vollume ii technical specifications section 2

TECHNICAL SPECIFICATION FOR FIRE PROTECTION SYSTEM, DUST

SUPPRESSION SYSTEM & PLANT WATER SYSTEM

TECHNICAL SPECIFICATION

VOLUME- II

SECTION-2

Client Project

SEW INFRASTRUCURE LIMITED DEVELOPMENT OF EQ-1A BERTH AT VIZAG PORT

Consultant: TPSC INDIA PVT LIMITED Doc No. VCT-EQ1A-C5-MZ-PT1-610-11-0101, Rev. 2

Date:20-10-2014 Page 1 of 54



Sl. No. PARTICULARS Page No.

1.00.00 INTENT OF THE SPECIFICATION 4

2.00.00 SYSTEM DESCRIPTION 4 3.00.00 SCOPE OF SUPPLY, WORK AND SERVICES 9 4.00.00 TERMINAL POINTS 20 5.00.00 EXCLUSIONS & FACILITIES PROVIDED BY OTHERS 21 6.00.00 DESIGN AND CONSTRUCTIONAL REQUIREMENTS 22 7.00.00 LAYOUT REQUIREMENTS 36 8.00.00 OPERATION & CONTROL PHILOSOPHY 37 9.00.00 CODES AND STANDARDS 40 10.00.00 PERFORMANCE GUARANTEES 43 11.00.00 QUALITY ASSURANCE , INSPECTION AND TESTING 44 12.00.00 DRAWINGS, DATA/ INFORMATION TO BE SUBMITTED BY

ALONG WITH THE BID 50

13.00.00 DRAWINGS, DATA/ INFORMATION TO BE SUBMITTED AFTER THE AWARD OF CONTRACT 52

Annexures ANNEXURE-I SCOPE SUMMARY SHEET Fire Protection System 1 page

ANNEXURE-II LIST OF SUB VENDORS 6 pages

ANNEXURE-III TECHNICAL SPECIFICATION FOR LOW VOLTAGE MOTORS 5 pages

ANNEXURE-IV TECHNICAL SPECIFICATION FOR LOW VOLTAGE CONTROL CABLES 5 pages

ANNEXURE-V TECHNICAL SPECIFICATION FOR PANELS 7 pages

ANNEXURE-VI ELECTRICAL LOAD LIST FORMAT 1 page

ANNEXURE-VII TECHNICAL SPECIFICATION FOR CONTROL & INSTRUMENTATION 38 pages

ANNEXURE-VIII SOURCE WATER ANALYSIS 2 pages

APPENDIX-IA FIELD QUALITY PLAN 1 page

APPENDIX-IB LIST OF ITEMS REQUIRING QUALITY PLAN AND SUB-SUPPLIER APPROVAL 1 page

APPENDIX-IC MANUFACTURING QUALITY PLAN 1 page

Attachments (Drawings) VCT-EQ1A-C5-MZ-

PT1-610-0106 Water Balance Diagram 1 SHEET

VCT-EQ1A-C5-MZ-PT1-610-0104 Scope and Concept Diagram for FDAPS, DS, SW & PW System 1 SHEET

VCT-EQ1A-C5-MZ-PT1-610-0101 P & ID for Fire Water Pumping System 1 SHEET

VCT-EQ1A-C5-MZ-PT1-610-0102 Flow scheme for Fire Protection System 1 SHEET

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Sl. No. PARTICULARS Page No. VCT-EQ1A-C5-MZ-

PT1-610-0103 Block Diagram for Fire Detection and Alarm System 1 SHEET

VCT-EQ1A-C5-MZ-PT1-456-0101 Flow Scheme for Service Water Treatment System 1 SHEET

WM-TPT1-115-0100 Plot plan 1 SHEET

MI-TSC1-812-8006 PLC SYSTEM CONFIGURATION FOR FIRE PROTECTION SYSTEM (FIRE WATER PUMPS) 1 SHEET

MI-TSC1-801-8007 UPS SYSTEM FOR FIRE PROTECTION SYSTEM (FIRE WATER PUMPS) PLC 1 SHEET

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1.00.00 INTENT OF SPECIFICATION 1.01.00 This specification is intended to cover the design, engineering, manufacture and assembly,

inspection, shop testing at manufacturers works, proper packing and transportation to site,

unloading at site, site storage, handling at site, construction / erection, site testing and

commissioning of Fire Detection and Protection system, Dust Suppression system, Service

Water system, Potable Water system and sump pumps/de-watering pumps as detailed in

the scope of work for the Coal handling plant at SEW Vizag port Terminal, EQ-1A, AP state

of India.

1.02.00 It is not the intent to completely specify all details of design and construction herein.

Nevertheless, the equipment and installation shall conform to high standards of engineering

design and workmanship in all respects and shall be capable of continuous operation in a

manner acceptable to the Purchaser.

1.03.00 In the event of any conflict between the detailed specification of equipment and specification

data sheet of the equipment, the specification data sheet shall govern. In the event of

conflict between the General technical specification and the detailed technical specification

of the equipment, the latter shall govern. Henceforth, the terms Bidder and Sub-Contractor

will be used interchangeably in this document as applicable.

Any deviation or variation from the Scope requirement and/or intent of the specification shall

be clearly defined under Deviation Schedule of the Bid Proposal Sheets irrespective of the

fact that such deviation/variations may be standard practice or a possible interpretation of

the specification by the Bidder. Except for these deviations/variations covered under

Deviation Schedules which are accepted by the Purchaser 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 departure of the specification whatsoever

from the specification except for the declared deviation submitted by the Bidder with his

proposal shall be considered. Bids not complying with requirement shall be treated as non-

responsive and hence liable for rejection. The interpretation of the Purchaser in respect of

the scope, details and services to be performed by the Bidder, shall be binding, unless

specifically clarified otherwise by the Purchaser in writing before the Award of Contract.

2.00.00 SYSTEM DESCRIPTION

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2.01.00 Fire Detection & Protection system The type of fire Detection & protection system envisaged for various areas / buildings /

equipment facilities of this proposed plant are tabulated in Annexure-1 (Allocation summary

sheet for fire protection system).

Fire Protection system for the proposed plant shall be in accordance with TAC India (Tariff

Advisory Committee) / NFPA (latest edition).

2.01.01 Fire Water pumping system Fire water pumps for this proposed plant will be installed in fire pump house taking suction

from fire cum service water storage tank. Fire water pumps shall be of horizontal centrifugal

type. Fire water pumping system for this proposed plant shall have the following

Electrical Motor Driven main Pumps, 2 Nos. of 273 m3/hr capacity at rated head of 95 MWC.

Diesel Engine Driven stand by Pump, 1 No. of 273 m3/hr capacity at rated head of 95 MWC complete with Diesel Engine control panels with battery and battery chargers.

Jockey pumps (2 Nos. of 20m3/hr. each) at rated head of 105 MWC. Jockey pumps (1W+1S) pressure set points shall be selected to maintain the minor pressure losses in

the entire network as per the desired functional requirements.

All these pumps shall be controlled and monitored by a dedicated programmable logic

control system.

Necessary piping & fittings, valves, strainers, instruments, cables to complete the system.

Recommended Material of construction for Fire Pumps

2.01.02 Fire hydrant system (Indoor / Outdoor) Fire hydrant system for this plant shall consist of aboveground ring mains, hydrant valves,

risers and above ground branch headers with isolation valves. Fire water network for this

proposed plant shall be designed in order to cover entire Plant area including all buildings.

Ring main with individual tap-offs for the other Fire Protection System such as HVWS and

MVWS shall be provided. Suitable sectionalization valves shall be provided to ensure no

disturbance in the total system when a particular line segment or system has to be closed for

i. Casing Cast iron grade IS 210 FG-260

ii. Impeller Bronze IS 318, Gr.II or equivalent

iii. Shaft Carbon steel (EN 8 (BS 970) / IS 1570 Gr.40)

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maintenance. All the Tap offs shall be provided with isolation valves as envisaged. Landing

valves shall be provided with Isolation valves.

The firewater ring main distribution system is envisaged to feed all water-based fire protection

system such as hydrant system and deluge water spray system.

The hydrant system consists of outdoor hydrants, hose cabinets, water monitors and indoor

hydrants. The fire water supply shall be provided by a tee-off from the firewater ring main

distribution system.

External hydrants shall be located all around the periphery of the buildings and outdoor

equipment & storage areas. Outdoor type fixed water monitors shall be provided for locations

where water cannot reach from hydrant hoses.

The following areas shall be protected by hydrant system.

a) Coal Handling Areas Transfer towers, conveyor galleries, wagon tippler area, ship loader and jetty/berth area, coal stock pile etc.

b) Workshop and Stores Building c) Fire water pump house d) Cable trenches at SS-1 & ER-1 e) Miscellaneous buildings and Structures as per codes.

2.01.03 Water Spray system (Deluge system) The spray system shall consist of High Velocity Water Spray System (HVWS) and Medium

Velocity Water Spray System (MVWS). High Velocity Water Spray System is provided to

extinguish fires involving liquids with flash points of 65C or higher and shall be installed where

such flammable fluids constitute the hazard.

a. Automatic High Velocity Water Spray system (HVW Spray system)

The location of wet pilot type deluge valve shall be kept away from the equipment to be

protected. The detection system shall consist of heat sensing detectors of fusible type

(quartzoid bulb) mounted on water filled detector pipe network around the equipment to be

protected. Another network of water projectors shall be mounted around the equipment to

be protected and this network shall be connected to the water supply mains through the

deluge valve. The deluge valve shall be normally kept closed by the water pressure from

the downstream of deluge valve in the detector network against the water pressure in the

mains. When heat sensing detectors fuse due to bursting of quartzoid bulb, pressure in the

detector network drops thus causing the deluge valve to open and activate the spray

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system. Fast acting butterfly valves shall be provided at the downstream of the deluge

valve, so that the butterfly valves can be kept closed and operated manually in the event of

fire, if there is any malfunction of deluge valve. Gate valve shall be provided in the

upstream of deluge valve, further, fast acting butterfly bypass valve to deluge valve is to be

provided.

HVW spray system shall be provided for 2 nos. of 5 MVA transformers.

b. Automatic Medium Velocity Water Spray system (MVW Spray system)

In order to avoid total flooding of the area in the event of fire in a particular zone, the area

shall be divided into number of zones. Each zone shall have separate water supply network

controlled by a deluge valve. The fire in the cable trench and coal conveyors shall be

detected by a detection system which shall give an electrical signal for the operation of the

deluge valve. In the event of fire in a particular zone, the deluge valve of corresponding

zone and those of adjacent zone on either side shall be opened. The number of zones shall

be decided during detailed engineering. Opening of deluge valve shall result in starting of

pump. Fast acting butterfly valves shall be provided as a bypass to deluge valve, so that

this valve can be kept closed and can be operated manually, if there is any malfunction of

deluge valves. Isolation valves on upstream and downstream side of deluge valve shall

also be provided. The cable galleries shall have number of rows of cable trays and each

row shall have number of tiers of cable trays. Each of the cable rows shall be provided with

a network of water distribution piping and nozzles. The distribution network shall consist of

distribution header for each row of cable tray and on these header drop pipes located at an

interval not exceeding 3m shall be provided so as to cover all the tiers.

MVW spray system shall be provided for coal conveyors & cable trenches.

2.01.04 Portable Fire extinguishers Portable Fire Extinguishers of both floor mounted and trolley mounted with suitable capacity,

rating and medium in adequate numbers shall be provided for the entire coal handling Plant

including all buildings and berth area, equipments based on the hazard occupancy for this

proposed plant.

2.02.00 Fire Detection, Alarm & Control System Fire Detection and Alarm system shall be designed as per NFPA 72 and relevant IS

standards. Fire detection and alarm system for the proposed plant shall be Analogue

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Addressable type consisting of interface modules, various types of fire detectors, repeater

stations, local fire alarm panels and interconnecting cables. Manual call points and Notification

appliances will be provided for total plant areas and as mentioned in Annexure1 (Scope

Summary sheet).All the fire protection system shall be provided with interfacing modules for

alarm signals and automatic system activation and operation and also fire pumps status

signals from Fire protection pump PLC system.

Scope summary sheet attached herewith as Annexure-1 shall be referred to for various

protection and detection system applicable for the plant facilities.

2.03.00 Dust Suppression System The dust control system to be furnished under this specification is required for control of

fugitive dust emissions from dust generation points at transfer towers and coal stock pile. Dust

control is achieved by dust suppression system.

Contractor shall guarantee and offer dust control system which shall inhibit dust concentration

in the ambient air inside the buildings within acceptable limits as per internationally recognized

hygienic Standards/Codes, MOEF and state pollution control board.

2.04.00 Service Water System

Service water system shall be provided for complete coal handling plant and jetty/berth area

and buildings. The system shall comprise of water treatment/conditioning plant as envisaged

considering the source water quality (attached as Annexure-VIII with this document).

2.05.00 Service Water Treatment System Service water shall be produced from the treated sewage water which shall be fed to the feed

water tank. Service water treatment shall consist of pressure sand filters and activated carbon

filters in series. Feed water shall be chlorinated before it enters in to the filtration plant.

Necessary dosing tanks, dosing pumps and all other accessories shall be provided. Pressure

sand filter shall be provided mainly to remove the suspended solids and activated carbon

filters shall be provided to eliminate the organic material, oil & grease, residual chlorine and

other impurities.

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Product water from the filters shall be collected in the fire water cum service water tank and

back wash water required for the filter back wash shall be taken from this tank. Separate set of

back wash pumps shall be provided for the filter back wash. Necessary air blowers shall be

provided to clean the filter bed as and when required. The waste backwash generated during

the backwash of the filters shall be collected in the backwash collection and shall be disposed

suitably by waste back wash transfer pumps.

Normally filters provided shall be 2 x 100%, i.e., during normal service operation one filter is

working and other is standby but if required both the filters shall be put in to service mode.

Hence all the headers provided shall be designed for both the filters working condition. All the

headers shall be designed for 250 m3/h of the filter water. However, the capacity shall be

finalized based on discussion during detailed engineering.

2.06.00 Potable Water system

Potable water system shall be provided for complete coal handling plant and jetty/berth area

and buildings. The system shall comprise municipal water feed water tank, Potable water

pumps, PW overhead tanks with connections up to the facilities user points as identified in the

Scope and Concept Diagram for FFS, DSS, SWS & PWS (DWG. No. VCT-EQ1A-C5-MZ-PT1-

610-0104).

2.07.00 Sump Pumps Two sets of sump pumps located at respective drain pit/sump shall be provided at Wagon

tippler complex, ER-1, SS-1 cable trench pits, fire water pumps area. Pumps shall be

submersible type of pumps.

2.08.00 Coal Pile Run-Off System Coal stockpile run-off system shall constitute of 2-chamber coal settling sumps of suitable

capacity along with disposal 2x100% pumps of adequate capacity. The pump discharge will be

lead to nearest storm/plant water drain system.

2.09.00 Water Source

Water supply connections for dust suppression, service water system shall be taken from

common fire cum service water storage tank. Further network of piping including all pumps,

tanks, necessary accessories, supports and fittings etc. for distribution of water for dust

suppression and service water system in all Transfer towers, berth area, control rooms etc.

shall be part of the system scope.

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3.00.00 SCOPE OF SUPPLY, WORK AND SERVICES

3.01.00 Fire Protection System

The scope shall include but not limited to the following for full functioning and system

completeness. Onsite fire protection system shall be provided for the proposed plant as

described in scope summary sheet, Annexure -1.

3.01.01 Storage tank level control and level transmitter.

3.01.02 Fire water Pumps A. Two (2) sets of Electrical motor driven main pumps of capacity 273 m3/hr each at 95

MWC head complete with motor, base plate, foundation bolts and other accessories.

B. One (1) set of Diesel engine driven stand by pump of capacity 273 m3/hr at 95 MWC head complete with base plate, foundation bolts, diesel engine, Diesel engine control

panel with batteries and battery chargers, diesel oil tank, exhaust gas system, piping

and fittings for diesel supply, return and drain lines, and other accessories.

C. Two (2) sets of Electrical motor driven jockey pumps of capacity 20m3/hr at 105 MWC head complete with motor, base plate, foundation bolts and other accessories.

D. One (1) lot of valves (gate & check), piping, fittings, pipe support material, bolts / studs,

washers and nuts.

E. One (1) EOT crane for handling fire water pumps.

3.01.03 Hydrant system A. One (1) lot of single headed hydrant valves (Indoor and outdoor) complete with all the

accessories.

B. One (1) lot of water monitors (75 mm size having nozzle bore of 38 mm) with isolation

GATE valves complete with all the accessories.

C. One (1) lot of 15 m long hoses with male and female instantaneous couplings for

external hydrants.

D. One (1) lot of 7.5 m long hoses with male and female instantaneous couplings for

internal hydrants

E. One (1) lot of branch pipes, nozzles as per the TAC guidelines.

F. One (1) lot of hose boxes required for placing hoses, branch pipes, and nozzles etc. as

per the TAC guidelines.

G. One (1) lot of Underground piping (corrosion protected as per IS 10221- wrapping &

coating) with pipe support material, fittings, bolts and nuts

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H. One (1) lot of above ground piping (painted Two coats of grey zinc primer, two coats of

coal tar rubber paint/coal tar epoxy being saline atm.) with pipe support material, fittings,

bolts and nuts.

I. One (1) lot of sectionalization isolation valves with mating flanges, gaskets, bolts and

nuts.

J. One (1) lot of drain valves and air release valves

K. One (1) lot of Hume pipes for underground pipe road crossings.

L. One (1) lot of pressure gauges and pressure switches.

3.01.04 HVW & MVW spray system A. One (1) lot of deluge valves with automatic, remote and manual operation trim assembly

complete with manifold, pressure switches, pressure gauge, solenoid valve, water motor

alarm gong etc.

B. One (1) lot of isolation valves for upstream of deluge valves with mating flanges,

gaskets, studs/bolts and nuts.

C. One (1) lot of butterfly valves as by-pass and downstream valves for deluge valves.

D. One (1) lot of High velocity spray nozzles or projectors

E. One (1) lot of Medium velocity spray nozzles or sprayers

F. One (1) lot of quartzoid bulb (QB) detectors as detection system for HVW spray

protected equipments.

G. One (1) lot of above ground piping (painted Two coats of grey zinc primer, two coats of

coal tar rubber paint/coal tar epoxy being saline atm.) with pipe support material, pylon

supports, fittings, bolts/studs, washers and nuts.

H. One (1) lot of above ground galvanized (As per IS 4736) piping (at downstream of

deluge valve) with pipe support material, pylon supports, fittings, bolts/studs, washers

and nuts.

I. One (1) lot of isolation valves with mating flanges, gaskets, bolts/studs, washers and

nuts.

3.01.05 Portable fire extinguishers One (1) lot of following extinguishers with all the accessories shall be provided

Sl. No Type of Fire extinguisher Capacity

1 CO2 type 4.5 kg (Conforming to IS 2878)

2 Trolley mounted Mobile type CO2 22.5 kg

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(Conforming to IS 2878)

3 Dry chemical powder type 5 kg (Conforming to IS 2171)

4 Trolley mounted Mobile type dry chemical powder type

50 kg (Conforming to IS 10658)

3.02.00 Dust Suppression System

Complete dust suppression system for control of fugitive dust shall be provided for following

facilities.

Transfer tower 1

Transfer tower 2

Transfer tower 3

Transfer tower 4

Transfer tower 5

Coal stock pile

Along with pumps, electrical works, drives, hoisting arrangements, piping, fittings, valves and

supports etc. as briefly specified below.

A. Plain water dust suppression around stockyard through sprinklers. The system shall comprise of 2 Nos. DSS pumps of capacity 125m3/hr (1w + 1sb). Capacity of the pumps shall be finalized based on discussion during detailed engineering.

B. Dry fog type dust suppression system at conveyor discharge shall be tapped from service water lines feeding WT, SR & SL etc. However, this concept shall be finalized during detailed engineering stage.

C. Air compressors and receivers of suitable capacity shall be provided; located at two separate locations (one set near TT-2 and other set near TT-3 or TT-4 area); each location having 2 Nos. Air compressors (1w+1sb), for dry frog dust suppression system.

The capacity of air compressors located at TT-3 shall also include additional service air requirement catering to compressed air requirement at water treatment plant area.

3.03.00 Service Water System and Water Treatment System 2x100% service water pumps of 85 m3/hr. capacity at rated head of 35 MWC along with level & pressure switches and piping up to terminal points of water treatment system (Refer

Water treatment system Flow Scheme, Dwg. No. TM-PT1-456-0101) and other user points

in the plant area. Capacity and head of the service water pumps shall be finalized based on

discussions during detailed engineering.

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Complete service water distribution system with water supply system, valves, quick couplings,

hose pipes with nozzle, piping, pumps, drive motors with canopy, couplings with enclosure,

electrical works, including supporting structures, handling for equipments, civil and structural

works and necessary accessories shall be provided throughout the coal handling plant area in

Contractors scope.

Water treatment/conditioning plant shall have stream capacity of 2 x 50m3/hr. which shall be finalized during detailed engineering (1 stream working and another standby) with provision to

operate both the stream simultaneously. The treatment plant shall have:

A. One (1) no of feed water storage tank of RCC construction (By Purchaser) complete with all the accessories.

B. Two (2) nos. of hypo dosing tanks for feed water along with two (2) nos. (1W+1S) dosing pumps complete with all the accessories

C. Two (2) nos. (1W+1S) filter feed pumps complete with all the accessories

D. Two (2) nos. (1W+1S) pressure sand filters complete with all the accessories

E. Two (2) nos. (1W+1S) of blowers for pressure sand filters complete with all the accessories

F. Two (2) nos. (1W+1S) of activated carbon filters complete with all the accessories

G. Two (2) nos. (1W+1S) filter backwash pumps complete with all the accessories

H. One (1) no. of filter water cum fire storage tank of RCC construction (By Purchaser) complete with all the accessories.

I. One (1) no. of filter back wash water collection tank of RCC construction (By Purchaser) complete with all the accessories

J. Two (2) nos. (1W+1S) SSF back wash transfer pumps complete with all the accessories

3.04.00 Potable Water System

Potable water system for this facility shall be provided for the following areas

SS1 building user points

EQ berth user points

Wagon Tippler complex user points

Potable water system shall comprise of RCC feed water tank (provided by others), potable

water pumps, Potable water Overhead Tanks with connections to respective areas user points.

Along with pumps, electrical works, drives, piping, fittings, valves and supports etc. as briefly

specified below.

A. 2 Nos. PW pumps of capacity 5 m3/hr (1w + 1sb) at 50 MWC. Capacity of the pumps shall

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be finalized based on discussion during detailed engineering.

B. 3 Nos. of HDPE Overhead tanks of capacity 2 cu.m each with floating valve, drain valve, vent and overflow provisions.

C. Necessary piping, valves, pipe supports and required accessories to complete the system from the RCC feed water tank to the user points.

3.05.00 Sump Pumps

Total 2x100% (1W+1S) sump pumps of 25 m3/hr. capacity at rated head of 25 MWC along with level switches and piping up to nearest drain (max. up to 50.0 meters from outside the building)

shall be provided at Wagon tippler complex, Sump pumps/de-watering pumps for SS-1, ER-1

and fire water pump house area.

The pumps shall be of wet pit types, vertical shaft and impeller shall be specially designed to

pass large solids or unscreened liquids. The construction and material shall be suitable for

pumping coal/dust contaminated water with a minimum of maintenance. All bearings of the

pump shall be located above the water level.

The piping system shall be designed to suit operations of pumps including standby pump.

Capacity and head of these pumps shall be decided during detailed engineering, all these

pumps shall be submersible type.

3.06.00 Electrical Scope

Bidder shall supply the below specified Electrical equipments.

A. LT panels for Dust suppression system (Single incomer Scheme) in Stockpile area & Transfer tower T1, T2, T3, T4 & T5. Panels shall be in line with attached Technical Specification for LV Switchgear

B. LT panel for Fire Protection system Pumps (2 incomer scheme)

C. All motors along with terminal boxes in line with attached Technical Specification for Induction Motors.

D. Supply, laying and termination of LV power & control cables, cable accessories, cable carrier system between bidder supplied equipments shall be in Bidders scope.

E. Cabling & Cable carrier system between bidders supplied equipments shall be in bidders scope.

F. Special cables & cable carrier system as required for Dust suppression system

G. Total Six (6) nos. of 3ph 415 V AC feeders suitably rated l be provided by Purchaser for dust suppression panels located in above mentioned areas. Quantity and of the feeders shall be finalized at later stage after finalization of quantity, capacity and head of the pumps. Any other voltage AC/DC if required the same shall be derived by Bidder using 415

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V AC. Bidder shall clearly indicate in his offer the No. of LT panels along with location and power supply requirements.

H. Junction Boxes as required.

I. Local Push Button stations.

J. Valve actuators with integral starters

K. Above Ground Earthing. Purchaser will terminate one (1) nos. of 415V LT power cables up to the Bidder supplied 415V Dust suppression system LT panels and two (2) nos. of 415V LT power cables up to the Bidder supplied 415V Firefighting LT panels placed in above mentioned locations. Further the complete electrical scope is by Bidder. Specific Electrical requirements: All the electrical equipment shall be capable of continuous operation at specified rating without overheating under the following conditions:

Voltage variation: : 10%

Frequency variation: : 5%

Combined voltage and

Frequency variation : 10%

The voltage level of motors is considered based on the following:

i) For the drives rated > 110 KW : 6.6 KV

ii) For the drives rated < 110KW : 415 V

Degree of protection for various enclosures as per IEC shall be as follows:-

i) Indoor motors IP 54

ii) Outdoor motors IP 55 (With Suitable canopy)

Note: Bidder shall furnish the electrical load list as per the attached format. Optional Quote: Bidder shall provide optional price for energy efficient motors along with the bid.

3.07.00 Control & Instrumentation The Scope of Control & Instrumentation control systems under this package are as below.

Please refer to enclosed Annexure VII for detailed specification for Control &

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Instrumentation systems

Fire Water system PLC based Control System with Front panel

mounted Graphical User Interface (GUI) of 12 sized for operator Interface.

Dust Suppression System for CHP Transfer Towers (TT)

This will be controlled by E1 Package PLC (By owner) located at SS1. Bidders scope includes all the required field instrumentation for successful operation of DSS System up to Field Junction Boxes including Junction boxes and cabling up to JBs.

Dust Suppression System for Coal Stock Pile.

PLC based Control System with table mounted Graphical User Interface (GUI) of 21 sized for operator Interface

Service Water System for WT, SR & SL etc. Potable Water system

Shall be controlled and operated by Fire water system PLC.

Diesel Engine driven Fire Fighting Pump

One (1) Diesel engine local control panel with battery and battery charger, same will be controlled and operated by Fire water system PLC

UPS Dedicated Package UPS System of desired rating shall be provided by bidder along with each of the PLC Based Control System

A. One (1) lot complete instrumentation and control cables as required with in bidders battery limits of each system

B. One (1) lot of automatic operating devices, manual actuation devices / abort switches, audio-visual safety warning devices, instrumentation associated control systems.

C. Fire Protection system (Fire water Pumps) & Stockyard DSS System PLC system interfaced to SS1 PLC (provided by Owner) to transfer data through Modbus TCP /IP. Communication through redundant fiber optic cable. All necessary hardware required at SS1 PLC end and FFS PLC shall be in Owners scope. In addition to soft connectivity, hard wired interface with SS1 PLC (provided by Owner) shall also be provided. Exact signal exchange shall be decided during award stage.

D. All the necessary interface Software / hardware like switches, converters servers & F.O.Cable etc. as required at both ends i.e SS1 PLC End and Respective Local Control Systems, to establish two-way link between PLC / Micro Controller and the E1 Package PLC System located at SS1 Control Room area shall be taken care by Owner .However Bidder has to provide .necessary ports and Power supply facilities to these accessories at his PLC End.

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E. All the control panels shall be accessible and located near their respective equipment and shall be complete with all the required controls, interlocks, indicating lamps etc. Further, necessary controls, indications and annunciations for all the above equipment shall be provided at Fire Protection system (Fire water Pumps) PLC system in Fire water pump house.

F. Standalone UPS system of adequate capacity with 60 min battery back-up shall be provided for the Fire Protection system (Fire water Pumps) PLC system & DSS PLC System, local panel, Instruments and GIU equipment etc. The battery shall be Ni-Cd type.

G. Owner shall provide one number of NTP Server based time signal from main SS1 PLC system which shall be interfaced with Fire Protection system & DSS (Fire water Pumps) PLC system for uniform time tagging purpose. however required cable and accessories shall be in bidder scope.

H. Graphics of the Fire Protection system (Fire water Pumps) PLC system shall be replicated on the SS1 PLC OWS in CCR by Owner. However, the graphic software for the above purpose shall be included in the FDAPS vendor scope.

I. All instrumentation cables within the battery limits of FDPS & DSS Systems are in the scope of Bidder. Also all instrument cable shall be armored type. Inner and outer sheath shall be FRLS PVC compound. All the loop cables, connecting various detectors, DVs, MCPs, Hooter, LHS etc shall be fire survival type. data sheets shall be finalized DDE.

J. All 415V LT switchgear incomer/bus tie/outgoing power feeder breakers etc. shall be

controlled and monitored from Fire Protection & DSS system (FPS & DSS) PLC system.

Necessary signal exchange for the above, please refer signal interface specified in

enclosed Annexure-VII. Each above breaker is provided with multi-function meter for

monitoring analogue values through RS 485 protocol. The same shall be interfaced with

Fire Protection system (Fire water Pumps) PLC system and necessary provision shall be

provided.

K. All other motor feeders shall be controlled from Fire Protection system (Fire water Pumps)

PLC system. The MCC to PLC Interface cabling shall be by Owner

L. PLC system configuration shall be redundant in CPU, communication system, power

supply modules and redundancy in digital and analogue output modules only for critical

loops (which shall be finalized during detailed engineering).

M. Separate Laptop shall be provided by bidder as engineering tool for programmable

functions with required software for Fire Protection System (Fire Water Pumps) PLC.

Please refer to enclosed PLC System Configuration for Fire protection system & DSS

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System and Scheme for Standalone UPS System.

All the above shall be accessible and located near their respective equipment and shall be

complete with all the required controls interlocks, indicating lamps etc. Further, necessary

controls, indications and annunciations for all the above equipment shall be provided at

Fire Protection System (Fire Water Pumps) PLC system located in raw/fire water pump

house.

3.08.00 Fire Detection and Alarm System

Fire detection and alarm system required for Coal handling areas including conveyors,

Transfer towers, Wagon tippler complex shall be by the bidder. Fire detection & alarm

system for this coal handling areas shall be hooked up with the plant main fire alarm system

panel (provided by others) located in SS1 building.

A. One (1) Lot of fiber optic linear heat sensing cable with necessary control unit and

interface modules.

B. One (1) lot of automatic photoelectric smoke detectors if applicable.

C. One (1) lot of heat detectors of various types if applicable

D. One (1) lot of response indicators

E. One (1) lot of fault isolator modules, monitor modules and control modules as required.

F. One (1) lot of deluge valve local control panels with necessary interlocks, relays, instrumentation for all the fire protection system operated by deluge valve.

G. One (1) lot of all the necessary instruments for monitoring / controlling such as pressure gauges, pressure switches, pressure transmitters, solenoid valves, level switches, level indicators, limit switches etc. to complete the system.

H. All the above control panels / devices / modules shall be accessible and located near their respective equipment and shall be complete with all the required controls, interlocks, indicating lamps etc. Further, necessary controls, indications and annunciations for all the above equipment shall be hooked up at Main Fire Alarm Panel (MFAP) located in SS-1 (provided by others)

I. One (1) lot of indoor, outdoor manual call points.

J. One (1) lot of hooters / sounders.

K. One (1) siren.

L. One (1) lot of complete terminal boxes, junction boxes.

M. One (1) of necessary relay modules, input and output modules.

N. One (1) lot of complete detector, control and network cables with cable carrying and

supporting system.

O. One (1) lot complete cable installation accessories

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3.09.00 Scope of services

Bidder shall provide the following services under the scope of this specification.

3.09.01 Design, engineering, manufacture and assembly, inspection, shop testing at manufacturers

workshop, transportation to site, unloading at site, site storage, preservation, handling at

site, construction / erection, site testing and commissioning of the proposed fire protection

system.

3.09.02 Fire protection system & Stockyard DSS System shall be interfaced with the E1 Package

PLC. E1 package contractor, FPS and Dust suppression contractor shall provide required

input and cooperate for successful interfacing.

3.09.03 Though the minimum basis for system capacity selection is given in this document, bidder

shall re-assess and submit design criteria and capacity selection calculations for all the

systems for review and approval.

3.09.04 Bidder to provide the total water demand required for dust suppression, fire protection,

service water, potable water as input to enable the design of storage tank.

3.09.05 Hydraulic analysis for ensuring adequacy of the completed system shall be within the

Bidders scope.

3.09.06 Surface preparation, application of primer, intermediate and final painting at shop and site

as applicable.

3.09.07 The following civil works shall be included in Bidders scope.

Excavation and back filling for laying of underground pipes

Construction of deluge valve sheds as envisaged

Construction of pedestal supports wherever required

Grouting of all foundations

Making openings in the walls for routing of pipes

Sealing/Making good of the openings

Laying of sleeve pipes for pipes crossing roads

Base Frame for all the equipment & Anchor bolts are in bidder scope.

Bidder to consider Passive Fire Protection System in their scope - Optional Price (Unit price per meter square) shall be provided for the same by bidder.

3.09.08 Transportation and delivery of all materials and equipment by rail / road to site.

3.09.09 Carrying out erection, testing and commissioning, and performance test of all equipment

and accessories.

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3.09.10 Providing certified copies of test reports for all tests and examinations specified and also for

the mandatory tests and analyses required by the applicable material specification for the

materials used.

3.09.11 Bidder shall furnish training to the Owners operation and maintenance personnel at his

work shop / his sub-vendors works and at site.

3.09.12 Obtaining necessary authority approvals from various agencies Chief Fire Officer,

Hyderabad. OISD guidelines or applicable international codes/practices/Local authorities as

applicable.

3.09.13 Consumables

Supply of all consumables as applicable for commissioning and performance test shall be

included in the scope of bidder and the same shall be supplied by the bidder at appropriate

time.

3.09.14 Lubricants

All flushing oil required together with the first fill of oil / lubricants / grease as applicable for all

parts of the equipment where lubrication is required shall be provided by the bidder up to taking

over. All types of lubricants of equivalent grade of other makes shall be readily obtainable

locally.

3.09.15 Spare Parts

Necessary Spare Parts listed in this specification under clause 1.04.00 shall be supplied

a. Start-up & commissioning spares, bidder shall provide the list of these spares. b. Recommended spares for 2 years of trouble free operation. Bidder to provide the list

with Unit price as per FOR site basis.

Start-up & commissioning spares shall be considered as included in the Bidders Offer Price for

this Package.

3.09.16 Special tools and tackles

One (1) lot of special tools and tackles as listed in Appendix I2 of section 1,shall be supplied

by the bidder for operation and maintenance.

a. Supply of all erection hardware.

b. Name plate, Tag plates, rating plate, caution tag for each equipment

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4.00.00 TERMINAL POINTS 4.01.00 Mechanical:

A. Source water supply at one point by municipality/VPT; treatment/conditioning and

metering (1w+1sb) in Bidders scope.

B. One service water receiving terminal point at wagon tippler complex for usage by WT

and SAC facilities; required TP data is flow: 62m3/hr and pressure 2bar.

C. Four service water receiving terminal points at each Stacker-cum-Reclaimer area for

usage by Stacker-cum-Reclaimer facilities; required TP data is flow: 4.5m3/hr. for each

stacker/reclaimer and pressure 2bar for each TP.

D. One service water receiving terminal point at center of the travelling length of Ship

loader/Jetty area for usage by Ship loader/Jetty facilities; required TP data is flow:

7.0m3/hr and pressure 2bar.

E. Fire detection & alarm system for coal handling areas shall be hooked up with MFAP

located in SS1 buidling.

4.02.00 Electrical

A. At LT panels incomer of Fire water pump house MCC.

B. At LT panels incomer of Dust suppression system MCC

C. Riser of underground earthing strip or above ground earthing strip.

4.03.00 Civil

Fire Water Pump house and fire water pumps foundations shall be provided by the Purchaser.

Further, the service cum fire water storage tank will also be provided by others (RCC tank)

Potable water system RCC feed tank will also be provided by others.

Bidder to provide necessary nozzle details for his pumps/equipment, foundation load data for civil design. However base plates, foundation bolts, embedded parts etc. as required shall be in the scope of Bidder.

4.04.00 Controls & Instrumentation

Fire Protection system Outgoing signal terminal block / Port for Interface from FPS PLC to E1 Package PLC


This will be controlled by E1 Package PLC (By owner) located at SS1. Bidders scope

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includes all the required field instrumentation for successful operation of DSS System up to Field Junction Boxes including Junction boxes and cabling up to JBs.

Dust suppression System for Coal Stock Pile

Outgoing signal terminal block / Port for Interface from DSS PLC to E1 Package PLC

Service Water System for WT, SR & SL etc.

Shall be controlled and operated by Fire water system PLC.

UPS Redundant 1 Ph 230 V AC feeders of desired rating will be provided by Owner up to Bidders UPS. Reception and terminating the same with necessary auto changeover circuitry shall be by Bidder.

5.00.00 EXCLUSIONS & FACILITIES PROVIDED BY OTHERS 5.01.00 Construction of pump house, pump foundations, fire water storage tank and other civil

structures in the port facility are excluded except mentioned in the scope.

Fire tenders are excluded from the scope of bidder.

5.02.00 Electrical

A. Switchgear / MCC

B. Power & control cables beyond Bidder supplied equipment.

C. Cable trays / trenches for power, control and instrumentation cabling beyond bidders supplied equipment.

D. Underground Earthing.

E. Lightning Protection

5.03.00 Raw / Fire water pump house area CCTV system interface to Fire protection System (Fire

Water pumps) PLC splice box (patch card) connection cable 5.04.00 MCC to PLC Interface cabling. This will be done by E1 Package bidder as per approved

Drive Philosophy. 5.05.00 FPS, DSS System PLC Interface with E1 Package system PLC is excluded from Bidders

scope. Necessary cabling and Hardware required at both ends shall be taken care by E1

Package Supplier. However Bidders shall have all the provisions required for Interfacing at

his end.

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6.00.00 DESIGN AND CONSTRUCTIONAL REQUIREMENTS 6.01.00 Fire Protection system

The fire protection system shall be designed as per recommendations of TAC and NFPA

guidelines. As per TAC regulations, the electric generating stations (other than Hydro) come

under the Ordinary Hazard category. Hence the entire fire protection system shall be designed

accordingly, wherever NFPA and TAC guidelines are not available, other codes and standards

(refer clause 2.09.00) as applicable shall be followed

6.01.01 Fire water pumps Fire water pumps for this proposed shall consist of

Electrical Motor Driven main Pumps, Two nos. of 273 m3/hr. capacity each at rated head of 95 MWC.

Diesel engine driven stand by Pump, one no. of 273 m3/hr. capacity at rated head of 95 MWC. Diesel Engine control panels with battery and battery chargers will be provided.

Jockey pumps (2 Nos. of 20m3/hr. each) at rated head of 105 MWC. Jockey pumps

(1W+1S) pressure set points shall be selected to maintain the minor pressure losses in

the entire network as per the desired functional requirements.

Recommended Material of construction for Fire Pumps

i. Casing Cast iron grade IS 210 FG-260

ii. Impeller Bronze IS 318, Gr.II or equivalent

iii. Shaft Carbon steel (EN 8 (BS 970) / IS 1570 Gr.40)

6.01.02 Hydrant system Hydrants (external, internal and water monitors) shall be provided as per the

recommendations of TAC. Hydrant protected areas shall be as per the scope summary

sheet enclosed as Annexure 1. Fire hydrant system for this plant shall consist of aboveground ring mains, hydrant

valves, risers and above ground branch headers with isolation valves. In case of

underground piping, proper coating and wrapping shall be carried out as per IS: 10221

and TAC recommendations. The pressurized hydrant pipe work feeds water to a number of hydrants (indoor as well

as outdoor) and to outdoor type fixed water monitors around the plant and buildings.

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All hydrants served by the ring main system shall be positioned at strategic locations around the plant and located in such a way that all buildings and risk areas shall be

suitably protected by them. Hose pipes of suitable lengths along with standard accessories like hose boxes, central

hose houses etc. shall be provided. Each internal hydrant valve shall be provided with individual hose box having glass

front containing hoses, branch pipes, nozzles, and spanners etc. as per TAC

guidelines. For outdoor or yard hydrants, required hoses , branch pipes, nozzles etc shall be kept

in a hose box alongside of hydrants or the required accessories for 10 hydrants each

can be grouped and kept in a central hose house at strategic locations as per TAC

guidelines. In case of fire, these hoses are coupled to the respective hydrant valves through

instantaneous coupling and the hydrant / landing valve is opened to direct a jet of water

to the seat of fire. The water required for the hydrant system shall be supplied from the Fire water pumps

located in the Fire water pump house. It shall be ensured that the sufficient quantity of water is available for fire protection

purposes as per the guidelines of TAC. Ring main shall be terminated with Isolation valves and a blind flange at all tap offs

consisting of 3 or 4 hydrants, for every other fire protection system tap off and the

corners to enable future expansion / modification by the Owner.

Interconnection for fire hydrant system with isolation valve with M/s Adani and M/s Vedanta hydrant system as per VPT requirement.

Material of construction

i. Hydrant valves Stainless steel (conforming to IS: 5290)

ii. Water monitors As per IS 8442

iii. Hoses Non-percolating type (type-A or equivalent) (As per IS 636)

iv. Branch pipes Nozzles SS 316 conforming to IS: 6529

v. Nozzles SS 304 conforming to IS: 6529

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6.01.03 HVW Spray system HVW spray system shall be provided for transformers. Water requirement of HVW spray shall be estimated considering the total surface

area of the equipment including bottom surface, radiators and conservators in case of

transformer. All the surfaces of the transformers / equipments are covered with a

spray density of 10.2 lpm/m2 as per TAC guidelines. Water required for HVWS system

for the transformer shall be considered as the one of the maximum water demand

criteria of HVW spray system for this plant. The system shall automatically detect control and extinguish any out-break of fire and

simultaneously gives audible alarm. Water line forms a ring around the equipment to be protected with projected outlets at

various points fitted with nozzles. Water under pressure is directed to the projector

network through a deluge valve from a pipe network laid exclusively for the spray

system. The system shall be hydraulically so designed the minimum water pressure at any

remote projector shall be 3.5 kg/cm2 and not greater than 5.0 kg/cm2 and the velocity

in the feed pipes shall not exceed 10 m/s. Discharge density of 10.2 lpm/m2 of

projected surface area for transformers / equipment shall be used as per TAC

recommendations. In case of detection of fire in transformers/equipment, deluge valve in spray water line

shall be opened by operation of quartzoid bulb detectors (bulbs thermally expand on

the rise of temperature and bursts) and spray water system shall come into operation

automatically, pressurized water shall be discharged through the nozzles forming an

emulsion & impinge on the surface to be protected. The system shall have remote

and manual actuation facilities also. All the materials, equipment, devices shall be of approved standards (UL Listed/ FM

approved / BIS approved) and shall be in accordance with TAC guidelines. Body of projectors and the detection sprinkler bulbs shall be of Stainless steel or

Brass with chrome plating. An Isolation valve shall be provided at both the upstream (gate valve) and

downstream (butterfly valve) of each of the deluge valve. The size shall be as that of

Deluge valve. Further, butterfly bypass valve to deluge valve shall be provided.

6.01.04 MVW Spray system

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MVW spray system shall be provided for the following areas. 1. Coal Conveyors gallery, Conveyor tunnel 2. Cable trenches

Operation of MVWS system shall be automatic. Upon detection of fire either by the detectors, deluge valve in the spray line shall be opened automatically. In the event of

fire detection, the protected areas shall be sprayed with water. Suitable zoning shall be

done to limit the extent of spray coverage and each zone shall be operated with a zonal

deluge valve. MVWS protected areas such as coal Conveyors shall be divided in

different zones to facilitate operation in 3 zones simultaneously one forward and one

behind the affected zone to avoid the spread of fire to other zones. The system shall be hydraulically so designed the minimum water pressure at any

remote sprayer is not less than 1.4 kg/cm2 and not greater than 3.5 kg/cm2 and the

velocity in the distribution pipes shall not exceed 5 m/s. The minimum water pressure at

any projector or nozzle shall be 1.4 bar for conveyors. Discharge density of 10.2 pm/m2

shall be provided for conveyors as per TAC recommendations.

All the materials, equipment, devices shall be of approved standards (UL Listed/ FM approved / BIS approved) and shall be in accordance with TAC guidelines. Body of

nozzles shall be of Stainless steel or Brass with chrome plating. An Isolation valve shall be provided at both the upstream (gate valve) and downstream

(butterfly valve) of each of the deluge valve. The size shall be as that of Deluge valve.

Further, butterfly bypass valve to deluge valve shall be provided.

6.01.05 Portable fire extinguishers In addition to various types of fire protection system described above, Mobile (trolley mounted)

& portable (floor or wall mounted) fire extinguishers of different types shall be provided at

various locations and inside the off-site buildings as per TAC recommendations. Distribution of

these extinguishers in various locations shall be as per the TAC guidelines.

Portable fire extinguishers of the following type shall be provided.

Sl.

No

Type of Fire extinguisher Capacity Quantity *

2 CO2 type 4.5 kg (Conforming to IS 2878)

10 Nos

3 Trolley mounted Mobile type CO2

22.5 kg (Conforming to IS 2878)

5 Nos

4 Dry chemical powder type 5 kg 10 Nos

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(Conforming to IS 2171)

5 Trolley mounted Mobile type dry chemical powder type

50 kg (Conforming to IS

10658)

5 Nos

(*Extinguisher quantities shall be worked out based on finalized building layouts and in

accordance with TAC recommendations)

6.01.06 Fire detection, alarm and control system Analogue addressable type fire detection, alarm and control system shall comprise of:

Programmable / configurable PC station with historical archive facility and printer. Various types of fire detectors Power supplies, battery and battery charger. Complete interconnecting cabling between fire detectors, devices, junction boxes

and panels. In addition to the above, manual call points and hooters shall be provided at

strategic locations within the total plant area. Suitable provision shall be made to

interchange signals from for fire pump status. The fire detection system shall indicate the fire location and shall display the

occurrences visually and audibly both locally and centrally at substation.

Fire detection, alarm and control system shall cover the following areas: 1. LHS type detection system for Cable galleries, coal conveyors, coal

tunnels, protected by MVW spray system.

2. Quartzoid bulb heat detection system for Equipment protected by HVW

spray system

All fire panels shall be provided with Ni Cd battery and battery chargers. Battery shall be capable of 24 hours back-up supply in case of power supply failure.

The fire detection & alarm system apart from exhibiting audio & visual alarms and initiation of extinguishing system in the relevant areas shall also carry out the

control function such as shut down of draft fans, air conditioning & ventilation

system damper/equipment, shut down of power supply and tripping of transformer

(as per transformer manufacturer recommendation) etc as envisaged for system

safety. Detector cables and other control cables shall be armored, screened and twisted

FRLS type in external areas and shall be of unarmored FRLS type inside the

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buildings in conduits. Detectors Loop cables and FAPs interface cables shall be

Fire survival cable.

6.02.00 Dust Suppression system 6.02.01 Dry Fog Dust Suppression (Transfer Towers- 1,2,3,4,5)

At specified locations dry fog dust suppression system shall be provided which comprises spray

nozzles discharging plain water & air in a fine spray to form dry fog to capture air borne dust

particles and direct them into the main coal flow. This dry fog shall be discharged through spray

heads at the dust suppression zones.

The dry fog dust suppression system shall consist of the following:

a. Fogging system & controls consisting of: Spray assemblies. Pressure regulating units Flow activation system Instrumentation for auto spray

b. Compressed air system consisting of: air compressors (screw type). Air receivers Applicable instrumentation & valves.

6.02.02 Plain Water Dust Suppression System(Coal Stock pile)

Water shall be drawn from the water storage tank by electric motor driven pumps(1W+1S) and

discharged via a pipe network system through spray heads. Spray heads shall comprise of

swiveling type spray units spaced at an interval of approximately 40 meters around each coal

pile. Manually operated globe valve shall be provided to control water supply to each spray unit.

Pressure at inlet to spray unit shall not be less than 4.5 kg/cm2(g), orifice plates shall be

provided if required for the spray nozzles where the residual pressure is more than 4.5

kg/cm2(g)

6.03.00 Service Water System Service water connections are to be provided in conveyor galleries and tunnels at 50 meter

intervals. Adequate number of these connections shall be provided in all transfer towers within

1mts of ER-1, SS-1, berth office, workshop, stores, gate house and any other buildings. 32 NB

globe valve and quick coupling. One (1) no. hose pipe with nozzle shall be provided in each

building.

6.04.00 Water Treatment System

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Description Details

Feed water tank

Type Rectangular above ground.

Effective capacity One (72) hour retention time

Material of construction RCC

Hypo dosing tank

Effective Capacity Each twenty four (24) hours storage volume at dosing concentration

Material of Construction FRP

Agitator type Vertical

MOC of agitator SS

Dissolving basket In SS Construction with 10 mm dia holes on 50mm triangular pitch.

M.O;C. for piping valves, & fittings. CPVC PN 10

Free board 0.30 m

Dosing pumps

Type Diaphragm / plunger type with stroke adjustment metering pumps.

MOC of wetted parts PP/ SS

Minimum dosing rate to be considered. 3 ppm

Capacity of each dosing pump To be decided by the Vendor

Stroke Variable 0 - 100%

Pressure relief piping Back to solution tank

Pressure relief valve SS316, one per pump

Pressure gauge Diaphragm type

Suction strainer One per pump

Tank cover Flat, hinged/removable cover

Tank bottom Flat sloped

Level gauge As indicated in the flow scheme

MOC of pipes, valves and fittings CPVC PN 10

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Pressure sand filters

Quantity (1W+1S)

Capacity To provide filter water of 50 m3/h when one filter is working

When both the filters are working then 100 m3/h

Design Code IS 2825 or ASME Sec VIII Div 1

Design Pressure Pump Shut off Head+ 5% Margin

Design Temperature 60o C

Material of construction IS:2062 for shell and IS:2002, Gr I/ SA 515 Gr 70 for dish, internally epoxy coated.

Filter Medium Sand and Gravel

Supporting bed Rounded and graded gravel free from clay and lime stone

Backwash frequency Once in 24 hours

Activated carbon filters

Quantity (1W+1S)

Capcity To provide filter water of 50 m3/h when one filter is working

When both the filters are working then 100 m3/h

Design Code IS 2825 or ASME Sec VIII Div 1

Design Pressure Pump Shut off Head+ 5% Margin

Design Temperature 60o C

Material of construction IS:2062 for shell and IS:2002, Gr I/ SA 515 Gr 70 for dish, internally epoxy coated.

Internal/ External painting Two (2) coats of high built epoxy zinc phosphate DFT 500 microns/ Three (3) coats of chlorinated rubber paint DFT 500 microns

Filter Medium Granular Activated Carbon as per AWWA 8604 De-chlorination grade.

Supporting bed Rounded and graded gravel free from clay and lime stone

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Backwash frequency Once in 24 hours

Activated Carbon Media Depth

(Excluding supporting bed depth)

1200 mm (min)

Freeboard 75% of bed depth

Surface flow rate < 12 m3/hr/m2 (max)

Outlet Chlorine, ppm as Cl2 Less than 0.1

Outlet water, oil, colour, odour NIL

Mode of backwash Flow reversal from feed line

Waste back wash tank


Effective capacity Total back wash water produced in one day when all the filters are working


Fire cum service water tank


Effective capacity 1500 m3. Which includes 1100 m3 of fire water storage requirement


Pumps Filter Feed pumps

Back wash pumps

Waste back wash

transfer pumps

Quantity 2 Nos

(1W+1S) 2 Nos (1W+1S)

2 Nos (1W+1S)

Capacity,

m3/hr

25 m3/h Bidder to decide

Bidder to decide

Design margin on flow 10% 10% 10%

Discharge pressure, mwc Bidder to decide

Bidder to decide

Bidder to decide

Type Horizontal centrifugal

Horizontal centrifugal

Horizontal centrifugal

MOC

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Casing CI to IS 210 FG 260 CI to IS 210

FG 260 CI to IS 210

FG 260

Impeller SS316 SS316 SS316

Performance Criteria:

Product water quality: The quality of water at various equipment outlets shall be as follows:

1 Pressure Sand Filter (PSF)

Maximum TSS < 5 ppm

2 Activated Carbon Filter (ACF)

Residual Chlorine, color & organics

Not traceable

6.05.00 Sump Pumps

Sump pumps along with level switches & piping up to nearest drain (max upto 50.0 mtrs. from

outside the building) shall be provided at wagon tippler complex, SS-1, ER-1 and fire water

pump house area.

The capacity of each pump shall not be less than 25 M3/hr. Minimum 10% margin on capacity

and 20% margin on computed head shall be considered for selection of pumps.

Size of the sump pit shall not be less than 2.0 meters x 2.0 meters x 1.8 meters deep. One no.

of settling pit shall also be provided before sump pit so that water without heavy coal particles

goes into sump pump pit. High and low level switches shall be provided in the sump pump pit.

Capacity and head of these pumps shall be decided during detailed engineering, all these

pumps shall be submersible type.

6.06.00 Piping, valves, fittings and accessories 6.06.01 Piping & Fittings

Mild steel as per IS: 1239 (Part-I) medium grade (up to 150 NB) & as per IS: 3589 Gr. 410 (200 NB and above) or Equivalent for pipes normally filled with water.

Mild steel as per IS: 1239 (Part-I) medium grade (up to 150 NB) & as per IS: 3589 Gr.410 (200 NB and above) or Equivalent and galvanized as per IS: 4736 for pipes

normally empty and periodically charged with water and foam system application.

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Minimum pipe thickness shall be 6.30 mm for pipes of 200 NB to 350 NB, 7 mm for 400 NB and 8 mm for beyond 400 to 600 mm.

Unless otherwise specified all elbows/bends shall be of long radius type. The material shall conform to ASTM A 234 Gr. WPB or ASTM A 105 or equivalent and

dimensional standard conforming to ANSI B 16.11 (socket & threaded type), ANSI B

16.9 (for butt welded fittings) and ANSI B 16.5 (for flanges and flanged fittings) as the

case may be. Further, galvanized malleable cast iron fittings as per IS: 1879 in Cast iron

fitting as per BS-1641 are also acceptable. The fittings shall be galvanized as per IS: 4736 for galvanized pipe application. In case

of branching connections from GI mains for spray piping network, socket may be welded

for more than two pipe reduction instead of standard tees. Fabricated fittings shall not be acceptable up to pipe size to 300 NB. For sizes 350 NB

and above, fittings may be fabricated as per BS: 2633 / BS: 534. Welding of galvanized iron pipes / fittings shall be permitted provided the same is carried

out by means of special electrodes suitable for the above application. After, welding welded portions shall be applied with three coats of zinc silicate

treatment/rich paint over one coat of suitable primer.

Pipes and Fittings Summary

Sr. No. Particulars Design Data

1 Manufacturer As per the approved Supplier list

2 Underground piping

2.1 Pipe specification

Mild steel as per IS 1239 (Part-I) medium grade for sizes 150 NB and below & IS 3589 Gr. 410 for sizes 200 NB and above (wall thickness min 6.30 mm for pipes of 200 NB to 350 NB, 7 mm for 400 NB and 8 mm for above 400 NB up to 600 NB)

2.2 Pipe to pipe joints Butt welded for sizes 50 NB and above & Socket welding for sizes below 50 NB

2.3 Pipe to valve joints Flanged with neoprene gaskets in between. Flanges shall be drilled to

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ANSI B16.5 150#

2.4 Pipe fittings ASTM A234 Gr. WPB for sizes 65 NB and above ASTM A105 for sizes 50 NB and below

2.5 Wrapping & Coating Wrapping and coating to be done in line with IS-10221

3 Above ground piping (normally filled with water)


Mild steel as per IS 1239 (Part-I) medium grade for sizes 150 NB and below & IS 3589 Gr. 410 for sizes 200 NB and above (wall thickness min 6.30 mm for pipes of 200 NB to 350 NB, 7 mm for 400 NB and 8 mm for above 400 NB up to 600 NB)


3.3 Pipe to valve joints Flanged with neoprene gaskets in between. Flanges shall be drilled to ANSI B16.5 150#

3.4 Pipe fittings ASTM A234 Gr. WPB for sizes 65 NB and above & ASTM A105 for sizes 50 NB and below

3.5 Bolts, nuts and washers Hot dip galvanized MS

3.6 Pipe supports Required

4 Above ground piping (normally empty)


Mild steel as per IS 1239 (Part-I) medium grade for sizes 150 NB and below & IS 3589 Gr. 410 for sizes 200 NB and above and galvanized as per IS 4736 (Wall thickness min 6.30 mm for pipes of 200 NB to 350 NB, 7 mm for 400 NB

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and 8 mm for above 400 NB up to 600 NB)


4.3 Pipe to valve joints Flanged with neoprene gaskets in between. Flanges shall be drilled to ANSI B16.5 150#

4.4 Pipe fittings ASTM A234 Gr. WPB for sizes 65 NB and above & ASTM A105 for sizes 50 NB and below

4.5 Bolts, nuts and washers Hot dip galvanized MS

4.6 Pipe supports Required

6.06.02 Valves & other Accessories Valves & Specialities shall be used to start, stop or regulate the flow. All valves/specialties

below 50 mm size in service water/dust suppression/ potable water lines should be plug

type of proven make. Bib cocks provided for potable water system shall be made of Copper Alloy / Cast Iron.

a. Strainers

Strainers shall be of Y Type. Strainer wire shall be of SS (AISI316) and Strainer Body as per IS: 2062 (tested). Strainer area shall be at least 4 times the cross section at the pipe end. Strainer shall be of 30 SWG & 30 mesh and pressure drop across the strainer at

design flow shall be limited to 10 MWC in clean condition. Strainers in DS system shall be of duplex type designed with 3 way valves so that

one filter can be cleaned while the other is in operation. Suitable vent and drain

valves shall also be provided. Screen opening area shall be at least four times the

pipe cross sectional area. Pressure drop in clean conditions shall not exceed 1.5

MWC at full flow.


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i. Body Cast iron grade IS 210 FG-200

ii. Wire mesh SS 316

b. Gate Valves

Gate valves shall be of rising spindle type conforming to IS 14846 / 780 with MOC as per the below.


i. Body Cast iron IS 210 Gr. FG 200 or CI ASTM A 216 Class B

ii. Stem Steel ASTM A 276 Type 410/304/316 or Leaded Tin Bronze IS 318 LTB2

iii. Disc ASTM A 217 Gr. CA 15 or Bronze

iv. Seat Ring ASTM A 217 Gr. CA 15 or Bronze

v. Hand wheel Cast iron IS 210 Gr. FG 200 or CI ASTM A 216 Class B

vi. Packing Asbestos

c. Check / Non return Valves

Check / Non return Valves shall be of reflux swing disc type conforming to IS 5312 with MOC as per the below.


i. Body Cast iron IS 210 Gr. FG 200

ii. Flap Cast iron IS 210 Gr. FG 200

iii. Body ring Leaded Tin Bronze IS 318 LTB2

iv. Flap Ring Leaded Tin Bronze IS 318 LTB2

v. Gasket Rubber

vi. Packing Rubber

All valves shall be as per applicable IS/BS codes & approved by TAC for specific fire protection system.

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Flanges: Flanges and counter flanges shall conform to ANSI B 16.5 CI 150.

6.06.03 Pipe supports All piping supports shall be designed with incidental structural sub framing. The supports shall be spaced in accordance with standard engineering practice as

outlined in applicable codes and standards. The location of the supports shall not increase the forces and moments on the

equipment beyond their allowable values.

7.00.00 LAYOUT REQUIREMENTS

The layout shall be strictly in compliance with TAC requirements especially regarding to

clearances of fire ring mains from buildings/ structures, spacing of hydrants, etc.

8.00.00 OPERATION & CONTROL PHILOSOPHY

8.01.00 Fire Protection system & Dust Suppression Systems

Fire Protection system (FPS) Operation, Control & Monitoring of FPS system is by dedicated PLC based Control System with Front panel mounted Graphical User Interface (GUI) of 12 sized for operator Interface. This PLC will Located near to the E1 Package PLC in SS1 First Floor


The Operation, Control & Monitoring of DSS of CHP Transfer tower by E1 Package PLC (By owner) located at SS1. Bidders scope includes all the required field instrumentation for successful operation of DSS System up to Field Junction Boxes including Junction boxes and cabling up to JBs.

Dust suppression System for Coal Stock Pile

The Operation , Control & Monitoring of DSS of Coal Stockpile is by dedicated PLC based Control System with Front panel mounted Graphical User Interface (GUI) of 21 sized for operator Interface. This PLC will Located near to the E1 Package PLC in SS1 First Floor

Service Water System Shall be operated and controlled by Fire fighting system PLC.

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The fire pumps control system will be from microprocessor based programmable logic control

(PLC) system, local control panels for Diesel engine drive fire water pumps, local/remote

instruments, instrumentation & control cables , erection hardware and Standalone UPS

System with Maintenance Bypass Switch for PLC system.PLC based control system will be

provided for implementation of control logics of the Fire Water Pumps, covering the total

functional requirement of sequential control, interlock, monitoring, alarm & data logging.

PLC system configuration will be redundant in CPU, communication, Power supply modules

and non-redundancy in I/O modules for normal loops and for critical loops redundancy at

output card level can be achieved externally by extra hardware only. 1 no. Graphical Interface Unit (GIU) based Operator Station will have minimum 12 size of

Panel Mounted type will be provided.

Comprehensive annunciation and indication scheme integrated in PLC will be provided such

that, it will be possible for the operator to locate and identify the fault from the GIU.

One no. Lap top will be provided as engineering tool for programmable functions with required

software for Fire Protection System (Fire Water Pumps) PLC.

Diesel Engine driven fire pump local control panel will be accessible and located near their

respective equipment and will be complete with all the required controls, interlocks, indicating

lamps etc. and further interface Fire Protection System (Fire Water Pumps) PLC system.

8.01.01 Specific C&I Requirements

All panels, desks cabinets and enclosures will comply with the protection classes as indicated

below:

Indoor air conditioned (A.C) areas : IP 32

Indoor non A.C areas:

- Ventilated enclosures : IP 42

- Non ventilated : IP 55

Outdoor : IP-55/ IP 65 (As per the requirement)

All equipment/systems located in the field will be suitable for continuous operation without loss

of function, departure from specification or damage at the ambient temperature of 50 Deg C

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and relative humidity of 90%. For hazardous area, instruments will be intrinsically safe and

field instruments will be explosion proof as per relevant area classification.

All junction boxes, power supply distribution boards, marshalling cabinets (if applicable),

instrument erection materials, interposing relays, accessories and process hook-up hardware

will be supplied.

Standalone package UPS of adequate capacity with 60 min battery back-up will be provided

for the PLC system and GIU, equipment, instruments etc.

Individual pair shielded and overall shielded twisted pair copper cables will be used for analog

signals and overall shielded cables will be used for digital signals. Individual and overall

screened quadruplet cable will be used for RTDs through LJB to PLC control system.

vollume ii technical specifications section 2

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