T3.

00 design,

INTENT OF SPECIFICATION This sub-chapter is intended to cover

materials procurement, manufacture/fabrication, testing and supply of various types of fabricated and boughtout pipes,fittings,expansion joints, gates, screens and other miscellanious items connected with the circulating water system of 2 x 210 MW units. C.W.PIPING Scope of Work design, accessories, insurance, at pipes, painting, testing system. like / and required The contractor's scope of work shall supply of steel include

engineering, loading,

plates,

unloading at site, of

comprehensive piping of

fabrication site,

required circulating water

outside surface coating and wrapping

inside painting for pipes above 1600mm dia., handling of fabricated pipes at site, erection, and The commissioning of circulating water piping scope of work also includes Civil works

excavation, and back filling, construction of anchor thrust blocks chamber of man holes / air valves

other miscellaneous civil works that would be for installation of piping. Scope of Services

drawings final inlet heat

All

piping

systems

as

shown

in

enclosed

No.MEC/S/P123/A04/S4/01 and 02 complete with all joint welding at Battery limits viz., piping from and outlet of condensers, cooling water pipe for

piping and

exchangers (inlet and outlet), connection of C.W at cooling tower inlet, make up water pipes

blowdown pipes. ends the All bends , reducers, tees distance pieces, dished etc. of all sizes and shape required for complete

system. instruments stubs All piping and fittings for vents, drains, tapping points with stubs and root valves and

for the thermowell connections etc. necessary gaskets All counter flanges, blank flanges, caps etc. for the piping. All necessary bolts, nuts, and

required for installation of the system.

tees valves the nos. (Double be be gate

All with

flanges, manhole and manhole covers, flanged blank on flanges, above automatic piping are air-vent included in

required

contractor's scope of supply.A minimum number of 6 automatic air vent) air release cum vacuum break valves for each unit (total 12 nos.) shall

provided of

on CW piping.The air release valves shall isolation

200 mm dia with separate 200mm dia

valves. the for Manhole Butterfly shall be provided on either side of

valves for maintenance purpose

(except

300mm dia.). also The pipework covered under this section shall

and other with various work air is -

include

internal pipework for the

pumphouse

piping between pump house and main plant and units the as indicated in the drawings enclosed specification and described in pipe

paragraphs

of the specification. G.I.

for drinking water, service air and instrument piping etc., pipe work for service water air

also included in the scope of the contractor. generally tees, unions, pieces, T3.01 specified The The term 'pipework' referred (such herein as bends,

covers

pipes,

fittings

reducers,

plugs,

nipples,

sockets,

flanges, crosses, etc) valves, throttling stubs for primary sensing instruments etc. pipes shall be manufactured/supplied as

below: pipes ISPart-I With ii) 200 mm to 350 mm size i) Upto 150 mm nominal size M.S ERW Black conforming 1239-1984 (Medium Duty) to

Plain ends. Pipes ISthickspecified Nominal Dia DN DN DN DN 200 250 300 350 mm mm mm mm : : : : M.S. ERW to

conforming

3589-1973 but ness as

below : O.D X Thickness in mm 219.1 273.0 323.9 355.6 x x x x 6.35 7.14 7.14 7.14

iii) 400 mm to 600 mm size M.S. Pipes( Steel commercial Nominal Dia DN DN DN DN M.S. specified a) 1984 b) 1984 For Instrument Air : For Service Air : iv) 400 450 500 600 mm mm mm mm : : : : Manufactured

Spirally Welded

at

Rourkela

Plant) of quality. O.D X Thickness in mm 406.4 457.0 508.0 610 x x x x 7.14 7.14 7.90 9.50 Fabricated from plates as in para T3.02 IS:1239 - 1984 (Part-I) Heavy duty/IS:1978 St.25 seamless IS:1239 - 1984 (Part-I) Heavy duty/IS:1978 St.25 seamless (Hot dip galvanised) c) d) T3.02 T3.02.01 Drinking water Service water : : IS:1239 - 1984 (Part-I) Heavy G.I. IS:1239 - 1984 (Part-I) Heavy / IS:3589.

1600 mm and above

Fabricated Steel Pipe lines All fabricated pipelines specified below shall

be conforming welding thickness

fabricated to

from tested quality M.S. plates Grade -A by submerged arc

IS-2O62-1992

process as per IS-10234

or equivalent having

indicated against the pipe dia:

------------------------------------------------------Nominal dia Outside dia Plate of pipe mm of pipe mm ------------------------------------------------------16OO mm 24OO mm 1632 2432 16 16

thickness mm

-------------------------------------------------------

T3.02.02 cold plates so plate.The plate

All

fabricated using

pipes shall be a plate bending

manufactured machine. The

by

bending shall that

be gradually bent to true cylindrical no undue stress develops in the

shape

tolerances on dimensions of pipe fabricated from shall be as follows: i) On outer diameter as calculated from circumference Out of roundness

: :

+ 1/4 of plate + 3 mm & -1.5 mm

thickness. ii)

iii) Out of straightness : T3.02.03 a any T3.02.04 erection field be site The

1 mm per metre length (Max.)

pipe circumferential weld shall be done in such

way that the longitudinal welds become staggered in two consecutive sections. Pipe sections in straight lengths delivered at site joints done at shall be of suitable length to minimise shall

as far as possible. the fabrication

End preparation yard to

facilitate

welding.Straps shall be provided at field joints.

drawings

T3.02.05

The of

contractor shall submit detailed working pipelines and fittings including

fabrication These complete fabrication proposed T3.03 II from

drawings for approval by Purchaser/ Consultants. drawings bill shall indicate design parameters, other

of materials, welding and all

details.

Details of hydrostatic and ND tests

to be done shall also be specified. Pipe fittings Fittings shall be supplied as per IS:1239-1992 Part for pipes upto 150 mm dia and shall be fabricated

pipes for dia 200 mm and above. air, etc., All root joint welding from headers for service

instrument air, service water and drinking water shall be carried out by the contractor.

flanges, etc required the

Gate valves, Drain valves, Root valves, Blind pipe shall flanges, Gaskets, Bolts, nuts and washers

be supplied in quantities and sizes as

during detailed engineering with price included in lumpsum quoted.

T3.04 tools, and gas welding for T3.04.01

Fabrication of pipelines and welding of pipe joints The contractor welding shall arrange at his cost transformers, all

plant,

instruments and oxygen

consumables

including any acytelene

cylinders, welding electrodes for electric arc and filler rods, fluxes etc. for gas welding

welding per

carrying out the welding at site. Submerged orc as per IS 10234-1982 shall be carried out as

relevant International code. going of T3.04.02 The contractor shall indicate the procedure he is to follow for fabrication/erection/hydraulic testing M.S.Pipes. all The contractor shall arrange at his own cost for

tests outlined in this section. T3.04.03 requirements Requirement of welded joints The contractor shall ensure the following while welding the plates/ pipejoints etc. i) ii) less agressive T3.04.04 contractor, make Strength-equality with parent metal Absence of defects

iii) Corrosion resistance of the weld shall not be than that of the parent metal in

environment. Method of Quality Control in Welded Joints Following besides steps shall be taken quality in by the to

controlling

general,

effective control in carrying out welded joints. with tests Number like a adherence b) a) Welding procedures shall be prepared in line IS:7307(Part-I)-1974, reaffirmed in 1991 and shall be carried out to quality procedures. of procedures will depend on variables

positions of welding, thickness range etc. Once welding procedure is qualified, strict

to it shall be made during actual welding. IS:7310 Welders employed shall be qualified as per

passing

(Part-I)-1974, necessary tests.

reaffirmed in 1987

after

c) type. to 1991. approved Besides, be d)

Welding Such

consumables consumables

shall be of are, however,

approved subject

qualifying initial check tests as per IS:814The contractor shall strictly follow

welding procedures during actual welding. the following stages of inspection shall also

carried out : proper slag etc., ii) i) Weld edge preparation before welding, fit up, position of welding, cleaning of between the passes, proper weld profile shall be checked visually, amongst others. welded approved T3.04.05 the per in Non-destructive joints tests of weld of

shall be carried out as per

procedures/ drawings. Preparation of joints The contractor shall prepare the edge correctly to shape, ANSI size and dimensions of the vee-grooves B-16.25 unless otherwise as

specified

drawings/documents. free may loose The welding surfaces shall be smooth, uniform and from fins, teers, notches or any other defect which adversely afect welding and shall be free from

other to avoid material T3.04.06 and about contractor at using of quality

scale, slag, rust, grease, paint, moisture or any foreign about material. 10 mm The clean surface shall the welding faces extend to

beyond

contamination

of the weld metal with foreign

and to avoid unsound weld deposit. Assembly, Alignment & Welding The sequence of welding shall be so planned

followed that there shall be a balance of welding the shall neutral axis of the fabrication. The working

employ sufficient number of welders

the same time in diagonal quadrants of the shell back-step each method of welding. The rate of shall be more or less equal progress and

welder

uniform. the shell to The general direction of welding shall be towards

free end of the joint, but in a long joint as in fabrication, back-step technique shall be used

reduce distortion.

welding, and horizontal the complete their

To minimise internal locked up stresses due to the vertical joints for the shell shall be welded

completed to a circular course and then the circumferential welding of seam welded. seam However, started, before the

horizontal

circular course shall be aligned and adjusted for correct axes.

each prein same axis each penstock bigger

Alternatively, course in

the

contractor

shall

complete then and the placed the

all respects on ground and course In shall be lifted

assembled position. principle

such a sequence and planning,

of balancing of weld about the neutral

shall be followed and the method of fabrication of course pipes shall be similar to fabrication of of

or transmission/industrial pipelines

diameter. by If fused T3.04.07 Pipe and attachment and shall be aligned properly welding. either

accurate tack

permanent methods prior to are used, the tack shall be

welds

into the first layer of weld or else chipped out. Tests on welded joints (a) and all close less other magnifying and mm from following The Visual examination contractor shall conduct visual examination

measurement of external dimensions of the weld for joints. Before examining the welded joints, areas to than it on both sides of the weld for a width 20 mm shall be cleared of slag not and

impurities. glass

Examination shall be done by a

which has a magnification power of ten (10)

measuring instrument which has an accuracy of + 0.1 or by weld gauges. Welded joints shall be examined both sides. The contractor shall examine the during the visual examination :-

the

i)

Check

the

correctness of shape and size

of

welded joints ii) Incomplete penetration of weld metal

iii) Influx iv) v) Burns Under cuts

vi)

Unwelded crates

vii) Cracks in welded spots and heat affected zones viii)Porosity in welds and spot welds ix) of contact x) The as about by test Compression electrode welding Displacement of welded element. contractor shall carryout any or all tests in welded while joints as a out result

impact

carrying

specified

hereinafter to satisfy the

Purchaser

the acceptability of the welded joints, as directed the Purchaser. However minimum 10% DPT or MP

shall be carried out in the fabricated pipes. (b) Liquid Dye-penetrant Test dye-penetrant tests shall be carried out 1991

Liquid in for

accordance

with IS:3658-1981, reaffirmed in

surface/sub-surface defects. (c) The Test by Blowing surface of the weld shall be of covered of with water

soap and be to and

solution

consisting

one (1) litre

hundred (100) grammes of soap. Compressed air shall blown 5 from the opposite side at pressure of 4

kg/cm. sq. The distance between the tip of base

of Portable if

the weld shall not be more than 50 mm. Any formation soap buble will indicate shall welding defects. the contractor,

compressor

be arranged by

necessary, for this purpose. Tolerance be Deviations for assembly of welded joints may

permitted to the following extent : Tolerance ------------------------Automatic a) Source butt-joints i) Gap between the ends of plates + 2.00 mm - 1.00 mm + 1.00 mm Manual arc

Tolerance ------------------------Automatic ii) Stepping of one plate over the other Manual arc

1.00 mm

2.00 mm

b)

Single Vee-groove Joints i) ii) Bevol angle Gap between two + 5 deg. + 2.00 mm - 1.00 mm 2.00 mm + 5 deg. + 1.00 mm

iii) Stepping of one plate over other c) Lap Joint i) Overlap

2.00 mm

5.00 mm

5.00 mm

ii) d)

Gap between the surface

2.00 mm

1.00 mm

Tee-filler joints i) Gap between the edge of the web and the surface of the flange 2.00 mm 2.00 mm

T3.05 T3.05.01 the and data joint is

Rubber Expansion Joints Design and Construction Design of the expansion joint shall take care of

axial, angular or rotational movement of the bellow / or the equipment vibration, as stipulated in the specification shall sheets enclosed. The expansion

be designed such that no periodic adjustment

required.

T3.05.02 construction natural with of holding T3.05.03 used the shall to

Body Expansion bellow shall be of heavy duty

manufactured from high grade abrasion resistant or synthetic rubber, as specified in data sheets, Split retaining rings

integral flanges at both ends. adequate

design shall be supplied for securely

the expansion joint with connecting pipe flanges. Carcass Fabrics of high strength synthetic fibres shall be in suitable number of plies to hold the shape of

bellow at the working condition. be

All fabric plies components

impregnated with rubber or synthetic

permit flexibility between them.

embedded the T3.05.04 shall carcass

Copper coated steel wire or solid endless rings in the carcass shall be used for reinforcement of

expansion bellow. Cover The exterior and interior surfaces of the bellow

be coated with suitable material to protect the from outside damage and fluid corrosion.

the T3.05.05 rod contraction of washers, assembly

Protective exterior.

hypalon

coatings

may

be

applied

at

Control Rod Assembly Each expansion joint shall be supplied with control assembly to prevent excessive elongation or of long the bellow. bolt, nuts Control rod assembly will & lock nuts, spherical consist

connecting plates (gusset plate) for fixing the with mating flanges.

and of

Control

rod

assembly

shall

allow

transverse

rotational movements under limiting axial conditions the expansion joints.

of on the

Design

of the control rod assembly shall take

care

the maximum axial thrust across the bellow calculated the basis of maximum fluid internal pressure and

internal diameter of the arch.

T3.05.06

End Flanges

fabric on the face. the be during T3.05.07

The

expansion

joint

shall

have

integral The bolt hole

reinforced

full face rubber flanges.

the flange shall have no eccentricity in relation to corresponding bolt hole of the flange on the other The end rubber flange shall be drilled to suit

companion pipe flanges. suitably match

The companion flanges shall identification

marked for easy

erection by others. Counter Flanges Counter flanges shall be as per AWWA C-207. washers 7.05.08 Required numbers of carbon steel nuts, bolts,

and rubber gaskets shall be furnished. Hydrostatic Pressure Test and Vacuum Test a) internal half the All Pressure Test expansion bellows shall be subjected to

hydrostatic (1.5) times

pressure test at a value of one and a the maximum working pressure under

following conditions for thirty (30) minutes: i) ii) lateral Free position of the bellow With permitted (design) elongation and

deflections iii) With design contraction and lateral deflection Inspection for leakage from the bellow shall be out during pressure test.

carried

over, check

Before the hydro test and after the hydro test is the bellow shall be dimensionally inspected to

deformation, if any. suitably During the test, the control assembly shall be adjusted to obtain the test conditions of the bellow. b) Vacuum Test

All expansion joint shall be subjected to a vacuum test in thirty positions at 700 mm of Hg vacuum. The test shall be conducted

three different positions for a minimum period of (30) minutes duration in each position. are as described above for pressure test. These

c) additional assurance. extra T3.05.09 the

Additional Tests shall have the right to demand

Purchaser

tests as may be found necessary for quality All the above tests shall be carried out without cost to Purchaser. The Rubber Expanson Joints shall conform to

following standards/codes: i) Expansion standards ii) Fluid sealing Association, USA joints manufacturers' Association,

USA

Design of Expansion joint shall take care of the axial, or angular or rotational movements of the bellow and/

the equipment vibration. The body of expansion joint shall be made from

abrasion

resistant rubber. The expansion joints shall have integral flanges

at

both ends complete with split retaining rings. The external shall and internal surfaces of the with

expansion a

joint

be of Neoprene of 3 mm thickness

shore hardness of 65 + 5 deg.

for

Steel

wire/synthetic

fabric

shall

be

used

reinforcement of the expansion bellows. Tie rods shall be provided in the expansion joints. T3.05.10 Design Requirement i) ii) Qty. Nominal diameter 5 Nos. 1600 mm. Single arch type. 6 Kg/cm2 Circulating water (for analysis see Annexure-D & E). 44/30

iii) Type iv) v) Design pressure

Liquid to be handled-

vi)

Working temperature (oC) (Max./Min.) -

vii) Maximum flow (M3/hr) viii)Location ix) x) xi) Test pressure (kg/cm2g) Vacuum design Vacuum test

16500 Indoor 7.5 750mm of Hg vacuum 700mm of Hg vacuum Manufacturers std. AWWA-C 207, 1-50 lb slip on type

xii) Freelength (mm) class xiii)Counter flange

xiv) Axial elongation(mm)xv) Axial contraction (mm) -

15 15 15 0.5

xvi) Lateral deflection (mm) xvii)Angular deflection (deg.)

xviii) Torsional movement (deg.) xix) Pump speed (rpm) T3.05.11 Materials of Construction Bellow Carcass Stiffening ring External cover Internal cover Control assembly Retaining ring -

0.5 497

Synthetic Rubber Synthetic fibre Manufacturers standard Hypalon or approved equivalent Manufacturer's standard Manufacturer's standard Galvanised Steel

Flanges/Counter flanges Gasket Nuts, bolts and washers 307 Pipe thickness

Carbon Steel IS:2062 3 mm thick reinforced rubber Carbon Steel - ASTM A Grade A

16 mm

DATA SHEET FOR RUBBER EXPANSION JOINT 1.00.00 1.01.00 1.02.00 1.03.00 1.04.00 GENERAL Service Nominal size (NB)/Qty. Duty Type : : : : C.W.System 1600mm - 5 Nos. Continuous Spool type

1.05.00 1.06.00 1.07.00 2.00.00 2.01.00 2.02.00 2.03.00 2.04.00 2.05.00 2.06.00 2.07.00t 2.08.00

Overall dimensions (mm) Gross weight of the complete assembly (kg) Model No. PERFORMANCE CAPABILITY

: : :

750 1750 kgs (appx) During Detail engg.

Axial elongation / contraction (mm) : Lateral deflection (mm) Angular movement Torsional movement (degrees) Axial spring rate (N/mm) Torsional spring rate (kg/mm/deg) Frequency of vibration (Hz) : : : : : :

15/15 15 0.5o 0.5 1925 (Appx) 180 During detail Engg.

Maximum pressure drop through the expansion joint at design flow rate, Kg/cm2g : DESIGN AND CONSTRUCTION Design standard Design pressure (kg/cm2g) : :

< 0.01

3.00.00 3.01.00 3.02.00 3.03.00 3.04.00

As per spec. 6 750 60

Design vacuum in mm of mercury: Design Temperature (oC) :

3.05.00 3.06.00 3.07.00 3.08.00 4.00.00

No. of arch / corrugation Flange pressure rating and drilling standard No. of limit / control rods Bursting pressure of bellow (kg/cm2g) MATERIAL OF CONSTRUCTION

: : : :

Single BS 4504 PN-10 6Nos./Per Joint Twice the design pressure

4.01.00 4.02.00 4.03.00 4.04.00 Ring 4.05.00 4.06.00 4.07.00 4.08.00 4.09.00 4.10.00

Bellow Carcass Bellow exterior Bellow interior

: : : :

Synthetic Rubber Synthetic fibre Neoprene Rubber Neoprene Rubber IS 2062 Gr. A Sq. Annular IS1367 Gr.63.8/6.0, stretcher plate IS-2062 Gr.A.

Metal reinforcement : Control rod assembly:

Retaining ring segments: IS:2062 Gr.A Galvanised Flanges/counter flanges: IS:2062 Gr.A Fasteners Gaskets : : IS:2062 Gr.4.6/4.0 Not recommended as Internal Rubber flange shall act as self gasket

5.00.00 5.01.00 5.02.00 5.03.00 5.04.00

INSPECTION AND TESTING INCLUDED Materials Test Certificates Certificates for bought out items Dimensional tolerance as per specification Hydrotest as per specification : Yes : Yes : Yes : Yes

6.00.00 6.01.00 6.02.00 7.00.00 7.01.00 7.02.00 7.03.00

ACCESSORIES INCLUDED Control rod assembly with gusset plate, nuts spherical washers etc. : Yes Counter flanges with nuts, bolts etc. : Yes

LIST OF TECHNICAL DOCUMENTS ENCLOSED WITH THE CONTRACT Dimensional General Arrangement drawing as specified A cross-sectional drawing of the expansion bellow Manufacturers standard catalogues and Literature : Yes : Yes : No

7.04.00

A write-up on the manufacturing inspection and testing facilities available at the manufacturer's works Any other information

: :

7.05.00

LIST OF MANDATORY SPARES FOR R.E. JOINTS 1. 2. 3. 4. Note: particular Rubber Expansion Joint Complete assembly of 1600 mm dia. Slip-on type matching flange with bolts, nuts and gaskets Reinforced Rubber Gasket for above R.E. Joints Control rod assembly complete with nuts etc. One set corresponds to the quantity of part used in one R.E. Joint. : 1 set : 1 set : N.A. : 2 sets

GUARANTEED DATA FOR R.E.JOINTS. joint performance The for data. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 Design working pressure of bellow (kg/cm2 g) : 6 Kg/cm2 12 kg/Cm2 15/15 15 0.5 0.5 BS 4504 PN-10 contractor guarantees that each rubber expansion minimum

CW system shall meet the following

Minimum bursting pressure of bellow (kg/cm2 g) : Axial elongation/contraction (mm) : Lateral deflection (mm) Angular movement (degrees) : :

Torsional movement (degrees) : Flange standard :

SIGNATURE ......................... NAME .............................. DESIGNATION ....................... NAME AND ADDRESS OF COMPANY .. DATE .............................. .................................