAINTENANCE ETC.

18. ISOLATION VALVES HAVE LOCKING PROVISIONS. VALVES TO BE

LOCKED IN THE OPEN POSITION PRIOR TO OPERATION.

2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION

INCLUDED IN MLI 0438 APPLY.

3. THE TERM "OTHERS” USED ON THIS DRAWING IS DEFINED AS THE PLANT

DESIGNER AND/OR PLANT INSTALLER.

15. GAS FUEL MUST MEET GAS FUEL SPECIFICATION PROVIDED ON MLI 0438.

20. THE SAFETY SHUT OFF VALVE AND SAFETY SHUT OFF VENT VALVE ARE TO

BE INSTALLED OUTDOORS. THE PIPING VOLUME BETWEEN THE OUTLET OF

THE SAFETY SHUT OFF VALVE AND FG1 MUST NOT EXCEED 63.5 CUBIC FEET

[1.8 CUBIC METERS]. THE SAFETY SHUT OFF VALVE AND SAFETY SHUT OFF

VENT VALVE MUST BE INSTALLED SUCH THAT THEY ARE PROTECTED

AGAINST ICING.

14. N/A

12. N/A.

16. PRESSURE TAP FOR DELTA P PRESSURE TRANSMITTERS (MLI 557T)

MUST BE LOCATED SUCH THAT THE LINE WILL SLOPE CONTINUOUSLY BACK

FROM THE PRESSURE TRANSMITTER ARRANGEMENT TO THE MANIFOLD AND

COMPRESSOR DISCHARGE CASING.17. STRAINER VENTING VALVE HAS PROVISIONS FOR A LOCK AND MUST BE

LOCKED IN THE CLOSED POSITION DURING OPERATION. IN ORDER TO

REMOVE ELEMENTS FOR REPLACEMENT OR CLEANING FOLLOWING

SHUTDOWN, ISOLATE FUEL GAS SUPPLY VIA AN UPSTREAM ANSI CLASS VI

ISOLATION VALVE, VENT PRESSURE IN STRAINER AND ATTACHED PIPING BY

OPENING THE VALVE. VERIFY PRESSURE HAS COMPLETELY VENTED BY

CHECKING PRESSURE GAUGE PI-FG-1 AND BY MONITORING OUTPUT TRANSMITTER PT 96FG-1 BEFORE REMOVING STRAINER ELEMENTS IN

ACCORDANCE WITH STRAINER MANUFACTURERS INSTRUCTIONS IN

SERVICE MANUAL.

4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND

ASSOCIATED NOTES. CONNECTIONS MARKED WITH ”PC” INDICATE

CONNECTION BY OTHERS, CONNECTIONS NOT MARKED WITH ”PC” ARE GEE

GEE CONNECTIONS, REQUIRED NO INTERFACE BY OTHERS, AND ARE NOT

SHOWN ON MLI 4063.

6. N/A

5. FOLLOW API 14.3 / AGA REPORT 11 FOR INSTALLATION AND REQUIREMENTS

FOR PIPE LENGTH PRECEDING AND FOLLOWING METER TUBE, MG2-4.

19. THE HOT AND COLD FUEL MIXING TEE MUST BE LOCATED AT LEAST 15 LINEAR FT [4.57 M] OF PIPING FROM FG1 AND MUST NOT BE GREATER THAN 100 LINEAR FT [6.10 M] FROM FG1.

21. REFER TO MLI 0482 FOR ADDITIONAL INFORMATION CONCERNING FUEL GAS

HEATING AND CONDITIONING EQUIPMENT.

WILLIAPA

GR1039/EDWARDSPORT

0637

TC

PT-G1-1

TC

PT-G1-2

TC

PT-G1-3

D5

TO

PIGTAIL

#18

TO

PIGTAIL

17

SEE SHEET 3

SEE NOTE 16

TYPICAL 18 PLACES

COMBUSTION CHAMBER

MG1-1

INSTRUMENT AIR

FG7FG3

VTA

FG2

VTA

8 7 6 5 4 3 2 1

H

G

F

E

D

C

B

A

8 7 6 5 4 3 2 1

H

G

F

E

D

C

B

A


E

SIZE

g GE Energy

SCALE SHEET

CAGE CODE DWG. NO.

EDRAWN

ISSUED

GENERAL ELECTRIC COMPANY

DISTR

TO

2 of 4

143E2781CLAUDIA LINAN

SEE PLM

DT1N

143E2781 2 -

A160ACCESSORY MODULE

GAS COMPARTMENT

SEE

NOTE 9

GAS FUEL PIPING 0962557T

FULL BORE ORIFICE

TYPICAL 6 PLACES

FG166

FROM MLI 0417, CLG & SLG

AIR SYSTEM, “ LINE AD-5A”

AD-5A

LH

PT

96GN-1

NO NO

PITCH

SEE NOTE 11

PITCH

FG138

SEE NOTE 7

SEE NOTE 10

0962

SEE NOTE 16

PM1

TO

PIGTAIL

#18

TO

PIGTAIL

17

COMBUSTION CHAMBER

TYPICAL 18 PLACES

MG1-2

SEE

NOTE 9

FG167


AIR SYSTEM, “ LINE AD-5B”

AD-5B

LH

PT

96GN-2

NO NO

PITCH

SEE NOTE 11

PITCH

FG139

SEE NOTE 7

SEE NOTE 10

0962

SEE NOTE 16

PM4

TO

PIGTAIL#18

TO

PIGTAIL17

COMBUSTION CHAMBER

TYPICAL 18 PLACES

MG1-3

SEE

NOTE 9

FG168


AIR SYSTEM, “LINE AD-5C”

AD-5C

LH

PT

96GN-3

NO NO

PITCH

SEE NOTE 11

PITCH

FG140

SEE NOTE 7

SEE NOTE 10

0962

PC PC PC

Ø 0.136 [3.45 MM]

Ø 0.136 [3.45 MM]

Ø 0.136 [3.45 MM]

0512

0512

0512

TRANSMITTER ARANGMENT

SEE NOTES 13 & 15

GAS FUEL

SUPPLY

FG1

ZS

33VG-9

ZS

33VG-8

VTA

20VG-8

VTA

FOVA13-18

0572SAFETY SHUT OFF VENT VALVE

INSTRUMENT AIR

SEE NOTE 20

FC

VS4-4

ZS

33VS4-5

ZS

33VS4-4

VTA

20VS4-4

VTA

0572SAFETY SHUT OFF VALVE

FG427

INSTRUMENT AIR

SEE NOTE 20FG440

VTA

FG426

FG438

FG428B

FG425

FG439

PCPC

PC

PCPC

PC

PC

PC

VTC-100

ZS

96VTC-100

I / P

0588

FG20

FG21

PT

96FM-4

FUEL GAS FLOW MEASUREMENT SYSTEM 0639

SEE NOTE 5

SEE NOTE 5

PC

PC

90VTC-100

MG2-4

VTC-200

ZS

96VTC-200

I / P

0588

90VTC-200

FG992

PC

FG995

PC

FG997

PC

FG996

PC

INSTRUMENT AIR

FO

FG988

PC

FG989

PC

FG991

PC

FG990

PC

INSTRUMENT AIR

FC

COLD FUEL GAS TEMPERATURE CONTROL VALVE

HOT FUEL GAS TEMPERATURE CONTROL VALVE

FG428A

PC

SEE NOTE 21

SEE NOTE 19

VTA 20VTC-100

VTA 20VTC-200

8 7 6 5 4 3 2 1

H

G

F

E

D

C

B

A

8 7 6 5 4 3 2 1

H

G

F

E

D

C

B

A


E

SIZE

g GE Energy

SCALE SHEET

CAGE CODE DWG. NO.

EDRAWN

ISSUED


DISTR

TO

3 of 4


SEE PLM

DT1N

143E2781 3 -

1.00T

1.00T

1.00T

FROM MLI 0434,HYDRAULIC

OIL, “LINE OH-2”

OH-20

OH-19

OH-18

OH-2

TO MLI 0434, HYDRAULIC

OIL, “LINE OH-20”

TO MLI 0434

HYDRAULIC OIL, “LINE OH-19”

TO MLI 0434


NO

SEE NOTE 18

H

FC

VGC-1

SEE SHEET 4

FG138

PA-4

GPL-2

FROM MLI 0477, FUEL

PURGE, “LINE PA-4”

NO

OH-2

OLT-2

OH-18

0509

PI

D5

H

FC

VGC-2

SEE SHEET 4

FG139

GPL-3

NO

OH-2

OH-19

0509

PI

PM1

H

FC

VGC-3

SEE SHEET 4

FG140

PA-6

GPL-4

FROM MLI 0477, FUEL


NO

OH-2

OH-20

0509

PI

PM4

0507

FG1

NO NO

NC

FG3

TO MLI 0477, PURGE AIR

SYSTEM

TO MLI 0420, COOLINGWATER SYSTEM

TO MLI 0434


PDS

63FGD-1

FO

VTA

1

23

S

20VG-1

ZS

33VG-4

VA13-15

FROM MLI 0477, FUEL


OH-2

OH-2

OH-17

FG2

NC

SEE NOTE 18

ACCESSORY MODULE GAS COMPARTMENT A160

IA-2

IA-1

PA-10

OH-17

SEE NOTE 17

SEE NOTE 8

0929

TC

FTG-1A

TC

FTG-1B

TC

FTG-1C

PDI

FG-3

AL-87

AL-88

ASW-44

DL-51

DL-52

2

13

2

13

H

SEE SHEET 4

FC

GPL-1

VSR-1

2

13 NO

NO

PI

FG-1

PT

96FG-1

2

13

FG7

PT

96FG-2A

PT

96FG-2B

PT

96FG-2CPI

FG-2

NO

PCPC

PC

PC

FC

ZS

33VS4-2

ZS

33VS4-1

GPL-6VTA

20VS4-1

VTA

VS4-1

0507

8 7 6 5 4 3 2 1

H

G

F

E

D

C

B

A

8 7 6 5 4 3 2 1

H

G

F

E

D

C

B

A


E

SIZE

g GE Energy

SCALE SHEET

CAGE CODE DWG. NO.

EDRAWN

ISSUED


DISTR

TO

4 of 4


SEE PLM

DT1N

143E2781 4 -

90SR-1

VH5-1 ZE

96SR-1

IN

SEE SHEET 3

OUT

FH7-1

PDI

FH7-1

ZE

96SR-2

VSR-1

20FGS-1

OH-2

OH-17

GPL-1

65GC-1

VH5-2ZE

96GC-1

ZE

96GC-2

IN

SEE SHEET 3

0509

OUT

FH8-1

PDI

FH8-1

ZE

96GC-3

VGC-1

20FGC-1

OH-2

OH-18

GPL-2

65GC-2

VH5-3ZE

96GC-4

ZE

96GC-5

IN

SEE SHEET 3

0509

OUT

FH8-2

PDI

FH8-2

ZE

96GC-6

VGC-2

20FGC-2

OH-2

OH-19

GPL-3

65GC-3

VH5-4ZE

96GC-7

ZE

96GC-8

IN

SEE SHEET 3

0509

OUT

FH8-3

PDI

FH8-3

ZE

96GC-9

VCG-3

20FGC-3

OH-2

OH-20

GPL-4

0507

ANNEXURE-1: MANDATORY SPARES AND UNIT ASSEMBLIES

Fuel Gas Conditioning System Mandatory Spares

A. MechanicalSno. Item Description Quantity

1 Elements for Filter seperator/scrubber at Fuel Gas conditioning system Two Sets

2 Full set of gaskets, 'O' rings etc. and gland seals for all islolation, control and bypass valve of the system Two sets of each type

3 Element Filter separator for Fine Filter Four Sets

B. Control and instrumentstionSno. Item Description Quantity

1 Measuring Instrumentsa. Pressure/ Differential pressure transmitters, switches, level switches,

gauges/ local indicators etc.1 no. of each type, range & model

b. Mass Flow meter 1 no.c. Temperature elements 1 no. of each type, range and length

2 PLC systema. All Electronic modules like I/O, Controller or CPU, Communication,

Interface and Power supply module (as applicable).One no. of each type

b. Power supply (if applicable). Two no of each type and size.c. Cooling Fan in PLC system/ cabinet One no.

Work station complete with all hardware,accessories and System & application and Engineering softwareincluding monitor.

e. Batteries used for battery backup of RAM’s Two nos. of each typef. Pre-fab cables with connectors One no. of each typeg. All type of fuses 20% of each type & rating

Relays 10% of each type, model & rating

3 UPSAll Electronic modules of Charger, Inverter and Bypass module. 10 % of each type/model OR

minimum one no whichever ishigher.(Any fraction to beconsidered as next higher digit)

4 Process connection & piping

b. Valve manifolds 10% of each type, class, size and model

c. Fittings of each type 10%d. Filter regulators 20% of each model5 Control Valvesa. Actuator 1 no. of each type/ model/ ratingb. Valve trim (Cage, plug, stem, seat rings, guide bushings etc.) 1 set for each type of control valve

c. Diaphragms, ‘O’ rings’, seals etc. of all types 1 complete set for each type of control valve

d. Positioner unit (Complete) 1 no. of each typee. Air Lock relay 1 no. of each type6 Solenoid valves One no. of each type & rating.

d. 1 set.

a. Valves of all types 10% of total population

SAMALKOT CCPP EXPANSION SPECIFICATION FOR FUEL GAS CONDITIONING SYSTEM



REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION B Page 1 of 9

Part II

SECTION - B



REL-SKCCP-NEG-E24-P-00003, Rev.00 PART II SECTION B Page 2 of 9

1.00.00 SYSTEM DESIGN BASIS & OPEARTING CAPABILITY 1.01.00 General

The equipments of the Fuel gas conditioning system shall be designed to meet all the operational condition that system is expected to run during normal and transient operation. Dry, clean natural gas should be supplied to the GT’s in order to prevent corrosion, erosion and the formation of deposits on the system components. The gas conditioning system should be designed considering that the pressure of the natural gas at the skid outlet must be relatively constant regardless of the rate at which it is supplied.

The purposes of the Fuel Gas Conditioning System are targeted to achieve the following a. Supply of fuel Gas to the Gas Turbine at required pressure and

temperature.

b. Remove the condensate and dust particles from Fuel Gas.

c. Metering of fuel gas supplied to the plant

d. Analysis of the fuel gas composition

e. Provide heating of fuel gas during startup and for improvement of

performance during normal operation of gas turbine.

1.02.00 Fuel Gas Conditioning System Performance

The system must be guaranteed to provide the Fuel gas at Gas Turbine Accessory module gas compartment inlet as per attachment GEI41040k_FuelGasSpec.

1.03.00 Design Philosophy

Each equipment of the system shall be designed for the fuel gas flow and pressure requirement corresponding maximum Gas Turbine output at Minimum ambient temperature as specified in Part-II Section –C of this specification

1.04.00 Basic Design Parameters

The components of the fuel gas supply system shall be designed for the parameter as specified in Part-II Section C of this specification

1.05.0 Design and Operating Conditions

The fuel gas conditioning system shall be designed for the gas flow when Gas Turbine is running at Max. Capability point (EC ON, ISO condition)




1.06.00 Insulation and Cladding

Insulation shall be provided at all the equipments, piping, valves and fittings with temperature more than 60°C

1.07.00 Control & Instrumentation The equipments of Fuel gas supply system shall be provided controls and

instrumentation for the safe and efficient operation. 1.08.00 CONTROL & OPERATION PHILOSOPHY An indicative control & operation philosophy is outlined below. The details of the

same shall be discussed & finalized during detailed engineering taking into consideration Bidder’s standard practices and applicable codes/ standards.

The plant Emergency shutdown valve at the plant boundary shall close on major

hazardous conditions like fire etc. It would typically be gas operated with solenoid on the gas line. The valve operation shall be safe and reliable. The design shall be such that false trips are avoided.

The knock-out drum shall have auto draining facility on level/ operator selectable

timer. The absolute filter/ Filter separator shall also have auto draining facility on level/

operator selectable timer (if applicable). The Pressure reducing station shall be self-regulating type. The response shall be

fast enough to ensure meeting the requirements of the Gas turbines as outlined elsewhere.

Temperature control shall be provided for the water bath heater as per the standard

practice of the Bidder. The control of the Water bath heater may be implemented either by means of an integral microprocessor or by means of the PLC system being supplied under the package. In case an integral microprocessor based controller is provided with the Water Bath heater, then the same shall be connected to the PLC system of the Fuel Gas system.

Temperature control at Efficiency heater outlet shall be by means of control valves

on the Steam line to the heater. All required parameters shall be made available to the operator through suitable

displays on the Operator workstation along with alarms on the same exceeding pre-set limits. As a minimum, these shall include instantaneous values of Fuel gas flow, Fuel gas composition/ Calorific value (from Chromatograph), Fuel gas pressure, temperature at different locations in the Gas path, alarm on Differential pressure across Filter separators, high level in knock out drum, low pressure/ temperature, high temperature, high level in condensate tank, fire etc. Further, integration of the fuel gas flow shall also be incorporated in the PLC system to monitor cumulative flow.

The drain pump from condensate tank shall be manually operable from the PLC

system HMI and Local PB station.




2.00.00 CODES AND STANDARDS 2.01.00 The design, manufacture, fabrication, installation, identification and testing of

equipment covered by this specification shall comply with the latest edition of the appropriate standards of the following unless specified otherwise,

• American Society of Mechanical Engineers - Boiler and Pressure Vessels

Code. • ASME Performance Test Codes • American Society for Testing of Materials. • Standards of the Heat Exchange Institute of USA. • Standards of the Hydraulic Institute of USA. • IEC Publication Nos. 45 & 46 on specification and rules for testing steam

turbines. • Indian Electricity Act • Indian Electricity Rules • Tubular Exchanger Manufacturer’s Association Standards • Other national equivalent or higher quality than stipulated above shall be

acceptable.

3.00.00 PERFORMANCE GUARANTEES 3.01.00 The bidder shall guarantee that the equipment offered shall meet the rated

performance and functional requirement stipulated in this specification. All equipments and accessories shall be guaranteed to operate without pulsation, noise or vibration while operating under normal operating conditions. The contractor shall carryout the performance test for establishing the guarantee parameters as mentioned in Part II Section A Clause No. 8.00.00 of the specification.

3.02.00 If the equipment does not meet the guarantee in any respect or for any reason

whatsoever, it would be necessary for the manufacturer to make the alteration for meeting the performance guarantee. The alterations shall be made and additional test required showing the effect of such alteration shall be performed by the manufacturer at no contractual obligation to the Owner.

4.00.00 SYSTEM TRIAL OPERATION 4.01.00 In accordance with the Part III Section I General Technical Requirement, after

commissioning the complete system described above & before handing over the complete system shall be subjected to system trial operation and performance and Guarantee Tests to demonstrate the guarantee of the system offered. Duration of the trial operation of the complete equipment shall be (14) days with minimum operation of 16 hrs a day out of which at least seventy two (72) hours shall be continuous operation on full load

4.02.00 On completion of all pre commissioning activities/tests and as a part of

commissioning the complete facilities shall be put on 'Trial Operation' during which period all necessary adjustments shall be made while operating over the full load range enabling the facilities to be made ready for the Guarantee Tests.




4.03.00 The Initial Operation shall be considered successful, provided that each item/part of the facility can operate continuously at the specified operating characteristics, for the period of Initial Operation with all operating parameters within the specified limits and at or near the predicted performance of facility/equipment.

4.04.00 For the period of 'Trial Operation', the time of operation with any load shall be

counted. Minor interruptions not exceeding four (4) hours at a time caused during the 14 days trial operation period shall not effect the total duration of Initial Operation. If in the opinion of the Owner the interruption is long, the Trial Operation shall be prolonged for the period of interruption.

4.05.00 A Trial Operation report comprising of observations and recordings of various

parameters to be measured in respect of the above Trial Operation shall be prepared by the Contractor. This report, besides recording the details of the various observations during trial operation shall also include the dates of start and finish of the Trial Operation and shall be signed by the representatives of both the parties. The report shall have log sheets, recording all the details of interruptions occurred, adjustments made and any minor repairs done during the Trial Operation. Based on the observations, necessary modifications/repairs to the plant shall be carried out by the Contractor to the full satisfaction of the Project Manager to enable the latter to accord permission to carry out the Guarantee tests on the facilities. However, minor defects which do not endanger the safe operation of the equipment, shall not be considered as reasons for with- holding the aforesaid permission.

5.00.00 PERFORMANCE AND GUARANTEE TEST PROCEDURE 5.01.00 The term “Performance Guarantees” wherever appears in the Technical

Specifications shall have the same meaning and shall be synonymous to “Functional Guarantees”. Similarly the term “Performance Tests” wherever appears in the Technical Specifications shall have the same meaning and shall be synonymous to “Guarantee Test(s). The plant shall be subjected to performance and guarantee tests on successful completion of trial operations. Detailed P&G test procedure shall be submitted for Owner’s approval.

5.02.00 Performance Testing shall be done based on code subject to owner’s approval. 5.03.00 Test shall be conducted at the manufacturer’s works / site in accordance with the

specification and if the shop / site performance tests indicate the failure of the guaranteed performance for the equipment concerned, it would be necessary for the manufacturer to make good the deficiency at his own cost by incorporating the necessary modification, alteration and replacement. The alterations shall be made and additional test required showing the effect of such alteration shall be performed by the manufacturer at no expense to the Owner.

5.04.00 Test Records: The certificates and records of all tests shall be submitted to the

owner for approval. The manufacturer shall maintain records of all tests required in the specification during manufacturing, erection and commissioning. A list of records shall be submitted to the owner on completion of the job. The Owner shall be able to obtain certified copies of such records at any time.




6.00.00 SPARE PARTS 6.01.01 The contractor shall indicate and include in his scope of supply all the necessary

mandatory spares and recommended spares in the relevant schedules. The variation in quantity of spares based on unit rates (rates as quoted for mandatory spares and rates as mutually agreed for recommended spares), if desired by the owner shall be acceptable to the contractor.

6.01.02 The owner reserves the right to buy any or all mandatory and recommended

spares. The contractor shall identify service expectancy period for all items of spares, under normal operating conditions before order placement.

6.01.03 The Contractor shall also indicate the unit wise population of each item and the

service expectancy period for the spare parts (both mandatory and recommended) under normal operating conditions before order placement.

6.01.04 All spares supplied under this contract shall be strictly interchangeable with the

parts for which they are intended for replacements. The spares shall be treated and packed for long storage under the climatic conditions prevailing at the site, e.g. small items shall be packed in sealed transparent plastic bags with desiccator’s packs as necessary.

6.01.05 Each spare part shall be clearly marked or labeled on the outside of the packing with the description. When more than one spare part is packed in single case, a general description of contents shall be on the outside of such case and a detailed list enclosed. All cases, containers and other packages must be suitably marked and numbered for the purposes of identification.

6.01.06 Purchase specification & addresses of procurement sources of all mandatory

spares & recommended spares shall be furnished. 6.02.00 MANDATORY SPARE PARTS 6.02.01 The list of mandatory spares which are considered essential by the owner is

indicated in enclosed Annexure – I. The owner reserves the right to buy any or all mandatory spares. The Bidder shall include all the mandatory spares in his proposal. The bidder shall furnish in the relevant schedule of Bid Proposal sheets, the item wise (including unit rates) and total price for these spares mentioned in the Annexure I. Further whenever the spares are indicated in percentage and numerical figures, arrived is in fraction, the same shall be converted to the next whole number.

6.02.02 In line with the requirements, the prices for mandatory spares indicated separately

shall be used for bid evaluation purposes. All mandatory spares shall be delivered at site at least two months before scheduled date of trial operation of the gas conditioning and heating system. However, spares shall not be dispatched before dispatch of corresponding main equipment.

6.03.00 RECOMMENDED SPARES 6.03.01 In addition to the spares mentioned above, the contractor shall also provide a list of

recommended spares with unit and total prices for 3 years of normal operation of the equipment for indigenous spares and 5-years for imported spares in relevant schedule of Bid Proposal Sheets. The recommended spare list shall take into consideration the mandatory spares specified in Annexure – I and shall be




independent of the list of the mandatory spares. The Owner reserves the right to buy any or all recommended spares. The recommended spares shall be delivered at project site at least two months before the scheduled date of trial operation of the equipment. However the same shall not be dispatched before the dispatch of the main equipment.

6.03.02 Prices for recommended spares will not be used for evaluation of Bids. The prices

of these spares will remain valid up to 12 months after placement of order for equipment. The Owner reserves the right to buy any or all recommended spares. Further, the prices of recommended spares wherever common with the mandatory shall be the same as those of mandatory spares. Prices of recommended spares not listed as mandatory spares shall be reviewed by Owner and shall be mutually agreed upon with the contractor. However, the contractor shall be liable to provide necessary justification for the quoted prices for the spares described by the Owner.

6.04.00 START – UP COMMISSIONING SPARES

Start-up commissioning spares are those spares which may be required during the start-up and commissioning of the equipment. All spares used until the system is handed over to the owner shall come under this category. The contractor shall provide for an adequate stock of such start-up commissioning spares to be brought by him to the site for plant erection and commissioning. They must be available at site before the equipments are energized and the unused spares, if any, should be removed from there only after the issue of taking over certificate. All start up spares which remain unused at that time shall remain the property of the Contractor. The list of commissioning spares to be brought by the contractor to ensure smooth commissioning of the plant shall be subject to Owner’s approval. The Contractor shall submit a complete list of all such start-up commissioning spares. The cost of above spares if any and that consumed before the handing over of the plant shall be deemed to have been included in the lump sum proposal price of the package and the Contractor shall have no claim on this account to the Owner. All cases, containers, other packages are liable to be opened for such examination, as may be considered necessary by the Owner.

7.00.00 TYPE TESTS & TYPE TEST CHARGES 7.01.00 All equipment to be supplied shall conform to type tests as per relevant standards

and proven type. 7.02.00 The Bidder / contractor shall furnish the reports of all the type tests carried out

within five years for electrical equipment / items from the date of bid opening as per specification and relevant standards for all components / equipment/ systems. For other equipment / systems, the type test shall be applicable as mentioned in the Part II, Section C of the specification. These reports should be for the tests conducted on identical / similar components / equipment / systems to those offered / proposed to be supplied under this contract.

7.03.00 In case contractor is not able to submit type test(s) reports conducted in the last

five years (applicable for electrical equipment / items only), or in case type test reports are not found to be meeting the specification / relevant standard requirements/ finalized document for any item/equipment, then all such tests shall be conducted under this contract by the contractor, without any contractual implications what so ever and reports shall be submitted for approval.




7.04.0 All acceptance and routine tests as per prevalent standard and specification shall be

carried out. Charges for these shall be deemed to be included in the bid price.

8.00.0 DATASHEET

8.01.0 Fuel Gas Supply System

Sl.No. Description Unit Data 1.0.0 Fuel Gas Supply System 1.1.0 Location of Supply point At one point in plant boundary.

1.2.0 Terminal pressure/temperature Pr. 60 Bar (g) and

22 °C

1.3.0

Fuel gas design flow rate (Total for 3 modules at Max. GT capability+ 2 LMS

100 GTs) kg/s 100

2.0.0 Emergency Shutdown Valve 2.1.0 Numbers 1x100% for Station

2.2.0 Gas fuel design flow rate (Total for 3

modules at Max. GT capability) kg/s 100 2.3.0 Location Upstream of Metering station 2.4.0 Material of construction Carbon steel

3.0.0 Fuel gas Metering Staion 3.1.0 Numbers 1x100% for Station

3.2.0 Type Coriolis type mass flow meter/ultrasonic type

3.3.0 Range Kg/sec Zero to 100

4.0.0 Knock out drum 4.1.0 Numbers 1 x 100% for Station

4.2.0 Rated Capacity kg/s 100

4.3.0 Internals Fixed/ double Cyclone 4.4.0 Construction code ASME Sec.VIII, Div. I

4.5.0 Material of construction(Shell, Head) ASTM A 106 Gr.B

5.0.0 Filter separator 5.1.0 Number 3x50 % skid for Station 5.2.0 Rated Capacity of each filter kg/s 50 5.3.0 Construction code ASME Sec.VIII, Div. I

6.0.0 Fuel Gas Startup Heater

6.1.0 Numbers 2x50 % for Station

(Total 2 nos.) 6.2.0 Type Indirect Water bath/ Glycol Heater type 6.3.0 Rated Capacity kg/s 50

7.0.0 Gas Pressure Reducing Station 7.1.0 Numbers 3x50 % skid for Station 7.2.0 Type Self regulating type 7.3.0 Range of each skid Kg/sec Zero to 50




8.0.0 Absolute Filter

8.1.0 Numbers 2x100 % for each Gas Turbine

(Total 12 Nos.) 8.2.0 Flow rate kg/s 14.5 8.3.0 Internals Fibre Glass Cartridge /AISI 316 Vanes 8.4.0 Droplet removal efficiency % As per “GEI41040k_FuelGasSpec” 8.5.0 Dust removal efficiency As per “GEI41040k_FuelGasSpec” 8.6.0 Construction code ASME Sec. VIII, Div. I 8.7.0 Material of construction(Shell, Head) ASTM A 106 Gr.B

9.0.0 Fuel Gas Efficiency Heater

9.1.0 Numbers 1x100 % for each Gas Turbine

(Total 6 Nos.) 9.2.0 Type Shell and tube 9.3.0 Flow rate kg/s 14.5

10.0.0 Scrubber skid

10.1.0 Numbers 1x100 % each GT

(Total 6 nos.)

10.2.0 Construction code ASME Sec.VIII, Div. I

10.3.0 Rated Capacity of each kg/s 14.5

11.0.0 Condensate collection tank

11.1.0 Numbers

Total 7 (One at plant boundary for knockout drum + one each for 6 GTs

for absolute filters and scrubber)

11.2.0 Type Horizontal, Atmospheric

11.3.0 Capacity* 3 m3 (for Knockout drum)

1 m3 (for absolute filters and scrubber)

11.4.0 Fluid Natural gas condensate

11.5.0 Construction code ASME Sec.VIII, Div. I

11.6.0 Material of construction(Shell, Head) ASTM A 106 Gr.B

* To be confirmed during detail engineering



REL-SKCCP-NEM-161-P-00001 (Rev.00) Part II/ Section C Page 1 of 8

PART II SECTION C

MECHANICAL

CHAPTER – M 1




1.00.00 GENERAL This Chapter describes the System description, Basic Design Criteria and Minimum

Technical Requirements of Fuel Gas Conditioning System The fuel gas conditioning system shall be capable of providing clean, dry gas as

acceptable to the gas turbine's fuel gas quality requirements. The system shall be capable of providing the required quantity under the maximum fuel consumption condition without affecting the operation and efficiency of the gas conditioning system.

2.00.00 CODES AND STANDARDS It is intended that Bidder shall offer his standard and proven equipment for this

specification. Material of construction, design and construction of components, performance testing of equipment and system, etc. shall be in accordance with

- ASME - Code for pressure vessels section - VIII Division – 1

- Applicable standards of API - ANSI standards - IEC /VDE standards. 3.00.00 TECHNICAL REQUIREMENT 3.01.00 Fuel gas conditioning plant shall be designed to meet the 9FA & LMS 100 gas turbine

requirements and as a minimum arrest liquid droplets and solid particles with a combined efficiency of 99% down to 1 micron or lower subject to the acceptable limit of GT. Liquid carryover in the gas stream shall not be more than 0.25% by weight.

3.02.00 Gas conditioning plant including the main pressure reducing station shall be designed

to handle combined gas flow for unit (s) running at maximum load conditions. A slam shut valve shall be provided to isolate the system in emergency. The piping between the downstream of reducing station and individual GT should have buffer volume to ensure safe changeover to between regulating valves, should the active control valve fail.

3.03.00 Unit shall be capable of running smoothly through out the operating load range of GT

unit (s). 3.04.00 Equipment shall be installed in power plant battery limits and as such

the same shall be suitable considering the safety and environmental requirements as per the statutory codes. T

3.05.00 The equipments and piping are to be assembled in a neat and compact

manner on skid with adequate maintenance access and shall be suitable for outdoor installation.

3.06.00 The gas velocity through the pipes shall be restricted to 20 m/s.




3.07.00 Emergency Shut Down Valve (Slam Shut Off) (1x100% for 3 modules)

The Emergency Shut down Valve (ESD) valve shall be of solenoid operated pneumatic valve type with manual isolation valves and shall have 100% capability by pass valve.

(a) Design Pressure: 65 kg/cm2 (g) (b) Design Temperature 50°C

(c) Flow range 0 to 100Kg/sec

3.08.00 Knock Out Drum (1x100% for 3 modules) (a) Function: Shall separate any carry over liquid in the incoming gas supply (b) Material of construction ASTM A515 Gr. 70 (c) Design Pressure: 65 kg/cm2 (g) (d) Design Temperature 50°C

(e) Flow range 0 to 100 Kg/sec (f) Removal efficiency 100 % of particles > 8 microns

(f) Design Codes: ASME Boiler and unfired pressure vessel code, Section-VIII, Div.1 (g) Accessories: Automatic level control and Liquid control drain valves. (h) Max allowable pressure drop 0.05 bar 3.08.01 Knock out drum shall be provided common for all three modules. Knockout drum shall

be designed to remove bulk suspended gas borne dirt and liquid particle in the gas stream. The separator shall be of fixed internal type with double cyclone, feed deflectors, liquid level controller, level gauges, relief valves, pressure gauges, differential pressure indicator/transmitter, sludge drain, purging connection, temperature gauge supports, etc.

3.08.02 Knockout drum shall be of vertical construction. A liquid collection zone with automatic

draining facility shall be provided in drum bottom for collection of any liquid separated from the gas stream. A separate drain nozzle shall also be provided.

3.08.03 Gas supply line shall have tangential entry to the gas liquid vessel.




3.08.04 The equipment shall be fitted with drain valves, a lockable vent valve connection leading to the vent system, a pressure safety valve and vessel purge connection

3.09.00 Fuel Gas Metering Station (1x100% for 3 modules)

A Gas flow meter in common supply line to three modules at a location downstream of ESD valve shall be provided to measure the total fuel consumption for the plant The Fuel gas flow metering station shall be of coriolis type mass flow meter/ultrasonic flow meter. It shall have isolation as well as bypass valve arrangement. For further details of the meter refer C&I portion of this specification in Section-C of this specification

3.10.00 Filter Seperator (3x50 % for station)

3X50% filter separator skid shall be provided for removing dust and moisture from the fuel gas. The features of the filter separator shall be as follows Material of construction Steel plate as per ASTM A 515

Design pressure 65 Kg/cm2

Design Temperature 50 °C

Flow range for each filter 0-50 Kg/sec

Design code ASME boiler and unfired pressure vessel code,

Section- VIII , Div. 1

Dust separation efficiency 99.5%, >=5 micron

Accessories Gauge glass for drain pots, pneumatically

operated drain control valve & liquid level

controller, a differential pressure switch,

pressure gauge at the outlet flange of each

seperaor.

3.11.00 Fuel Gas Startup Heater (2x50 % for three module)

The bidder shall check the gas analysis from the standpoint of hydrate formation downstream of the pressure reducing station under the worst ambient temperatures prevalent at site. Accordingly, a suitable rated natural gas fired water bath/ Glycol heater shall be provided ahead of the pressure reducing station for individual gas turbine units.

3.11.01 The heater shall be designed for getting Gas Temperature of 70ºC at inlet of fuel gas accessory module of Gas Turbine. It shall be ensured that the temperature of gas after pressure reducing station is at least 20 deg.C higher than the hydrate forming temperature or the gas dew point, whichever is higher.

3.11.02 Control system shall ensure that the temperature of gas at the outlet of heater is constant for gas flow range of 0-50% (0 to 50 Kg/sec).




3.11.03 The design pressure shall be 65 Kg cm2 (g) 3.11.04 A full capacity bypass of the heater shall also be provided. 3.11.05 Max. allowable pressure drop shall be 0.5 Bar

3.12.00 Gas Pressure reducing station (3x50 % for Station)

2X100% Gas pressure reducing stations with necessary control and instrumentation suitable for each module. One low load control valve capable of handling 10% of full flow of the control station shall be furnished for the low load and startup fuel demand of the station. The pressure reducing station shall be designed to reduce maximum incoming pressure to the pressure needed for the gas turbine after accounting for the losses in the piping and valves.

(a) The pressure at outlet : 40 bar (to be confirmed during

detailed engineering)

(b) Maximum Fuel Gas Flow : 50 Kg/sec

(c) Minimum Temperature at inlet : 15 °C

(d) Maximum Temperature at inlet : Out let temp. of Start up heater

(e) Maximum Allowable downstream pressure : 59 bar

(f) Maximum Allowable inlet pressure : 60 bar

(g) Maximum allowable pressure drop : 0.5 bar

(h) The pressure reducing skid shall have self actuated pressure control vale, slam

shut off valve and safety blow off valve with all required instrumentation and

accessories. The Pressure control requirement shall be as follows

Closing time (Safety shut-off valve) s ≤ 1 Response time (Safety shut-off valve) s ≤ 0.3 Regulating precision steady state Regulating precision transient operation

% %

+/- 2% +/- 5%

Closing precision % 2.5 Response pressure category % 3 Travel time full stroke (for pneum. Valve only) s 0.8

3.13.00 Absolute Filter (2x100 % for each Gas Turbine)

2x100 % Absolute filters shall be provided for each Gas Turbine to meet the quality of gas as required by Gas turbine. These filters are provided on the fuel gas line downstream of the fuel gas performance heater. The filter provides the final level of




filtration for Gas Turbine as per attached document “GEI41040k_FuelGasSpec” for Gas quality (a) Maximum Fuel Gas Flow : 14.5 Kg/sec

(b) Minimum Temperature at inlet : 15 °C

(c) Operating Temperature : Out let temp. of Start up heater

(d) Design pressure : 45 bar

(e) Maximum allowable pressure drop : 0.2 bar

Fine filter shall be equipped with differential pressure transmitter and pressure and temperature indicator at inlet and outlet

3.14.00 Fuel Gas Performance/ Efficiency Heater(1x100 % for each Gas Turbine)

Performance heater shall be provided for individual gas turbine units. It shall be designed for Gas Temperature of 185ºC at Heater Outlet. One IP water fuel gas heater with flow from IP economizer and condensate going to the condenser/condensate discharge pump line shall be provided. A gas separator shall be provided downstream of the performance heater to avoid water intrusion in the event of a tube leak. Furthermore, exit water shall be monitored and vented for gas entrainment. The heater shall have temperature control valve on heating line and cold leg bypass line up to the to hot and cold mixing point.

a) Design Temperature

Water side :260 °C

Gas Side :185 °C

b) Design Pressure

Water side :80 Bar g

Gas Side :45 Bar g

c) Min. Gas Temperature at inlet of heater : 15 °C

d) Max. Gas Temperature at inlet of heater : 50 °C

e) Gas Temperature at outlet of heater

Minimum : 62.2 °C

Maximum : 185 °C

Operating : 107 °C

f) Maximum Gas Flow : 14.5 Kg/sec

g) Maximum Allowable pressure drop

Water side : 0.7 bar

Gas Side : 0.5 bar




h) IP Economiser outlet parameters :38 Bar g and 230 °C (to be

confirmed during detail

engineering)

3.14.01 Shell and tube type design with u tubes is preferred Stainless steel material shall be used on gas side.

3.14.02 Flanges shall be welded type

3.15.00 Scrubber units(1 x 100% for each GT): (a) Material of construction: Steel plates as per ASTM A 515 grade 70. (b) Design Pressure: 40 kg/cm2 (g) (c) Design Temperature 200°C

(d) Flow range 0 to 14.5 Kg/sec (e) Design Codes: ASME Boiler and unfired pressure vessel code, section - viii, Div.1. (g) Accessories: Gauge glass for drain pots, pneumatically

operated drain control valve & liquid level controllers, a differential pressure switch, pressure gauges at the outlet flange of each separator.

(h) Max allowable pressure drop 0.2 bar

3.15.01 The 1x100% capacity Scrubber shall remove any leftover moisture in the gas. 3.15.02 Each type of separator shall be provided with a drain collection chamber with

automatic draining facility. 3.15.03 Filter unit shall be of horizontal / vertical construction. Liquid collection zone shall be

provided at the bottom with automatic draining facility. 3.16.00 Gas Vents All vents and safety relief valves in the fuel gas system and condensate drain tanks

shall be sized to cope with the maximum gas flow. Vent lines shall be suitably routed through individual pipes to a common cold stack for venting/flaring.

3.17.00 Fuel Condensate drainage

All hydrocarbon drains shall be connected to a suitably sized condensate drain tank (one for Knock out drum and one for each module for Fine filters).




Necessary arrangements and means to collect the condensate in condensate drain tank, and pumping it to a burning pit (located at an isolated place within the plant boundary) or transferring to barrels meeting the entire statutory requirement shall be provided by the bidder.

3.18.00 Valves

i) Ball valves shall be used in gas lines. All ball valves shall be of fire safe design (class VI shutoff). The trims of all the ball valves, safety valves, slam shut off valves and control valves etc. in the fuel gas system shall be made of stainless steel material of suitable grade to avoid the possibility of corrosion.

ii) Proper access and operating platforms shall be provided for the operation and maintenance of the equipments / valves etc.

3.19.00 The entire gas piping system shall have provision for nitrogen purging. 3.20.00 All Electricals and instruments in connection with fuel gas handling shall be of flame

proof / explosion proof type. 3.21.00 Welding shall be generally as per ASME. Stress relieving as required shall also

conform to the same. 3.22.00 Bidder shall submit sizing calculation for Gas supply system's equipment during

detailed engineering for Owner's approval. 3.23.00 The Fuel Gas supply Piping system shall be designed in accordance with the

applicable provisions of the latest editions of ANSI B 31.3 and ANSI B31.8. 3.24.00 All pressure vessels in the Gas Supply system i.e. knockout Drum, scrubber units,

and Fine filter separator units shall be provided with pressure Relief Valves. Relief valves shall be designed such as to protect downstream equipment in case of pressure rise above the safe limit.

3.25.00 All pressure vessels shall be constructed in accordance with ASME code for pressure

vessel section VIII Div. 1 with the exception of being required to by hydro-tested at 1.5 times the design pressure to allow for piping and equipment to be hydro-tested as a system. The shell and the heads shall be provided with a corrosion allowance of 3 mm. In addition mill tolerance and thinning allowance shall be provided. All pressure vessels shall be equipped with a sentinel relief to control overpressure due to pressure changes as a function of ambient temperature variations.

3.26.00 Manhole of at least 500 mm diameter shall be provided for Knockout drum and filter

separator, if applicable, with suitable clean out connections at bottom, drain, vents, etc.

Note: The design parameters given above for all the equipments are to be verified by the vendor as basic engineering is in their scope. These parameters shall be finalized during detail engineering.




PART II

SECTION C

MECHANICAL

CHAPTER- M 2

LP PIPING SYSTEM & ACCESSORIES




CHAPTER NO. BM8

LP PIPING SYSTEM & ACCESSORIES

INDEX

CLAUSE NO. DESCRIPTION

1.00.00 GENERAL INFORMATION

2.00.00 CODES AND STANDARDS

3.00.00 SCOPE OF SUPPLY / SERVICES

4.00.00 TECHNICAL REQUIREMENTS

5.00.00 INSPECTION AND TESTING




1.00.00 GENERAL INFORMATION 1.01.00 Interconnecting piping and valves for the systems which include Raw Water

Supply System, Circulating Water and Auxiliary Cooling Water System, Auxiliary Water System, DM Water System, Compressed Air System, Gas Fuel, Effluent lines, Service and Portable water supply and distribution system including Service water tank and portable water tank etc. between various power plant equipment / areas in the plant battery limit are covered in this specification.

1.02.00 It is not possible to specify all interconnecting piping and valves associated with

systems of balance of plant, however, piping and valves for any service whether mentioned or otherwise required for completion of the system of power plant are deemed to have been included in the scope of specification.

2.00.00 CODES AND STANDARDS The design, manufacture, fabrication, installation and testing of piping covered by

this specification shall comply with latest edition of the appropriate equivalent international standards, all currently applicable statutes, regulations and safety codes in the locality where the piping shall be installed. Minimum following standards or equivalent Indian / International standard shall be followed:

AISC American Institute of Steel Construction Specification

MSS Manufacturers Standardization Society of the Valve and Fittings Industry

IS 780 Specification for sluice valves for water works purposes (50 to 300 mm size)

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

API 5L/6L Specification for Pipeline

API-598 Valve inspection and testing.

API-600 Steel gate valve (flanged or butt welding ends)

AWWA American water works association steel pipe manual.

EJMA Expansion Joint Manufacturers Association.

IS-8062 (Part II)

Code of practice for cathodic protection of steel structure

IS - 226 Structural Steel standard quality

IS-554 Dimensions for pipe threads where pressure tight joints are required on the threads.




IS-778 Gunmetal gate, globe and check valves for general purposes

IS-1239 (Part - I & II)

Mild steel tubes, tubular and other wrought steel fittings.

IS-1363 Black hexagon bolts, nuts and lock nuts (dia 6 to 39 mm) and black hexagon screws (dia 6 to 24mm)

IS-1364 Precision and Semi-precision hexagon bolts screws, nuts and lock nuts (dia 6 to 39mm)

IS-2016 Plain Washers

IS-2062 Structural Steel (fusion welding quality).

IS-2685 Code of practice for selection, installation and maintenance of sluice valves.

IS-3138 Hexagonal bolts and nuts (M 42 to M 150)

IS - 3589 Electrically welded steel pipes for water, gas, sewage (200 to 2000mm nominal diameter)

IS-4682 (Part-I)

Code of practice for lining of vessels and equipment for chemical process - rubber lining.

IS-4736 Hot dip zinc coating on steel / steels.

3.00.00 SCOPE OF SUPPLY / SERVICES 3.01.00 The Scope of Low Pressure (LP) piping & Accessories shall cover complete piping

systems for the various systems as described in chapters of Part II, Seaction A & Section C of this technical specification read together with the corresponding P&IDs.

The scope shall include complete fuel gas piping from terminal point at plant

boundary upto the Fuel Gas Accessory compartment of individual Gas Turbine consisting broadly of the following systems and any Other piping system as per agreed schematic

(i) Pipes and fittings

(a) Piping, fittings, plugs, stubs, flanges and other accessories for the

piping systems identified above and as per approved schemes. (b) The Bidder shall supply all standard and non-standard matching

pieces as may be needed within the piping system and for connection of piping systems at various equipments/tanks/vessels/valves and components.

(c) Pipe stubs for mounting thermo wells and other instrumentation

along with necessary reducers/matching pieces and instrument tubing.




(ii) Valves and Specialities

(a) Valves, actuators and specialities including expansion joints, orifice

plate assemblies, steam traps, strainers, instrument root valves, etc. for the systems specified and approved schemes.

(b) The Bidder shall also supply special accessories like floor stands,

chain operator, extended spindle etc. as required. Valves, especially for which approach from existing floors are not possible for O&M, bidder shall provide appropriate platforms with the access ladders for the same.

(iii) Hangers and Supports

(a) All pipe supporting elements such as constant load spring hangers,

variable spring hangers, supports, guides, restraints, stops, etc. and all associated auxiliary steel and hardware such as beams, channels, insert plates section attachments to pipe supports, pipe and beam clamps, straps, slings, stools, shoes, saddles, devices, rods, turn buckles, graphite/Stainless steel plate/ Teflon sheet etc. for all the systems specified.

(b) Dampers to control pipeline vibration. (c) The Bidder shall also design and provide for additional guides/

stops/restraints etc. along with auxiliary steel for control of pipeline vibration within allowance/acceptable limits

(iv) Snubbers

Snubbers or shock absorbers as required for the critical steam piping

systems to take up forces due to impact and surge forces arising from sudden closure of turbine stop valves and blowing of safety valves etc. The requirement of snubbers shall be decided based on the requirement of dynamic analysis of the piping systems. The snubbers shall be of hydraulic type. It shall be the responsibility of the Bidder to Owner and supply snubbers required for the above piping systems.

(v) Terminal connections

a) The terminal connection in all cases shall be ASME dimensions unless otherwise approved or specified.

b) Supply of all fittings, flanges, short pieces, etc. as necessary for

connection of piping at all terminal points shall be included in Bidder's scope.

3.02.00 Scope of supply/ work/ services shall include but not be limited to Pipes, headers

and manifolds, bends, elbows, returns, tees, laterals, crosses, reducers/expanders, caps and closures, couplings, plugs, sleeves, and saddles, stubs and bosses, unions and other similar fittings, flanges, gaskets, fasteners




and sealants, ring joints, backing rings, all types of valves including drain/ vent/ air release valves, 3-way valves (where applicable) with test connection for instruments/ manifolds, actuators, specialities, orifices, flow nozzles, expansion joints, bellows etc. as per finalised single line flow diagrams and layout drawings/ isometric drawings.

3.03.00 Bidder shall supply Condensate storage tank, Service water tank and portable

water tank. Quantity and capacity of the tank shall be as per finalised/approved P&ID.

3.04.00 Flexibility analysis for piping systems wherever required. 3.05.00 Complete assemblies of hangers, supports anchor, guides, restraints, etc.

including welded attachments, clamps, clevises, rods, turn-buckles, springs and spring cages, clamps, shoes, rollers, trapezes etc.

3.06.00 Weather hoods for pipes crossing ceilings and walls. 3.07.00 Instrument tapping and stub connections, root valves, 3-way valves (where

applicable) with test connections, drains & vents valves & expanders / reducers as required, entire impulse pipings, fittings as indicated elsewhere for instruments supplied by the Bidder.

3.08.00 Drain funnels, drip pans, moisture traps etc wherever required shall be provided. 3.09.00 Thrust/ anchor blocks where ever required shall be designed and provided by the

bidder and detail drgs. shall be submitted by him to the Owner. 3.10.00 All supporting attachments like plates, saddles, stools, shoes, base plate, special

plates, angles, channels, I-beams, trapeze, nuts, bolts, cleats, clamps, needed to complete the erection of piping system covered under this specification. Valve access platforms, associated support frame structure, etc. wherever required shall be provided by the bidder.

3.11.00 Paints and varnishes, primers, thinners etc. as required for anti-corrosive

protection of piping/ equipment above ground. Surface preparation, priming and painting of all non-insulated above ground piping and equipment except galvanised steel pipings & surfaces and stainless steel pipings & surfaces.

3.12.00 Bidder shall provide anti-corrosive protection to all directly buried piping including

galvanised carbon steel piping and painting for all above ground piping except galvanised pipes and stainless steel pipes. On the internal surface of all pipes 1000 mm and above, a coat of primer followed by a hot coat of coal tar enamel paint or coal tar epoxy paint shall be applied. In case of pipes of size 1000 mm NB and above, the bidder shall stiffen them and/or increase the thickness of pipe adequately against ovality formation in use.

3.13.00 Bidder shall supply all necessary drains and vents with drain & vent valves

including anti-flash funnels and moisture traps for compressed air system as required for the safe and effective draining-venting of the piping systems based on the approved flow scheme / single line diagram. It is bidder’s responsibility to identify the requirements of drains, vents, and supply the necessary pipe work, fittings, hangers and supports etc. for the same.




3.14.00 Bidder shall supply and install necessary matching pieces as may be needed for

connection of piping systems with equipment terminals, valves and specialities. 3.15.00 The Bidder shall prepare the flow diagrams, detailed dimensional piping layout/

Isometric/ fabrication/ As built drawings of all the systems along with Cross sectional drawings, showing all supports and equipment as required

3.16.00 In addition to submission of drawings as stipulated above bidder shall also furnish

the data/ documents with respect to following : i) Support, Anchor, Thrust block design calculations. ii) Calculation to establish adequacy of size and provision of Air Release

Valves in a piping system etc. Transient/surge analysis for long (1 kilometre or more) pipe lines, and/or large diameter (i.e. large volume) pipe lines.

3.17.00 The Bidder shall include in his offer a complete set of special tools and tackles

required for handling the various equipment / piping system during maintenance. 3.18.00 All consumables, lubricants till handing over of the plant / equipment. 3.19.00 Start up and Commissioning spares. 3.20.00 Mandatory Spares. 3.21.00 Recommended spares for 3 (three) years of operation and maintenance. 3.22.00 Erection, Testing, Commissioning. 3.23.00 Scope of Other Services for power cycle piping (i) The Bidder shall identify and satisfy all other statutory code requirements

as may be required for the piping systems covered in this specification. (ii) All shop tests and field tests as required by the applicable codes (ANSI

standards, IBR and other standards enumerated . (iii) Complete design, engineering, etc. for the power cycle piping systems and

other piping systems included in this specification shall be the responsibility of the Bidder. Owner's responsibility/function in this connection shall be limited to review and approval of Bidder's design/calculation, engineering, drawings, and documents. Bidder's scope of services for complete engineering of the misc cycle piping systems shall include but not be limited to the following :

(a) Preparation of Engineering piping diagram indicating flow

schematic, flow parameter, pipe sizes, line designations and tag nos. of various components etc. and submission of same to Owner for review.




(b) Design parameter selection, pipe sizing calculation, pipe schedule, valve schedule, insulation schedule, painting schedule, specialities schedule, hanger schedule for the systems included in the Bidder's scope and submission of same to Owner for their review.

(c) The Bidder shall carryout stress analysis of piping system and

submit for Owner's approval. Bidder shall carryout the dynamic analysis of piping systems as required and submit for Owner's approval. Bidder shall also provide soft copy of stress analysis program files for Owner’s record and use.

The Bidder shall design in detail all piping supports including

restraints, guides, stops etc., after deciding the final location of hangers and supports based on final stress analysis and hanger / support load data originated by him.

. (d) Preparation of preliminary as well as final composite piping layout

drawings of pipe size 65 mm NB & above and submission of same to Owner for review and approval.

(e) Preparation of isometric drawings, fabrication/erection isometric

(with material take off) drawings for shop fabricated piping which are of size 65 mm NB and above and submission of the same to the Owner for review and approval. Piping isometric sketch may be required to be prepared for certain important tubes and pipe lines (<65 NB). The list of such lines shall be decided during detail engg. Stage.

(f) Preparation of layout drawings & isometric drawings for site routed

piping and submission of the same to the Owner for records. (g) Design and engineering of all temporary piping that are required for

the commissioning activities of misc cycle piping system. (h) AS BUILT drawing of the piping layout shall also be prepared by

the Bidder based on any layout modifications made at site and submitted to Owner for records.

4.00.00 TECHNICAL REQUIREMENTS 4.01.00 Piping 4.01.01 Design Basis Inside diameter of piping shall first be calculated for the flow requirement of

various systems considering following design velocity. (i) Water/Oil Application Water/Oil Velocity in m/sec Pipe Size Below 50-150 200 mm




50mm mm & above (a) Pump suction < 1.0 1.2-1.5 1.2-1.8 (b) Pump discharge 1.2-1.8 1.8-2.4 2.1-2.5 and recirculation (c) Header ------ 1.5-2.4 2.1-2.4

Pipeline under gravity flow shall be restricted to a flow velocity of 1 m/sec generally. Channels under gravity flow shall be sized for a maximum flow velocity of 0.6 m/sec.

WILLIAM & HAZEN formula shall be used for calculating the friction loss in piping

system with the following “C” value:

Carbon steel pipe : 100 C.I Pipe / Ductile Iron : 100

Rubberlined steel pipe : 120

Stainless steel pipe : 100

For calculating the required pump head for pump selection, at least 10% margin

shall be taken over the pipe friction losses and static head shall be calculated from the minimum water level of the tank/ sump/ reservoir from which the pumps draw water.

(ii) Compressed Air Application 6.0 – 10.0 m/sec. (iii) Gas piping 15-25 m/s 4.01.02 Pipe wall thickness calculations shall be made on the basis of procedure and

formula given in ANSI B31. In any case the thickness selected shall not be less than standard thickness specified in ANSI 36.10/IS-1239 heavy or as mentioned in IS-3589.

4.01.03 Corrosion allowance of 1.6 mm or as per standard ANSI B31 for the piping shall

be added to the thickness calculated. Bend thinning allowance/ manufacturing allowance shall be additionally taken, if required.

4.01.04 All high points in piping system shall be provided with vents. All low points shall be

provided with drains along with valve. Material of drain & vent shall be as that of parent pipe. Drain & vents shall be adequately sized so as to clear condensate in the lines.

4.01.05 Joints in piping system shall be welded / flanged / screwed. 4.01.06 Recirculation pipes along with valves, break-down orifices etc. shall be provided

for important pumping systems as indicated in respective processes and instrumentation diagrams (P&IDs). The recirculation pipe shall be sized for




minimum 30% design flow of single pump operation or the recommended flow of the pump manufacturer whichever is higher.

4.01.07 All low pressure piping systems shall be capable of withstanding the maximum

pressure in the corresponding lines at the relevant temperatures. However, the minimum thickness as specified in the following clauses and or respective codes for pipes and fittings shall be adhered to. The bidder shall furnish the pipe sizing/ thickness calculation as per the criteria mentioned under this Technical Specification.

4.01.08 Piping and fittings coming under the purview of IBR shall be designed satisfying

the requirements of IBR as a minimum. 4.01.09 Supporting arrangement of piping systems shall be properly designed for systems

where hydraulic shocks and pressure surges may arise in the system during operation. Bidder should provide necessary protective arrangement like anchor blocks/anchor bolt etc. for the safeguard of the piping systems under above mentioned conditions. The requirement shall be, however, worked out by the bidder and he shall submit the detailed drawings for thrust/anchor block to the Owner. External, and internal, attachments to piping shall be designed so as not to cause flattening of pipes and excessive localised bending stresses.

4.01.10 Bends, loops, off sets, expansion or flexible joints shall be used as required in

order to prevent overstressing the piping system and to provide adequate flexibility. Flexibility analysis (using software packages such as Caesar-II etc.) shall be carried out for sufficiently long piping (wherever straight run more than 300M).

4.01.11 Wherever Bidder's piping coming under this specification, terminates at an

equipment or terminal point not included in this specification, the reaction and the thermal movement imposed by bidder's piping on equipment terminal point shall be within limits to be approved by the Owner.

4.01.12 The hot lines shall be supported with flexible connections to permit axial and

lateral movements. Flexibility analysis shall be carried out for pipelines, which have considerable straight run as, indicated above and necessary loops/ expansion joint etc. shall be provided, as may be necessary depending on layout.

4.01.13 An approved manufacturer of repute shall manufacture piping and fittings. They

should be truly cylindrical of clear internal diameter, of uniform thickness, smooth and strong, free from dents, cracks and holes and other defects.

4.01.14 For rubber lined ERW pipes, beads shall be removed. 4.01.15 Inspection holes shall be provided at suitable locations for pipes of 800 NB and

above as required for periodic observations and inspection purposes. 4.01.16 At all intersection joints, it is Bidder's responsibility to design and provide suitable

reinforcements as per the applicable codes and standards. 4.01.17 For large size pipes/ducts, at high point and bends/change of direction of flow, air

release valves shall be provided. Sizing criteria for air release valves shall be




generally on the basis of valve size to pipe diameter ratio of 1:8. Requirement shall be decided as per relevant code.

Transient analysis /surge analysis where ever specified and required shall be

conducted in order to determine the location, number and size of the Air-Release valve on certain long distance/high volume piping systems, if applicable within the scope of work of the package.




4.02.00 Piping Material S.No. Description Raw

Water Clarified Water

Drinking Water DM Water Fuel Gas/ Oil Air

1 Pipe Material

ASTM A-36/ASTM A-53 type 'E'Gr.B/ IS-3589 Gr. 410 /IS-1239 Heavy.

ASTM A-53 type E Gr.B galvanized/ IS:1239 Gr. heavy galvanised/IS;3589 Gr 410 galvanized to IS-4736 or equivalent.

Stainless steel to ASTM-A-312 Gr.304 ERW or seamless sch-40 for sizes above 50mm and seamless for sizes 50mm and below.

ASTM 306 upstream of fine filter and SS 316 downstream of fine filter

ASTM A-53 type E Gr.B galvanised/IS:1239 Gr. heavy galvanised/IS:3589 Gr. 410 galvanized to IS- 4736 or equivalent

2 Fittings a - 200 NB &

larger Fabricated fittings out of parent carbon steel pipe.

Fabricated pipe fittings out of material same as pipe.

SS

b - 150 NB & below

Hot bends out of seamless carbon steel pipes with butt welding ends to ASA-B-16.9, dimensions matching with IS:1239 Heavy Class piping.

Fabricated pipe fittings out of stainless steel type 304 Sch-10S thick. BW ends to ASA-B-16.9.

SS Heavy class galvanized MS screwed fittings to IS: 1239 Part-II or equivalent with screwed ends to IS: 554

3 Flanges Single piece plate cut flanges out of IS: 2062 plates drilled to 150#ASA B-16.5. Multi segment flanges for large dia pipes shall be 100% radio graphed.

150#ASA class carbon steel rubber lined flanges drilled to ASA-B-16.5 with a set of bolts, nuts & gaskets

SS 150 # ASA galvanized screwed flanges drilled to ASA-B-16.5 with bolts, nuts & gaskets.

4 Bolts and nuts

Hexagonal head machined carbon steel bolts and hot forged carbon steel hexagonal nuts to IS: 1367 Class 4.6

Stainless Steel SS Hexagonal head machined carbon steel bolts and hot forged carbon steel hexagonal nuts to IS: 1367 Class 4.6

5 Gasket 3mm thick cloth inserted white rubber full faced gaskets dimensions to suit associated flange drilling details

1.5 mm thick. compressed asbestos, ring type gaskets dimensions to suit associated

SS 3 mm thick cloth inserted white rubber full faced gaskets dimensions to




flange drilling details suit associated flange drilling details

6 Joints a 50 mm and

smaller Line joints socket welded type Line joints socket welded type SS Screwed

b - 65 mm and larger

Line joints butt welded type Flanged SS Screwed Flanged

c - joints at valves

Socket weld/flanged for sizes 65 NB and above

Socket weld/flanged for sizes 50 NB and below

SS Screwed Flanged

d Joints at equipment

As per Manufacturers Standard As per Manufacturers Standard SS As per Manufacturers Standard




4.03.00 Piping layout 4.03.01 Piping shall be grouped together where practicable and routed to present a neat

appearance. 4.03.02 Piping routing shall be such as to provide sufficient clearance for removal and

maintenance of equipment, easy access to valves, instruments and other accessories. The piping shall not encroach on the withdrawal space of various equipments.

4.03.03 Over head piping shall have a normal minimum vertical clearance of 2.5 meters

above walkways and working areas and 8M above roadways/railways. When several pipe lines are laid parallel, flanged joints must be staggered. Welded and flanged joints should as far as possible be located at one third span from supports. If the support is situated right under the welded joints this joint must be reinforced with a strap. Flanged and welded joints must be avoided in the middle of the span. Valves should be located in such a manner so as to ensure their convenient operation from the floor or the nearest platform.

4.03.04 Piping shall be erected as per approved drawing. 4.03.05 All piping shall be routed so as to avoid interference with other pipes and their

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

4.03.06 Piping shall generally be routed above ground but where specifically

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

4.03.07 Sufficient up stream and down stream lengths shall be provided for flow

measuring devices, control valves and other specialities. 4.03.08 All local instruments shall be located on pipe lines as to render them observable

from the nearest available platforms. 4.03.09 Openings provided in the wall for pipelines must be closed with bricks and mortar

with 10-12 mm clearance between brick work and pipe after taking care of insulation and thermal movement, if any. The clear space must be filled with felt or asbestos or approved filling compound.

4.04.00 Slope/Drains and Vents 4.04.01 Suitable slope shall be provided for all pipelines towards drain points. It is Bidder

responsibility to identify the requirements of drains and vents, and supply the necessary pipe work, valves, fittings, hangers and supports etc. In addition to the system requirement all low points in the pipelines shall be provided with suitable draining arrangement and all high points shall be provided with vent connections where air or gas pockets may occur. Vent for use during hydrostatic test shall be plugged after the completion of the test. Vent shall not be less than 15mm size. Drains shall be provided at low points and at pockets in piping such that complete drainage of all systems is possible. Drain shall not be less than 15mm for line size




upto 150mm, not less than 20mm upto 300mm and not less than 25mm for 350mm to 600mm pipes and not less than 50mm for 600mm and above pipes.

4.04.02 Air piping shall be sloped so that any part of the system can be drained through

the shut-off drain valve or drain plugs. 4.05.00 Specification of Hydrogen, nitrogen and carbon-dioxide cylinders

The water holding capacity of each Hydrogen , nitrogen and CO2 cylinder shall be 46.7 litres.

The H2 , Nitrogen and CO2 cylinders shall conform to IS-8198 ; 2004 and IS-7285 /or equivalent standard and Gas cylinder Rules. Design and Manufacturing of cylinder shall be approved by CCOE.

The Gas Cylinders shall be located in a separate facility. Each cylinder shall be supplied with an integral isolating valve as per IS: 3224 including cap and neck rings. The inlet side of these valves shall match with the threads of the cylinder neck ring and the outlet shall be as per IS-3224 (latest revision)/equivalent standard for further connection downstream.

Each cylinder shall be tested as per the guide lines of Chief Controller of Explosives, Nagpur. Test certificates from Chief Controller of Explosives certifying suitability of each cylinder for filling and transportation shall be submitted to client before dispatch of the cylinder to site for approval. The cost of testing and furnishing test certificates shall be included in the quoted price.

No. of H2 Cylinders: As per technical requirements No. of N2 Cylinders: As per technical requirements No. of CO2 Cylinders: As per technical requirements

4.06.00 Bends/elbows/mitre bends/ Tees/ Reducers & other fittings 4.06.01 Unless otherwise specified elbows shall be of long radius type. 4.06.02 For pipe sizes upto 65Nb, long radius forged elbows or seamless pipe bends shall

be used. Pipe bends, if used, shall be cold bent to a radius measured to the centre line of pipe of 3 to 5 times the pipe diameter.

4.06.03 For steel pipes 80 Nb and above, seamless long radius forged elbows shall be

used. For pipe size 350Nb and above mitre bends may be used for all pipes except rubber lined pipes. The bend radius shall be 1½ times the nominal pipe diameter. 90 deg. bends (mitre) shall be in 4 pieces (3 cuts) and 45 deg. mitre bends shall be in 3 pieces 22½ deg. Fabrication of mitre bends shall be as detailed in BS 2633/BS534.

4.06.04 Mitre bends are not acceptable in case of rubber lined mild steel pipes, if

applicable for any piping system. 4.06.05 For pipe fittings such as reducers and tees, the material shall be to ASTM-A-234

Gr. WPB up to 300 NB. For pipe reducers and tees above 300 NB, the fittings




may be fabricated conforming to parent pipe material. Provision of compensation pads shall be kept as per ANSI B 31.1. The fitting shall conform to the dimensional standard of ANSI B-16.9.

However, for pipes up to 150 NB, pipe fittings may be supplied with material and

dimension conforming to IS 1239 in case parent pipes also conform to IS 1239. For pipes, above 1200 NB, reducer and tees shall be to dimensional standard of

AWWA-C-208. 4.06.06 For stainless steel (SS) pipes, the fittings shall be of forged stainless steel

conforming to ASTM-A-403. 4.07.00 Flanges 4.07.01 Flanges shall be slip on type. Welding of flanges in tension is not permitted., 4.07.02 All flanges and-flanged drilling shall be to ANSI B 16.5/BS EN-1092 of relevant

pressure/temperature class. Flanges shall be fabricated from steel plates conforming to ASTM A 105/IS 2062 gr.B.

4.08.00 Specific technical requirement of laying buried pipe with anti corrosive

treatment The pipe in general shall be laid with the top of the pipe minimum 1.0 (one) metre

below finished general ground level. 4.08.01 Trenching (a) The trench shall be cut true to the line and level and shall follow the

gradient of the pipeline. The width of the trench shall be sufficient to give free working space on each side of the pipe. Trenches shall conform to IS 5822.

(b) Free access shall be provided for the welding of the circumferential joints

by increasing the width and depth of the trench at these points. There should be no obstruction to the welder from any side so that good welded joint is obtained.

(c) The free working space shall conform to IS:5822. The trench shall be

excavated so as to provide minimum cover of 1000mm between the top of the pipe and finished grade.

(d) Prior to lowering and laying pipe in any trench, the Bidder shall backfill and

compact the bottom of the trench or excavation in accordance with IS:5822 to provide an acceptable bed for placing the pipe.

(e) Coating and Wrapping shall be done as under 4.08.02 Preparation and cleaning of piping (a) The pipeline shall be thoroughly cleaned of all rust, grease, dirt, weld

scales and weld burrs etc. moisture or other foreign matter by power




cleaning method such as sand blasting, power tool cleaning, etc. Grease or heavy oil shall be removed by washing with a volatile solvent such as gasoline. Kerosene shall not be permitted for cleaning. This cleaning operation shall be immediately followed by priming with the mechanical priming machine.

(b) Certain inaccessible portions of the pipe line (which otherwise not possible

to be cleaned by power cleaning methods) may be scrubbed manually with a stiff wire brush and scrapped where necessary.

(c) The cleaning and priming operation shall be carried out at site. The entire

pipe length shall be cleaned but the ends of the pipes shall be left without coating for a distance of 230mm for joints, which shall be coated manually at site after laying, welding and testing the pipe.

(d) On the internal surface for pipes 1000 Nb and above, a coat of primer

followed by a hot coal-tar enamel or coal tar epoxy painting (cold) shall be applied.

4.08.03 Coating and wrapping (a) Burried piping shall be coated and wrapped, as per specification, after

completion of welded and/or flanged connections, and after completion and approval of Hydro testing. Materials to be used for coating and wrapping of underground pipelines are :

(1) Coating primer (coal tar primer) (2) Coating enamel (coal tar enamel) (3) Wrapping materials. (b) All primer/coating/wrapping materials and methods of application shall

conform to IS:10221 except asphalt/bitumen material. Materials (primer/coating/wrapping) as per AWWA-C-203 are also acceptable.

(c) Protective coating shall consist of coal tar primer, coal tar enamel coating,

glass fibre tissue inner wrap followed by coal tar impregnated glass fibre or kraft paper outer wrap or finish coat.

(d) Number of coats and wraps, minimum thickness for each layer of

application shall be as per IS-10221. Number of coats and wraps shall be decided based on soil corrosivity/ resistivity as indicated in IS-10221. Soil data-for this purpose shall be collected by the Bidder, if required.

(e) Total thickness of completed coating shall not be less than 4.0 mm. (f) Alternatively, the anti-corrosive protection can consist of anti-corrosive

protection Coal-tar tapes. material and application of tapes shall conform to AWWA-C-203. These-tapes shall be applied hot over the cold coal tar primer. The total thickness of the finished protective coating shall be 4mm minimum.




4.08.04 Trench bed preparation and back filling Prior to lowering and laying pipe in any excavated trench, the bottom of the trench

may require to be back filled and compacted (or as the case may be) to proved an acceptable bed for placing the pipe. Bed preparation in general shall be as per IS:5822.

Bed preparation and back filling of excavated trenches for buried pipes depend on

type of soil. Soil types are classified into 3 categories: (a) Rocky Soil. (b) Sandy/ silty soil (including non-expansive clay). (c) Expansive soil (including water logged/ marshy soil). The bidder shall note that the cross-country raw water piping as well as other in-

plant pipings may travel underground through all types of soils and combination of soils described above.

4.08.05 Laying of galvanised steel (GI) pipes All the joints shall be screwed or flanged. Screwed ends of GI pipes shall be

thoroughly cleaned and painted with a mixture of red and white lead before jointing Threaded portion on either side of the socket joint shall be applied with Zinc silicate paste.

All the provisions for trenching/bed preparation/laying the pipe application of

primer/coating/wrapping with tapes/back filling etc. as indicated for "laying of burried piping" and " anti corrosive protection for burried piping" are applicable for burried galvanised steel (GI) pipes also.

4.09.00 Valves 4.09.01 General a. This covers specific technical requirements for gate, globe, check, angle,

butterfly, air release, float, safety and relief valves, alongwith all accessories such as actuators, gear operators, extension spindles, integral bypass valves, etc.

b. The design fabrication and testing of valves, shall generally conform to the

requirements of ANSI B 16.34 unless specified otherwise under valve code specification.

c. All valves shall have full sized ports. d. For globe and check valves the direction of flow shall be clearly embossed

on the body of the valve. e. All valves shall be suitable for installation in horizontal as well as vertical

pipe line.




f. All globe / gate valves shall be capable of being closed against the design pressure.

g. Where globe valve are to be required for regulation purpose, the disc shall

be tapered plug type and suitable for controlling through its lift. h. All gate and globe valves shall have bonnet back seating arrangement to

facilitate easy replacement of packing with the valves in service. i. Stop check valves shall have full floating and accurately guided discs. j. The internal diameters of the valve ends shall be same as the internal

diameter of the connecting pipe at least for those valves which are of the same nominal bore as the connecting pipe.

k. All valves shall be provided with embossed name plate giving details such

as tag number, type, size etc. 4.09.02 Hand Wheels Hand wheels for all the valves shall close the valve in clockwise direction when

viewing from the top. All hand wheels shall be clearly marked indicating the direction of opening / closing. Hand wheel shall be of malleable iron.

4.09.03 Position indicators. a. All valves with rising stem shall have visual indication through plastic stem

covers. Others shall be provided with continuous mechanical position indicators.

b. Wherever required for monitoring and control/purposes, valves shall be

provided with potentiometric type remote position indicators. Source voltage for such transducers shall be 240 V AC / 220 V DC. These position indicators shall conform to Section on valve actuator.

c. Limit switches on manual valves shall conform to Section on valve

Actuators. 4.09.04 Manual Gear Operators Manual gear operators shall be provided to open / close the valve against the

maximum differential pressure across the valve such that the effort required to operate does not exceed 25 kgf.

Manual gear operator shall be reputed make, proven quality conforming to internationally accepted standards and suitable for outdoor installation.

4.09.05 Locking Arrangements Locking arrangement where specified shall be of non-detachable type, subject to

approval of Owner.




4.09.06 Chain Wheel Operator Chain & chain wheel shall be provided by bidder wherever required for easy

operation of valves. Chain wheel for the valves shall be constructed to five good traction for the chain. Roller guides shall be provided to hold the chain to a greater part of the circumference of the wheel to increase traction and to prevent the chain from jumping off the wheel.

4.09.07 Floor stand and extension spindle For floor stand and extension spindle arrangement for valves, the height of floor

stand shall be about one (1) meter from the floor / platform. The floor stand shall be of sturdy construction with column, nut plate and hand wheel made of cast iron conforming to material ASTM A 126 Gr B. Suitable thrust bearing shall be provided between the hand wheel and the floor stand. The connection of the extension spindle to the valve stem shall be through a flexible coupling and shall be designed to permit valve thermal movements. Necessary nuts, bolts, etc. for mounting the floor stand on platform shall be provided.

4.09.08 Rubber Lining of Valves For rubber lined valves, following requirement are to be met. a. Rubber shall be of Neoprene / Nitrile. b. All wetted surfaces of valve internals shall be fully rubber lined extending

upto the edges of flanges with out any joint. c. Lining shall be of manufacturer’s standard thickness subject to a minimum

of 3 mm. d. Rubber lining shall be spark tested for checking the continuity. 4.09.09 Electric motor actuated valves In case of motor operated valves, electric motor actuators shall conform to the

requirements of Section on valve actuators./ For all motor actuated valves, by pass valves shall also be motor actuated.

4.09.10 Testing Requirements a. All valves shall be tested as per the general requirement given in various

sections of this specification. Specific testing requirement are indicated against valves specification codes below.

b. Where practical, each valve assembly shall be shop tested to open and

close against the maximum differential pressure specified in the specification.

4.09.11 Valve Body Material Valve body material for various services shall be as follows:




Valve body material for Raw water, service water, clarified water make-up to CW system, clarified cooling water, DM cooling water, CW blow down water, circulating water, compressed air & drinking water shall be as follows:

a) Cast iron for water and galvanised cast carbon steel for compressed air for

sizes 65NB and above b) Gun-metal for sizes 50 Nb and below c) DM water : SS body and disc alongwith SS internals d) Condensate : Cast Carbon Steel 4.09.12 End Connections The end connections, shall comply with the following : Socket welding (SW) - ANSI B 16.11 Butt Welding (BW) - ANSI B 16.25. Threaded (SC) - ANSI B 2.1 Flanged (FL) - ANSI B 16.5& AWWA-C-207(steel flanges), ANSI B 16.1 (Cast Iron

flanges) All cast iron/ ductile-Ni iron body valves (gate, globe and non-return) shall have

flanged end connections, (screwed ends for cast iron D.2NI body valves are not acceptable).

All steel and stainless steel body valves of sizes 65 mm and above shall have

flanged or butt welded ends. Valves of sizes below 65 mm shall have flanged or socket welded ends. Compatibility of welding between valve body material and connecting pipe material is a pre-requisite in case of butt-welded joints.

All gun metal body valves shall have screwed ends. All flanged end valves/specialities shall be furnished alongwith matching counter

flanges, fasteners, gaskets etc. as required to complete the joints. 4.09.13 Material of Construction (Butterfly Valves) Materials and other design details shall be as indicated below : (a) Cast Iron Butterfly Valves Body & Disc ASTM A48, Gr. 40 with 2% Ni/ IS:210 Gr. FG-260,

with 2% Ni and epoxy coated Shaft BS 970 431 S:291 / EN 57, or AISI-410 or

AWWA-permitted shaft material equivalent to EN-57/AISI-410 or better.




Seat ring 18-8 Stainless steel Seal Nitrile Rubber (b) Stainless Steel Butterfly Valves Body & Disc ASTM A 351, Gr. CF8M Shaft ASTM A 182, Gr. 316 Disc & Seat Rings EPT/BUNA-N/Neoprene (c) Carbon steel Butterfly Valves Body & Disc ASTM A 216, Gr. WCB

Shaft ASTM A 182, Gr. 304 Disc & Seat Rings EPT/BUNA-N/Neoprene 4.09.14 Material of Construction (Gate/Globe/Check valve) The materials shall generally comply with the following : (a) Cast Steel Valves

Body & bonnet ASTM A 216 Gr. WCB/ ASTM A 105

Disc for non-return valves ASTM A 216 Gr. WCB/ ASTM A 105 Trim. ASTM A 182 Gr. F6 (b) Stainless Steel Valves Body & Bonnet ASTM A 351 Gr. CF 8M/ ASTM A 182 Gr.

304 Disc ASTM A 351 Gr. CF 8M/ ASTM A 182 Gr.

304 Trim. ASTM 182 Gr. F. 316 (c) Cast Iron Valves Body & bonnet BS 1452 Gr. 14/ IS-210 Gr. FG 260 Seating surfaces and rings 13% chromium steel Disc for non-return valves BS 1452 Gr. 14/IS-210 Gr FG 260 Hinge pin for non-return AISI 316 valves




Stem for gate globe valves 13% chromium steel Back seat 13 % chromium steel (d) Gun Metal valves Body and bonnet IS:318 Gr.2/Equivalent Standard Trim. IS:318 Gr.2/Equivalent Standard (e) Cast iron body valves shall have stainless steel stem and seat. (f) Material for counterflanges shall be the same as for the pipings. 4.09.15 Material of construction (Ball valve) Body ASTM-A-216 Gr. WCB Galvanised/

ASTM-A-105 Galvanised Ball ASTM-A-351 Gr. CF8M/ASTM-A-276 Type

316 Stem ASTM-A-276 Type 316 Gland ASTM-A-276 Type 316 Anti-Static Device SS-304 Stem Seal PTFE. 4.09.16 Gate Valves a) All gate valves shall be of the full-way type, and when in the full open

position the bore of the valve shall not be constricted by any part of the gate.

b) Gate valves shall be of the solid/elastic or articulated wedge disc and

rising stem type. 4.09.17 Globe Valves Globe valves shall have the following characteristics: a) Straight conveyed flow. b) Right angle preferably, the valves shall be of the vertical stem type. c) Globe valves shall preferably have radiused or spherical seating and discs

shall be free to revolve on the spindle. d) The pressure shall preferably be under the disc of the valve. However,

globe valves, with pressure over the disc shall also be accepted provided (i) no possibility exists that flow from above the disc can remove either the




disc from stem or component from disc (ii) manual globe valves can easily be operated by hand. If the fluid load on the top of the disc is higher than 40-60 KN, bypass valve shall be provided which permits the downstream system to be pressurised before the globe valve is opened.

e) Globe valves with NB smaller than or equal to 2" shall be of the integral

type. Valves of this type shall be so as to permit the easiest disassembly of the internals (stem and disc).

f) For the regulating valves, valves with regulating plug & parabolic outline

disc type is preferred. g) All motorised globe valves with regulating plug for which indication of

percentage (%) opening are required in the control room shall be provided with necessary position transmitter.

4.09.18 Check Valves Check valves shall comply with the following characteristics: a) For bore greater than 2" the valves must be swing check type or dual plate

check type suitable for installation in all positions (vertical and horizontal); b) For bore smaller than or equal to 2" the valves must be of the piston type

to be installed, in horizontal position. c) In the case of swing check valves, the body seat shall be inclined at such

an angle from the vertical as shall facilitate closing and prevent chatter. d) Drilling on flanges of flanged valves must correspond to the drilling on

flanges of the piping system on which the valves are to be installed. e) All flanged valves intended for installation in steel piping systems shall

have their flanges drilled to ANSI B 16.5 (or equivalent) and according to the pressure class.

f) Counter flanges to be installed on air pipes shall be screwed-on type

irrespective of size. 4.09.19 Butterfly Valves The valves shall be designed for the design pressure/temperature of the system

on which it is installed and in accordance with AWWA-C-504, BS:5155 or any other approved equivalent standard latest edition.

(a) The valves shall be suitable for installation in any position

(horizontal/vertical etc.) and shall be of double-flanged construction. However, for sizes 150NB and below the valves shall be of either double-flanged or wafer construction (U-Section type or double lugged type).

(b) The seals, both on the body (sleeve) and on the disc shall be of the

material specified. Necessary shaft seal shall be provided and adequately designed to ensure no leakage across the seal. This seal shall be




designed so that they shall allow replacement without removal of the valve shaft. The sealing ring on the disk shall be continuous type and easily replaceable.

(c) For all types of valves, the design with shaft eccentric to the disc is

preferred. The shaft shall be solid type and shall pivot on bushings. Bushings/sleeve type bearings shall be contained in the hub of valve body. The bearing shall be self-lubricated type with low coefficient of friction and should not have any harmful effect on water and on valve components.

(d) The design of the shaft shall be such that it shall safely sustain maximum

differential pressure across the closed valve. The shaft and any key (taper pin etc.) for transmitting the torque between shaft and disc shall be capable of withstanding the maximum torque required to operate the valve. However, the shaft diameter shall not be less than the minimum shaft diameter specified in relevant code. Necessary Torque Calculation and the torque class selected on the basis of the same shall be furnished to the Owner for information.

(e) The disc shall rotate from the full open to the tight shut position. The disc

shall be contoured to ensure the least possible resistance to flow and shall be suitable for throttling operation. While the disc is in the throttled position, valve shall not create any noise or vibration.

(f) The operating mechanism shall be mounted directly on or supported from

the valve body. g) Limit and torque switches (if applicable) shall be enclosed in water tight

enclosures alongwith suitable space heaters for motor actuated valves, which may be either for On-Off operation or inching operation with position transmitter.

4.09.20 Ball Valves a) Ball valves shall be manufactured as per standard BS-5351 latest version. b) Ball position indicator shall be provided. c) Anti static device shall be provided for the ball valves. d) Galvanising of carbon steel parts such as Body, adapter, stud & nuts and

handle, etc. shall be done. e) Body of stud & nuts shall be ASTM-A-193 Gr.-B-7 and A-194 Gr. 2H

respectively. f) Fire safe design as per API-607 shall be provided. g) For sizes 80 NB and above the design shall be full-port type. However for

sizes below 80 NB the reduced-bore design may be provided. 4.09.21 Float Operated Valves




a) Valve shall automatically control the rate of filling and shall shut off when a predetermined level is reached and close to prevent over flow on pre-set maximum water level. Valve shall also open and close in direct proportion to rise or fall of water level.

b) Design and construction features i) Valves shall be right angled or globe pattern. ii) Valves shall be balance piston type with float ball. iii) Leather liner shall not be provided. c) The body and cover material shall be cast iron conforming to ASTM-A 126

Grade 'B' or IS:210 Grade 200 or equivalent, and Float shall be of copper with epoxy painting of two (2) coats.

d) Valves shall be suitable for flow velocities of 2 to 2.5m/sec. 4.09.22 Air Release Valves (a) The air release valves shall be of automatic double air valve with two

orifices and two floats. The float shall not close the valve at higher air velocities. The orifice contact joint with the float shall be leak tight joint.

(b) The valve shall efficiently discharge the displaced air automatically from

ducts/pipes while filling them and admit air automatically into the ducts/pipes while they are being emptied. The valve shall also automatically release trapped air from ducts/pipes during operation at the normal working pressure.

(c) Body material of automatic air release valves shall comply generally with

BS 1452 Gr. 14/IS:210 Gr. FG 260. and spindle shall conform to high tensile brass.

(d) Air release valves shall not have any integral isolation device within them.

Each Air release valve shall be mounted, preceded by a separate isolation gate/ butterfly valve.

4.09.23 Moisture Drain Trap (a) Automatic ball float type moisture separator (trap) shall be provided in

compressed air distribution headers at strategic loacations warranted by actual layout of Instrument/Plant air piping in order to achieve positive shut-off in the absence of water and positive lift of float when trap is filled with water.

(b) Design and Construction Features Type Float type Service Automatic draining of condensate Operating pressure 8.0 kg/cm2(g)




Operating temperature 50deg.C Design temperature 80 deg.C Hydrotest pressure 15.0 kg/cm2(g) Body Cl IS210 FG220 Cover Cl IS210 FG220 Valve seat SS type 410 ASTM A 276 Valve seat gasket SS type 304 ASTM A 240 Rivot frame assly SS type 304 IS 1364 Ball float & level SS type 304 ASTM A 240 Plug ASTM-A-105 ASME B16.11 Support frame SS type 304 ASTM A 240 Rivot frame SS type 304 ASTM A 240 Cover gasket Compressed asbestos fibre IS:2712 End connection Screwed BSPT Max. differential pr. (Bars) 10 Strainer 'Y' type Mesh size 40 Installation Horizontal 4.10.00 Hangers & Supports The bidder shall design and detail all piping hangers and supports, restraints,

guides, stops, snubbers, anchors, dampers etc. including pipe attachments, etc. The bidder’s design documents shall be submitted for Owner’s review / approval.

Hangers & supports / restraints shall be designed such that they do not become

disengaged due to normal piping movements / vibrations during operation. Hanger / supports / restraint / snubber / anchor locations shall be indicated on the

pipe layout / isometric drawings furnished by the bidder. The hangers shall have provision to lock at any position & the same shall be supplied at site after adjusting for cold position. All springs shall be locked before by hydro testing.

The bidder shall check for interference of hangers and supports with structures,

piping, cable trays, others hangers, etc.




The bidder shall furnish detailed arrangement sketches for each support, restraint, anchor, snubber etc. The sketches shall include the keyplan, identification no., bill of quantities, design load, operating load, spring-stiffness, amount of pre-compression, centre line elevation of pipe, springbox position / orientation etc.

Hanger for piping 65 mm NB and larger and all spring support assemblies

regardless of size shall be completely engineered in conformance with the provision of power piping code ANSI B 31.1.

Hangers, saddles, supports etc. shall be capable of carrying the sum of all

concurrently acting loads and shall be fabricated from plates/ pipes sections conforming to ASTM A 53/ IS:2062/ IS:226/ or equivalent. They shall be designed to provide the required supporting effects and allow pipe line movements as necessary. The structural steel work shall be as per IS:800/ BS:4360. Insulation protection saddles shall be used at support point of all insulated piping.

The maximum spans of the supports of straight lengths shall not exceed the

recommended values indicated in ANSI B 31.1. All pipe supports shall be designed to provide an absolute minimum head room of 2.5 m from floor in passages/ walkways.

4.11.00 Metallic Expansion Joints 4.11.01 General a. The design, material construction, manufacture, inspection, testing and

performance of the expansion joints shall comply with the currently applicable requirements of EJMA, ASME boiler and pressure vessel code section III, ANSI B 31.1 and all statutes, regulations and safety codes of the locality where the equipment is to be located.

b. The expansion joints shall be designed to operate without malfunction, under any conditions that can be reasonably expected in the operation of power station from zero to full load.

4.11.02 Construction Details a. Bellows i. The bellow shall be hydraulically or roll formed from perfect

cylinders of single ply, 304 grade stainless steel. ii The number of longitudinal weld seams shall be minimum and

there shall be no circumferential weld seam. iii Cold formed stainless steel bellows shall not be heat treated. iv. All bellow elements shall be pickled after forming. v. Equalising rings, where required, shall be either from high quality

castings or from fabricated metal. vi. Flanged expansion joints shall be provided with adequate pipe

stubs.




vii Butt welded expansion joints shall have adequate length of pipe so

that site welding does not impair or reduce the joints efficiency. b. Sleeves i. Expansion joints shall be furnished with internal sleeves of the

same material as the bellows and installed with sufficient clearance to allow full rated deflection. The sleeves shall be welded on the flow inlet end of the joints only.

ii. Bellows shall have external sleeves with an arrow indicating the

direction of flow on the outside. The external steel covers provided to protect bellows from physical damage. It shall be suitable for supporting insulation where necessary and shall be detachable.

c. Tie Bars i. Joints shall be shipped provided with suitable knock-off type

temporary tie bars to prevent damage and misalignment during transit and also with permanent tie bars along with necessary nuts, bolts etc.

ii Tie rods on pressure balanced type expansion joints shall be

adequately sizes to prevent buckling in vacuum services or services with other external loads.

4.11.03 Inspection and Tests a. Bellows shall be subjected to all tests and inspections as called for by

applicable codes / standards specified herein. The bidder shall fully shop assemble the bellow and test / demonstrate that its performance is satisfactory.

b. All welds shall be dye penetrant tested as per ASTM E 165 method B. c. Material test certificates (chemicals & mechanical) as per code

requirements shall be furnished. d. The expansion joints shall be assembled and hydrostatically tested at shop

at 1.5 times the design pressure for a period of half an hour. e. The expansion joints shall be subject to a vacuum test at shop at a

pressure of 12 mm Hg absolute for a period of half an hour. 4.11.04 The bidder shall furnish GA Drg. of bellows with complete BOM and data sheet

indicating type, type of construction, design code/standard and parameters, size, test code / standard and duration of test, system, deflection, material of various components etc. for Owner’s review and approval.

4.12.00 Rubber Expansion Joints




a. The design, material, construction, manufacture, inspection and testing of rubber expansion joints shall comply with the requirement of Expansion Joint Manufacturer Association (EJMA) standards, USA, Fluid Sealing Association, USA.

b. The expansion joints shall be single bellow type. The arches of the

expansion joints shall be filled with soft rubber. c. The design shall be suitable for working pressure, temperature and type

of fluid flowing through it. d. The inner cover (tube) and the outer cover (outer) shall be made of

natural or synthetic rubber of adequate hardness. The shore hardness shall not be less than 60 degrees for outer and 50 degrees for inner cover. The carcass between the tube and cover shall be made of high quality cotton duck preferably square woven to provide equal strength in both directions of the weave. The fabric pipes shall be impregnated with age resistant rubber or synthetic compound and laminated into a unit. Reinforcements consisting of solid metal rings embedded in carcass shall be provided.

e. The split retaining rings shall be galvanised steel of 10 mm thick to ASTM

A - 36 equivalent. Steel washers shall be provided at the bolt holes where retaining rings are split.

f. All exposed surfaces of expansion joint shall be given a 3 mm thick

coating of neoprene. This surface shall be reasonably uniform and free from blisters, porosity and surface defects.

g. Expansion joints shall be complete with stretcher bolt assembly. The

expansion joints shall be suitable to absorb piping movements and accommodate mismatch between pipe lines.

h. The expansion joints shall be of heavy duty construction made of high

grade abrasion-resistant natural or synthetic rubber compound. The basic fabric for the' duck' shall be either a superior quality braided cotton or synthetic fibre having maximum flexibility and non-set characteristic.

i. The expansion joints shall be adequately reinforced, with solid steel rings,

to meet the service conditions under which they are to operate. j. The expansion joints shall have integral fabric reinforced full-face rubber

flanges. The bolt on one flange shall have no eccentricity in relation to the corresponding bolt hole on the flange on the other face. The end rubber flanges shall be drilled to suit the companion pipe flanges.

k. Each control unit shall consist of two (2) numbers of triangular stretcher

bolt plates, a stretcher bolt with washers, nuts, and lock nuts. Each plate shall be drilled with three holes, two for fixing the plate on to the companion steel flange and the third for fixing the stretcher bolt.

l. Each joint shall have a permanently attached brass or stainless steel

metal tag indicating the tag numbers and other salient design features.




m. Bidder to note that any metallic part which comes in contact with DM

/corrosive water shall be of Stainless Steel material. 4.13.00 Tanks and Accessories The designer and manufacturer of storage tanks shall comply with and obtain

approval of all currently applicable statutory regulations and safety codes in the locality where the equipment shall be installed. The tanks shall conform to IS 803/IS804/IS 805/ IS 2825/BS1564/ API 650/ IS 4049/ IS 4682 (part-I) and IS 4864 to 4870/ ASME B & PV code as the case may be.

Actual quantity, capacity, sizing of each tank to be minimum supplied shall be as

covered in respective systems. However, It is bidder's responsibility to design/size these tanks depending upon system requirement/ design during detail engg. and submit the design calculations to Engineer for approval alongwith tank GA drg. Additional Control & Instrumentation facilities specified elsewhere in the technical specification shall also be incorporated by the bidder.

4.13.01 Design and Construction Design of all vertical atmospheric storage tanks containing water, acid, alkali and

other chemical shall conform to IS:803 & API 650. Design of all horizontal atmospheric storage tanks containing water, acid, alkali

and other chemicals shall generally conform to IS:2825 as regards to fabrication and general construction taking care of combined bending, shear & hoop stresses developed due to supporting arrangement.

Design temperature of vessels shall be 10 deg.C higher than the maximum

temperature that any part of the vessel is likely to attain during the course of operation.

Tank shall be made from mild steel plates to BS 4360/IS-2062 Gr.B (or

equivalent). The material for flanges shall be of ASTM A 105/ IS-2062 Gr.B. The joint efficiency factors to be adopted for design calculations shall be in

accordance with the specified design code. Tank shall be provided with suitable supporting joints. All vessels shall be provided with lifting lugs, eye bolts etc. for effective handling during erection.

For cylindrical tanks, the plates shall be cold rolled through plate bending machine

by several number of passes to true curvature. Vessel seams shall be so positioned that they do not pass through vessel connections. For cylindrical vessel consisting of more than two sections longitudinal seams shall be offset.

Tanks shall be provided with float operated level indicators/level gauges/level

transmitters and level switches, as required, with complete assembly. Suitable flanged pads for level switches mounting shall also be provided. The level indicator can be top or side mounted as the case may be.

In addition to inlet and outlet nozzles, the tanks shall be provided with vents,

overflow, drain nozzles complete for various connections on tanks. Drains &




overflow lines from storage tanks is to be routed to the nearest surface drains/plant drains. For tanks containing DM water, Alkaline water or Power cycle water the vent to atmosphere shall be through carbon-di-oxide absorber vessel suitably mounted on the tank. CO2 absorber vessel shall be provided with the initial fill of chemicals. Similarly for equipment cooling water overhead tank, the overflow & drain from tank shall be combined together and shall be led to nearest drain (at zero level) via. a seal-trough so as not to come directly in contact with atmosphere.

Tanks shall have suitable stairs/ladders on inside and outside of the tanks,

manholes/inspection covers as required and also platform suitably located. Tank supporting arrangement as approved by Owner shall be provided with all plates/angles/joints/flats and supporting attachment including lugs, saddles, legs etc.

Piercing nozzles/pipes from tank body / dish ends shall be adequately

compensated with suitable reinforcement pad as per relevant code. Manholes shall be provided for easy access into the vessels. The size shall be

minimum 500 mm and shall be with cover plate, nuts bolts, etc. to ensure leak tightness at the test pressure. Each tank, shall be provided with drilled cleats welded to the tank for electrical grounding. Material of cleats shall be same as that of the shell.

All tank /vessel roofs and supporting structures shall be designed to support dead

load plus a uniform live load of not less than 125 Kg/M2 of projected area and wind load as specified. Flat heads, side plated etc. shall be adequately stiffened to support the loads as specified.

Tank fabrication drg. and design calculations shall be approved by the Owner Handrails shall be provided around the roof of the storage tanks. Toe (skid) plate

shall be provided 4.13.02 Corrosion Allowance & Protection Corrosion allowance as per code requirement shall be considered for calculating

the plate thickness for tanks irrespective of whether a protective internal lining/coating is provided or not.

Wherever corrosion allowance has not been specifically mentioned in code/std, a

minimum of 1.6 MM shall be considered over and above the calculated minimum .thickness of plate.

Epoxy-coating shall be provided on the inside of vessel in three coats (minimum)

resulting in total thickness of not less than 150 micron wherever required, such as equipment cooling water overhead tank, condensate storage tank/ Reserve feed water tank, DM Water tank, Service Water tank , Portable water tanketc.

4.13.03 Cleaning & Painting




Inside surface of all tanks including inside ladder and appurtenances shall be protected by anti-corrosive paints/coating as required and specified elsewhere.

For tanks/vessel requiring epoxy painting, all inside surface shall be blast cleaned

using non-siliceous abrasive after usual wire brushing. Outside surfaces of all other vessels shall be provided with two coats of primer

with three (3) coats of epoxy resin based paint of approved colour. 4.13.04 Technical Particulars of Tanks and Accessories ------------------------------------------------------------------------------------------------- Sl.No. Description Tech. Particulars ------------------------------------------------------------------------------------------------- Condensate Storage Tank i) Quantity per module/Total Quantity One (1) / Three(3) ii) Useful Capacity of Each Tank Two hours make-up requirement

considering 5% cycle make-up iii) Size (Dia. x length) Adequate vi) Design Standard ASME Section-VIII. Div.I/ IS:2825 (Class-3) vii) Material of Construction MS Plates to IS:2062 Gr.B/ ASTM A36. xi) Accessories : (a) Vent, overflow and drain Required (b) Sample Connection Required (c) Level Indicator Required (Gauge glass ) (d) Level Switch LO-LO, LO, High, Hi-Hi. (e) Level Transmitter Required ------------------------------------------------------------------------------------------------- Note: Number/capacity/size of tank are minimum for bidder's offer purpose. It is

bidder's responsibility to design/size these tanks depending upon system requirement/ design during detail engg. and submit the design calculations to Engineer for approval alongwith tank GA drg. Additional Control & Instrumentation facilities specified elsewhere in the technical specification shall also be incorporated by the bidder.

4.14.00 STRAINERS 4.14.01 Simplex type




The strainers shall be basket type and of simplex construction. The strainer shall be provided with plugged drain/blow off and vent connections. The free area of the strainer element shall be at least four (4) times the internal area of the connecting pipe lines. The strainer element shall be 20 mesh. Pressure drop across the strainers in new condition shall not exceed 1.5 MWC at full flow. Wire mesh of the strainers shall be suitably reinforced, to avoid buckling under operation. Strainer shall have screwed blow off connection fitted with a removable plug. The material of construction of various parts shall be as follows:

(a) Body IS:318, Gr. 2 upto 50 mm Nb, and IS: 210

Gr. FG 260 above 50 mm Nb. (For DM water/sea water Body : AISI 316 or equivalent)

(b) Strainer Element Stainless steel (AISI 316) (c) End connection Screwed upto 50 mm Nb, and

Flanged above 50 mm Nb 4.14.02 Duplex type The strainers shall be basket type and of duplex construction. The strainer shall

be provided with plugged drain/blow off and vent connections. The free area of the strainer element shall be at least four (4) times the internal area of the connecting pipe. The mesh of strainer element shall be commensurate with the actual service required. Pressure drop across the strainer in new condition shall not exceed 4.0 MWC at full flow.

Wire mesh (if applicable) of the strainers shall be suitably reinforced. The material

of construction of various parts shall be as follows. Body IS:318, Gr. 2 (SS-316 or Duplex S.S for sea-

water) upto 50 mm Nb, and IS:210, Gr. FG 260 or ASTM-A-515 Gr. 75/ IS-2062 Gr. B & internally epoxy-painted above 50 mm NB.

Strainer element. Stainless steel (AISI 316) End connection Screwed upto 50mm Nb, and flanged above

50 mm Nb. Gasket shall be of full face type The strainer shall have a permanent stainless steel tag fixed on the strainer body

indicating the strainer tag number and service and other salient data. The size of the strainer and the flow direction shall be indicated on the strainer

body casting. Thickness of the strainer element should be designed to withstand the pressure

developed within the strainer due to 100% clogged condition exerting shut-off pressure on the element.

Two shop coats of paint preceded by two coats of primer shall be applied to all

exposed surfaces as required to prevent corrosion. All parts shall be adequately




protected for rust prevention. The use of grease or oil other than light grade mineral oils for corrosion protection is prohibited.

4.14.03 Cleaning Prior to factory inspection, all manufacturing waste such as metal chips, fillings,

debris and foreign matters shall be removed from the interior. All rust, oil, grease, chalk, crayon, paint marks shall be removed from interior and exterior surfaces.

4.14.04 Painting Two (2) shop coats of primer followed by three (3) coats of synthetic enamel paint

as per approved colour code resulting in a DFT of at-least 150 micron shall be applied to all exposed surfaces as required to prevent corrosion, after release has been given for painting and dispatch. All parts shall be adequately protected for rust prevention. The use of grease or oil other than light grade mineral oil for corrosion protection is prohibited. If any part of the shop-finished paint is damaged, the same shall be made good after erection with touch-up painting and or repair painting.

5.00.00 INSPECTION & TESTING A detailed quality assurance plan covering stagewise tests to be carried out during

the manufacturing of equipment / vessels including testing at site indicating involvement of bidder, subvendor and Owner categorically shall be furnished along with the bid.

5.01.00 Tests at manufacturing unit The tests at manufacturing unit of vendor / subvendor shall include but not be

limited to following : a) Physical and chemical properties of material of construction. b) Dimensional check, Die penetration test, Radiography of all weld joints. c) Hydrotesting at 1.5 times the design pressure for underground and over

ground piping. The quality assurance plan shall be approved by Owner. 5.02.00 Testing at Site All equipment shall be guaranteed by the bidder for workmanship, materials and

satisfactory performance. The guarantee for performance shall cover individual items and systems.

5.02.01 Testing at site for L.P. Piping and associated auxiliaries shall generally include but

not limited to following: a) Hydrotesting of pipe loops and system as a hole at 1.5 times the design

pressure.




b) Non destructive testing as per applicable manufacturing standard for welding axes.

c) Satisfaction performance and functional test of associated auxiliaries i.e.

expansion joints, valves and actuators, etc.

DESIGN GUIDE FOR DIVISION OF WORK FOR

MECHANICAL PACKAGES

CORE ENGG ELECTRICAL

Document Number : REL-COENG-NEE-E21-P-000XX Sheet 1 / 3

ANNEXURE A: DIVISION OF WORK MATRIX General Notes:

The following points shall be appended below the DOW Matrix for every package 1. The vendor shall supply and erect all miscellaneous material, hardware, consumables, Secondary

earthing material, Treated-earth pit material, Lightning protection material, Fire protection coating system material and Fire-proof sealing system material required for the complete installation under his scope. • Miscellaneous material: All foundation steels such as ISMC, ISA, base frame, base plate,

foundation bolts, anchor fastener, rubber mat, mounting brackets, insert plates etc. • Hardware : GI bolts, nuts, washers, screws, brackets, supports, clamps, hangers, saddles,

cleats, sills, shims, ferrules, socket, PVC sleeve, cotton thread, adhesive / non adhesive PVC tapes etc.

• Consumables : Welding rods and gas, oil and grease, cleaning fluids, paints, electrical tape, soldering materials, cleaning cloths, cotton waste etc.

2. Cabling accessories include Termination Kits, Jointing Kits, Glands, Lugs, Ferrules, Cable Tags, Dressing Material, Bricks, Sand and Slab for Buried Cables, Clamps, Cleats and Route Markers etc.

3. Illumination includes Foundation Material, Installation of Foundation, Poles, Fixtures, Luminaries, Lamps, Control Gear, Lighting Transformer, LDB, MLDB, LP, FPB, Portable Emergency Lighting Unit, Ladder, DC-ELDB, Brackets, Fixing Accessories, Electrical Winch Operated High Mast, Switchboxes, Cable, Wires, Conduits, Earth Wires, Receptacles, Ceiling Fans, JBs etc.

4. Abbreviations used: ETC : Erection, Testing & Commissioning R Infra : Reliance Infrastructure Limited EEC : R Infra’s contractor for Electrical erection, testing & commissioning LEC : R Infra’s contractor for Lighting erection Vendor : R Infra’s contractor for mechanical package MEC : R Infra’s contractor for Mechanical erection, testing & commissioning ES : Equipment supplier

5. Variable Frequency Drives: This item may be added to the matrix of applicable packages, as per

project requirement. The Supply & ETC of all equipments and accessories as required from Isolation / Rectifier / Step down Transformer like Isolation / Rectifier / Step down Transformer, VFD panel, LV PMCC/MCC, Cables from transformer to motors, Cables from LV PMCC / MCC to motors, Cable tray, Cabling accessories etc shall be in Vendor’s scope. The Supply & ETC of Air-Conditioning System as required for VFD room shall also be in Vendor’s Scope.

Equipment Description

Supply ETC Terminal points

Inclusion in vendor’s scope

Exclusion from vendor’s scope

VFD complete with all accessories.

Vendor Vendor Incoming supply terminals of Isolation / Rectifier / Step down Transformer

As above


MECHANICAL PACKAGES



Fuel Gas Conditioning System

Equipment Description

Supply ETC Terminal points

Inclusion in vendor’s scope

Exclusion from vendor’s scope

MV switchgear NA NA HT Cable NA NA Auxiliary transformer / NGR

NA NA

LT Busduct NA NA PMCC / PCC / MCC NA NA Charger / Battery / DCDB

NA NA

Sub DCDB NA NA LT Power and Control cable

R Infra

EEC

Switchgear Supply and ETC of all cables to vendor supplied equipment

Cable Tray / Support / Conduits

R Infra

EEC

Switchgear

Cabling Accessories R Infra

EEC

Fire-Proof Coating / Fire Protection Sealing System

NA NA

Secondary Earthing Vendor Vendor R Infra’s earth riser

For all equipment erected by the vendor

Primary Earthing / untreated Earth pits

R Infra Civil

Treated Earth pits NA NA Local starter panel Vendor Vendor ACDB with 3 phase / single phase feeders

R Infra EEC

Three phase PDB with single phase feeders

NA NA

Welding / Single Phase Receptacles

NA NA

LPBS Vendor Vendor Motors and Actuators with accessories/ Solenoid Operated Valves

Vendor Vendor

Illumination Vendor Vendor Skid illumination Indoor illumination Lightning protection NA NA Communication (EPABX, PA system, Wireless System)

NA NA

Special Cable (if any) Vendor Vendor

NOTES:


MECHANICAL PACKAGES



1. All supply and erection work related to the internal illumination and earthing of skid mounted

equipment shall be in the vendor’s scope. Bidder may refer to the Chapter E14 for Hazardous area 2. R Infra will connect up the power supply / secondary earth to the terminal points on the skid.

ELECTRICAL SYSTEM DESCRIPTION

STANDARD SPECIFICATION

Document Number: REL-COENG-NEE-E21-P0039 R0

Part II, Section C Electrical Section (E0) Sheet 1 of 2

E0 - ELECTRICAL SYSTEM DESCRIPTION

ELECTRICAL SYSTEM DESCRIPTION




1.0 System Voltage & Frequency S.No. System Volt. &

Frequency Fault Level

Application Grounding

1.1 6.6 kV ± 10%, 3Ph, 3 wire, 50 Hz ±5%

40 KA (1 sec)

Motors above 200 kW Low Resistantearthed

1.2 415V ± 10%, 3Ph, 4 wire, 50 Hz ±5%

50 KA (1 sec)

Motors up to 200 kW Effectively earthed

1.3 240V ± 10%, 1Ph, 2 wire, 50 Hz ±5%

50 KA (1 sec)

Motors up to 200 W, Heaters up to 1 kW, Lighting, Control supply

Effectively earthed

1.4 110V ± 10%, 1Ph, 2 wire, 50 Hz ±5%

- MCC Control Supply Effectively Earthed

1.5 Combined variations of voltage & frequency are 10% in all above 1.6 220 V DC (-) 15% to

(+) 10%, 2 wire

25 KA (1 sec)

Control/Protection Supply, DC motors, Emergency Lighting

Unearthed

Any other supply voltage (not covered above) if needed shall be developed through transformation / rectification by the bidder.

2.0 Service Condition 2.1 Ambient air temperature -5°C to 50°C 2.2 Humidity 95% 2.3 Altitude ≤ 1000 meter 2.4 Ambient air pollution as per IEC 60068 3 2.5 Prevailing wind velocity Refer to the main specification 2.6 Seismic zone Refer to the main specification 2.7 Rain fall Refer to the main specification

3.0 Differential Protection 3.1 Differential protection will be provided for motor > 2000 kW 3.2 The bidder shall provide neutral terminal box & CT on neutral lead of each

phase

LT MOTOR STANDARD

SPECIFICATION



E1 – LT MOTOR

LT MOTOR STANDARD

SPECIFICATION



1.0 Not Used

2.0 Codes and Standards The installation shall meet the requirements of Indian Electricity rules. Materials, equipment and methods used in the manufacture shall conform to the latest edition of IS and IEC standards, including the following. If standard other than IS/IEC are used in design, manufacturing & testing, a copy of the same in English shall be submitted with the Bid.

IEC 60034 Rotating electrical machines IEC 60079-1 Equipment protection by flameproof enclosures "d" IEC 60085 Electrical insulation - Thermal evaluation and designation IS 325 Three-Phase Induction Motors CEA Standardisation of Motors for Thermal Power Station Auxiliaries, April

93 NEMA Application Guide for AC Adjustable Speed Drive Systems

3.0 Design Parameters 3.1 Service condition Refer to Electrical system description 3.2 System parameter Refer to Electrical system description for system voltage

/ frequency / fault level / neutral earthing 3.3 Rated Continuous

Output i. To be arrived at, with 10% margin over the maximum

required mechanical output ii. If higher margin is specified in mechanical

specification, the same shall be provided iii. The motor kW shall be chosen from the prescribed

series, and shall be more than the calculated value iv. Up to 110 kW, Clause 8.3 of IS 325 shall be followed v. Above 110 kW, R20 series (IS 1076) shall be

followed 3.4 Temperature Rise

(above 50°C ambient)

i. Shall not exceed the values given in Table-1 of IS 12802

ii. For Air cooled motors - 70 deg. C by resistance method for both class B&F insulation

iii. For outdoor motors exposed to sunrays, the effect of solar radiation shall be considered

3.5 Motor type i. Unless otherwise specified, the AC motor shall be a constant speed squirrel cage three phase induction motor

ii. DC motor shall be continuous rated, shunt / compound wound and shall be supplied with a single-stage resistance starter panel

3.6 Duty Cycle / designation

i. S1 / continuous for all general purpose motors ii. S4 / Intermittent periodic duty with starting OR S5 /

Intermittent periodic duty with starting and electric braking for crane duty motors

3.7 Method of Starting DOL unless exclusively specified elsewhere 3.8 Starting current in %

of full load current at rated voltage

i. Limited to 600% (with no positive tolerance) for AC motors

ii. Limited to 200% (with no positive tolerance) for DC motors

LT MOTOR STANDARD

SPECIFICATION



3.9 Minimum voltage at motor terminals during starting

80%

3.10 Operation at reduced voltage

i. Motor shall not stall at 70% voltage for a duration of 2 sec

ii. Motors shall run satisfactorily for at least five minutes at 75% supply voltage, without injurious heating

3.11 Number of successive hot starts

i. Three for coal handling motors (conveyer & crusher) ii. Two for all other motors iii. If higher number of starts is specified in mechanical

specification, the same shall be provided 3.12 Number of equally

spread starts in an hour

i. Three ii. If higher number of starts is specified in mechanical

specification, the same shall be provided 3.13 Relation between

starting time & locked-rotor withstand time

Locked-rotor withstand time (TLR ) - Starting time (TST) shall be greater than 3 sec, at same voltage (applicable at 80%, 100% and 110% voltages)

3.14 Torque requirement i. Pull-out torque at the rated voltage shall not be less than 205% of the rated torque with no negative tolerance

ii. The torque characteristics shall be matched with drive requirement over the range of operation

3.15 Vibrations Unless otherwise specified the vibration level shall meet the requirement laid out in IS12075 for normal class & also meet the drive requirement

3.16 Noise level at a distance on 1.0 metre

85 dB (A)

3.17 Class of insulation i. Up to 0.2 kW - B (limited to class E Temp rise) ii. Above 0.2 kW - F (limited to class B Temp rise)

3.18 Direction of rotation i. Motors shall be suitable for bidirectional rotation unless otherwise exclusively specified elsewhere

ii. Wherever uni-directional is provided, mechanical ratchet shall be provided to prevent reverse rotation

iii. Normal direction unless specified shall be clockwise from the coupling end when ABC is the connection

3.19 Tropicalisation All motors shall have tropical protection involving special treatment of insulation and metal for fungus protection and corrosion protection.

3.20 Starting under reverse rotation condition

Pump motor subject to reverse rotation shall be designed to withstand the stresses encountered when starting with shaft rotating at 125% rated speed in reverse direction.

3.21 Over-speed capability

120% for 2 minutes

3.22 Minimum power factor

0.85 at rated voltage, frequency and load

3.23 Efficiency class Improved efficiency class-Eff2 as defined in IS 12615

LT MOTOR STANDARD

SPECIFICATION



4.0 Construction

4.1. Stator 4.1.1 Stator lamination Silicon steel / magnetic steel sheet varnished on both

sides and pressed to form a rigid core

4.2. Rotor 4.2.1 Assembly Rigid cage construction with die-cast aluminium / copper

alloy / copper bars firmly wedged in bar slots and brazed to the end rings

4.3. Winding 4.3.1 Winding i. Electrolytic copper

ii. Shall be given special treatment to render them non-hygroscopic, flame resistant and oil-resistant

4.4. Bearing 4.4.1 Type i. Antifriction type

ii. Sleeve type for special application iii. Thrust & guide type for vertical motors (Motors

furnished with spherical roller thrust bearing will be furnished with deep groove radial guide bearings)

iv. Motors with belt pulley coupling shall be provided with roller bearing on DE side

v. For fractional kW motors bearing shall be double sealed type

4.4.2 Bearing life i. At least 40,000 Hrs when direct coupled ii. At least 20,000 Hrs when coupled with belt or chain

4.4.3 Bearing cooling 4.4.3.1 Self cooling Bearing shall be self cooled 4.4.4 Sealing / greasing It shall be effectively sealed against dust ingress and

shall be pressure grease gun lubricated type fitted with grease nipple and shall have grease relief devices

4.5. Degree of Protection, Enclosure and Cooling 4.5.1 Motors installed

indoor IP 54 of IS 4691

4.5.2 Motors installed outdoor

IP 55 of IS 4691

4.5.3 Motors installed in hazardous area

According to the area classification, Flameproof / increased safety design confirming to Chapter E14 for Hazardous Area.

4.5.4 Enclosure TEFC as per IC-0141 of IS 6362 (It shall be possible to reverse the fan if required without effecting balance)

4.5.5 Drain plug All motors shall be provided with a drain plug to drain condensed water

4.5.6 Lifting hook Adequate lifting hooks shall be provided

LT MOTOR STANDARD

SPECIFICATION



4.6. Coupling 4.6.1 Coupling Except when otherwise specified, the motor shall be

provided with a bare shaft extension having a key slot and a key at DE

4.7. Terminal box 4.7.1 Main terminal box

Power cable termination

i. Shall be detachable type and can be turned 360° in steps of 90°

ii. Removable, undrilled gland plates of thickness 3 mm (hot/cold rolled sheet steel) or 4 mm (non magnetic material for single core cables) shall be provided

iii. The terminals shall be clearly identified by phase markings, with corresponding direction of rotation marked on the NDE of the motor

iv. Rated Short circuit current (System fault level as specified in Electrical section E0) withstand for duration of at least 0.12 sec.

v. Stud type terminals shall be used vi. Terminal box shall be suitable for XLPE/PVC

insulated, armoured, overall FRLS PVC sheathed cable with stranded aluminium conductor

vii. The distance from the motor terminals to the cable gland plate shall be adequate to accommodate trifurcation requirement of three core cables. Final dimensions will be decided during detailed engineering based on the cable size

viii. The location (left, right or top) shall be subject to approval of the purchaser during detail engineering

4.7.2 Terminal box for space heater

Dedicated terminal box shall be provided for space heater

4.8. Anti-condensation heaters 4.8.1 Application Motor rating 30 kW and above 4.8.2 Location It shall be placed in easily accessible position in the

lowest part of motor frame 4.8.3 Supply 240 V, 50Hz single phase supply

4.9. Earthing 4.9.1 Earthing conductor for phase TBs

i. Motor rating ≤ 5 kW ii. 5 kW < Motor rating ≤ 30 kW iii. 30 kW < Motor rating ≤ 90 kW iv. Motor rating > 90 kW

4 mm (dia) GI wire 25 X 3 mm GI strip 35 X 6 mm GI strip 50 X 6 mm GI strip

4.9.2 Earthing conductor for other TBs 4 mm (dia) GI wire 4.9.3 Earthing points complete with

hardware shall be provided (on opposite sides)

i. Two points for motor body ii. Two points each for phase terminal

box iii. One point each for other terminal

boxes

LT MOTOR STANDARD

SPECIFICATION



4.10. Marking The following indelible markings shall be provided on the rating plate fixed on each motor:

4.10.1 Motor type 4.10.2 Name of manufacturer, Manufacturer’s number and frame reference 4.10.3 Rated voltage, Current, frequency and winding connections, Rated output in

kW, Service factor 4.10.4 Efficiency at rated output, Type of duty, Class of insulation, Degree of

protection 4.10.5 Speeds in revolutions per minute, at rated output 4.10.6 Bearing identification number, Lubricant, Lubrication material 4.10.7 Weight, Frame size 4.10.8 Direction of rotation 4.10.9 Location of insulated bearing

5.0 Inspection and Testing

5.1. Routine test 5.1.1 The motor shall be fully assembled and tested at the factory. Routine tests

shall be performed in accordance with IS 325 & IEC 60034-1 and as provided below

5.1.2 Verification of dimensions 5.1.3 Insulation resistance / PI test As per clause 30.2 of IS 4722 5.1.4 Measurement of resistance of windings of

stator and wound rotor

5.1.5 Reduced voltage running up test at no load (for squirrel cage motors up to 37 kW only

As per clause 23.2 of IS 325

5.1.6 No load test at rated voltage to determine input current power and speed


5.1.7 Locked rotor readings of voltage, current and power input at a suitable reduced voltage

As per IS 4029

5.1.8 High voltage test As per IS 4029 5.1.9 Vibration measurement 5.1.10 Noise measurement

5.2. Type test 5.2.1 Type tests reports as listed below shall be submitted with the bid, and not be

older than 5 years on the date of submission 5.2.2 The type tested motor shall be identical to the offered motor in essential

details. The kW rating may be one step higher or lower in the kW series (Clause 8.3 of IS 325 / R20 series of IS 1076 as applicable)

5.2.3 Full load test to determine efficiency power factor and slip


5.2.4 Temperature rise test As per clause 14.0 of IS 325 5.2.5 Momentary overload test As per clause 13.1 of IS 325 5.2.6 Test for vibration severity of motor As per clause 15.0 of IS 325 5.2.7 Test for noise levels of motor As per clause 16.0 of IS 325 5.2.8 Test for degree of protection by enclosure As per clause 5.0 of IS 325

LT MOTOR STANDARD

SPECIFICATION



5.2.9 Temperature rise test at limiting values of voltage and frequency variation

5.2.10 Over-speed test As per clause 26.0 of IS 325 5.2.11 Test on insulation system As per clause 27.0 of IS 325 5.2.12 Fault withstand test on terminal box

5.3. Special test Apart from the above mentioned test, the following shall be performed on one motor of each rating

5.3.1 Full load test (Efficiency, power factor and slip) 5.3.2 Temperature rise test 5.3.3 Momentary overload test 5.3.4 Speed – Torque characteristics

5.4. Test witness 5.4.1 At least 14 days’ advance notice shall be given to the Buyer / Owner to enable

them to witness the test, at their discretion 5.4.2 Routine tests of Motors shall be witnessed 100%

5.5. Test reports / Certificates 5.5.1 Routine Tests and Special tests: Certified reports to be submitted for approval.

The Motor shall be dispatched from works only after the Buyer’s written approval is received

5.5.2 Tests reports shall be furnished for the Type tests, as specified. Otherwise, the bidder shall get the Motor Type-tested to prove the design at his cost

MOTOR OPERATED ACTUATOR




E3 – MOTOR OPERATED ACTUATOR





1.0 Not Used


IEC 60034 Rotating electrical machines IS 325 Three-Phase Induction Motors IS 4722 Rotating Electrical Machines IS 9334 Electric motor operated actuators

3.0 Design Parameters

3.1. Design inputs Design ambient temperature 3.1.1 Service condition Design humidity System Voltage & variations System Frequency & variations Combined voltage, frequency variations

3.1.2 System parameter

Neural earthing, Fault level

Refer Electrical System Description

3.2. Design criteria 3.2.1 Torque

requirement i. Sufficient torque will be provided to open or close the

valve, gate, or damper against maximum differential pressure, static pressure, and seating or unseating torque at any voltage range between minimum and maximum voltage range specified on the data sheets

ii. Shall be capable of meeting 150 percent of unseating torque at specified voltage

3.2.2 Operating speeds, differential and static process line pressures, and process line flow rates

i. Included on the prime equipment data sheets, supporting lists, or other reports

ii. The operating speeds and torques (if not specified) will be coordinated by the Supplier with the actuated equipment requirements and will be acceptable to the Purchaser

3.2.3 Performance requirement

i. Open and close the valve completely and make leak tight valve closure, without jamming

ii. Attain full speed operation before valve load is encountered and impart an unseating blow to start the valve in motion (hammer blow effect)

iii. Operate the valve stem at standard stem speed and shall function against design differential pressure across the valve seat

iv. The entire mechanism shall withstand shock resulting from closing with improper setting of limit switches or from lodging of foreign matter under the valve seat





3.2.4 Gear trains i. It will have all-metal gear trains ii. Fibre gears are not acceptable for the transmission

components developing output effort iii. Gear ratios shall be self-locking

4.0 Construction

4.1. Actuator 4.1.1 Assembly The actuator will essentially comprise the drive motor,

torque/limit switches, gear train, clutch, hand wheel, position indicator, position transmitter, motor starter, control transformer, integral control station, space heater, internal wiring and terminals

4.1.2 Hand wheel i. Actuators are to automatically revert back to motor operation, disengaging the hand wheel, upon energizing the motor

ii. Clockwise operation of the hand wheel will provide a closing action of the valve, gate, or damper

iii. Declutching mechanism shall be provided to allow hand wheel engagement at any time, except when the motor is energized

iv. Rim pull will not exceed 18 kg 4.1.3 Dial position

indicator A local mechanical dial position indicator that continuously indicates the exact (0 to 100 %) position of the valve, gate, or damper will be provided

4.1.4 Mounting The actuator will be designed for mounting in any position without any lubricant leakage or operating difficulty

4.2. Motor 4.2.1 Type i. Surface cooled 3-phase squirrel cage induction

motors ii. If direct current motor is used it will be of the shunt-

wound type 4.2.2 Starting Shall be direct on-line 4.2.3 Minimum starting

voltage 85% of the rated voltage

4.2.4 Capability during under voltage

Shall be running for 5 minutes at i. 80% of rated voltage ii. 85% of rated voltage at 33% excess rated torque

4.2.5 Starting current Shall not exceed six times full load current 4.2.6 Insulation Class F non-hygroscopic standard insulation, suitable for

dusty and corrosive atmospheres 4.2.7 Temperature rise

protection Embedded thermostat in motor winding should be provided so as to disconnect the motor control circuit when the maximum winding temperature is reached

4.2.8 Bearing i. Shall be antifriction ii. Minimum rating life of not less than 15,000 hours

4.2.9 Motor flanges If used, will have dimensions in conformance with IS 93344.2.10 Sealing Preferably be “O” ring sealed for complete environmental

protection 4.2.11 Painting 2 coats of corrosion-proof epoxy resin paint





4.3. Limit Switches 4.3.1 Type Shall be either changeover types or make-and-break

contact types 4.3.2 Auxiliary contacts All limit switches will have at least two NO and two NC

contacts 4.3.3 Switching capacity i. At least 5 amperes on 250 volt ac on resistive load

ii. At least 0.5 ampere on 250 volt dc 4.3.4 Number of

operations Limit switches shall be capable of 6000 operations per hour

4.3.5 Enclosure Limit switches shall be housed in a separate enclosure with the same protection class as that of an actuator

4.3.6 Torque limit switches

i. Two torque limit switches, one at each end of travel ii. Each switch will be independently adjustable and will

permit settings between rated full load torque and 40% or less of that value

iii. Shall be used to limit the torque and thrust loads in both closing and opening directions

iv. Shall function to stop motor on closing. Upon actuation by the torque clutch, it is restricted in its attempt to open or close, thereby causing an overloading torque

v. Means shall also be provided to prevent the open torque switch tripping while the initial unseating hammer blow effect is applied

vi. Once the torque switch actuates and trips, the switch shall not reset until the motor is energized in the opposite direction (non self-reset type)

4.3.7 Position limit switches

i. Four position limit switches, two for open and two for close

ii. Each set of two switches will be independently adjustable to trip at any position between the fully open and fully closed positions

4.3.8 Travel / Intermediate limit switch

i. Requirement shall be finalised during detailed engineering

ii. Four travel / intermediate limit switch (if required)

4.4. Non modulating type actuator 4.4.1 Starting torque Will not be less than 500 percent of rated full load torque 4.4.2 The motor time rating for normal opening and closing service will not be less

than whichever of the following is greatest: 4.4.2.1 Electric actuators specified for non-modulating service will be capable of

three successive open-close operations with no time interval between operations, when operating at an average load of 33 percent maximum driven equipment torque in a 50°C ambient temperature

4.4.2.2 Fifteen (15) minutes at maximum driven equipment torque in a 50° C ambient temperature

4.4.2.3 As specified elsewhere 4.4.2.4 As required for the service

4.5. Modulating type actuator 4.5.1 Starting torque Will not be less than 200 percent of rated full load torque





4.5.2 The motor time rating for normal opening and closing service will not be less than whichever of the following is greatest:

4.5.2.1 Electric actuators specified for modulating service will be capable of continuous modulation with not less than 60 starts/stops per minute at full rated torque without overheating or requiring separate cooling provisions

4.5.2.2 As specified elsewhere 4.5.2.3 As required for the service

4.6. Integral starter 4.6.1 Components Close-coupled power disconnect switch or circuit breaker

capable of being locked in the open position, forward and reverse contactors, control power transformer 415/240 V, and motor overload protection devices

4.6.2 Enclosure protection

Power disconnect switch or circuit breaker shall be weatherproof, dust-tight and suitable for outdoor service

4.6.3 Capacity against short circuit

Rated to withstand (disconnect switch) or interrupt (circuit breaker) the short-circuit current specified in the Electrical System Description

4.6.4 Motor Overload device

i. Shall be wired to de-energize the contactors on motor overload, and will be capable of either automatic or manual reset

ii. Motor thermal sensing devices with automatic reset may be used instead of motor overload devices provided it is the manufacturer’s standard practice

4.6.5 Interlocks The forward and reverse contactors will be mechanically and electrically interlocked to ensure that only one contactor coil can be energized at a time

4.6.6 Control power transformer

i. The primary winding of the control power transformer, complete with two primary fuses, will be connected to two of the three incoming power source phases

ii. Each ungrounded conductor on the control power transformer secondary will be fused

iii. The primary and secondary winding fuses will be easily replaceable without removing any internal components

iv. The control power transformer will have the necessary taps and capacity as required to energize the contactor coils, actuator and motor space heaters, and internal electrical controls

4.6.7 For Direct Current motors

i. Protective devices will not trip or open the contactor for locked-rotor currents

ii. Overload devices will have contact closure for remote alarm on motor overload

iii. The dc starter will be mounted separately from the electric actuator

4.7. Enclosure, Degree of protection 4.7.1 Material Cast iron / cast aluminium alloy / steel 4.7.2 Type Totally enclosed, non-ventilated, dust-tight, and

weatherproof suitable for outdoor service without necessity of any canopy





4.7.3 Valve stem cover Weather tight, closed end, metallic valve stem cover of the appropriate length

4.7.4 Ingress protection i. Minimum IP 55, weather proof type ii. Shall be finalised during detailed engineering for

special applications iii. If IP 67 enclosure is provided, it shall be capable of

submersion in water with 3 meters head for 48 hours 4.7.5 Installation in

hazardous classified area

i. The surface temperature for electric actuators with dust ignition proof features will not exceed 120° C

ii. Shall have weatherproof features conforming to the dust and water requirements of IP 65 enclosures

iii. The enclosure of the actuator shall have a nameplate identifying hazardous area rating of the electric actuators and the name of the certifying institution

iv. In confirmation with chapter E14 for Hazardous Area. 4.7.6 Drain plug If the Supplier’s design requires enclosures equipped with

drain plugs to control condensation, the drain plugs will be combination water drain-breather type

4.8. Termination 4.8.1 The terminal boxes will be weatherproof and fitted with a removable cover

plate in front 4.8.2 Motor terminal box and actuator terminal box shall be provided with cable

glands to suit cable type and size. Cable glands shall be supplied by the bidder4.8.3 Provisions will be provided to terminate Purchaser’s field cables at terminal

points that can be made accessible during operation of the actuator 4.8.4 The terminal box of motor shall be capable of being turned through 360° in

steps of 90° 4.8.5 Internal wiring diagram printed on corrosion resistant sheet shall be attached

on the inside cover of the terminal box

4.9. Anti-condensation heaters 4.9.1 Supply Shall be powered from the control transformer

4.10. Earthing 4.10.1 Size and material for

earthing conductor 8SWG (4 mm dia) GI wire

4.10.2 Earthing terminal locations

Shall be provided either side of the motor

5.0 Control The following minimum controls shall be provided. Other requirements if any arising during detailed engineering shall be provided by the bidder at no additional cost.

5.1. Local control 5.1.1 The actuator shall be provided with an integral control station 5.1.2 The control station will consist of an “open-stop-close” push-button station with

open/close indicating lights and an integral selector switch that is lockable in the “local,” “remote,” and “off” positions





5.1.3 The push buttons and selector switch will be accessible from outside the enclosure

5.2. Remote Control 5.2.1 For modulating type actuator 5.2.1.1 Command Shall be a 4 to 20 mA signal from the control system,

proportional to the desired operator position. Positioning and protection circuits are to be provided in the actuator

5.2.1.2 Status / Alarm feedback

(OPEN, CLOSE, FAULT) shall be potential-free contacts from the actuator

5.2.1.3 Continuous position feedback

i. Will be a 2-wire (loop powered) optically isolated 4 to 20 mA output signal which is proportional to operator position

ii. The accuracy of this system will be ±1 percent linear over the full range of the output

5.2.2 For non-modulating type actuator 5.2.2.1 Command i. (OPEN, CLOSE) commands shall be potential-free

contacts from the Control system ii. The interrogating voltage shall come from the actuator iii. Interposing relays shall be provided inside the actuator

5.2.2.2 Status / Alarm feedback

(OPEN, CLOSE, REMOTE, FAULT) shall be potential-free contacts from the actuator

5.2.2.3 Logic building i. Open close command termination logic shall be inside actuator

ii. All logics shall be freely configurable by the user


6.1. Routine Test 6.1.1 Routine test on motor As per clause 22.3.2. of IS325 6.1.2 Functional & calibration test for

torque and limit switches As per clause 9.2 of IS 9334

6.1.3 Response time test As per clause 9.4 of IS 9334 6.1.4 Variation of supply voltage As per clause 9.5 of IS 9334 6.1.5 Variation of frequency As per clause 9.7 of IS 9334

6.2. Acceptance Test 6.2.1 Acceptance tests on actuator As per clause 9.1.3 of IS 9334

6.3. Type Test 6.3.1 Type test on motor As per clause 9.1.1 of IS 9334

6.4. Test witness 6.4.1 At least 14 days’ advance notice shall be given to the Purchaser / Owner to

enable them to witness the test, at their discretion

6.5. Test reports / certificates 6.5.1 Routine / Acceptance Tests: Certified reports to be submitted for approval. The

Actuator shall be dispatched from works only after the Purchaser’s written approval is received





6.5.2 Tests reports shall be furnished for the Type tests, as specified. Otherwise, the bidder shall get the Actuator Type-tested to prove the design at his cost

MISCELLANEOUS LV BOARDS STANDARD

SPECIFICATION

Document Number : REL-COENG-NEE-E21-P-00043

Rev (00)

Part II, Section C Electrical Section (E4) Sheet 1 / 9

E-4 MISCELLANEOUS LV BOARDS


SPECIFICATION


Rev (00)


1.0 GENERAL TECHNICAL INFORMATION

1.1 Service Condition Refer to Electrical system description

1.2 Technical Parameters

For PDB / LSP 1. Rated operational voltage Ue 415Vac ± 10% 2. Rated insulation voltage Ui 1000Vac rms 3. Rated frequency 50 Hz (+3%, -5%) 4. Rated Normal Current Refer Attachment, Standard SLD for

Miscellaneous LV boards 5. Temperature rise of Bus and Bus

taps (over ambient of 50°C) i. Plain / tinned joints - 40°C ii. Silver plated joints - 55°C

6. Rated short time withstand current 50 kA rms 7. Rated duration of short time

withstand current 1 Sec

8. Control voltage for Contactor Module

110Vac±10%

9. Service supply for heating, lighting and power sockets

240Vac±10%, 50 Hz (+3%, -5%) (applicable for LSP)

10. System neutral earthing Effectively earthed 11. Number of phases Three phase + Neutral 12. Paint shade RAL7032 for complete panel

2.0 Not used

3.0 DETAILED TECHNICAL SPECIFICATION

3.1 Codes and Standards

The equipment shall meet the requirements of Indian Electricity rules. Materials, equipment and methods used in the manufacture shall conform to the latest edition of IS and IEC standards, including the following. If standard other than IS/IEC are used in design, manufacturing and testing, a copy of the same in English shall be submitted with the Bid.

IEC 60038 IEC Standard Voltages IEC 60044-2 / IS 3156

Instrument Transformer - Inductive Voltage Transformer

IEC 60439 Low Voltage Switchgear and Controlgear assemblies - Type tested and partially type tested assemblies

IEC 60529 Degrees of protection provided by enclosures (IP Code) IEC 60947-1 Low Voltage Switchgear and Controlgear - General Rules IEC 60947-4-1 Low Voltage Switchgear and Controlgear - Contactors and Motor

Starters IS 5 Colours for Ready Mixed Paints and Enamels IS 613 Copper Rods and Bars for electrical purposes


SPECIFICATION


Rev (00)


IS 694 PVC Insulated cables for working voltages up to and including 1100 V

IS 2551 Danger notice plates IS 2544 Porcelain post insulators for system with nominal voltage greater

than 1000 V IS 3231 Electrical Relays for power system protection IS 3842 Application Guide electrical relays for ac system IS 5082 Wrought Aluminium and Aluminium alloy bars, rods, tubes and

sections for electrical purpose IS 6865 Control switches (switching devices for control and auxiliary circuits

including contactor relays) for voltages up to and including 1000 V AC and 1200 V DC

IS 12021 Specification for Control Transformers for Switchgear and Controlgear for Voltages not Exceeding 1 000 V ac

IS 13703 LV Fuses for voltage not exceeding 1000V ac or 1500V dc IS 10118 Code of Practice for Selection, Installation and Maintenance of

Switchgear and Controlgear

3.2 Switchgear description

1. LSP (Local starter panel) LSP shall mean a single panel with SDF operated incomer and SDF + contactor operated feeders. LSP shall be three phase four wire type and shall be fed from upstream PMCC / MCC. LSP shall provide complete control and protection for local starting of one or several motors. It shall house Start / Stop / Overload reset push buttons, SDF, contactor, overload relay and indicating lamp and any others required for starting of the motors. 2. LPBS (Local Push Button Station)

LPBS shall mean a push button station with Emergency Stop push button and/or Start push button.

3.3 Switchgear design criteria

3.3.1 PDB / LSP 1. Service i. PDB: Indoor

ii. LSP: Outdoor, with canopy 2. Type Metal Clad, Non compartmentalized 3. Mounting i. Structure / Wall

ii. Larger boards may be floor mounted on channel sills 4. Connections Cable entry - Bottom 5. Configuration Single front 6. Panel height <= 2500 mm 7. Enclosure degree

of protection i. Indoor : IP 52 ii. Outdoor : IP 55

8. Spare feeder i. 20% spare outgoing feeders for each type and rating, subject to minimum one number

ii. The spare feeder shall be fully equipped 9. Enclosure Material CRCA sheets

10. Enclosure Sheet Thickness

i. Minimum 2.0 mm for load bearing members ii. Minimum 1.6 mm for doors and covers


SPECIFICATION


Rev (00)


11. Short circuit withstand

The offered design should have been type tested for the Rated short time withstand current and Rated duration mentioned in Technical parameters

12. Power Cable Termination

i. Suitable for XLPE insulated, armoured, PVC FRLSH sheathed cable with stranded aluminium conductor

ii. Size of cable shall be finalised by purchaser during detailed engineering and design shall be adequate

13. Accessibility i. All equipment mounted inside the panels shall be so located that their terminals and adjustments are readily accessible for inspection or maintenance

ii. On opening of front door, access shall be provided only to the operating and indicating components like switches and lamps. Live parts shall not be exposed

14. Ratings Shall be as per requirement 15. Feeder sizing i. Continuous in-panel rating of feeders and their

associated electrical equipments shall be their actual rating plus 10% margin, rounded off to the next higher standard rating

ii. All motor feeders shall be continuously rated to their name plate rating

16. Accessories for LSP

Refer to Chapter E14 Hazardous Area

3.3.2 LPBS 1. Service Indoor / Outdoor 2. Type Metal Clad with canopy for all outdoor LPBS 3. Mounting Structure / Wall 4. Connections Cable entry - Bottom 5. Enclosure degree

of protection i. Indoor : IP 54 ii. Outdoor : IP 55 iii. In dusty area: IP 65 iv. Flame proof LPBS shall be suitable for the specified

Zone, Gas group and Temperature class 6. Enclosure Material CRCA sheets of minimum 1.6 mm 7. Push button guard Hinged MS guard shall be provided to prevent

inadvertent operation of push button 8. Type options As per requirement 9. Selection of Type Bidder shall select the type as per the application


SPECIFICATION


Rev (00)


3.4 Construction

3.4.1 Contactor 1. Type Unlatched, triple pole, air break type with non bouncing

silver/silver alloy contacts 2. Rated Duty Class-3 3. Utilization Category

according to IEC 60947-4-1; Table-1

i. AC3 for unidirectional motors ii. AC4 for reversible motors

4. Rated operational current (Ie)

Refer attachment, Standard SLD for Miscellaneous LV boards

5. Number auxiliary contact

2 NO + 2 NC, rated 10 Amp at 240 V AC

6. Permissible voltage Capable of pull-in at 85% of rated voltage and shall not drop out at 70% of rated voltage or greater

7. Interlocking provision

Contactors for forward and reverse direction of reversible drives shall preferably be mechanically interlocked

3.4.2 Meters 1. Voltmeter i. Flush mounted, 96 x 96 mm size, with 90° scale,

anti-glare glass ii. Each meter shall have zero adjuster on the front iii. Accuracy class 1.0

3.4.3 Lamps, Switches, Pushbuttons and Fuses 1. Lamps i. Shall be clustered type LED module pilot lights in

thermoplastic enclosure with polycarbonate lens and diffuser

ii. LED shall be protected by in-built fuse with surge suppressor and leakage voltage glow protection

iii. Lamp and lens shall be replaceable from front 2. Meter selector

switch i. It shall be four position, maintained contact and

stay-put type, with knob handle ii. Ammeter selector switches shall have make before

break contacts, to prevent open circuiting of CT secondary

3. Switch details Dust protected, heavy duty, switchboard type, complete with escutcheon plate

4. Push button i. Shall be heavy duty, shrouded ii. Push to actuate type with coloured button and

inscription plate iii. 2 NO + 2 NC contacts iv. Emergency STOP push-buttons shall have

mushroom head actuator with press-to-latch and key-to-release feature. Other push buttons shall be of spring-return-to-normal type


SPECIFICATION


Rev (00)


5. Contact details i. Contacts shall be silver surfaced with conventional enclosed thermal current of 10A

ii. Utilization category AC15, 3A rated operational current at 240Vac

iii. Utilization category DC13, 1.1A rated operational current at 250Vdc

3.4.4 Control and Indication 1. Control As per requirement 2. Indicating Lamps As per requirement

3.4.5 Wiring of Auxiliary and Control circuits 1. Wire i. Flexible, 650V grade, PVC insulated, with stranded

copper conductors ii. 2.5 mm2 for current circuits iii. 1.5 mm2 for control and voltage circuits iv. 4 mm2 Bus wire for 220Vdc, 110 Vac and 240 Vac

2. Colour coding i. CT / PT wires shall be colour coded, as per phase ii. Earth wires shall be Green and Neutral wires shall

be Black 3. Termination and

identification i. Each wire shall be identified, at both ends, with

interlocking type permanent markers bearing wire numbers (one additional red colour ferrule for all wires in trip circuit)

ii. Wire termination shall be made with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals

iii. Each group shall be adequately supported along its run to prevent sagging or strain on the termination

iv. Adhesive type support are not accepted v. No of wires per terminal shall be limited to two (2)

3.4.6 Terminal Block 1. Terminal block i. Terminal blocks shall be located to allow easy access

ii. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals

iii. 650V grade, with insulating cover complete with mounting channel, binding screws and washers

iv. Marking strip for circuit identification shall be provided for terminating the panel wiring

v. TBs shall be stud type for all CT, PT and 220V dc control circuits

2. Control Terminals Suitable for 2 nos. 2.5 mm2 stranded copper conductor 3. Power terminals Suitable for one 10 mm2 stranded aluminium conductor 4. Spare terminals Equal to 20% of active terminals shall be provided for

each Terminal Block 5. TB shrouds and

separators Moulded non- inflammable plastic material

i. Between 2 rows of Terminal Box 100 mm ii. With cable gland plate 250 mm

6. Clearance

iii. Between AC / DC set of Terminal Box 100 mm


SPECIFICATION


Rev (00)


3.4.7 Cable Termination 1. Cable entry As specified in Design criteria 2. Power cable details Cable size will be finalized during detailed engineering 3. Gland plate and

supports Removable, 3mm thick CRCA sheet steel for multi core cables

4. Nut bolt and washer

Cadmium plated Nut bolt and washer set for terminal bus bars in cable compartment of each panel

3.4.8 Equipment Earthing i. Earth bus 50 x 6mm GI bus provided with two holes with G.I. bolts

and nuts at each end to receive external earth conductor 1. External earth

conductor i. 50 x 6 mm GI flat (for PDB / LSP) ii. 8 SWG GI wire (for LPBS)

2. Each stationary unit Shall be connected directly to the earth bus 3. Earth connection of

meters/relays With two distinct connections

4. Hinged door Earthed through flexible insulated copper braid 5. CT and PT neutral Earthed at one place at the terminal blocks through links

so that earth of one circuit may be removed without disturbing other.

3.4.9 Nameplate and Warning boards 1. Location of

nameplates i. Switchgear nameplate at the front ii. Feeder nameplate at the front and rear. This is to be

fixed on the frame and not on the removable covers iii. Instruments and devices nameplate at the front and

rear 2. Warning symbol for

dangerous voltages as per IS 8923

On removable covers

3. Danger Sign Board as per IS 2551

On all four sides of switchgear

4. Material, text and size

Subject to approval during detailed engineering

5. Engraving With white letters on black background

3.4.10 Space heaters, Power socket and Illumination 1. Panel space heater i. Non exposed type, thermostat controlled

ii. To be provided to each panel / cable alley iii. Shall maintain the enclosure at a temperature above

the dew point iv. Shall be mounted on insulator base

2. Motor space heater supply

i. Provided for Motor feeders rated 30kW and above ii. Wired-up for feeding the motor space heater

through auxiliary contactor when the main Contactor is off or isolated.

3. Power socket and Lighting

Shall be provided in each panel / cable alley


SPECIFICATION


Rev (00)


3.4.11 Painting and Tropical Protection 1. Surface preparation Surface shall be sand blasted, pickled and ground as

required to produce a smooth, clean surface free of scale, grease and rust

2. Painting The surface shall be given a phosphate coating followed by 2 coats of high quality primer. The coating shall be done electro-statically followed by stoving

3. Tropical protection Shall have fungus protection, involving special treatment of insulation and metal against fungus, insects and corrosion

4. Suitability i. Shall withstand heat and weather conditions. ii. Shall not scale - off or crinkle or get removed by

abrasion due to normal handling


3.5.1 Routine Test 1. The switchgear shall be fully assembled, wired and tested at the factory.

Routine tests shall be performed in accordance with IEC60439-1 2. The switchgear shall be operated under simulated service condition to

demonstrate accuracy of wiring, correctness of control scheme and proper functioning of the equipment

3. Primary current and voltage shall be applied to all instrument transformers and verified in all secondary devices like meters and relays

4. Verification of dimensions and clearances shall be demonstrated 5. Dielectric tests on Main and control circuits

3.5.2 Test Witness 1. At least 14 days’ advance notice shall be given to the Purchaser / Owner to

enable them to witness the test, at their discretion

3.5.3 Test Reports / Certificate 1. Routine Tests: Certified reports to be submitted for approval. The equipment

shall be dispatched from works only after the Purchaser’s written approval is received

2. Tests reports shall be furnished for the Type tests, as specified. Otherwise, the bidder shall get the equipment Type-tested to prove the design at his cost

3.6 Documentation The bidder may note that the drawings, data and manuals listed herein are minimum requirement only. The bidder shall ensure that all other necessary write-up, information, etc required to fully describe the equipment are to be submitted. The manual shall clearly indicate in English the installation and connection method. Check up, maintenance and calibration method shall also be provided in the manuals.

After award S.No. Documents to be Submitted With

the Bid

For approval

For reference


SPECIFICATION


Rev (00)


After award S.No. Documents to be Submitted With the Bid

For approval

For reference

1. Leaflets on equipment and other accessories explaining their constructional details, principle of operation, special features. Components data on all electrical and control devices being provided, including electrical rating

X

2. Typical general arrangement drawing of the equipment and foundation plan, Cable Opening Size and Locations, Mounting Details, and Cable Entry Area and Door Swing Requirement

X X

3. Feeder List (as per sample provided as Attachment) filled in with Ratings and Quantities

X X

4. Proposal sheets (Data sheet) duly filled in X X 5. Bill of material with make / type of all

components X X

6. Type test reports and certificates for the specified type tests X

7. Coordination report for Contactor starter to demonstrate proper coordination between fuse and relay

X

8. Components data on all devices X 9. Sizing calculation of Bus bar X

10. Quality assurance plan X 11. Board-wise Single Line Diagram X 12. Control schematics X 13. Component selection chart for motor starters X 14. Certified reports of Routine tests, prior to

dispatch X

X: Applicable

HAZARDOUS AREA STANDARD

SPECIFICATION

Document Number: REL-COENG-NEE-E21-P-00090


E14 – HAZARDOUS AREA


SPECIFICATION




IEC 60079 Electrical Equipment for Explosive Gas Atmospheres IS5571 Guide for the Selection of Electrical Equipment for Hazardous

Areas IS 5572 Classification of Hazardous Areas for Electrical Installations

2.0 Area Classification and Selection of Electrical Equipment The definition of areas shall be in accordance with IEC 60079, “Electrical Equipment for Explosive Gas Atmospheres” or IS 5572, “Classification of Hazardous Areas for Electrical Installations”. Electrical equipment for use in a hazardous area shall be in accordance with IEC 60079, Electrical Equipment for Explosive Gas Atmospheres. Electrical equipment shall be selected in accordance with IS5571 Guide for the Selection of Electrical Equipment for Hazardous Areas. Unless otherwise specified the following basis of selection shall be followed:

Zone 1 Areas (a) Flameproof or explosion proof, Ex(d) equipment (b) Pressurised, Ex(p) equipment (c) Intrinsically safe, Ex(ia) or Ex(ib) equipment Zone 2 Areas (a) Non sparking, Ex(n) equipment (b) Increased safety, Ex(e) equipment (c) Equipment complying with the requirements for Zone

I areas Unclassified Areas (a) Standard industrial equipment (b) Equipment complying with the requirements for Zone

1 and 2 areas.

The bidder shall select his equipment to suit the gas-group and temperature class in conformance with the hazardous area classification. Earthing conductor should be designed such that the surface temperature is limited to 200°C when carrying the designed short circuit current as per E0 Electrical System Description.


3.1. Type test 3.1.1 Type tests reports as listed below shall be submitted with the bid, and not be

older than 5 years on the date of submission 3.1.2 Maximum surface temperature rise Test As per clause 26.5.1.3 of IEC

60079-0


SPECIFICATION



3.1.3 Metallic Enclosures Resistance to impact Test As per clause 26.4.2 of IEC

60079-0 Drop Test As per clause 26.4.3 of IEC

60079-0 Test for Degree of Protection As per clause 26.4.5 of IEC

60079-0 3.1.4 Non-metallic Enclosures Group I, II & III Electrical equipments Thermal Endurance to Heat Test As per clause 26.8 of IEC 60079-

0 Thermal Endurance to Cold Test As per clause 26.9 of IEC 60079-

0 Resistance to impact Test As per clause 26.4.2 of IEC

60079-0 Drop Test As per clause 26.4.3 of IEC

60079-0 Test for Degree of Protection As per clause 26.4.5 of IEC

60079-0

3.2. Other Tests for Ex(d) Equipment 3.2.1 Method of test for ascertainment of

maximum experimental safe gap As per IEC 60079-1-1

3.2.2 Determination of explosion pressure (reference pressure)

As per clause 15.1.2 of IEC 60079-1

.

3.3. Test witness 3.3.1 At least 14 days’ advance notice shall be given to the Buyer / Owner to enable

them to witness the test, at their discretion

3.4. Test reports / Certificates 3.4.1 Equipment of Indian origin for installation in hazardous areas shall have a test

certificate from the Central Mining Research Institute (CMRI) and approval certificates from the Chief Controller of Explosives (CCE).

3.4.2 Hazardous area equipment of non-Indian origin shall carry a valid test certificate from a CENELEC listed testing authority.

3.4.3 For Ex n type equipment, certification as described above or a manufacturers statement of compliance as stipulated in IEC 60079-15 shall be provided

3.4.4 Tests reports shall be furnished for the Type tests, as specified. Otherwise, the bidder shall get the Equipment Type-tested to prove the design at his cost

Guidelines for Lux Level

STANDARD DOCUMENT

Sheet 1 / 1

Minimum Illumination Levels to be maintained for Different Areas

Sr. No. Location Lux Level

1. Fuel Gas Supply & Conditioning Out Door Area 100 2. Gas Room 100 3. Office Rooms (without false Ceiling) 300 4. Office Room (With false ceiling) 300 5. Main road 20 6. Secondary road 10

Notes:

1. Lux level for A.C. Emergency lighting in control room, Emergency PMCC Switchgear room, DG PCC room and DG Building will be 50 and for other areas 20 lux.

2. Maintenance Factor for different areas shall be: For Indoor Non-AC Area : 0.65 For Indoor AC Area : 0.75 For Outdoor Area : 0.5

3. The lux level mentioned above is in line with IS 3646.

TECHNICAL SPECIFICATION FOR

PACKAGE NAME


Document Number : Part II, Section 2 Technical Specification - Electrical Sheet 1 / 5

LT MOTOR DATA SHEET

The buyer’s requirements are specified in Section E2 and in column below A-TO BE SUBMITTED ALONG WITH THE BID / AFTER AWARD S.NO. DESCRIPTION DATA BY BUYER DATA BY BIDDER1.0 GENERAL 1.1 Application/Driven Equipment 1.2 Quantity 1.3 Motor type 1.4 Service (Indoor / outdoor) 1.5 Make 1.6 Frame Size 1.7 Applicable Standard IS 325 & IEC 60034 2.0 RATING 2.1 Rated Continuous Output 2.1.1 At 40°C ambient (kW) 2.1.2 At 50°C ambient (kW) 2.2 Rated Voltage & % variation Refer section E0 2.3 Rated Frequency & % variation Refer section E0 2.4 Combined voltage & frequency variation Refer section E0 2.5 Rated speed (r.p.m.) 2.6 Over speed capacity 120% for 120 sec 2.7 Uni-directional or Bi-directional 2.8 Direction of rotation from NDE 2.9 Duty Cycle/Designation 2.9.1 For crane duty motors S4 / Intermittent

periodic duty with starting OR S5 / Intermittent periodic duty with starting and electric braking

2.9.2 For all general purpose motors S1 / continuous 2.10 Full load current (Amp) 2.11 No load current (Amp) 2.12 Full load torque (N-m) 2.13 Overload capacity % of full load torque 60% for 15 sec in hot

condition

3.0 PERFORMANCE 3.1 Method of Starting DOL 3.2 Maximum number of successive start at full

load in hot condition Two (Three for coal handling conveyor / crusher motors)

3.3 Maximum number of equally spread starts per hour

Three

3.4 Starting Current in % full load current


PACKAGE NAME



3.4.1 At 100% rated voltage 3.4.2 At 110% rated voltage 3.5 Starting Torque in % full load torque 3.5.1 At rated voltage 3.5.2 At 80% rated voltage 3.6 Minimum accelerating torque in % of full

load torque at rated voltage and frequency

3.7 Break down torque in % of full load torque at rated voltage and frequency

3.8 Starting time (full load) TST 3.8.1 At 80% voltage 3.8.2 At 100% voltage 3.8.3 At 110% voltage 3.9 Locked rotor withstand time TLR

(hot condition)

3.9.1 At 80% voltage 3.9.2 At 100% voltage 3.9.3 At 110% voltage

(TLR - TST) > 3 sec at same voltage

3.10 Locked rotor withstand time

(cold condition)

3.10.1 At 80% voltage 3.10.2 At 100% voltage 3.10.3 At 110% voltage 3.11 Power Factor (starting) 3.12 Power Factor (running) at rated V, f 3.12.1 At 100% load 3.12.2 At 75% load 3.12.3 At 50% load 3.12.4 At 25% load 3.13 Efficiency at rated voltage & frequency 3.13.1 At 100% load 3.13.2 At 75% load 3.13.3 At 50% load 3.13.4 At 25% load 3.14 Noise level at 1.0 metre in dB 85 dB (A) 3.15 Max. Vibration 3.15.1 At no load 3.15.2 At full load 4.0 CONSTRUCTION 4.1 Degree of Protection of Enclosure 4.2 Type of mounting 4.3 Method of motor Cooling 4.4 Insulation class 4.5 Temperature rise (over 50°C ambient) of

winding by winding resistance method (°C)

4.6 Treatment of insulation


PACKAGE NAME



4.7 Tropicalisation required YES / NO 4.8 Winding Connection 4.8.1 Stator 4.8.2 Rotor 4.9 DE Bearings 4.9.1 Make 4.9.2 Type 4.9.3 Insulation from shaft current provided YES / NO 4.10 NDE Bearings 4.10.1 Make 4.10.2 Type 4.10.3 Insulation from shaft current provided YES / NO 5.0 TERMINATIONS 5.1 Motor Terminal Box 5.1.1 Fault current withstand with time 5.1.2 Position as viewed from NDE Left / Right 6.0 ACCESSORIES 6.1 Space Heaters (240Vac, 50Hz)

Nos. x Watt

6.2 Temperature indicators 6.2.1 Type 6.2.2 Nos. furnished 6.2.3 Location 7.0 SPECIAL CONSIDERATION 7.1 Area classification 7.1.1 Zone (1 / 2 / 3) 7.1.2 Temperature class (T1 / T2 / T3 / T4 / T5 /

T6)

7.1.3 Gas group (IIA / IIB / IIC) 7.1.4 Type of protection (ExN / Exe / Exd / Exp /

Ind)

7.1.5 Certifying authority 7.1.6 Certificate number B-TO BE SUBMITTED AFTER AWARD S.NO. DESCRIPTION DATA BY BUYER DATA BY BIDDER1.0 CONSTRUCTION 1.1 DE Bearings 1.1.1 Recommended lubricant 1.1.2 Life in hours at rated speed 1.2 NDE Bearings 1.2.1 Recommended lubricant 1.2.2 Life in hours at rated speed 2.0 MISCELLANEOUS 2.1 Shaft orientation 2.2 Shaft extension if required YES / NO


PACKAGE NAME



2.3 Type of coupling 2.4 Half coupling if required YES / NO 2.5 Grounding pads size, nos. & location 2.6 Moment of Inertia (GD2) 2.7 Weight of Motor in Kg 2.8 Overall dimensions (LxBxH) in mm 2.9 Paint shade 3.0 MOTOR PARAMETERS 3.1 Locked rotor impedance Zb (Ω @ 20°C) 3.2 Locked rotor reactance Xb (Ω @ 20°C) 3.3 Rotor resistance Rr (Ω @ 20°C) 3.4 Stator resistance Rs (Ω @ 20°C) 3.5 Steady state reactance X (%) 3.6 Transient reactance X’ (%) 3.7 Sub-transient reactance X” (%) 3.8 X’’ / R ratio 3.9 Open circuit transient time constant T’do

Data required for motors > 90kW

3.10 Heating time constant (minute) 3.11 Cooling time constant (minute) 3.12 Rotor air gap (mm) 3.13 Rotor end float (±mm) 3.14 Rotor end play (mm) 3.15 Capacity derating applicable due to 10%

THD arising from static drives, VFDs

3.16 Losses 3.16.1 Iron loss (kW) 3.16.2 Copper loss (kW) 3.16.3 Friction, Windage & Stray losses (kW) 4.0 DRAWINGS / DOCUMENTS 4.1 Type test reports and certificates for the

specified type tests Submitted Yes / No

4.2 Equipment / component technical data sheet and brochure

Submitted Yes / No

4.3 Typical general arrangement drawing of the motor and foundation plan / Loading, Mounting Details

Submitted Yes / No

4.4 Bill of material with Make / Type of all components Submitted Yes / No

4.5 Individual datasheet Submitted Yes / No 4.6 Assembly and Erection drawings Submitted Yes / No 4.7 Cable termination box details/drawing Submitted Yes / No


PACKAGE NAME



4.8 Following characteristic curves: i. Motor Current Vs Speed curves &

supporting tabulated data ii. Superimposed motor driven equipment

Speed-Torque curves & supporting tabulated data

iii. Superimposed thermal limit and Time-Current curves & supporting tabulated data

iv. Efficiency, power factor, slip, current plotted against power output

v. Negative sequence current Vs time curve

Submitted Yes / No

4.9 Quality assurance plan Submitted Yes / No 4.10 Certified reports of Routine tests and

Special tests, prior to dispatch Submitted Yes / No

4.11 Instruction manuals of Motors (Erection & Commissioning, Operation & Maintenance) Submitted Yes / No

4.12 Manufacturer’s instruction for transport, storage & installation including unpacking, lifting, assembly, mounting & connections prior to dispatch

Submitted Yes / No

Stamp / seal of bidder - ……………………………….

Name of Bidder’s contact person

Email id

Telephone no

Address of the office


PACKAGE NAME



LV SWITCHGEAR DATA SHEET

Instruction to bidders – 1. Bidder to fill up only “Data by Bidder” column and shall not change description in other column 2. Bidder to submit GTP with data in numerical values wherever asked 3. Bidder shall not use words like, ‘Adequate’, ‘As per standard’, ‘Later’, ‘After award’ etc. This will

be considered as a deviation

Design engineer to update as per requirement

S. No.

Description Data by Purchaser

Data by Bidder

1.0 Technical parameters for LSP 1.1 Rated operational voltage Ue 415Vac ± 10% 1.2 Rated insulation voltage Ui 1000Vac rms 1.3 Rated frequency 50 Hz (+3%, -5%) 1.4 Rated short time withstand current 50 kA rms 1.5 Rated duration of short time withstand

current 1 Sec

1.6 Rated impulse (1.2/50 µs) withstand voltage

6 kVpeak

2.0 Temperature rise (over ambient of 50ºC) for all LV switchgear (AC and DC)

2.1 Contacts – Bare copper 40ºC 2.2 Contacts – Tin Plated 55ºC 2.3 Contacts – Silver Plated 60ºC 2.4 Accessible parts – manual operating means:

Metallic and Non-metallic 05ºC and 15 ºC respectively

2.5 Accessible parts – not intended to be handled: Metallic and Non-metallic

20ºC and 30 ºC respectively

2.6 Exteriors of enclosures adjacent to cable entries: Metallic and Non-metallic

30ºC and 40 ºC respectively

3.0 Design Parameters for LSP 3.1 Make 3.2 Type Metal enclosed, non

compartmentalized with sloping roof

3.3 Reference Standard 3.4 Rated Normal Current 3.5 Mounting Floor / Structure / Wall 3.6 Connections Cable entry – Bottom 3.7 Panel height <= 2500 mm 3.8 Enclosure degree of protection i. Indoor : IP 52

ii. Outdoor : IP 55

3.9 Enclosure Material CRCA sheets


PACKAGE NAME



3.10 Enclosure Material Thickness i. Minimum 2.0 mm for load bearing members

ii. Minimum 1.6 mm for doors and covers

3.11 Power Cable Termination 3.12 Paint shade RAL9002 for complete

panel and RAL5012 for end covers

4.0 Design Parameters for LPBS

4.1 Make 4.2 Type Metal enclosed with

sloping roof

4.3 Reference Standard 4.4 Mounting Structure / Wall 4.5 Connections Cable entry – Bottom 4.6 Enclosure degree of protection i. Indoor : IP 54

ii. Outdoor : IP 55 iii. In dusty area: IP 65 iv. For the classified area

LPBS should be flameproof, conforming to IS 2148

4.7 Enclosure Material CRCA sheets 5.0 Construction

5.1 Minimum clear space required at i. Front for breaker withdrawal in mm ii. Rear in mm

5.2 Typical vertical section (Overall dimension (mm) and weight ( Kg)) i. Incomer ii. Bus-coupler iii. Motor feeder iv. Line feeder

5.3 Relays, meters, control switches, selector switches and indicating lamps

Flush mounted type with touch proof terminals

6.0 Contactor / Fuse combination

6.1 Make and model number 6.2 Type 6.3 Reference standard 6.4 Rated operational current Ie 6.5 Rated making capacity (Isc) 6.6 Rated breaking capacity (Ima) 6.7 Rated duty Intermittent duty Class 3


PACKAGE NAME



6.8 Utilization Category 6.9 Coordination with SCPD Type-II as per IEC 60947 6.10 Control Voltage 110 V AC (90% - 110%) 6.11 Single phasing protection Required 6.12 Switching times

i. Opening time(Lower and Upper limit) ii. Closing time(Lower and Upper limit)

6.13 Highest cut-off current of the SCPD 7.0 Thermal Overload Relay

7.1 Type 7.2 Resetting Manual and Auto reset type 7.3 Single phase preventer Shall be provided Yes/No 8.0 Bus and Bus Taps

8.1 Make 8.2 Material and grade of buses and joints 8.3 Reference standard 8.4 Cross sectional Area 8.5 Continuous Current (at site condition, 50°C

ambient) within cubicle

8.6 DC resistance at 85°C ohm/m/ph 8.7 Skin-effect ratio 8.8 Reactance ohm/m/ph 8.9 Losses-middle phase w/m/ph 8.10 Minimum clearance of bus bar and joints

i. Phase to phase (mm) ii. Phase to ground (mm)

8.11 Bus bar insulation i. Heat shrinkable sleeves rated for maximum operating voltage

ii. Phase barriersiii. Cast resin shrouds for

joint

8.12 Bus joints Silver 8.13 Bus bar support insulator

i. Spacing (mm) ii. Make iii. Type iv. Reference standard v. Voltage class (kV) vi. Minimum creepage distance (mm) vii. Cantilever strength (Kg/sq.cm.)

9.0 Ammeters and Voltmeters


PACKAGE NAME



9.1 Type Flush mounted, 96 x 96 mm size, with 90° scale, anti-glare glass

9.2 Accuracy class 1.0 % 10.0 Control and Indications

10.1 Push Buttons i. Make ii. Type and Catalogue Number iii. Contact rating at 220V dc a. Make and continuous Amps b. Break (Inductive) Amps and circuit time

constant

10A ac / dc at operating voltage 2A ac / dc at operating voltage, time constant 20mS

10.2 LEDS i. Make ii. Type and Catalogue Number iii. Watts/Voltage iv. Series resistance (Ohm) v. LEDS and Lens replaceable from front

(Yes/No)

10.3 Selector Switch i. Make ii. Type and Catalogue Number iii. Contact rating at a. Make and continuous Amps b. Break (Inductive) Amps and circuit time

constant

10A ac / dc at operating voltage 2A ac / dc at operating voltage, time constant 20mS

11.0 Wiring of Auxiliary and Control circuits 11.1 Type 11.2 Insulation 11.3 Conductor material 11.4 Minimum conductor size

i. Current circuit ii. Control and voltage circuit iii. 415Vac Bus wire for Service power iv. 220Vdc, 240Vac and 110Vac Bus wire

2.5 mm2 1.5 mm2 6.0 mm2 4.0 mm2

11.5 Termination and identification 11.6 Colour coding 12.0 Terminal blocks

12.1 Make 12.2 Type 12.3 Cat. Number


PACKAGE NAME



12.4 Spare terminals Equal to 20% of active terminals in each TB

12.5 Control terminal Suitable for 2 nos. 2.5 mm2 stranded copper conductor

12.6 Power terminal Suitable for one 10 mm2 stranded aluminium conductor

13.0 Cable termination

13.1 Gland plate material and thickness for i. Multi-core power cable ii. Single-core power cable

13.2 Nut bolt and washer type for Power cables Cadmium plated 14.0 Earth bus

14.1 Material 14.2 Size 14.3 Earth bus rating To carry Rated short circuit

withstand current for rated duration of short circuit

15.0 Painting

15.1 Painting procedure adopted (details of each coat)

15.2 Finish of switchgear i. Inside ii. Outside

16.0 Tropical protection

16.1 Any special treatment for tropical protection

17.0 Tests

17.1 Confirmation of routine tests to be performed as per Section 3.5.1 of specification

Yes / No

17.2 Confirmation of Type tests to be performed (or report submitted) as per Section 3.5.2 of specification

Type test report number / date

17.3 Dielectric tests on Main, Auxiliary and Control circuits of assembled switchgear

17.4 Temperature rise Test of assembled switchgear

17.5 Test for Internal arc classification of assembled switchgear (preferable)


PACKAGE NAME



17.6 Verification of short circuit withstand strength of the protective devices

17.7 Verification of rated making and breaking capacities of Contactors

17.8 Coordination with fuse of Contactors 17.9 Ability of contactors to withstand overload

current

17.10 Verification of the degree of protection



Email id

Telephone no



PACKAGE NAME



MOTOR OPERATED ACTUATORS DATA SHEET

The purchaser’s requirements are specified in Specification and in column below A-TO BE SUBMITTED ALONG WITH THE BID S.NO. DESCRIPTION DATA BY

PURCHASER DATA BY BIDDER

1.0 ACTUATOR 1.1 Application 1.2 Make 1.3 Model 1.4 Type (modulating / non-modulating) 1.5 Type of enclosure (ingress protection) 1.6 Type of enclosure (hazardous classification) 1.7 Travel stroke/ Angular rotation mm/ Deg. 2.0 MOTOR 2.1 Type 2.2 Duty cycle/ Designation To match drive

requirement

2.3 Motor Rating 2.3.1 Output (KW) 2.3.2 Voltage/ phase/ frequency (V/ No./ Hz) 2.3.3 Speed (rpm) 2.3.4 Admissible voltage fluctuation 2.3.5 Admissible frequency fluctuation 2.3.6 Admissible voltage and frequency

fluctuation (absolute sum)

2.3.7 Full load torque (N-m) 2.3.8 Starting torque (N-m) 2.3.9 Power factor at full load 2.3.10 Full load efficiency 2.4 Motor Current 2.4.1 Starting (Amp) 2.4.2 Running (Amp) 2.4.3 Stalling (Amp) 2.5 Insulation Class Class F 2.6 Design ambient temperature °C 50°C 2.7 Method of Starting DOL 2.8 Type and No. of bearing 2.9 Lubrication (Motor) 3.0 LIMIT SWITCHES 3.1 No. of Limit Switches furnished 3.1.1 Torque limit switch 3.1.2 Position limit switch 3.1.3 Travel / Intermediate limit switch


PACKAGE NAME



3.2 No. of N.O. + N.C contacts provided for each limit switch

3.3 Switch Contact Rating 3.3.1 At 250Vac 5 A 3.3.2 At 250Vdc 0.5 A 3.4 Torque limit switch type Non self- resetting type 3.5 Range of adjustment for: 3.5.1 Torque limit switch 3.5.2 Position limit switch 3.5.3 Travel / Intermediate limit switch 4.0 POSITION INDICATOR 4.1 Provided locally 4.2 Type 5.0 SPACE HEATER 5.1 No. x Watt 5.2 Voltage 6.0 INTEGRAL STARTER 6.1 Short circuit protection details 6.2 Overload protection details 6.3 Contactors’ mechanical interlock details 6.4 Control transformer details 7.0 CONTROLS 7.1 Integral Control Station 7.1.1 Local / Remote selector switch 7.1.2 Close / Open push buttons with indication 7.1.3 Accessibility of push buttons and selector

switch Accessible from outside

7.2 Internal Logics Freely configurable by the user

7.3 Remote control for Modulating type actuator

7.3.1 Control command signal type 4 to 20 mA 7.3.2 Status / Alarm feedback Potential-free contacts

from the actuator

7.3.3 Continuous position feedback 2-wire (loop powered) optically isolated 4 to 20 mA

7.4 Remote control for Non-modulating type actuator

7.4.1 Close / Open command Potential-free contacts from the Control system

7.4.2 Status / Alarm feedback Potential-free contacts from the actuator

8.0 TERMINATIONS 8.1.1 Sizes / quantity of glands provided 8.1.2 Type and Nos. of terminals brought out


PACKAGE NAME



9.0 ACCESSORIES 9.1 Specify accessories if provided

B-TO BE SUBMITTED AFTER AWARD S.NO. DESCRIPTION DATA BY

PURCHASER DATA BY BIDDER

1.0 DRAWINGS / DOCUMENTS 1.1 Type test reports and certificates for the

specified type tests Submitted Yes / No

1.2 Equipment / component technical data sheet and brochure

Submitted Yes / No

1.3 Typical general arrangement drawing of the Actuator / motor and Mounting Details

Submitted Yes / No

1.4 Bill of material with Make / Type of all components

Submitted Yes / No

1.5 Torque switch & limit switch contact development

Submitted Yes / No

1.6 Internal wiring diagram and suggested control schematic

Submitted Yes / No

1.7 Assembly and Erection drawings Submitted Yes / No 1.8 Cable termination box details/drawing Submitted Yes / No 1.9 Quality assurance plan Submitted Yes / No 1.10 Certified reports of Routine tests and

Special tests, prior to dispatch Submitted Yes / No

1.11 Instruction manuals of Actuators / Motors (Erection & Commissioning, Operation & Maintenance)

Submitted Yes / No

1.12 Manufacturer’s instruction for transport, storage & installation including unpacking, lifting, assembly, mounting & connections prior to dispatch

Submitted Yes / No



Email id

Telephone no


BASIC DESIGN CRITERIA STANDARD SPECIFICATION

DOC. NO.: REL-COENG-NEN-441-P-00001 R0 SUB-SECTION: I-0 Page 1 of 6

I0 : BASIC DESIGN CRITERIA



1.01.00 GENERAL REQUIREMENTS

1.01.01 The Contractor shall provide Control System, UPS, Relay based control system, all required instruments and Instrumentation, Control & Power Supply Cables, Process connection piping etc. as identified under Scope of C&I Works of this specification. It may be noted that typical requirements for all C&I items are enumerated in this section. Only those clauses which are relevant for the equipment under the scope of the package shall be applicable for the package.

1.01.02 The Contractor shall provide all material, equipment and services so as to make a totally integrated Instrumentation and Control System together with all accessories, auxiliaries and associated equipments ensuring operability, maintainability and reliability. This work shall be consistent with modern power plant practices and shall be in compliance with all applicable codes, standards, guides, statutory regulations and safety requirements in force.

1.01.03 Further Bidder shall also include in his proposal and shall furnish all equipment, devices and services which may not be specifically stated in the specification but are needed for completeness of the equipment/systems furnished by the Bidder and for meeting the intent and requirements of the specification.

1.01.04 It is to be noted that where equipment or system for the generating units are described, it shall be understood that the quantities described are to be provided per unit basis i.e. identical sets to be furnished by the Contractor for each of the units unless specifically indicated otherwise. Where equipment or systems for plant common facilities are described, it will be understood that the quantities described are the total quantities required. Wherever quantity has been specified as “On as required” basis, the same is to be supplied by the contractor on as required basis by the contractor within his quoted lump sum price.

1.01.05 Bidder shall include in his bid a detailed Bill of Material (BOM) for each of the systems/ Instruments/ equipment.

1.01.06 In addition to requirements specified under this chapter, all C&I systems/ sub-systems/ equipment/ devices shall also meet other requirements stipulated under other chapters/ parts/ sections of specification.

1.01.07 Contractor also indicate KKS code for all instruments, drives, devices & equipment etc in P&ID, I/O/ Drive/ Alarm & measurement point lists, logics etc.

1.02.00 PROVENNESS CRITERIA

I0.02.01 All field instruments and UPS offered for this package shall have at least two year’s satisfactory operation as on the date of LOA in one power station having unit rating of 200 MW or above. For PLC system refer relevant chapter.

I0.02.02 All equipment, systems and accessories furnished under this specification shall be from the latest proven product range of a reputed experienced manufacturer whose successful performance has been established by a considerable record of satisfactory operation in coal fired utility power stations. Bidder shall furnish satisfactory evidence regarding successful operation and high reliability of the



proposed equipments/systems in coal fired utility stations for similar applications for meeting this requirement as specified elsewhere.

I0.02.03 Not withstanding anything stated above, the Purchaser reserves the right to assess the Bidder's capability and capacity to perform and to relax the qualifying requirements, if necessary, in the light of overall interest of the Project.

I0.02.04 The Bidder shall furnish a complete list of bought out items (i.e., items not from manufacturing range) which the Bidder has included in his proposal along with the names of proposed sub-vendors as a part of his proposal. However the make and model of all bought out items supplied by the Contractor shall be as approved by Employer during detailed engineering stage.

1.03.00 RELIABILITY AND AVAILABILITY

I0.03.01 Each component and system offered by the Bidder shall be of established reliability. The minimum target reliability of each piece of equipment like each electronic module/card, Power supply, Peripheral etc. shall be established by the Bidder, considering its failure rate/mean time between failures (MTBF), meantime to repair (MTTR), such that the availability of the complete C&I system is assured for 99.7%.

I0.03.02 When more than one device uses the same measurement or control signal, the transmitter and other components/ module shall be fully equipped to provide all signal requirements. All the 4-20 mA output signals from transmitters/other control system shall be able to drive minimum 500 Ohms load resistance. The system shall be arranged so that the failure of any monitoring device or control components or spurious intermediate grounding in the signal path shall not open the signal loop nor cause the loss or malfunction of signal to other devices using the same signal.

I0.03.03 To ensure availability, adequate redundancy in system design shall be provided at hardware, software and sensor level to satisfy the availability criteria mentioned above. For the protection system, independent sensing devices shall be provided to ensure adequate safety of plant equipment.

1.04.00 STANDARDISATION AND UNIFORMITY OF HARDWARE

I0.04.01 Bidder shall ensure that various C&I instruments /equipment that are being furnished by the Bidder, are of the same make, series and family of hardware so as to ensure smooth and optimal maintenance, easy interchangeability and efficient spare parts management.

1.05.00 OPERABILITY & MAINTAINABILITY

I0.05.01 The design of the control systems and related equipment shall adhere to the principle of ‘Fail Safe’ Operation wherever safety of personnel / plant equipment is involved. ‘Fail Safe’ operation signifies that the loss of signal, loss of excitation or failure of any component shall not cause a hazardous condition. However, it shall also be ensured that occurrence of false trips are avoided / minimized.



I0.05.02 The types of failure that shall be taken into account for ensuring operability of the plant shall include but not be limited to:

— Failure of sensor or transmitter.

— Failure of main and/or redundant controller/other modules.

— Loss of motive power to final control element.

— Loss of control power.

— Loss of instrument air.

I0.05.03 The choice of hardware shall also take into account sound maintainability principles and techniques. The same shall include but shall not be limited to the following:

— Standardization of parts.

— Minimum use of special tools.

— Grouping of functions.

— Interchangeability.

— Malfunction identification facility/self surveillance facility.

— Easy modular replacement.

— Fool proof design providing proper identification and other features to preclude improper mounting and installation.

— Appropriate de-rating of electronic components and parts.

I0.05.04 The equipment shall employ latest state of the art technology to guard against obsolescence. In any case, Bidder shall be required to ensure supply of spare parts for lifetime of the plant. In case, the Bidder feels that certain equipment/component (barring HMI hardware and networking components) is likely to become obsolete, the Bidder shall clearly bring out the same in his Bid and indicate steps proposed to deal with such obsolescence. For HMI hardware and networking components, Bidder need not bring out the same in the bid; but shall inform the Employer in case of obsolescence so that Employer can take appropriate actions as necessary ( both during the tenure and outside the tenure of the contract ).



1.06.00 ENVIRONMENTAL CONDITIONS

Instruments, devices and equipments for location in outdoors/indoor/air-conditioned areas shall be designed to suit the environmental conditions indicated below and shall be suitable for continuous operation in the operating environment of a gas fired utility station and also during periods of air conditioning failure without any loss of function, or departure from the specification requirements covered under this specification.

Ambient Temperature (outside cabinets)

Pressure Relative humidity

Atmosphere Required protection Class of panels/ cabinets / desks to be provided by contractor.

Outdoor Location

55 degree C max. Atmosphere 100 % Max. Air (dirty) IP 65

4 degree C min. Atmosphere 5 % min. Air (dirty) IP 65

Indoor Location

55 degree C max. Atmosphere 95 % Max. Air IP 54**

4 degree C min. Atmosphere 5 % min. Air IP 54**

Air Conditioned Areas

24 +/- 5 degree C normal

Atmosphere 95 % Max. Air IP 22***

50 degree C max.* Atmosphere 5 %min. Air IP 22***

* During air conditioning failure.

**For non-ventilated enclosures. For ventilated enclosures, protection class shall be IP 42.

***With a suitable canopy at the top to prevent ingress of dripping water, if required.

For Hazardous areas, the protection class shall be in accordance with the requirements of the relevant NEC code for the location, i.e explosion proof enclosure as per the area classification shall be provided.



PCs, OWS/GUI, EWS, Servers, Network Switches, Printers, mini UPS and other peripherals, maximum temperature limit shall be 35 Deg. C. For LVS, the same shall be around 25 Deg. C

For the remote I/O cabinets mounted in non-AC areas, if the Remote I/O and other electronic modules do not meet the requirement of maximum temperature of 10 Deg. C above the maximum site ambient temperature i.e. the design maximum temperature of the modules is less than maximum site ambient temperature (outside cabinet) + 10 deg C, considering a temperature rise of 10 deg C inside the Remote I/O Cabinet, then Contractor shall provide suitable cooling arrangement to meet the specification requirement within the quoted lump sum price.

1.07.00 GROUNDING SYSTEM

All panels, desks, cabinets shall be provided with a continuous bare copper ground bus. The ground bus shall be bolted to the panel structure on bottom on both sides. The bolts shall face inside of panels.

The system ground shall be isolated from the panel ground with suitable isolators. All internal component grounds or common shall be connected to the system ground, which shall be fabricated of copper flat (size 25mm x 6mm min., length as applicable).

Shield on instrumentation cables shall be grounded on panel side. When shielding termination is required in cabinets furnished under this specification, suitable terminals shall be furnished on copper flat forming system ground. System and shield ground shall be connected to Employer provided earthing strip at suitable location.

The Contractor shall submit with the offer recommended grounding scheme required for his system. The exact grounding scheme shall be finalized during detailed engineering.

Owner shall provide the redundant C&I Signal earth, Panel and Power supply earth risers on their electrical earth mat away from the transformer/ Motor earth point. Contractor scope shall be to supply, lay and terminate the redundant earth cable from their Control system to the risers.

Technical Specification for PLC system with UPS Standard

DOC. No. REL-COENG-NEN-442-P-00001 SUB-SECTION – I 1 Page 1 of 21

SUB-SECTION – I 1


PROGRAMMABLE LOGIC CONTROLLER SYSTEM ALONG WITH UPS



1- SPECIFICATION FOR PLC SYSTEM WITH POWER SUPPLY 1.00.00 GENERAL REQUIREMENTS: 1.00.01 This chapter covers the specification requirement of PLC system.

1.00.02 The System shall perform effective Operation and Control of the Process/Equipments and electrical (Incomers, isolator, bus coupler) equipment/drives etc and shall be designed for maximum integrity and reliability.

1.00.03 The microprocessor based PLC system shall provide for Manual and Automatic, Sequence & drive interlock & protection control for on/off & modulating drives, electrical equipments(Incomers, isolator, bus coupler) monitoring, alarm, data logging, reporting, calculations, Operator interfacing and printing.

1.00.04 Control system shall be designed to prevent abnormal swings due to loss of Control System power supply, failure of any Control System component, open circuit/short-circuit etc. On any of these failures the controlled equipment/ parameter shall either remain in last position before failure or shall come to fully open/close or on/off state as required for the safety of plant/ personnel/ equipment and as finalized during detailed engineering. System shall be designed such that there will be no upset when power is restored.

1.00.05 The PLC Control system shall include on-line self-surveillance, monitoring and diagnostic

facility giving the details of the fault on the MMI. The diagnostic system shall ensure that the faults are detected before any significant change in any controller output has taken place. The faults to be reported on OWS/EWS shall include fault in main & standby power supplies, sensor fault, Input/ Output card failure, Memory Status, Controller fault, failure of Communication/ Network links to PLCs etc.

1.00.06 The PLC system shall provide safe operation under all plant disturbances and on any

hardware/software failure so that under no condition the safety of plant, personnel or equipment is jeopardized. Control System shall be designed to prevent abnormal swings due to loss of Control System power supply, failure of any Control System component, open circuits/short circuits, instrument air supply failure etc. On any of these failures the control system output shall either remain in last position before failure or shall come to fully open/close or on/off state as required for the safety of plant/personnel/equipment and as finalized during detailed engineering. System shall be designed such that there will be no upset when power is restored.

1.00.07 The control system shall include the following components as a minimum:

• Redundant Processors (Hot, warm/cold as applicable, as indicated in Scope Section)

• Input/ Output modules

• Power supplies

• PLC communication system.

1.00.08 It shall be possible to remove/ replace online various modules (like any I/O module, interface module, controller etc.) from its slot for maintenance purpose without switching off power supply to the corresponding rack. System design shall ensure that while doing so, undefined signaling and releases do not occur and controller operation in no way is affected (including controller trip to manual, etc) except that information related to



removed module is not available to controller. The on-line removal/ insertion of controller, I/O modules shall in no way jeopardize safety of plant and personnel.

1.00.09 The PLC system shall operate in air conditioned area and shall meet the minimum requirements as specified below. However, PLC system shall be able to operate satisfactorily even during periods of AC failure.

1.00.10 Bidder to provide I/O’s for the system as per specification and system requirement “On as required basis” only within the quoted lump sum price. During any stage of the contract if it is found that PLC system is not meeting the loop reaction time, spare capacity and other parametric requirement, then Contractor is to provide additional sets of processor/controller etc without any cost to the Owner.

1.00.11 The PLC system shall be complete in all respects and shall meet all the functional and parametric requirements of the specification. Refer Drg. No. REL-COENG-NEN-442-J-00001 for typical configuration. The basic configuration diagram is enclosed herewith. However, other specific requirements like connectivity to other third party systems etc. as defined in the scope section shall be taken care while finalizing the configuration.

1.01.00 PROGRAMMABLE LOGIC BASED CONTROL SYSTEM 1.01.01 PLC PROCESSOR

The processor shall be 100% redundant (Hot, warm/cold as applicable) and shall perform the following functions as a minimum.

Receiving binary and analog signals from the field and providing command output to MCC/ SWGR/ Drive etc. through Input / Output modules and operator initiated commands from MMI.

Implementing all logic functions for control, protection and annunciation of the equipment and systems.

Implementing modulating control function for certain application as specified elsewhere in the specification.

Providing supervisory information for alarm, various types of displays, status

information, trending, historical storage of data etc. Performing self-monitoring and diagnostic functions.

1.01.02 Bidder to provide the PLC system as specified in the scope section from the following

configuration options (A) HOT REDUNDANT PROCESSOR

OR (B) WARM/ COLD REDUNDANT PROCESSOR

HOT REDUNDANT PROCESSOR

One set of hot redundant processors/ Controllers, one for normal operation and one as hot standby. In case of failure of Main working processor, there shall be an appropriate alarm and simultaneously the hot standby processor shall take over the complete plant operation automatically. The transfer from main processor to standby processor shall be totally bumpless and shall not cause any disturbance. Both main & standby processor should be completely identical and failure of any processor should not affect the performance of other processor in any manner. In the event of both processors failing, the system shall revert to fail safe mode. It shall be possible to keep any of the



processors as master and other as standby. The main/ standby processor shall be updated (including updation of tables, logic, database etc) automatically in line with the changes made in any one of Main or standby processor. Further, forcing of any inputs should be updated simultaneously in both main and standby processor.

WARM/ COLD REDUNDANT PROCESSOR One set of redundant processors/controller, one for normal operation and one as

cold/warm standby. In case of failure of working processor, there shall be an appropriate alarm and the system shall revert to fail safe mode, further operator/engineer can manually replace the main faulty processor by means of cold/ warm standby processor. The exact standby processor option of cold/ warm stand by shall be finalized during detailed engineering and Owner decision will be final in this regard.

1.01.03 The memory shall be sufficient for the complete system Operation & Control and shall

have at least 20% spare capacity for future expansion. All dynamic memories shall be provided with buffer battery back up for at least 360 hours. Low battery power indication/alarm shall be provided. The entire memory rating shall be available for program storage. Executive or housekeeping programs shall not be counted in the memory size rating.

1.01.04 Priority of different commands shall be as follows:

Manual intervention shall be possible at any stage of operation. Protection commands shall have priority over manual commands and manual commands shall prevail over auto commands.

1.02.00 INPUT/OUTPUT MODULES

1.02.01 I/O module should be designed according to the location of the input/output cabinets as specified.

1.02.02 Input / Output modules, as required in the Control System for all type of field input signals (4-20 mA, RTD, Thermocouple, non change over/ change over type of contact inputs etc.) and outputs from the control system (non change over/ change over type of contact, 24 VDC output signals for energizing interface or coupling relays, 4-20 mA output etc.) are to be provided by the Contractor.

1.02.03 Suitable Electrical isolation with optical couplers between the plant input/output and controller shall be provided on the I/O cards. The isolation shall ensure that any inadvertent voltage or voltage spikes (as may be encountered in a plant of this nature) shall not damage or mal-operate the internal processing equipment.

1.02.04 The Input/output system shall facilitate modular expansion in fixed stages. The individual input/ output cards shall incorporate indications on the module front panels for displaying individual signal status.

1.02.05 Individually fused output circuits shall be provided. Input circuits shall be provided with fuses preferably for each input; alternatively suitable combination of inputs shall be done and provided with fuses such that for any fault, fuse failure shall affect the particular drive system only without affecting other systems. Suitable monitoring shall be provided for these fuses provided in the I/O circuits.

1.02.06 All input/ output cards shall have quick disconnect terminations allowing for card replacement without disconnection of external wiring and without switching off power supply.

1.02.07 The Contractor shall provide the following monitoring features:

Power supply monitoring.



Contact bounces filtering.

Optical isolation between input and output signals with the internal circuits

In case of power supply failure or hardware fault, the outputs shall be automatically switched to the fail-safe mode. The fail-safe mode shall be intimated to the successful Contractor during detailed engineering.

1.02.08 Binary Output modules shall be rated to switch ON/OFF coupling/interposing relays of approx. 3 VA at 24 VDC. Analog output modules shall be able to drive a load impedance of 500 Ohms minimum.

Interposing relay for MCC shall be provided inside MCC module and for Solenoid valves, interposing relay shall be provided inside PLC termination cabinet.

1.02.09 Output module shall be capable of switching ON/OFF inductive loads like solenoid valves through interposing relays and other auxiliaries relays without any extra hardware etc.

1.02.10 Only one changeover contact shall be provided in MCC for control and interlock requirement. Further multiplication, if required, shall be done by the contractor in PLC system.

1.02.11 All input field interrogation voltage shall be 24V DC minimum.

1.02.12 In case of loss of I/O communication link with the main processing unit, the I/O shall be able to go to predetermined fail safe mode (to be decided during detailed engineering) with proper annunciation.

1.02.13 Each of the triple redundant binary & analog inputs shall be wired to separate input modules. Similarly each of the dual redundant binary & analog inputs shall be wired to separate input modules. Implementation of multiple measurement schemes of these inputs will be performed in the redundant hardware. Loss of one input module shall not affect the signal to other modules. Other channels of these modules can be used by other inputs of the same functional group.

1.02.14 All single analog & binary inputs including the limit switches of valves/ dampers MCC/ SWGR check-backs of all drives & information related signals may be wired to single (i.e. non-redundant) input modules.

1.02.15 Inputs and Outputs related to each of the redundant drives/ equipments (eg. each of the 3x50 % drives, each of the storage vessel/ sump/ tank storing same fluid, each of the streams and its related drives etc.) shall be wired to separate input and output modules.

1.02.16 The signal conditioning functions like multiple measurement schemes, square root extraction for flow signals, pressure and temperature compensation, limit value computation can be performed either in the controllers or in signal conditioning and processing hardware outside controllers.

1.02.17 The maximum number of inputs/ outputs to be connected to each type of module shall be as follows:

1. Analog input module 16

2. Analog output module 16

3. Binary input module 32

4. Binary output module 32

5. Analog input & output (combined) if applicable 16

6. Binary input and output (combined) if applicable 32



1.02.18 Any single sensor/ transducer/ transmitter failure alarm shall be provided on Engineering work station screens for all sensors/ transducers/ transmitters. Similarly sensor break alarm for thermocouples etc. shall also be displayed on the screens.

1.02.19 Remote I/O cabinet and I/O modules Remote I/O cabinets with I/O modules shall be used to reduce field cabling costs under

the following cases. (i) Where the BOP Package vendor’s furnished equipment includes multiple skids,

panels/cabinets with multiple signals.

(ii) Wherever it is possible to group sufficiently various Instruments/ drives in a particular location and the cable route distance from I/O cabinets/ racks exceeds a distance of at least 400 meters from the PLC system.

Remote I/O cabinets/ Racks shall be connected through Fiber optic/ coaxial cable to PLC system meeting all other specification requirement.

1.03.00 HUMAN MACHINE INTERFACE SYSTEM (HMIS)

1.03.01 PC based OWS (Operator Work Station) shall be used to perform control, monitoring and

operation of all auxiliaries/ drives interacting with PLC based control system. It shall be possible to use OWS as programming station of the PLC. In case the PC based OWS can not be used as programming station of the PLC, then separate PC based programming station shall be provided. Suitable industrial furniture for the Operator workstations, engineer/ programmer station, printers etc. shall be provided by the Contractor, details of which shall be finalized during detailed engineering.

The operator functions shall be achieved by GUI (wherever specified, as indicated in

Scope section). GUI shall as a minimum include Control System Operation (A/M selection, raise/lower, set point/ bias change, on/off, bypassing criteria, sequence auto, start/stop selection, drive auto selection, local-remote selection etc.); alarm acknowledge; displays, reports etc.; printing of reports; retrieval of historical data; and any other functions required for smooth operation as finalized during detailed engineering. Wherever GUI is specified as the main Operator interface, a separate Laptop shall be provided for programming functions if the same cannot be achieved from the GUI.

1.03.02 All OWSs of the HMIS shall be fully interchangeable i.e. all operator functions including control,

monitoring and operation of any plant area on drive shall be possible from any of the OWSs at any point of time without the necessity of any action like downloading of additional files. Operator shall be able to access all control/ information related data under all operating conditions including a single processor/ computer failure in the HMI.

1.03.03 PLC system shall be time synchronized with Owner supplied master clock system. Owner

shall provide NTP signal for time synchronizing through BOP-PLC network system. Incase, Bidder proposed system require different type of synchronizing signal then the details of the same are to be included in his bid.

1.03.04 SPECIFICATIONS OF OPERATOR WORK STATION (OWS)

The minimum requirement for PC based OWS shall be as below:

CPU Latest generation CPU

Main memory 1 GB, minimum (Expandable to 5GB)

Drives 52 x CD ROM drive or latest version



Note: Contractor to supply latest version available at the time of finalization of technical

datasheet.

1.03.05 SPECIFICATIONS OF GRAPHICAL INTERFACE UNIT (wherever specified):

Sl no. Features Description

1. Power supply 230 V AC from UPS

2. Display Type, size Color, TFT screen, 15 “

3. Humidity/ temperature 5-95%/ 55 Deg. C

4. Protection class IP-65 Enclosure shall be provided to prevent ingress of dust.

5. Keys Function keys and numeric keys

6. Interfacing requirements Interface with respective control systems

7. Functional requirements Ability to operate drives locally using function keys.

Ability to do programming. (In case programming is not possible from the GUI, a separate laptop with requisite software shall be provided for

Hard disk 80 GB, minimum(Expandable to 160 GB)

Removable bulk storage drive (MOD / DVD / DAT)

6 GB (minimum)

Removable Bulk Storage Media for above

10 nos

Monitor 21" Full Flat TFT Resolution 1600 x 1280, refresh rate min 85 Hz.

Graphic Memory 16 MB Min.

Communication port 2 serial plus, one parallel, 1 USB port, Dual 100 Mbps Ethernet.

Expansion slots 3

Other Features 101 Keys Keyboard and Optical Mouse

Power supply 230 V from UPS

a General MS Windows (latest), MS-Office, Microsoft Visual Studio, Adobe Acrobat, anti-virus McAfee or equivalent, etc.

Software

b Application & Programming/Engineering software - to suit project specific requirement



programming.

Graphics display including alarms and operator guidance messages.

8. Mounting On table Top/ panel as decided during detailed engineering.

Note: Contractor to ensure that latest version is supplied. 1.03.06 Printer:

Bidder is to provide Heavy duty A4, high speed color laser printer of reputed make for industrial application as per individual package specification requirement.

1.03.07 The Operator functions for each OWS shall as a minimum include Control System operation (A/M selection, raise/lower, set point/ bias change, on/off, open/close operation, mode/device selection, bypassing criteria, sequence auto, start/stop selection, drive auto selection, local-remote/ other multi-position selection etc.); alarm acknowledge; call all kind of displays, logs, summaries, calculation results, etc.; printing of logs & reports; retrieval of historical data; and any other functions required for smooth operation, control & management of the equipment, as finalized during detailed engineering.

1.03.08 When any drive or sequence is being controlled from one OWS, the system shall inhibit control access of the same drive or sequence from other OWS.

1.03.09 The display selection process shall be optimized so that the desired display can be selected with the minimum no. of operations. Navigation from one display to any other should be possible efficiently through paging soft keys as well as through targets defined on the displays. There should be no limitation on number of such targets.

1.03.10 The system shall have built-in safety features that will allow/ disallow certain functions and entry fields within a function to be under password control to protect against inadvertent and unauthorized use of these functions. Assignment of allowable functions and entry fields shall be on the basis of user profile. The system security shall contain various user levels with specific rights as finalized by the Employer during detailed engineering. However, no. of user levels, no. of users in a level and rights for each level shall be changeable by the programmer (Administrator).

1.04.00 PROGRAMMING FUNCTIONALITIES

Programming of the PLC Processor/ controller as well as programming of HMIS shall be user friendly with graphical user interface and shall not require knowledge of any specialized language. For example, the programming of PLC shall use either of the following:-

- Flow-chart or block logic representing the instructions graphically (preferable).

- Ladder diagrams.

The programming of HMIS (like development and modification of data base, mimics, logs/ reports, HSR functionalities etc.) shall also be possible through user-friendly menus etc

All programming functionalities shall be password protected to avoid unauthorized modification.

A forcing facility shall be provided for changing the states of inputs and outputs, timers and flags to facilitate testing, commissioning, fault finding etc. It shall be possible to monitor the signal flow during operation of the program.



1.05.00 SOFTWARE REQUIREMENT 1.05.01 All necessary software required for implementation of control logic, operator station

displays / logs, storage & retrieval and other functional requirement shall be provided. The programs shall include high level languages as far as possible. The contractor shall provide sufficient documentation and program listing so that it is possible for the Employer to carry out modification at a later date.

1.05.02 The Contractor shall provide all software required by the system for meeting the functional/parametric requirements of the specification.

1.05.03 Industry standard operating system like MICROSOFT WINDOWS (latest version) etc. to ensure openness and connectivity with other system in industry standard protocols (TCP-IP/ OPC etc.) shall be provided. The system shall have user friendly programming language & graphic user interface.

1.05.04 All system related software including Real Time Operating System, File management software, screen editor, database management software. On line diagnostics/ debug software, peripheral drivers software and latest versions of standard PC-based software and MICROSOFT WINDOWS (latest) etc. and any other standard language offered shall be furnished as a minimum.

1.05.05 All application software for PLC system functioning like input scanning, acquisition, conditioning/ processing, control and communication and software for operator interface of monitors, displays, trends, curves, bar charts etc. Historical storage and retrieval utility, and alarm functions shall be provided. Software to enable communication with other third party systems/ main plant DCS on Industry standard protocols like OPC etc. shall also be included.

1.05.06 The Contractor shall provide software locks and passwords to Employer’s engineers at site for all operating & application software so that Employer’s engineers can take backup of these software and are able to do modifications at site.

1.06.00 PARAMETRIC REQUIREMENTS

The control system shall be designed such that under worst case loading conditions the response time shall not be worst than the following:-

On/Off Command - The response time for screen update after the execution of the control command from the time the command is issued (for example command to start a motor to the time the screen is updated) shall be two seconds (excluding the drive actuation time).

On screen Updating - 1 second.

All Control related displays - 1 second.

Bar Chart displays - 2 to 3 seconds.

Plant Mimic displays - 2 to 3 seconds.

Group review displays - 2 to 3 seconds.

X-T Plot Displays - 3 - 4 seconds.

Plant Summary Displays - 3 - 4 seconds.



Even under worst case loading condition of HMIS and system Bus, each HMIS processor shall have 50 % spare time when measured over any one minute period and the system bus shall have at least 50 % spare duty cycle.

1.07.00 SYSTEM REACTION TIME

1.07.01 The reaction time of the programmable control system from input signals at the input cards to output of the associated signals or commands of the output card inclusive of programmed logic processing, comprising a mixture of logic gates, arithmetic operations and other internal operations shall be less than 100 milli seconds under the worst case operating conditions.

1.08.00 SYSTEM SPARES CAPACITY

1.08.01 Over and above the equipment and accessories required to meet the fully implemented system as per specification requirements, Control System shall have spare capacity and necessary hardware/ equipment/ accessories to meet following requirement for future expansion at site:

1.08.02 10% spare channels in input/ output modules fully wired up to cabinets TBs.

1.08.03 Wired-in "usable" space for 20% modules in each of the system cabinets for mounting electronic modules wired up to corresponding spare terminals in system cabinets. Empty slots between individual modules/ group of modules, kept for ease in maintenance or for heat dissipation requirement as per standard practice of Contractor shall not be considered as wired-in "usable" space for I/O modules.

1.08.04 20% spare Terminal Blocks shall be provided for future expansion.

1.08.05 Each processor/ controller shall have 30% spare functional capacity to implement additional function blocks, over and above implemented logic/ loops. Further, each processor / controller shall have spare capacity to handle minimum 30% additional inputs/ outputs of each type including above specified spare requirements, over and above implemented capacity. Each of the corresponding communication controllers shall also have same spare capacity as that of processor/controller.

1.08.06 The PLC COMMUNICATION SYSTEM shall have the capacity to handle the additions mentioned above.

1.08.07 Ten (10) percent spare relays of each type and rating mounted and wired in cabinets TBs. All contacts of relays shall be terminated in terminal blocks of cabinets.

1.08.08 The spare capacity as specified above shall be uniformly distributed throughout all cubicles. The system design shall ensure that above mentioned additions shall not require any additional controller/ processor/ peripheral drivers in the system delivered at site. Further, these additions shall not deteriorate the system response time / duty cycle, etc. from those stipulated under this specification.

1.09.00 PLC COMMUNICATION SYSTEM 1.09.01 The PLC COMMUNICATION SYSTEM shall include a redundant Bus from I/O modules

to the controller and from controller to HMIS. Other applicable bus systems like cubicle bus, local bus, I/O bus etc shall be redundant except for backplane buses which can be non-redundant.

The PLC COMMUNICATION SYSTEM shall have the following minimum features :

a Redundant communication controllers (if applicable) shall be provided to handle the



communication between I/O Modules (including remote I/O) and PLCs and between PLCs and operator work station.

b The design shall be such as to minimize interruption of signals. It shall ensure that a single failure anywhere in the media shall cause no more than a single message to be disrupted and that message shall automatically be retransmitted. Any failure or physical removal of any station/ module connected to the system bus shall not result in loss of any communication function to and from any other station/ module.

c If the system bus requires a master bus controller philosophy, it shall employ redundant master bus controller with automatic switchover facility.

d Built-in diagnostics shall be provided for easy fault detection. Communication error detection and correction facility (ECC) shall be provided at all levels of communication. Failure of one bus and changeover to the standby system bus shall be automatic and completely bumpless and the same shall be suitably alarmed/logged.

e The design and installation of the system bus shall take care of the environmental conditions as applicable.

f Data transmitting speed shall be sufficient to meet the responses of the system in terms of displays, control etc. plus 25% spare capacity shall be available for future expansion.

g Passive coaxial cables or fiber optic cables shall be employed.

The Contractor shall furnish details regarding the communication system like communication protocol, bus utilization calculations etc.

1.09.02 If specified in the scope section, the PLC system shall be provided with necessary

interface hardware and software for dual fiber optic connectivity & interconnection with BOP PLC NETWORK SYSTEM for two-way transfer of signals for the purpose of operation & control from a remote centralized location. The Remote plant operation & control shall be made available through an Ethernet link following TCP/ IP standard through separate Owner procured BOP PLC NETWORK SYSTEM. The exact Operation & control philosophy shall be finalized during detailed engineering and Owner’s decision will be final and binding. The system shall be OPC compliant. The exact data structure shall be as decided during detailed engineering. All required plant data shall be transferred through this link ensuring complete security. The exact number of points to be transferred through the above communication link and the format of the data shall be finalized during detailed engineering. Further the Contractor is to ensure that link response time as per process requirement is achieved successfully for remote operation & control and in case for achieving the same, any additional hardware/ software is required at PLC end, the same is to be provided by the bidder without any additional price. In addition of providing all required inputs/data in proper agreeable formats, Contractor to also provide all necessary assistance to the Owner’s BOP PLC NETWORK SYSTEM supplier for smooth operation of the link.

1.10.00 OPERATOR INTERFACE DISPLAYS/ LOGS/ REPORTS 1.10.01 Suitable Operator Interface Displays/ Logs/ Reports for control operation & monitoring

shall be provided. The details shall be finalized during detailed Engg. Stage.



Various displays on the OWS shall as a minimum include P&ID displays or mimic, bar chart displays, X-Y & X-T plot (trend) displays, operator guidance message displays, group displays, plant start-up/shutdown message displays, system status displays etc. Number of displays and the exact functionality shall be on as required basis and as finalized during detailed engineering.

The assignment for the above will be done by the contractor as per the requirement of operation of BOP systems as well as for maintenance. Provision shall be kept for future modification/ addition of different types of displays.

1.11.00 HISTORICAL STORAGE AND RETRIEVAL SYSTEM (HSRS) 1.11.01 The HSRS shall collect, store and process system data from HMIS data base. The data

shall be saved online on hard disk and automatically transferred to erasable long term storage media once in every 24 hours periodically for long term storage. Provision shall be made to notify the operator when hard disk is certain percentage full. The disk capacity shall be sufficient to store at least seven days data.

1.10.02 The data to be stored in the above system shall include alarm and event list, periodic

plant data, selected logs/ reports. The data/ information to be stored & frequency of storage and retrieval shall be as finalized during detailed engineering. The system shall provide user-friendly operator functions to retrieve the data from historical storage. It shall be possible to retrieve the selected data on OWS or printer in form of trend/report by specifying date, time & period. Further, suitable index files/directories shall also be provided to facilitate the same. The logs/ reports for at least last seven (7) days shall be available on the disk.

1.11.03 The bulk storage devices (DVD, Hard disk) shall be provided.

In addition to above, the system shall also have facility to store & retrieve important plant data for a very long duration (plant life) on portable long term storage media). These data will include any data from the database as well as processed/computed data based on various calculations/ transformation. The retrieved data from long term storage media should be possible to be presented in form of X-T display, X-Y display, logs, reports, etc.

1.12.00 CONTROL & POWER SUPPLY SCHEME 1.12.01 For PLC system, Contractor shall provide UPS system as described below. Further

requirement of low level AC/DC power conversion and/or stabilization for controller, interrogation power etc required for PLC system shall be met by the Contractor by providing redundant stabilized power supplies and any other additional equipment etc within the quoted lump sum price. Power Supply module shall have 20% spare capacity for future use.

1.12.02 Following are the two UPS configurations. Refer Drg. No. REL-COENG-NEN-442-J-

00002 for typical UPS configuration diagrams. Bidder to supply UPS system as specified in the scope section.

UPS Configuration I There will be 2 x 100% inverter and charger modules with 1x100% battery bank with 30

minutes back-up, 1X 100 % standby AC source with servo controlled stabilizer. Each inverter shall be rated to cater the load of PLC System (Controllers, I/O Modules/

Communication Modules), HMI System and other instruments requiring 230 VAC. The UPS power supply system shall be rated at 50 deg C and include 10% spare capacity for future expansion. Each Inverter shall be so sized so that it can clear the maximum branch circuit fuse on its own without bypass support. Necessary redundant transformers shall



be provided by the Contractor to derive power supply from 415 V, 3-phase incomers. The static switch shall be provided to perform the function of transferring UPS loads automatically without any break from -

i. faulty inverter to healthy inverter in case of failure of one of the two inverters

and

ii. faulty inverter to standby AC source in case of failure of both the inverters. The transfer time shall be ¼ cycle maximum. Manual by-pass switch shall be provided to

isolate any inverter for maintenance or repair without interruption to the UPS load. The switch shall have the facility of by-passing both the inverters during start-up at the option of the operator. Contact shall be make-before-break type. The switch shall have current rating equal to the full load inverter current and necessary short time load carrying and interrupting capacity to meet the requirement of UPS system. The voltage stabilizer should be servo controlled.

The chargers shall be self regulating, solid state silicon controlled, full-wave rectifier type

designed for single and parallel operation with battery and shall have automatic voltage regulators for close voltage stability even when AC supply voltage fluctuates, effective current limiting features and filters to minimize harmonics. The charger output regulation shall be ± 1% from no load to full load with an input power supply variation of ± 10% in voltage and ± 5% in frequency. The static inverter shall be of continuous duty, solid state type using proven Pulse Width Modulation (PWM)/ Quasi square wave/ step wave technique. The steady state voltage regulation shall be +/-1% or better. Frequency regulation for all conditions of input supplies, loads and temperature occurring simultaneously or in any combination shall be better than ± 0.1% (automatically controlled). The total harmonic content shall be 5% maximum and content of any single harmonic shall be 3% maximum. The inverter efficiency shall be at least 90% on full load and 85% at 50% load.

UPS Configuration II There will be 1 x 100% inverter and charger modules with 1x100% battery bank with 30

minute back up, 1X 100 % Standby AC source with solid state stabilizer. The inverter shall be rated to cater the load of PLC System (Controllers, I/O Modules /

Communication Modules), HMI System and other instruments requiring 230 VAC. The UPS power supply system shall rated at 50 deg. C and include 10% spare capacity for future expansion. The Inverter shall be so sized so that it can clear the maximum branch circuit fuse on its own without bypass support. Necessary redundant transformers shall be provided by the Contractor to derive power supply from 415 V, 3-phase incomers. The static switch shall be provided to perform the function of transferring UPS loads automatically without any break from faulty inverter to standby AC source in case of failure of the inverter.

The transfer time shall be ¼ cycle maximum. Manual by-pass switch shall be provided to

isolate inverter for maintenance or repair without interruption to the UPS load. The switch shall have the facility of by-passing the inverter during start-up at the option of the operator. Contact shall be make-before-break type. The switch shall have current rating equal to the full load inverter current and necessary short time load carrying and interrupting capacity to meet the requirement of UPS system. The voltage stabilizer should be solid state.

The charger shall be self regulating, solid state silicon controlled, full-wave rectifier type

designed for single and parallel operation with battery and shall have automatic voltage regulators for close voltage stability even when AC supply voltage fluctuates, effective



current limiting features and filters to minimize harmonics. The charger output regulation shall be ± 1% from no load to full load with an input power supply variation of ± 10% in voltage and ± 5% in frequency. The static inverter shall be of continuous duty, solid state type using proven Pulse Width Modulation (PWM)/ Quasi square wave/ step wave technique. The steady state voltage regulation shall be +/-1% or better. Frequency regulation for all conditions of input supplies, loads and temperature occurring simultaneously or in any combination shall be better than ± 0.1% (automatically controlled). The total harmonic content shall be 5% maximum and content of any single harmonic shall be 3% maximum. The inverter efficiency shall be at least 90% on full load and 85 at 50% load. The details of the Power supply system shall be finalized during detailed engineering and subject to Owner’s approval.

1.12.03 All the drives shall be switched ON/OFF through 24V DC coupling relays to be provided

in HT/LT SWGR panels. 1.12.04 Power supply distribution from Contractor’s power supply cabinets shall be in the scope

of Contractor. The exact power supply scheme shall be as approved by Employer during detailed Engineering stage.

1.12.05 The battery shall be sealed maintenance-free Valve Regulated Lead Acid (VRLA)

batteries with long life and shall be able to provide a back-up for 30 minutes at full load requirement of the complete control system.

1.12.06 For remote I/O cabinets, separate redundant power supplies, suitable for Employer

supplied redundant 415V, 3-phase redundant incomers, shall be provided. The equipment of power supply unit can be mounted as an integral part of the enclosure and the same shall provide all voltages necessary to power the processor and I/O modules. All required redundant power packs etc. with inbuilt chargers; with minimum one hour battery back-up shall be provided. Power supply module shall be of ample capacity to supply all modules. In addition 20% spare capacity for future shall be provided. However, the exact power supply scheme shall be as approved by Employer during detailed Engineering stage.

1.12.07 Contractor shall provide power supply distribution panels/ cabinets/ boxes for sub-

distribution of main UPS/ DC/ Utility feeder(s) on as required basis. These shall include necessary auto-change over circuitry, switch-fuse units, MCBs, terminal blocks etc. suitable for the application. The design of these distribution panels/ cabinets/ boxes shall be as approved by Owner during detailed engineering stage. Each of the control cabinets, however, shall be provided with redundant DC/UPS feeders.

1.13.00 CONTROL CABINETS / PANELS / DESKS

1.13.01 The cabinets shall be IP-22 protection class. The Contractor shall ensure that the

packaging density of equipment in these cabinets is not excessive and abnormal temperature rise, above the cabinet temperature during normal operation or air-conditioning failure, is prevented by careful design. This shall be demonstrated to the Employer during the factory testing of the system. The Contractor shall ensure that the temperature rise is limited to 10 deg. C above ambient and is well within the safe limits for system components even under the worst condition. Ventilation blowers shall be furnished as required by the equipment design and shall be sound proof to the maximum feasible extent. Dual blowers with blower failure alarm shall be provided in each cabinet with proper enclosure and details shall be furnished with proposal. Suitable louvers with wire mesh shall be provided on the cabinet.

1.13.02 The cabinets shall be designed for front access to system modules and rear access to wiring and shall be designed for bottom entry of the cables.

1.13.03 The cabinets shall be totally enclosed, free standing type and shall be constructed with minimum 2 mm thick steel plate frame and 1.6 mm thick CRCA steel sheet or as per



supplier's standard practice for similar applications. The cabinets shall be equipped with full height front and rear doors. The floor mounting arrangement for other cabinets shall be as required by the Employer and shall be furnished by the Contractor during detailed engineering.

1.13.04 Cabinet doors shall be hinged and shall have turned back edges and additional bracing where required ensuring rigidity. Hinges shall be of concealed type. Door latches shall be of three-point type to assure tight closing. Detachable lifting eyes or angles shall be furnished at the top of each separately shipped section and all necessary provisions shall be made to facilitate handling without damage. Front and rear doors shall be provided with locking arrangements with a master key for all cabinets. If width of a cabinet is more than 800 mm, double doors shall be provided.

1.13.05 Two spray coats of inhibitive epoxy primer-surface shall be applied to all exterior and interior surfaces. A minimum of 2 spray coats of final finish colour shall be applied to all surfaces. The final finished thickness of paint film on steel shall not be less than 65-75 micron for sheet thickness of 2 mm and 50 microns for sheet thickness of 1.6 mm. The finish colors for exterior and interior surfaces shall be finalized during detailed engineering.

1.13.06 Paint films which show sags, checks or other imperfections shall not be acceptable.

1.13.07 As an alternative, single coat of anodic dip coat primer along with single textured powder coating with epoxy polyester meeting the thickness requirement is also acceptable.

1.13.08 Suitable arrangement shall be made for system ground (electronic ground), panel body grounding and power supply grounding.

1.13.09 The type of termination and terminal blocks to be used in the PLC Field Termination cabinets shall be Cage clamp type .Screw type terminals are not acceptable. The terminals used for terminating the spare cores/ pairs of field cables shall not be employed for terminating the spare channels of I/O modules.

.” 1.14.00 ALARM SYSTEM 1.14.01 Only OWS based alarm system shall be provided with audio alarm facility (beep/tone

generator). No facia annunciation is envisaged in the control room. The system shall display history of alarms in chronological order on any of the OWS. The HMIS shall have the capability to store a minimum of 500 alarms each with paging features allowing the operator to view any page. The system shall have all alarm functions and related function keys like alarm acknowledge, reset, paging, summaries etc. Other design features like set point/dead band adjustments, provision of alarm priority, manual inhibition & automatic inhibition based on predefined logic etc. shall be provided and shall be as finalized during detailed engineering. The alarm display/report format shall be as approved by the Employer.

1.14.02 Facility of audio alarming shall be provided in OWS upon the occurrence OWS alarms irrespective of whether alarms are displayed or not. Facility to disable the audio alarming on OWS shall be provided.

1.14.03 At least three levels of alarm priority shall be available which will be displayed in different colour. It shall be possible to display & print alarms of any of the three levels only on a per OWS basis.

1.14.04 Alarm boxes shall be provided in each display to alert the operator about an alarm when he is viewing some other picture. The number of alarm boxes shall be finalized during detailed engineering for each process area & each priority therein.

1.15.00 SOFTWARE DOCUMENTATION AND SOFTWARE LISTINGS 1.15.01 All technical manuals, reference manuals, user’s guide etc. in English required for

modification/ editing/ addition/ deletion of features in the software of the PLC System



shall be furnished. The Contractor shall furnish a comprehensive list of all system/ application software documentation after system finalization for Employer’s review and approval.

1.15.02 All the software listings including Source code for application software, all special-to-project data files etc. shall be submitted by the Contractor.

1.16.00 SOFTWARE LICENCES 1.16.01 The Contractor shall provide software license for all software being used in Contractor’s

System. The software licenses shall be provided for the project (e.g. organization or site license) and shall not be hardware/ machine-specific. That is, if any hardware/ machine is upgraded or changed, the same license shall hold good and it shall not be necessary for Employer to seek a new license/ renew license due to up gradation/ change of hardware/ machine in Contractor’s System at site. All licenses shall be valid for the continuous service life of the plant.

1.16.02 As a customer support, the Contractor shall periodically inform the designated officer of

the Employer about the software upgrades/ new releases that would be taking place after the system is commissioned so that if required, same can be procured & implemented at site.

1.17.00 CODES AND STANDARDS 1.17.01 Bidder shall supply the PLC system complying the following Industry Standard codes and

standard as a minimum. All prevailing standard shall be complied for

IEEE 383/1974: Flammability test IEC 754-1 Acid gas generation test ASTM - D - 2843 Smoke generation test IEEE - 1050 Guide for Instrumentation and Control

Equipment Grounding in Generating Stations

ANSI C 37.90.1 Surge Withstand Capability (SWC) Tests ISA-S 50.0:ANSI MC 12.1-1975 Compatibility of Analog Signals for

Electronic Industrial Process Instruments. IEC 326 C Printed Circuit Boards NEMA ICS Part-2-125, A600 Contact Rating for AC services NEMA ICS Part-2-125, N600 Contact Rating for DC services ISO 1745 Control procedures for Data

Communication System NEMA Std. ICS-6-110.15 Types of enclosures through 110.22 (Type 4 to 13). EIA: RS-310-B Racks, panels, and associated (ANSI C83.9 - 1972) equipments



IS-13947. Protection Class for Enclosure,

Cabinets, Control Panels and Desks ISA RP 19.1-1979. Specifications and guides for the use of

general purpose annunciators IEEE std.3.13. Relays and relay system associated

with electric power apparatus BS 5887 Code of Practice for Testing of

Computer-based Systems BS EN60801 Electromagnetic Compatibility for

Industrial Process Measurement and Control

1.18.00 DOCUMENT SUBMITTAL REQUIREMENT

1.18.01 The Contractor during detailed engineering shall provide configuration diagram, write

ups, hardware/ software details, I/O & drive list(Owner format) ,MMI documents ,logic diagram (Owner format)& write ups ,power supply diagram, load list, panel GA and layout & wiring drawings , bill of material, Quality plan, Grounding scheme, technical data sheets ,FAT procedure, spare parts list, cable interconnection diagrams, cable list ,optic fiber cable laying details, O&M and installation manuals, etc. for complete PLC system covered under this contract.

1.18.02 Data and documents to be furnished by the Bidder along with bid:

i. PLC Configuration, write ups, hardware/ software details, I/O & drive list

ii. Power supply and distribution arrangement.

iii. Bill of materials

iv. GA and layout drawing.

v. Schedule of type and routine tests

vi. Recommended grounding system.

vii. Quality assurance plan

viii. Final list of sub vendors as per Owner.

ix. Data requirements.

x. Details of post commissioning services

xi. Proposed delivery schedule

xii. Deviation sheet (if any) shall be furnished mentioning the specification clause

number against which the deviation has been sought and the specific deviation taken against the clause. Any departure from the specification, not specifically mentioned in the deviation sheet, shall be ignored even though deviation may be mentioned, hinted or implied otherwise in any other section of the offer, it will be presumed that Bidder shall comply with the specification in totality in the event of award of contract.



1.19.00 PERFORMANCE TESTS

1.19.01 The system / equipment to be supplied under this specification shall meet the parametric requirement stated in clause no. 1.06.00, 1.07.00, 1.08.00 when operated at the rated / specified conditions. The acceptance of the system/ equipments shall be subject to satisfying required parameters during shop test at vendor’s works and/ or at site installation in complete assembled condition.

1.19.02 The vendor without any extra cost will rectify any decline in performance from the guaranteed performance figures.

1.20.00 WORK SCHEDULE:

1.20.01 Bidder shall ensure that the delivery of the equipment/ instrument shall meet the project schedule, which shall be furnished to the bidder during issuing of the tender documents.

1.20.02 Bidder shall indicate the phase wise design, engineering, manufacturing, testing and

delivery for the complete package in the form of a bar-chart to match the project schedule in co-ordination with package vendor.

1.20.03 Bidder shall furnish a detailed supply programme for manufacturing and assembly for

approval and will be subsequently form a part of the contract document. 1.21.00 TYPE TEST REQUIREMENTS

1.21.01 General Requirements

The Contractor shall furnish the type test reports of all type tests as per relevant standards and codes as specified by the owner. If the bidder proposes a different standard/code from that indicated, same is acceptable provided the equivalence of the proposed standard is established by the bidder.

(a) Submission of type test results and certificate shall be acceptable provided.

i. The same has been carried out by the Bidder/ sub-vendor on same series of

PLC system and similar rating of UPS as the equipment being offered.

ii. There has been no change in the components from the offered equipment & tested equipment.

iii. The test has been carried out as per the latest standards along with amendments as on the date of Bid opening.

(b) In case the approved equipment is different from the one on which the type test had been conducted earlier or any of the above grounds, then the tests have to be repeated and the cost of such tests shall be borne by the Bidder/ sub-vendor within the quoted price and no extra cost will be payable by the Owner on this account.

1.22.00 TYPE TEST

1.22.01 PLC SYSTEM:-

The minimum type test reports, over and above the requirements of above clause, which are to be submitted for the PLC systems shall be as indicated below:



i) Surge Withstand Capability ( SWC) for Solid State Equipments/ Systems

All solid state systems/ equipments shall be able to withstand the electrical noise and surges as encountered in actual service conditions and inherent in a power plant. All the solid state systems/ equipments shall be provided with all required protections that needs the surge withstand capability as defined in ANSI 37.90.1/ IEEE-472. Hence, all front end cards which receive external signals like Analog input & output modules, Binary input & output modules etc. including power supply, data highway, data links shall be provided with protections that meets the surge withstand capability as defined in ANSI 37.90.1/ IEEE-472. Complete details of the features incorporated in electronics systems to meet this requirement, the relevant tests carried out, the test certificates etc. shall be submitted along with the proposal. As an alternative to above, suitable class of EN 61000-4-12 which is equivalent to ANSI 37.90.1/ IEEE-472 may also be adopted for SWC test.

ii) Dry Heat test as per IEC-68-2-2 or equivalent.

iii) Damp Heat test as per IEC-68-2-3 or equivalent.

iv) Vibration test as per IEC-68-2-6 or equivalent.

v) Electrostatic discharge tests as per EN 61000-4-2 or equivalent.

vi) Radio frequency immunity test as per EN 61000-4-6 or equivalent.

vii) Electromagnetic Field immunity as per EN 61000-4-3 or equivalent.

Test listed at item no. v, vi, vii, above are applicable for electronic cards only as defined under item (i) above.

1.22.02 UPS SYSTEM: -

Test certificates for the following test to be furnished for Owner’s review/approval.

Sr.No. TEST REQUIREMENT STANDARD 1 Degree of protection test IS-2147 2 Load Test For finalized capacity. 3 Audible Noise Test IEC 162 4 Fuse Clearing Capability As per specification

requirement. 5 Radio interference IEC-164 6 Synchronous transfer test IEC-164 7 Input Voltage Variation Test As per specification

requirement 8 Over Load Test on Inverter & charger As per specification

requirement 9 Insulation Test IEC 146

10 Restart Test IEC 146-2 11 Short Circuit current capability IEC 146-2 12 Output voltage & frequency tolerance IEC 146-2 13 Voltage Current Division IEC 146-2 14 Relative Harmonic content IEC 146-2



1.23.00 QUALITY REQUIREMENTS 1.23.01 The PLC shall meet the specification requirements and shall be manufactured / tested

(inclusive for functional tests also) as per applicable codes & standards as well as approved quality assurance plans.

1.23.02 The manufacturer is to furnish a detailed quality plan indicating the practice and procedure along with relevant supporting documents.

1.24.00 SPARES 1.24.01 Start-up and commissioning spares to be supplied with PLC. 1.24.02 Separate list of recommended spare for 5 years of the normal trouble free operation also

be quoted.

1.24.03 Mandatory spare as specified by the owner.

1.24.04 All spares required for operation/ maintenance by the owner shall be delivered in unused new condition.

1.24.01 Spares, which may be required during tests, trial and commissioning, shall be arranged separately.

1.25.00 TOOLS & TACKELS 1.25.01 The Bidder in his proposal shall indicate a list of tools & tackles, which may be required

for maintenance, overhaul, and replacement of instrument / equipment / component to be supplied under this specification.

1.26.00 FACTORY ACCEPTANCE TESTS:

1.26.00 The Owner shall witness the factory acceptance test of PLC system at

manufacturer works as per approved FAT procedure. 1.27.00 TRAINING 1.27.00 Contractor shall provide training on PLC systems for Owner personnel at their works. Details shall

be worked out during detailed engineering.

SPECIFICATION FOR RELAY BASED CONTROL SYSTEM/

PANELS


DOC. NO.: REL-COENG-NEN-449-P-00001 R0 SUB-SECTION – I 10 Page 1 of 3

SUB-SECTION – I 10

TECHNICAL SPECIFICATION

FOR

RELAY/ MICROCONTROLLER BASED CONTROL PANELS/ LOCAL CONTROL PANELS


PANELS



1.01.00 RELAY BASED/ MICRO-CONTROLLER BASED CONTROL PANELS

Bidder shall supply complete relay based/ micro controller based control panels, wherever required, with all requisite relays/ micro-controllers, transformers, timers, push buttons, indicating lamps etc., so as to enable control & operation of the various equipment being supplied under the package, as per the operation philosophy. Suitable terminal blocks, gland plates, vibration dampeners, illumination etc. shall be provided in the panels. The panels shall meet the typical specifications outlined below. The details shall be finalized during detailed engineering and subject to Owner’s approval.

1.02.00 LOCAL CONTROL PANELS WIRED THROUGH PLC SYSTEM

Bidder shall supply dummy local control panels wired through PLC System, wherever required, with all requisite push buttons, indicating lamps etc., so as to enable local control & operation of the various equipment being supplied under the package, as per the operation philosophy. Suitable terminal blocks, gland plates, vibration dampeners, illumination etc. shall be provided in the panels. The panels shall meet the typical specifications outlined below. The details shall be finalized during detailed engineering and subject to Owner’s approval.

1.03.00 SPECIFICATIONS FOR PANELS

a. The panels shall be with protection class of IP-22 (for AC Room), IP-42 (for indoor ventilated location), IP-54 (for indoor non-ventilated location), and IP-55 (for outdoor location). The Contractor shall ensure that the packaging density of equipment in these cabinets is not excessive and abnormal temperature rise is prevented and considering ease of access/ maintenance. Ventilation blowers shall be furnished as required by the equipment design and shall be sound proof to the maximum feasible extent. Suitable louvers with wire mesh shall be provided on the panel.

b. The cabinets shall be designed for front access to major components and rear access to wiring and shall be designed for bottom entry of the cables.

c. The panels shall be totally enclosed, free standing type and shall be constructed with minimum 2 mm thick steel plate frame and 1.6 mm thick CRCA steel sheet. The panels shall be equipped with full height front and rear doors, wherever applicable.

d. The doors shall be hinged and shall have turned back edges and additional bracing where required ensuring rigidity. Hinges shall be of concealed type. Door latches shall be of three-point type to assure tight closing. Detachable lifting eyes or angles shall be furnished at the top of each separately shipped section and all necessary provisions shall be


PANELS



made to facilitate handling without damage. Front and rear doors shall be provided with locking arrangements with a master key for all panels. If width of a cabinet is more than 600 mm, double doors shall be provided.

e. Two spray coats of inhibitive epoxy primer-surface shall be applied to all exterior and interior surfaces. A minimum of 2 spray coats of final finish color shall be applied to all surfaces. The final finished thickness of paint film on steel shall not be less than 65-75 micron for sheet thickness of 2 mm and 50 microns for sheet thickness of 1.6 mm. The finish colors for exterior and interior surfaces shall be finalized during detailed engineering.

f. Paint films which show sags, checks or other imperfections shall not be acceptable.

g. As an alternative, single coat of anodic dip coat primer along with single textured powder coating with epoxy polyester meeting the thickness requirement is also acceptable.

h. Suitable arrangement shall be made for system ground (electronic ground), panel body grounding and power supply grounding.

SPECIFICATION FOR CONTROL VALVES, ACTUATORS &

ACCESORIES STANDARD SPECIFICATION


SUB-SECTION – I11


CONTROL VALVES, ACTUATORS & ACCESSORIES




1.01 GENERAL REQUIREMENTS 1.01.1 The control valves and accessories equipment furnished by the Bidder shall be

designed, constructed and tested in accordance with the latest applicable requirements of code for pressure piping ANSI B 31.1, the ASME Boiler & pressure vessel code, Indian Boiler Regulation (IBR), ISA, and other standards specified elsewhere as well as in accordance with all applicable requirements of the "Federal Occupational Safety and Health Standards, USA" or acceptable equal standards. All the Control Valves, their actuators and accessories to be furnished under this Sub-section will be fully suitable and compatible with the modulating loops covered under the Specification. The specifications outlined below typically pertain to control valves regulated from PLC system through suitable E/P converters.

1.01.2 All the control valves and accessories offered by the Bidder shall be from reputed,

experienced manufacturers of specified type and range of valves. 1.02 CONTROL VALVE SIZING & CONSTRUCTION 1.02.1 The design of all valve bodies shall meet the specification requirements and shall

conform to the requirements of ANSI (USA) for dimensions, material thickness and material specification for their respective pressure classes.

1.02.2 The valve sizing shall be suitable for obtaining maximum flow conditions with valve

opening at approximately 80% of total valve stem travel and minimum flow conditions with valve stem travel not less than 10% of total valve stem travel. All the valves shall be capable of handling at least 120% of the required maximum flow. Further, the valve stem travel range from minimum flow condition to maximum flow condition shall not be less than 50% of the total valve stem travel. The sizing shall be in accordance with the latest edition of ISA handbook on control valves. While deciding the size of valves, Bidder shall ensure that valves trim exit outlet velocity as defined in ISA handbook does not exceed 8 m/sec for liquid services, 150 m/sec. for steam services and 50% of sonic velocity for flashing services. Bidder shall furnish the sizing calculations clearly indicating the outlet velocity achieved with the valve size selected by him as well as noise calculations, which will be subject to Employer's approval during detailed engineering.

1.02.3 Control valves for steam and water applications shall be designed to prevent

cavitation, wire drawing, flashing on the downstream side of valve and down stream piping. Thus for cavitation/flashing service, only valve with anti cavitation trim shall be provided. Detailed calculations to establish whether cavitation will occur or not for any given application shall be furnished. The control valves shall have leakage rate as per leakage Class-IV.

1.02.4 The control valve induced noise shall be limited to 85 dBA at 1 meter from the valve

surface under actual operating conditions. The noise abatement shall be achieved by valve body and trim design and not by use of silencers.




1.03 VALVE CONSTRUCTION 1.03.1 All valves shall be of globe body design & straightaway pattern with single or double

port, unless other wise specified or recommended by the manufacturer to be of angle body type. Rotary valve may alternatively be offered when pressure and pressure drops permit.

1.03.2 Valves with high lift cage guided plugs & quick-change trims shall be supplied. 1.03.3 Cast Iron valves are not acceptable. 1.03.4 Bonnet joints for all control valves shall be of the flanged and bolted type or other

construction acceptable to the Employer. Bonnet joints of the internal threaded or union type will not be acceptable.

1.03.5 Plug shall be of one-piece construction cast, forged or machined from solid bar stock.

Plug shall be screwed and pinned to valve stems or shall be integral with the valve stems.

1.03.6 All valves connected to vacuum on down stream side shall be provided with packing

suitable for vacuum applications (e.g. double vee type chevron packing) 1.03.7 Valve characteristic shall match with the process characteristics. 1.03.8 Flanged valves shall be rated at no less then ANSI press class of 300 lbs. 1.04 VALVE MATERIALS Sr. No. Service Body material Trim Material 1 Heating line Alloy steel ASTM 217 316 SS stellited Gr. WC9 ----------------------------------------------------------------------------------------------------------------------------- NOTE Valve body rating shall meet the process pressure and temperature requirement as per

ANSI B16.34. However, Bidder may offer valves with body and trim materials better than specified materials and in such cases Bidder shall furnish the comparison of properties including cavitation resistance, hardness, tensile strength, strain energy, corrosion resistance and erosion resistance etc. of the offered material vis-a-vis the specified material for Employer's consideration and approval.

1.05 END PREPARATION 1.05.1 Valve body ends shall be either butt welded/ socket welded, flanged (Rubber lined for

condensate service) or screwed as finalised during detailed engineering and as per Employer's approval. The welded ends wherever required shall be butt welded type as per ANSI B 16.25 for control valves of sizes 65 mm and above. For valves size 50 mm




and below welded ends shall be socket welded as per ANSI B 16.11. Flanged ends wherever required shall be of ANSI pressure-temperature class equal to or greater than that of the control valve body.

1.06 VALVE ACTUATORS 1.06.1 All control valves shall be furnished with pneumatic actuators (pneumatically

operated). The Bidder shall be responsible for proper selection and sizing of valve actuators in accordance with the pressure drop and maximum shut off pressure and leakage class requirements. The valve actuators shall be capable of operating at 60 deg.C continuously.

1.06.2 Valve actuators and stems shall be adequate to handle the unbalanced forces

occurring under the specified flow conditions or the maximum differential pressure specified. An adequate allowance for stem force, at least 0.15 Kg/ sq.cm. per linear millimeter of seating surface, shall be provided in the selection of the actuator to ensure tight seating unless otherwise specified.

1.06.3 The travel time of the pneumatic actuators shall not exceed 10 seconds. 1.07 CONTROL VALVE ACCESSORY DEVICES 1.07.1 All pneumatic actuated control valve accessories such as air locks, hand wheels/hand-

jacks, limit switches, Microprocessor based electronic Positioner with integral E/P converter & Position transmitter, diffusers, external volume chambers, reversible pilot for Positioner, tubing and air sets, solenoid valves and junction boxes etc. shall be provided as per the requirements.

1.07.2 SPECIFICATIONS FOR MICROPROCESSOR BASED ELECTRONIC POSITIONER

Input Signal 4-20 mA Hart Protocol Compatibility For Remote

Calibration & Diagnostics (Super-Imposed HART Signal On Input Signal(4-20 mA)

Power Supply Loop Powered from the output card of Control System

1. Electrical

Valve Position Position Sensing (Non Contact- Sensing Type), 4-20 Ma O/P Signal for Control System to be provided.

2. Environment Protection Class IP-65 Minimum 3. Diagnostics Diagnostic/ Test Features Advanced Diagnostic Features

Like Stroke Counter Or Travel Counter, Leakage In Actuators, On Line Partial Closure Test, Valve Signature Analysis, Step Response Test, Valve Friction




/Jamming Detection Etc To Be Provided

4. Factory Valve Signature Tests Reports (Pr Vs Valve Travel And Travel Vs I/P Signal) are to be provided.

Valve Action Direct & Reverse acting 5. Modes Flow Characterization Possible To Fit Valve

Characteristic Curve Linear & Equal Percentage.

6. Fail Safe/Fail Freeze

Fail Safe/ Fail Freeze Feature is to be provided.

Air Capacity Sufficient To Handle The Valves Selected/ Boosters To be supplied if required.

Air Supply Pressure To Suit The Air Supply Pressure/ Quality Available.

7. Pneumatic

Process Connection 1/4 Inch NPT 8. Performance Characteristic Deviation <=0.5 % Of Span

In Built Operator panel Hand Held Hart Calibrator Valves Mounting Assembly

9. Accessories

Press Gauge Block ----------------------------------------------------------------------------------------------------------------------------- 1.08 TEST AND EXAMINATION 1.08.1 All valves shall be tested in accordance with the quality assurance programme agreed

between the Employer and Contractor, which shall meet the requirements of IBR and other applicable codes mentioned elsewhere in the specifications. The tests shall include but not be limited to the following:

1.08.2 Non Destructive Test as per ANSI B-16.34. 1.08.3 Hydrostatic shell test in accordance with ANSI B 16.34 prior to seat leakage test. 1.08.4 Valve closure test and seat leakage test in accordance with ANSI-B 16.34 and as per

the leakage class indicated above. 1.08.5 Functional Test: The fully assembled valves including actuators control devices and

accessories shall be functionally tested to demonstrate times from open to close position.

1.08.6 CV Test: CV test shall be carried out as type test on each size, type and design of

the valves as per ISA 75.02 standard and test report shall be furnished for Employer's approval.

SPECIFICATION FOR PRESSURE MEASUREMENT

INSTRUMENTS STANDARD SPECIFICATION

DOCUMENT NO.: REL-COENG-NEN-443-P-00001 R0 SUB-SECTION – I 2 Page 1 of 8

SUB-SECTION: I 2


PRESSURE MEASUREMENT INSTRUMENTS




1.0 General

The specifications for the pressure measurement instruments viz. Pressure/ Differential Pressure gauges/ switches, Pressure/ Differential pressure transmitters etc. are outlined below. The technical specifications are outlined below. The ranges and other particulars shall be as per the process requirement, finalized P&IDs, BOQ/ Instrument List etc.. All required accessories for the completeness of the instruments shall be supplied along with the instruments.

1.01 Codes & Standards The design, manufacture, inspection, testing, site calibration and installation of all

equipment and systems covered under this specification shall conform to the latest editions of codes and standards mentioned below and all other applicable ANSI, ASME, IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their equivalents.

1.01.1 Pressure Measurement

a) Instrument and apparatus for pressure measurement - ASME PTC 19.2 (1964)

b) Bourdon tube pressure and vacuum gauges - IS 3624 – 1996

c) Specification for absolute and gauge pressure transmitters with electrical outputs - BS 6447/ IEC 60770

1.01.2 Electronic measuring Instruments & Control hardware a) Automatic null balancing electrical measuring instruments - ANSI C 39.4

(Rev. 1973)

b) Safety requirements for electrical and electronic measuring and controlling instrumentation - ANSI C 39.5 - 1974.

c) Compatibility of analog signals for electronic industrial process instruments - ISA-S 50.1: ANSI MC 12.1 - 1975.

d) Surge withstand capability (SWC) tests - ANSI C 37.90.1/ IEC - 254.1

e) Printed circuit boards - IPC TM-650, IEC 326 C

f) General requirements and tests for printed wiring boards -IS 7405 (Part-I) - 1973

g) Edge socket connectors - IEC 130-11.

h) Dimensions of attachment plugs & receptacles ANSI C73-1973.

i) Direct acting Electrical Indicating Instruments: IS-1248-1968.

1.01.3 Instrument Switches and Contacts




a) Contact rating - AC services NEMA ICS Part-2 125, A600 b) Contact rating - DC services NEMA ICS Part-2-125, N600.

1.01.4 Enclosures

a) Types of enclosures - NEMA Std. ICS-6-110.15 through 110.22 (Type 4 to 13). b) Racks, panels, and associated equipment - EIA: RS-310-B (ANSI C83.9 -

1972) c) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-60947.

1.01.5 Apparatus, enclosures and installation practices in hazardous areas

a) Classification of hazardous area - NFPA Art. 500, Vol.70-1984.

b) Electrical Instruments in hazardous dust locations - ISA-RP 12.11

Notes:

1. All the field instruments shall also be provided with SS tag nameplate and double compression type Nickel-plated brass cable gland. Counter and mating flange shall also be included wherever required with instruments.

2. All instruments falling under hazardous area shall have suitable explosion proof EExd housing or provided with an intrinsic barrier that shall meet the area classification guidelines as per the service and applicability requirement.

3. The equipments shall be designed and constructed to withstand ambient temperature extremes and relative humidity conditions as specified under project environment conditions. For the various Instruments which are employed in the sea side environment, suitable protective coating like epoxy coating etc. shall be provided on the instruments body/ impulse piping etc. For applications where the medium is sea water based, the wetted parts of the instruments shall be of corrosion resistant material like Hastelloy C or Monel etc.




2.0 Technical specifications 2.01 Pressure/ Differential Pressure Gauge

01. Type : Bourdon / Bellows / Diaphragm

02. Sensing Element Material

: AISI SS 316 ( Also Refer Note 3 )

03. Movement Materials : AISI 304 SS

04. Case Material : Die cast aluminum

05. Protection Class IP 65 or better

06. Dial Size : 100 mm

07. Scale : Black lettering on white background in 270 °C arc

08. Range Selection : Normally operate at 75% of its maximum pressure range. Instruments measuring varying pressures shall operate in a band of 60%-80% of its maximum pressure range.

09. Over range Protection

: 150% of maximum range by internal stop. External stop below zero.

10. Adjustment : External Micrometer screw for zero adjustment. Internal micrometer screw for range adjustment.

11. Stop at Max. Reading : Shall be provided

12. Element Connection : Argon welding

13. Process Connection : ½” NPT(M) bottom connection for local mounting, back connection for panel mounting

14. Accuracy : +1.0% of span or better

15. Operating Ambient Temperature

: 50 ˚C (Max. continuous)

16. Safety Feature : Neoprene Safety Diaphragm (Blowout disc) at the back

17. Feature : Shatter-proof glass




18. Chemical Seal Unit : SS 316 Flange and Diaphragm(Silver coated for corrosive services), PTFE coated/ block, Silicone Oil filling fluid

19. Accessories : Pulsation dampers for pulsating fluid applications / 3-way gauge cock / 2-valve manifold / Pigtail / Siphon for steam service / Gauge Saver, if maximum or Design Pressure is very high than the Operating Pressure/ Counter Flange/ Bolts, Nuts, Gaskets / SS Tag Plate

2.02 Pressure / Differential Pressure Switch

01. Type : Diaphragm / Bourdon / Bellows / Piston actuated – Teflon back-up sheath protection, as required.

02. Sensing Element material

: AISI 316 SS ( Also Refer Note 3 )

03. Wetted Parts material : SS 316 ( Also Refer Note 3 )

04. Case Material : Epoxy coated Die Cast Aluminium

05. Setter Scale : Black graduation on white linear scale. Graduation 0 – 100% with red pointer for set points.

06. Over range for Pressure / Vacuum Switch

: 150% of maximum pressure

07. Set Point : Adjustable in switch operating range.

08. Static Pressure for Differential Pressure Switch

: Maximum Line Pressure or Static Pressure on either side without permanent deformation or loss of accuracy.

09. Adjustments Internal – set point

10. Process Connection : ½” NPT(M) bottom connected

11. Switch Configuration : 2 SPDT / 1 DPDT

12. Switch Rating : 230 V, 5A AC / 60 V, 0.1A DC




13. Switch Type : Snap acting, shock and vibration-proof

14. Terminal Block : Suitable for full ring lugs for 0.5 to 1.5 Sq.mm. cable connection

15. Cable Connection : ¾” ET conduit connection or compression gland

16. Enclosure Class : IP 65 or better.

17. Performance a. b.

Accuracy of setting : 1% of span up to 3Kg/cm2 & 0.5% of span for more than 3 Kg/cm2. Repeatability : 0.5% of span


: 50 Deg. C (maximum continuous)

19. Accessories : a) Snubbers for pulsating fluid application.

b) Tag Number, service engraved in SS tag plate.

c) i) Remote diaphragm seal with SS 316 armored capillary for viscous, slurry & corrosive applications. MOC (Material of Construction) of seal material shall be as per process fluid requirement. ii) Silver/ Teflon coated diaphragm for highly corrosive services like chlorinated water.

d) Retention ring and screws for surface mounting.

e) 3-way Gauge Cock (SS 316) for PS / 5-Valve Manifold (SS 316) for DPS.

f) ¾” ET double compression brass cable gland etc.

2.03 Transmitters: PT / DPT

01. Type : 2-Wire, Smart (HART)

02. Output Signal : 4-20 mA signal superimposed with HART signal.




03. Signal Processing Unit

: Microprocessor based

04. Static Pressure/ Overload Pressure for DPT, Static Pressure/ Overload Pressure for PT

: Maximum line (or static) pressure on either side without permanent deformation or loss of accuracy, 150 percent of maximum span continuously, without affecting the calibration.

05. Turn-down Ratio : 10: 1 for vacuum/ very low pressure applications. 30:1 for other applications.

06. Span and Zero : Continuously adjustable, non-interacting & both local & remote calibration facility.

07. Enclosure Class : IP 65 or better with durable corrosion resistant coating.

08. Zero Suppression/ Elevation

: At least 100% of span

09. Local Indicator : To be provided

10. Display : Digital LCD Integral Display (minimum 5 digit) Engineering Unit

11. Body and its rating

: a) Stainless Steel/ 1.5 times the maximum fluid pressure for DPT.

b) Forged Carbon Steel Rating : 1.5 times the maximum fluid pressure (minimum) for PT.

12. MOC of Electrical Housing

: Aluminum Alloy or better

13. Ambient Temperature

: 65 Deg. C

14. Operating Voltage : 16 – 48 Volts DC

15. Load : 600 Ohms (minimum) at 24 Volts DC

16. Accuracy : ± 0.075% of span or better

17. Sealing / Isolation : i) Extended diaphragm with 5 mtrs. SS




armored capillary for corrosive, viscous and dirty fluid applications. Material for separator diaphragm, depending on application. ii) Silver/ Teflon coated diaphragm for highly corrosive services like chlorinated water.

18. Accessories : a) Universal mounting bracket suitable for 2 inch pipe and wall mounting.

b) High tensile carbon steel U-bolts.

c) Installation accessories as per relevant installation drawing.

d) Snubbers for pulsating pressure, siphons for steam and hot water services.

e) 3-valve SS 316 manifold for DPT/ 2-valves SS 316 manifold for PT/ 3-valve SS 316 manifold whenever DPT are used for pressure measurement, constructed from bar stock. Manifold shall be non-integral type. Manifold process side and instrument side connection shall be ½ NPT (F). Suitable drain/ vent holes with caps shall be provided.

f) Companion flange with nuts, bolts and gaskets.

g) Brass, Double compression cable gland with each instrument.

SPECIFICATION FOR TEMPERATURE MEASUREMENT


DOC. NO.: REL-COENG-NEN-444-P-00001 R0 SUB-SECTION- I 3 Page 1 of 7

SUB-SECTION - I 3


TEMPERATURE MEASUREMENT INSTRUMENTS




1.00 General

The specifications for the Temperature measurement instruments viz. Temperature gauges/ switches, Resistance Temperature Detectors (RTDs) etc. are outlined below. The technical specifications are outlined below. The ranges and other particulars shall be as per the process requirement, finalized P&IDs, BOQ/ Instrument List etc.. All required accessories for the completeness of the instruments shall be supplied along with the instruments.

1.01 Codes & Standards The design, manufacture, inspection, testing, site calibration and installation of all equipment and systems covered under this specification shall conform to the latest editions of codes and standards mentioned below and all other applicable ANSI, ASME, IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their equivalents.

1.01.1 Temperature Measurement

a) Instrument and apparatus for temperature measurement ASME PTC 19.3 (1974)

b) Temperature measurement - Thermocouples ANSI-MC 96.1 - 1982.

c) Temperature measurement by electrical resistance thermometers-IS 2806, DIN 43760.

d) Thermometer-element-platinum resistance - IS-2848.

1.01.2 Electronic measuring Instruments & Control hardware a) Automatic null balancing electrical measuring instruments - ANSI C 39.4

(Rev. 1973)



d) Dynamic response testing of process control instrumentation - ANSI MC 4.1 (1975): ISA-S26 (1968).

e) Surge withstand capability (SWC) tests - ANSI C 37.90.1

f) Printed circuit boards - IPC TM-650, IEC 326 C

g) General requirements and tests for printed wiring boards - IS 7405 (Part-I) - 1973

h) Edge socket connectors - IEC 130-11.

i) Dimensions of attachment plugs & receptacles ANSI C73-1973.

j) Direct acting Electrical Indicating Instruments: IS-1248-1968.





a) Contact rating - AC services NEMA ICS Part-2 125, A600

b) Contact rating - DC services NEMA ICS Part-2-125, N600.

1.01.4 Enclosures

a) Types of enclosures - NEMA Std. ICS-6-110.15 through 110.22 (Type 4 to 13).

b) Racks, panels, and associated equipment - EIA: RS-310-B (ANSI C83.9 - 1972)

c) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-60947.




Notes:



3. The equipments shall be designed and constructed to withstand ambient temperature extremes and relative humidity conditions as specified under project environment condition later. For the various Instruments which are employed in the sea side environment, suitable protective coating like epoxy coating etc. shall be provided on the instruments body/ impulse piping etc. For applications where the medium is sea water based, the wetted parts of the instruments shall be of corrosion resistant material like Hastelloy C or Monel etc.




2.0 Technical Specifications 2.01 Temperature Indicator (Temperature Gauge)

01. Type : Bimetallic type/ Mercury filled

02. Stem : SS 316

03. Movement Materials : SISI 304 SS / Direct Bourdon tip connection to pointer spindle

04. Case Material : Die cast aluminium

Protection Class IP65 or better.

05. Dial Size : 100 mm

06. Scale : Black lettering on white background in 270 °C arc

07. Adjustment : Micrometer screw for zero adjustment. Internal micrometer screw for range adjustment.

08. Pointer : Externally Adjustable

09. Range Selection : Normal Process Temperature – approximately two third of Temperature range.

10. Stop at Max. Reading : Shall be provided

11. Over range Protection : 150% of FSD

12. Instrument Connection : Bottom connection for local mounting, back connection for panel mounting.

13. Process Connection : ½” NPT with Thermowell

14. Accuracy : +1.0% of full scale or better


: 50 ˚C (Max. continuous)

16. Accessories : Counter Flanges / Bolts, Nuts, Gaskets / SS Tag plate, SS Thermowell etc.

17. Feature : All angle type




2.02 Temperature Switch

1. Type : Bi-Metallic/ Mercury filled Type 2. Movement material : AISI 304 SS 3. Enclosure : Die cast aluminum conforming IP 65 or

better. 4. Setter scale : Black lettering on white background 5. Over range protection : 120 percent up to 400 Deg.C. 6. Instrument connection : Bottom connection for local mounting, back

connection for panel mounting 7. Switch configuration : 2 SPDT 8. Switch rating : 240V, 5A AC/60 V, 0.1 A DC 9. Switch type : Snap acting, shock and vibration proof 10. Adjustability : Set point adjustable over span range 11. Cable connection : 3/4” with cable gland 12. Performance a) Accuracy : ±1.0% of full scale b) Repeatability : Less than 0.5 percent of full range c) Response time : Less than 8 Secs. Bared

2.03 Resistance Temperature Detector (RTD)

01. Type : Platinum ( Duplex) Ungrounded

02. Resistance : 100 ohm at 0 deg C

03. Base : Wound on Ceramic ( anti – inductive)

04 Wiring : 3 Wire

05 Response Time : < 15 seconds

06 Sheath Material & OD : 316 SS with swaged type Magnesium oxide insulation, spring loaded & 6mm.




07 Accuracy & Characteristic

: As per DIN-43760 Class – A for RTD.

08 Immersion length/ Extension neck length

: As required. Bidder shall furnish calculations for length based on pipe size, fluid velocity etc.. Consideration for stub/ insulation etc. shall be suitably kept.

09 Process Connection : ½ “ NPT (M) with thermowell

10 Head

Protection : IP 65

Material : Die Cast Aluminium.

11 Cable Connection : ¾ “ ET Brass, Double compression cable gland

12 Accessories : a) Adjustable Nipple-Union-Nipple with thermowell

b) Compression fittings / unions

c) Flanges etc.

d) Thermowell

2.04 Thermo well

01. Material : a. AISI 316 SS drilled from bar stock, for normal applications b. Monel for corrosive services

02. Process connection : Based on equipment manufacturer process connection/ stubs. Typically M33 x 2.

03. Max Internal bored dia : Shall match with temperature Element

04. Bore Connection : ±5% wall thickness

05. Identification Mark : Tag Number punched on head

06. Surface Treatment : Polish after machining

07. Element Connection : ½ “ NPT (F)

08. Certification : ASME Performance Test Code 19.3-1974




09. Accessories : Plug and chain for test thermowells

SPECIFICATION FOR FLOW MEASUREMENT

INSTRUMENTS/ FLOW ELEMENTS STANDARD SPECIFICATION


SUB- SECTION – I 4


FLOW MEASUREMENT INSTRUMENTS/ FLOW ELEMENTS




1.00 General

The specifications for the flow measurement instruments viz. Flow gauges/ switches, Flow transmitters, Flow meters etc. are outlined below. The technical specifications are outlined below. The ranges and other particulars shall be as per the process requirement, finalized P&IDs, BOQ/ Instrument List etc.. All required accessories for the completeness of the instruments shall be supplied along with the instruments.

1.01 Codes & Standards

The design, manufacture, inspection, testing, site calibration and installation of all equipment and systems covered under this specification shall conform to the latest editions of codes and standards mentioned below and all other applicable ANSI, ASME, IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their equivalents.


a) Instrument and apparatus for pressure measurement - ASME PTC 19.2 (1964)

b) Bourdon tube pressure and vacuum gauges - IS 3624 – 1996

c) Specification for absolute and gauge pressure transmitters with electrical outputs - BS 6447/ IEC 60770

1.01.2 Flow Measurement

a) The flow elements (Orifice plates) shall be designed in accordance with ASME PTC – 19.5 (Pt – II), ISA RP3.2, 1960 or BS 1042.

b) The flow elements (Flow Nozzles) shall be designed in accordance with ASME PTC – 19.5 (Pt – II), or BS 1042.

1.01.3 Electronic measuring Instruments & Control hardware

a) Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev. 1973)




e) Surge withstand capability (SWC) tests - ANSI C 37.90.1/ IEEE Std. 472 (1974). IEC - 254.1







i) Requirements and methods of testing of wire wrap terminations DIN 41611 Part-2.

j) Dimensions of attachment plugs & receptacles ANSI C73-1973.

k) Direct acting Electrical Indicating Instruments: IS-1248-1968.




1.01.5 Enclosures



c) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-60947.




Notes:



3. The equipments shall be designed and constructed to withstand ambient temperature extremes and relative humidity conditions as specified under project environment conditions. For the various Instruments which are employed in the sea side environment, suitable protective coating like epoxy coating etc. shall be provided on the instruments body/ impulse piping etc. For applications where the medium is sea water based, the wetted parts of the instruments shall be of corrosion resistant material like Hastelloy C or Monel etc.




2.0 Technical Specifications 2.01 Rotameter

01. Type : ON-LINE for line up to and including 50 mm NB Bypass type with orifice for line size above 50 mm.

02. Metering tube : Borosilicate

03. Float material : AISI 316 SS unless the process fluid demands some other material

04. End fittings : AISI 316 SS unless otherwise mentioned in the data sheets

05. Packing material : Teflon / PTFE

06. Casing material : Die cast aluminum conforming to IP 65 or better

07. Gland Rings / Followers material

: Steel

08. Scale : 250 mm nominal length

09. Graduation : Direct reading

10. Process Connection : Flanged (RF) to line size as per ANSI standards for on-line type & 1/4 inch 150 lbs (RF) ANSI flange for bypass type.

11. Accuracy : +/- 2% of full scale reading

12. Reproducibility : Within 0.5% of instantaneous reading

13. Accessories : Slip-on orifice plate of 316 SS Carrier range Orifice - for bypass type rotameters. (For line size above 50mm)

2.02 Flow Switch

01. Type : Vane / Paddle Type

02. Switch Configuration : 2 SPDT / 1 DPDT , micro type

03. Switch Rating : 240 V, 5A AC / 60 V, 0.1A DC

04. Enclosure : Die cast aluminium conforming IP 65 or better




05. Repeatability : + / - 0.5% of FSD or better

06 Adjustments : a) Internal – set point adjustable in switch operating range

b) ON-OFF differential

07 Connection type : Flanged / Screwed

2.03 Transmitters: DPT Type Flow Tx (to be provided along with flow element)



03. Signal Processing Unit

: Microprocessor based

04. Static Pressure / Overload Pressure for DPT


05. Turn-down Ratio : 10: 1 for vacuum/ very low pressure applications. 30:1 for other applications.








: a) Stainless Steel/ 1.5 times the maximum




fluid pressure for DPT.

b) Forged Carbon Steel Rating : 1:5 times the maximum fluid pressure (minimum) for PT.



13. Ambient Temperature

: 65 Deg. C




17. Sealing / Isolation : i) Extended diaphragm with 5 mtrs. SS armored capillary for corrosive, viscous and dirty fluid applications. Material for separator diaphragm, depending on application. ii) Silver/ Teflon coated diaphragm for highly corrosive services like chlorinated water.




d) Snubbers for pulsating pressure, siphons for steam and hot water services.

e) 3-valve SS 316 manifold, oval flange connection to transmitter body, constructed from barstock. Manifold shall be non-integral type. Manifold process side and instrument side connection shall be ½ NPT (F). Suitable drain/ vent holes with caps shall be provided.

f) Companion flange with nuts, bolts and




gaskets.


h) Two handheld Calibrators for each unit.

2.04 Electromagnetic Flow Meter / Transmitter

2.04.01 Sensor

01. Type : Sensor with flanges

02. Electrodes : 316 SS

03. Liner : Hard rubber or Neoprene

04. Enclosure : IP 65 or better with durable corrosion resistant coating.

05. Accessories : Counter flanges, Mounting nuts, bolts, gaskets etc.

06 Pipe Dia. As per P&ID/ Instrument List

2.04.02 Transmitter

01. Input Signal Processing : Microprocessor based

02. Display : Digital Display (LCD)

03. Output : 4-20 mA DC

04. Power Supply : 230 V AC, 50 Hz/ 24 V DC (loop powered)

05. Turn Down : 100 : 1

06. Accuracy : ±0.5% of calibrated span

07. Repeatability : ±0.05%

08. Housing : IP 65 or better with durable corrosion resistant coating

09. Accessories : a) Counter Flanges as required for field




mounting

b) Handheld Configurator

c) Mounting U-bolts, nuts, bolts, prefab cable etc.

d) ¾ “ ET Cable Gland.

e) SS Tag plate etc.

2.05 Ultrasonic Flow Meter/ Transmitter

01. Type : Transit time Clamp On Ultrasonic meter

02. Mounting Style : Dual path with two sets of transceivers on the same pipe

03. Flow measurement : Instantaneous Flow rate as well as totalized flow

04. Power supply : 230 V AC, 50 Hz/24 V DC (loop powered)

05. Outputs : Analog Current Binary Communication ports

:

Isolated 4-20mA linear outputs for each path Contact relay outputs, 2 NO + 2 NC for alarm RS 232 C digital Hand held terminal port

06. Display/ Indication

:

Flow meter with LCD screen backlight based local display and keypad. If required, transmitter shall be suitably located away from the sensor for better access and visibility.

07. Recording/ Totalizing/ Logging Facilities :

Yes. Should be able to compute cumulative flow over intervals selectable by owner i.e., daily, weekly, monthly etc. The data shall be stored in the memory of flow computer for access in future.

08. Software features : Compensation for any cross path errors Programming, configuration shall be




possible from front panel.

09. Diagnostics : False signal tolerance , power supply failure etc.

10. Protection class :

IP 65 or better, Weather protection against direct sunlight, rain etc for Flow meter and suitable for Cooling water for Transducer

11. Accuracy : +/- 1%

12. Electrical connection : Plug and socket

13. Accessories

:

All mounting hardware required like clamping fixtures, mechanism to remove the transducers online, interconnecting cables etc All weather canopy for protection from direct sunlight and direct rain. Material of all fittings shall be SS 316.

2.06 Vortex Flow transmitter

01. Type : 2-Wire, Smart (HART) 02. Output Signal : 4-20 mA

03. Signal Processing Unit : Microprocessor based

04. Accuracy : 1.0% of reading

05. Repeatability : 0.5% of reading

06. Vortex Shedder : SS 316

07. Mounting : In Line 08. Construction : Stainless steel wetted parts with

ceramic/ Cast Aluminium transducers 09. Display : LCD Based 10. Enclosure :

IP 65 2.07 Parshall Flume type Flow Transmitter For flow measurement in open channel, Parshall flume type flow meter shall be provided.

The flow shall be computed by measuring the head difference in the Parshall flume. The level measurement shall be carried out by using ultrasonic type level transmitter. Bidder shall provide all required primary sensors, transmitters, flow computation electronics,




flow indicator & totalizer and other required accessories. System shall be of reputed make and acceptable to Owner / Engineer.

Flow signal from the system shall be in the form of analog output of 4 – 20 mA DC with

an accuracy of + 1 % or better. Field mounted local flow indication facility shall also be provided. The enclosure should conform to IP 65 or better and corrosion resistant. Bidder shall provide all required details of weir/ flume construction and the

calculations. 2.08 Mass Flow Meter This shall typically be used for fuel oil/gas flow metering.

Type : Smart

Working Principle : Coriolis principle

Output signal : 4-20 mA signal superimposed with HART signal

Operating Voltage : 16-48 V DC.

Transmission : 2-wire

Material Of Wetted Parts

: SS 316L

Enclosure Class : IP-65 with durable corrosion resistant coating/ Ex. Proof as required.

Display : LCD for flow rate, temp, density & total flow.

Process connection : ANSI RF Companion flange with nuts, bolts and gaskets.

Performance

i)Accuracy (Combined)

: + 0.15% of span or better.

ii) Repeatability : + 0.5% of span or better.

Accessories : a) ANSI RF Counter Flange; rating as per process pressure. Necessary nuts, bolts, gaskets etc.




Nameplate : Tag no. , range service, make, model no. etc. engraved in stainless steel tag plate.

FLOW ELEMENTS 2.09 Orifice Plate

01. Type : Concentric square edge type or Segmental bored type as per type of process.

02. Design Standard : BS1042 / ISO 5167.

03. Material of Orifice Plate & Rating : 316 SS, Orifice flange rating will be the same as the

piping class.

04 Thickness : 3 mm for the pipe diameter up to 300 mm and 6 mm for the pipe diameter above 300mm.

05 Beta Ratio : Between 0.4 and 0.7

06 Pressure Tap : Flange type, 3 (Triple) sets

07 No. of Root Valves per tapping

: 1) Two for static pressure above 40kg/ cm2. 2) One for static pressure up to 40 kg/cm2.

08 Root valve type/ material

Globe valve/ 316 SS

09 Vent Hole / Drain Hole : Yes (Vent hole for liquid applications & Drain hole for steam/ gas applications)

10 Accuracy : +/-1%

11 Accessories

:

a) Orifice plate will be provided with a Handle. Tag number, orifice plate material, measured bore and ID of the pipe will be stamped or deep engraved on the upstream face of the Handle.

b) Jack bolt shall be provided for easier removal.

c) Male female carrier ring of SS316 material shall be provided

d) Studs and nuts material shall be ASTM A193 Gr. B7 / A194 Gr. 2H




e) Other mounting accessories as applicable

12 Data/ Documents to be submitted

Beta Ratio calculation, DP Vs Flow curves, Assembly drawing, Calibration certificate

2.10 Flow Nozzle

01 Design Standard/ Type : BS 1042, ASME PTC 19.5 (1972)/ Long Radius, welded type

02 Material of Nozzle : AISI 316 SS or better

03 Pressure Taps : D – D/2 taps– 3 Sets

04 Beta Ratio : Around 0.7

05 No. of Root Valves per tapping

: 1) Two for static pressure above 40kg/cm2.

2) One for static pressure up to 40 kg/cm2.

06 Root valve type/ material Globe valve/ 316 SS

07 Accessories : Mounting accessories including branch pipe/ spool piece of same material as main pipe, as applicable

08 Vent Hole / Drain Hole Yes (Vent hole for liquid applications & Drain hole for steam applications)

09 Data/ Documents to be submitted

Beta Ratio calculation, DP Vs Flow curves, Assembly drawing, Calibration certificate

2.11 Impact Head Type Flow Element / Averaging Pitot Tube This will typically be used for CW flow measurement.

01. Type : Flanged with opposite side support.

02. Number of Holes : As per Chebyshef Calculus

03. Material of Construction a) Sensor b) Instrument Head c) Instrument Valve

: 316L SS 316 SS Carbon Steel




d) Mounting Hardware

Carbon Steel

04. Piping Orientation : Horizontal

05. Accuracy : + 1.0 % of actual value or better

06. Repeatability : + 0.1 % of actual value or better

07. Flow Turn Down : Greater than 10:1

08. Process Connection : 3” ANSI 300#

09. Accessories : Mounting accessories as applicable, complete flushing arrangement with requisite piping valves etc. using instrument/ service air.

SPECIFICATION FOR LEVEL MEASUREMENT



SUB-SECTION - I 5


FOR

LEVEL MEASUREMENT INSTRUMENTS




1.00 General

The specifications for the level measurement instruments viz. level gauges, different types of level switches, different types of level transmitters etc. are outlined below. The technical specifications are outlined below. The ranges and other particulars shall be as per the process requirement, finalized P&IDs, BOQ/ Instrument List etc.. All required accessories for the completeness of the instruments shall be supplied along with the instruments.

1.01 Codes & Standards The design, manufacture, inspection, testing, site calibration and installation of all

equipment and systems covered under this specification shall conform to the latest editions of codes and standards mentioned below and all other applicable ANSI, ASME, IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their equivalents.


a) Specification for absolute and gauge pressure transmitters with electrical outputs - BS 6447/ IEC 60770

1.01.2 Electronic measuring Instruments & Control hardware

a) Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev. 1973)




e) Surge withstand capability (SWC) tests - ANSI C 37.90.1




i) Dimensions of attachment plugs & receptacles ANSI C73-1973.

j) Direct acting Electrical Indicating Instruments: IS-1248-1968.







1.01.4 Enclosures



c) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-60947




Notes:



3. The equipments shall be designed and constructed to withstand ambient temperature extremes and relative humidity conditions as specified under project environment condition later. For the various Instruments which are employed in the sea side environment, suitable protective coating like epoxy coating etc. shall be provided on the instruments body/ impulse piping etc. For applications where the medium is sea water based, the wetted parts of the instruments shall be of corrosion resistant material like Hastelloy C or Monel etc.




2.00 Technical Specifications 2.01 Level Indicator (Gauge Glasses)

01. Type : Reflex

02. Glass : Toughened in moulded borosilicate resistant to thermal shock

03. Glass Cover : Carbon Steel

04. Gauge Body Material : Die cast aluminum conforming to IP 65 or better.

05. Integral Cocks and Valves : i) SS 316

ii)

Rubber lined corrosion resistant stainless steel (for Demineralised and Osmosis water service)

06. Fittings : i) SS 316 / Rubber lined Steel / PVC for Corrosive liquids, Demineralised and Osmosis Water Service).

ii)

304 Stainless Steel for non-corrosive liquids

07. Packing material : Teflon

08. Scale : Aluminum

09. Scale Details : Graduated in mmwc (10 mm minimum)

10. Accuracy : +1.0% of span or better

11. Vessel Connection : ANSI Flanged SS 316 with SS 316 mating flanges, steel bolts and nuts, CAF gaskets

12. Accessories : a) Integral Cocks

b) Drain Valves

c) Bolts, nuts and gaskets

d) Companion flange with fastener




13. Tests : Tested at two hundred (200) percent of the maximum process pressure

14. Other Details : For larger lengths (greater than 1200 mm), additional gauge glasses shall be provided with minimum of 50 mm overlap.

2.02 Level Indicator (Float & Board)

01. Type : Float and Board

02. Float Material : ANSI : 316 SS

03. Pulley Material : Cast Aluminium pulley housing with SS 304 pulley and pulley shaft

04. Guide Wire : AISI : 316 SS

05. Scale Board : Anodized Aluminium with engraved marking (minimum graduation 10 mm)

06. Flange : RF, ANSI 150, CS

07. Accuracy : + 10 mm or better

08. Protection Class : IP 65 or better

09. Accessories : All mounting accessories including SS 316 Anchor Bar

2.03 Float Operated External Cage Type Level Switch

01. Float Material : AISI 316 Stainless Steel

02. Wetted Parts : AISI 316 Stainless Steel

03. Float Chamber : Carbon Steel, Welded Construction

04. Float Chamber Mounting : Side Mounted

05. Fluid Connection : Side – Side

06. Size of the float chamber : To suit requirement

07. Fluid Connection Size : 1” ANSI RF Flange (rubber line, if




required).

08. Drain : ½” NPT(F) with Plug

09. Pressure Rating of Chamber

: Minimum 1.5 times of design pressure

10. Repeatability : ±1.5 mm or better

11. Accuracy : +15mm or better

12. Switch Housing : Die cast aluminum conforming IP-65 or better

13. Type of Switch : Snap acting , shock and vibration-proof

14. Switch Configuration : 2 SPDT / 1 DPDT

15. Switching Differential : Preferably Adjustable

16. MOC of Switching Mechanism

: AISI 304 Stainless Steel

17. Contact Rating : 5A, 240 V AC / 0.1A, 60 V DC

18. Cable Entry : ¾” ET

19. Cable Gland : Brass, Double Compression

20. Accessories : a) Counter flange, nuts & bolts, suitable gasket etc.

b) SS Tag Plate etc.

21. Preferred Feature : Switch operating point marked on cage.

2.04 Top Mounted Displacer Operated Level Switch

01. Displacer : SS 316

02. Displacer Assembly : ANSI SS 316 Stainless Steel

03. Wire Rope / Spring : SS 316

04. Guide Pipe : Mild Steel

05. Process : ANSI CS Flange with Gaskets, Nuts & Bolts




Connection

06. Repeatability : ±3 mm or better

07. Switch Housing : Die cast Aluminium with anti-corrosive paints

08. Switch Housing Protection

: IP-65

09. Type of Switch : Snap acting, vibration resistant, mercury bottle or hermitically sealed micro switch type magnetically coupled to the displacer.

10. Switch Configuration

: 2 SPDT / 1 DPDT

11. MOC of Switching Mechanism

: AISI 304 Stainless Steel

12. Contact Rating : 5A, 240 V AC / 0.1A, 60VDC

13. Cable Entry : ¾” ET

14. Cable Gland : Brass, Double compression

15. Accessories : Counter flange, nuts & bolts, suitable gasket etc.

SS Tag Plate etc 2.05 Capacitance Type Level Switch 1. Type : Capacitance type 2. Probe : a) Rod or suspended electrode

b) Stainless steel 1-1/2 ANSI RF Flange / ¾“ NPT (M)

c) Material : SS 316

d) Insulation: Part / Full as required by service

condition (Polypropylene / Teflon).

e) Rope type probes may be used only where required probe length is greater than 3 meters. Rope shall be made of 316 SS.

f) Coated with PTFE sheath.




3. Pre-amplifier : a) Solid state electronic module to be mounted on probe head b) Protection class - IP -65.

c) Ambient temperatures-0 Deg.C. to 80 Deg.C. (Automatic temperature compensated.).

d) Function: The pre-amplifier unit converts the variation in capacitance into a variable voltage signal.

4. Control Unit Function : The control unit converts the output of pre-amplifier into contact output

5. Enclosure : Powder/Epoxy coated Die cast aluminium. 6. Ambient temperature : 0-80 ºC. 7. Supply voltage : 240V AC, 50Hz 8. Relay output : 2 SPDT 9. Contact rating : 5A, 240V AC / 0.1A, 60VDC 10. Cable connection : ¾” ET

11. Accessories : Counter flange, Cable gland, prefab / special cable and stainless steel name plate engraved with alpha-numeric.

2.06 RF Type Level switch 1. Sensing Probe : RF type a) Material : SS 316 b) Mounting : Threaded / Flange c) Enclosure Protection : IP 65 d) Enclosure Housing : Cast Aluminium. e) Probe Insertion length : By Bidder (As per Vessel G.A)

f) Rated pressure and : By Bidder (As per process parameter) temperature




2. Electronic Controller : a) Power Supply : 240VAC, 50 Hz b) Relay Output : 2 SPDT c) Contact Rating : 240V AC, 5A / 0.1A, 60VDC d) Enclosure Protection : IP 65 e) Enclosure Housing : Cast Aluminium. f) Repeatability : + / - 0.5% of FSD 3. Cable : Coaxial from probe to controller. 4. Gland : ¾ inch ET 5. Accessories : i) Mounting Hardware, as required. ii) SS Tag plate 6. Application : ESP/ECO/AHP Hoppers 2.07 Oil Level switch for cooling towers gear box

As specified under scope of work, oil level switch shall be provided on the gear reducer for cooling towers. The switch shall disengage the fan motor on low oil level. This shall be typically external cage type float operated level switch. Suitable arrangement shall be made to mount this instrument outside the fan enclosure.

2.08 DPT Type Level Transmitter



03. Signal Processing Unit : Microprocessor based

04. Static Pressure / Overload Pressure for DPT


05. Turn-down Ratio : 10: 1 for vacuum / very low pressure applications. 30:1 for other applications.











: a) Stainless Steel/ 1.5 times the maximum fluid pressure for DPT.

b) Forged Carbon Steel Rating : 1:5 times the maximum fluid pressure (minimum) for PT.



13. Ambient Temperature : 65 Deg. C




17. Sealing / Isolation : i) Extended diaphragm with 5 mtrs. SS armored capillary for corrosive, viscous and dirty fluid applications. Material for separator diaphragm, depending on application. ii) Silver/ Teflon coated diaphragm for corrosive services.




d) Snubbers for pulsating pressure, siphons for




steam and hot water services.

e) 3-valve SS 316 manifold, oval flange connection to transmitter body, constructed from barstock. Manifold shall be non-integral type. Manifold process side and instrument side connection shall be ½ NPT (F). Suitable drain/ vent holes with caps shall be provided.

f) Companion flange with nuts, bolts and gaskets.


h) Two handheld Calibrators for each unit.

1.01 Ultrasonic Level Transmitter

1.01.1 Signal processing : Microprocessor controlled Signal Processing

1.01.2 Connection : 2 wire 1.01.3 Operating frequency : 10 KHz to 50 KHz (typical) 1.01.4 Display : Large alpha-numeric back lit LCD / LED 1.01.5 Calibration & : Accessible from front of panel Configuration 1.01.6 Diagnosis : On-line 1.01.7 Status : For power, Hi / LO / V. Hi / V. LO-level Indication, fault etc. 1.01.8 Construction : Plug-on board 1.01.9 Power supply : 24 V DC (loop powered) 1.01.10 Signal output : 4-20 mA DC (isolated)- 600 Ohm load. 1.01.11 Accuracy & : 0.25 % of span or better Repeatability 1.01.12 Resolution : 0.1 % of span




1.01.13 Operating temp. : Transmitter- 50 deg C and Sensor - 80 deg C 1.01.14 Enclosure : IP 65 or better Epoxy painted die cast aluminium

or Polycarbonate housing. 1.01.15 Cable connection : ¾” ET 1.01.16 Mounting : 2” for sensor (Top / Vertically Mounted) The transmitter shall be suitably mounted

locally or on panel- to be decided during detailed engineering.

1.01.17 Accessories : Transducer & Counter Flange with Nuts, Bolts &

Gaskets. SS Tag Plate etc Brass, Double Compression Cable Gland.

1.02 Contact less Radar type level transmitter

Contact less radar type level transmitters shall be provided for level measurements of the Sulphuric Acid tanks applications.

Type Contactless Radar

Principle Time of Flight

Probe Type & Material Coaxial, SS316/316L. If required, probe shall be suitable for overfill prevention.

Signal o/p 4-20mA with HART signal suitable for overfill

prevention.

Display Integral

Power supply 24 VDC

Accuracy 5mm

Electromagnetic compatibility Shall meet EN 61326-1 (1997) and AmdtA1, class A equipment/EN 50081-2 & EN 5008 1-2 & EN 50082-2

Mounting Top mounted The transmitters shall be provided with IP-65 protection class with durable corrosion resistant coating.

The transmitters shall be able to provide digital signals super imposed on 4-20 mA signals as per HART protocol.




1.03 Ultrasonic Type Coal Bunker Level Monitoring System

1. Type of Sensor Non-contact Ultrasonic type with connecting cable 2. Sensor Material Corrosion resistant material to suit application

requirement. 3. Type of

Transmitter Microprocessor based

4. Output signal Galvanically isolated 4-20mA DC (Analog) – two outputs – one for CHP and one for DCS, along with local indication

5. Measurement Accuracy

+/- 2.0 % of calibrated span

6. Power supply 230 V AC/ 24 V DC By Contractor 7. Temperature

compensation To be provided integral with Sensor/Transmitter

8. Configuration It shall be possible to mount the Electronic unit at a remote accessible location from the Sensor. All cables and weather proof fittings to interconnect Sensor to electronic unit shall be provided by Bidder.

9. Housing Weather proof as per IP-65 with durable corrosion resistant coating.

10. Zero and Span adjustment

Continuous, tamper proof, adjustability from instrument. It shall be possible to calibrate the instrument without any level in the bunker.

11. False signal Tolerance

Transmitter shall be capable of ignoring false echoes from internal coal bunker obstructions. Also transmitter shall have adjustable damping circuitry

12. Range As per coal Bunker height

13. Display Minimum 4 character LCD display with integral keypad, access protected by user code

14. Diagnostics To be provided

15. Load Impedance 500 ohms minimum 16. Accessories • Canopy.

• All mounting hardware and accessories required for erection and commissioning.

• Alignment (Aiming) System for each sensor

SPECIFICATION FOR PROCESS CONNECTION AND

PIPING STANDARD SPECIFICATION

DOC. NO.: REL-COENG-NEN-448-P-00001 R0 SUB-SECTION – I 8 PAGE 1 OF 4

SUB-SECTION – I 8


PROCESS CONNECTION AND PIPING




1.00.00 PROCESS CONNECTION PIPING

1.00.01 The Contractor shall provide, install and test all required material for completeness of Impulse Piping System and Air Piping System as per the requirements of this Sub-section, on as required basis for the connection of instruments and control equipment (provided by the Contractor) to the process/ main equipment/ systems. The Contractor shall furnish during detailed engineering Installation drawings, GA and fabrication drawings of Instrument racks, other relevant drawings, material and technical data sheets of various items service wise for Owner's approval/ information.

1.00.02 All materials, furnished under this sub-section and the installation thereof shall conform to the latest editions of American National Standard Code for Pressure Piping, Power Piping, ANSI B 31.1, ANSI B16.11, ASME Boiler and Pressure Vessel Codes, IBR and other applicable ASME, ANSI and state standards.

1.00.03 All materials supplied under this Sub-section shall be suitable for intended service, process; operating conditions and type of instruments used and shall fully conform to the requirements of this specification. The bidder is responsible for the performance of equipment furnished under this specification on system basis. The Bidder may offer suggestions for improvement based on his experience, during detailed engineering, which shall be subjected to the Owner's approval.

1.00.04 Contractor to note that any reducers, nipple etc. for proper connection of the impulse piping system to Owner’s root valves / isolation valves / stubs etc. (if applicable) shall be in Contractor’s scope only, unless otherwise clearly excluded.

1.01.00 Impulse piping, tubing, fittings, valves and valve manifolds

1.01.01 All impulse pipes shall be of seamless type conforming to ANSI B36.10 for schedule numbers, sizes and dimensions etc. The material of the impulse pipe shall be generally same as that of main process pipe. For low pressure applications i.e. pressure less than 40 kg/ cm2, it may be impulse tube of SS 316. For coastal projects, all impulse pipes, fittings etc shall be provided with durable epoxy coating with poly urethane finish for protection against sea environment.

1.01.02 Stainless steel tube shall be provided inside racks from tee connection to valve manifold and then to instrument. For high pressure/ temperature applications, the material shall be ASTM A 213 TP 316H it and for other applications material shall be ASTM A 213 TP 316L. The wall thickness of the tube shall be in accordance with the ANSI B31.1 standard. The bending radius of the tube shall be greater than 6D.

1.01.03 All fittings shall be forged steel and shall conform to ANSI B16.11. The material of forged tube fittings for shaped application (e.g. Tee, elbow etc.) shall be ASTMA 182 Gr. 316 H for high pressure/ temperature applications (as defined above) and ASTMA 182 Gr. 316L for other applications. The material for bar stock tube fitting (for straight application) shall be 316 SS. Metal thickness in the fittings shall be adequate to provide actual bursting strength equal to or greater than those of the impulse pipe or SS tube, with which they are to be used.

1.01.04 The source shut-off (primary process root valve) and blow down valve shall be of 1/2 inch size globe valve type for all applications except for air and flue gas service wherein no source shut-off valves are to be provided. For various applications the valve body material, stem material and pressure class shall be suitable for the service they are intended for. The end connections of valves shall be of socket welded type. The disc and seat ring materials of carbon steel and alloy steel valves be ASTM A-105 and ASTM A-182, Gr. F22, hard faced with stellite (minimum hardness - 350 BHN.) The surface finish of 16 RMS or greater is required in the area of stem packing. The valve design shall be such that the seats can be reconditioned and stem and disc may be replaced without removing the valve body from the line.




1.01.05 The valve manifolds shall be of 316 stainless steel with pressure rating suitable for intended application. 2-valve manifold and 3-valve manifold shall be used for pressure measurements using pressure transmitters/ pressure switches and differential pressure transmitter/ switches respectively. 3-valve manifold shall be used for remaining applications like DP, flow and level measurements.

1.01.06 For Pressure/ D.P gauges in fluid application, two-way globe valve on each impulse line to the instrument and in Air/ Flue gas application two-way gate valve on each impulse line to the instrument shall be provided near the instrument. These shall be in addition to the three ways gauge cock provided along with the pressure/ D.P gauges.

1.02.00 Air supply piping

1.02.01 All pneumatic piping, fittings, valves, air filter cum regulator, purge Rotameter and other accessories required for instrument air for the various pneumatic devices/ instruments shall be provided. This will include as a minimum air supply to pneumatically operated valves, actuators, instruments, continuous and intermittent purging requirements etc.

1.02.02 For individual supply line and control signal line to control valve, Stainless steel TP321 tubes shall be employed. The fittings shall be of SS / brass.

1.02.03 All other air supply lines of 1/2 inch to 2 inch shall be of mild steel hot dipped galvanized inside and outside as per IS-1239, heavy duty with threaded ends. The threads shall be as per ASA B.2.1. Fittings material shall be of forged carbon steel A234 Gr. WPB galvanized inside and outside, screwed as per ASA B2.1. Dimensions of fittings shall be as per ASA B16.11 of rating 3000 lbs.

1.02.04 An instrument air filter cum regulator set with mounting accessories shall be provided for each pneumatic device requiring air supply. The filter regulators shall be suitable for 10-kg/ sq.cm max. inlet pressure. The filter shall be of size 5 microns and of material sintered bronze. The air set shall have 2-inch size pressure gauge and built in filter housing blow down valve. The end connection shall be 1/4 inch / 1/2 inch / 3/4 inch NPT as per the requirement to be finalized during detailed engineering.

1.02.05 All the isolation valves in the air supply line shall be gate valves as per ASTM B62 inside screw rising stem, screwed female ends as per ASA B2.1. Valve bonnet shall be union type & trim material shall be stainless steel, body rating 150 pounds ASA. The valve sizes shall be ½ inch to 2 inch.

1.03.00 Installation and routing

1.03.01 All instrument piping, tubing and its accessories shall be supported in a safe manner to prevent excessive vibrations and anchored sufficiently to prevent undue strain on connected equipment. Instrument piping & tubing shall not be routed across equipment removal areas, above or below monorails, cranes, removable gratings, cable trays.

1.03.02 Instrument Piping System

For steam and liquid measurements, the impulse pipe should preferably slope downward from source connection to instrument and instrument shall be installed below the source point. If due to any reason instrument is installed above the source point, the impulse pipe should slope upwards continuously and a 'pigtail' should be provided at the instrument to assure water seal for temperature protection. For vacuum measurements instrument shall be installed above source point and impulse pipe should slope upwards.




(a.) Impulse piping for air and flue gas shall slope upwards and instrument shall be installed above source point. If this requirement cannot be met special venting or drain provision shall be provided with vent & drain lines along with isolation valves and other accessories including drainpipes. This drain is to be connected to plant drain through open funnel also. Horizontal runs must have a slope of not less than 40 mm per meter and must be adequately supported to maintain a constant slope and to prevent sag in piping.

All impulse piping shall be installed to permit free movement due to thermal expansion. Wherever required expansion loops shall be provided.

Special accessories such as condensing pots/ reservoirs/ chemical seals (along with requisite capillary tubing to instrument) shall be provided and installed wherever required. In any case condensing pots shall be provided for all level measurements in steam and water services, all flow measurement in steam services and flow measurements water services above 120 Deg. C. Chemical seal diaphragm shall be provided for all viscous, corrosive and dirty fluid (e.g. slurry) applications.

Colour coding of all impulse pipes shall be done by the Contractor in line with the colour coding being followed for the parent pipes.

1.03.03 Instrument Air & Service Air Piping/ Tubing System

The air supply headers, sub-headers and branch pipes shall be supported properly by clamps or supports to be provided and fabricated by the Contractor. Air supply piping shall be installed with a slope of over 1/100 to prevent accumulation of condensed water within the pipe. Signal/control air tubing shall run with the minimum number of changes in direction. Suitable identification tags shall be provided for easy link up and checking of proper connections. Single and multi tubes shall run with the minimum number of changes in direction. Suitable identification tags shall be provided for easy checkup and for connections.

1.04.0 Piping/ tubing support

Impulse piping shall be supported at an interval not exceeding 1.5 meters. Each pipe shall be supported individually using slotted angle mounted clamps with necessary fixtures. Tubing shall run in proper perforated trays with proper cover. Tubing shall be supported inside the trays by aluminium supports. Hangers and other fixtures required for support of piping and trays shall be provided, either by welding or by bolting on walls, ceilings and structures. Hanger clamps and other fastening hardware shall be of corrosion resistant metals and hot-dip galvanized.

1.05.00 DRAWINGS AND DOCUMENTS Bidder shall submit Instrument Installation drawings for each type of instrument showing clearly

the root valves, impulse piping/ fittings and all other accessories like Chemical seals, valve manifolds etc. for Owner’s review & approval. The material and other details like schedule etc. for the various components shall also be brought out in the instrument installation drawings.

SPECIFICATION FOR INSTRUMENTATION AND

CONTROL CABLES


DOCUMENT NO.: REL-COENG-NEN-404-P-00001 R0

Sub-section – I 9 Page 1 of 14

SUB- SECTION – I 9


FOR

INSTRUMENTATION AND CONTROL CABLES


CONTROL CABLES




1.01.00 GENERAL REQUIREMENTS

1.01.01 All Instrumentation, Control and Special Cables like Pre fabricated, Optic fiber, Cat5e, Coaxial and network cables as required for the interconnection of the various instruments/ devices/ equipment/ cabinets/ HMI/ Switchgear with the PLC system shall be supplied ,laid and terminated by the Bidder “On as required basis” .

1.01.02 Instrumentation, Control and Special Cables shall be supplied “On as required basis” as per this specification, however for estimation purpose, Contractor can refer the attached plot plan and cabling scope diagram attached.

1.01.03 Cables laid in trenches and buried in ground (typically out side buildings) shall be armored.

1.01.04 All cables shall be flame retardant low smoke (FRLS) outer sheathed type having rodent and termite repulsion property.

1.01.05 Single/ Multi-Pair cables with individual pair & overall shielding shall be used for analog signals (4-20 mA, RTDs etc.). Multi-pair cables with overall shielding shall be used for binary signals. Compensating/ extension cables (if applicable) shall be used for Thermocouples.

1.01.06 Multi core cables of 1.5 sq mm shall be employed for carrying control signals, typically the command extension from the control system to the solenoid-operated valves, power supply wiring etc as finalized during detailed engineering.

1.01.07 Conductor size will be 1.5 mm2 for local short run cables (except thermocouple extension cable) and 0.5 mm2 for trunk cables.

1.01.08 Two pair/ four pair 1.5 mm2 cables shall be used from analog instruments like transmitters/ RTDS to field junction boxes and multi-pair 0.5-mm2 cables shall be used from JB onwards up to marshalling cabinet/ PLC system with provision of 10% spare pair in each multi-pair cable.

1.01.09 Four pair 1.5 mm2 cable shall be used from process switches to field junction boxes and multi-pair 0.5 mm2 cables shall be used from JB onwards up to marshalling cabinet / PLC system with provision of 10% spare pair in each multi-pair cable.

1.01.10 In case of duplex RTDs, both the elements shall be wired up to the local JB, from where one of the elements shall be connected to the control/ monitoring system. Similarly in the case of process switches (with two SPDT), the spare contact shall also be also be wired up to the local JB.

1.01.11 All cables required for grounding of PLC cabinets, equipments etc. shall be provided by the Bidder. All cables/ isolated flats etc. used for grounding shall be of copper or aluminum of proper size to avoid any increase in ground potential. All the cables used for grounding of the individual panels/ equipments/ instruments/ devices etc. and the complete system shall be provided by the Contractor.

1.01.12 All data high way and network cables required for interconnecting PLC cabinets, Remote I/O cabinets, HMI etc. supplied under this specification shall be Optical Fibre / Shielded twisted pair Cat.-5e. All the hardware that may be required for installation of the same


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including cables sub-trays/ troughs, flexible & rigid conduits, GI/HDPE Conduits, fittings, junction boxes, accessories etc. shall be provided by the Contractor within his quoted lump sump price. The routing of these cables shall be separate from other Instrumentation cables.

1.01.13 Contractor to furnish lay, terminate & test on both ends all power feeders, which provide power to all equipments furnished by the bidder under this specification

1.02.00 SPECIFICATION OF INSTRUMENTATION CABLE

1.02.01 Common Requirements

S. No.

Property Requirement

1 Voltage grade 225 V (peak value)

2. Codes and standard All instrumentation cables shall comply with VDE 0815, VDE 0207, Part 4, Part 5, Part 6, VDE 0816, VDE 0472, SEN 4241475, ANSI MC 96.1, IS-8784, IS-10810 (latest editions) and their amendments read along with this specification.

3. Continuous operation suitability At 70 deg. C for all types of cables

4. Progressive automatic on-line sequential marking of length in meters

To be provided at every one meter on outer sheath.

5. Marking to read ‘FRLS’ To be provided at every 5 meters on outer sheath.

6. Allowable Tolerance on overall diameter

+/- 2 mm (maximum) over the declared value in data sheet

7. Variation in diameter Not more than 1.0 mm throughout the length of cable.

8 Ovality at any cross-section Not more than 1.0 mm

9 Others Durable marking at intervals not exceeding 625 mm shall include manufacturer’s name, insulation material, conductor’s size, number of pairs, voltage rating, type of cable, year of manufacturer to be provided. Cables shall be suitable for laying in


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S. No.

Property Requirement

conduits, ducts, trenches, racks and underground-buried installation Repaired cables shall not be acceptable.

1.02.02 Specific Requirements

Specification Requirements

Thermocouple Extension cable(if

applicable)

Analog and Digital Type cable

A. Conductors

Cross section area

0.5 sq. mm

Note: For shorter analog and Digital signals, cables

from Instruments upto J.Box/LIE/LIR shall be 1.5 sq.mm (Except T/C extension cable) .

Conductor material

ANSI type KX (K type TC extension- Cr/Ni, Al/ Ni), TX (T type TC Extension - Cu- Constantan), RX/ SX (Compensation cable for R/ S-type TC- Cu, Cu/ Ni), EX (E type TC Extension – Cr/ Ni, Constantan)

High conductivity Annealed bare copper

Color code Yellow-Red for KX

Blue-Red for TX

Black-Red for Sx/ Rx and Purple –Red for EX

As per VDE-815

Conductor Grade As per ANSI MC 96.1

Electrolytic

No & dia of strands

7x0.3 mm (nom) for 0.5 mm2

Note: For 1.5 sq. mm, Min 7 strands

No. of Pairs 2 2,4,8,12,16,24 for 0.5 mm2 cable


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and 1/2/4 pair for shorter run cable of 1.5 sq.mm

Max. conductor resistance per Km (in ohm) at 20 deg. C

As per ANSI MC 96.1 73.4 ohm (loop) for 0.5 sq.mm

12.6 ohm per km for 1.5 sq.mm.

Reference Standard

As per ANSI MC 96.1 VDE 0815

B. Insulation

Material PVC type YI 3 as per VDE 0207 part 4

Thickness in mm (Min/Nom/Max)

0.25/0.3/0.35

Volume Resistivity (Min) in ohm-cm

1 x 1014 at 20 deg. C & 1x1011 at 70 deg. C.

Voltage Rating 225 V peak operating voltage

Reference Standard

VDE 0207 Part 4

Core diameter above insulation

Suitable for cage clamp connector

C. Pairing & Twisting

Max. lay of pairs (mm)

50

Single layer of Numbered binder tape on each pair provided

Numbered Tape Yes

Unit formation of four pairs with printing of no. of Unit provided

N.A.

Yes

Conductor /pair identification as per VDE0815

N.A.

To be provided (color coding as per standard)


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D. Shielding

Type of shielding Al-Mylar tape

Individual pair shielding

No To be provided for cables carrying analog signals.

Minimum thickness of Individual pair shielding

No 28 micron

Overall cable assembly shielding

To be provided

Minimum thickness of Overall cable assembly shielding

55 micron

Shielding coverage

100% with at least 20% overlap

Drain wire provided for individual shield

N.A.

Yes (for Analog signal cable) 7-strand 20 AWG (0.51 mm2 ) annealed Tin coated copper

Drain wire provided for overall shield

Yes. 7-strand 20 AWG (0.51 mm2) annealed Tin coated copper

E. Fillers

Non-hygroscopic, flame retardant

To be provided

F. Outer Sheath

Material Extruded PVC compound YM1 with FRLS properties

Minimum Thickness at any point

1.8 mm

Nominal Thickness at any point

>1.8 mm


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Color Blue

Resistant to water, fungus, termite & rodent attack

Required

Oxygen index as per ASTMD-2863

Not less than 29%

Temperature index as per ASTMD-2863

Not less than 250 deg.C

acid gas generation by weight as per IEC-60754-1

Maximum 20%

Smoke Density Rating as per ASTMD-2843

Maximum 60%

(defined as the average area under the curve when the results of smoke density test plotted on a curve indicating light absorption vs. time as per ASTMD-2843)

Reference standard VDE207 Part 5

G. Electrical Parameters

Mutual Capacitance Between Conductors At 0.8 Khz (Max.)

200 nF/km 120 nF/km for Analog signal cable

100 nF/km for Digital signal Cable

Insulation Resistance(Min.)

100 M Ohm/Km

Cross Talk Figure (Min.) At 0.8 Khz

60 dB 60 dB

Characteristic Impedance (Max) At 1 Khz

N.A. 320 ohm for Analog signal cable

340 ohm for digital signal cable

Attenuation Figure At 1 Khz (Max)

N.A. 1.2 db/km

H. Complete Cable


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Complete Cable assembly

Shall pass Swedish Chimney test as per SEN-SS 4241475 class F3.

Flammability Shall pass flammability as per IEEE-383 read in conjunction to this specification

I. Accessories

Cable accessories of flame retardant quality.

Yes. (Accessories such as harnessing components, markers, bedding, cable jointer, binding tape etc.)

J Cable Drum

Type Non-returnable wooden drum (wooden drum to be constructed from seasoned wood free from defects with wood preservative applied to the entire drum) or steel drum.

Outermost layer covered with waterproof paper

Yes

Painting Entire surface to be painted

Length 1000 m + 5% for cable sizes up to & including 12 pairs

500 m + 5% for cable size above12 pairs

K. Type tests Type test reports for tests as per clause below

1.03.00 OPTICAL FIBER CABLE DESCRIPTION :-

1.03.01 Optic Fiber cable shall be 4/8/12/24 core, galvanized corrugated steel taped armored, fully water blocked with dielectric central member for outdoor/indoor application so as to prevent any physical damage. The cable shall have multiple single-mode fibers/ multi-mode fibers on as required basis so as to avoid the usage of any repeaters. The core and cladding diameter shall be 9 +/- 1 micrometer for single mode fibers and around 62.5 micrometer for multi mode fibers. The outer sheath shall have Flame Retardant, UV resistant properties and are to be identified with the manufacturer’s name, year of manufacturer, progressive automatic sequential on-line marking of length in meters at every meter on outer sheath.

1.03.02 The cable core shall have suitable characteristics and strengthening for prevention of damage during pulling viz. Steel central member, Loose buffer tube design, 4 fibers per buffer tube (minimum), Interstices and buffer tubes duly filled with Thixotropic jelly etc.


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The cable shall be suitable for a maximum tensile force of 2000 N during installation, and once installed, a tensile force of 1000 N minimum. The compressive strength of cable shall be 3000 N minimum& crush resistance 4000 N minimum. The operating temperature shall be –20 deg. C to 70 deg.C

1.03.03 All testing of the fiber optic cable being supplied shall be as per the relevant IEC, EIA and other international standards.

1.03.04 Cables shall be suitable for laying in conduits, ducts, trenches, racks and under ground buried installation.

1.04.00 CONTROL CABLES

1.04.01 Control cables shall be sized based on the following considerations:

(a) The minimum conductor cross-section shall be 1.5 sq.mm.

(b) The minimum number of spare cores in control cables shall be as follows:

No. of cores in cable Min. No. of spare cores

2C, 3C NIL

5C 1

7C-12C 2

14C & above 3

1.04.02 The Control Cables shall be of 1.1 KV Grade and have stranded copper conductor of 1.5 sq.mm.

1.04.03 The insulation shall be PVC and the inner (for armoured cables) and outer sheath shall be PVC conforming to IS:1554. (Part-I). The outer sheath shall be FRLS type.

1.04.04 Cores of the cables shall be suitably identified by coloring of insulation.

1.05.00 TESTS

1.05.01 All equipments to be supplied shall be of type tested quality. The Contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last five years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.

1.05.02 In case the Contractor is not able to submit report of the type test(s) conducted within last five years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, free of cost to the Owner and submit the reports for approval.


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The reports for the following type tests shall be submitted on one size each type of cables.

1.05.03 Type Tests for control cables

S.No. Type Test Remarks

For Conductor 1. Annealing test For copper conductor only. 2.

Resistance test

For Armour Wires/ Formed Wires 3. Measurement of Dimensions 4. Tensile Test 5. Elongation test 6. Torsion test For round wires only 7. Wrapping test For aluminum wires/formed wires only 8. Resistance test 9.(a) Mass of Zinc Coating test For G.S. Formed wires /wires only. 9.(b) Uniformity of zinc coating For G.S. Formed wires /wires only. 10. Adhesion test For G.S. Formed wires /wires only. For PVC insulation & PVC Sheath 11. Test for thickness 12. Tensile strength & elongation tests before ageing and after ageing

13. Ageing in air oven

14. Loss of mass test For PVC insulation and sheath only

15. Hot deformation test For PVC insulation and sheath only

16. Heat shock test For PVC insulation and sheath only

17. Shrinkage test

18. Thermal stability test For PVC insulation and sheath only

19. Hot set test(Not for control cables)

For XLPE insulation only

20. Water absorption test (Not for control cables)

For XLPE insulation only

21. Oxygen index test For outer sheath only


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22. Smoke density test For outer sheath only

23. Acid gas generation test For outer sheath only

For completed cables 24 Insulation resistance test

(Volume resistivity method)

25 High voltage test

26 Flammability test as per IEC - 332 Part-3 (Category -B)

1.05.04 Type tests for Instrumentation Cables

01. Oxygen Index test as per ASTM-D-2863 : Min. 29 at room temp.

02. Acid Gas Generation test as per IEC 754 Part-I: Max. 20 % by weight 03. Temperature Index test as per ASTM-D-2863 : Min. 250 DEG C at 21Oxygen

Index 04. Smoke Density test as per ASTM-D-2843 Max. 60 % 05. Flammability Test: As per IEC 332 Part-I/ IEEE 383/1974 06. Swedish Chimney Test- As per SS-424-1475 (F3) 07. Insulation Resistance test 08. Water immersion test: As per VDE - 0815. 09. Fire resistance test to IS-5831 for 20 minutes (PVC insulation & sheath of

electrical cables) 10. Thermal EMF test as per ASME 96.1 11. Thermal stability at 200°C to IEC-540 for 100 meters 12. Heat shock test to IEC-502 13. Rodent & termite proof test


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1.06.00 CABLE LAYING AND ACCESSORIES

1 Cable laying: Cables shall be laid strictly in line with cable schedule.

2 Identification tags for cables.

Indelible tags to be provided at all terminations, on both sides of wall or floor crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in cable trench/tray.

3 Cable tray numbering and marking.

To be provided at every 10m and at each end of cable way & branch connection.

4 Joints for less than 250 meters run of cable shall not be permitted.

5 Buried cable protection

With concrete slabs; route markers at every 20 meters along the route & at every bend.

6 Road crossings

Cables to pass through buried high density PE pipes encased in PCC. At least 300 mm clearance shall be provided between

- HT power & LT power cables,

- LT power & LT control/instrumentation cables,

Spacing between cables of same voltage grade shall be in accordance with the derating criteria adopted for cable sizing.

7

A All cable associated with the unit shall be segregated from cables of other units.

B Interplant cables of critical drives shall be segregated in such a way that not more than half of the drives are lost in case of single incident of fire.

8 Cable clamping

All cables laid on trays shall be neatly dressed up & suitably clamped/tied to the tray. For cables in trefoil formation, trefoil clamps shall be provided.


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9 Optical fiber cables shall be laid inside conduit on cable trays wherever available and feasible. In areas where the same are required to be buried, the same shall be buried in separate trench approx.1.6 meter depth, to be laid in 2” GI/ rodent proof HDPE conduits covered with sand, brick and soil along the pipe line route; While crossing roads - to be laid in GI/ rodent proof HDPE conduits with sand filling at bottom and sand, soil filling at top with cement concrete; While crossing canals/ river- to be laid in GI/rodent proof HDPE conduits within hume pipe.

1.06.01 Bidder shall supply and install all cable accessories as applicable and fittings like Light Interface Units, Op to isolators, Interface Converters, Fibre Optic Card Cage, Fibre Optic Line Driver, cable glands, grommets, lugs, termination kits etc. on as required basis.

1.06.02 Bidder shall furnish one complete new sets of cable termination kits like Crimping tools, etc., which are required for maintenance of the system as per the type of termination used.

1.06.03 Cables, which terminate in cabinets of draw out sections shall have sufficient cable coiled in the bottom of the cabinet to permit full withdrawal of draw out sections without disconnecting the cables.

1.06.04 The Bidder shall be responsible for proper grounding of all C&I equipment. Further, proper termination of cable shields shall be verified and the grounding of the same shall be coordinated so as to achieve grounding of all instrumentation cable shields at same potential. This shall be completed prior to system tests. All the cables etc. required for grounding of all equipments supplied under this package are to be supplied by the Bidder.

1.06.05 The Contractor shall take full care while laying / installing cables as recommended by cable manufacturers regarding pulling tensions and cable bends. Cables damaged in any way during installation shall be replaced at the expense of the Contractor.

1.07.00 PACKING AND TRANSPORT

1.07.01 Cables shall be placed on drums in such a manner that it shall be protected from injury during transit. Each end of cable shall be firmly and properly secured to the drum. The end of each length shall be sealed before shipment. The drums shall be secured firmly in position so that they do not shift during transit. Purchaser may advise Bidder about the restriction of shipping length during detail engineering.

1.07.02 Drums shall be of heavy construction. On one side of the drum the purchase order’s number, length of cable, size of conductor, number of cores, type of cable and voltage for which it is suitable, shall be painted. A tag containing this information shall be attached to the leading end of the cable. An arrow and suitable wording shall be marked on the side of the drum to indicate the direction in which it should be rolled.


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1.07.03 Packing shall be sturdy and adequate to protect the cables and materials from injury by corrosion, dampness, heavy rains, breakage and vibration encountered during transportation, handling and storage at the plant site.

1.08.00 MARKING

1.08.01 All markings on the case shall be made of waterproof materials to prevent obliteration during transit.

1.08.02 The following details shall be marked on the packing case

a. Project Name b. Contract or Purchase Order No. c. Case No. d. Complete description of Cable e. Net weight in Kilograms f. Gross weight in Kilograms g. Dimensions of packing case h. Sling position & CG position i. Storage position j. Date of Shipment.



REL-SKCCP-NEM-161-P-00001 (Rev.00) Part III Page 1 of 42

PART III

SECTION 1

GENERAL TECHNICAL REQUIREMENTS




CONTENTS

CLAUSE NO.

DESCRIPTION

G1.01.00 INTRODUCTION G1.02.00 BRAND NAME G1.03.00 BASE OFFER & ALTERNATE PROPOSALS G1.04.00 COMPLETENESS OF FACILITIES G1.05.00 CODES & STANDARDS G1.06.00 EQUIPMENT FUNCTIONAL GUARANTEE G1.07.00 DESIGN OF FACILITIES / MAINTENANCE & AVAILABILITY

CONSIDERATIONS G1.08.00 DOCUMENTS, DATA, DRAWINGS AND ENGINEERING CO-

ORDINATION PROCEDURE G1.09.00 PROTECTIVE GUARD G1.10.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS G1.11.00 MATERIAL OF CONSTRUCTION

G1.12.00 RATING PLATES, NAME PLATES & LABELS G1.13.00 TOOLS AND TACKELS G1.14.00 WELDING G1.15.00 COLOR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE

SERVICES G1.16.00 QUALITY ASSURANCE PROGRAMME G1.17.00 PROTECTION AND PRESERVATIVE SHOP COATING

PROTECTION

G1.18.00 QUALITY ASSURANCE PROGRAMME G1.19.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES G1.20.00 INITIAL OPERATION G1.21.00 PERFORMANCE & GUARANTEE TEST

G1.22.00 TAKING OVER G1.23.00 TRAINING OF EMPLOYER'S PERSONNEL G1.24.00 NOISE LEVEL G1.25.00 PACKAGING AND TRANSPORTATION G1.26.00 ELECTRICAL ENCLOSURE G1.26.00 INSTRUMENTATION AND CONTROL G1.27.00 ELECTRICAL NOISE CONTROL




G1.00.00 GENERAL TECHNICAL REQUIREMENTS

G1.01.00 INTRODUCTION

This part covers technical requirements, which will form an integral part of the Contract. The following provisions shall supplement all the detailed technical requirements brought out in the Technical Specifications and the Technical Data Sheets.

G1.02.00 BRAND NAME

Whenever a material or article is specified or described by the name of a particular brand, manufacturer or vendor, the specific item mentioned shall be understood to be indicative of the function and quality desired, and not restrictive; other manufacturer's products may be considered provided sufficient information is furnished to enable the Employer to determine that the products proposed are equivalent to those named.

G1.03.00 BASE OFFER & ALTERNATE PROPOSALS

The Bidder's proposal shall be based upon the use of equipment and material complying fully with the requirements specified herein. It is recognized that the Contractor may have standardized on the use of certain components, materials, processes or procedures different than those specified herein. Alternate proposals offering similar equipment based on the manufacturer's standard practice may also be considered, provided the base offer is in line with technical specifications and such proposals meet the specified design standards and performance requirement and are acceptable to the Sufficient amount of information for justifying such proposals shall be furnished to Employer along with the bid to enable the Employer to determine the acceptability of these proposals.

G1.04.00 COMPLETENESS OF FACILITIES

G1.04.01 Bidders may note that this is a contract inclusive of the scope as indicated elsewhere in the specification. Each of the plant shall be engineered and designed in accordance with the specification requirement. All engineering and associated services are required to ensure that a completely engineered plant is provided.

G1.04.02 All equipments furnished by the Contractor shall be complete in every respect,

with all mountings, fittings, fixtures and standard accessories normally provided with such equipment and/or those needed for erection, completion and safe operation & maintenance of the equipment and for the safety of the operating personnel, as required by applicable codes, though they may not have been specifically detailed in the respective specifications, unless included in the list of exclusions.

All similar standard components/ parts of similar standard equipment provided

shall be interchangeable with one another.

G1.05.00 CODES & STANDARDS




G1.05.01 In addition to the codes and standards specifically mentioned in the relevant technical specifications for the equipment / plant / system, all equipment parts, systems and works covered under this specification shall comply with all currently applicable statutory regulations and safety codes of the Republic of India as well as of the locality where they will be installed, including the following:

1. Bureau of Indian Standards (BIS) 2. Building and Other Construction Workers (Regulation of Employment and

Conditions of Service) Act 1996. 3. Building and Other Construction Workers (Regulation of Employment and

Conditions of Service) Central Rules 1998. 4. Explosives Rules 1983 (Not Applicable) 5. Petroleum Act 1984(Not Applicable) 6. Petroleum Rules.1976(Not Applicable) 7. Gas Cylinders Rules 1981 8. Static & Mobile Pressure Vessels (Unified) Rules,1981 9. Workmen’s Compensation Act, 1923 10. Workmen Compensation Rules, 1924 11. RINFRA Safety Rules for Construction and Erection. 12. RINFRA Safety Policy 13. Indian electricity act 14. Indian electricity rules 15. Indian Explosives Act(Not Applicable) 16. Indian Factories Act and State Factories Act 17. Indian Boiler Regulations (IBR) (Not Applicable) 18. Regulations of the Central Pollution Control Board, India 19. Regulations of the Ministry of Environment & Forest (MoEF), Government of

India 20. Pollution Control Regulations of Department of Environment, Government of

India 21. State Pollution Control Board. 22. Rules for Electrical installation by Tariff Advisory Committee (TAC). 23. Any other statutory codes / standards / regulations, as may be applicable.

G1.05.02 The codes, and/or standards referred to in these specifications shall govern, in all

the cases wherever such references are made for design of various equipments /system etc. Latest edition shall be followed by the Contractor for all the codes and /or Standards. In case of a conflict between such codes and/or standards and the specifications, the latter shall govern. Such codes and/or standard referred to shall mean the latest revision, amendments/changes adopted and published by the relevant agencies. In case of any further conflict in this matter the same shall be referred to the Engineer, whose decision shall be final and binding.




G1.05.03 Other internationally acceptable standards which ensure equal or higher performance than those specified shall also be accepted subject to the Employer's approval, for which the Bidder shall furnish, adequate information to justify that these standards are equivalent or superior to the standards referred. In all such cases the Bidder shall furnish specifically the variations and deviations from the standards mentioned else where in the specification together with the complete word to word translation of the standard that is normally not published in English.

G1.05.04 In case of any change in codes, standards & regulations between the date of bid

opening and the date when vendors proceed with fabrication, the Employer shall have the option to incorporate the changed requirements or to retain the original standard. It shall be the responsibility of the Contractor to bring to the notice of the Employer such changes and advise Employer of the resulting effect.

G1.06.00 EQUIPMENT FUNCTIONAL GUARANTEE

G1.06.01 The functional guarantees of the equipment under the scope of the Contract are given elsewhere in the technical specification. These guarantees shall supplement the general functional guarantee provisions covered under General Conditions of Contract.

G1.06.02 Liquidated damages for shortfall in meeting functional guarantee(s) during the

performance and guarantee tests shall be assessed and recovered from the Contractor as specified elsewhere in this specification.

G1.07.00 DESIGN OF FACILITIES/MAINTENANCE & AVAILABILITY CONSIDERATIONS

G1.07.01 Design of Facilities

All the design procedures, systems and components proposed shall have already been adequately developed and shall have demonstrated good reliability under similar conditions elsewhere.

The Contractor shall be responsible for the selection and design of appropriate equipments to provide the best coordinated performance of the entire system. The basic requirements are detailed out in various clauses of the Technical Specifications. The design of various components, assemblies and subassemblies shall be done so that it facilitates easy field assembly and dismantling. All the rotating components shall be so selected that the natural frequency of the complete unit is not critical or close to the operating range of the unit.

G1.07.02 MAINTENANCE AND AVAILABILITY CONSIDERATIONS

Equipment/facilities offered shall be designed for high availability, low maintenance and ease of maintenance. The Bidder shall specifically state the design features incorporated to achieve high degree of reliability/ availability and ease of maintenance.




Lifting devices i.e. hoists and chain pulley, jacks, etc. shall be provided by the contractor for handling of any equipment or any of its part having weight in excess of 500 Kgs during erection and maintenance activities.

Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist / crane shall be provided by the contractor for lifting the equipment and accessories covered under the specification.

All the valves and other equipments shall be provided with operating platforms, ladders, lifting lugs etc as required by Employer and such appurtenances if required during /after commissioning of the plant shall be provided by the Contractor at plant within the contract price.

G1.08.00 DOCUMENTS, DATA, DRAWINGS AND ENGINEERING CO-ORDINATION

PROCEDURE.

G1.08.01 Bidders may note that this is a contract inclusive of the scope as indicated elsewhere in the specification. Each of the plant and equipment shall be fully integrated, engineered and designed to perform in accordance with the technical specification. All engineering and technical services required ensuring a completely engineered plant shall be provided in respect of mechanical, electrical, control & instrumentation, civil & structural works as per the scope.

The Contractor shall furnish engineering data/drawings and manuals in

accordance with the schedule of information as specified in Technical Specification and data sheets.

G1.08.02 The number of copies/prints/floppy discs/CD-ROMs/manuals to be furnished for

various types of documents is given in Annexure-A of this Section.

G1.08.03 The documentation that shall be provided by the Contractor is indicated in the various sections of specification. This documentation shall in general include (whichever applicable for the package) but not be limited to the following as mentioned below.

G1.08.03.01 DETAILED ENGINEERING DOCUMENTS

General layout o Layouts, general arrangements, elevations and cross-sections drawings for

all the equipment and facilities of the plant. o Flow diagrams, Process & Instrumentation Diagrams. o Piping isometric /composite layout and fabrication drawings. o Piping engineering diagrams, pipe and fittings schedules, valve schedules,

hanger and support schedules, insulation schedules. o Technical data sheets for all bought out and manufactured items. Contractor

shall use the RINFRA specifications as a base for placement of orders on their sub-vendors.

o Detailed design calculations for components, system, piping etc., wherever applicable.




o Transient, hydraulic and thermal stress analysis of piping and system wherever applicable & input and output data alongwith stress analysis isometrics showing nodes.

o Characteristic Curves/ Performance Correction Curves applicable for various equipments.

o Comprehensive list of all terminal points which interface with Employer's facilities, giving details of location, terminal pressure, temperature, fluid handled & end connection details, forces, moments etc.

o Power supply single line diagram, control schematics, etc. o Operation and control write up. o Logic diagram with write up. o Interconnection cable and signal flow diagram, Cable list and Cables

schedules. o Instrument schedule, Measuring point list, Alarm list, I/O and drive list. o PLC documents such as Configuration ,Hardware/software details BOQ,

Cabinet GA drawing, Power supply diagram, MMI functions such as Graphics, Log /Report, Alarm etc , Functional write-ups, implemented logic schemes, FAT procedure , Type test reports Interconnection & wiring diagram, FAT Reports , O&M Manuals ,Grounding scheme.

o UPS documents such as Technical datasheet, sizing, configuration, write up,test report, etc.

o Control Room layout. o Instruments technical data sheet, wiring diagram, O&M Manuals etc. o Instrument and control, Optic fibre and cable datasheet, cross sectional

drawings, test reports. o Civil drawings for architectural works, foundations and super-structural

works, civil calculation sheets including structural analysis and design along with output results.

o Underground facilities, leveling, sanitary, landscaping drawings. o Model study reports wherever applicable. o Functional & guarantee test procedures and test reports. o Documentation in respect of Quality Assurance System as listed out

elsewhere in this specification. o Field Quality Plan entire scope of supply.

Electrical Along With Bid

o Compliance with scope of work o Technical Particulars o Load list as per load list format o Operation & Control Philosophy




o Type test certificates. (All equipments shall be type tested one, type tested at third party reputed test agencies. Type test certificate conducted not earlier than 5 years shall be submitted for all equipment during drawing approval stage. Should the bidder is not able to meet this criteria shall have to conduct at his own cost & time type tests as per relevant standards and submit the certificates for purchaser's approval. Implications any arise out of this shall be to bidders account) Equipment/component technical data sheet/ brochure.

o Complete BOQ with Make o Equipment/component technical data sheet/ brochure.

After the Bid

o Along with above documents and as mentioned in General Technical Specifications for Electrical

o Detailed Engineering Documents/Drawings for all equipments. o SLD, Control schematics, Logic diagram, Cable Schedule &

interconnection Scheme. o Sizing Calculation of Transformer, Cable, Earthing. o Layout Drawings with BOQ. i.e. Earthing ,cable route, equipment ,

conduit layout etc. o Equipment erection drawings, Pre commissioning & commissioning

checks o Calibration certificates for testing & measurement instruments shall be

submitted for approval before use at site. o Motor characteristics curves. o Relay setting. o Notes & Details: Cabling, Earthing, Erection, Lightning, Illumination. o Routine Test & Shop Test Certificates. o Painting Procedure. o FQP for entire scope of supply. o QAP o As built drawings. o Manual: Equipment/component, Erection, Instruction, O&M. o List of sub vendors for supply and erection.

Note: All documents/ drawings are subjected to approval from purchaser. The list

mentioned is suggestive only. It is to be elaborated during detailed engineering.

The Contractor's while submitting the above documents/ drawings for approval/

reference as the case may be, shall mark on each copy of submission the reference letter along with the date vide which the submissions are made.




G1.08.03.02 INSTRUCTION MANUALS

The Contractor shall submit to the Employer, draft Instruction Manuals for all the equipments and as well as for the complete system covered under the Contract within the time agreed upon between the Employer and the Contractor. The Instruction manuals shall contain full details required for erection, commissioning, operation and maintenance of each equipment. The manual shall be specifically compiled for this project.

The Instruction Manuals shall comprise of the following:

i) Erection Manuals

The erection manuals shall be submitted at least three (3) months prior to the commencement of erection activities of particular equipment/system. The erection manual should contain the following as a minimum.

a) Erection strategy. b) Sequence of erection. c) Erection instructions. d) Critical checks and permissible deviation/tolerances. e) List of tool, tackles, heavy equipments like cranes, dozers, etc. f) Bill of Materials g) Procedure for erection. h) General safety procedures to be followed during erection/installation. i) Procedure for initial checking after erection. j) Procedure for testing and acceptance norms. k) Procedure / Check list for pre-commissioning activities. l) Procedure / Check list for commissioning of the system. m) Safety precautions to be followed in erection all equipments and electrical

supply distribution during erection. n) PG Test Procedure.

ii) Operation & Maintenance (O & M) Manuals

a) The manual shall be a two rim PVC bound stiff sided binder able to withstand constant usage or where a thicker type is required it shall have locking steel pins, the size of the manual shall not be larger than international size A3. The cover shall be printed with the Project Name, Services covered and Volume / Book number Each section of the manual shall be divided by a stiff divider of the same size as the holder. The dividers shall clearly state the section number and title. All written instructions within the manual not provided by the manufacturers shall be typewritten with a margin on the left hand side.

b) The arrangement and contents of O & M manuals shall be as follows:




1) Chapter 1 -Plant Description : To contain the following sections specific to the

equipment/system supplied

(a) Description of operating principle of equipment / system with schematic drawing / layouts.

(b) Functional description of associated Equipments/Systems / controls. Control interlock protections write up.

(c) Integrated operation of the equipment along with the intended system. (This is to be given by the supplier of the Main equipment by taking into account, the operating instruction given by the associated suppliers).

(d) Exploded view of the main equipment, associated accessories and auxiliaries with description. Schematic drawing of the equipment along with its accessories and auxiliaries.

(e) Design data against which the plant performance will be compared. (f) Master list of equipments, Technical specification of the equipment/

system and approved data sheets. (g) Identification system adopted for the various components, (it will be of

a simple process linked tagging system). (h) Master list of drawings (as built drawing - Drawings to be enclosed in a

separate volume).

2)Chapter 2.0 - Plant Operation: To contain the following sections specific to

the equipment supplied

(a) Protection & Interlock logics and Control loop diagram for the complete

System/equipment along with brief logic /loop write up (b) Limiting values of all protection settings. (c) Various settings of annunciation/interlocks provided. (d) Startup and shut down procedure for equipment along with the associated

systems in step mode. (e) Do's and Don'ts related to operation of the equipment. (f) Safety precautions to be take during normal operation. Emergency

instruction on total power failure condition/lubrication failure/any other conditions.

(g) Parameters to be monitored with normal value and limiting values. (h) Equipment isolating procedures. (i) Trouble shooting with causes and remedial measures. (j) Routine testing procedure to ascertain healthiness of the safety devices

alongwith schedule of testing. (k) Routine Operational Checks, Recommended Logs and Records (l) Change over schedule if more than one auxiliary for the same purpose is

given. (m) Preservation procedure on long shut down. (n) System/plant commissioning procedure.

3)Chapter 3.0 - Plant Maintenance: To contain the following sections specific to

the equipment supplied.




(a) Exploded view of each of the equipments. Drawings along with bill of

materials including name, code no. & population. (b) Exploded view of the spare parts and critical components with dimensional

drawings (In case of Electronic cards, the circuit diagram to be given) and spare parts catalogue for each equipment.

(c) List of Special T/ P required for Overhauling /Trouble shooting including special testing equipment required for calibration etc.

(d) Stepwise dismantling and assembly procedure clearly specifying the tools to be used, checks to be made, records to be maintained etc. Clearance to be maintained etc.

(e) Preventive Maintenance schedules linked with running hours/calendar period along with checks to be carried out.

(f) Overhauling schedules linked with running hours/calendar period along with checks to be done.

(g) Long term maintenance schedules (h) Consumables list along with the estimated quantity required during normal

running and during maintenance like Preventive Maintenance and Overhauling.

(i) List of lubricants with their Indian equivalent, Lubrication Schedule including charts showing lubrication checking, testing and replacement procedure to be carried daily, weekly, monthly & at longer intervals to ensure trouble free operation and quantity required for complete replacement.

(j) Tolerance for fitment of various components. (k) Details of sub vendors with their part no. in case of bought out items. (l) List of spare parts with their Part No, total population, life expediency &

their interchange ability with already supplied spares to RINFRA. (m) List of mandatory and recommended spare list along with manufacturing

drawings, material specification & quality plan for fast moving consumable spares.

(n) Lead time required for ordering of spares from the equipment supplier, instructions for storage and preservation of spares.

(o) General information on the equipment such as modification carried out in the equipment from its inception, equipment population in the country / foreign country and list of utilities where similar equipments have been supplied.

G1.08.03.03 After finalization and approval of the Employer, the O & M Manuals shall be

submitted as indicated in Annexure-A. The Contract shall not be considered to be completed for purposes of taking over until the final Instructions manuals (both erection and O & M manuals) have been supplied to the Employer.

If after the commissioning and initial operation of the plant, the instruction

manuals (Erection and /or O &M manuals) require modifications/additions/ changes, the same shall be incorporated and the updated final instruction manuals shall be submitted by the Contractor to the Employer for records and number of copies shall be as mentioned in Annexure-A.

G1.08.03.04 PROJECT COMPLETION REPORT




The Contractor shall submit a Project Completion Report at the time of handing over the plant.

G1.08.04 ENGINEERING DATA / DRAWINGS

G1.08.04.01 All data/information furnished by Contractor /Vendor in the form of drawings/ documents/catalogues or in any other form for RINFRA’s information/ interface and or review and approval are referred by the general term “drawings”.

G1.08.04.02 All documents submitted by the Contractor for Employer's review shall be in

electronic form (soft copies) along with the desired number of hard copies as per Annexure-A . The soft copies to be supplied shall be either in CDs, Floppies or through direct transfer via E-mail, etc. depending upon the nature/volume/size of the document. The drawings submitted for approval shall be in the Image form / AutoCAD drawing format / PDF format readable through Acrobat Reader as mutually agreed to between Contractor and Employer before award of Contract. All documents/text /calculations etc information shall be in MS Office application such as MS – WORD or MS-Excel as the case may be.

G1.08.04.03 All drawings submitted by the Contractor including those submitted at the time of

bid shall be in sufficient detail indicating the type, size, arrangement, weight of each component for packing and shipment, the external connection, fixing arrangement required, the dimensions required for installation and interconnections with other equipments and materials, clearance and spaces required between various portions of equipment and any other information specifically requested in the drawing schedules.

G1.08.04.04 Each drawing submitted by the Contractor (including those of sub vendors of

Contractor) shall bear a title block at the right hand bottom corner with clear mention of the name of the Employer, the system designation, the specifications title, the specification number, the name of the Project, drawing number and revisions. If standard catalogue pages are submitted the applicable items shall be indicated therein. All titles, noting, markings and writings on the drawing shall be in English. All the dimensions should be in metric units.

G1.08.04.05 The drawings submitted by the Contractor (or their sub vendors) shall bear

Employer’s drawing number in addition to contractor’s (their sub-vendor’s) own drawing number. Employer’s drawing numbering system shall be made available to the successful bidder so as to enable him to assign Employer’s drawing numbers to the drawings to be submitted by him during the course of execution of the Contract.

G1.08.04.06 The Contractor shall also furnish a “Master Document List” which shall be a

comprehensive list of all drawings/ documents/ calculations/QP/FQP/WPS/Test Procedure envisaged to be furnished by him during the detailed engineering to the Employer along with the schedule of submission of each drawing/document. Such list should clearly indicate the purpose of submission of these drawings i.e. “FOR APPROVAL” or “FOR INFORMATION ONLY”.

G1.08.04.07 The review of these drawings by the Employer will cover only general

conformance of the data to the specifications and documents interfaces with the equipment provided under specifications, external connections, and of the dimensions which might affect plant layout. This review by the Employer may




not indicate a thorough review of all dimensions, quantities and details of the equipment, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by the Employer shall not be relieving the Contractor of any of his responsibilities and liabilities under this Contract.

G1.08.04.08 After the approval of the drawings, further work by the Contractor shall be in

strict accordance with these approved drawings and no deviation shall be permitted without the written approval of the

G1.08.04.09 All manufacturing, fabrication and execution of work in connection with the

equipment / system, prior to the approval of the drawings, shall be at the Contractor’s risk.

G1.08.04.10 The Contractor is expected not to make any changes in the design of the

equipment /system, once they are approved by the However, if some changes are necessitated in the design of the equipment/system at a later date, the Contractor may do so, but such changes shall promptly be brought to the notice of the Employer indicating the reasons for the change and get the revised drawing approved again in strict conformance to the provisions of the Technical Specification.

G1.08.04.11 Drawings shall include all installations and detailed piping layout drawings.

Layout drawings for all piping of 65 mm and larger diameter shall be submitted for review/ approval of Employer prior to erection. Small diameter pipes shall however be routed as per site conditions in consultation with site authority / representative of Employer based on requirements of such piping indicated in approved / finalized Flow Scheme / Process & Instrumentation Diagrams and/or the requirements cropping up for draining & venting of larger diameter piping or otherwise after their erection as per actual physical condition for the entire scope of work of this package.

G1.08.04.12 Assessing & anticipating the requirement and supply of all piping and equipment

shall be done by the contractor well in advance so as not to hinder the progress of piping & equipment erection, subsequent system charging and its effective draining & venting arrangement as per site suitability.

G1.08.04.13 Final copies of the approved drawings shall be submitted in vector form on CD-

ROM along with the requisite number of hard copies as per Annexure-A.

G1.08.04.14 AS BUILT DRAWINGS

After final acceptance of individual equipment / system by the Employer at the plant/site, the Contractor will update all original drawings and documents for the equipment / system to “as built” conditions.

All engineering data submitted by the Contractor after final process including review and approval by the Employer/Project Manager shall form part of the contract documents and the entire works covered under these specification shall be performed in strict conformity with technical specifications unless otherwise expressly requested by the Employer / Project Manager in writing.




G1.08.05 ENGINEERING INFORMATION SUBMISSION SCHEDULE

Prior to the award of Contract, a Detailed Engineering Information Submission Schedule shall be tied up. For this, the bidder shall furnish a detailed list of engineering information along with the proposed submission schedule. This list would be a comprehensive one including all engineering data / drawings / information for all bought out items and manufactured items. The information shall be categorized into the following parts. (a) Information that shall be submitted for the approval of the Employer before proceeding further, and (b) Information that would be submitted for Employer’s information only.

The schedule should allow adequate time for proper review and incorporation of changes/ modifications, if any, to meet the contract without affecting the equipment delivery schedule and overall project schedule. The early submission of drawings and data is as important as the manufacture and delivery of equipment and hardware and this shall be duly considered while determining the overall performance and progress.

G1.08.06 Engineering Co-ordination Procedure

G1.08.06.01 The following principal coordinators will be identified by respective organizations at time of award of contract: RINFRA Engineering Coordinator (RINFRA EC): Name : Designation : Address : a) Postal : b) Telegraphic / e-Mail : c) FAX : TELEPHONE : Contractor’s/ Vendor’s Engineering Coordinator (VENDOR EC): Name : Designation : Address : a) Postal : b) Telegraphic / e-Mail : c) FAX : TELEPHONE :

G1.08.06.02 All engineering correspondence shall be in the name of above coordinators on behalf of the respective organizations.

G1.08.06.03 Contractor’s/Vendor’s Drawing Submission and Approval Procedure:

a) All data/information furnished by Vendor in the form of drawings/

documents/catalogues or in any other form for RINFRA’s information/ interface and or review and approval are referred by the general term “drawings”.




b) The ‘Master document list’ indicating titles, Document Number, Date of submission and approval etc. shall be finalized mutually between Contractor and Employer before the award of contract. This list shall be updated if required at suitable interval during detailed engineering.

c) All drawings (including those of sub vendor’s) shall bear at the right hand

bottom corner the ‘title plate’ with all relevant information duly filled in. The Contractor shall furnish this format to his sub vendor along with his purchase order for sub vendor’s compliance.

d) Employer and contractor shall follow their own numbering systems for the

drawings. However, Employer shall intimate the contractor, RINFRA drawing number on receipt of the first submission of each drawing. Vendor, thereafter, shall indicate RINFRA’s drawing number in subsequent Submission, in the space provided for this purpose in title plate, in addition to his own drawing number.

e) The contractor shall make a visit to site to see the existing facilities and

understand the layout completely and collect all necessary data / drawings at site which are needed as an input to the engineering. The contractor shall do the complete engineering including interfacing and integration of all his equipment, systems & facilities within his scope of work as well as interface engineering & integration of systems, facilities, equipment & works under Employer’s scope and submit all necessary drawings/ documents for the same.

f) Drawings must be checked by the Contractor in terms of its completeness,

data adequacy and relevance with respect to Engineering schedule prior to submission. In case drawings are found to be submitted without proper endorsement for checking by the Contractor, the same shall not be reviewed and returned to the Contractor for re-submission.

g) The Contractor shall submit adequate prints of drawing / data / document for

Employer’s review and approval. The drawings submitted by the Contractor/vendor shall be reviewed by RINFRA and their comments shall be forwarded within four (4) weeks of receipt of drawings. Upon review of each drawing, depending on the correctness and completeness of the drawing, the same will be categorized and approval accorded in one of the following categories:

CATEGORY- A : Approved

CATEGORY- B : Approved, subject to incorporation of comments/

modification as noted. Resubmit revised drawing incorporating the comments.

CATEGORY –C : Not approved. Resubmit revised drawings for approval after incorporating comments/ modification as noted.

CATEGORY -D : For information and records.

h) Contractor shall resubmit the drawings approved under Category B, C & D within three (3) weeks of receipt of comments on the drawings, incorporating all comments. Every revision of the drawing shall bear a revision index




wherein such revisions shall be highlighted in the form of description or marked up in the drawing identifying the same with relevant revision Number enclosed in a triangle (eg. 1, 2, 3 etc). Contractor shall not make any changes in the portions of the drawing other than those commented. If changes are required to be made in the portions already approved, the Contractor shall resubmit the drawing identifying the changes for Employer’s review and approval. Drawings resubmitted shall show clearly the portions where the same are revised marking the relevant revision numbers and Employer shall review only such revised portion of documents.

i) In case, the Contractor/ Vendor does not agree with any specific comment,

he shall furnish the explanation for the same to RINFRA for consideration. In all such cases the Contractor shall necessarily enclose explanations along with the revised drawing (taking care of balance comments) to avoid any delay and/or duplication in review work.

j) It is responsibility of the Contractor/ Vendor to get all the drawings approved

in the Category A & D (as the case may be) and complete engineering activities within the agreed schedule. Any delay arising out of submission and modification of drawings shall not alter the contract completion schedule.

k) If Contractor/ Vendor fails to resubmit the drawings as per the schedule,

construction work at site will not be held up and work will be carried out on the basis of comments furnished on previous issues of the drawing.

l) These comments will be taken care by the contractor while submitting the

revised drawing. m) The contractor shall use a single transmittal for drawings. Submission. This

shall include transmittal numbers and date, number of copies being sent, names of the agencies to whom copies being sent, drawing number and titles, remarks or special notes if any etc.

G1.08.06.04 Engineering Progress Reporting /Exception Report

The contractor shall prepare every calendar month, at his own cost progress

reports describing the engineering activities in the reporting month, in a from and size acceptable to the Engineering coordinator. The progress report shall be in three sections.

In the first, all major engineering activities that took place during the reporting

month shall be clearly described, indicating major delays the agency responsible and any corrective actions taken.

The second section shall show an exception report showing the list of

drawings/engineering information which remains unapproved for more than four (4) weeks after the date of submission.

The third shall comprise drawings. Submission and approval status, listed

separately (i.e). for drawings submitted during the reporting month and drawings commented and approved during the reporting month.




Lastly the fourth section shall contain the ordering status of bought out items. The formats for ‘Drawing submission and approval Status’ and ‘Bought out’ items ordering status shall be furnished to the Bidder for his compliance, at the time of award of contract.

G1.08.06.05 TECHNICAL CO-ORDINATION MEETING

a) The Contractor shall be called upon to organize and attend monthly Design/

Technical Co-ordination Meetings (TCMs) with the Employer/Employer’s representatives and other Contractors of the Employer during the period of contract. The Contractor shall attend such meetings at his own cost at NOIDA or at mutually agreed venue as and when required and fully co-operate with such persons and agencies involved during the discussions.

b) The Contractor should note that Time is the essence of the contract. In order

to expedite the early completion of engineering activities, the Contractor shall submit all drawings as per the agreed Engineering Information Submission Schedule. The drawings submitted by the Contractor will be reviewed by the Employer as far as practicable within four (4) weeks from the date of receipt of the drawing .The comments of the Employer shall then be discussed across the table during the above Technical Co-ordination Meeting (s) wherein best efforts shall be made by both sides to ensure the approval of the drawing.

c) The Contractor shall ensure availability of the concerned experts /

consultants/ personnel/sub-vendor who are empowered to take necessary decisions during these meetings. The Contractor shall be equipped with necessary tools and facilities so that the drawings/documents can be resubmitted after incorporating necessary changes and approved during the meeting itself.

d) Should any drawing remain unapproved for more than six (6) weeks after it’s

first submission, this shall be brought out in the monthly Engineering Progress and Exception Report with reasons thereof.

e) Any delays arising out of failure by the Contractor to incorporate Employer’s

comments and resubmit the same during the TCM shall be considered as a default and in no case shall entitle the Contractor to alter the Contract completion date.

G1.08.07 DESIGN IMPROVEMENTS

The Employer or the Contractor may propose changes in the specification of the equipment or quality thereof and if the parties agree upon any such changes the specification shall be modified accordingly.




If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any changing the price and/or schedule of completion before the Contractor proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly.

G1.08.08 EQUIPMENT BASES

A cast iron or welded steel base plate shall be provided for all rotating equipment which is to be installed on a concrete base, unless otherwise specifically agreed to by the Each base plate which support the unit and its drive assembly, shall be of a neat design with pads for anchoring the units, shall have a raised lip all around, and shall have threaded drain connections.

G1.09.00 PROTECTIVE GUARDS

Suitable guards shall be provided for protection of personnel on all exposed rotating and/or moving machine parts. All such guards shall be designed for easy installation and removal for maintenance purpose.

G1.10.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS

G1.10.01 The Bidder’s scope includes all the first fill and one year’s topping, requirements of consumables such as oils, lubricants including grease, servo fluids, gases and essential chemicals etc. Consumption of all these consumables during the initial operation and final filling after the initial operation shall also be included in the scope of the Bidder. Bidder shall also supply a quantity not less than 10% of the full charge of each variety of lubricants, servo fluids; gases, chemicals etc. used which is expected to be utilized during the first year of operation. This additional quantity shall be supplied in separate Containers.

G1.10.02 As far as possible lubricants marketed by the Indian Oil Corporation shall be

used. The variety of lubricants shall be kept to a minimum possible.

Detailed specifications for the lubricating oil, grease, gases, servo fluids, control fluids, chemicals etc. required for the complete plant covered herein shall be furnished. On completion of erection, a complete list of bearings/ equipment giving their location and identification marks shall be furnished to the Employer along with lubrication requirements.

G1.10.03 Equipment shall be lubricated by systems designed for continuous operation. Lubricant level indicators shall be furnished and marked to indicate proper levels under both standstill and operating conditions.

G1.11.00 MATERIAL OF CONSTRUCTION




All materials used for the construction of the equipment shall be new and shall be in accordance with the requirements of this specification. Materials utilized for various components shall be those which have established themselves for use in such applications.

G1.12.00 RATING PLATES, NAME PLATES & LABELS

a) Each main and auxiliary item of plant including instruments shall have permanently attached to it in a conspicuous position, a rating plate of non-corrosive material upon which shall be engraved manufacturer’s name, equipment, type or serial number together with details of the ratings, service conditions under which the item of plant in question has been designed to operate, and such diagram plates as may be required by the

b) Each item of plant shall be provided with nameplate or label designating the

service of the particular equipment. The inscriptions shall be approved by the Employer or as detailed in appropriate section of the technical specifications.

c) Such nameplates or labels shall be of white non-hygroscopic material with

engraved black lettering or alternately, in the case of indoor circuit breakers, starters, etc. of transparent plastic material with suitably colored lettering engraved on the back. The name plates shall be suitably fixed on both front and rear sides.

d) Items of plant such as valves, which are subject to handling, shall be

provided with engraved chromium plated nameplate or label with engraving filled with enamel. The name plates for valves shall be marked in accordance with MSS standard SP-25 and ANSI B 16.34 as a minimum.

e) Hanger/ support numbers shall be marked on all pipe supports, anchors,

hangers, snubbers and restraint assemblies. Each constant and variable spring support shall also have stamped upon it the designed hot and cold load which it is intended to support. Suitable scale shall also be provided to indicate load on support/hanger.

f) Valves, steam traps and strainers shall be identified by Employer’s tag

number of a metal tap permanently attached to non pressure parts such as the yoke by a stainless steel wire. The direction of flow shall also be marked on the body.

g) Safety and relief valves shall be provided with Manufacturer’s identification,

Nominal inlet and outlet sizes in mm, Set pressure in Kg/cm2 (abs), Blow down and accumulation as percentage of set pressure and Certified capacity in Kg of saturated steam per hour or in case of liquid certified capacity in liters of water per minute.




h) All such plates, instruction plates, etc. shall be bilingual with Hindi inscription first, followed by English. Alternatively, two separate plates one with Hindi and the other with English inscriptions may be provided.

i) All segregated phases of conductors or bus ducts, indoor or outdoor, shall

be provided with colored phase plates to clearly identify the phase of the system.

G1.13.00 TOOLS AND TACKLES

The Contractor shall supply with the equipment one complete set of all special tools and tackles and other instruments required for the erection, assembly, disassembly and proper maintenance of the plant and equipment and systems (including software). These special tools will also include special material handling equipment, jigs and fixtures for maintenance and calibration / readjustment, checking and measurement aids etc. A list of such tools and tackles shall be submitted by the Bidder along with the offer.

The price of each tool / tackle shall be deemed to have been included in the total bid price. These tools and tackles shall be separately packed and sent to site. The Contractor shall also ensure that these tools and tackles are not used by him during erection, commissioning and initial operation. For this period the Contractor should bring his own tools and tackles. All the tools and tackles shall be of reputed make acceptable to the employer.

G1.14.00 WELDING

If the manufacturer has special requirements relating to the welding procedures for welds at the terminals of the equipments to be per formed by others the requirements shall be submitted to the Employer in advance of commencement of erection work. All welding procedures and welders shall be approved by Employer prior to start of fabrication at site.

G1.15.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES

All equipment/ piping/ pipe services are to be painted by the Contractor in accordance with Employer’s standard colour coding scheme, which will be furnished to the Contractor during detailed engineering stage.

G1.16.00 PROTECTION AND PRESERVATIVE SHOP COATING PROTECTION

G1.16.01 All coated surfaces shall be protected against abrasion, impact, discoloration and any other damages. All exposed threaded portions shall be suitably protected with either metallic or a nonmetallic protection device. All ends of all valves and pipings and conduit equipment connections shall be properly sealed




with suitable devices to protect them from damage. The parts which are likely to get rusted, due to exposure to weather, should also be properly treated and protected in a suitable manner. All primers/paints/coatings shall take into account the hot humid, corrosive & alkaline, subsoil or over ground environment as the case may be.

G1.16.02 PRESERVATIVE SHOP COATING

All exposed metallic surfaces subject to corrosion shall be protected by shop application of suitable coatings. All surfaces which will not be easily accessible after the shop assembly, shall be treated beforehand and protected for the life of the equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides and other coatings and prepared in the shop. The surfaces that are to be finish-painted after installation or require corrosion protection until installation, shall be shop painted with at least two coats of primer unless otherwise mentioned in the technical specification..

G1.16.03 Shop primer for all steel surfaces which will be exposed to operating temperature below 95 degrees Celsius shall be selected by the Contractor after obtaining specific approval of the Employer regarding the quality of primer proposed to be applied. Special high temperature primer shall be used on surfaces exposed to temperature higher than 95 degrees Celsius and such primer shall also be subject to the approval of the employer.

G1.16.04 All other steel surfaces which are not to be painted shall be coated with suitable rust preventive compound subject to the approval of the employer.

G1.16.05 All piping shall be cleaned after shop assembly by shot blasting or other means approved by the Lube oil piping or carbon steel shall be pickled.

G1.16.06 Painting for Civil structures shall be done as per relevant part of technical specification

G1.17.00 QUALITY ASSURANCE PROGRAMME

G1.17.01 The Contractor shall "Prepare, submit and get it approved by the employer” for suitable quality assurance programme to ensure that the equipment and services under the scope of contract whether manufactured or performed within the Contractor’s works or at his sub-contractor’s premises or at the Employer’s site or at any other place of work are in accordance with the specifications. Such programmes shall be outlined by the Contractor and shall be finally accepted by the Employer/authorised representative after discussions before the award of the contract. The QA programme shall be generally in line with IS/ISO-9001.A quality assurance programme of the contractor shall generally cover the following: a) His organization structure for the management and implementation of the

proposed quality assurance programme b) Quality System Manual c) Design Control System




d) Documentation and Data Control System e) Qualification data for bidder’s key personnel. f) The procedure for purchase of materials, parts, components and selection of

sub-contractor’s services including vendor analysis, source inspection, incoming raw-material inspection, verification of materials purchased etc.

g) System for shop manufacturing and site erection controls including process, fabrication and assembly.

h) Control of non-conforming items and system for corrective actions and resolution of deviations.

i) Inspection and test procedure both for manufacture and field activities. j) Control of calibration and testing of measuring testing equipment. k) System for Quality Audits. l) System for identification and appraisal of inspection status. m) System for authorizing release of manufactured product . n) System for handling, storage and delivery. o) System for maintenance of records, and p) Quality plans for manufacturing and field activities detailing out the specific

quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component.

G1.17.02 GENERAL REQUIREMENTS - QUALITY ASSURANCE

G1.17.02.01 All materials, components and equipment covered under this specification shall

be procured, manufactured, erected, commissioned and tested at all the stages, as per a comprehensive Quality Assurance Programme. An indicative programme of inspection/tests to be carried out by the contractor for some of the major items is given in the respective technical specification. This is, however, not intended to form a comprehensive programme as it is the contractor’s responsibility to draw up and implement such programme duly approved by the Employer The detailed Quality Plans for manufacturing and field activities shall be drawn up by the Bidder and will be submitted to Employer for approval. Schedule of finalization of such quality plans will be finalized before award. Monthly progress reports on Manufacturing Quality Plan (MQP)/ Field Quality Plan (FQP) submission/approval shall be furnished on enclosed formats.

G1.17.02.02 MQP will detail out for all the components and equipment, various

tests/inspection, to be carried out as per the requirements of this specification and standards mentioned therein and quality practices and procedures followed by Contractor’s/ Sub-contractor’s/ sub-supplier's Quality Control Organization, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of materials procurement, manufacture, assembly and final testing/performance testing. The Quality Plan shall be submitted on electronic media e.g. floppy or E-mail in addition to hard copy, for review and approval. After approval the same shall be submitted in compiled form on CD-ROM.




G1.17.02.03 FQPs will detail out for all the equipment, the quality practices and procedures

etc. to be followed by the Contractor’s "Site Quality Control Organization", during various stages of site activities starting from receipt of materials/equipment at site.

G1.17.02.04 The Bidder shall also furnish copies of the reference documents/plant

standards/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans along with Quality Plans. These Quality Plans and reference documents/standards etc. will be subject to Employer’s approval without which manufacturer shall not proceed. These approved documents shall form a part of the contract. In these approved Quality Plans, Employer shall identify customer hold points, i.e. test/checks which shall be carried out in presence of the Employer’s Project Manager or his authorised representative and beyond which the work will not proceed without consent of Employer in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to Employer along with technical justification for approval and disposition.

G1.17.02.05 No material shall be dispatched from the manufacturer’s works before the same

is accepted, subsequent to pre dispatch final inspection including verification of records of all previous tests/inspections by Employer’s Project Manager/Authorised representative and duly authorised for dispatch by issuance of Material Dispatch Clearance Certificate (MDCC).

G1.17.02.06 All material used for equipment manufacture including casting and forging etc.

shall be of tested quality as per relevant codes/standards. Details of results of the tests conducted to determine the mechanical properties; chemical analysis and details of heat treatment procedure recommended and actually followed shall be recorded on certificates and time temperature chart. Tests shall be carried out as per applicable material standards and/or agreed details.

G1.17.02.07 The contractor shall submit to the Employer Field Welding Schedule for field

welding activities in the enclosed format. The field welding schedule shall be submitted to the Employer along with all supporting documents, like welding procedures, heat treatment procedures, NDT procedures etc. it shall be " submission of documents shall be within a month progressively after the placement of the order"

G1.17.02.08 All welding and brazing shall be carried out as per procedure drawn and

qualified in accordance with requirements of ASME Section IX/BS-4870 or other International equivalent standard acceptable to the

G1.17.02.09 All welding/brazing procedures shall be submitted to the Employer or its

authorized representative for approval prior to carrying out the welding/brazing.

G1.17.02.10 All brazers, welders and welding operators employed on any part of the contract either in Contractor’s/sub-contractor works or at site or elsewhere shall be




qualified as per ASME Section-IX or BS-4871 or other equivalent International Standards acceptable to the Employer.

G1.17.02.11 Welding procedure qualification & Welder qualification test results shall be

furnished to the Employer for approval. However, where required by the Employer, tests shall be conducted in presence of Employer/authorized representative.

G1.17.02.12 For all pressure parts and high pressure piping welding, the latest applicable

requirements of the IBR (Indian Boiler Regulations) shall also be essentially complied with. Similarly, any other statutory requirements for the equipment/systems shall also be complied with. On all back-gauged welds MPI/LPI shall be carried before seal welding.

G1.17.02.13 Unless otherwise proven and specifically agreed with the Employer, welding of

dissimilar materials and high alloy materials shall be carried out at shop only.

G1.17.02.14 No welding shall be carried out on cast iron components for repair.

G1.17.02.15 All the heat treatment results shall be recorded on time temperature charts and verified with recommended regimes.

G1.17.02.16 All non-destructive examination shall be performed in accordance with written

procedures as per International Standards, The NDT operator shall be qualified as per SNT-TC-IA (of the American Society of non-destructive examination). NDT shall be recorded in a report, which includes details of methods and equipment used, result/evaluation, job data and identification of personnel employed and details of co-relation of the test report with the job.

All plates of thickness above 40mm & all bar stock/Forging above 40mm dia shall be ultrasonically tested. For pressure parts, plate of thickness equal to or above 25mm shall be ultrasonically tested.

G1.17.02.17 The Contractor shall list out all major items/ equipment/ components to be

manufactured in house as well as procured from sub-contractors (BOI). All the sub-contractor proposed by the Contractor for procurement of major bought out items including castings, forging, semi-finished and finished components/ equipment etc., list of which shall be drawn up by the Contractor and finalized with the Employer, shall be subject to Employer's approval. The contractor’s proposal shall include vendor’s facilities established at the respective works, the process capability, process stabilization, QC systems followed, experience list, etc. along with his own technical evaluation for identified sub-contractors enclosed and shall be submitted to the Employer for approval within the period agreed at the time of pre-awards discussion and identified in "DR" category prior to any procurement. Monthly progress reports on sub-contractor detail submission / approval shall be furnished on enclosed on format. Such vendor approval shall not relieve the contractor from any obligation, duty or responsibility under the contract.




G1.17.02.18 For components/equipment procured by the contractors for the purpose of the

contract, after obtaining the written approval of the Employer, the contractor’s purchase specifications and inquiries shall call for quality plans to be submitted by the suppliers. The quality plans called for from the sub-contractor shall set out, during the various stages of manufacture and installation, the quality practices and procedures followed by the vendor’s quality control organization, the relevant reference documents/standards used, acceptance level, inspection of documentation raised, etc. Such quality plans of the successful vendors shall be finalized with the Employer and such approved Quality Plans shall form a part of the purchase order/contract between the Contractor and sub-contractor. With in three weeks of the release of the purchase orders /contracts for such bought out items /components, a copy of the same without price details but together with the detailed purchase specifications, quality plans and delivery conditions shall be furnished to the Employer on the monthly basis by the Contractor along with a report of the Purchase Order placed so far for the contract.

G1.17.02.19 Employer reserves the right to carry out quality audit and quality surveillance of

the systems and procedures of the Contractor’s or their sub-contractor’s quality management and control activities. The contractor shall provide all necessary assistance to enable the Employer carry out such audit and surveillance.

G1.17.02.20 The contractor shall carry out an inspection and testing programme during

manufacture in his work and that of his sub-contractor’s and at site to ensure the mechanical accuracy of components, compliance with drawings, conformance to functional and performance requirements, identity and acceptability of all materials parts and equipment. Contractor shall carry out all tests/inspection required to establish that the items/equipment conform to requirements of the specification and the relevant codes/standards specified in the specification, in addition to carrying out tests as per the approved quality plan.

G1.17.02.21 Quality audit/surveillance/approval of the results of the tests and inspection will

not, however, prejudice the right of the Employer to reject the equipment if it does not comply with the specification when erected or does not give complete satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring complete conformance of the materials/equipment supplied to relevant specification, standard, data sheets, drawings, etc.

G1.17.02.22 For all spares and replacement items, the quality requirements as agreed for the

main equipment supply shall be applicable.

G1.17.02.23 Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Employer/ authorized representative.

G1.17.02.24 Burn in and Elevated Temperature Test Requirement for Electronics Solid

State Equipment




Contractor/ Sub Contactor shall confirm that all solid state electronic system/ equipment/ sub assembly is free from infant motile components and established procedure is followed. In case during any stage of the contract, if it is established that contractor and their sub-contractor haven’t followed the established procedure then all liabilities arising out of this shall be born by the contractor within the quoted lump sum price.

G1.17.03 QA DOCUMENTATION PACKAGE

G1.17.03.01 The Contractor shall be required to submit the QA Documentation in two hard copies and two CD ROMs, as identified in respective quality plan with tick (#) mark.

G1.17.03.02 Each QA Documentation shall have a project specific Cover Sheet bearing name & identification number of equipment and including an index of its contents with page control on each document.

The QA Documentation file shall be progressively completed by the Supplier’s sub- supplier to allow regular reviews by all parties during the manufacturing.

The final quality document will be compiled and issued at the final assembly place of equipment before dispatch. However CD-Rom may be issued not later than three weeks.

G1.17.03.03 Typical contents of QA Documentation are as below:- a) Quality Plan b) Material mill test reports on components as specified by the specification

and approved Quality Plans. c) Manufacturer / works test reports/results for testing required as per

applicable codes and standard referred in the specification and approved Quality Plans.

d) Non-destructive examination results/reports including radiography interpretation reports. Sketches/drawings used for indicating the method of traceability of the radiographs to the location on the equipment.

e) Heat Treatment Certificate/Record (Time- temperature Chart). f) All the accepted Non-conformance Reports (Major/Minor)/ deviation,

including complete technical details/repair procedure). g) Demineralization plant / Inspection reports duly signed by the Inspector of

the Employer and Contractor for the agreed Customer Hold Points. h) Certificate of Conformance (COC) wherever applicable. i) MDCC

G1.17.03.04 Similarly, the contractor shall be required to submit two sets (two hard copies

and two CD ROMs), containing QA Documentation pertaining to field activities




as per Approved Field Quality Plans and other agreed manuals/ procedures, prior to commissioning of individual system.

G1.17.03.05 Before dispatch / commissioning of any equipment, the Supplier shall make sure

that the corresponding quality document or in the case of protracted phased deliveries, the applicable section of the quality document file is completed. The supplier will then notify the Inspector regarding the readiness of the quality document (or applicable section) for review.

If the result of the review carried out by the Inspector is satisfactory, the Inspector shall stamp the quality document (or applicable section) for release. If the quality document is unsatisfactory, the Supplier shall endeavor to correct the incompleteness, thus allowing finalizing the quality document (or applicable section) by time compatible with the requirements as per contract documents. When it is done, the quality document (or applicable section) is stamped by the Inspector.

If a decision is made to dispatch, whereas all outstanding actions cannot be readily cleared for the release of the quality document by that time, the supplier shall immediately, upon shipment of the equipment, send a copy of the quality document Review Status signed by the Supplier Representative to the Inspector and notify of the committed date for the completion of all outstanding actions & submission. The Inspector shall stamp the quality document for applicable section when it is effectively completed. The submission of QA documentation package shall not be later than 3 weeks after the dispatch of equipment.

G1.17.03.06 TRANSMISSION OF QA DOCUMENTATION

On release of QA Documentation by Inspector, one set of quality document shall be forwarded to Corporate Quality Assurance Department and other set to respective Project Site.

For the particular case of phased deliveries, the complete quality document to the Employer shall be issued not later than 3 weeks after the date of the last delivery of equipment.

G1.17.04 PROJECT MANAGER’S SUPERVISION

G1.17.04.01 To eliminate delays and avoid disputes and litigation, it is agreed between the

parties to the Contract that all matters and questions shall be referred to the Project Manager and without prejudice to the provisions of ‘Arbitration’ clause in Section GCC of Vol.I, the Contractor shall proceed to comply with the Project Manager's decision.




G1.17.04.02 The work shall be performed under the supervision of the Project Manager. The scope of the duties of the Project Manager pursuant to the Contract will include but not be limited to the following:

a) Interpretation of all the terms and conditions of these documents and specifications:

b) Review and interpretation of all the Contractor’s drawing, engineering data, etc:

c) Witness or his authorised representative to witness tests and trials either at the manufacturer’s works or at site, or at any place where work is performed under the contract :

d) Inspect, accept or reject any equipment, material and work under the contract :

e) Issue certificate of acceptance and/or progressive payment and final payment certificates

f) Review and suggest modifications and improvement in completion schedules from time to time, and

g) Supervise Quality Assurance Program implementation at all stages of the works.

G1.17.05 INSPECTION, TESTING AND INSPECTION CERTIFICATES

G1.17.05.01 The word ‘Inspector’ shall mean the Project Manager and/or his authorised

representative and/or an outside inspection agency acting on behalf of the Employer to inspect and examine the materials and workmanship of the works during its manufacture or erection.

G1.17.05.02 The Project Manager or his duly authorised representative and/or an outside

inspection agency acting on behalf of the Employer shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection and if part of the works is being manufactured or assembled on other premises or works, the Contractor shall obtain for the Project Manager and for his duly authorised representative permission to inspect as if the works were manufactured or assembled on the Contractor’s own premises or works.

G1.17.05.03 The Contractor shall give the Project Manager/Inspector fifteen (15) days written

notice of any material being ready for testing. Such tests shall be to the Contractor’s account except for the expenses of the Inspector’s. The Project Manager/Inspector, unless the witnessing of the tests is virtually waived and confirmed in writing, will attend such tests within fifteen (15) days of the date on which the equipment is noticed as being ready for test/inspection failing which the contractor may proceed with test which shall be deemed to have been made in the inspector’s presence and he shall forthwith forward to the inspector duly certified copies of test reports in two (2) copies.

G1.17.05.04 The Project Manager or Inspector shall within fifteen (15) days from the date of

inspection as defined herein give notice in writing to the Contractor, or any




objection to any drawings and all or any equipment and workmanship which is in his opinion not in accordance with the contract. The Contractor shall give due consideration to such objections and shall either make modifications that may be necessary to meet the said objections or shall inform in writing to the Project Manager/Inspector giving reasons therein, that no modifications are necessary to comply with the contract.

G1.17.05.05 When the factory tests have been completed at the Contractor’s or sub-

contractor’s works, the Project Manager/Inspector shall issue a certificate to this effect fifteen (15) days after completion of tests but if the tests are not witnessed by the Project Manager /Inspectors, the certificate shall be issued within fifteen (15) days of the receipt of the Contractor’s test certificate by the Project Manager /Inspector. Project Manager /Inspector to issue such a certificate shall not prevent the Contractor from proceeding with the works. The completion of these tests or the issue of the certificates shall not bind the Employer to accept the equipment should it, on further tests after erection be found not to comply with the contract.

G1.17.05.06 In all cases where the contract provides for tests whether at the premises or

works of the Contractor or any sub-contractor, the Contractor, except where otherwise specified shall provide free of charge such items as labour, material, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Project Manager /Inspector or his authorised representatives to carry out effectively such tests on the equipment in accordance with the Contractor and shall give facilities to the Project Manager/Inspector or to his authorised representative to accomplish testing.

G1.17.05.07 The inspection by Project Manager / Inspector and issue of Inspection

Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed Quality Assurance Programme forming a part of the contract.

G1.17.05.08 To facilitate advance planning of inspection in addition to giving inspection

notice as specified above the Contractor shall furnish quarterly inspection programme indicating schedule dates of inspection at Customer Hold Point and final inspection stages. Updated quarterly inspection plans will be made for each three consecutive months and shall be furnished before beginning of each calendar month.

G1.17.05.09 All inspection, measuring and test equipment used by contractor shall be

calibrated periodically depending on its use and criticality of the test/measurement to be done. The Contractor shall maintain all the relevant records of periodic calibration and instrument identification, and shall produce the same for inspection by RINFRA. Wherever asked specifically, the contractor shall re-calibrate the measuring/test equipment in the presence of Project Manager / Inspector.

G1.17.06 Associated Document for Quality Assurance Programme:




a) List of items requiring quality plan and sub supplier approval. (Annexure-B).

b) Status of items requiring Quality Plan and sub supplier approval. (Annexure-C).

c) Field Welding Schedule (Annexure-D). d) Manufacturing Quality Plan (Annexure-E). e) Field Quality Plan (Annexure-F).

G1.18.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES

a) As soon as the facilities or part thereof has been completed operationally

and structurally and before start-up, each item of the equipment and systems forming part of facilities shall be thoroughly cleaned and then inspected jointly by the Employer and the Contractor for correctness of and completeness of facility or part thereof and acceptability for initial pre-commissioning tests, commissioning and start-up at Site. The list of pre-commissioning tests to be performed shall be as mutually agreed and included in the Contractor’s quality assurance programme as well as those included elsewhere in the Technical Specifications.

b) The Contractor’s pre-commissioning/commissioning/start-up engineers,

specially identified as far as possible, shall be responsible for carrying out all the pre-commissioning tests at Site. On completion of inspection, checking and after the pre-commissioning tests are satisfactorily over, the commissioning of the complete facilities shall be commenced during which period the complete facilities, equipments shall be operated integral with sub-systems and supporting equipment as a complete plant.

c) All piping system shall be flushed; steam blown, air blown as required and

cleanliness demonstrated using acceptable industry standards. Procedures to accomplish this work shall be submitted for approval to the Employer six months prior to the respective implementations. The Employer will approve final verification of cleanliness.

d) The time consumed in the inspection and checking of the units shall be

considered as a part of the erection and installation period.

e) The check outs during the pre - commissioning period should be programmed to follow the construction completion schedule. Each equipment/system, as it is completed in construction and turned over to Employer's commissioning (start-up) Engineer(s), should be checked out and cleaned. The checking and inspection of individual systems should then follow a prescribed commissioning documentation [SLs (Standard Check List) / TS (Testing Schedule) / CS (Commissioning Schedule)] approved by the employer.

f) The Contractor during initial operation and performance testing shall

conduct vibration testing to determine the ‘base line’ of performance of all




plant rotating equipment. These tests shall be conducted when the equipment is running at the base load, peak load as well as lowest sustained operating condition as far as practicable.

g) Contractor shall furnish the commissioning organization chart for review &

acceptance of employer at least eighteen months prior to the schedule date of synchronization of 1st unit. The chart should contain : i) Biodata including experience of the Commissioning Engineers. ii) Role and responsibilities of the Commissioning Organization members. iii) Expected duration of posting of the above Commissioning Engineers at

site.

G1.19.00 INITIAL OPERATION a) On completion of all pre-commissioning activities/tests and as a part of

commissioning the complete facilities shall be put on 'Initial Operation' during which period all necessary adjustments shall be made while operating over the full load range enabling the facilities to be made ready for the Guarantee Tests.

b) The duration of initial Operation of the complete equipment shall be fourteen

(14) days out of which at least seventy two (72) hours shall be continuous operation on full load or any other duration as may be agreed to between the Engineer and the Contractor.

c) The initial operation shall be considered successful provided that each item

of the equipment can operate continuously at the specified operating characteristics, for the period of initial Operation. For the period of Trial Operation, the time of operation with any load shall be counted. Minor interruptions not exceeding four (4) hours at a time caused during the continuous operation shall not affect the total duration of trial Operation. However if in the opinion of the Engineer the interruption is long, the initial operation shall be prolonged for the period of interruption.

d) An initial operation report comprising observations and recordings of various

parameters to be measured in respect of the above initial operation shall be prepared by the contractor. This report, besides recording the details of the various observations during initial run shall also include the dates of start and finish of the initial operation and shall be signed by the representatives of both the parties. The report shall have sheets, recording all the details of interruptions occurred, adjustments made and any minor repair done during the initial operation. Based on the observations, necessary modifications/ repair to the plant shall be carried out by the contractor to the full satisfaction of the engineer to enable to the latter to accord permission to carry out performance and guarantee tests on the plant. However, minor defects, which do not endanger the safe operation of the equipment, shall not be considered as reasons for with holding the aforesaid permission.

G1.20.00 PERFORMANCE & GUARANTEE TEST

G1.20.01 The final test as to performance and guarantees shall be conducted at site by the Contractor. Such tests will commence, with in a period of two (2) months




after successful completion of trial operations. Any extension of time beyond the above two (2) months shall be mutually agreed upon.

G1.20.02 These tests shall be binding on both the parties of the contract tom determine

compliance of the equipment with the performance guarantees. G1.20.03 The available instrumentation and control equipment will be used during such

tests and the Engineer will calibrate all such measuring equipment and devices as far as practicable. However, unmeasurable parameters shall be taken in to account in a reasonable manner by the Engineer, for the requirement of these tests. The tests will be conducted at the specified load points and as near the specified cycle condition as practicable. The engineer will apply proper corrections in calculation, to take into account conditions which do not correspond to the specified conditions.

G1.20.04 Any special equipment, tools and tackles required for the successful completion

of the Performance and Guarantee tests shall be provided by the Contractor, free of cost.

G1.20.05 The guaranteed performance figures of the equipments shall be proved by the

Contractor during these Performance and Guarantee tests. Should the results of these tests show any decrease from the guaranteed values, the Contractor shall modify the equipments as required to enable it to meet the guarantees. In such case, Performance and Guarantee tests shall be repeated within one month, from the date the equipment is ready for retest and all cost for modifications including labour, materials and the cost of additional testing to prove that the equipment meets the guarantees shall be borne by the Contractor.

G1.20.06 The specific tests to be conducted on equipment have been brought out in the

Technical Specifications.

G1.20.07 Performance and Guarantee test shall make allowance for instrumentation errors, as may be decided by the Engineer-in-Charge.

G1.21.00 TAKING OVER

Upon successful completion of Initial Operations and all the tests conducted to the Employer's satisfaction, the Employer shall issue to the Contractor a Taking over Certificate as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably be with held nor will the Employer delay the issuance thereof, on account of minor omissions or defects which do not affect the commercial operation and/or cause any serious risk to the equipment. Such certificate shall not relieve the Contractor of any of his obligations which otherwise survive, by the terms and conditions of the Contract after issuance of such certificate.

G1.22.00 TRAINING OF EMPLOYER'S PERSONNEL

G1.22.01 The scope of service under training of Employer’s engineers shall include a training module in the areas of Operation & Maintenance.

Such training should cover the following areas as a minimum in order to enable these personnel to individually take the responsibility of operating and maintaining the complete system and all the equipments covered in this contract.




G1.22.02 The scope of services under training shall necessarily include training of Employer’s O & M personnel covering a training module for a period mutually agreed to between Employer and Contractor. This shall cover all disciplines viz., Mechanical, Electrical, and C&I etc. and shall include all the related areas like Basic design of the system, design basis of each equipment, trouble shooting in plant operation, and O & M aspects of each equipment including all the electrical and C&I equipments and associated operational software used for the project covering all the Bidder’s equipments and as well as their sub-vendor equipments.

G1.22.03 Such training shall be arranged in this project or in any other operating power

station where Bidder’s/Sub-vendor’s equipments are installed and/or at manufacturer’s works of the equipment supplier. The details and module of training shall be submitted and mutually agreed to between the Employer and Contractor before the take over of the plant by exact details, extent of training and the training schedule shall be finalized based on the Bidder's proposal later.

G1.22.04 All traveling and lodging/boarding expenses of the Employer's personnel to be

trained shall be borne by the In the event, any other expenditure is required from Contractor's side for purpose of arrangement and/or giving training facilities to get the operators trained, the same shall be borne by the contractor.

G1.23.00 NOISE LEVEL

The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m above floor level in elevation and at a distance of one (1) metre horizontally from the nearest surface of any equipment / machine, furnished and installed under these specifications, expressed in decibels to a reference of 0.0002 microbar, shall not exceed 85 dBA.

G1.24.00 PACKAGING AND TRANSPORTATION

All the equipments shall be suitably protected, coated, covered or boxed and crated to prevent damage or deterioration during transit, handling and storage at Site till the time of erection. While packing all the materials, the limitation from the point of view of the sizes of railway wagons available in India should be taken account of. The Contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. The Contractor shall ascertain the availability of Railway wagon sizes from the Indian Railways or any other agency concerned in India well before effecting dispatch of equipment. Before dispatch it shall be ensured that complete processing and manufacturing of the components is carried out at shop, only restricted by transport limitation, in order to ensure that site works like grinding, welding, cutting & pre-assembly to bare minimum. The Employer's Inspector shall have right to insist for completion of works in shops before dispatch of materials for transportation.

G1.25.00 ELECTRICAL ENCLOSURE




All electrical equipments and devices, including insulation, heating and condensing devices shall be designed for ambient temperature and a maximum relative humidity as specified elsewhere in the specification.

G1.26.00 INSTRUMENTATION AND CONTROL

All instrumentation and control systems/ equipment/ devices/ components, furnished under this contract shall be in accordance with the requirements stated in this specification.

G1.27.00 ELECTRICAL NOISE CONTROL

The equipment furnished by the Contractor shall incorporate necessary techniques to eliminate measurement and control problems caused by electrical noise. Areas in Contractor’s equipment which are vulnerable to electrical noise shall be hardened to eliminate possible problems. Any additional equipment, services required for effectively eliminating the noise problems shall be included in the proposal. The equipment shall be protected against ESD as per IEC-801-2. Radio Frequency interference (RFI) and Electro Magnetic Interference (EMI) protection against hardware damage and control system mal-operations/errors shall be provided for all systems.

Annexure-A

S. No. Description Of Documents f Prints (Sets) NO. OF CD-ROMs 1. Drawings for Initial Submission (Either

"FOR APPROVAL" or “FOR INFORMATION Category) and re-submissions after review by RINFRA (including Data sheets/ Calculations, all Equipment/instrument schedule, BOM etc)

8 1 Soft Copy (through 1 no of CD-Rom or

through E-Mail)

2. Final Approved Drawings (Cat-I & Cat – IV Approved) (As referred in Sl no: 1 above)

3 4 CD- ROMs

3. Documents / Drawings "AS BUILT " 3 4 CD- ROMs 4. Type test reports (Initial) 8 1 Soft Copy (through

1 no of CD-Rom or through E-Mail)

5 Type test reports (Final) 1 2 CD-ROMs 6. Piping / Equipment Analysis (Transient) etc,

Model study reports (Draft) Including the input/ output data etc.


through E-Mail)




Annexure-A S. No. Description Of Documents f Prints (Sets) NO. OF CD-ROMs

7. Piping / Equipment Analysis (Transient) etc, Model study reports (Final Approved) Including the input/ output data etc.

2 4 CD-ROMs

8 Erection manual "Draft " 4 sets 1 CD ROMS 8 Erection manual "Final " 4 sets 1 CD ROMS 9 Operation & Maintenance manual "DRAFT" 4 sets 2 CD ROMS

10 Operation & Maintenance manual "FINAL” 4 sets 4 CD ROMS 11 Commissioning Procedure (If applicable)

(DRAFT) 4 sets 1 CD ROMS

12. Commissioning Procedure (If applicable) (FINAL)

4 sets 1 CD ROMS

13 Performance and Guarantee test Procedure (Draft)


through E-Mail)

14. Performance and Guarantee test Procedure (Final)

8 1 Soft Copy ( 1 no of CD-Rom or through E-

Mail)

16 Progress Reports 8 Through e-mail 16 Project completion report 3 Sets 3CD ROMS 17 QA programme including Organization for

implementation and QA system manual (with revision-servicing)

1 1 CD-ROM

18 Vendor details in respect of proposed vendors including contractor’s evaluation report.

1 1 CD –ROM

19 Manufacturing QPs, Field QPs, Field welding schedules and their reference documents like test procedures, WPS, POR etc.

i) For review/comment - 3 1 set of soft copy

(ii) For final approval 1 set floppies

4 1 CD ROM

20 Welding Manual, Heat Treatment Manuals, Storage & preservation manuals

Draft 4 sets Final 4 sets 2 CD ROMS

21 Monthly Vendor Approval /QP approval status 2 sets 1 CD rom




Annexure-A S. No. Description Of Documents f Prints (Sets) NO. OF CD-ROMs

22 QA Documentation Package for items / equipment manufactured and dispatched to site

2 Sets 2 CD ROMS

23 QA Documentation Package for field activities on equipment / systems at site

2 Sets 2 CD ROMS


2400 MW CCPP SAMALKOT Expansion

REL -SKCCP-NEG-E24-P-00003 R0 Part III Page 37 of 42

ANNEXURE-B

DOC. NO.: REV. NO.: DATE :

Project : Stage :Package : Supplier : Contractor No. :

LIST OF ITEMS REQUIRING QUALITY PLAN AND SUB-SUPPLIER APPROVAL

SUB-SYSTEM : PAGE : OF

S. N.

Item QP/ Insp. Cat.

QP No.

QP Sub. Schedule

QP approval schedule

Proposed sub-

supplier

Place Sub-suppliers approval status/ category

Sub-supplier Details submission schedule

Remarks




LEGENDS SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY REL) A – For these items proposed vendor is acceptable to REL. To be indicated with letter “A” in the list along with the condition of approval, if any. DR – For these items “Detailed required” for REL review. To be identified with letter “DR” in the list. NOTED – For these items vendors are approved by Main Supplier and accepted by REL without specific vendor approval from REL. To be identified with “NOTED.’ QP/INSPN CATEGORY: CAT-I: For these items the Quality Plans are approved by REL and the final acceptance will be on physical inspection witness by REL. CAT-II: For these items the Quality Plans approved by REL. However no physical inspection shall be done by REL. The final acceptance by REL shall be on the basis review of documents as per approved QP. CAT-III: For these items Main Supplier approves the Quality Plans. The final acceptance by REL shall be on the basis certificate of conformance by the main supplier. UNITS/WORKS: Place of manufacturing Place of Main Supplier of multi units/works. FORMAT NO.: 1/1 Engg. Div. / QA&I




ANNEXURE-C


Project : Stage : : Package : Contractor : Contractor No. :

STATUS OF ITEM REQUIRING QP& SUB-SUPPLIER APPROVAL

PAGE : OF S. N.

Item / Service QP/ Insp. Cat.

QP Sub. Schedule Approval schedule

Date of sub-mission

Date of commt Appl.

Status Code C/II/I

Proposed Sub-suppliers

Place of manufacturing

works

Approval Status

Sub-supplier detail submission schedule

Remarks

FORMAT NO.: 1/1 Engg. Div. / QA&I




Annexure-D


Project : Stage :Contractor : Contractor No. : System :

FIELD WELDING SCHEDULE (To be raised by the contractor)

Welding Code: ………………………………………

PAGE : OF Dimension

s

Heat treatment REF Sl. No.

DRG No. for Weld Location and Identification mark

Description of parts to welded

Matl. Spec

Process of welding

Type of Weld

Electrode filler spec.

WPS. No.

Min. pre-heat

Temp. Holding time

NDT method/ Quantum

Spec. No.

ACC Norm Ref.

Remarks

NOTES:

SIGNATURE FORMAT NO.: 1/1 Engg. Div. / QA&I




Annexure-E

MANUFACTURING QUALITY PLAN MFGR.’s LOGO

MANUFACTURER’S NAME AND ADDRESS ITEM :

SUB-SYSTEM:

QP NO.: REV.NO.: DATE: PAGE: …. OF….

PROJECT : PACKAGE : CONTRACT NO. : MAIN-SUPPLIER:

AGENCY SL.

NO

COMPONENT & OPERATIONS

CHARACTERISTICS

CLASS

TYPE OF CHECK

QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE NORMS

FORMAT OF RECORD

M C N

REMARKS

1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11.

DOC. NO.: REV…… CAT…..

MANUFACTURER/ SUB-SUPPLIER

MAIN-SUPPLIER

SIGNATURE

LEGEND: * RECORDS, INDENTIFIED WITH “TICK” ( √ ) SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. ** M: MANUFACTURER/SUB-SUPPLIER C: SUPPLIER/NOMINATED INSPECTION AGENCY, N: REL P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE, CT: REL SHALL IDENTIFIED IN COLUM “N”

FOR REL USE

REVIEWED BY

APPROVED BY

APPROVAL SEAL

Annexure-F




FIELD QUALITY PLAN

MFGR.’s LOGO

SUPPLIER’S NAME AND ADDRESS ITEM :

SUB-SYSTEM :

QP NO.: REV.NO.: DATE: PAGE: …. OF….

PROJECT : PACKAGE : CONTRACT NO. : MAIN-SUPPLIER:

SLNO

ACTIVITY AND OPERATION

CHARACTERISTICS / INSTRUMENTS

CLASS# OF CHECK

TYPE OF CHECK

QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE NORMS

FORMAT OF RECORD

REMARKS

1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.

DOC. NO.: REV…… CAT ….

MANUFACTURER/ SUB-SUPPLIER

MAIN-SUPPLIER

SIGNATURE

LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (√) SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR, C=MINOR; ‘A’ SHALL BE WITNESSED BY REL FQA, ‘B’ SHALL BE WITNESSED BY REL ERECTION / CONSTRUCTION DEPTT. AND ‘C’ SHALL BE WITNESSED BY ERECTION SUPPLIER (A & B CHECK SHALL BE REL COOLIGN TOWER STAGE) FOR REL

USE

REVIEWED BY

APPROVED BY

APPROVAL SEAL

Format No.: 1/1 Engg. Div./QA&I



REL-SKCCP-NEM-161-P-00001(Rev.00) PART III, SECTION 2

ERECTION CONDITIONS OF CONTRACT

Page 1 of 45

PART III

SECTION 2






Page 2 of 45

1.00.00 GENERAL 1.01.00 The following provisions shall supplement the conditions already contained in the

other parts of these specifications and documents and shall govern that portion of the work of this contract which is to be performed at site. The erection requirements and procedures not specified in these documents shall be in accordance with the recommendations of the equipment manufacturer, or as mutually agreed to between the Employer and the Contractor prior to commencement of erection work.

1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project Coordinator, nominate another responsible officer as his representative at Site suitably designated for the purpose of overall responsibility and co-ordination of the Works to be performed at Site. Such a person shall function from the Site office of the Contractor during the pendency of Contract.

2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES 2.01.00 In addition to the local laws and regulations, the Contractor shall also comply with

the Minimum Wages Act and the Payment of Wages Act (both of the Government of India) and the rules made there under in respect of its labour and the labour of its sub-contractors currently employed on or connected with the contract.

2.02.00 All registration and statutory inspection fees, if any, in respect of his work pursuant to this Contract shall be to the account of the Contractor. However, any registration, statutory inspection fees lawfully payable under the provisions of the Indian Boiler Regulations and any other statutory laws and its amendments from time to time during erection in respect of the plant equipment ultimately to be owned by the Employer, shall be to the account of the Employer. Should any such inspection or registration need to be re-arranged due to the fault of the Contractor or his Sub-Contractor, the additional fees for such inspection and/or registration shall be borne by the Contractor.

3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING

The welding of all pressure parts and high pressure piping shall be in accordance with the following requirements:

3.01.00 Qualification of Weld Procedures

Only qualified welding procedures as per ASME Section IX shall be used by contractor at site. Procedure qualification records along with WPS shall be submitted to RINFRA for review. Welding procedure shall indicate all essential and non-essential parameters as per ASME Section IX. Makes of welding consumables shall be subject to employer’s approval.

3.02.00 Welder's Qualification

Only welders, who are qualified in accordance with the latest applicable requirements of the Indian Boiler Regulations, shall be permitted to perform any welding work on the pressure parts and its attachment welding. In addition to such statutory qualification requirements, the welders shall also undergo a satisfactory





Page 3 of 45

pre-production qualification test to be conducted by the Contractor at site as per ASME Sec IX in presence of employer’s representative(s), prior to performing work under these specifications. The services of an independent testing laboratory shall be retained by the Contractor to perform welder qualification tests for welders.

All the welders carrying out welding at site shall carry an identification badge, which shall indicate the category and the grade of welding for which they have been tested and authorized to carry out welding. All such badges shall be countersigned by the Employer.

3.03.00 Records

Welders performance shall be monitored regularly and record of their performance shall be maintained by contractor in a manner acceptable to the employer. Contractor shall maintain such records including record of procedure qualification & welder qualification and hand-over to the employer at the end of work.

3.04.00 MARKING

On completion of each welded joint, the welder shall mark his regularly assigned identification mark near the joint. The welder's identification numbers, inspection stamps or code symbol stamps and any other information shall not be directly stamped on any alloy steel piping. In alloy steel piping, all such information shall be stamped on separate marking plate which shall be tack welded on pipe near the weld.

4.00.00 HEAT TREATMENT 4.01.00 Pre-heating, post-heating and post-weld stress relief operations of all welds, shall

be performed in accordance with the requirements of applicable code. Local post weld stress relieving heat - treatments shall be adopted only in cases where it is normally impracticable to subject the entire assembly as such for stress relieving operations. Heating may be by means of electric induction coils or electric resistance coils. Oxy-acetylene flame heating or exothermic chemical heating methods will not be permitted. Complete recording of the temperatures through out the stress relieving cycle of the material and the weld subjected to heat treatment shall be made by means of a potentiometric recorder. Recorders other than those of potentiometric type shall not be used for such temperature recording during stress relieving operations.

The contractor & employer’s representative, at start and at the end of HT Cycle shall sign the time and temperature charts for heat-treatment.

4.02.00 After setting up the weld joint for heat treatment operation, the Employer's signature shall be obtained on the strips chart of the recorder prior to starting of heat treatment cycle. The right hand corner of the strip chart at the starting point of the heat treatment cycle shall contain details like the weld number, material, diameter and thickness, method of heating adopted, prescribed ranges of heat treatment temperatures, date of heat treatment, reference to item number of the Field welding Schedule (as specified at clause no 7.00.00-of this chapter) etc.





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5.00.00 WELD EDGE PREPARATION

Preparation at site of weld joint shall be in accordance with details acceptable to the Employer. Wherever possible, machining or automatic flame cutting shall be used for edge preparation. Hand flame cutting will be permitted only where edge preparation otherwise is impractical. All slag shall be removed from cuts and all the hand cuts shall be ground smooth to the satisfaction of the Employer. Flame cutting of alloy steel pipe shall be avoided. Wherever such cutting is done, a 200mm length at the cut face shall be removed by machining. Pneumatic hand tools such as edge preparation, tube cutting machine can be used.

6.00.00 CLEANING AND SERVICING 6.01.00 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and loose

scales before being erected. All the pipelines shall be thoroughly blown and/or flushed. Each steam and water tubes shall be blown with compressed air and shall be subjected to 'ball test' before erection to ensure that no obstructions exist. A system for recording of all such operations shall be developed and maintained in a manner to ensure that no obstructions are left inside the tubes and no tubes are left uncleaned and untested.

6.02.00 All valves and valve actuators, and dampers and damper actuators, if any, shall be thoroughly cleaned and serviced prior to pre-commissioning tests and/or Initial Operations of the plant. A system for recording of such servicing operation shall be developed and maintained in a manner acceptable to the Employer and to ensure that no valves or dampers including their actuators are left unserviced.

6.03.00 All interior surfaces of the turbine shall be thoroughly cleaned prior to boxing - up to remove all traces of oil preservations.

7.00.00 FIELD WELDING SCHEDULE

The Contractor shall submit to the Employer, a certified and complete field welding schedule for all the field welding activities to be carried out in respect of the pressure parts involved in the equipment furnished and erected by him, at least 90 days prior to the scheduled start of erection work at site. Such schedule will be strictly followed by the Contractor during the process of erection. The above field-welding schedule to be issued by the Contractor shall contain the following:

(a.) Drawing No (s)

(b.) Location of the weld

(c.) Size of the weld (outside diameter and thickness)

(d.) Type of joints

(e.) Material specifications

(f.) Size of fillet on backing ring, when the type of joint is with backing ring

(g.) Electrode/ filler metal specifications

(h.) Number of welds per unit





Page 5 of 45

(i.) Quantity of filler metal per weld

(j.) Indication of required Non-destructive Examination (NDE) for each weld

(k.) Pre-heat temperatures for welding

(l.) Process of welding

(m.) Post-welding heat treatment temperature ranges, duration, under as specified at clause no 4.00.00- of this chapter entitled "Heat Treatment".

(n.) Qualification details of weld procedures to be adopted as specified under as specified at clause no 3.01.00- of this chapter entitled 'Qualification of Weld Procedures'.

8.00.00 SITE RUN MISCELLANEOUS PIPING

Sketches or diagrams of the proposed routings of all piping, not already indicated and routed on the shop drawings which were reviewed by the Employer, shall be submitted to the Employer for review, Employer's acceptance of such site routings shall be obtained before the piping is erected. All these site run piping shall be installed in such a manner as to present an orderly and neat installation. They shall be located as to avoid obstruction of access and passages. Valves, instruments or any other special items shall be located convenient for operation by the operating personnel. Pipe runs shall be plumb or level except where pitch for drainage is required. Pipe runs that are not parallel to the building structure, walls or column rows shall be avoided so that deflection of pipes between hangers does not exceed 6 mm. No miscellaneous pipe shall be routed and installed above or adjacent to electrical equipment.

9.00.00 THERMAL EXPANSIONS

All piping installation shall be such that no excessive or destructive expansion forces exist either in the cold condition or under condition of maximum temperature. All bends, expansion joints and any other special fittings, necessary to provide proper expansion, shall be incorporated. During installation of expansion joints and anchors, care must be taken to make sure that full design movement is available at all times for maximum to minimum temperature and vice-versa.

10.00.00 PIPING SUPPORTS 10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe,

reliable and complete pipe installation. All supports shall be properly leveled and anchored when installed. The anchors shall be so placed that thermal expansion will be absorbed by bends without subjecting the valves or equipment to excessive strains.

10.02.00 The hanger assemblies shall not be used for the attachment of rigging to hoist the pipe into place. Other means shall be used to securely hold the pipe in place till the pipe support is completely assembled and attached to the pipe and building structures and spring support is set to accommodate the pipe way. All temporary rigging shall be removed in such a way that the pipe support is not subjected to any sudden load. All piping, having variable spring type supports, shall be held





Page 6 of 45

securely in place by temporary means during the hydraulic test of pipe system. Constant support type spring hangers used during hydraulic test shall be pinned or blocked solid during the test. After complete installation and insulation of the piping and filling of the piping with its normal operating medium, the pipe support springs shall be adjusted to the cold positions. If necessary, the spring support shall be re-adjusted to the hot positions after the line has been placed for service at its normal maximum operating temperature conditions. Electric arc welding only shall be used to weld all pipe supports to structural steel members that form part of the building supporting structure. The structural beams shall not be heated more than necessary during welding of supports and such welds shall run parallel to the axis of the span. All lugs or any other attachments welded to the piping shall be of the same material as the pipe.

11.00.00 PRESSURE TESTING 11.01.00 On completion of erection of pressure parts, a hydraulic test in accordance with

the requirements of the Indian Boiler Regulations shall be performed by the Contractor.

11.02.00 All the valves, high pressure pipes and inter-connected pipes connecting the pressure parts shall be tested along with pressure parts. All blank flanges or any removable plugs required for openings not closed by the valves, and piping provided, shall be furnished by the Contractor. The pressurization equipment including water piping from the supply, needed for the above test shall also be furnished by the Contractor. Any defects noticed during the testing are to be rectified and the unit re-tested. If any welding is done on the pressure parts after the Hydraulic test, the Hydraulic test for that portion of pressure parts shall be repeated.

11.03.00 Thy hydraulic test shall be considered successful only on certification to that effect by the concerned inspecting Authority as per the provisions of the Indian Boiler Regulations and the Employer.

12.00.00 THERMOWELLS AND FLOW NOZZLES 12.01.00 All the thermowells and flow nozzles in the equipment furnished under the

technical specifications shall be installed as a part of this work.

12.02.00 All thermowell connections incorporated in the steam service shall be plugged during the pressure testing and the blow out of steam piping systems. Upon completion of the blow out operation, all thermowells shall be installed and seam welded. Similarly, all flow nozzles in the steam lines shall also be installed only on completion of steam blowing operations unless otherwise agreed to by the Employer, depending upon the sequence of cleaning and purging operations to be adopted by the Contractor at the field.

13.00.00 INSULATION, LAGGING AND CLADDING

The provision of insulation, lagging and cladding of the various equipments and portion of the equipment covered under the Contract, shall be furnished by the Contractor as specified elsewhere or agree to separately in writing. Welds





Page 7 of 45

required for holding insulation on pressure parts shall be carried out by IBR qualified welder.

13.01.00 In case of equipment other than steam turbine, Lugs made out of MS rods of 5 mm dia conforming to IS280 or equivalent shall be welded on the surface at intervals of 250 mm pitch zigzag to support insulation. Mineral wool mats with wire netting on both sides shall be applied against the surface with lugs piercing through. The edges of mattress shall be laced together with galvanized MS 0.71 mm dia (22 SWG) IS 280 or equivalent (soft) lacing wire. Galvanized binding wire of 1.63 mm dia (16 SWG) IS 280 or equivalent (soft) will be used criss-cross between lugs to hold it. The lugs will then be bent over the netting.

13.02.00 Unless otherwise specified, all equipment insulation shall be covered with aluminium cladding/ jacketing. The thickness of aluminium sheet shall not be less than 0.63 mm. Galvanic corrosion shall be prevented by carefully avoiding permanent contact of aluminium cladding with copper, copper alloys, tin, lead nickel or nickel alloys including monel metal. Where cladding is attached to carbon steel or low alloy steels, the steel shall first be prime painted with zinc chromate and then painted with aluminium paint. The use of lead base paints for this purpose shall be avoided.

13.03.00 Prior to application of cladding, all surface imperfections such as ducts, cracks and voids shall be filled with insulation cement so as to form a smooth base for the final shall be machine rolled and formed. All overlaps at longitudinal joints shall face downwards. The fixing of cladding shall be by means of screws and they shall be adequate in number and be so place is such location as to produce tight joints eliminating ' bellying'. The screws, as far as possible, shall be uniformly placed and on centres not exceeding 150 mm except where insulated outside diameters are smaller than 230 mm in which case spacing shall be on centres not exceeding 100mm. Self tapping type screws, of 12 mm size of stainless steel/aluminium alloy as per the requirements shall be used. All joints wherever possible shall be lapped a minimum of 50 mm. The overlaps of longitudinal joints shall be a 10 mm turn back edge. Butt joints such as those at piping tees, shall be made using a rolled seam. Suitable provisions for expansion movement shall be provided in joints. Hinged or sliding doors for convenience shall be provided in the cladding at all access openings, non-projecting connections, important codes stampings etc.

13.04.00 Piping, Pipe Fittings & Valves

All piping insulation and metal cladding furnished with the equipment to be erected shall be applied as specified herein.

13.04.01 Piping

The insulation on piping shall be applied using wire loops on 150mm centres. These wire loops shall be thoroughly embedded into the outer insulation surface





Page 8 of 45

and all cracks, voids and depressions shall be filled with insulating cement suitable for the piping temperature so as to form a smooth base for application of cladding. The wires used for piping insulation shall be of 16 SWG. The surface shall be smooth and uniform before applying the outer covering . All piping insulation ends shall be terminated at a sufficient distance from flanges to facilitate removal of bolts.

13.04.02 Flanges

Insulation on flanges shall be by means of blocks of insulating material securely bound to the flange by wire loops. Such blocks of insulation shall be long enough to overlap the adjacent pipe insulation by an amount equal to the thickness of adjacent pipe insulation. Smooth finish shall be obtained by the application of insulating cement. Alternatively, sectional pipe insulation of proper diameter may be used. Insulation on flanges shall not be done until the pipe and equipment have been in service during the initial operation and till all the flange bolts have been re-tightened.

13.04.03 Bends and Elbows

Insulation on bends and elbows shall be cut into sections sufficiently short to form a reasonable smooth external surface. After the application of insulation material in place, it shall be smoothly coated with insulating cement. Elbows may be insulated as above or alternatively by means of specially moulded insulation enclosures.

13.04.04 Cladding

Cladding shall be of aluminium sheet of thickness as per details given in detail Technical Specification or will be provided during detail engineering shall be machine rolled and formed to accurately fit insulation curvatures. Cladding shall be secured using self-tapping screws. Screws shall be adequate number and so located as to produce tight joints. The spacing of screws shall be as far as possible uniform and on centres not exceeding 150 mm. For outside diameters less than 230 mm, spacing of screws shall be on centres not exceeding 100 mm. adequate number of screws shall be provided for fixing the cladding and be so placed in such locations, as to produce a smooth cladding finish without bellying'. Insulated elbows having insulated diameters less than 330 mm shall be provided with preformed smooth aluminium elbow jackets. Wherever possible, all joints should be lapped a minimum of 50 mm with joints facing downwards and so placed that they are obscured from normal points of vision. All the joints in the cladding shall be made with suitable provisions for expansions. All butt joints such as those at piping tees shall be made using rolled seams. In addition, to prevent galvanic corrosion, suitable action, as stipulated as specified at clause no 13.02.00- of this chapter, shall be taken.

13.04.05 Valves and Fittings

All valves and fittings installed in the pipelines shall also be applied with insulation and furnished with suitably shaped boxes so as to facilitate easy dismantling of





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the fittings. The insulation thickness for valves, valve fittings etc., shall be same as that used on the line on which they are installed. All voids shall be properly filled up with insulating material and as per the directions of the Employer.

13.05.00 Protection of Equipment during Insulation Applications

All equipment and structures shall be suitably protected from damage while applying insulation after completion of insulation. All equipment and structures shall be thoroughly cleaned and remove insulating materials which might have fallen on them.

14.00.00 CODE REQUIREMENTS

The erection requirements and procedures to be followed during the installation of the equipment shall be in accordance with the relevant Indian Electricity Rules & Codes, Indian Boiler Regulations, ASME codes and accepted good practices, the Employer's Drawings and other applicable Indian recognised codes and laws and regulations of the Government of India.

15.00.00 REMOVAL OF MATERIAL

No material brought to the Site shall be removed from the Site by the Contractor and/or his Sub-Contractors without the prior written approval of the Employer.

16.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES

The provisions of the clause entitled Inspection, Testing and Inspection Certificates given in Part - C of the Technical Specification, shall also be applicable to the erection portion of the Works. The Employer shall have the right to re-inspect any equipment though previously inspected and approved by him at the Contractor’s works, before and after the same are erected at Site. If by the above inspection, the Employer rejects any equipment, the Contractor shall make good for such rejections either by replacement or modification/ repairs as may be necessary to the satisfaction of the Employer. Such replacements will also include the replacements or re-execution of such of those works of other Contractors and/or agencies, which might have got damaged or affected by the replacements or re-work done to the Contractor’s work.

17.00.00 ACCESS TO SITE AND WORKS ON SITE 17.01.00 Suitable access to site and permission to work at the Site shall be accorded to the

Contractor by the Employer in reasonable time.

17.02.00 In the execution of the Works, no person other than the Contractor or his duly appointed representative, Sub-Contractor and workmen, shall be allowed to do work on the Site, except by the special permission, in writing by the Employer or his representative.

18.00.00 CONTRACTOR’S SITE OFFICE ESTABLISHMENT

The Contractor shall establish a Office at the Site and keep posted an authorised representative for the purpose of the Contract. Any written order or instruction of the Employer or his duly authorised representative shall be communicated to the





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said authorised resident representative of the Contractor and the same shall be deemed to have been communicated to the Contractor at his legal address.

19.00.00 CO-OPERATION WITH OTHER CONTRACTORS 19.01.00 The Contractor shall co-operate with all other Contractors or tradesmen of the

Employer, who may be performing other works on behalf of the Employer and the workmen who may be employed by the Employer and doing work in the vicinity of the works under the Contract. The Contractor shall also arrange to perform his work as to minimize to the maximum extent possible, interference with the work of other Contracts and their workmen. Any injury or damage that may be sustained by the employees of the other Contractors and the Employer, due to the Contractor’s work shall promptly be made good at his own expense. The Employer shall determine the resolution of any difference or conflict that may arise between the Contractor and other Contractors or between the Contractor and the workmen of the Employer in regard to their work. If the work of the Contractor is delayed because of the any acts of omission of another Contractor, the Contractor shall have no claim against the Employer on that account other than an extension of time for completing his works.

Employer shall have full access to visit the contractor’s site at any time for inspection and surveillance checks.

19.02.00 The Employer shall be notified promptly by the Contractor of any defects in the other Contractor’s works that could affect the Contractor’s Works. The Employer shall determine the corrective measures if any, required to rectify this situation after inspection of the works and such decisions by the Employer shall be binding on the Contractor.

20.00.00 DISCIPLINE OF WORKMEN

The Contractor shall adhere to the disciplinary procedure set by the Employer in respect of his employees and workmen at Site. The Employer shall be at liberty to object to the presence of any representative or employee of the Contractor at the Site, if in the opinion of the Employer such employee has mis-conducted himself or is incompetent, negligent or otherwise undesirable then the Contractor shall remove such a person objected to and provide in his place a competent replacement.

21.00.00 CONTRACTOR’S FIELD OPERATION 21.01.00 The Contractor shall keep the Employer informed in advance regarding his field

activity plans and schedules for carrying out each part of the works. Any review of such plan or schedule or method of work by the Employer shall not relieve the Contractor of any of his responsibilities towards the field activities. Such reviews shall also not be considered as an assumption of any risk or liability by the Employer or any of his representatives and no claim of the Contractor will be entertained because of the failure or inefficiency of any such plan or schedule or





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method of work reviewed. The Contractor shall be solely responsible for the safety, adequacy and efficiency of plant and equipment and his erection methods.

21.02.00 The Contractor shall have the complete responsibility for the conditions of the Work-Site including the safety of all persons employed by him or his Sub-Contractor and all the properties under his custody during the performance of the work. This requirement shall apply continuously till the completion of the Contract and shall not be limited to normal working hours. The construction review by the Employer is not intended to include review of Contractor’s safety measures in, on or near the Work-Site, and their adequacy or otherwise.

22.00.00 PHOTOGRAPHS AND PROGRESS REPORT 22.01.00 The Contractor shall furnish three (3) prints each to the Employer of progress

photographs of the work done at Site. Photographs shall be taken as and when indicated by the Employer or his representative. Photographs shall be adequate in size and number to indicate various stages of erection. Each photograph shall contain the date, the name of the Contractor and the title of the photograph.

22.02.00 The above photographs shall accompany the monthly progress report detailing out the progress achieved on all erection activities as compared to the schedules. The report shall also indicate the reasons for the variance between the scheduled and actual progress and the action proposed for corrective measures, wherever necessary.

22.03.00 The Contractor shall submit the progress of work in video cassettes (2 copies) quarterly highlighting the progress and constraints at site.

23.00.00 MAN-POWER REPORT 23.01.00 The Contractor shall submit to the Employer, on the first day of every month, a

man hour schedule for the month, detailing the man hours scheduled for the month, skill-wise and area-wise.

23.02.00 The Contractor shall also submit to the Employer on the first day of every month, a man power report of the previous month detailing the number of persons sched-uled to have been employed and actually employed, skill- wise and the areas of employment of such labour.

24.00.00 PROTECTION OF WORK

The Contractor shall have total responsibility for protecting his works till it is finally taken over by the Employer. No claim will be entertained by the Employer or the representative of the Employer for any damage or loss to the Contractor’s works and the Contractor shall be responsible for complete restoration of the damaged works to original conditions to comply with the specification and drawings. Should any such damage to the Contractor’s Works occur because of other party not being under his supervision or control, the Contractor shall make his claim directly with the party concerned. If disagreement or conflict or dispute develops between the Contractor and the other party or parties concerned regarding the responsibility for damage to the Contractor’s Works the same shall be resolved as per the provisions of the as specified at clause no 20.00.00- of this chapter entitled “Co-operation with other Contractors.” The Contractor shall not cause any





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delay in the repair of such damaged Works because of any delay in the resolution of such disputes. The Contractor shall proceed to repair the Work immediately and no cause thereof will be assigned pending resolution of such disputes.

25.00.00 EMPLOYMENT OF LABOUR 25.01.00 In addition to all local laws and regulations pertaining to the employment of labour

to be complied with by the Contractor pursuant to GCC, the Contractor will be expected to employ on the work only his regular skilled employees with experience of the particular work. No female labour shall be employed after darkness. No person below the age of eighteen years shall be employed.

25.02.00 All travelling expenses including provisions of all necessary transport to and from Site, lodging allowances and other payments to the Contractor’s employees shall be the sole responsibility of the Contractor.

25.03.00 The hours of work on the Site shall be decided by the Employer and the Contractor shall adhere to it. Working hours will normally be eight (8) hours per day - Monday through Saturday.

25.04.00 Contractor’s employees shall wear identification badges while on work at Site.

25.05.00 In case the Employer becomes liable to pay any wages or dues to the labour or any Government agency under any of the provisions of the Minimum Wages Act, Workmen Compensation Act, Contact Labour Regulation Abolition Act or any other law due to act of omission of the Contractor, the Employer may make such payments and shall recover the same from the Contractor’s Bills.

26.00.00 FACILITIES TO BE PROVIDED BY THE EMPLOYER 26.01.00 Space

The Contractor shall advise the Employer within thirty (30) days from the date of acceptance of the Notification of Award about his exact requirement of space for his office, storage area, pre-assembly and fabrication areas, labour and staff colony area, toilets, etc. The above requirement shall be reviewed by the Employer and space as decided by Employer will be allotted to the Contractor for construction of his temporary structures/ facilities like office, storage sheds, pre-assembly and fabrication areas, labour and staff colony, toilets, etc. for Contractor's as well as his Sub-Contractor’s use.

26.02.00 Electricity The Contractor shall make all arrangement himself for the construction power required by him as well as for his labour and other personnel at work site and colony.

26.03.00 Water

Contractor shall make all arrangements himself for the supply of construction water as well as potable water for labour and other personnel at the worksite/colony.





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26.04.00 Communication

The Employer will extend the telephone facilities, if available at Site, for purposes of Contract. The Contractor shall be charged at actuals for such facilities.

26.05.00 Cranes

Turbine hall EOT cranes may be used by the Contractor on chargeable basis for erection of the units / equipments under this package. For the equipments which cannot be handled by these Turbine hall EOT cranes, the Contractor shall make his own arrangements.

27.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR 27.01.00 Contractor's site office Establishment

The Contractor shall establish a site office at the site and keep posted an authorized representative for the purpose of the contract, pursuant to GCC.

27.02.00 Tools, tackles and scaffoldings

The Contractor shall provide all the construction equipments, tools, tackles and scaffoldings required for pre-assembly, installation, testing, commissioning and conducting Guarantee tests of the equipments covered under the Contract. He shall submit a list of all such materials to the Employer before the commencement of pre-assembly at Site. These tools and tackles shall not be removed from the Site without the written permission of the Employer. The Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of fabrication, erection and commissioning.

27.03.00 Testing Equipment and Facilities:

The contractor shall provide the necessary testing, equipment and facilities.

27.04.00 NOT USED 27.05.00 First-aid 27.05.01 The Contractor shall provide necessary first-aid facilities for all his employees,

representatives and workmen working at the Site. Enough number of Contractor’s personnel shall be trained in administering first-aid.

27.05.02 The Employer will provide the Contractor, in case of any emergency, the services of an ambulance for transportation to the nearest hospital.

27.06.00 Cleanliness 27.06.01 The Contractor shall be responsible for keeping the entire area allotted to him

clean and free from rubbish, debris etc. during the period of Contract. The Contractor shall employ enough number of special personnel to thoroughly clean his work-area at least once in a day. All such rubbish and scrap material shall be stacked or disposed in a place to be identified by the Employer. Materials and stores shall be so arranged to permit easy cleaning of the area. In areas where equipment might drip oil and cause damage to the floor surface, a suitable





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protective cover of a flame resistant, oil proof sheet shall be provided to protect the floor from such damage.

27.06.02 Similarly the labour colony, the offices and the residential areas of the Contractor’s employees and workmen shall be kept clean and neat to the entire satisfaction of the Employer. Proper sanitary arrangements shall be provided by the Contractor, in the work-areas, office and residential areas of the Contractor.

28.00.00 LINES AND GRADES

All the Works shall be performed to the lines, grades and elevations indicated on the drawings. The Contractor shall be responsible to locate and layout the Works. Basic horizontal and vertical control points will be established and marked by the Employer at Site at suitable points. These points shall be used as datum for the works under the Contract. The Contractor shall inform the Employer well in advance of the times and places at which he wishes to do work in the area allotted to him so that suitable datum points may be established and checked by the Employer to enable the Contractor to proceed with his works. Any work done without being properly located may be removed and/or dismantled by the Employer at Contractor’s expense.

29.00.00 FIRE PROTECTION Required Fire Protection Measures are described under Clause titled “WORK &SAFETY REGULATIONS” of this Sub-section.

30.00.00 SECURITY

The Contractor shall have total responsibility for all equipment and materials in his custody stores, loose, semi-assembled and/or erected by him at Site. The Contractor shall make suitable security arrangements including employment of security personnel to ensure the protection of all materials, equipment and works from theft, fire, pilferage and any other damages and loss. All materials of the Contractor shall enter and leave the Employer Site only with the written permission of the Employer in the prescribed manner.

31.00.00 CONTRACTOR’S AREA LIMITS

The Employer will mark-out the boundary limits of access roads, parking spaces, storage and construction areas for the Contractor and the Contractor shall not trespass the areas not so marked out for him. The Contractor shall be responsible to ensure that none of his personnel move out of the areas marked out for his operations. In case of such a need for the Contactor’s personnel to work out of the areas marked out for him the same shall be done only with the written permission of the Employer.

32.00.00 CONTRACTOR’S CO-OPERATION WITH THE EMPLOYER

In case where the performance of the erection work by the Contractor affects the operation of the system facilities of the Employer, such erection work of the





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Contractor shall be scheduled to be performed only in the manner stipulated by the Employer and the same shall be acceptable at all times to the Contractor. The Employer may impose such restrictions on the facilities provided to the Contractor such as electricity, etc. as he may think fit in the interest of the Employer and the Contractor shall strictly adhere to such restrictions and co-operate with the Employer. It will be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up and operation of the equipment systems which are erected by him. The Contractor shall also be responsible for flushing and initial filling of all the oil and lubricants required for the equipment furnished and installed by him, so as to make such equipment ready for operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants unless otherwise specified elsewhere in documents and specifications.

33.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES 33.01.00 GENERAL 33.01.01 The Contractor upon completion of installation of equipments and systems, shall

conduct pre-commissioning and commissioning activities, to make the equipment/systems ready for safe, reliable and efficient operation on sustained basis. All pre-commissioning/commissioning activities considered essential for such readiness of the equipment/systems including those mutually agreed and included in the Contractor’s quality assurance programme as well as those indicated in clauses elsewhere in the technical specifications shall be performed by the contractor.

33.01.02 The pre-commissioning and commissioning activities including Guarantee tests, checks and trial operations of the equipment/systems furnished and installed by the contractor shall be the responsibility of the Contractor as detailed in relevant clauses in Technical Specification. The Contractor shall provide, in addition, test instruments, calibrating devices etc. and labour required for successful performance of these operations. If it is anticipated that the above test may prolong for a long time, the Contractor’s workmen required for the above test shall always be present at site during such operations.

33.01.03 The following activities shall be carried out by the contractor, 18 month prior to schedule date of commissioning of the equipment/systems installed by him.

(a.) The contractor shall furnish the organization chart of his operation and commissioning engineers for the acceptance of employer. Adequate number of operation and commissioning engineers shall be deployed by the contractor to effectively meet the requirement of round the clock operation in shifts also, till the plant is taken over by the employer.

(b.) The contractor shall submit the bio-data containing the details of experience of his operation and commissioning engineers for the acceptance of employer.

(c.) The contractor shall furnish the deployment schedule of his operation and commissioning engineers for the acceptance of the employer.





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(d.) Apart from above, contractor shall ensure deployment of sufficient skilled/semi-skilled/unskilled manpower during pre-commissioning and commissioning activities.

33.01.04 It shall be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up and initial operation of the equipment/systems which are installed by him.

33.01.05 The Contractor shall also be responsible for flushing and initial filling of all oils and lubricants required for the equipment furnished and installed by him so as to make such equipment ready for operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants unless otherwise specified elsewhere in these specifications and documents.

33.02.00 COMMISSIONING DOCUMENTATION 33.02.01 The contractor shall submit the commissioning documentation, comprising of

Standard checklists, pre-commissioning procedures, testing schedules, commissioning schedules and commissioning networks for various equipment/systems covered under the contract, for the approval of employer.

33.02.02 Standard checklist, as the name suggests, shall be a fairly general documents, containing the list of all checks required to be carried out for similar and repetitive type of equipment to ensure consistent and thorough checking. An indicative list of such equipment is enclosed as Annexure I.

33.02.03 The testing schedule is a document, designed for safe and systematic commissioning of individual equipment/sub-system (for example Boiler Feed Pump, condensate pump, compressor etc) Commissioning schedule is a document envisaged for commissioning of a system (for example feed system, Condensate system, Compressed Air system, Fire water system, Unit commissioning etc). The testing/Commissioning schedule shall have a standard format in order to maintain consistency of presentation, content and reporting. A brief write up on the contents of the Testing Schedule/Commissioning Schedule is enclosed as Annexure-II.

33.02.04 The contractor shall submit the list of commissioning documentation to be submitted by him, alongwith their submission schedule for various equipment/systems covered under the contract, with in 6(six) month from the date of award of contract, for the acceptance of employer.

33.02.05 The Contractor shall submit the commissioning documentation, for various equipment/covered under the contract, for the approval of employer, at least 18 months before the scheduled date of commissioning of the equipment/systems.

33.03.00 COMMISSIONING ACTIVITIES 33.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall initiate

commissioning of facilities. During commissioning the Contractor shall carry out system checking and reliability trials on various parts of the facilities.

33.03.02 Contractor shall carry out the checks/tests at site to prove to the Employer that each equipment of the supply complies with requirements stipulated and is installed in accordance with requirements specified.





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33.03.03 Before the plant is put into initial operation the Contractor shall be required to conduct test to demonstrate to the Employer that each item of the plant is capable of correctly performing the functions for which it was specified and its performance, parameters etc. are as per the specified/approved values. These tests may be conducted concurrently with those required under commissioning sequence.

33.03.04 The Contractor shall also demonstrate the performance of all C&I equipment, the tests on main equipment of prior to that as the case may be.

33.03.05 Other tests shall be conducted, if required by the Employer, to establish that the plant equipment are in accordance with requirements of the specifications.

33.03.06 The Contractor shall conduct all the commissioning tests and undertake commissioning activities pertaining to all other auxiliaries and equipments including all electrical and C&I equipment/systems not specifically brought out above but are within the scope of work and facilities being supplied and installed by the Contractor and follow the guidelines indicated above or elsewhere in these technical specifications(Section-VI)

33.04.00 Initial Operation

Upon completion of system checking/Tests as above and as a part of commissioning of facilities, complete plant/facilities shall be put on initial operation as stipulated in General Technical Requirements.

34.00.00 MATERIALS HANDLING AND STORAGE 34.01.00 All the equipments furnished under the Contract and arriving at Site shall be

promptly received, unloaded and transported and stored in the storage spaces by the Contractor.

34.02.00 Contractor shall be responsible for examining all the shipment and notify the Employer immediately of any damage, shortage, discrepancy etc. for the purpose of Employer's information only. The Contractor shall submit to the Employer every week a report detailing all the receipts during the week. However, the Contractor shall be solely responsible for any shortages or damage in transit, handling and / or in storage and erection of the equipment at Site. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor.

34.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out the list of all equipment received by him for the purpose of erection and keep such record open for the inspection of the Employer.

34.04.00 All equipment shall be handled very carefully to prevent any damage or loss. No bare wire ropes, slings, etc. shall be used for unloading and/or handling of the equipment without the specific written permission of the Employer. The equipment stored shall be properly protected to prevent damage either to the equipment or to the floor where they are stored. The equipment from the store shall be moved to the actual location at the appropriate time so as to avoid damage of such equip-ment at Site.





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34.05.00 All electrical panels, controls gear, motors and such other devices shall be properly dried by heating before they are installed and energised. Motor bearings, slip rings, commutators and other exposed parts shall be protected against moisture ingress and corrosion during storage and periodically inspected. Heavy rotating parts in assembled conditions shall be periodically rotated to prevent corrosion due to prolonged storage.

34.06.00 All the electrical equipment such as motors, generators, etc. shall be tested for insulation resistance at least once in three months from the date of receipt till the date of commissioning and a record of such measured insulation values maintained by the Contractor. Such records shall be open for inspection by the Employer.

34.07.00 The Contractor shall ensure that all the packing materials and protection devices used for the various equipments during transit and storage are removed before the equipment are installed.

34.08.00 The consumables and other supplies likely to deteriorate due to storage must be thoroughly protected and stored in a suitable manner to prevent damage or dete-rioration in quality by storage.

34.09.00 All the materials stored in the open or dusty location must be covered with suitable weatherproof and flameproof covering material wherever applicable.

34.10.00 If the materials belonging to the Contractor are stored in areas other than those earmarked for him, the Employer will have the right to get it moved to the area earmarked for the Contractor at the Contractor’s cost.

34.11.00 The Contractor shall be responsible for making suitable indoor storage facilities to store all equipment which require indoor storage. Normally, all the electrical equipments such as motors, control gear, generators, exciters and consumables like electrodes, lubricants etc. shall be stored in the closed storage space . The Employer, in addition, may direct the Contractor to move certain other materials, which in his opinion will require indoor storage, to indoor storage areas which the Contractor shall strictly comply with.

35.00.00 CONSTRUCTION MANAGEMENT 35.01.00 The field activities of the Contractors working at Site, will be coordinated by the

Employer and the Employer decision shall be final in resolving any disputes or conflicts between the Contractor and other Contractors and tradesmen of the Employer regarding scheduling and coordination of work. Such decision by the Employer shall not be a cause for extra compensation or extension of time for the Contractor.

35.02.00 The Employer shall hold weekly meetings of all the Contractors working at Site, at a time and place to be designated by the Employer. The Contractor shall attend such meetings and take notes of discussions during the meeting and the decisions of the Employer and shall strictly adhere to those decisions in performing his Works. In addition to the above weekly meeting, the Employer may call for other meeting either with individual Contractors or with selected number of Contractors and in such a case the Contractor if called, will also attend such meetings.





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35.03.00 Time is the essence of the Contract and the Contractor shall be responsible for performance of his works in accordance with the specified construction schedule. If at any time, the Contractor is falling behind the schedule, he shall take necessary action to make good for such delays by increasing his work force or by working overtime or otherwise accelerate the progress of the work to comply with the schedule and shall communicate such actions in writing to the Employer, satisfying that his action will compensate for the delay. The Contractor shall not be allowed any extra compensation for such action.

35.04.00 The Employer shall however not be responsible for provision of additional labour and/or materials or supply or any other services to the Contractor except for the co-ordination work between various Contractors as set out earlier.

36.00.00 FIELD OFFICE RECORDS

The Contractor shall maintain at his Site Office up-to- date copies of all drawings, specifications and other Contract Documents and any other supplementary data complete with all the latest revisions thereto. The Contractor shall also maintain in addition the continuous record of all changes to the above Contract Documents, drawings, specifications, supplementary data, etc. effected at the field and on completion of his total assignment under the Contract shall incorporate all such changes on the drawings and other Engineering data to indicate as installed conditions of the equipment furnished and erected under the Contract. Such drawings and Engineering data shall be submitted to the Employer in required number of copies.

37.00.00 CONTRACTOR’S MATERIALS BROUGHT ON TO SITE 37.01.00 The Contractor shall bring to Site all equipment, components, parts, materials,

including construction equipment, tools and tackles for the purpose of the Works under intimation to the Employer. All such goods shall, from the time of their being brought vest in the Employer, but may be used for the purpose of the Works only and shall not on any account be removed or taken away by the Contractor without the written permission of the Employer. The Contractor shall nevertheless be solely liable and responsible for any loss or destruction thereof and damage thereto.

37.02.00 The Employer shall have a lien on such goods for any sum or sums which may at any time be due or owing to him by the Contractor, under, in respect of or by reasons of the Contract. After giving a fifteen (15) days notice in writing of his intention to do so, the Employer shall be at liberty to sell and dispose off any such goods, in such manner as he shall think fit including public auction or private treaty and to apply the proceeds in or towards the satisfaction of such sum or sums due as aforesaid.

37.03.00 After the completion of the Works, the Contractor shall remove from the Site under the direction of the Employer the materials such as construction equipment, erection tools and tackles, scaffolding etc. with the written permission of the Employer. If the Contractor fails to remove such materials, within fifteen (15) days of issue of a notice by the Employer to do so then the Employer shall have the liberty to dispose off such materials as detailed under as specified at clause no





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38.02.00- of this chapter and credit the proceeds thereto to the account of the Contractor.

38.00.00 PROTECTION OF PROPERTY AND CONTRACTOR’S LIABILITY 38.01.00 The Contractor shall be responsible for any damage resulting from his operations.

He shall also be responsible for protection of all persons including members of public and employees of the Employer and the employees of other Contractors and Sub- Contractors and all public and private property including structures, building, other plants and equipments and utilities either above or below the ground.

38.02.00 The Contractor will ensure provision of necessary safety equipment such as barriers, sign - boards, warning lights and alarms, etc. to provide adequate protection to persons and property. The Contractor shall be responsible to give reasonable notice to the Employer and the Employers of public or private property and utilities when such property and utilities are likely to get damaged or injured during the performance of his Works and shall make all necessary arrangements with such Employers, related to removal and/or replacement or protection of such property and utilities.

39.00.00 PAINTING

Unless otherwise mentioned in other sub-sections. all exposed metal parts of the equipment including pipings, structure railings, etc. wherever applicable, after installation unless otherwise surface protected, shall be first painted with at least two coats of suitable primer which matches the shop primer paint used, after throughly cleaning all such parts of all dirt, rust, scales, greases, oils and other foreign materials by wire brushing, scraping or sand blasting and the same being inspected and approved by the Employer for painting. Afterwards, the above parts shall be finished painted with three coats of allowed resin machinery enamel paints. The minimum thickness of paint film shall not be less than 100 microns. The quality of the finish paint shall be as per the standards of Bureau of Indian Standards (BIS) or equivalent and to be of the colour as approved by the Employer.

40.00.00 INSURANCE 40.01.00 In addition to the conditions covered under the Clause entitled “Insurance” in

Section General Conditions of Contract (GCC), the following provisions will also apply to the portion of works to be done beyond the Contractor’s own or his Sub-Contractor’s manufacturing Works.

40.02.00 Workmen’s Compensation Insurance

This insurance shall protect the Contractor against all claims applicable under the Workmen’s Compensation Act, 1948 (Government of India). This policy shall also cover the Contractor against claims for injury, disability disease or death of his or his Sub-Contractor’s employees, which for any reason are not covered under the Workmen’s Compensation Act, 1948. The liabilities shall not be less than the following:





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Workmen's Compensation - As per Statutory Provisions

Employee's Liability - As per Statutory Provisions

40.03.00 Comprehensive Automobile Insurance

This insurance shall be in such a form to protect the Contractor against all claims for injuries, disability, disease and death to members of public including the Employer’s men and damage to the property of other arising from the use of motor vehicles during on or off the Site operations, irrespective of the Ownership of such vehicles. The liability covered shall be as herein indicated :

Fatal Injury : Rs.100,000 each person

: Rs.200,000 each occurrence

Property Damage : Rs.100,000 each occurrence

40.04.00 Comprehensive General Liability Insurance 40.04.01 The insurance shall protect the Contractor against all claims arising from injuries,

disabilities, disease or death of members of public or damage to property of others, due to any act or omission on the part of the Contractor, his agents, his employees, his representatives and Sub-Contractors or from riots, strikes and civil commotion. This insurance shall also cover all the liabilities of the Contractor arising out of the Clause entitled “Defence of Suits” in Section General Conditions of Contract (GCC).

40.04.02 The hazards to be covered will pertain to all the Works and areas where the Contractor, his Sub-Contractors, his agents and his employees have to perform work pursuant to the Contract.

40.05.00 The above are only illustrative list of insurance covers normally required and it will be the responsibility of the Contractor to maintain all necessary insurance coverage to the extent both in time and amount to take care of all his liabilities either direct or indirect, in pursuance of the Contract.

41.00.00 UNFAVOURABLE WORKING CONDITIONS

The Contractor shall confine all his field operations to those works which can be performed without subjecting the equipment and materials to adverse effects during inclement weather conditions, like monsoon, storms, etc. and during other unfavourable construction conditions. No field activities shall be performed by the Contractor under conditions which might adversely affect the quality and efficiency thereof, unless special precautions or measures are taken by the Contractor in a proper and satisfactory manner in the performance of such Works and with the concurrence of the Employer. Such unfavorable construction conditions will in no way relieve the Contractor of his responsibility to perform the Works as per the schedule.

42.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS





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The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc. which he may come across during the course of performance of his Works either during excavation or elsewhere, are properly protected and handed over to the Employer. Similarly the Contractor shall ensure that the bench marks, reference points, etc., which are marked either with the help of Employer or by the Employer shall not be disturbed in any way during the performance of his Works. If, any work is to be preformed which disturb such reference, the same shall be done only after these are transferred to other suitable locations under the direction of the Employer. The Contractor shall provide all necessary materials and assistance for such relocation of reference points etc.

43.00.00 WORK & SAFETY REGULATIONS 43.01.00 General:

i) The contractor shall comply with all the requirements of "The Building and Other Construction Workers (Regulation of Employment & Conditions of Service) Act," 1996 and its Central Rule 1998 / State Rules and any other statutory requirements as applicable.

ii) The Contractor shall follow RINFRA Safety Rules as issued from time to time with respect to safety in construction & erection.

iii) The contractor shall have the approved Safety; Health and Environment (SHE) Policy in respect of Safety and health of Building Workers and it shall be circulated widely and displayed at conspicuous place in Hindi and local language understood by the majority of the workers. A copy of the safety policy should be submitted to Engineer-in-charge.

iv) The contractor shall prepare the safety plan comprising of methods to implement the Safety Policy/ Rules, Risk assessment and ensuring Safety at work areas. Safety audits, inspections and its compliance, Supervision and responsibility to ensure Safety at various levels, Safety training to employees, review of Safety and accident analysis, ensure Health and Safety Procedures to prevent accidents and submit to Engineer-in-charge for approval as per the format of Safety plan as per the Table below:

SAFETY PLAN 1) Safety policy of the contractor to be enclosed 2) When was the safety policy last reviewed 3) Details of implementation procedure/methods to implement Safety

Policy/Safety Rules

4) Name, qualification, experience of Safety Officer 5) Review of Accident, Analysis Method, Methods to ensure Safety and

Health

6) Unit executive responsible to ensure Safety at various levels in work area

7) List of employees trained in safety employed before execution of the job. Give the details of training.

8) Safety training Targets, Schedules, Methods adopting to provide safety training to all employees

9) Details of checklist for different jobs/ work and responsible person to ensure compliance (copy of checklist to be enclosed.)





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10) Regular Safety Inspection Methods and Periodicity and list of members to be enclosed

11) Risk Assessment, Safety Audit by Professional Agencies, Periodicity 12) Implementation of Recommendations of Audit / Inspections.

Procedures for implementation and follow up.

13) Provision for treatment of injured persons at work site 14) Review of overall safety by top Management and Periodicity 15) System for Implementation of Statutory legislations 16) Issue of PPEs to employees, Periodicity / stock on hand etc. Head of the Organization With date & stamp

v) The Contractors shall ensure proper safety of all the workmen, materials, plant and equipment belonging to him or to the Employer or to others, working at the Site.

vi) All equipments used in construction and erection by the contractor shall meet BIS / International Standards and where such standards do not exist, the Contractor shall ensure these to be absolutely safe. All equipments shall be strictly operated and maintained by the contractor in accordance with manufacturer’s operation manual. The contractor should also follow Guidelines / Rules of the Employer in this regard.

vii) The Contractors shall provide suitable latest Personal Protective Equipments of prescribed standard to all their employees and workmen according to the need. The Engineer In charge shall have the right to examine these safety equipments to determine their suitability, reliability, acceptability and adaptability. The contractor should also ensure these before their use at worksite.

viii) The Contractor shall provide safe working conditions to all workmen and employees at his workplace including safe means of access, railings, stairs, and ladders, scaffolding, work platforms, toe boards etc. The scaffoldings shall be erected under the control and supervision of an experienced and competent person. For erection of scaffolds, access, work platforms etc. shall be good and the contractor shall use standard quality of material.

ix) The Contractor shall follow and comply with all the Safety Rules, standards, code of practices of RINFRA and relevant provisions of applicable laws pertaining to the safety of workmen, employees, plant and equipment as may be prescribed from time to time without any protest or contest or reservation. In case of any’ unconformity between statutory requirement and the Safety Rules of the Employer referred above, the latter shall be binding on the Contractor unless the statutory provisions are more stringent. As and when required he can refer / obtain copy of RINFRA safety documents as stated above.

x) The contractor shall have his own arrangements with nearby hospitals for shifting and treatment of sick and injured. The medical examination of the workers employed in hazardous areas shall be conducted as per Rule 223 of The Building and Other Construction Worker (Regulation of Employment and Condition of Service) Central Rule 1998. Their health records shall be maintained accordingly and to be submitted to Engineer In-charge when asked for. If any worker found suffering from occupational health hazard, the worker should be shifted to suitable





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place of working and properly treated under intimation to Engineer In-charge. The medical fitness certificate to be submitted to Engineer In-charge.

xi) First Aid boxes equipped with requisite articles as specified in the Rule 231 of The Building and Other Construction Worker (Regulation of Employment and Condition of Service) Central Rule 1998 shall be provided at construction sites for the use of workers. Training has to be provided on first aid to workmen & office bearers working at site.

43.02.00 Emergency Action Plan. The contractor shall prepare an emergency action plan approved by his competent authority to handle any emergency occurred during construction work. Regular mock drills shall be organized to practice this emergency plan. The Emergency Action Plan should be widely circulated to all the employees and suitable infrastructure shall be provided to handle the emergencies.

43.03.00 Scaffolding. The contractor shall take all precautions to prevent any accidental collapse of scaffolding or fall of persons from scaffolding. The contractor should ensure that scaffolding are designed by a competent person and it erection and repairs should be done under the expert supervision- The scaffolding shall meet the required strength and other requirements for the purpose for which the scaffold is erected. The material used for scaffold should conform to the BIS / International standards.

43.04.00 Opening.

The contractor shall ensure that there is no opening in any working platform/any floor of the building, which may cause fall of workers or material. When ever an opening on a platform/any floor of the building is unavoidable, the opening should be suitably fenced and necessary measures for protection against falling objects or building workers from such platform are taken by providing suitable safety nets, safety belts or other similar means.

43.05.00 Explosives. The contractor shall take all precautions while handling, using, storing or transporting of all explosives. Before usage of any explosive necessary warning / danger signals be erected at conspicuous places to warn the workers and general public. The contractor should strictly ensure that all measures and precautions required to be complied for use, handling, storing or transportation of explosives under the rules framed under the Explosives Act, 1884.

43.06.00 Coffer Dam and Caissons The Contractor shall ensure that the cofferdam and caissons are of good construction and adequate strength. The cofferdam and caissons should be provided with adequate means for workers to reach safely at the top of such dams in the even of an in-rush of water. The workers should be allowed to work in a cofferdam or caisson only after inspection and found safe by Engineer-in –charge. Such inspection is to be maintained in a Register. Where the workers are





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employed to work in a compressed air environment at the work site of cofferdam or caissons a Construction Medical Officer assisted by a Nurse or trained first aid attendant should be available at all the times during such work.

43.07.00 Fencing of Machinery. The contractor shall provide suitable fencing or guard to all dangerous and moving parts of machinery.

The contractor shall not allow any of the employees to clean, lubricate, repair, adjust or examine during machinery in motion, which may cause injury to the person.

Working Platforms should be fenced and shall have means of access

43.08.00 Carrying of Excessive Weight by a Worker. The worker shall not be allowed to lift by hand or carry over his head, back or shoulder more than the maximum limit set by the prescribed rules for the construction Workers.

43.09.00 Dangerous and Harmful Gases/Equipment. The contractor shall ensure that the workers are not exposed to any harmful gases during any construction activity including excavation, tunneling, confined spaces etc. The contractor should not allow any worker to go into the confined space unless it is certified by Engineer in-charge to be safe and fit for the entry to such work place. Proper record and work permits should be followed to carry out such works.

43.10.00 Overhead Protection.

The contractor shall ensure that any area exposed to risk of falling materials, articles or objects is roped off or cordoned off or otherwise suitably guarded from inadvertent entry of any person.

Wherever there is a possibility of falling of any material, equipment or construction workers while working at heights, a suitable and adequate safety net should be provided. The safety net should be in accordance with BIS Standards.

43.11.00 Working at Heights. a) All working platforms, ways and other places of construction work shall be free

from accumulations of debris or any other material causing obstructions and tripping.

b) Wherever workers are exposed to the hazard of falling into water, the contractor shall provide adequate equipment for saving the employees from drowning and rescuing from such hazards. The contractor shall provide boat or launch equipped with sufficient number of life buoys, life jackets etc. manned with trained personnel at the site of such work.

c) Every opening at elevation from ground level through which a building worker, vehicle, material equipment etc. may fall at a construction work shall be covered and/or guarded suitably by the contractor to prevent such falls.





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d) Wherever the workers are exposed to the hazards of falling from height, the contractor shall provide full harness safety belts fitted with fall arresting systems to all the employees working at higher elevations and life line of 8 mm diameter wire rope with turn buckles for anchoring the safety belts while working or moving at higher elevations. Safety nets shall also be provided for saving them from fall from heights and such equipment should be in accordance with BIS standards.

e) Wherever there is a possibility of falling of any material, equipment or construction workers while working at heights, a suitable and adequate safety net should be provided. The safety net should be in accordance with BIS Standards.

f) The contractor shall provide standard prefabricated ladders on the columns where the workers are required to use them as an access for higher elevations till permanent staircase is provided. The workers shall be provided with safety belts fitted with suitable fall arresting system (Fall arresters) for climbing/getting down through ladders to prevent fail from height.

g) Rungs shall not be welded on columns. All the Stairs shall be provided with handrails immediately after its erection.

43.12.00 Handling of Hazardous Chemicals. a) The Contractor will notify well in advance to the Engineer-in-charge of his intention

to bring to the Site any container filled with liquid or gaseous fuel or explosive or petroleum substance or such chemicals which may involve hazards. RINFRA shall have the right to prescribe the conditions, under which such container is to be stored, handled and used during the performance of the works and the Contract shall strictly adhere to and comply with such instructions. The Engineer-in-charge shall have the right at his sole discretion to inspect any such container or such construction plant / equipment for which material in the container is required to be used and if in his opinion, its use is not safe; he may forbid its use. No claim due to such prohibition shall be entertained by RINFRA and RINFRA shall not entertain any claim of the Contractor towards additional safety provisions / conditions to be provided for / constructed.

b) Further, any such decision of the Engineer-in-charge shall not, in any way, absolve the Contractor of his responsibilities and in case, use of such a container or entry thereof into the Site area is forbidden by RINFRA, the Contractor shall use alternative methods with the approval of the RINFRA without any cost implication to the RINFRA or extension of work schedule.

c) Where it is necessary to provide and / or store petroleum products or petroleum mixtures and explosives, the Contractor shall be responsible for carrying-out such provision and / or storage in accordance with the rules and regulations laid down in Petroleum Act 1934, Explosives Act 1948, and Petroleum and Carbide of Calcium Manual published by the Chief Inspector of Explosives of India. All such storage shall have prior approval of the Engineer In-charge In case any approvals are necessary from the Chief Inspector (Explosives) or any statutory authorities; the Contractor shall be responsible for obtaining the same.

d) The Contractor shall be fully responsible for the safe storage of his and his Sub-contractor's radio-active sources in accordance with BARC/DAE (Bhabha Atomic





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Research Centre/ Department of Atomic Energy, Govt. of India) Rules and other applicable provisions- AU precautionary measures stipulated by BARC/DAE in connection with use, the contractor would take storage and handling of such material.

e) The contractor shall provide suitable personal protective equipments to the workers who are handling the hazardous and corrosive substances including alkalis and acids.

f) As a precautionary measure the contractor should keep the bottles filled with distilled water in cupboard / Boxes near work place for emergency eye wash by worker exposed to such hazardous chemicals.

43.13.00 Eye Protection. The contractor shall provide suitable personal protective equipment to his workmen depending upon the nature of hazards and ensure their usage by the workers engaged in operations like welding, cutting, chipping, grinding or similar operations which may cause injuries to his eyes.

43.14.00 NOT USED 43.15.00 Electrical Hazards.

a) The contractor should ensure that all electrical installations at the construction work comply with the requirements of latest electricity acts / rules.

b) The contractor shall take all adequate measures to prevent any worker from coming into physical contact with any electrical equipment or apparatus, machines or live electrical circuits which may cause electrical hazards during the construction work. The contractor shall provide the sufficient ELCBs / RCCBs for all the portable equipments, electrical switchboards, distribution panels etc. to prevent electrical shocks.

c) The contractor should ensure use of single / double insulated hand tools or low voltage i.e., 110 volts hand tools.

d) The contractor should also ensure that all temporary electrical installations at the construction works are provided with earth leakage circuit breakers.

e) No electric cable in use by the Contractor /Employer will be disturbed without prior permission. No weight of any description will be imposed on any cable and no ladder or similar equipment will rest against or attached to it.

f) The Contractor shall employ necessary number of qualified, full time Electricians/electrical supervisors to maintain his temporary electrical installations.

43.16.00 Vehicular Traffic. The contractor should employ vehicle drivers who hold a valid driving license under the Motor Vehicles Act, 1988.

43.17.00 Lifting Appliances, Tools & Tackles. Lifting Gear And Pressure Plant & Equipment etc. The contractor shall ensure alt the lifting appliances, tools & tackles including cranes etc., lifting gear including fixed or movable and any plant or gear, hoists,





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Pressure Plant and equipment etc. are in good condition and shall be examined by competent person and only certified shall be used at sites. Periodical Examination and the tests for all lifting / hoisting equipment & tackles shall be carried out. A register of such examinations and tests shall be properly maintained by the Contractor and will be promptly produced as and when desired by the Engineer I/c or by the person authorized by him.

43.18.00 Excessive Noise, Vibration. The contractor shall take adequate measures to protect the workers against the harmful effect of excessive noise or vibration. The noise should not exceed the limits prescribed under the concerned rules. Noise Pollution (Regulation and Control) Rules, 2000.

43.19.00 Electrical Installations. a) The Contractor shall not interfere or disturb electric fuses, wiring and other

electrical equipment belonging to the Employer or other contractors under any circumstances, whatsoever, unless expressly permitted in writing by the Engineer I/c to handle such fuses, wiring or electrical equipment.

b) Before the Contractor connects any electrical appliances to any plug or socket belonging to the other contractor or the RINFRA, he shall :-

♦ Satisfy the Engineer I/C that the appliance is in good working condition;

♦ Inform the Engineer I/C of the maximum current rating, voltage and phases of the appliances;

♦ Obtain permission of the Engineer-in-Charge detailing the sockets to which the appliances may be connected.

c) The Engineer in-charge will not grant permission to connect until he is satisfied that :-

♦ The appliance is in good condition and is fitted with suitable plug; having earth connection with the body.

♦ Wherever armored / metallic sheathed multi core cable is used, the same armored / sheathed should be connected to earth.

d) No repair work shall be carried out on any live equipment. The Engineer-in-Charge must declare the equipment safe and a permit to work shall be issued by the RINFRA / contractor as the case may be to carry out any repair / maintenance work. While working on electric lines / equipments whether live or dead, suitable type and sufficient quantity of tools will have to be provided by the contractor to electricians / workmen / Officers.

e) The contractor shall employ necessary number of qualified, full time Electricians / Electrical Supervisors to maintain his temporary electrical installation.

f) The installations are provided with suitable ELCBs and RCCBs wherever required.

43.20.00 Safety Organisation. a) The contractor employing more than 250 workmen whether temporary, casual,

probationary, regular or permanent shall employ at least one full time safety officer





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exclusively to supervise safety aspects of the equipments and workmen, who will coordinate with the RINFRA Safety Officer. Further requirement of safety officers, if any, shall be guided by Rule 209 of The Building and Other Construction Worker (Regulation of Employment and Conditions of Service) Central Rule 1998. In case the work is being carried out through subcontractor, the employees / workmen of the sub contractor shall also be considered as the contractor's employees/workmen for the above purpose.

b) In case of contractor deploying less than 250 workmen he should designate one of his Engineer / supervisor or the contractor himself (if he is directly supervising the work) as safety officer in addition to his existing responsibilities. The Engineer./ supervisor should get at least 2 days safety training from any reputed organization or from RINFRA before resuming the work. If already trained in past the declaration along with training. Certificate to be furnished to RINFRA safety officer.

c) The name and address of such Safety Officer of the Contractor will be promptly informed in writing to the EIC with a copy to the Project Safety Officer before he starts work or immediately after any change of the incumbent is made during currency of the Contract.

43.21.00 Reporting of Accident and Investigation.

In case any accident occurs during the construction / erection or other associated activities undertaken by the Contractor thereby causing any near miss, minor or major or fatal injury to his employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to promptly inform the same to the Engineer in-charge, RINFRA Safety Officer with a copy to RINFRA Head of Project in the prescribed form and also to all the authorities envisaged under the applicable laws.

43.22.00 Right to stop Work. a) The Engineer I/C shall have the right at his sole discretion to stop the work, if in

his opinion the work is being carried out in such a -way that it may cause accidents and endanger the safety of the persons and / or property, and / or equipments. In such cases, the contractor shall be informed in writing about the nature of hazards and possible injury / accident and he shall comply to remove shortcomings promptly. The Contractor after stopping the specific work can, if felt necessary appeal against the order of stoppage of work to the Project Manager within 3 days of such stoppage of work and decision of the Project Manager in this respect shall be conclusive and binding on the Contractor.

b) The Contractor shall not be entitled for any damages / compensation for stoppage of work due to safety reasons and the period of such stoppage of work shall not be taken as an extension of time for Completion of the Facilities and will not be the ground for waiver of levy of liquidated damages.

43.23.00 Fire Protection.





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a) The contractor shall provide sufficient fire extinguishers at place /s of work. The fire extinguishers shall be properly maintained as per relevant BIS Standards. The employees shall be trained to operate the fire extinguishers / equipment.

b) The Contractor shall provide enough fire protection equipment of the types and number for the warehouses, office, temporary structures, labour colony area etc. Access to such fire protection equipment, shall be easy and kept open at all time.

c) The work procedures that are to be used during the erection shall be those which minimise fire hazards to the extent practicable. Combustible materials, combus-tible waste and rubbish shall be collected and removed from the Site at least once each day. Fuels, oils and volatile or flammable materials shall be stored away from the construction and equipment and materials storage areas in safe containers. Untreated canvas, paper, plastic or other flammable flexible materials shall not at all be used at Site for any other purpose unless otherwise specified. If any such materials are received with the equipment at the Site, the same shall be removed and replaced with acceptable material before moving into the construction or storage area.

d) Similarly corrugated paper fabricated cartons etc. will not be permitted in the construction area either for storage or for handling of materials. All such materials used shall be of water proof and flame resistant type. All the other materials such as working drawings, plans etc. which are combustible but are essential for the works to be executed shall be protected against combustion resulting from welding sparks, cutting flames and other similar fire sources.

e) All the Contractor’s supervisory personnel and sufficient number of workers shall be trained for fire-fighting and shall be assigned specific fire protection duties. Enough of such trained personnel must be available at the Site during the entire period of the Contract.

43.24.00 Penalties. a) If the Contractor fails in providing safe working environment as per the Safety

Rules of RINFRA or continues the work even after being instructed to stop the work by the Engineer –in- Charge as provided above, the Contractor shall be penalized at the rate of Rs. 25,000/-- per day or part thereof till the instructions are complied with and so certified by the Engineer I/C- However, in case of accident, the provisions contained below shall also apply in addition to the penalties mentioned in this sub-clause.

b) If the Contractor does not take all safety precautions and / or fails to comply with the Safety Rules as prescribed by the Employer or under the applicable law for the safety of the plant and equipment and for the safety of personnel and the contractor does not prevent hazardous conditions which cause injury to this own employees or employees of other contractors, or RINFRA's employees or any other person who are at the Site or adjacent thereto, the Contractor shall be responsible for payment of penalty to RINFRA as per the following schedule; -

a) Fatal injury or accident causing Penalty @10% of contract value death or Rs. 5,00,000/- per person,





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death: which ever is less.

b) Major injuries or accident causing 25% or more permanent disablement to workmen or employees.

Penalty @2.5 % of contract value or Rs.1,00,000/- per person, which ever is less.

Permanent disablement shall have the same meaning as indicated in The Workmen's Compensation Act' 1923. The penalty mentioned above shall be in addition to the compensation payable to the workmen / employees under the relevant provisions of the Workmen's Compensation Act' 1923 and rules framed there under or any other applicable laws as applicable from time to time.

c) If any contractor worker found working without using the safety equipment like safety helmet, safety shoes, safety belts, etc. or without anchoring the safety belts while working at height the Engineer in-charge / Safety Officer of RINFRA shall have the right to penalize the contractor for Rs. 200/- per person per day and such worker shall be sent out of the workplace immediately and shall not be allowed to work on that day. Engineer in-charge / Safety Officer of RINFRA will also issue a notice in this regard to the contractor.

d) If two or more fatal accidents occur at same RINFRA site under the control of contractor during the period of contract and he has :-

(1) not complied with keeping adequate PPEs in stock,

(2) defaulted in providing PPR's to his workmen

(3) not followed statutory requirements /RINFRA safety rules

(4) been issued warning notice/s by RINFRA head of the project on non observance of safety norms

(5) not provided safety training to all his workmen,

the contractor can be debarred from getting tender documents in RINFRA for two years from the date of last accident.

e) The safety performance will also be one of the overriding criteria for evaluation of overall performance of the contractors by RINFRA. The contractor shall submit the accident data including fatal / non-fatal accidents for the last 3 years where he has undertaken the construction activities Projects-wise along with the tender documents. This will also be considered for evolution of tender documents. If the information given by the contractor found incorrect, his contract will be liable to be terminated.

43.25.00 Award. If the Contractor's performance on safety front is found satisfactory i.e. without any fatal/reportable accident in the year of consideration; he may be considered for suitable award "ACCIDENT FREE SAFETY MERITORIOUS AWARD" as per scheme of the employer.

44.00.00 FOREIGN PERSONNEL





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44.01.00 The Contractor shall submit to the Employer data on all personnel he proposes to bring into India from abroad for the performance of the Works under the Contract, at least sixty (60) days prior to their departure to India. Such data will include for each person the name, his present address, his assignment and responsibility in connection with the works, and a short resume of his qualification, experience etc. in relation to the work to be performed by him.

44.02.00 Any person unsuitable and unacceptable to the Employer shall not be brought to India. Any person brought to India, if found unsuitable or unacceptable by the Employer, the Contractor shall within a reasonable time make alternate arrangements for providing a suitable replacement and repatriation of such unsuitable personnel.

44.03.00 No person brought to India for the purposes of the works shall be repatriated without the consent of the Employer in writing, based on a written request from the Contractor for such repatriation giving reasons for such an action to the Employer. The Employer may give permission for such repatriation provided he is satisfied that the progress of work will not suffer due to such repatriation.

44.04.00 The cost of passports, visas and all other travel expenses to and from India, incurred by the Contractor shall be to his account. The Employer will not provide any residential accommodation and/or furniture for any of the Contractor’s personnel including foreign personnel and Contractor shall make his own arrangements for such facilities in the area allotted at Site, to him by the Employer for that purpose.

44.05.00 The Contractor and his expatriate personnel shall respect all Indian Acts, Laws, rules and regulations and shall not in any way interfere with Indian political and religious affairs and shall conform to any other rules and regulations which the Government of India and the Employer may establish from time to time, on them. The Contractor’s expatriate personnel shall work and live in close co-operation and coordination with their co-workers and the community and shall not engage themselves in any other employment neither part-time or full-time nor shall they take part in any local politics.

44.06.00 The Employer shall assist the Contractor, to the extent possible, in obtaining necessary permits to travel to India and back, by issue of necessary certificates and other information needed by the Government agencies.

45.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT BASES

45.01.00 The surfaces of foundations shall be dressed to bring the top surface of the foundations to the required level, prior to placement of equipment/equipment bases on the foundations.

45.02.00 All the equipment/ equipment bases, shall be grouted and finished as per these specifications unless otherwise recommended by the equipment manufacturer.

45.03.00 The concrete foundation surfaces shall be properly prepared by chipping, grinding as required to bring the top of such foundation to the required level, to provide the necessary roughness for bondage and to assure enough bearing strength.





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45.04.00 Grout

The grout shall be high strength grout having a minimum characteristic compressive strength of 60 N/mm2 at 28 days. The grout shall be chloride - free, cement based, free flowing, non-metallic grout.

The Grout shall have good flowability even at very low water/ grout powder ratio.

The Grout shall have characteristics of controlled expansion to be able to occupy its original volume to fill the voids and to compensate for shrinkage. Grout shall be of pre-mix variety so that only water needs to be added before use.

The mixing of the Grout shall conform to the recommendations of the manufacturer of the Grout.

45.05.00 Placing of Grout 45.05.01 After the base has been prepared, its alignment and level has been checked and

approved and before actually placing the grout, a low dam shall be set around the base at a distance that will permit pouring and manipulation of the grout. The height of such dam shall be at least 25mm above the bottom of the base. Suitable size and number of chains shall be introduced under the base before placing the grout, so that such chains can be moved back & forth to push the grout into every part of the space under the base.

45.05.02 The grout shall be poured either through grout holes if provided or shall be poured at one side or at two adjacent sides to make the grout move in a solid mass under the base and out in the opposite side. Pouring shall be continued until the entire space below the base is thoroughly filled and the grout stands at least 25 mm higher all around than the bottom of the base. Enough care should be taken to avoid any air or water pockets beneath the bases.

45.05.03 In addition to the above, recommendations of Grout manufacturer shall also be followed.

45.06.00 Finishing of the Edges of the Grout

The poured grout should be allowed to stand undisturbed until it is well set. Immediately thereafter, the dam shall be removed and grout which extends beyond the edges of the structural or equipment base plates shall be cut off, flushed and removed. The edges of the grout shall then be pointed and finished with 1:2 cement mortar pressed firmly to bond with the body of the grout and smoothened with a tool to present a smooth vertical surface. The work shall be done in a clean and scientific manner and the adjacent floor spaces, exposed edges of the foundations, and structural steel and equipment base plates shall be thoroughly cleaned of any spillage of the grout.

45.07.00 Checking of Equipment After Grouting

After the grout is set and cured, the Contractor shall check and verify the alignment of equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals, centering of rotors with respect to their sealing bores,





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couplings, etc. as applicable and the like items to ensure that no displacement had taken place during grouting. The values recorded prior to grouting shall be used during such post grouting checkup and verifications. Such pre and post grout records of alignment details shall be maintained by the Contractor in a manner acceptable to the Employer.

46.00.00 SHAFT ALIGNMENTS

All the shafts of rotating equipment shall be properly aligned to those of the matching equipments to as perfect an accuracy as practicable. The equipment shall be free from excessive vibration so as to avoid overheating of bearings or other conditions which may tend to shorten the life of the equipment. The vibration level of rotating equipments measured at bearing housing shall not exceed forty (40) microns and shall conform to VDI 2056.All bearings, shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated before starting.

47.00.00 DOWELLING

All the motors and other equipment shall be suitably doweled after alignment of shafts with tapered machined dowels as per the direction of the Employer.

48.00.00 CHECK OUT OF CONTROL SYSTEMS

After completion of wiring, cabling furnished under separate specification and laid and terminated by the Employer, the Contractor shall check out the operation of all control systems for the equipment furnished and installed under these specifications and documents.

49.00.00 COMMISSIONING SPARES 49.01.00 It will be the responsibility of the Contractor to provide all commissioning spares

including consumable spares required for initial operation till the Completion of Facilities. The Contractor shall furnish a list of all commissioning spares within 60 days from the date of Notification of Award and such list shall be reviewed by the Employer and mutually agreed to. However. such review and agreement will not absolve the Contractor of his responsibilities to supply all commissioning spares so that initial operation do not suffer for want of commissioning spares. All commissioning spares shall be deemed to be included in the scope of the Contract at no extra cost to the Employer.

49.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to the schedule date of commencement of initial operation of the respective equipment and utilised as and when required. The unutilised spares and replaced parts, if any, at the end of successful completion of guarantee tests shall be the property of the Contractor and he will be allowed to take these parts back at his own cost with the permission of Employer.

50.00.00 EQUIPMENT DELIVERY AND ERECTION





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50.01.00 General Requirements (a.) This part covers Contractor's responsibilities for packing, shipping, ware-

housing and the installation of all equipment and materials furnished and installed under this specification.

(b.) The Contractor shall submit for Employer's approval draft manual for Equipment Delivery and Erection (EDE Manual) covering detailed instructions, write up, technical data, drawings, check-lists, documentation formats for all activities after equipment manufacture upto installation of equipment. This manual shall cover general instructions for all equipment and specific instructions for individual equipment wherever required and shall include at least the following :

(1.) Instructions for packing, shipping, receiving handling, ware-housing and storage.

(2.) Instructions for location and installation of equipment furnished by this specification.

(3.) Installation drawings for field mounted equipment, panels, cubicles and other equipment covered under this specification.

(4.) Instruction relating installation of piping/ tubing, support and routing drawings of impulse pipes/signal tubes and tube/cable trays.

(5.) Check lists and quality assurance hold points.

(6.) Format for all related documentation.

(c.) The EDE Manual shall conform to the requirements of this specification, all applicable codes and standards, recommendations of equipment manufacturers and accepted good engineering practices and shall be subject to Employer approval during detailed engineering.

(d.) The Contractor shall ensure that all work under this part shall be performed as per the requirements of this specification, Employer approved EDE Manual and drawing/documents approved by the Employer during detailed engg.

50.02.00 Crating (a.) All equipment and materials shall be suitably coated, wrapped, or covered

and boxed or crated for moist humid tropical shipment and to prevent damage or deterioration during handling and storage at the site.

(b.) Equipment shall be packed with suitable desiccants, sealed in water proof vapour-proof wrapping and packed in lumber of plywood enclosures, suitably braced, tied and skidded. Lumber enclosures shall be solid, not slatted.

(c.) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to provide the required surface area and activated prior to placing in the packaging. Calcium sulphate desiccants shall be of a chemical nature to absorb moisture. In any case, the desiccant shall not be of a type that will absorb enough moisture to go into solution. Desiccants shall be packed in porous containers, strong enough to withstand handling encountered during





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normal shipment. Enough desiccant shall be used for the volumes enclosed in wrapping.

(d.) Review by the Employer of the Contractor's proposed packaging methods shall not relieve the Contractor of responsibility for damage or deterioration to the equipment and materials specified.

(e.) All accessory items shall be shipped with the equipment. ; Boxes and crates containing accessory items shall be marked so that they are identified with the main equipment. The contents of each box and crates shall be indicated by markings on the exterior.

(f.) All boxes, crates, cases bundles, loose pieces, etc. shall be marked consecutively from No.1 upward throughout all shipments from a given port to completion of the order without repeating the same number.

(g.) An itemized list of contents shall be enclosed inside each case and one other copy securely fastened to the outside of the case in a tin or light weight sheet metal envelope or pocket. The lists shall be plainly marked and placed in accessible locations to facilitate receipt and inspection. The packing list shall indicate whether shipment is partial or complete and shall incorporate the following information on each container, etc., according to its individual shipping number :

(1.) Export case markings

(2.) Case number

(3.) Gross weight and net weight in Kilograms

(4.) Dimensions in centimeters

(5.) Complete description of material

(h.) Packaging or shipping units shall be designed within the limitations of unloading facilities and the equipment which will be used for transport. Complications involved with ocean shipment and the limitations of ports, railways and roads shall be considered. It shall be the Contractor's responsibility to investigate these limitations and to provide suitable packaging to permit safe handling during transit and at the job site.

(i.) Electrical equipment, control and instrumentation shall be protected against moisture and water damage. All external gasket surfaces and flange faces, couplings, motor pump shafts, bearing and like items shall be thoroughly cleaned and coated with rust preventive compound as specified above and protected with suitable wood, metal or other substantial type covering to ensure their full protection.

(j.) Equipment having antifriction or sleeve bearings shall be protected by weather tight enclosures.

(k.) Coated surfaces shall be protected against impact, abrasion, discolouration and other damage. Surfaces which are damaged shall be repaired.

(l.) All exposed threaded parts shall be greased and protected with metallic or other substantial type protectors. All female threaded openings shall be





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closed with forged steel plugs. All pipings, tubing, and conduit equipment and other equipment openings shall be sealed with metallic or other rough usage covers and tapped to seal the interior of the equipment piping, tubing, or conduit.

(m.) Provisions shall be made to ensure that water does not enter any equipment during shipment or in storage at the plant site.

(n.) Returnable containers and special shipping devices shall be returned by the manufacturer's field representative at the Contractor's expense.

(o.) While packaging the material, care shall be taken for the limitation from the point of view of availability of railway wagon sizes in India.

50.03.00 Factory Assembly (a.) Instrument enclosures shall be supplied and erected completely in the

factory with instrument, air supply and blow down piping with necessary valves, fittings, etc. and also all electrical wiring between the instruments and the enclosure terminal blocks. Control panel and cubicles shall also be fully wired in the factory. Control panel mounted equipments are to be dismounted from the panels before shipment and individually packed for shipment. Electronic control modules of the plug-in type are to be removed from equipment racks after factory checkout are individually packed for shipment. Other equipment shall be fully assembled at the factory, except for necessary shipping splits in panels.

(b.) All separately packaged accessories items and parts shall be shipped with the equipment. Containers for separately packaged items shall be marked so that they are identified with the main equipment. An itemized packing slip, indicating what is in that carton only, shall be attached to the outside and inside of each container used for packing.

A master packing slip covering all accessories items for a given piece of equipment which are shipped in separate containers, shall be attached to one container.

50.04.00 Equipment Installation (a.) General Requirements

(1.) The Contractor shall furnish all construction materials, tools and equipment and shall perform all work required for complete installation of all control and instrument equipment furnished under this specification.

(2.) Contractor shall prepare detailed installation drawings for each equipment furnished under this specification for Employer's approval. Installation of all equipment/systems furnished by this specification shall be as per Employer's approval.

(3.) Erection procedures not specified herein shall be in accordance with the recommendations of the equipment manufacturers. The procedures shall be acceptable to the Employer.





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(4.) The Contractor shall coordinate his work with other suppliers where their instruments and devices are to be installed under specifications.

(b.) Installation Materials

All materials required for installation, testing and commissioning of the equipment shall be furnished by the Contractor.

(c.) Regulatory Requirements

All installation procedures shall confirm with the accepted good engineering practice and with all applicable governmental laws, regulations and codes.

(d.) Cleaning

All equipment shall be cleaned of all sand, dirt and other foreign materials immediately after removal from storage and before the equipment is brought inside the power plant building or to other installation sites. All piping and tubes shall be air blown.

(e.) Equipment Assembly

Equipment installed under these specifications shall be assembled if shipped unassembled. The equipment shall be dismantled and reassembled as required to perform the installation and commi ssioning work described in these specifications.

(f.) Equipment Setting

Field mounted instruments and accessories shall be bracket or sub panel mounted on the nearest suitable firm steel work or masonry. The brackets, stands, supports and other miscellaneous hardware required for mounting instruments and accessories such as receiver gauge, air set, valve manifold, purge-meter etc. shall be furnished and installed. No field mounted instruments shall be installed such that it depends for support or rigidity on the impulse piping or on electrical connection to it.

Indicating type field mounted instruments shall be installed in such a way that centre of indicating dial shall be about 1600-1800mm from operating floor level. Non-indicating type field instruments shall be installed such that operating handle of manifold block / isolating cock comes within 1600 mm from operating floor level.

All free standing instrumentation cabinets and panels shall be located within the construction tolerances of +/- 3 mm of the location dimensions indicated on the Employer's plant arrangement drawings.

(g.) Free-Standing Equipment

Free-standing Cabinets shall be attached to the floor, concrete equipment bases or supporting steel as indicated on the manufacturer's drawings and the





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Employer's Plant Arrangement Drawings. The cabinets shall be shimmed for proper alignment before bolting them to the floor. Adjacent enclosures shall be shimmed to maintain mutually level appearance before they are attached to floor. Vibration dampening mounts shall be installed between supporting structures and panels when specified.

(h.) Non-free Standing Equipment (1.) Non-free standing local enclosures and cabinets shall be mounted in

accessible locations on columns, walls, or stands in locations as indicated on the Employer's Plant Arrangement Drawings. Bracket and stands shall be fabricated as required to install the local enclosures and cabinets in a workman like manner.

(2.) Rough edges and welds on all fabricated supports shall be ground smooth. The supports shall be finished with two coats of primer and two coats of paint as specified in this part.

(i.) Equipment Location (1.) All individual items of equipment not located in cabinets or on panels

and racks are located approximately according to the floor elevation and the nearest building column designated by the Employer.

(2.) Solenoid valves not located in enclosures or mounted on valves shall be mounted in easily accessible protected locations near the components with which they are associated.

(3.) All brackets, stands, supports and other miscellaneous hardware required for mounting devices shall be furnished and installed.

(4.) Thermometers shall be installed in the process lines and ducts as required and adjusted for ease in reading.

(5.) Permanent temperature wells on the main steam, hot reheat and cold reheat piping shall not be installed until steam blowing has been completed. Temporary temperature wells shall be installed in the main and reheat steam piping during steam blow and discarded after completion.

(6.) Any required adapting hardware such as pipe bushings, nipples, drilled caps and the like shall be provided for complete installation of control devices into process connections.

For location of C&I related equipment/devices, the requirement specified elsewhere in the technical specification may be referred.

(j.) Installation of Field Mounted Instruments and Devices

The Contractor shall submit installation drawings for all field mounted equipment furnished under this specification for Employer's approval. These drawings shall meet the requirements of this specification, installation drawings, applicable codes and standards and recommendations of manufacturers of instruments/devices. All installation work under this specification shall be strictly as per installation drawings approved by the Employer during detailed engineering stage.





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In addition to above relevant Portion as specified elsewhere in technical specification may be referred.

(k.) Piping Connections (1.) All equipment having piping connections shall be levelled, aligned and

wedged in place but shall not be grouted or bolted prior to the initial fitting and alignment of connecting piping. All equipment shall, however, be grouted or bolted to its foundation prior to final bolting or welding of the connection piping.

(2.) All flanged joints shall be checked and retightened after approximately 10 days of operation at normal operating temperature.

(l.) Equipment Checkout (1.) All equipment shall be cleaned after installation. Equipment subject to

pressure differentials shall be checked for leakage.

(2.) After erection, all equipment having moving parts, having electrical apparatus, or subject to pressure differentials shall be trial-operated.

(m.) Defects (1.) All defects in erection shall be corrected to the satisfaction of the

Employer and the Project Manager. The dismantling and reassembly of Contractor furnished equipment to remove defective parts, replace parts, or make adjustments shall be included as a part of the work under these specifications.

(2.) The removal of control and instrument equipment in order to allow bench calibration, if required, and the re-installation of the said equipment after calibration shall also be included as a part of the work under these specifications.

(n.) Equipment Protection (1.) All equipment to be erected under these specifications shall be

protected from damage of any kind from the time of contract award until commissioning of each unit.

(2.) The equipment shall be protected during storage as described herein.

(3.) Equipment shall be protected from weld spatter during construction.

(4.) Suitable guards shall be provided for protection of personnel on all exposed rotating or moving machine parts. All such guards with necessary spares and accessories shall be designed for easy removal and maintenance.

(5.) Equipment having glass components such as gauges, or equipment having other easily breakable components, shall be protected during the construction period with plywood enclosures or other suitable means. Broken, stolen, or lost components shall be replaced by the Contractor.





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(6.) Machine finished surfaces, polished surfaces, or other bare metal surfaces which are not to be painted, such as machinery shafts and couplings shall be provided temporary protection during storage and constructional periods by a coating of a suitable non- drying, oily type, rust preventive compound.

51.00.00 WELDING - SPECIAL REQUIREMENTS

If the manufacturer has special requirements relating to the welding procedures for welds at the terminals of the equipments to be performed under separate specifi-cations, the requirements shall be submitted to the Project Manager in advance of commencement of erection work.

52.00.00 DEVIATIONS DISPOSITIONING:

Any deviation to the contract and employer approved documents shall be properly recorded in the format prescribed by RINFRA. Al the deviations shall be bought to the knowledge of employer’s representative for suitable dispositioning.

53.00.00 NON-DESTRUCTIVE TESTING ( NDT):

The contractor shall record results of NDTs carried out at site in the format acceptable to employer. All the radiographs & its report duly signed & correlated to the job shall be handed over to the employer. Sensitivity of all the test equipment shall be compatible to the job & acceptance norms agreed.

54.00.00 TESTING EQUIPMENT & FACILITIES:

Contractor shall provide the testing equipment and facilities necessary to carry out tests & inspections.





Page 42 of 45

ANNEXURE-I

STANDARD CHECKLIST –

COMMISSIONING/TESTING ESSENTIAL PRE-REQUISITE

(a.) Mechanical

Sl. No. DESCRIPTION

(1.) Valves- All Types as applicable

(2.) Tanks And Pressurre Vessels as Applicable

(3.) Pumps as applicable

(4.) Pipe Work System as applicable

(5.) Strainer And Filter as applicable

(6.) Heat Exchangers/ Cooling Towers/ Resin vessels as applicable

(7.) Fans And Compressors as applicable

(8.) Dampers & Gates as applicable

(9.) Duct Work as applicable

(10.) Cranes. Hoists And Elevators as applicable

(11.) Power Transmission (Gear Box, Bearings & Couplings) as applicable

(b.) Electrical

Shall be as per General Technical Specifications for Electrical

(c.) Control & Instrumentation

(1.) Conductivity Analysing Equipment including Test procedures

(2.) pH ANALYSER INCLUDING TEST PROCEDURE





Page 43 of 45

(3.) Silica analyser

(4.) LEVEL SWITCH (FLOAT ACTUATED)

(5.) LEVEL SWITCH (ELECTRODE TYPE)

(6.) Level Switch Displaced actuated)

(7.) Transmitter (Float Operated Pneumatic Output)including testing procedure

(8.) Level Indicator (Float/Pulley Type)

(9.) LOCAL TEMPERATURE INDICATORS INCLUDING TEST PROCEDURE

(10.) Resistance Thermometer Element including Test Procedure

(11.) THERMOCOUPLE ELEMENT AND CONNECTING CABLE

(12.) Thermocouple and Resistance Thermometer Convertor/Transmitter including Test Procedures.

(13.) Temperature Switch/Thermostat including test procedures

(14.) COLD JUNCTION BOXES

(15.) ZENER BARRIER

(16.) O2 Analyser

(17.) O2 IN HYDROGEN INCLUDING TEST PROCEDURES

(18.) Pressure and Vacuum Gauge

(19.) PRESSURE AND VACUUM SWITCH INCLUDING TEST PROCEDURE

(20.) Differential Pressure Transmitter including test procedure

(21.) Differential Pressure switch including test procedure.

(22.) Flow Indicator(variable area)

(23.) ORIFICE PLATE

(24.) TURBINE FLOW TRANSMITTER

(i.) FLOW SWITCH (ii.) WEIR (iii.) NOZZLE





Page 44 of 45

(iv.) Flow Indicator(Pneumatic input)including test procedure (v.) Flow integrator (Pneumatic input)including test procedure (vi.) Flow indicator (float operated)including test procedure (vii.) VENTURI (FLUID) (viii.) Flow switch(Magnetic Type) (ix.) AVERAGING INLET (x.) LIMIT SWITCHES

(25.) TURBINE SUPERVISORY MEASURING SYSTEM

(26.) Position Measurement and indication including Test Procedures

(i.) TACHOMETER (ii.) VIBRATION MEASUREMENT (iii.) DIGITAL INDICATOR (iv.) MOVING COIL INDICATOR INCLUDING TEST

PROCEDURE (v.) RECORDER INCLUDING TEST PROCEDURE (vi.) FLAME SCANNER (vii.) ELECTRICAL AUTO MANUAL CONTROL STATION (viii.) PUSH BUTTON MODULE (ix.) ALARM ANNUNCIATOR EQUIPMENT INCLUDING TEST

PROCEDURE (x.) Test procedure for electronic Modules of DDCMIS (xi.) THERMO CONTROL VALVE (xii.) Test Procedure for adjustment of modulating Controller –

PID Terms (xiii.) Test Procedure indicating Controller-Electrical Input and

Pneumatic Output

Note: The items which are not part of this specification may be considered as not applicable.

Annexure-II

BRIEF WRITE UP ON THE CONTENTS OF TESTING SCHEDULE / COMMISSIONING SCEHDUELE

Testing Schedules should be designed to ensure that the plant area, equipment or apparatus are tested and commissioned and will operate as per the employer’s specifications and good engineering practices.

Testing Schedule/Commissioning Schedule is required to be of a standard format in order to maintain consistency of presentation, content and reporting.

Testing Schedule/Commissioning Schedule should contain the following sections to make the document a self contained one:

(a.) Plant Details/Design data





Page 45 of 45

(b.) Testing Objective/Proposals

(c.) State of the Plant

1) Erection Status with respect to Mech. Elect and C&i

2) Availability of the services required

3) Safety requirements as per manufacturer’s data

(d.) Test method including completion/acceptance criteria

(e.) Results

(f.) Appendix

(1.) Testing Programme

(2.) Mech/Elect/C&I –Plant item completing list

(3.) List of Drawing/documents required for carrying out the testing.



EXPANSION

REL-SKCCP-NEM-161-P-00001(Rev.00) Part IV Page 1 of 5

PART IV

SECTION 1

DATASHEET



EXPANSION


FUEL GAS CONDITIONING SYSTEM

1.00.00 Gas Conditioning System i. Gas pipe line from terminal point a. O.D. and thickness of pipe ........................................... (mm x mm) b. Material of pipe ........................................... c. Insulating material .......................................... d. Coating used ........................................... d. No. of block valves ........................................... e. Details of block valves ........................................... f. Details of the metering facility ..........................................

ii) Emmergency stop valve

a. Type and make .......................................... b. No. provided ........................................... c. Pressure drop during full flow (Kg/cm2) ......................... d. Max design pressure (Kg/cm2) ......................... e. Material of construction 1. Body ........................................... 2. Seat ........................................... 3. Plug ........................................... 4. Stem ...........................................

iii) Fuel Gas metering station

a. Type and make ..........................................

b. No. provided ........................................... c. Pressure drop during full flow (Kg/cm2) ......................... d. Max design pressure (Kg/cm2) ......................... e. Material of construction ...........................................



EXPANSION


iv) Knock out drum a. Type and make .......................................... b. No. provided ........................................... c. Number operating during full load ........................................... operation d. Pressure drop during full flow (Kg/cm2) ......................... e. Max design pressure (Kg/cm2) ......................... f. Max allowable solid content ........................................... at separator outlet. v) Filter separators a. Type, make and material ........................................... b. No. provided ........................................... c. Number operating during full load …………..............................

operation d. Size and mesh of strainer .......................................... e. Pressure drop during full flow .......................................... f. Max allowable solid content ........................................... at filter outlet

vi) Startup Heater a. Type, make and material ........................................... b. No. provided ........................................... c. Duty of Heater ........................................... d. Pressure drop during full flow .......................................... e. Max design pressure(Kg/cm2) ........................................... vii) Pressure regulating control valve a. Number ........................................... b. Size (mm) ............................... c. Type ........................................... d. Pressure drop 1. at max load ..........................................



EXPANSION


2. at no load ........................................... e. Control valve characteristics ........................................... f. Materials of construction 1. Body ........................................... 2. Seat ........................................... 3. Plug ........................................... 4. Stem ........................................... g. Total Pressure drop across Fuel ........................................... Gas conditioning system when all gas turbines are operating at full load

vii) Absolute filter

a. Type, make and material ........................................... b. No. provided ........................................... c. Number operating during full load …………..............................

operation d. Size and mesh of strainer .......................................... e. Pressure drop during full flow .......................................... f. Max allowable solid content ...........................................

at filter outlet viii) Efficiency Heater

a. Type, make and material ........................................... b. No. provided ........................................... c. Duty of Heater ........................................... d. Pressure drop during full flow .......................................... e. Max design pressure(Kg/cm2) ........................................... Gas side ……………………………… Water side ……………………………….. vi) Scrubber a. Type, make and material ........................................... b. No. provided ...........................................



EXPANSION


c. Number operating during ........................................... full load operation d. Size and mesh of strainer .......................................... e. Pressure drop during full flow .......................................... f. Max allowable solid content ........................................... at filter outlet g. Material of Pipeline downstream of filter ...........................................

Instrumentation & control Cables

Technical Data sheets


REL-SKCCP-NRM-161-P-00001 (Rev.00) Instrumentation & Control Cables Page 1 of 5

INSTRUMENTATION & CONTROL CABLES TECHNICAL DATA TO BE FILLED IN BY THE BIDDER

Note: Bidder shall furnish technical datasheets for each type of cable coming under his

scope of supply.

Sr. No. Particulars To Be Filled Up By Bidder 1 GENERAL

Design ambient Temperature (Deg. C)

2 CABLES

Name of the Manufacturer

Place of manufacture

Cable type

Applicable specifications & Standards

Voltage grade

No. of pairs/ cores and size

Suitable for neutral earthed/ Unearthed system (Yes/ No)

Permissible voltage and frequency variation for satisfactory operation

Maximum conductor Temp.( For Information only)

1) Continuous (Deg. C)

2) Short time (Deg. C)

3 Conductor

Material

Shape of conductor

Nominal cross section area (mm2)

Number of strands

Diameter of each strand (mm)





Sr. No. Particulars To Be Filled Up By Bidder Nom. Diameter (mm)

Conforming standard of conductor material

Grade

Class

Shielding on Conductor

A) Material

B) Type/applicable standard

C) Thickness in mm

D) Tolerance of thickness

4 Insulation

Material

Thickness of insulation

Tolerance on thickness of insulation (%)

Diameter of core over insulation (mm)

Specific insulation resistance at eighty five degrees centigrade (ohm-cm) and min. volume resistivity at 27 deg C ( ohm-cm)

Type/applicable standard

Shielding on Insulator

A) Material

B) Type/applicable standard

C) Thickness in mm individual pair / overall shield

D) Coverage / Overlap (%)

E) Material and size of drain wire

Approximate dia of cable over shielding

(Approx dia under inner sheath) mm





Sr. No. Particulars To Be Filled Up By Bidder 5 Inner sheath (If applicable)

Material

Thickness (mm) Min

Diameter of cable over inner sheath (mm)

Type/Applicable standard

Colour

Filler material

6 Armouring (If applicable)

Material

Type of armouring

Diameter of wire (mm) / Strip size (mm)

Whether galvanized (Yes/No)

Diameter of cable over armoring(mm)


Calculated dia over inner sheath in mm

7 Outer sheath

Material

Thickness of sheath(mm)

Tolerance on Thickness of sheath (mm)

Overall diameter of cable(mm)


Colour Scheme for identification

8 Cable constants

DC resistance per core at (ohm/km)

Twenty degrees centigrade





Sr. No. Particulars To Be Filled Up By Bidder AC resistance per core at (ohm/km)

Twenty degrees centigrade

Reactance per core (ohm/km)

Capacitance per core (µf/km)

Dielectric constant

Maximum cable charging current at normal operating voltage

9 Factory tests (Enumerate in detail for each type of cable)

10 Is the offered cable guaranteed to safely withstand continuous conductor temperature of 70 degree C (Yes / No)

11 Cable weight (kg/km)

12 Recommended minimum bending radius (mm)

13 Safe pulling force(kg)

14 Maximum allowable spacing for (mm) angle iron supports

15 Length of cable per drum(m)

16 a. Tolerance of individual drum length

b. Tolerance on overall quantity

17 Cable drum

Drum Material

Drum weight (kg) for 100 mts

Cable weight (kg) for 100 mts

Shipping weight (kg) for 100 mts

18 Other technical information

Twisting lay ( for pair )

Marking on outer sheath

Properties of outer sheath





Sr. No. Particulars To Be Filled Up By Bidder i) Min.Oxy. ind as per ASTMD 2863

ii) Min.temp. ind as per ASTMD 2863

iii) Max HCL emission as per IEC-754-1

iv) Max.smoke density rating as per ASTMD2843

v) Flammability test on completed cable as per IEEE 383 (Yes/ No)

Min insulation resistance at 20 degC of completed cable ( Mohm / Km )

Characteristic impedance of conductor at 0.8KHz (Max) (Ohms)

Attenuation at 1 KHz(dB/ Km)

Cross talk at 0.8kz (dB/ km)

Mutual capacitance at 0.8KHz

High voltage test

Conductor to conductor

Conductor to shield

Signature : .......................

SEAL OF COMPANY

Name : .......................

Designation : ......................

Measuring Instruments, VMS & Control Valves


2200-2400 MW CCPP SAMALKOT Expansion

REL-SKCCP-NRM-161-P-00001 (Rev.00) Measuring Instruments, VMS & Control

Valves Page 1 of 23

MEASURING INSTRUMENTS, VIBRATION MONITORING SYSTEM & CONTROL VALVES

TECHNICAL DATA TO BE FILLED IN BY THE BIDDER

This is a typical requirement listing all types of instruments/ devices. Bidder has to fill the data for the instruments/ devices which are in the scope of the Bidder under the package

1.00.01 Local Indicators A) Temperature Indicator (Temperature Gauge)

Make :

Model No. :

Type :

Stem :

Movement Materials :

Case Material :

Dial size :

Scale :

Adjustment :

Pointer :

Range Selection :

Stop at Max. Reading :

Over range protection :

Instrument Connection :

Process Connection :

Performance a) Accuracy :





Valves Page 2 of 23

b) Response Time

Operating Ambient Temperature :

Accessories :

Feature :

Service :

B) LEVEL INDICATOR (FLOAT & BOARD)

Make :

Model No. :

Type :

Float Material :

Pulley material :

Guide wire :

Scale Board :

Flanges :

Accuracy :

Accessories :

Service :

C. ROTAMETER

Make : Model No. : Type : Metering tube : Float : End fittings :





Valves Page 3 of 23

Packing material : Casing material : Gland Rings /Followers :

Scale :

Graduation : Process Connection :

Accuracy : Reproducibility :

Accessories :

D) Pressure Indicators / Gauges

Make :

Model No. :

Type :

Sensing Element Material :

Movement material :

Case Material / Protection class :

Dial Size :

Scale :

Range Selection :

Over range Protection :

Adjustment :

Stop at Max. Reading :





Valves Page 4 of 23

Element connection :

Process connection :

Accuracy :

Operating ambient temperature :

Safety feature :

Chemical Seal Unit :

Accessories :

Service : E) Level Indicators (Gauge Glasses)

Make :

Model No. :

Type :

Glass :

Glass Cover :

Gauge Body :

Integral cocks and valves :

Fittings :

Accuracy :

Scale :

Scale details :





Valves Page 5 of 23

Vessel Connection :

Accessories :

Tests :

Other details :

Service : 1.00.02 Process Switches

A) Pressure / Differential Pressure Switch/ Vacuum Switch

Make :

Model No. :

Type :

Sensing Element :

Wetted parts :

Case Material :

Setter Scale :

Over range :

Set Point :

Static Pressure for DPS :

Adjustments :


Switch configuration :

Switching Differential :

Switch Rating :





Valves Page 6 of 23

Switch type :

Cable connection :

Enclosure Class :

Repeatability :

Operating ambient temperature :

Accessories : Service :

B) Top Mounted Displacer operated Level Switch

Make :

Model No. :

Displacer :

Displacer Assembly :

Wire Rope / Spring :

Guide pipe :

Repeatability :

Switch housing Protection :

Type of switch :


Switch configuration : MOC of Switching mechanism :

Contact rating :

Cable Entry :

Cable gland :

Accessories :

Service :





Valves Page 7 of 23

C) Float Operated External Cage Type Level Switch

Make :

Model No. :

Float material :

Wetted parts :

Float chamber :

Float chamber mounting :

Fluid connection :

Size of the float chamber :

Fluid connection size :

Drain :

Pressure rating of chamber :

Repeatability :

Switch housing type :

Type of switch :


Switch configuration : MOC of Switching mechanism :

Contact rating :

Cable Entry :

Cable gland :

Accessories :

Service :

D) Capacitance Type Level Switch





Valves Page 8 of 23

Make :

Model No. :

Type : Probe

a) Type b) Mounting c) Material d) Insulation

:

Preamplifier a) Type b) Protection class c) Ambient Temp. d) Function

:

Enclosure :

Contact rating :

Accessories :

Supply Voltage :

Relay output :

Service :

E) Flow Switch

Make

:

Model No.

:

Type

:

Switch Configuration :

Switch Rating :

Enclosure :

Repeatability :





Valves Page 9 of 23

Adjustments :

Connection type :

Accessories

:

Service :

1.00.03 TRANSMITTERS

A) PT / DPT / DP Type Flow TX / DP Type Level TX / Vacuum Type

Make :

Model No. :

Type :

Output signal :

Signal Processing Unit :

Measuring Element :

Measuring Diaphragm or

Capsule Material :

Static Pressure / Overload

Pressure for DPT :

Static Pressure / Overload Pressure for PT

:

Turn-down ratio :

Span and Zero :

Enclosure Class :

Zero suppression /

elevation :

Output Indicator :

Display :





Valves Page 10 of 23

Body and its rating :

MOC for Electrical

Housing :

Ambient Temperature :

Operating Voltage :

Load :

Accuracy :

Repeatability :

Sealing/Isolation :

Accessories :

Service :

B) Ultrasonic Level Transmitter

Make :

Model No. :

Mounting :

Electronic Housing

Protection Class :

Accuracy :

Resolution :

Power Supply :

Out Put :

Cable Length :

Accessories :

C) Electromagnetic Flow Transmitter






Make :

Model No. :

Sensor

Type :

Electrodes :

Liner :

Enclosure :

Accessories :

Transmitter

Input Signal Processing :

Display :

Output :

Power supply :

Turn Down :

Accuracy :

Repeatability :

Housing :

Accessories :

Service :

D) Ultrasonic Flow Meter

Make :

Model No. :






Type :

Mounting Style :

Power supply :

Outputs :

Display/ indication :

Recording/ Totalizing /

Logging Facilities :

Electronic Housing

Protection Class :

Display :


Accessories :

Accuracy :

Resolution :

Service :

E) Mass Flow Meter

Make :

Model No. :

Type :

Working Principle :

Output Signal :

Operating Voltage :






Transmission :

Material of wetted parts :

Electronic Housing

Protection Class :

Display :


Accessories :

Accuracy :

Resolution :

Service :

F. Guided wave radar type level transmitter

Make :

Model No. :

Type :

Principle :

Probe Type & Material :

Signal O/P :

Display :

Power Supply :

Accuracy : Electromagnetic Compatibility :

Mounting :

Electronic Housing Protection Class :






Service :

1.00.04 PRIMARY SENSORS

A) Resistance Temperature Detectors

Make :

Model No. :

Type :

Resistance :

Base :

Wiring :

Response time :

Sheath Material :

Accuracy :

Immersion Length / Extension neck length

:


Head

Protection :

Material :

Cable connection :

Accessories :

Thermowell






Make :

Model No. :

Material :


Max internal bored dia :

Bore concentricity :

Identification mark :

Surface treatment :

Element connection :

Certification :

Accessories :

Service :

B) Flow Elements 1) Orifice Plate

Make :

Model No. :

Type :

Design Standard :

Material of Orifice Plate & Rating

:

Thickness :

Beta Ratio :

Pressure Tap :

No. of Root Valves per tapping

:

Root valve type/ material :






Vent Hole / Drain Hole :

Accuracy

Accessories :

Service :

2) Impact Head Type Flow Element / Averaging Pitot tube

Make :

Model No. :

Type :

Number of Holes :

Material of Construction a) Sensor

b) Instrument Head

c) Instrument Valve

d) Mounting Hardware

:

Piping Orientation :

Accuracy :

Repeatability :

Flow Turn Down :


Accessories :

Service :

1.00.05 Analysers

A) pH Analyser

Make :






Model No. :

Type of Cell :

Case Material :

Analyzer power supply :

Output :

Accuracy :

Repeatability :

Resolution :

No. of Streams : Response Time :

Connection : Operating ambient Temperature

Temp. Compensation :

Mounting :

Calibration :

Enclosure Class :

Range :

Accessories :

Service :

B) Turbidity Analyser

Make :

Model No. :

Type :






Measurement Principle :

Case Material :

Analyzer power supply :

Output :

Accuracy :

Repeatability :

No. of Streams : Response Time :

Connection : Operating ambient Temperature

Mounting :

Calibration :

Enclosure Class :

Range :

Accessories :

Service :

Signature : .......................

SEAL OF COMPANY

Name : .......................

Designation : ......................






1.00.06 Vibration Monitoring System 1. Vibration Pick-ups

01. Make

02. Model

03. Type :

04. Mounting :

05. Case material :

06. Connector :

07. Sensitivity :

08. Frequency response :

09. Environmental Temperature :

10. Relative Humidity :

11. Enclosure :

12. Accessories

2. Key Phasor

01. Make

02. Model






03. Type :

04. Mounting :

05. Case material :

06. Connector :

07. Sensitivity :

08. Frequency response :

09. Environmental Temperature :

10. Relative Humidity :

11. Enclosure :

12. Accessories

3. Vibration Monitor/ Signal conditioning module

01. Make

02. Model

03. No. of channels :

04. Sensitivity :

05. Frequency Response :

06. Accuracy :

07. Transducer supply voltage :

08. Recorder output :






09. Alarm contacts :

10. Contact rating :

11. Contact life :

12. Alarm Adjustment :

13. Operating temperature :

4. Power Supply

01. Make

02. Model

03. Input Supply voltage :

04. Output :

05. Rating :

06. Operating Temp :

07. Humidity :

08. Weight :

09. Overall Dimensions(WXHXD)

:

5. HMI/ GUI

01. Make

02. Model






03. Additional Information :

Note: Bidder shall furnish technical datasheets for all other instruments, if not specified above but coming under their scope of supply.

Signature : .......................

SEAL OF COMPANY

Name : .......................

Designation : ......................






1.00.07 Control Valve

Make :

Model No. :

Valve Size & Type :

Design Parameters 1. Temperature 2. Pressure 3. Flow 4. Valve opening

:

Min. Flow Normal Flow Max. Flow

Body Material :

Trim (Stem, plug, cage) Material

End Connection :

Positioner type, features as specified : Yes/ No

All required accessories (AFR, volume booster, Gauges etc.) provided as per specification)

: Yes/ No

Air Filter Regulator Type :

Actuator Type :

Electronics items provided with Explosion proof EExd Housing

: Yes / No

Valve position on air supply failure :

Valve position on signal failure

Formatted: Font: 11 pt

Formatted: Font: 11 pt

PLC System



REL-SKCCP-NRM-161-P-00001 (Rev.00) PLC Page 1 of 6

PLC SYSTEM

TECHNICAL DATA SHEETS

PLC System




CONTENTS

SECTION TOPIC

TECHNICAL DATA SHEETS

1. Programmable Logic Controller

2. UPS

PLC System




1. PLC System

S.No Description Response

1 Make

2 Series/ Model No.

3 Place of Manufacture/ testing

4 PLC panel make

5 Confirmation of Erection & Commissioning of total PLC system (Y/N)

6 Confirmation of scope of work as per spec. (Y/N)

7 Confirm that all additional hardware and software, over & above those indicated in the proposal, if required during detail engineering stage for fully meeting the intent and requirements of Specs, shall also be supplied by the contractor within the quoted price

8

Supply of Spares:- a) Commissioning spares list

b) Mandatory spares list

9 PLC System Architecture Diagram (Y/N)

10 Bill of material furnished at

11 Processor details (Make/ Model/ Data length- 32/ 64 bit etc.))

12 No. of Redundant Controllers proposed for each PLC system

13 Spare capacity requirement of Controller, I/O modules, cabinets etc as per specification requirement. (Y/N)

14 Parametric requirements and loop reaction time as per specification requirement (Y/N)

15 System goes to Fail safe mode on Power failure (Y/N)

16 On-line configuration via programmer console (engineering station) (Y/N)

17 On-line diagnostic up to module level provided

18 I/O cards:

i) I/O modules shall be provided on as required basis. (Y/N)

PLC System





ii) Spare channels provided as specified (Y/N)

iii) Number of channels for each type of card

a) AI :

b) AO :

c) T/C :

d) RTD :

e) DI :

f) DO :

iv) Analog Signal Conditioning

a) Galvanic isolation of input Yes/No

b)Galvanic isolation of output : Yes/No

c)Current Limiting: Yes/No

d)Channel to Channel isolation :Yes/No

e)All inputs fuse protected on per point basis and short circuit proof : Yes/No

f)Fuse monitoring :Yes/No

v)Binary Signal Conditioning :-

a)Contact interrogation voltage :

b)Contact bounce filtering: Yes/No

c)Per point fuse protection: Yes/No

d)Opto isolation of input : Yes/No

e)Interposing relay at output :Yes/No

f)Wire break monitoring: Yes/No

g)Differential input: Yes/No

vi)On line replacement of I/O module (Y / N)

19 Operator work station:

PLC System





a) Make & Model

b) Qty

c) Screen size of TFT monitor

d) Type/ Number/ Length of highway (Fibre optic/co-axial cable)

e) On-line diagnostics as specified (Y/N)

f) All HMI functions including HSRS functions provided as specified (Y/N)

20 Panels / Cabinets

Panels/ Cabinets provided meeting specification requirements (Y/N)

21 HMI/ Programming station/ Printer Furniture provided (Y/N)

22 System Reliability

a) Surge protection for electronic control systems, annunciation system and other solid state systems conforming to SWC test per ANSI C 37.90a (IEEE standard 472)

b) Self Diagnostics :-

a)Online diagnostics down to the level of individual modules displayed on OWS Yes/No

b) Local indication in the module and cabinet (Y/N) c)Failure of controller, communication etc. (Y/N)

23

Colour Laser Printer :-

a) Make/Model No.

b) Speed c) A4 Paper provided as specified (Yes / No)

24 Software Requirements

As per specification requirement (Y/N)

25 Documentation as per specification requirement confirmed . (Y/N)

26 Long term support details furnished: (Y/N) 2. UPS


PLC System





1.0.0 Make

2.0.0 Series/ model

3.0 Capacity at 50 Deg.C (after derating from lower temperature)

4.0 Specification requirement compliance (Y/N)

5.0 Write up, Configuration, BOM furnished (Y/N)

Technical Specifications for Fuel Gas

Conditioning System 2400 MW SAMALKOT

CCPP EXPANSION

REL-SKCCP-NEM-161-P-00001(Rev.00) Part IV, Section 2

SCHEDULES Page 1 of 33

PART IV

SECTION 2

SCHEDULES



CCPP EXPANSION



LIST OF SCHEDULES

CONTENTS

SECTION

S SCHEDULES TOPIC

S0 Schedule of General Particulars of Bidder

S1 Schedule of Technical Evaluation

S2 Schedule of Mandatory Information

S3.1 Schedule of Load and Weight Data

S3.2 Schedule of Electrical Load data

S4 Schedule of Experience List of Bidder

S5 Schedule of Recommended Spares

S6 Schedule of Mandatory Spares

S7 Schedule of Deviation ( Technical)

S8 Schedule of Delivery Erection and Commissioning

S9 Schedule of Drawing / Documents Submission & Distribution

S10 Schedule of Tools and Tackles

S11 Schedule of Sub-Vendors’ List

S12 Schedule of Performance Guarantees

S13.1 Schedule of price break-up of recommended spares

S13.2 Schedule of price break-up of Start up & Commissioning spares.

S13.3 Schedule of price break-up of mandatory spares

S13.4 Schedule of price break-up of special tools & tackles

S13.5 Schedule of price summary

S13.6 Schedule of price for water & power at construction time

S13.7 Schedule For Evaluation Of Concrete, Cement & Steel Involved In The Package

S14 Schedule of alternate proposals.

S15 Schedule of Engineering & Deliverables

S16 Schedule of Safety


Conditioning System 2400 MW SAMALKOT CCPP EXPANSION



S.0 – SCHEDULE OF GENERAL PARTICULARS OF BIDDER

The Bidder shall furnish the general particulars about the organization as follows.

S. No Description Details To be Filled by Bidder

1 Name of Bidder with registered office address

2 Telephone No.

3 Fax No.

4 E – Mail

5 Name and Designation of the Official of the Bidder to whom all reference shall be made

6 Financial Details

a) Enclose copies of Audited Balance sheet and Profit and Loss Account for past three (3) years. Yes / No

b)

Indicate following for the past three (3) years with projection for next three (3) years. I) Annual turnover: ii) Annual profit:

c) Name and Address of the Bankers to the Company

7 Project organization chart showing staffing, furnished Yes / No

8 List of important personnel curriculum vitae, furnished Yes / No

……………………………

Bidder’s Stamp & Signature





S.1 – SCHEDULE OF TECHNICAL EVALUATION The bidder shall furnish the general particulars about the organization as per the following format:

S. No. Particulars Parameter By Bidder

1. Experience Details Please fill up Schedule S 2 with details

2. Manufacturing Capabilities ( write up attached) Yes/No

3. Details of collaboration agreements if any is enclosed

Yes/No

4. In case of foreign bidder details of experience of Indian counter part if any

5. List of major installations/orders in the relevant field executed during last 10 years enclosed.

Yes/No

6. Major equipment/ system supplied, (indicate capacity of each equipment) for above installations

7. Extent of electrical, mechanical and instrumentation works in above installations.

Compliance to Scope

8. Scope of work as per Technical Specification

Yes / No

9. Scope of Work (Services) as per Technical Specification

Yes / No

10. List of Mandatory Spares as per Technical Specification

Yes / No

11 List of Recommended Spares as per Technical Specification

Yes / No

12 Erection & Commissioning Spares as per Technical Specification

Yes / No

13 List of Tools & Tackles to be deployed duly filled up as per Schedule S.10

Yes / No

14 Deviation from Scope of Supply and Services(If Yes, Please fill up Schedule S-7)

Yes / No

Deliverables

15. Schedule of completion period as stipulated in bid documents.

Months






16. Drawing/ Document Schedule attached along with the Bid

Yes/ No

17 Duly filled technical datasheets for all the items specified in Technical Specifications

Yes/ No

18. Guaranteed power consumption for applicable fans have been filled up in Schedule S-12

Yes/ No

Quality

19. Quality Control manual and facilities to be established at site

Yes/ No

a. Site facilities for testing Yes/ No

b. Procedures and compliance to quality requirement as per technical specs

Yes/ No

……………………………






S-2 SCHEDULE OF MANDATORY INFORMATIONS

The Bidder shall fill up the schedule of mandatory information’s as requested. The same will be utilized for the evaluation of his offer. The bidder shall furnish documentary back up against each and every item. The data is to be filled up for CONDENSING system having capacity not less than that stipulated in Qualifying Requirements Sl no Description of Item Project 1 Project 2

1. Name and address of system supplier

2. Name and address of the installation

3. Name, address and contact number of the client

4. Date of Order and Order Value

5. Date of commissioning

6. Capacity

7. Number of Units with above capacity supplied

8. Scope Included

a) Design

b) Supply

c) Erection

d) Commissioning

9 Performance certificate for satisfactory operation of system for two years as on date of bid opening attached?

Yes/No Yes/No

10 As an evidence to other qualifying requirements, copy of Purchase order, commissioning certificate etc, attached?

Yes/No Yes/No

……………………………






S-3.1 SCHEDULE OF LOAD & WEIGHT DATA

The Bidder shall fill up the schedule of mandatory information’s as requested. The same will be utilized for the evaluation of his offer. The bidder shall furnish documentary back up against each and every item.

S. No Item Description A] LOADING DATA 1. Horizontal and Vertical -Static and Dynamic

Loads of each rotating equipment for foundation Design (Kg.f.)

2. Horizontal and Vertical -Static and Dynamic Loads of each static equipment for foundation Design (Kg.f.)

B] WEIGHT DATA

1. Weight of eacfh part of condensing plant

2. Weight of the largest single piece to be handled for :

a. Erection

b. Maintenance

3 Shipping weight (Kgs.) and volume (Cu.M) of all specified components

4 Over all dimensions of other large items ( Please specify)

……………………………






S-3.2 SCHEDULE OF ELECTRICAL LOAD DATA

VoltageNo. ofWires

WorkingStand

by Total KW KVAA -

RunningA -

Starting KW KVA

(a) (b) (c) =(a)+(b) (d) (e) (f) (g) (h) ('i)(j)=(a)x(d)x(g) x(h)/('i) (k)=(j)/0.85

No. of Equipment Rating of each equipment Nett Demand

Starting time less

than 5 sec yes/no

Speed of

Motor (RPM)

(415Vac / 240Vac / 220Vdc)

(2W, 3W, 4W) A

LOAD LIST FORMAT

Consumer Type

(SFU / Starter / DOL / RDOL)

Duty Category

(Continious or

Intermittent)SI. NO. System Tag No.

Description

of Loads

Local Starter Panel

VendorControlPanel

Interposing Relays

LocalPush

ButtonStationA

Feeder Type

(Normal AC/

Emergency

AC/DC)Locationof Drive DCS

Feeder Rating Point of Control (Start/Stop)

kVAkW

Utilization / Load factor

Duty / Coincidenc

e factor

Efficiency ofElectrical

equipment

Voltage of

relay coil

Locationof

relaysPLC

……………………………






S-4 SCHEDULE OF EXPERIENCE LIST OF BIDDER

The Bidder shall furnish a list of similar jobs executed by him to whom reference may be made by the Purchaser in case the Purchaser considers such a reference necessary.

S. No. Name &

Description of contract

Value of Contract Order date & number

Contract execution duration

Contact Person

……………………………






S-5 SCHEDULE OF RECOMMENDED SPARES

The bidder shall furnish this schedule for 3 years for Indian Origin / 5 years of non-Indian origin for maintenance of the plant. The bidder shall indicate the unit price in a separate cover which shall remain valid during the execution of the contract..

Sl. No. Description Quantity

……………………………






S-6 SCHEDULE OF MANDATORY SPARES The bidder shall furnish this schedule as a part of Supply.

Sl. No. Description Quantity

……………………………






S-7 SCHEDULE OF DEVIATION (TECHNICAL)

If the proposal has got any deviation from the technical specification the Bidder shall tabulate those deviations in this list. It is understood that except these deviations as tabulated here in under the Bid is in complete agreement with the specification requirements.

We have no deviation/ following deviations from the Technical specifications ( Strikeout whichever is not applicable)

Sl. No

Specification Reference Requirement as per Specifications

Details of Deviations Bidder to indicate alternative and the reduction in price for acceptance of such deviation.

Remarks

Section Clause Page No

Date:

……………………………




CCPP EXPANSION



S-8 SCHEDULE OF DELIVERY, ERECTION AND COMMISSIONING

The Bidder shall indicate below the period for design, manufacture, shop testing, erection, site testing, and commissioning of the complete equipment under the scope of this specification. A detailed schedule in the form of a network shall also be furnished. Periods shall be counted from the data of issue of letter of intent. Schedule should comply with the requirements of the specification as stipulated in Bid document.

SL. NO. DESCRIPTION WEEKS AFTER L.O.I.

……………………………




CCPP EXPANSION



S-9 SCHEDULE OF DRAWING / DOCUMENTS SUBMISSION & DISTRIBUTION

The Bidder shall submit a comprehensive drawing / documents submission and distribution schedule covering all equipment, system, sub systems as described in the specification.

SL. NO. DRAWING / DOC. NO. Data of submission after issue of L.O.I.

……………………………




CCPP EXPANSION



S-10 SCHEDULE OF TOOLS AND TACKLES

The Bidder shall tabulate below the unpriced list of the tools & tackle for operation, maintenance and replacement of equipment and components supplied under the specification.

SL. NO. EQUIPMENT DESCRIPTION QUANTITY

……………………………




CCPP EXPANSION



S-11 SCHEDULE OF SUB VENDORS’ LIST

The Bidder shall indicate the list of sub vendor for different equipment / sub systems as indicated in the preferred list. The choice of sub vendor shall be subject to the approval of the Employer.

SL. NO. ITEM PARTICULARS SUB VENDOR ‘S NAME &

CONTACT DETAILS

……………………………






S-12 SCHEDULE OF PERFORMANCE GUARANTEES

The Bidder shall guarantee the performance of each and every equipment and system components in line with the requirements of technical specification. However, Following guaranteed parameters as declared by the bidder shall be used for evaluation and Liquidated damages in case of shortfall in Performance. Non submission of the same will lead to rejection of the Bid.

Sl. No Equipment Capacity

in CuM./Hr

Static Pressure in mmWC

Power consumption at motor input terminals per fan in KW

……………………………






S 13.1 SCHEDULE OF PRICE BREAK-UP OF RECOMMENDED SPARES

S. No.

Item Description

Qty Unit Price Total Price Sales tax on direct transaction only

Total Price FOR site

CIF (For spares supplied from abroad)

Ex-works (For indigenous spares)



Rate (%) Amount

Local transportation charges (including inland insurance, port clearance & port charges)

For spares supplied from abroad

For Indigenous spares

1 2 3 4 5 6 = 3 x 4 7 = 3 x 5 8 9 10 = 6 + 8 + 9 11 = 7 + 8 + 9

Note: 1. All the recommended spare parts indicating the item-wise cost shall be submitted along with the bid. 2. Continuation sheets of like size and format may be used as per Bidder’s requirements and shall be annexed to this schedule for each system separately. *: Bidders at its option may quote the price of imported component in Indian Rupees (Bidders to specify).

……………………………






S.13.2 SCHEDULE OF PRICE BREAK-UP OF START UP & COMMISSIONING SPARES.

S. No.

Item Description







Rate (%) Amount




1 2 3 4 5 6 = 3 x 4 7 = 3 x 5 8 9 10 = 6 + 8 + 9 11 = 7 + 8 + 9

Note : 1. All the mandatory spare parts indicating the item-wise cost shall be submitted along with the bid. 2. Continuation sheets of like size and format may be used as per Bidder’s requirements and shall be annexed to this schedule for each system

separately. *: Bidders at its option may quote the price of imported component in Indian Rupees (Bidders to specify).

……………………………

Bidder’s Stamp & Signature S13.3 – SCHEDULE OF PRICE BREAK UP OF MANDATORY SPARES





S. No.

Item Description







Rate (%) Amount




1 2 3 4 5 6 = 3 x 4 7 = 3 x 5 8 9 10 = 6 + 8 + 9 11 = 7 + 8 + 9

Note: 1. All the mandatory spare parts indicating the item-wise cost shall be submitted along with the bid. 2. Continuation sheets of like size and format may be used as per Bidder’s requirements and shall be annexed to this schedule for each system separately. *: Bidders at its option may quote the price of imported component in Indian Rupees (Bidders to specify).

……………………………






S 13.4 SCHEDULE OF PRICE BREAK-UP OF SPECIAL TOOLS & TACKLES

S. No.

Item Description







Rate (%) Amount




1 2 3 4 5 6 = 3 x 4 7 = 3 x 5 8 9 10 = 6 + 8 + 9 11 = 7 + 8 + 9

Note: 1. All the tools indicating the item-wise cost shall be submitted along with the bid. 2. Continuation sheets of like size and format may be used as per Bidder’s requirements and shall be annexed to this schedule for each system separately. *: Bidders at its option may quote the price of imported component in Indian Rupees (Bidders to specify).

……………………………






S.13.5 SCHEDULE OF PRICE SUMMARY

1.00.00 Proposal Lump sum Price

Total proposal price for the CONDENSING & its auxiliaries System as specified, including design, manufacture, fabrication, assembly/reassembly, testing at manufacturer's works, forwarding (duly packed for transportation), transportation, delivery at site, loading/ unloading, storage at site, handling and in plant transportation at site, erection, testing at site, commissioning, acceptance testing and handing over, painting, Mandatory spare parts and special tools and tackles excluding execution of civil & architectural works.. (Price shall be inclusive of all taxes & duties and also marine freight and insurance port handling & clearance & customs duties for the imported components, if any.)

Transit Insurance from Indian works/ port of shipment to project site Shall be arranged by RInfra.

: Rs...........................

2.00.00 Separate lump sum prices for the following (included in Sl. No. 1.00.00 above)

Transportation from works/ port of shipment to project site

Transit Insurance

Excise Duty

Sales Tax

Octroi

Other taxes, if any

Supply (ex-works basis) of all mechanical, process and electrical equipment & accessories

complete with all instrumentation & controls for the entire CONDENSING & its auxiliaries System other than imported components.





Complete Civil, Structural & Architectural work as specified for the System.

Unloading and storage at site, handling at site, complete erection, painting, sustained load test, commissioning guarantee and acceptance testing for the entire CONDENSING System.

3.00.00 Price of Imported components/items (if any) as included in offer (included in Sl. No. 1.00.00 above).

a) Supply F.O.B. port of shipment of all mechanical, process (including instrumentation & controls, if any) and electrical equipment & accessories.

b) Marine freight and insurance

c) Port handling & clearance

d) Customs duties

e) Other charges

4.00.00 Bidder's ex-works proposal price for supply of mandatory spares, properly packed for transportation to Site (included in Sl. No. 1.00.00 above). (List and Unit price to be indicated in Schedule-S6)

4.01.00 Bidder's total charges on mandatory spare for :

4.01.01 Ocean freight

4.01.02 Marine Insurance

4.01.03 Port Clearance

4.01.04 Custom's Duty





4.01.05 Inland Transportation from Port of Delivery/ Station of Dispatch to Project Site.

4.01.06 Transit Insurance (Transit insurance is under RInfra’s scope).

4.01.07 Excise duty, if any

4.01.08 Sales Tax

4.01.09 Octroi

4.01.10 Other Taxes, if any

4.02.00 Charges indicated in clause 4.01.00 included in clause 4.00.00 above. (Answer yes or no )

4.03.00 Bidder's total proposal price for mandatory spare F.O.R. site (sum of 4.00.00 + 4.01.00 through' 4.01.10)

5.00.00 Bidder's ex-works proposal price for supply of special tools & tackles, properly packed for transportation to Site (included in Sl. No. 1.00.00 above). (List and Unit price to be indicated in Schedule-S10)

5.01.00 Bidder's total charges on special tools & tackles for :





5.01.05 Inland Transportation from Port of Delivery/ Station of Dispatch to Project Site





5.01.06 Transit Insurance is under RInfra’s scope.


5.01.08 Sales Tax

5.01.09 Octroi


5.02.00 Charges indicated in clause 5.01.00 included in clause 5.00.00 above. (Answer yes or no)

5.03.00 Bidder's total proposal price for special tools & tackles F.O.R. site (sum of 5.00.00 + 5.01.00 through' 5.01.10)

6.00.00 Separate lump sum prices for the major items

a) Transportation from works/ port of shipment to project site

b) Transit Insurance - is under RInfra’s scope.

c) Excise Duty

d) Sales Tax

e) Octroi

f) Other taxes, if any

g) Supply (ex-works basis) of all mechanical, electrical equipment & accessories complete with all

instrumentation & controls for the entire CONDENSING System other than imported components.





h) Unloading and storage at site, handling at site, complete erection, painting, sustained load test, commissioning guarantee and acceptance testing for the CONDENSING System.

7.00.00 Bidder's ex-work proposal price for supply of recommended spares for five (5) years' operation properly packed for transportation to Site. (List and Unit prices indicated in Schedule-S5)

7.01.00 Bidder's total charges on recommended spares for :





7.01.05 Inland Transportation from Port of Delivery/ Station of Dispatch to Project Site

7.01.06 Transit Insurance - is under RInfra’s scope.


7.01.08 Sales Tax

7.01.09 Octroi


7.02.00 Charges indicated in clause 12.01.10 included in clause 12.00.00 above. (Answer yes or no )

7.03.00 Bidder's total proposal price for recommended spare F.O.R. site (sum of 12.00.00 + 12.01.01 through' 12.01.10).





8.00.00 Optional Prices

8.00.01 By pass Stack

8.00.02 Guillotine Damper : Rs..............

8.00.03 Diverter Damper : Rs..............

8.00.04 Auxiliary boiler : Rs..............

8.00.05 Service Tax + Cess on Freight : Rs..............

8.00.06 Transit insurance : This shall be in R-Infra Scope

8.00.07 Octroi & other charges : Rs.................

8.00.08 Other applicable taxes & duties, (Furnish details) : Rs................

8.00.09 All site services including Erection, testing & commissioning. : Rs.......................

8.00.10 Service Tax + Cess, above : Rs..............

9.00.00 Are the prices quoted firm till execution of contract? :

10.00.00 Bidder's proposal price for supply of final paints FOR site.





11.00.00 Bidder's proposal price for application of final paint to all equipment of CONDENSING System.

……………………………






S.13.6 SCHEDULE OF PRICE FOR WATER & POWER AT CONSTRUCTION TIME

Bidder is advised to quote optional price as per format enclosed incase both water & power are to be arranged by him.

……………………………


S. No. Item Description

I CONSTRUCTION WATER

For making own arrangement for supply of water for construction activity we intent to make following provisions: (Bidder to elaborate the proposed arrangement) We have included in our overall quoted price,the cost of provision of above mentioned facility which is Rs............................................... (Rupees.................................................)

II CONSTRUCTION POWER

For making own arrangement for supply of power for construction activity we intent to make following provisions. (Bidder to elaborate the proposed arrangement) We have included in our overall quoted price,the cost of provision of above mentioned facility which is Rs............................................... (Rupees.................................................)





S.13.7 SCHEDULE FOR EVALUATION OF CONCRETE, CEMENT & STEEL INVOLVED IN THE PACKAGE

Following table is given which will be filled up by the bidder along with his tender and will be considered for evaluation and also for arriving at

penal cost, if any during execution.

……………………………


Item Quantity Grade Water to cement ratio

Rate to be considered for evaluation

Allowable wastage

Penal rate to be levied on excess quantity

Remarks

Concrete

Cement

Reinforcement steel





S -14 -SCHEDULE OF ALTERNATE PROPOSAL Bidder to furnish this schedule as per Clause 2.01.00 (Main and Alternate Proposals), completely filled in with the following details as sub-sections: i Design Criteria and Technical details of the alternate proposal. ii Advantages over the Base Offer in terms of Capex, Opex (including recurring expenditure other than power consumption), and Area

required for Installation and life of equipments etc. iii Guaranteed Effluent Parameters in line with the Specification. iv Maintenance, availability of spares and Operation Ease.

….. …………………………


S.15 SCHEDULE OF ENGINEERING & DELIVERABLES





Bidder shall submit the under mentioned deliverables as per following schedule

S No. Deliverables Weeks from LOI CIVIL

1 Mechanical GA drawing along with equipment load data, type of foundation to be adopted along with the size of foundation, TOC for all items

ELECTRICAL 1 Preliminary Load List (90 % correct) 2 2 Sub-Vendor List 2 3 GA drawings and Single Line Diagram 4 4 Technical data sheet(final) 4 5 Final Load list (100% correct) 5 6 Balance drawings 5

…………………………… Bidder’s Stamp & Signature





S16 SCHEDULE OF SAFETY

The bidder shall furnish the general particulars about the Safety Plan and Facilities as per the following format:


1 Safety plan & facilities to be established at site

a. Safety facilities at site provided Yes/No

b. Bidder Confirms compliance to the Safety requirements as specified in Technical Specification. Yes/No

……………………………
