DM Plant

TENDER
NO
VOLUME
PSER:SCT:SRG-M1518:14
II SCOPE, TECHNICAL SPECIFICATION
JOB
Design, engineering, manufacturing, supply, erection

& commissioning of DM Plant Package for RRVUNL,
2x660 MW, Stage-V, Unit # 7 & 8 Suratgarh Super
Critical TPS, Rajasthan.
CAPACITY 2x660 MW,
PROJECT Suratgarh Super Critical TPS, Rajasthan. Stage-V,
Unit # 7 & 8.
BHARAT HEAVY ELECTRICALS LIMITED

(A Govt Of India Undertaking)
POWER SECTOR EASTERN REGION
PLOT DJ 9/1, SECTOR II, SALT LAKE
KOLKATA 700 091
2X660 MW Suratgarh Super Critical TPS, Stage-V Unit 7 & 8 at

Suratgarh, Rajasthan
VOLUME: II B & III
TECHNICAL SPECIFICATIONS
FOR
DM PLANT
SPECIFICATION NO.: PE-TS-392-163A-A001
BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR
PROJECT ENGINEERING MANAGEMENT
NOIDA, INDIA
TITLE: TECHNICAL SPECIFICATION FOR

DM PLANT
2X660 MW Suratgarh Super Critical TPS, Stage-V Unit 7
& 8 at Suratgarh, Rajasthan
SPEC NO: PE-TS-392-163A-A001

VOLUME:
SECTION:
REV NO: 00
CONTENTS
VOLUME-IIB & III
VOLUME-IIB
SECTION
DESCRIPTION
SECTION A
SCOPE OF ENQUIRY
PAGE
NO.
1-3
SECTION B
PROJECT INFORMATION
4-8
SECTION C
SPECIFIC TECHNICAL REQUIREMENTS
SECTION C1
SPECIFIC TECHNICAL REQUIREMENTS (MECHANICAL)

ANNEXURE I : QUALITY PLAN
ANNEXURE II : SUB VENDORS LIST
ANNEXURE III : DRAWING DOCUMENTS SUBMISSION PROCEDURE
ANNEXURE IV : PAINTING SPECIFICATION
ANNEXURE V : LIST & QUANTITY OF MANDATORY SPARES
DATA SHEET A
P&ID
SPECIFIC TECHNICAL SPECIFICATION (ELECTRICAL)
ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR
ELECTRICAL LOAD DATA FORMAT
SCOPE MATRIX FOR CONTROL OF SWITCHGEAR BREAKERS FROM PLC FOR
OFFSITE AREAS
SPECIFIC TECHNICAL SPECIFICATION (CONTROL & INSTRUMENTATION)
DM PLANT INSTRUMENTATION
10-23
24-27
28-61
62-63
64-78
79-81
82-96
97-99
100-102
103-105
106
107-110
SECTION D
GENERAL TECHNICAL REQUIREMENT
118
SECTION D1
GENERAL TECHNICAL REQUIREMENT (MECHANICAL)

TECHNICAL SPECIFICATION FOR PRESSURE & STORAGE VESSEL
TECHNICAL SPECIFICATION FOR PRESSURE & STORAGE VESSEL
(CONTINUED)
TECHNICAL SPECIFICATION FOR PIPING & VALVES
TECHNICAL SPECIFICATION FOR PIPING, VALVES AND FITTINGS
TECHNICAL SPECIFICATION FOR HORIZONTAL CENTRIFUGAL PUMPS
TECHNICAL SPECIFICATION FOR METERING PUMPS
GENERAL TECHNICAL REQUIREMENT (ELECTRICAL)
GENERAL TECHNICAL REQUIREMENTS FOR LV MOTORS
TECHNICAL SPECIFICATION FOR MOTORS & ACTUATORS
DATA SHEET A MOTORS & ACTUATORS
DATA SHEET C MOTORS & ACTUATORS
CABLES AND CABLE CARRIER SYSTEM
GENERAL TECHNICAL REQUIREMENT OF CONDUITS & PIPES
QUALITY PLAN (MOTOR)
GENERAL TECHNICAL REQUIREMENT (CONTROL AND INSTRUMENTATION)
119
120-138
139-148
SECTION C2
SECTION C3
SECTION D2
SECTION D3
VOLUME-III
SCHEDULE OF CLARIFICATIONS
SCHEDULE OF DEVIATIONS
SCHEDULE OF GUARANTEED CHEMICAL CONSUMPTION ANNEXURE I
SCHEDULE OF DECLARATION
SUGGESTIVE PRICE SCHEDULE
PS-PEM-MAX PPEI BUILDING, SECTOR 16A NOIDA
111-116
117
149-166
167-180
181-187
188-190
191
192-196
197-204
205-210
211-216
217-228
229-234
235-246
247-421
423
424
425
426
427-428
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
& 8 at Suratgarh, Rajjasthan
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: A
REV
V NO: 00

S
SECTION
NA
SCO
OPE OF ENQUIRY
E
Y

BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: A
REV
V NO: 00
1.0
SCOPE OF INQUIR
RY/ INTENT OF
O SPECIFIC
CATION
1.1
The spe
ecification iss intended to
t cover de
esign, engineering, man
nufacture, faabrication, assembly,
inspectio
on and testiing at vendo
or's & sub-vvendors worrks, painting
g, mandatoryy spares, errection &
commisssioning spare
es, forwardin
ng, proper pa
acking, shipm
ment and delivery at sitee, unloading, handling
& transp
portation at site
s , Erectio
on & Commisssioning, tria
al run, preparation & subbmission of As
Built
drawingss, Performance and gua
arantee test ing at site and
a
handing over of DM
M PLANT as
s per the
details in different sections
s
/ vo
olumes of th
his specificattion for 2X66
60 MW Suraatgarh Supe
er Critical
age-V Unit 7 & 8 at Suratgarh, Rajas than
TPS, Sta
1.2
ntractor shall be respon

nsible for prroviding all material, eq
quipment & services, which
w
are
The con
required
d to fulfil the intent of ens
suring operab
bility, mainta
ainability, reliability and coomplete safe
ety of the
complete
e work cove
ered under th
his specificattion, irrespec
ctive of whether it has beeen specifica
ally listed
herein o
or not. Omisssion of spec
cific referencce to any co
omponent / accessory nnecessary fo
or proper
performa
ance of the equipment
e
shall not relie ve them of the responsib
bility of provi ding such fa
acilities to
complete
e the supply, erection an
nd commissio
oning of DM PLANT.
1.3
It is not the intent to specify here

ein all the de
etails of desig
gn and manu
ufacture. How
wever, the eq
quipment
nform in all respects
r
to high
h
standarrds of design
n, engineering and workm
manship and
d shall be
shall con
capable of performin
ng the requirred duties in a manner acceptable
a
to
o purchaser w
who will inte
erpret the
g of drawings and speciffications and
d shall be en
ntitled to reje
ect any workk or material which in
meaning
his judgm
ment is not in
n full accorda
ance herewitth.
1.4
The exte
ent of supplyy under the contract
c
inclu
udes all items shown in the drawingss, notwithstan
nding the
fact thatt such items may have been
b
omitted from the sp
pecification or schedules.. Similarly, th
he extent
of supplyy also includ
des all items mentioned in
n the specification and /o
or scheduless, notwithstan
nding the
fact thatt such items may have be
een omitted iin the drawin
ng.
1.5
The gen
neral terms and
a conditions, instruction
ns to tendere
er and other attachment rreferred to elsewhere
are mad
de part of the
t
tender specification.
s
. The equip
pment materials and woorks covered
d by this
specifica
ation are sub
bject to compliance to alll attachments referred to
o in the speccification. Th
he bidder
shall be responsible for and gove
erned by all rrequirements
s stipulated herein.
h
1.6
While alll efforts havve been made to make th

he specificattion requirem
ment complette & unambiiguous, it
shall be bidders responsibility to
o ask for misssing informa
ation, ensure completenesss of specific
cation, to
ut any contradictory / conflicting requi rement in diffferent sectio
ons of the sppecification and within
bring ou
a section itself to the
e notice of BHEL
B
and to seek any clarification on
n specificatioon requireme
ent in the
enclosed und
der Vol-III of the specifica
ation. In abse
ence of any such clarificaations, in cas
se of any
format e
contradictory require
ement, the more
m
stringe
ent requirement as per interpretation
i
n of BHEL/C
Customer
evail and sha
all be complie
ed by the bid
dder without any commerrcial implicattion on accou
unt of the
shall pre
same. F
Further in case
c
of any
y missing in
nformation in
n the speciffication not brought out by the
prospecctive bidders as part of prre-bid clarific ation, the sa
ame shall be furnished byy BHEL/ Cus
stomer as
en brought to
t their notic
ce either by tthe bidder or
o by BHEL/ customer thhemselves. However,
H
and whe
such requirements shall be bin
nding on the
e successful bidder with
hout any coommercial & delivery
implicatiion.
1.7
Deviatio
ons along witth cost of withdrawal (po
ositive or neg
gative), if any, should bee very clearly
y brought
out clausse by clause
e in the enclo
osed schedu le; otherwise
e, it will be prresumed thaat the vendor's offer is
strictly in
n line with NIT
N specificattion and therre is no deviiation. Cost of
o withdrawaal to be prov
vided in a
sealed e
envelope.
1.8
In case all above req

quirements are
a not comp
plied with, the
e offer may be
b considereed as incomp
plete and
ecome liable
e for rejection
n.
would be
1.9
Unless sspecified othe

erwise, all through the sp
pecification, the
t word con
ntractor shall have same meaning
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: A
REV
V NO: 00
as succcessful bidde
er/vendor and Customerr/Purchaser/E
Employer will mean BH EL and/or Customer
C
(RRVUN
NL: Rajastha
an Rajya Vid
dyut Utpada
an Nigam Lttd., Jaipur) including theeir consultan
nt (TATA
Consultiing Engineerrs Limited, Be
engaluru) ass interpreted by BHEL in the
t relevant context.
0
1.10
The equ
uipment cove
ered under this specifica
ation shall no
ot be dispatc
ched unless the same ha
ave been
finally inspected, acccepted and dispatch
d
relea
ase issued by
b BHEL/Cus
stomer.
1.11
BHELs//Customers representativ
ve shall be g
given full acc
cess to the shop
s
in whichh the equipm
ments are
being manufactured or tested an
nd all test reccords shall be
e made availlable to him.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: B
REV
V NO: 00

S
SECTION
NB
PROJE
ECT INFO
ORMATIO
ON

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
THIS IS A PART OF TECHNICAL SPECIFICATION PE-TS-392-163A-A001
SPEC NO.
TCE.5750A-H-500-001
TATA CONSULTING ENGINEERS LIMITED

RRVUNL, 2 x 660 MW, Super-Critical TPS, Stage-V,
Unit # 7 & 8 at Suratgarh, Rajasthan
VOLUME II
SECTION B
SHEET 1 OF 3
GENERAL PROJECT INFORMATION
1.0
Owner
Rajasthan Rajya Vidyut Utpadan

Nigam Ltd., Jaipur
2.0
Consulting Engineer
TATA Consulting Engineers Ltd.

73/1, St. Marks Road,
Bangalore 560 001
Tel : 080 6622 6000
Fax : 080 22274874
3.0
Location of the plant
Prabat Nagar, Suratgarh

Sriganganagar district, Rajasthan.
4.0
Latitude and longitude
Latitude : 29 deg. 10 min. N

Longitude : 74 deg.01 min. E
5.0
Elevation above mean sea level
186 m (approximate)
6.0
Climatic conditions
Temperatures : Monthly basis
6.1
Mean of daily max.

Mean of daily min.
6.2
32.8 deg.C (in the month of May)

17.6 deg.C (in the month of Jan)
Temperatures : Annual basis

Mean of daily max.
Mean of daily min.
32.3 deg.C
19.6 deg.C
Highest temperature recorded
50 deg.C
Lowest temperature recorded

Design Ambient Temperature for
Electrical Equipment design
(-) 2.8 deg.C

50 deg C
6.3
Relative humidity
Varies between 21% and 81%
6.4
Annual average rain fall
312 mm
6.5
7.0
Annual mean wind speed :

Wind load
4 km / hr.
ISSUE
R1
FORM NO. 329 R5
5
SPEC NO.
TCE.5750A-H-500-001

VOLUME II
SECTION B
SHEET 2 OF 3
Calculations for wind effect shall be in accordance with IS:875-1987(Part-3)

taking into account the following:
a) Basic wind speed = 47 m/sec
b) Factor K1 = 1.07
c) Category of terrain = Category 2
d) K3 as per IS 875
Seismic data (As per IS: 1893 latest issue)
8.0
a) Zone
Zone II
Designs & design coefficients shall be based on IS 1893:2002

Design condenser cooling water
inlet temperature
9.0
33 Deg C
Auxiliary power supply:

Auxiliary electrical equipment to be supplied against this specification shall be
suitable for operation on the following system:
a) For motors rated 160 kW and
below.
415V AC, 3-phase, 3-wire effectively

earthed.
b) For motors rated above 160 kW

and up to 1500 kW
6600V AC, 3-phase, 3-wire, 50 Hz, noneffectively earthed
c)
For motors rated above 1500kW
11000V AC, 3-phase, 3-wire, 50 Hz,

non-effectively earthed
d) For motor control centres
415V AC, 3-phase, 3/4-wire effectively

earthed.
e) DC motor starters, DC solenoids,

DC alarm control and protection
220 V DC, 2-wire unearthed
f)
110 V 1 phase, 50Hz, 2 wire AC supply.

The single phase 110V AC supply shall
be derived by VENDOR by providing
415V / 110 V Control transformers of
adequate rating with MCCB / MCB on
both the primary and secondary sides.
AC control & protective devices
g) Uninterrupted power supply
230 V, 1-phase, 50 Hz, 2-wire, AC

ISSUE
R1
FORM NO. 329 R5
6
SPEC NO.
TCE.5750A-H-500-001

VOLUME II
SECTION B
SHEET 3 OF 3
supply (For all instrumentation and

control system equipment and solenoid
valves)
g) Lighting fixtures and space heaters

h) Construction supply
240 V, 1 phase, 2 wire, 50Hz,solidly

earthed system
415 V, 3 phase, 4 wire, 50Hz AC
supply with neutral lead solidly earthed.
i) The above voltages may vary as follows :

All devices shall be suitable for continuous operation over the entire range of
voltage and frequency indicated below without any change in their
performance.
AC supply
Voltage variation 10%

Frequency variation 5%
DC supply
j) For instrument and control system
of steam generator and steam
turbine generator.
10.0
Combined voltage & frequency

variation 10%
Voltage variation +10% ,-15%
230 V 5% AC UPS, 1-phase, 50 Hz,
2-wire. The 24 V DC required for
control system shall be generated from
this UPS.
All the electrical equipment shall be designed for 50 C reference ambient

temperature.
11.0 LOCATION :
The proposed power project shall be located in the state of Rajasthan, in Shriganganagar
Distt. The proposed power project is located within 393 km from Jaipur 169 km from
Bikaner and 367 Km from Delhi.
Major road distances of the project site are as follows:
Between
Distance in KMs.
Project - Suratgarh Junction
31 km (Nearest Railhead)
Project - Jaipur (State Capital)
393 km
Project - Delhi
367 km
Project Jaipur
393 km (Nearest Airport in Rajasthan)
Amritsar
378 km (Nearest Airport)
Project Bikaner
169 km
ISSUE
R1
FORM NO. 329 R5
7
*CLARIFIED WATER ANALYSIS FOR DM PLANT

SL. NO.
Constituent
Unit
Value
1.
pH
8.5
2.
Color and Odor
3.
Oil and grease
mg/l
ND
4.
BOD
5.
COD
20
6.
Suspended solids
mg/l
<15
7.
Turbidity
NTU
<15
8.
Calcium hardness as CaCO3
mg/l
74
9.
Magnesium hardness as CaCO3
mg/l
52
10.
Sodium as Na
mg/l
61
11.
Potassium
mg/l
12.
Chloride as cl
mg/l
39
13.
Sulphate as So4
mg/l
48
14.
Sulphide
mg/l
15.
M- Alkalinity as CaCO3
mg/l
140
16.
P-Alkalinity as CaCO3
mg/l
Nil
17.
Nitrates as No3
mg/l
17
18.
Nitrite
mg/l
Nil
19.
Silica as SiO2 Dissolved
mg/l
15
20.
Silica as SiO2 Colloidal
mg/l
0.6
21.
Iron as Fe-dissolved
mg/l
0.5
22.
Iron as Fe-suspended
mg/l
0.1
23.
Total dissolved solids
mg/l
393
24.
Conductivity at 25 degree C
-mho/cm
500
25.
Dissolved Oxygen as O2
mg/l
5.0
26.
Carbon dioxide free
mg/l
*Clarified Water Analysis should take care of the following dosing in Pre-Treatment Plant:
a) Alum Dosing 20ppm
b) Lime Dosing 30ppm
c) PE Dosing 1ppm
Above water analysis modified by the above chemical dosage rate + 10% margin, shall be considered
as basis for the design of DM Plant.
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C
REV
V NO: 00

S
SECTION
NC
SPEC
CIFIC TE
ECHNICA
AL REQUIREMEN
NT

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00

SECT
TION C1
C
SPECIFIC TECHN
NICAL R
REQUIRE
EMENT- MECHAN
M
NICAL

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
10
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
1.0
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
GENERA
RAL
M PLANT with
h regeneratio
on system a nd associate
ed accessories shall connform to the technical
The DM
ation for 2X
X660 MW Su
uratgarh Su
uper Critica
al TPS, Stag
ge-V Unit 7 & 8 at Su
uratgarh,
specifica
Rajasth
han.
2.0
Y (MECHAN
NICAL)
SCOPE OF SUPPLY
ng are in bidd
ders scope of
o supply:
Followin
ork of this package inclu
udes all equ
uipment and
d accessoriees. Please also
a
refer
Broad sscope of wo
Mechanical data sh
heet, P&ID and
a
the resspective section of Civil,Electrical aand C&I sec
ctions for
respectivve scopes.
1)
X70%) DM Plant Supp

ply Pumps along with motors, pipping, valves,, fittings,
Thrree nos (3X
insttrumentation
n etc.
2)
Thrree nos (3X

X70%) Dual Media Filterrs along with
h filter media
a, integral ppipe works, internals,
i
valvves, fittings, instrumentation and acccessories ass
sociated with
h the same.
3)
Tw
wo nos (2X10
00%) Air Blow
wers for Dua
al Media Filters along with suction fillter, silencerr, motors,
pip
ping, valves, fittings,
f
instru
umentation a
and accessories associatted with the ssame.
4)
ated Carbon Filters along with media, integral ppipe works, internals,
i
Thrree nos (3X70%) Activa
valvves, fittings, instrumentation and acccessories ass
sociated with
h the same.
5)
One no Filtered
d Water Tan
nk along with
h piping, valv
ves, fittings, instrumentaation and acc
cessories
h the same.
asssociated with
6)
Tw
wo nos (2X10
00%) DMF & ACF Backkwash Pump
ps along with
h motors, pi ping, valves
s, fittings,
insttrumentation
n and access
sories associ ated with the
e same.
7)
Thrree nos (3X7

70%) Strong Acid Cation
n Exchangers
s along with ion exchangge resin, inte
egral pipe
works, internalss, resin trap, valves, fittin
ngs, instrume
entation, and
d accessoriess associated
d with the
me.
sam
8)
Thrree nos (3X7

70%) Degass
ser Towers a
along with internals. integ
gral pipe worrks, internals
s, valves,
fittings, instrumentation and
d accessoriess associated with the sam
me
9)
S
Tan
nk along with
h piping, valv
ves, fittings, instrumenta
ation and
One no Degasssed Water Storage
h the same.
acccessories asssociated with
10) Sixx nos Degasssed Air Blo

owers (2X10
00% for each degasser tower) alonng with suction filter,
sile
encer, motorrs, piping, va
alves, fitting s, instrumen
ntation and accessories associated with the
sam
me.
11) Thrree nos (3X
X70%) Degassed Wate
er Pumps along
a
with motors, pipping, valves,, fittings,
insttrumentation
n and access
e same.
12) Thrree nos (3X70%) Weak Base Anion
n Exchangerrs along with
h ion exchannge resin, re
esin trap,
inte
egral pipe works,
w
interna
als, valves, ffittings, instrumentation and accessoories associa
ated with
the
e same.
13) Thrree nos (3X7
70%) Strong
g Bases Anio
on Exchange
ers along witth ion excha nge resin, re
esin trap,
inte
egral pipe works,
w
interna
als, valves, ffittings, instrumentation and accessoories associa
ated with
the
e same.
14) Thrree nos (3X7
70%) Mixed Bed Exchan
change resinn, resin trap, integral
ngers along with ion exc
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
11
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
pip
pe works, inte
ernals, valves
s, fittings, insstrumentation accessorie
es associatedd with the sa
ame.
wo nos (2X10
00%) Air Blow
wers for Mixxed Bed Exch
hangers (2 numbers)
n
aloong with sucttion filter,
15) Tw
sile
encer, motorrs, piping, va
alves, fitting s, instrumen
ntation and accessories associated with the
sam
me.
16) Tw
wo nos (2X
X100%) Acid
d Unloading
g Pump alo
ong with motors,
m
pipi ng, valves, fittings,
insttrumentation
n and access
e same.
17) Tw
wo nos (2X100%) Alka
ali Unloadin g Pump along with motors,
m
pipiing, valves, fittings,
insttrumentation
n and access
e same.
18) Tw
wo nos of hosse stations for
f unloading
g of acid. Th
he hose station shall havve two nos of
o 80 NB
heliflex hoses.
wo nos of hosse stations fo
or unloading of caustic. The
T hose sta
ation shall haave two nos of 50 NB
19) Tw
heliflex hoses.
wo nos Bulk Acid Stora
age Tanks a
along with piping, valve
es, fittings, instrumenta
ation and
20) Tw
h the same.
21) Tw
wo nos Bulk Alkali Stora
age Tanks along with piping, valves, fittings, instrumenta
ation and
h the same.
22) Tw
wo nos (2X10
00%) Alkali Transfer
T
cum
m Recirculation Pumps along
a
with m
motors, piping
g, valves,
fittings, instrumentation and
d accessoriess associated with the sam
me.
nos Acid Mea
asuring Tank
ks along with
h piping, valv
ves, fittings, instrumentaation and acc
cessories
23) 5 n
asssociated with
h the same.
24) 5 n
nos Alkali Measuring
M
Tanks along with agitato
ors, agitator motors, pipping, valves, fittings,
insttrumentation
n and access
e same.
25) One no Alkali Preparation Tanks alon
ng with agita
ator, agitatorr motors, pipping, valves, fittings,
n and access
e same.
insttrumentation
26) Sixx nos. (6 numbers)
n
Acid
A
Dosing Pumps allong with motors,
m
insttrumentation
n etc.
27) Sixx nos. (6 numbers)
n
Alkali
A
Dosing
g Pumps along
a
with motors,
m
insttrumentation
n and access
e same.
28) Acttivated Carb
bon Filter for Alkali (1 n
number) along with filter media, pipping, valves, fittings,
insttrumentation
n and access
e same.
29) Hott Water Tan
nk (1 numbe
er) along wiith heaters, piping, valv
ves, fittings, instrumenta
ation and
h the same.
30) Neutralization Pit (RCC- By BHEL). However in
nstrumentation, piping, valves, fittings and
h the same sshall be in bid
dders scope
e.
31) Tw
wo nos (2X10
00%) Air Blo
owers for Ne
eutralization Pit along witth suction fillter, silencer, motors,
pip
ping, valves, fittings,
f
instru
umentation a
and accessories associatted with the ssame.
ur nos Efflue
ent Disposall Pumps alo
otors, piping, valves, fittiings, instrum
mentation
32) Fou
ong with mo
and
d accessorie
es associated
d with the sam
me.
33) Tw
wo nos (2X1
100%) DM Regeneratio
on Pumps along
a
with motors, pipping, valves,, fittings,
insttrumentation
n and access
e same.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
12
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
34) Thrree nos (3X7

70%) UF Feed Pumps a
along with motors, piping
g, valves, fitttings, instrum
mentation
and
d accessorie
es associated
d with the sam
me.
35) Tw
wo nos (2X100%) UF Fast Flush
h Pumps along with motors,
m
insttrumentation
n and access
e same.
36) Tw
wo nos (2X
X100%) UF Backwash Pumps alo
ong with motors,
m
pipi ng, valves, fittings,
insttrumentation
n and access
e same.
37) Ultrra Filtration Units
U
(3X70%
%) along wit h piping, valves, fittings, instrumentaation and acc
cessories
asssociated with
h the same.
38) One no UF Feed Tank along
a
with p
piping, valve
es, fittings, instrumentatiion and acc
cessories
h the same.
asssociated with
39) All vessels as per
p P&ID& Data
D
Sheet-A
A complete with
w inlet and
d outlet connnections, bed
d support
m under drain system, inlets water diistributors, all fittings and
d appurtenannces etc. as specified
cum
and
d as required
d.
40) Extternal resin/m
media traps at the outle
et of each of
o the vessels, designed for in place
e manual
bacckwashing.
41) All tanks as pe
er P&ID& Data Sheet-A ccomplete witth inlet and outlet
o
conneections, drain
n system,
ets water con
nnection, all fittings
f
and a
appurtenance
es etc. as sp
pecified and aas required.
inle
42) Bid
dder to note that
t
the equipment, valv es, instrume
ents indicated
d in the P&ID
D (PE-DG-39
92-163AA00
01) attached
d in the tech
hnical speciffication are minimum an
nd are in biddders scope
e. During
dettailed engine
eering, bidder to furnish ccomplete and
d detailed sc
cheme in all respects including all
valvves, equipm
ments etc. for
f smooth, safe, efficie
ent and trou
uble free opperation of the
t
plant
me
eeting the spe
ecification re
equirement a
and also cons
sidering the applicable
a
sttatutory requirement.
43) Necessary pipin
ng, fitting, va
alves, drains,, vents, sampling etc. req
quired for thee complete DM
D Plant.
pe racks shalll be provided
d by BHEL w
wherever ava
ailable, wherever pipe raccks are not available,
a
Pip
pip
pe shall be la
aid on pedes
stal to be pro
ovided by BH
HEL. However all auxiliaary steel structure (Ub
channe
els etc) for fixxing pipes on
n pedestal or racks shall bbe in bidders
s scope.
clamps, nuts, bolts,
er, nuts and b
bolts, and fla
anges and ma
atching counnter flanges wherever
w
44) All insert platess, rung ladde
plicable.
app
45) All necessary valves
v
and fitttings for the installations
s with the actuators necesssary for their remote
eration.
ope
46) Em
mbedment pla
ates with lugs
s shall also b
be provided by bidder as per system requirementt.
47) All channels & brackets, mounting
m
plattes as required for mounting of mottors, pumps, stirrers,
nk etc shall be in bidders scope.
tan
48) Sta
art-up and co
ommissioning
g spares as rrequired.
49) Ma
andatory spares as per Annexure-V e
enclosed in Section
S
C1
50) All special tools necessary
y for proper maintenance
e or adjustm
ment of the eequipment packed
p
in
perrmanent box.
51) All necessary structural
s
ste
eel for pipe ssupporting sttructure, plattforms, walkw
ways / pathw
ways and
m
plant
p
and eq
quipment, me
echanical se
ervices and ppipe work as
ssociated
acccess stairs, mechanical
with
h DM Plant.
52) Fin
nish paints fo
or touch up pa
ainting of eq uipments aftter erection at
a site in sealled container.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
13
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
53) All Motorized va

alves with inttegral starterr as per requ
uirement and as indicatedd in the P&ID
D.
e till PG Test.
54) Inittial charge off all lubricantts and grease
55) All pipes, fitting
gs etc requirred for hand
d railing, plattforms, and ladders sha ll be in the scope of
bidder.
s
be of 32 mm nom
minal bore MS
M pipes (m
medium classs) as per IS: 1161
56) All handrails shall
ng 750 gm/s
sq. m of zincc. Hand railin
ng shall be a two-rail sysstem with the top rail
galvanised usin
00 mm abovve the walkw
way surface
e and the in
ntermediate rail 450 mm
m below the top rail.
100
Handrail post spacing
s
shall be limited to
o 1500 mm as far as pos
ssible but caan be proporrtioned to
e length of th
he opening. In such a casse spacing shall
s
not exceed 1850 m m centre to centre of
the
possts. Hand railing shall be
e shop fabriccated for spe
ecific locations and fieldd welded or bolted to
the
e erected stru
uctural steel. Railings sha
all be provide
ed with 100 mm
m wide andd
57) 8 m
mm thick MS strip at bottom as toe gu
uard all alon
ng the length of railing in horizontal plane. For
RC
CC stairs, ha
and railing with
w
20 mm
m square MS
S bar balusttrade with ssuitable MS flat and
Alu
uminium / Teakwood handrail shall be
e provided, unless
u
specifically mentiooned otherwis
se.
58) Mo
onitoring gadgets, instrum
ments and eq
quipments re
equired for co
ommissioninng & mainten
nance (till
PG
G test and pla
ant handoverr).
59) Insstrument hook up materia
al shall be in bidders scope.
der (not rung
gs) for appro
oaching the top of tanks
s, valves for All steel ins
serts with
60) Perrmanent ladd
lugs, plates, bolts, nuts, sleeves,
s
edg
ge angles an
nd all other embedding componentts etc as
quired to gro
out in civil works
w
and to
o support/hold the equipments beingg supplied under this
req
spe
ecification for opening/ma
aintenance p
purpose.
61) Wrapping, coatting and prottection of the
e entire burie
ed pipe shall be as per IS
S 10221 or AWWA
A
C
3-93.
203
62) Anyy item/work either supply
y of equipme
ent or erection material which have not been sp
pecifically
me
entioned in but
b are neces
ssary to com
mplete the wo
oks for troub
ble free and efficient ope
eration of
the
e plant shall be deemed to be includ
ded within th
he scope of this specificaation and sh
hall be in
bidders scope without any commercial, technical an
nd delivery im
mplication to BHEL.
a also inclu
uded in scop
pe of supply as
a specified in other partt of the speciification.
63) All other items are
bow, tee, pip
pe fittings etcc. required fo
or erection of
o the compllete system including
64) All required elb
ping shall be in bidders scope. Bidd
der to provid
de the detailed BOQ shaall be derive
ed during
pip
t consider 2
20% margin over and ab
bove the BO
OQ requirement of all
dettail engineerring. Bidder to
the
e fittings.
65) Bid
dder shall perform
p
the guarantee parameters
s as per specification requirement to the
sattisfaction of owner.
o
The exact
e
modalitties of verify
ying guarante
ee for the pa rameters ind
dicated in
the
e specification shall be fin
nally as agre
eed with the owner
o
during
g detailed enngineering & mutually
agrreed.
66) Saffety equipme
ents as per Data
D
Sheet-A
A.
67) Inittial fill of resin
ns, media an
nd degasser tower packin
ng for all vessels as requuired.
68) One no. Electric Hoist with
h Monorail off minimum 1000
1
kg capa
acity. Capaccity of hoists shall be
dering a minimum marg
gin of 10% over the maximum
m
weeight of the heaviest
selected consid
uipment / com
mponent to be
b handled b
by the Hoist.
equ
A.
PIPING
All the p
piping as liste
ed below sha
all be in bidd
ders scope. The below in
ndicated pipees shall be designed,
d
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
14
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
supplied
d, erected, llaid and tes
sted by the bidder. Elb
bows, tees, flanges Hanngers and supports,
s
embedm
ment plates with
w lugs etc
c required fo
or the below
w given pipin
ng shall alsoo be provide
ed by the
bidder.
1)
d outlet pipe
es for each vessel, pum
mps, other eq
quipments, etc.
e with pipee connection
ns to the
Inlet and
respectivve vessels/e
equipments.
2)
Minimum
m 150 NB of 300 meter piping from
m N.Pit to Blo
ow down Ta
ank confirminng to HDPE IS 4984
PN10 sh
hall be in bidders scope.
3)
All piping
g within the DM
D Plant shall be in bidd
ders scope.
4)
Service water piping

g, instrumentt air piping, sservice air piiping, potable
e water pipinng, etc. as applicable
he Terminal Points shall be in bidders scope.
as per th
5)
All SS P
Pipes shall be
e of minimum
m Schedule 1
10S.
6)
DM Watter piping uptto DM Waterr storage tan

nk shall be in bidders sco
ope.
In additio
on, any additional piping and associa
ated accesso
ories required
d to completee the system
m shall be
in bidders scope.
3.0
Y (ELECTRICAL)
SCOPE OF SUPPLY
ecification a nd details indicated in Section C22 (Specific Technical
T
Complette electrical as per spe
Requirement Electriccal) and D2 (General
(
Tecchnical Requ
uirement Elec
ctrical).
4.0
Y (C&I)
SCOPE OF SUPPLY
dicated in Section
S
C3 (Specific Technical
T
Complette C&I as per specification and details ind
Requirement C&I) an
nd D3 (Gene
eral Technica
al Requireme
ent C&I).
5.0
SCOPE OF SUPPLY
Y (CIVIL)
Total Ciivil is in BHELs Scope of work, ho
owever comp
plete grouting for equipm
ment, fixing and any
concreting inside the
e vessels and
d lining shall be in bidderrs scope.
Also dettailed Civil Input
I
drawin
ng shall be p
provided by bidder. Suc
ccessful biddder shall furnish civil
assignm
ment drawing
gs. The corresponding C
CIVIL drawin
ng prepared by BHEL / C
CIVIL agenc
cy, based
on civil a
assignment drawing
d
of biidder will be furnished to the success
sful bidder forr concurrenc
ce
CPU reg
generation syystem and DM
D Plant sha ll be kept under a commo
on shed.
6.0
CES
SCOPE OF SERVIC
ders scope also
a
includes
s following se
ervices for sc
cope under this specificaation:
The bidd
(i)
n and Commiissioning, un
nloading, storrage and han
ndling at site.
Erection
(ii))
Arrangement of all instruments

s, reagents, monitoring gadgets for monitoring,, pre-commissioning,
oning and PG
G test.
carrying out trial run & commissio
(iii)
ments required for mainten

nance.
Monitoring gadgets, instruments and equipm
(iv
v)
Complette grouting fo
or equipment, fixing and any concreting inside the
e vessels andd lining.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
15
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
(v))
All perso
onnel require
ed during ma
aintenance, C
Commissioning and PG test.
(vi)
Trial run
n for requisite
e period.
(vii)
Performance guaran
ntee testing.
(viii)
g shall be as specified in ANNEXURE

E- IV of this technical
t
spe
ecification. H
However any variation
Painting
ainting sched
dule as finallly approved by BHEL & Customer shall
s
be takeen care by th
he bidder
in the pa
without a
any commerrcial & delivery implication
n to BHEL & Customer.
x)
(ix
Final tou
uch up paint at site.
7.0
TS
TERMIINAL POINT
(i)
B Instrument air supply at

a 5 to 7 kg//cm2 (g) At
A 5 meter distance from
m the DM Pla
ant area.
25 NB
Howevver distributio
on and piping
g inside DM Plant area shall be in bid
dders scope..
(ii)
2 (g) - At 5 meter
m
distanc
ce from DM Plant area. However
25 NB Service air supply at 5 to 7 kg/cm2
ution and pip
ping inside DM Plant area
a shall be in bidders sco
ope. If servicee air required
d is more
distribu
than p
provided by BHEL,
B
bidde
er to provide necessary compressors
c
s/blowers annd associated
d valves,
piping,, fittings, flanges, instrum
ments etc. to m
meet the sys
stem requirem
ment.
(iii)
e water con
nnection (50 NB connecctions) at 5 meter distan
nce from DM
M Plant area
a. Piping
Service
inside DM Plant are
ea for mentio
oned service
es will be in bidders
b
scop
pe.
(iv)
ng water (or potable watter) of 25 N B connections - At 5 meter distancee from the DM

D Plant
Drinkin
area. H
However disttribution and piping inside
e DM Plant area
a
shall be in bidders sscope.
(v)
DM Wa
ater upto DM
M Water stora
age tank.
8.0
SIONS
EXCLUS
8.1
All civil works includ

ding foundattion of equip
pment. Howe
ever complete grouting ffor equipme
ent, fixing
sels and linin
ng shall be in the scope
e of the bid der. Also civ
vil works
and anyy concreting inside vess
including
g operating / maintenanc
ce platforms and intercon
nnection platfforms (if anyy) with ladderrs / stairs
& handrrails, structurral supports and hangerrs for pipes / cables / du
ucts, crane ra
rails, all emb
bedments
and inse
erts with lug
gs including anchor fassteners, bolts etc., dressing of founndations, gro
outing of
pockets and underp
pinning of ba
ase plates fo
or equipmen
nt / structures and fixing supports, fiilling and
g of openingss in walls, floors, cladding
g, roof and trrenches shall be in bidde rs scope.
finishing
8.2
Instrume
ent air & servvice air up to
o terminal poiints.
8.3
All chem
micals.
8.4
Air cond
ditioning, ven
ntilation & fire
e fighting faciilities.
8.5
Other exxclusions are

e mentioned in the electriical & C&I pa
arts of this sp
pecification.
8.6
Drinking
g water (or po
otable water)), service wa
ater up to term
minal points.
9.0
QP AND
D SUB VEND
DOR APPRO
OVAL
9.1
ailed QP, ins

spection che cklist, certific
cate of confo
ormance etcc. for each eq
quipment
Requirement of deta
b-vendor shall be finalized
d during deta
ailed engineering stage; decision of B
BHEL/custom
mer shall
and sub
be bindiing on vend
dor in this re
egard. Any cchanges/add
ditional tests insisted uppon by Owne
er during
approva
al of QAPs shall
s
be acc
cepted by bid
dder withoutt any comme
ercial and d elivery implication to
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
16
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
BHEL/C
Customer. Bid
dder shall submit the qu
uality plans in BHEL forrmat during detailed eng
gineering
stage. B
Bidder to notte further tha
at during dettailed engine
eering all the
e QAPs/cheeck lists etc. shall be
submitte
ed to Custo
omer/BHEL for approva
al. All inspe
ection & tes
sting etc. sshall be carrried out
accordin
ngly.
9.2
10.0
The sub
b vendor list enclosed
e
AN
NNEXURE-II is indicative
e only and is subject to aapproval / acc
ceptance
by custo
omer (RRUV
VNL). Bidder to propose his sub vendor list with back up doccuments (ex
xperience
list, end user certificcate as appliicable) etc. T
The same sh
hall subject to
t BHEL andd Customer approval
neering stage
e without anyy technical, commercial
c
& delivery im
mplication to BHEL.
during detailed engin
UIDATED DAMAGES
D
(LD)
TECHNIICAL EVALUATION AND LIQU
CONSUMPTION 33%
3
HCl perr annum AN D 48% NaOH per annum
m)
CRIT
TERIA
(CH
HEMICAL
BIDDER T
TO CONSIDER
R 365 REGENE
ERATION PER
R ANNUM FOR
R SAC, WBA & SBA AND 997 REGENERA
ATION PER
ANNUM F
FOR MB.
est chemicall consumptio

on (33% HCl per annum and
a 48% NaOH per annuum) guarante
eed by
The lowe
any Bidd
der would forrm the basis.
erential chem
mical consum
mption (33% HCl per annum and 48%
% NaOH per aannum) will be
b
The diffe
evaluate
ed as per dettails and eva
aluation facto
ors given belo
ow.
aranteed chemical consum
mption (33%
% HCl per ann
num and 48%
% NaOH perr annum) for Bidders
Let, gua
A, B and
d C as:
A: AH for 33%
% HCl per an
nnum and AN
N for 48% Na
aOH per ann
num
Bidder A
Bidder B
B: BH for 33%
% HCl per an
nnum and BN
N for 48% Na
aOH per ann
num
Bidder C
C: CH for 33%
% HCl per an
nnum and CN
N for 48% NaOH per ann
num
mical consu
umption (33%
% HCl per annum and 48%
4
NaOH p
per annum)
Evaluation for chem
he lowest as base and co
ompute the d
differential.
Select th
per annum consumption
e 1: If Bidderr A is lowest in 33% HCl p
c
and 48% NaaOH per ann
num
Example
consumption.
e 1):
Evaluation (Example
Loading on Bidder B = (BH-AH) X Evaluation
n factor for 33
3% HCl per annum
a
consuumption + (B
BN-AN)
ation factor for
f 48% NaO
OH per annum
m consumption
X Evalua
n factor for 33% HCl per annum conssumption + (C
CN-AN)
Loading on Bidder C = (CH-AH) X Evaluation
ation factor for
f 48% NaO
OH per annum
m consumption
X Evalua
per annum consumption
and Bidder B is lowest in
e 2: If Bidderr A is lowest in 33% HCl p
c
n 48%
Example
NaOH p
per annum co
onsumption.
e 2):
Evaluation (Example
n factor for 48
8% NaOH pe
er annum coonsumption
Loading on Bidder A = (AN-BN) X Evaluation
n factor for 33
3% HCl per annum
a
consuumption
Loading on Bidder B = (BH-AH) X Evaluation
n factor for 33% HCl per annum conssumption + (C
CN-BN)
Loading on Bidder C = (CH-AH) X Evaluation
ation factor for
f 48% NaO
OH per annum
m consumption
X Evalua
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
17
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
EVALUA
ATION FACT
TOR
a
of 33
3% HCl Evalu
uation Factorr is Rs. 0.0544 Million.
For everry Tonne diffferential per annum
a
of 48
8% NaOH Ev
valuation Fac
ctor is Rs. 0.55 Million.
ATED DAMA
AGES (LD) FACTOR
F
LIQUIDA
a
of 33
3% HCl LD Factor
F
is Rs 0.054
0
Million
a
of 48
8% NaOH LD
D Factor is Rs 0.5 Million
uaranteed chemical
c
con
nsumption (33% HCl pe
er annum an
nd 48% NaO
OH per
Bidder tto submit gu
annum)) in Annexurre I (as given
n in VOL. III ) in a sealed
d envelope.
11.0
0
DESIGN
N/ CONSTRU
UCTION
quirements of
o Section C & D the following shall also be com
mplied under scope of
In addition to the req
this speccification.
e
herrein in this se
ection for bid
dders complia
ance.
The P&I diagram is enclosed
nstruction sp
pecified in da
ata sheet-A are minimum requiremeents and ma
aterial of
The material of con
er componen
nts not speciified shall be
e similarly se
elected by thee bidder for intended
construcction for othe
duty wh
hich shall be
e subject to BHEL / Cu
ustomer app
proval during
g detail engiineering with
hout any
commerrcial & delivery implication
n to BHEL.
12.0
0
DRAWIN
NG/DOCUMENTS REQU
UIREMENT
After aw
ward of LOI, following
f
min
nimum drawiing/documen
nts shall be submitted
s
byy the bidder for
f BHEL
and Cusstomer appro
oval. Howeve
er any additio
onal drawing
g/document ifi found neceessary for co
ompletion
of the e
engineering, the same shall be su
ubmitted by bidder with
hout any co mmercial & delivery
implicatiion to BHEL.
Procedure, please
p
refer Annexure-IIII. The bidde
er has to
For the Drawings/Documents Submission P
d
ument along with the com
mpliance she
eet indicatingg enumerate
e reply to
submit tthe revised drawing/docu
all BHEL
L and custom
mer commen
nts or observvations. With
hout complia
ance sheet thhe submissio
on of the
drawingss/documentss will not be considered and the delay on this account
a
will bbe solely on bidders
side onlly. Bidder to
o comply witth the obserrvations of the
t
BHEL and CUSTOM
MER withoutt price &
delivery implication.
o note that the
t drawings
s to be subm
mitted by bidd
der in the ev
vent of awardd of contractt shall be
Bidder to
as per th
he below givven drawing/document lisst. Bidder to note that an
ny additional drawings/do
ocuments
requirem
ment during detailed engineering
e
p
by bidder witthout any technical,
t
shall be provided
commerrcial and delivery implica
ations to BH
HEL. Bidder confirmed drawings subbmission schedule as
follows:
wing/docume
ents submis
ssion schedu
ule: First su
ubmission off basic draw
wings/ docu
uments
a. Draw
(Pro
ocess Design
n & Sizing Calculation,
C
R
Resin Data Sheet
S
and P&
&ID shall be within 4 we
eeks from
the date of LOI and Operation & Cont rol Philosophy along with Control S
System Conffiguration
gram, and Eq
quipment Lay
yout within 6 weeks from
m the date of LOI.)
Diag
b. Every revised su
ubmission inc
corporating ccomments within 7 worrking days.
c.
BHE
al within 10 days
EL shall provvide observattion / approva
d
from the date of doccument subm
mission.
der further confirmed tha

at drawings submitted sh
hall be comp
plete in all rrespects with
h revised
d. Bidd
draw
wing submitte
ed incorpora
ating all comm
ments. Any incomplete drawing subm
mitted shall be treated
as n
non-submisssion with delays attributa
able to bidde
ers account. . Engineeriring meeting shall be
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
18
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
held
d fort nightlyy, for which the bidder sshall depute
e his concerned engineeer along with project
man
nager to BHE
EL PEM office or at custo
omer office. The
T meeting can also be held at site.
ocuments to be submitted
d after award
d of contract::List and schedule off drawings/do
S.No.
D
ocument
Drawing/Do
N
No.
P
PE-V2-392-1
163A-A001
P
PE-V2-392-1
163A-A002
P
PE-V2-392-1
163A-A003
P
PE-V2-392-1
163A-A004
P
PE-V2-392-1
163A-A005
P
PE-V2-392-1
163A-A006
7
8
9
10
P
PE-V2-392-1
163A-A007
P
PE-V2-392-1
163A-A008
P
PE-V2-392-1
163A-A009
P
PE-V2-392-1
163A-A010
11
P
PE-V2-392-1
163A-A011
12
P
PE-V2-392-1
163A-A012
13
14
P
PE-V2-392-1
163A-A013
P
PE-V2-392-1
163A-A014
15
P
PE-V2-392-1
163A-A015
16
17
18
19
P
PE-V2-392-1
163A-A016
P
PE-V2-392-1
163A-A017
P
PE-V2-392-1
163A-A018
P
PE-V2-392-1
163A-A019
20
P
PE-V2-392-1
163A-A020
21
22
23
24
25
P
PE-V2-392-1
163A-A021
P
PE-V2-392-1
163A-A022
P
PE-V2-392-1
163A-A023
P
PE-V2-392-1
163A-A024
P
PE-V2-392-1
163A-A025
26
P
PE-V2-392-1
163A-A026
27
P
PE-V2-392-1
163A-A027
28
P
PE-V2-392-1
163A-A028
29
P
PE-V2-392-1
163A-A029
30
P
PE-V2-392-1
163A-A030
Document Title
Drawing/D
P&I DIAGR
RAM FOR DM
M PLANT
EQUPMEN
NT LAYOUT OF DM PLA
ANT ALONG
G
WITH MEC
CHANICAL GA
G OF DM PLANT
P
BUILDING
PROCESS
S DESIGN AN
ND SIZING
CALCULAT
TIONS , RES
SIN DATA SHEET,
VESSEL T
THICKNESS AND PRESS
SURE DROP
P
CALCULAT
TIONS FOR DM PLANT
SUB-VEND
DOR LIST
OPERATIO
ON & CONTR
ROL PHILOS
SOPHY OF
DM PLANT
T ALONG WITH CONTROL SYSTEM
M
CONFIGUR
AGRAM
RATION DIA
CIVIL ASS
SIGNMENT DRAWING
D
FO
OR DM
PLANT
ELECTRIC
CAL LOAD DATA
D
PIPING LA
AYOUT OF DM
D PLANT
TECHNICA
AL DATA SH
HEET FOR VALVES
V
QAP FOR VALVES
TECHNICA
AL DATA SH
HEET OF HO
ORIZONTAL /
VERTICAL
L CENTRIFU
UGAL PUMPS
S
TECHNICA
AL DATA SH
HEET FOR METERING
M
PUMPS
TECHNICA
AL DATA SH
HEET OF BLO
OWERS
DATA SHE
EET FOR MO
OTOR
QAP FOR HORIZONTA
AL / VERTIC
CAL
UGALPUMPS
S WITH MOT
TOR
CENTRIFU
QAP FOR METERING PUMPS WIT
TH MOTOR
QAP FOR BLOWERS WITH MOTO
OR
DATA SHE
EET OF INST
TRUMENTS
DATA SHE
EET OF ANA
ALYSER
GA DRAW
WING OF ATM
MOSPHERIC
C TANKS OF
F
DM PLANT
T
QAP FOR ATMOSPHE
ERIC TANKS
S
GA DRAW
WING OF PRE
ESSURE VE
ESSELS
QAP FOR PRESSURE
E VESSELS
INSTRUME
ENT SCHED
DULE
VALVE SC
CHEDULE
DATASHE T OF RESIN
N TRAP, CAR
RBON
F
TRAP, ACF
DATA SHE
EET FOR HE
EATER
PLC DOCU
UMENTS FO
OR DM PLAN
NT--GA &
WIRING D ETAILS OF PLC PANEL
L, I/O LIST,
MIC DIAGRAM
M
BOM, MIM
QAP FOR PLC
ARCHITEC
CTURAL DR
RAWING OF DM PLANT
BUILDING
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
19
No. of weeks
w
for
drawing/document
sion after
submiss
placing LOI/PO
4
6
4
6
8
8
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
12
12
12
12
12
12
12
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
31
P
PE-V2-392-1
163A-A031
32
P
PE-V2-392-1
163A-A032
33
P
PE-V2-392-1
163A-A033
34
P
PE-V2-392-1
163A-A034
35
P
PE-V2-392-1
163A-A035
36
37
38
39
40
P
PE-V2-392-1
163A-A036
P
PE-V2-392-1
163A-A037
P
PE-V2-392-1
163A-A038
P
PE-V2-392-1
163A-A039
P
PE-V2-392-1
163A-A040
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
CIVIL DBR
R OF DM PLA
ANT BUILDING AND NPIT
GA AND R
RCC DETAIL OF FOUND
DATION
LEVEL, DR
RAIN TRENC
CH AND FLO
OOR
DETAILS,B
BEAM, PLINTH BEAM, ROOF
R
SLAB
AND N-PIT
T OF DM PLA
ANT
GA AND R
RCC DETAIL OF EQUIPM
MENT
FOUNDAT
TIONS INSID
DE AND OUT
TSIDE OF
BUILDING
CABLE TR
RAY/TRENCH
H & CONDUIT
ROUTING DIAGRAM AND
A
EARTH
HING
OF DM PLAN
NT
LAYOUT O
QAP / ICL OF DM PLA
ANT (FOR BA
ALANCE OF
ITEMS)
CABLE SC
CHEDULE OF DM PLANT
T
ERECTION
N PROCEDU
URE
PG test pro
ocedure for DM PLANT
ENGINEER
RING BOQ
O&M MAN
NUAL FOR DM
D PLANT
12
12
12
12
12
16
16
20
20
24
on of above following documents sha

all also be su
ubmitted by bidder
b
duringg detail engin
neering:In additio
x
Handling & Sttorage instruc
ctions
a.
b.
NOTE:Succe
essful bidder shall furnish
h detailed errection manu
ual for each of the equippment supplie
ed under
this contract at le
east 3 months before the schedulled erection of the conncerned equ
uipment /
onent or alon
ng with supply of concern
ned equipme
ent / compone
ent whicheveer is earlier
compo
ment approva
al by custom
mer under Ap
pproval categ
gory or inform
mation categgory shall nott absolve
Docum
the ve
endor of theirr contractuall obligations of completin
ng the work as per spec ification requ
uirement.
Any d
deviation from
m specified requirementt shall be re
eported by th
he vendor inn writing and
d require
written
n approval. Unless
U
any change
c
in sp
pecified requ
uirement has been brougght out by the vendor
during
g detail engineering in writing whille submitting
g the docum
ment to cusstomer for approval,
a
approvved docume
ent (with imp
plicit deviatio
on) will not be cited as
s a reason ffor not following the
speciffication requirement.
esponding d rawing, any delay in

c. In case vendor submits revised drawing aftter approval of the corre
ed drawing shall
s
be to vvendors acc
count and sh
hall not be uused as a re
eason for
approvval of revise
extenssion in contra
act completio
on.
(a)
at drawings//documents submission
n shall be through weeb based Document
D
Bidder to note tha
ement System
m. Bidder wo
ould be provi ded access to the DMS for
f drawings/
s/documents approval
Manage
and ade
equate trainiing for the same.
s
Detaiiled methodo
ology would be finalizedd during the
e kick-off
meeting. Bidder to ensure following at their e
end.
x
x
x
x
Internet explorer version Minimum Internet Exp

plorer 7
Internet speed 2 mbps
s (Minimum p
preferred)
Pop ups from
m our external DMS IP (1
124.124.36.1
198) should not
n be blockeed
Vendors internal proxy setting
s
shoul d not block DMS
D
applications link
o (http
p://124.124.3
36.198/wrencchwebaccess
s/login.aspx))
DMS user manuals

m
to be used byy BHEL PEM
M vendors for uploadinng, viewing, revising,
commenting
g and trackin
ng documentts on PEMs DMS have been uploadded on PEM
M internet
website (ww
ww.bhelpem.c
com) under tthe Vendor session.
s
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
20
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
For quick acccess bidder may refer th

he link
http://bhelpe
em.com/DMS
SManuals/DM
MSManuals.h
html
13.0
0
SPARES
S
i)
All the sspares for the

e equipmentt under the ccontract prov
vided by the vendor
v
will sstrictly conform to the
specifica
ations and do
ocuments an
nd will be ide
entical to the
e correspond
ding main eq uipment/com
mponents
supplied
d under the contract.
c
ii)
ality plan an
nd the insp
pection requ irement fina
alized for the main equuipment will also be
The qua
applicab
ble to the corrresponding spares.
s
ndor warrants:
The ven
at all spares supplied will be new an
nd in accordance with th
he contract ddocument an
nd will be
1. Tha
free
e from defectts in design, material and
d workmansh
hip and shall further guarrantee as und
der:
f
in the
e original com
mponent/equ
uipments due
e to faulty deesigns, mate
erials and
2. In ccase of any failure
worrkmanship, the
t corresponding spare parts if any
y, supplied will
w be replacced without any
a extra
cosst to the BH
HEL and cu
ustomer unle
ess a joint examination and analyssis by BHEL and/or
cusstomer of succh spare parrts prove thatt the defect found
f
in the original part that failed can safely
be assured not to be presen
nt in spare pa
arts.
e long term availability of spares tto the BHEL and the customer
c
foor the full liffe of the
3. The
equ
uipment cove
ered under the contract a
ut of producttion of spare
e parts of
and that beffore going ou
the equipment covered
c
under the contra
act, vendor and
a his sub-v
vendors shaall give the BHEL and
Twenty Four)) months adv
vance notice
e so that thee latter may order his
the customer at least 24 (T
nts of spares
s, if he so d esires. The same provis
sion will alsoo be applicab
ble to the
bulkk requiremen
sub
b-vendors. Fu
urther, in cas
se of disconttinuance of manufacture
m
endors or
of any sparres by the ve
his sub-vendorss the vendors and his ssub-vendors, will provide
e the BHEL and the cus
stomer, 2
o) years in advance,
a
witth full manu facturing dra
awings, mate
erial specificcations and technical
(two
info
ormation requ
uired by the BHEL and th
he customer for the purpo
ose of manuufacture of su
uch items
and
d also the right to manufa
acture such sspares for the
eir own requirements.
e of discontin
nuance of s upply of spa
ares by the vendors or his sub-vend
dors, the
4. Furrther in case
ven
ndor will provide the BH
HEL and the customer with
w full inforrmation for rreplacementt of such
spa
ares with othe
er equivalent makes, if so
o required by
y the BHEL and
a the custoomer.
g the above, the vendor sshall be resp
ponsible for supply
s
of spaares for the liifetime of
5. Nottwithstanding
the package at reasonable prices.
p
The p
prices of all future
f
require
ements of sppares shall be
e derived
m the corresponding ex-w
works price a
at which the orders for such
s
spares have been placed
p
by
from
the BHEL and the
t customer as a part o
of the manda
atory or long term or any other kind of
o spares.
e base indice
es for calcula
ating ex-worrks price sha
all be commissioning of llast equipme
ent under
The
main contract.
iii)
ndor will indiicate the delivery period

d of the sparres, which th
he BHEL annd the customer may
The ven
procure in accordancce with this clause.
c
iv)
dor would make

m
every eeffort to expedite the
In case of emergency requirements of sparres, the vend
h spares on the basis of mutually agrreed time schhedule.
manufaccture and delivery of such
v)
ails to supply
y the manda
atory or long term or any other kind off spares on the
t terms
In case tthe vendor fa
stipulate
ed above, th
he BHEL an
nd the custo
omer shall be
b entitled to
t purchase the same from the
alternate
e sources att the risk an
nd the cost o
of the vendo
or and recov
ver from thee vendor, the
e excess
amount paid by the BHEL and the
t customerr over the ra
ates as per the contract. In the event of such
e BHEL or the customer, the purchas
ses will be as
s per the woorks and proc
curement
risk purcchase by the
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
21
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
policy o
of the BHEL and the cu
ustomer prevvalent at the
e time of su
uch purchasees and BHE
EL & the
custome
er at his optio
on may include a represe
entative from
m the vendor in finalizing tthe purchase
es.
vi)
he final settle
ement betwe
een the partie
es in terms oof relevant clauses of
It is expressly underrstood that th
der documen
nt shall not re
elieve the ve
endor of any of his obliga
ations under the provision of long
the tend
term ava
ailability of sp
pares and su
uch provision
ns shall continue to be en
nforced till thhe expiry of 30
3 (thirty)
years pe
eriod reckoned from the scheduled d
date of comp
pletion of tria
al operation oof the last eq
quipment
unless o
otherwise disscharged exp
pressly in wriiting by the BHEL
B
or the customer.
c
0
14.0
BIDDER
R TO FURNIISH FOLLOW
WING DOCU
UMENTS/INF
FORMATION
N ALONG W
WITH THE BID
B (FOR
ELECTR
RICAL AND C&I PLEAS
SE REFER TH
HE RESPEC
CTIVE SECT
TION OF THE
E SPECIFICATION).
on/Clarificatio
on if any in the enclose
ed deviation
n/clarification schedule oonly with me
ention of
Deviatio
specifica
ation clause for which deviation/clarifification is beiing asked.
Equipme
ent layout of DM Plant.
Electrica
al Load List in BHEL form
mat
Price Scchedule duly filled in.
Followin
ng guarantee
ed chemical consumption
c
n required forr regeneration (in kg) to bbe furnished.
Quantityy of chemicalls required as 100% per day of
x Anyy other chem
mical Propriietary / Speccific Chemica
als shall be based on the suppliers
reco
ommendatio
ons during de
etailed engine
eering
x
x
x
x
0
15.0
MISCEL
LLENEOUS REQUIREMENT
i.
Bidders is advised to
t visit the siite in order tto familiarize
e themselves
s with existi ng conditio
on of site
der to make their offer complete.
c
Du
uring detail eengineering also, the
before submitting the bid in ord
sponsible forr the correc
ctness of de
etails wrt exiisting facility
y at site.
successful bidder shall be res
mer approval on any drrawing havin
ng details of
o existing fa
acility shall not be cited
d by the
Custom
successful bidder a valid reaso
on for any sshortcoming in the work
k by them. BHEL shall also not
mplication fo
or any lack off input data with
w regard to
o site during detail engineering.
entertain any cost im
ii.
The com
mplete system
m shall be proven
p
and n
necessary de
esign docum
mentation in ssupport of prroveness
shall be submitted by the succ
cessful bidd er in support of the sys
stems, if askked by the customer
c
nd delivery im
mplication to
o BHEL and customer.
c
withoutt any price an
iii.
Enginee
ering for this project is be
eing carried o
out in 3D env
vironment at BHEL end. Name of eng
gineering
platform
m on which BHEL is do
oing the pro
oject IS Sma
art Plant Suite. This is being done to have
automa
ated interface checking and therebyy minimising rework at site.
s
Hence bidder, in their
t
own
interestt, is requessted to prepa
are all layoutt drawings us
sing 3D Mod
delling softwaare. These drawings
will also
o be made available
a
to BHEL
B
in soft ffor checking interface with other ageencies in consolidated
layout drawings. Bidders
B
inab
bility to prep
pare drawing
g using 3D Modelling ssoftware willl not be
n for evaluattion of their bid.
b
criterion
iv.
System to be designed to meet

m
all the statutory requirements
r
s. Preparatioon of all necessary
gs/data/ docu
uments for obtaining
o
neccessary Apprroval of statu
utory authoritties like CCO
OE , IBR ,
drawing
Weightt & Measure
es Departme
ent and an
ny other age
ency/ compe
etent authoriity ,on beha
alf of the
custom
mer, related to
t installation
n of DM plan
nt (if required
d) is included in bidderss scope. All expenses
e
required to obtain the approval shall also be
e borne by the successfu
ul bidder. Suuccessful bid
dder shall
ell in advance requireme nt of authoritty letter along with formaat for the sam
me. After
inform customer we
y customer, itt will be vendors respon
nsibility to reggularly follow
w up with
issuancce of authority letter by
the con
ncerned auth
horities to ob
btain timely a
approval from
m these auth
horities. Anyy delay on ac
ccount of
the sam
me, unless any
a specific information
i
rrelated to ab
bove approva
al to be furniished by cus
stomer is
delayed
d by customer, shall be to
t vendors a
account and shall not be
e used as a reason for extension
e
in contrract completiion.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
22
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
v.
Vendor to attend regular

r
engin
neering mee
eting with BHEL
B
and customer
c
forrtnightly in BHEL
B
or
mer office as decided during deta
ail engineerin
ng. Vendor will deputee all his co
oncerned
custom
enginee
ering represe
entative alon
ng with the p roject manag
ger for discussion and appproval. Mee
eting can
be held
d at site also..
vi.
In case of any conflict and repetition of clau

uses in the specification,
s
the more sttringent requ
uirements
d with.
among them are to be complied
vii.
Latest ve
ersion of all codes and standards to b
be followed.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
23
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00

ANN
NEXUREI

QUA
ALITY PL
LAN

BHEL PS- PEM-PPE

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CTOR 16A, UP--201301
24
25 of 155
DM PLANT--MINIMUM QUALITY REQUIREMENT
DM PLANT
25
26 of 155
DM PLANT- MINIMUM QUALITY REQUIREMENT
26
27
SUB - ITEM
MAIN ITEM
``
TYPE / METHOD EXTENT REF. DOCUMENT /

OF CHECK
ACCEPTANCE NORM
4
5
6
RRVUNL, 2 x 660 MW, Super-Critical TPS,

P.O.NO. & DT.
Stage-V, Unit # 7 & 8 at Suratgarh, Rajasthan
CHARACTERISTICS
CHECKED
3
PROJECT
FORMAT OF
RECORD
7
TCE REF.
Q.P.DATE
Q.P. NO.
S SIGN.
NAME
M SIGN.
NAME
T SIGN.
NAME
C SIGN.
NAME
AGENCY
REMARKS /
S M T C
HOLD POINTS (H )
8
H
9
G. INSTRUMENTS FOR LEAK TESTS AND PERFORMANCE TESTS SHALL HAVE VALID CALIBRATION CERTIFICATE WITH TRACEABILITY TO NATIONAL LEVEL.
H. LEGENDS :
S - SUB - VENDOR, M - MAIN VENDOR,
T- TCE, C - TCES CLIENT,
1 - WITNESS,
2 - DOCUMENTS REVIEW,
H - HOLD POINT.
E. THE EXTENT INDICATED IN COLUMN 5 IS IN VENDORS SCOPE. TCE / CLIENT MAY INSPECT AS PER THIS COLUMN OR RANDOM SAMPLES.
F. COLUMN 6 SHALL BE AS PER TCE / CLIENT APPROVED DRAWINGS / DATA SHEETS / SPECIFICATIONS WHEREVER APPLICABLE.
C. FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY TCE, COPIES OF RELEVANT DOCUMENTS SHALL BE FURNISHED TO TCE.
D. TCES IDENTIFICATION STAMP ON MATERIALS SHALL BE PRESERVED / GOT TRANSFERRED BY TCE AT APPROPRIATE STAGES.
A. STATUTORY REQUIREMENTS SHALL BE COMPLIED WITH BY THE VENDOR.

B. MATERIAL TESTS OF SAMPLES DRAWN BY TCE SHALL BE WITNESSED BY TCE.
COMPONENT / OPERATION
RRVUNL
SUB - VENDOR
Note: This is typical schedule of quality plan. Bidder may incorporate more details.
N
O
T
E
SR.
NO.
1
OWNER
VOL-II;SECTION F-14
SCHEDULE OF QUALITY
PLAN
Spec No. TCE 5750A H-500-001 MAIN VENDOR
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
ANNEX
XURE-II
SUB--VENDOR
R LIST
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
28
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
SUB
B-VENDO R LIST (M
MECHANIC
CAL)
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
29
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
No
SN
ITEM
PRESSU
URE VESSEL
LS
ACTIVAT
TED CARBO
ON
AIR BLO
OWERS
METERIN
NG PUMPS
AGITATO
OR
SEC
CTION: C1
REV
V NO: 00
SUP
PPLIERS
PLACE
R&C
C
ISGE
EC
MUMBAI
YAMUNAN
NAGAR
ANU
UP ENGG.
AHMEDAB
BAD
FABTECH
SPA
ARK ENGINE
EERS
PUNE
PUNE
Q
QP /
IN
NSPN REMA
ARKS
C
CAT
WITH LLOYDS
APPD
D HEAT
TREA
ATMENT
AGEN
NCY
INDU
USTRIAL CA
ARBON
ANKLESHWAR
VVD
D & SONS
TUTICORIN
GLO
OBAL ABSO RBENT PVT
T
A
KOLKATA
LTD
SWA
AN PNEUMA
ATIC
NOIDA
EVEREST TRAN
NSMISSION NEW DELHI
NEW DELHI /
KAY
Y INTERNAT IONAL
T
SONEPAT
EVE
EREST BLOW
WER
BAHADUR
RGARH
KULKARNI POW
WER TOOLS INDIA
VK PUMPS
P
MILT
TON ROY IN
NDIA
SWE
ELLORE
NASIK
CHENNAI
AHMEDAB
BAD
REM
MI PEOCESS
S PLANT &
M/C
MUMBAI
FIBR
RE & FIBRE
MUMBAI /
SILVASA
KBL
MAT
THER & PLA
ATT
KSB
SAM
M TURBO IND
D LTD
KISH
HOR PUMPS
S
SULZER PUMP INDIA
WPIL
WADI
PUNE
PUNE
COIMBATORE
PUNE
PUNE
GHAZIABA
AD
HORIZONTAL
FUGAL PUM
MPS
CENTRIF
HORIZONTAL
FUGAL PUM
MPS
CENTRIF
(RUBBER LINED)
HOR PUMPS
S
KISH
SU MOTORS
M
PUNE
MUMBAI
NON ME
ETALLIC
HORIZONTAL
FUGAL PUM
MPS
CENTRIF
ENG
GINEERS CO
OMBINE
ANT
TICORROSIV
VE
THANE
VALSAD
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
30
UPTO
O 15 BHP
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
MISC. PU
UMP VERTIC
CAL
TURBINE
E
10
0
RESIN TRAP ELEME

ENT
11
1
UNDER B
BED NOZZL
LE
12
2
3
13
RESIN
HEATER
R
CCS VAL
LVES
4
14
5
15
6
16
17
7
BALL VA
ALVE (NON FIRE
SAFE TY
YPE)
SEC
CTION: C1
REV
V NO: 00
KBL
M&P
P
WPIL
JYOTI PUMPS
VOLTAS
PUNE
PUNE
GHAZIABA
AD
VADODRA
A
PUNE
JHONSONS SCR
REEN
AUSTRALIA
JONSONS SCRE
EEN
AUSTRALIA
ROH
HM & HASS
BAY
YERS
DOW
WEX
ESC
CORTS
RAC
COLDS
FRANCE / USA
GERMANY
Y.
LEADER ENGG WORKS

FOU
URESS ENG INEERING
KSB
BDK
K
AUD
DCO
KBL
KBL
JALANDHA
AR
AURANGA
ABAD
COIMBATORE
HUBLI
CHENNAI
PUNE
KONDHAP
PU
C
PEC
FLOWCHEM
BDK
K
MICR
ROFINISH V
VALVES
AK INDUSTRIES
S
LEADER
NASIK
AHEMDAB
BAD
HUBLI
CHENNAI /
URAM
KANCHIPU
HUBLI
HUBLI
JALANDHA
AR
VELA
AN INC
IL
REIN
NEKE
SAM
MPELL AG
CANADA
PALGHAT
T
GERMANY
Y
GERMANY
Y
AN
VELA
BRA
AY
CANADA
USA
FARIDABA
AD
FARIDABA
AD
AUD
DCO
ANGLE V
VALVE
BALL VA
ALVE (HIGH
PRESSU
URE)
SS BALL
L VALVE 150 LBS WEIR BDK
HUBLI
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
31
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
18
8
9
19
0
20
21
1
AUD
DCO
MICR
RO FINUISH
H
BRA
AY
3
23
REV
V NO: 00
CHENNAI
HUBLI
CHINA
AUD
DCO
TYCO
BUTTER
R-FLY VALVE
E
(MANUA
AL / PNEUMA
ATIC) WEIR BDK
CLASS 1
150
CRA
ANE FLOW P
PROCESS
CHENNAI
HALOL
HUBLI
SATARA
VANCE VALV
VES
LATE TYPE NON- ADV
DUAL PL
RETURN
N VALVE (S
SS & WEIR BDK
CI UPTO
O 100 NB, CL
LASS LEADER
150)
NOIDA
HUBLI
JALANDHA
AR
WEIR BDK
DIAPHRA
AGM VALVE
E
ANE FLOW P
PROCESS
(MANUA
AL / PNEUMA
ATIC) CRA
UPTO 80
0 NB
HUBLI
SATARA
GATE / G
GLOBEVALV
VES
UP TO 30
00 NB PN 10
0
2
22
SEC
CTION: C1
LEADER
H SA
ARKAR
BAN
NKIM & COM
MPANY
MAJESTIC WOR
RKS
WEIR BDK
CHECK V
VALVE / NR
RV
H SA
ARKAR
(LINED / UNLINED), FLAP
LEA
DER (FOR C
CHECK
ZE UPTO 50
0 NB
TYPE SIZ
VE ONLY)
VALV
Y-TYPE S
STRAINER /
STRAINE
ER (WATER
R
SERVICE
E)
OTO
OKLIN
GRA
AND PRIX
JAYP
PEE
GRE
EAVES COTT
TON
SAIL
L
JIND
DAL TUBES
SUR
RYA ROSHIN
NI
TISC
CO
WEL
LSPUN
MSL
L (FOR IS 35
589)
MS PIPE
ES (IS: 1239
9&
3589)
5
25
TNAMANI
RAT
SS PIPES
S (ERW /
SEAMLE
ESS) UPTO 100
1 NB REM
MI
JALANDHA
AR
HOWRAH
HOWRAH
MUMBAI
HUBLI
HOWRAH
JALANDHA
AR
MUMBAI
NEW DELHI
NEW DELHI
MUMBAI
NEW DELHI /
NOIDA
MUL
LTITEX
4
24
UPTO
O 200 NB
UPTO
O 40 NB
ROURKEL
LA.
GAZIABAD
D
BHADURG
GARH
JAMSHED
DPUR
ANJAR
RAIGAD
CHATTRA
AL
TARAPUR
R
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
32
UPTO
O 350 NB
UPTO
O 300 NB
UPTO
O 150 NB
UPTO
O 400 NB
200 NB TO 500 NB
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SEC
CTION: C1
REV
V NO: 00
APEX TUBES PV
VT LTD
(App
proved for SS
S welded
pipes
s up to 150 N
NB & 4.78
BEHROR
mm thick as per A
2 (ALWAR)
ASTM A 312
B
& seamless pipe up to 50 NB
as pe
er ASTM A 3
312)
26
6
7
27
ESS METAL
INDIAN SEAMLE
AHMEDAB
BAD
TUBES
CS PIPE (ASTM A 10
06 GR.
MAH
HARASHTRA
A
RAIGAD
O 400 NB
B) UPTO
SEA
AMLESS
VERTICA
AL TURBINE
E
PUMPS
8
28
MS PIPE
ES ERW AND
D
SEAMLE
ESS PIPES
29
9
SS PIPES
S
30
0
LP VALV
VES AND
SPECIAL
LITIES
31
1
BUTTER
RFLY VALVE
ES
32
2
ATMOSP
PHERIC TAN
NK
(CS/SS)
KBL
WPIL LTD
SAM
M INDUSTRIA
AL PUMPS
FAIR
R BANK MOR
RSE/FLOW
MOR
RE
KISH
HORE PUMP
PS
CO
TISC
JIND
DAL SURYA ROSHANI
PSL
MAH
HARASHTRA
A
SEA
AMLESS
INDIAN SEAMLE
ESS
SAW
W
RAM
MA STEEL TU
UBES
KALY
YANI
PRA
AKASH
SAW
W
L&T AUDCO
FOU
URESS ENG INEERING
LTD.
BDK
K ENGG. IND
DUSTRIES
LTD.
KIRL
LOSKAR BR
ROTHERS
LTD.
CRE
ESCENT VAL
LVES LTD.
R&D
D MULTIPLE
VAG
G
INTE
ERVALVE
URESS LTD.
FOU
I.L PALGHAT
P
KBL
FABTECH
TECHNOFAB
JASM
MINOT POLY
YMERTECH
H
KILOSKAR
RWADI
KOLKOTA
A
COIMBATORE
SAHIBABA
AD
PUNE
CHENNAI
BANGALO
ORE
HUBLI
PUNE
JALANDER
R
HYDERAB
BAD
PUNE
BANGALO
ORE
PUNE
NEW DELHI
PUNE
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
33
UPTO
O 150 NB
UPTO
O 350 NB
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
33
3
34
4
35
5
36
6
37
7
38
8
39
9
40
0
41
1
PRE
ESSURE VES
SSELS
INDU
USTRY
SPA
ARKON ENG INEERING
BELC
CO POLLUT
TION
CON
NTROL PVT LTD
FABTECH
TECHNOFAB
TANK /PIPING
BELC
CO POLLUT
TION
ATION
FABRICA
CON
NTROL PVT LTD
AQU
UATHERM
INDU
USTRIAL SE
ERVICE
SUN
NRISE
GAN
NDHI & ASSO
OCIATES
TANK (FRP)
MOD
DERN EQUIP
PMENTS
EAG
GLE PLAST
OME
EGA PLAST
V K PUMPS
MET
TACHEM
STROKE
E CONTROLLER
SWE
ELORE
MILT
TON ROY IN
NDIA
MET
TACHEM
YSTONE
SAFETY VALVES/RE
ELIEF KEY
VALVES
V K PUMPS
MILT
TON ROY
REM
MI
FIBR
RE & FIBRE PRODUTS
AGITATO
OR/STIRRER
R
STANDARD ENG
GINEERS
CRO
OMPTON GR
REAVES
OTO
OKLIN
GRA
AND PRIX
STRAINE
ER
AYPEE
MICR
RO PRECIS ION
INST
TRUMENTAIION LTD
ORIFICE
E PLATE
CAR
RLO DYNAM ICS
H SA
ARKAR
SLUICE G
GATE
HI TECH
ADV
VANCE VALV
VES
PVT.LTD
BDK
K
FOU
URESS ENGG
G.INDIA
3 WAY V
VALVE
LTD.
FLUIDLINEVALV
VES
MPANY PRIV
VATE LTD.,
COM
INST
TRUMENTAT
TION LTD.
KIRL
LOSKAR BR
ROTHERS
LTD.
SEC
CTION: C1
REV
V NO: 00
PUNE
GREATER
R NOIDA
PUNE
NEW DELHI
GREATER
R NOIDA
KOLKATA
KOLKATA
BARODA
AHMEDAB
BAD
CHENNAI
PUNE
MUMBAI
NASIK
MUMBAI
AHMEDAB
BAD
CHENNAI
MUMBAI
BARODA
NASIK
CHENNAI
MUMBAI
MUMBAI
AHAMADN
NAGAR
MUMBAI
NEW DELHI
NEW DELHI
FARIDABA
AD
PALGHAT
T
HYDERAB
BAD
KOLKATA
AHMEDAB
BAD
NOIDA
HUBLI
MUMBAI
MUMBAI
PALAKAD
PUNE
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
34
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
42
2
43
3
44
4
45
5
46
6
PLUG VA
ALVE
FITTINGS
S (CS/SS)
FLANGE
ES (SS/CS)
PIPE (CP
PVC)
VALVES
(GATE/G
GLOBE/NRV//BA
LL)-CPVC
C
47
7
Rubber L
Lining for
Pipes/Ta
anks
48
8
FILTER M
MEDIA
49
9
FLASH M
MIXER
VEN
NUS PUMP & ENGG.
WOR
RKS
Sury
ya Valves and
d
Instruments Man
nufacturing
Com
mpany
STAFFORD CON
NTROLS
LIMITED
MICO
ON VALVES
S (INDIA)
PVT.LTD
FISH
HER SANMA
AR LIMITED
BDK
K
LARSEN & TOU BRO LTD.
LEADER
MICO
ON VALVES
S (INDIA)
PVT.LTD
BHA
ARAT FORGE
E
RELIANCE FOR
RGE
EBY
Y
SIDD
DARTH & GA
AUTAM
MS FITTINGS
F
PRA
ADEEP META
ALS LTD
TUBE PRODUCT
T
INCO
OROPORAT
TION
PRA
ADEEP META
ALS LTD
TUBE PRODUCT
T
INCO
OROPORAT
TION
MS FITTINGS
F
HAW
WA ENGINEE
ERING
ALIA
ANCE PIPE & PLANGES
S
JAI AMBE
A
GER
ROGE FISHC
CHER IPING
G
SYSTEMS
PVT LTD
ASTROL PLYTE
ECHINC LTD
D
ROGE FISHC
CHER IPING
G
GER
SYSTEMS
PVT LTD
ASTROL PLYTE
ECHINC LTD
D
Rishi Industries
Industrial Lining Ltd
MIL
GLO
OBAL ABSOR
RBENT
BHA
ARAT MINER
RALS
GEO
O MILLER
VOLTAS
EIMC
CO KCP
SEC
CTION: C1
REV
V NO: 00
KOLKATA
Chennai
PUNE
MUMBAI
CHENNAI
HUBLI
MUMBAI
JALANDHA
AR
MUMBAI
PUNE
MUMBAI
FARIDABA
AD
KOLKATA
MUMBAI
BARODA
MUMBAI
BARODA
KOLKATA
KOLKATA
MUMBAI
DELHI
AHMEDAB
BAD
DELHI
AHMEDAB
BAD
Sonepat
Baroda
CHENNAI
KOLKATA
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
35
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
50
0
PAINT
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
REM
MI
BER
RGER
ASIA
AN PAINTS
SHA
ALIMAR
J&N
NOTE:
b vendor list enclosed
e
AN
NNEXURE-II is indicative
e only and is subject to aapproval / acc
ceptance
The sub
by custo
omer (RRUV
VNL). Bidder to propose his sub vendor list with back up doccuments (ex
xperience
list, end user certificcate as appliicable) etc. T
The same sh
hall subject to
t BHEL andd Customer approval
neering stage
e without anyy technical, commercial
c
& delivery im
mplications to
o BHEL.
during detailed engin

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
36
VENDORLISTFORC&I
ITEMS
MAKE
PLC
ABB/GEFANUC/L&TLTD/ROCKWELL/SIEMENS/SCHNEIDERELECTRIC
CONTROLVALVE
DeZURIK/CONTINENTAL/CONTROLCOMPONENTINC/DRESSER/FOURESSENGG/FISHER
/FORBESMARSHALL/WEIRVALVES/IL/MIL/R.K.CONTROL
LEVELSWITCH
BLISSANAND/CHEMTROLS/HITECHSYS/LEVCON/RAMANINST/SIGMA/SORINC/SBEM/V.
AUTOMAT/WAAREEINST
PRESSURESWITCH
DRESSER/INDFOS/SWITZER/SORINC/VASU
ANALYTICALINSTRUMENTS FORBESMARSHALL/FISHERROSEMOUNT/SIEMENS
PRESSUREGUAGE
A.N.INST/BUDENBERGGAUGE/DRESSERIND/FORBESMARSHALL/GENERALINST
CONSORTIUM/GLUCK/H.GURUIND/H.GURUINST/MANOMETER/WAAREEINSTRUMENTS
TEMPERATUREGUAGE
A.N.INST/BUDENBERGGAUGE/FORBESMARSHALL/H.GURUIND/H.GURUINSTWAAREE
INSTRUMENTS/GOAINST/GOATHERMOSTATICINST/
FLOWELEMENT
BRISTOLBABCOCK/BALIGALIGHTINGEQUIP/ENGINEERINGSPECIALITIES
/IL/MICRO/MINCO/STARMECH
TEMPETAUREELEMENT
GENERALINSTCONSORTIUM/DETRIVEINST&ELECTRONICS/PYROELECTRIC/TOSHNIWAL
BROS/WAAREEINST
TRANSMITTERS
BRISTOLBABCOCK/BIRLAKENTTAYLOR/BLISSANAND/FISHERROSEMOUNT/SIEMENS/SBEM
/SMARTINST/TATAHONEYWELL/V.AUTOMAT&INSTS/
TEMPERATURESWITCH
INDFOSS/DRESSER/SWITZER/SORINC/TOSHNIWALBRO/VASUTECH
SIGHTFLOWINDICATORS
BLISSANAND/CHEMTROLS/INSTRUMENTATIONENGINEERS/SIGMA/TELACEEQUIP
INSTPIPEFITTINGS
AURAINCORPORATED/HYDAIRENGG/METPRESSENGG/PRECISIONENGG/SWITZER
INST/VIKASINDUSTRIAL
DPSWITCH
KAUSTUBAUDYOG/SWITZER/SORINC/VASUTECH
ANUBAR
ENDRESS+HAUSERGmbH+Co.KG/SWITZER/STARMECH
CONTROLPANEL
CONTROL&SWGRCO/INDUSTRIALCONTROLS&APPS/PYROTECH/PROCONINST
JUNCTIONBOXES
BALIGALIGHTINGEQUIP/CREATIVEINST/DEVIPOLY/INFOCONTROL/K.S.INTRUMENTS
/MANISHAENTERPRISE/SUCHITRAINDUSTRIES
INSTTUBEFITTINGS
AURAINCORPORATED/HYDAIRENGG/METPRESSENGG/PRECISIONENGG/SWITZER
INST/VIKASINDUSTRIAL
ROTAMETERS
CHEMTROLSSAMIL/EUREKAIND/IL/TRANSDUCERSANDCONTROLS/
NOTE: The sub vendor list enclosed ANNEXURE-II is indicative only and is subject to approval /
acceptance by customer (RRUVNL). Bidder to propose his sub vendor list with back up documents
(experience list, end user certificate as applicable) etc. The same shall subject to BHEL and
Customer approval during detailed engineering stage without any technical, commercial & delivery
implications to BHEL.
37

SPEC.NO.
TCE.5750A-H-500-001

RRVUNL, 2 x 660 MW,Super-Critical TPS,Stage-V,
Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 1 OF 16
INSTRUMENTATION AND CONTROL EQUIPMENT

LIST OF SUB VENDORS
The list of acceptable makes for I&C equipment / system are as listed below: AIR FILTER REGULATORS
PLACKA
Shavo Norgan (India) Pvt Ltd.
ABB Ltd.
BELLS CONTROLS LTD.
Schrader Schorill Duncan Ltd., Mumbai.
Vel jan Hydrair Pvt Ltd., Hyderabad.
GAS ANALYSERS
Emerson Process Management
ABB Ltd.
Teledyne
Novatel
Codel
Land Combustion
Fuji.
Yokogawa Bluestar Ltd.
Chemtrols.
Siemens.
NITRIC OXIDE (NOX) ANALYSER
Land Combustion Ltd.
Horiba
Chemtrols
Siemens
ABB Ltd.
OXYGEN MEASUREMENT (ZIRCONIUM PROBE)
ABB Ltd.
H & B (HARTMANN & BRAUN)
Seco Controls
Land Combustion.
ISSUE
R1
TCE FORM 329 R5
FILE NAME: SEC TABLE-17.DOC

38

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 3 OF 16

LIST OF SUB VENDORS
Universal Cables Ltd

Reliance Cables
Gems Cab
CONTROL CABLES
Delton
Incab
Universal Cables ltd
Reliance Cables
Gems Cab.
CONDUCTIVITY MEASUREMENT
Honeywell
ABB Ltd.
Polymetron.
Yokogawa Bluestar Ltd
DISSOLVED OXYGEN MEASUREMENT
Honeywell
Polymetron
ABB
Yogokawa Bluestar Ltd.
HYDRAZINE ANALYSER
Hach
ABB
Polymetron
PH
Hach
Polymetron
Forbes Marshall
Honeywell
ABB Ltd
ISSUE
R1
TCE FORM 329 R5

39

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 4 OF 16

LIST OF SUB VENDORS
SILICA
Hach
Polymetron
Braun & Leube
ABB
CONTROL VALVES
Dresser Masoneilan - France,
Fisher
Yamatake
CCI
ABB
Welland & Tuxhorn
Gulde Regal Armtturen.
Pneucon
ELECTRICAL ACTUATORS
Vaas Bernard
Auma India Ltd.
Limitorque
Rotork Controls Ltd.
Antrieb
DIFFERENTIAL PRESSURE INDICATORS
Indfoss
AN Instruments
Switzer Instruments Ltd.
Waaree Instruments Ltd.
General Instruments (GIC)
H.Guru
A N Instruments
DIFFERENTIAL PRESSURE SWITCHES
Indfoss
Varma Trafag
Waaree Instruments Ltd
ISSUE
R1
TCE FORM 329 R5

40

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 5 OF 16

LIST OF SUB VENDORS

PRESSURE / DIFFERENTIAL PRESSURE TRANSMITTER
Honeywell
ABB
Yokogawa
Fuji
Yamatake
Endress & Hauser
SIEMENS
DIGITAL DISPLAY UNIT
Laxsons
Yogokawa Bluestar Ltd.
Tata Honeywell Ltd.
Gossien Metrawatt
DISPLACEMENT TYPE LEVEL TRANSMITTERS
Dresser Masoneilan
Magnetrol
Yamatake
Endress & Hauser
ELECTRIC METERS
AE
MECO
Gossien
ABB
E/P CONVERTERS
Bells Controls Ltd.
ABB
Sical Yamatake
ISSUE
R1
TCE FORM 329 R5

41

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 6 OF 16

LIST OF SUB VENDORS
FLOW ELEMENT
Starmech
Micro precision products
Engineering Specialities Pvt Ltd.
Mech Engg
Teleflow
Emerson
Dag Process Instruments
Hydropnematic
FLOW GLASSES
Eureka
General Instruments
Levcon
V.Automat & Instrument (p) Ltd.
Bliss Anand
FLOW INTEGRATORS
Lectrotek
Nishko
ABB Ltd.
Rockwin
ILLUMINATED PUSH BUTTONS
EAO
H&B
L&T
Ronan
Honeywell
Siemens
STANDALONE SER
Hathaway (Imported)
Ronan (Imported)
ISSUE
R1
TCE FORM 329 R5

42

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 7 OF 16

LIST OF SUB VENDORS
MICROPROCESSOR BASED ANNUNCIATION SYSTEM

Hathaway (Imported)
Ronan (Imported)
LEVEL GAUGES
Chemtrols Engg.
Levcon
Sigma Instruments co.
Technomatic (India) pvt. ltd.
Teleflo Instruments co. ltd.
Pune Techtrol
B K Equipment
V Automat
SBEM
Bliss Anand
LEVEL SWITCHES
Bells Control Ltd.
Levcon
Magnetrol
Placka
Pune Techtrol
B K Equipment
V Automat
SBEM
Bliss Anand
POSITION TRANSMITTER
Endress & Hauser
Yamatake
Siemens
Gulde
PRESSURE INDICATORS
H.Guru
Bells Controls ltd.
General Instruments
ISSUE
R1
TCE FORM 329 R5

43

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 8 OF 16

LIST OF SUB VENDORS
A.N. Instruments
Gauges Bourdon
Industrial Eqpt. co.
Waaree Instruments Ltd.
Odion
Druck India
Wika Instruments
PRESSURE SWITCHES
Indfoss (India) Ltd.
Switzer Instruments ltd.
Varma Trafag
A.N. Instruments
Dag Process Instruments
Chemtrols
PUSH BUTTONS
Honeywell
Larsen & Toubro ltd.
Siemens ltd.
Tele Mechanic
RECEIVER INDICATOR (BAR GRAPH)
Laxons
Masibus
Industrial Instrumentation
Yokogawa
Teletherm Instruments co.
RECEIVER RECORDER / MULTIPOINT RECORDER
Laxons Engg. & Electronic Pvt. ltd.
Yokogawa.
Tata Honeywell
ABB
Digital Electronics.
Penny & Guile
ISSUE
R1
TCE FORM 329 R5

44

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 9 OF 16

LIST OF SUB VENDORS
RELAYS
Jyothi
ABB
Paramount
Omron
SIEMENS
SAMPLE COOLER
Polymetron
Sentry
Lowe
SAMPLING RACK
Polymetron
SOLENOID VALVES
Asco
Avcon
Rotex
Schrader
Herion-Norgren
Schovill Duncan Ltd.
TEMPERATURE INDICATORS
G.I.Consortium
Bells Controls
Waaree instruments ltd
Dresser-USA
TEMPERATURE SWITCH
Ashcroft
Dresser-USA
ISSUE
R1
TCE FORM 329 R5

45

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 10 OF 16

LIST OF SUB VENDORS
TEMPERATURE TRANSMITTERS
ABB Ltd.
Camille-Baur
P & F.
THERMO COUPLE ASSEMBLY
General Instruments
Nagman Sensors (p) Ltd
Pyro Electric instruments
Toshniwal Industries Pvt. Ltd.
Altop
Temsens
Waaree
THERMOWELL
General Instruments
Nagman Sensors (p) Ltd.
Pyro Electric Instruments
Detriev Instrumentation
Toshniwal Industries ltd.
Altop
Temsens
Waaree
RTD
Nagman Sensors (p) Ltd.
Toshniwal Industries Pvt. Ltd
Pyro Electric Instruments
Altop
Temsens
Waaree
UNIT CONTROL PANELS
Industrial Controls & Appliances (P) Ltd.
J&H
ISSUE
R1
TCE FORM 329 R5

46

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 11 OF 16

LIST OF SUB VENDORS
Chemin
Rittal
LOCAL CONTROL PANELS
Industrial Controls & Appliances (P) Ltd.
J&H
Pyrotech
Rittal
Chemin
VARIABLE AREA FLOWMETERS
Eureka
Krone Marshall
Scientific Devices
Chemtrols
Trac
Instrument Engineers
CONDITION MONITORING SYSTEM
Bently Nevada
Schenk Avery
SPM Instruments Ltd.
Rockwell Automation.
Shinkawa.
ANNUBAR
Dietrich
ASSIGNABLE TREND RECORDER
Honeywell
Yokogawa
Penny & Guile
DESUPERHEATER
Fisher
Dresser Masoneilan
ISSUE
R1
TCE FORM 329 R5

47

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 12 OF 16

LIST OF SUB VENDORS
CCI
FLOAT & CHORD TYPE LEVEL INDICATOR
Jayati
Pune Techtrol
B K Equipment
V Automat
SBEM
Bliss Anand
LEVEL SWITCH (PROBE TYPE)
Level Stat
Solatron
Keystone
Yarway.
LAB INSTRUMENTS
Dead Weight Tester (Pneumatic)
Pressurements
PRESSURE AND VACCUM GENERATORS WITH FINE REGULATOR
Superb Instruments
HIGH PRECISION REGULATORS FOR PRESSURE & VACUUM
Fairchild
HIGH TEMPERATURE FURNACE
Nagman
DIGITAL STORAGE OSCILLOSCOPE
Phillips
ISSUE
R1
TCE FORM 329 R5

48

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 13 OF 16

LIST OF SUB VENDORS
AC CLAMP ON METER
Extech
DIGITAL STROBOSCOPE
Lutron
SLING SYNCHROMETER
Extech
PORTABLE FLUE GAS ANALYSER

BAROMETER
Standard make subject to purchasers approval
SMD REWORK STATION
Soldron
Hakko
OKS
LAB & Control room FURNITURE
Godrej
PNEUMATIC POSITIONER / ELECTRO PNEUMATIC POSITIONER
Masoneilan (India) Ltd.
ABB
ULTRASONIC TYPE LEVEL SWITCHES
Nivo Controls Pvt Ltd.
SB Electro Mechanics Ltd.
E & H.
ISSUE
R1
TCE FORM 329 R5

49

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 14 OF 16

LIST OF SUB VENDORS
RF Level Switch.
EIP Bulk Controls Pvt Ltd.
EIP Enviro Controls.
TERMINAL BLOCKS
Phoenix
Weidmueller
Wago
MINIATURE CIRCUIT BREAKERS
Siemens
ABB
L & T.
LARGE VIDEO SCREENS / PLASMA VIDEO WALLS
Barco
Synelec
SONY
SAMSUNG
LG
DCS
ABB
BHEL
Tatahoneywell
Invensys
Siemens
Yokogawa Bluestar Ltd
PLC
AllenBradley
ABB
Honeywell
ISSUE
R1
TCE FORM 329 R5

50

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 15 OF 16

LIST OF SUB VENDORS
BUNKER LEVEL INDICATORS

Pepper &Flucs
E&H
EIP Enviro Controls
PLASMA MONITORS
Sony
Samsung
LG
WORK STATIONS / MIS STATIONS/SERVERS
IBM
HP
DELL
MASS FLOW METER
E&H
SCREW PUMPS & DEAD WEIGHT TESTER(Hydraulic)
Manometer India
Budenberg
Nagman
Druck
VIBRATION ANALYSIS SYSTEM
Bentley Nevada
Bruelenzar
Rockwell
SKF
FURNACE FLAME ANALYSIS SYSTEM
Durag, Hitech(BFI)
EU tech scientific engg., GMBH
ISSUE
R1
TCE FORM 329 R5

51

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION:TABLE17
SHEET 16 OF 16

LIST OF SUB VENDORS
PADO
STEAG encotec (India) Pvt. Ltd. (Evonics)
Honeywell
Invensys
Emerson
CMMS
Honeywell
InvensysABB
TCS
AAQMS & MMS
Chemtrols
Campbell scientific canda corp
Honeywell (Teledyne)
Techmark engineers and cosultants (Horiba)
Nevco engg pvt. Ltd. (LSI lastern)
NOTE:
The sub vendor list enclosed ANNEXURE-II is indicative only and is subject to approval /
NOTES
1.
The final make selected out of the recommended makes listed above
shall be subject to purchaser / consultants approval during detailed
Engineering.
2.
Wherever the make is not specified for any item, the Bidder shall
indicate 2 or 3 reputed makes, out of which Purchaser /
Consultant shall select any one which is acceptable suggest an
acceptable make. This shall have no price implication.
ISSUE
R1
TCE FORM 329 R5

52

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LIST OF SUB-VENDORS FOR ELECTRICAL EQUIPMENT/SYSTEMS

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NOTE: The sub vendor list enclosed ANNEXURE-II is indicative only and is subject to approval /

!

60
LISTOFSUBVENDORSFORLV&MVMOTORS
Motors
Type
Vendor
Address
MOTORS LV
BHARAT
BIJLEE LTD.
Bharat Bijlee Limited,

1st Floor, 7-B, Rajindra Park,
Pusa Road, New Delhi - 110 060.
MOTORS LV
CROMPTON
GREAVES
VANDHANA
BUILDING
11, TOLSTOY MARG
NEW DELHI-110001
MOTORS LV
ASEA BROWN
BOVERI
IST FLOOR,QUTUB
HOTEL
SHAHID JEET SINGH

MARG
NEW DELHI-110016
MOTORS LV
P.O. BOX 5555
MALLESWARAM WEST
BANGALORE
560055
MOTORS LV
KIRLOSKAR
ELECTRIC CO
LTD.
NGEF
BANK OF BARODA
BDG
PBNO.633,16,SANSAD
MARG
NEW DELHI-110001
MOTORS LV
SIEMENS
4A, RING ROAD
I.P. ESTATE
NEW DELHI
110002
MOTORS LV
MARATHON
708, EROS APARTMENT 56, NEHRU PLACE NEW DELHI-110019
MOTORS LV
GE-POWER
150 AIRPORT ROAD
BANGALORE-560017
MOTORS LV
RAJINDRA
ELECT
INDUSTRIES
LAXMI
HYDRAULICS
PVT. LTD
BHEL
(INDUSTRY
SECTOR)
14 SHAH
IND.ESTATE
VEERA DESAI
RD,ANDHERI(W)
INTEGRATED
OFFICE COMPLEX
LODHI ROAD
NEW DELHI 110003
MOTORS MV
CROMPTON
GREAVES
VANDAHNA
BUILDING
11, TOLSTOY MARG
NEW DELHI-110001
MOTORS MV
P.O. BOX 5555
MALLESWARAM WEST
BANGALORE
560055
MOTORS MV
KIRLOSKAR
ELECTRIC CO
LTD.
NGEF
BANK OF BARODA
BLDG.
PB.NO.633,16,SANSAD
MARG
NEW DELHI-110001
MOTORS MV
GE-POWER
150 AIRPORT ROAD
BANGALORE-560017
MOTORS MV
MARATHON
708, EROS APARTMENT 56, NEHRU PLACE NEW DELHI-110019
MOTORS LV
MOTORS MV
MUMBAI-400053
129/130, INDUSTRIAL ESTATE PATIL NAGAR, HOTGI ROAD

SOLAPUR-413003, MAHARASHTRA

NOTE: VENDOR
TO vendor
PLEASE NOTE
THAT FINAL
SUB VENDOR SELECTED
OUT only
OF THE
ABOVE
RECOMMENDED
SUB /
NOTE:
The sub
list enclosed
ANNEXURE-II
is indicative
and
is subject
to approval
VENDORS SHALL SUBJECT TO CUSTOMER APPROVAL DURING DETAILED ENGINEERING WITHOUT ANY
acceptance
by customer& (RRUVNL).
Bidder to propose
his CUSTOMER.
sub vendor list with back up documents
TECHNICAL, COMMERCIAL
DELIVERY IMPLICATIONS
TO BHEL AND
(experience
list, SUB
endVENDOR
user certificate
as applicable)
etc.ALSO
TheSUBJECT
same shall
subject to AND
BHEL
and
Customer
ANY ADDITIONAL
OTHER THAN
ABOVE SHALL
TO CUSTOMER
BHEL
APPROVAL
DURING DETAILED
ENGINEERING
WITHOUT
ANY without
TECHNICAL,
& DELIVERY&IMPLICATIONS
TO BHEL to
approval
during detailed
engineering
stage
any COMMERCIAL
technical, commercial
delivery implications
AND CUSTOMER.
BHEL.
61
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
ANNEX
XURE III
DRAWING DOCUMNT
TS SUBMISSION PR
ROCEDUR
RE
er shall subm
mit soft copy
y/hard copy/C
CD ROMs of
o all the fina
ally approvedd drawings and
a O&M
x Bidde
Manu
uals as required by Custtomer/Custom
mer consulta
ant/BHEL-site/BHEL-PEM
M. The exact number
of ha
ard copies/CD
D ROMs of these
t
docum
ments to be submitted
s
sha
all be notifiedd to the bidd
der at the
time of detailed engineering and bidder shall submiit the same without anyy commercial/delivery
HEL/Customer.
impliccations to BH
x All th
he drawing documents
d
allong with the
e O&M manu
ual (of all the
e revisions) aare necessa
arily to be
subm
mitted in soft copies in addition to hard
d copies.
x Bidde
er to submit soft copies of all the drrawing and document along with quuality plans for
f BHEL
revie
ew and appro
oval.
able copy of all
a the drawin
ngs and docu
d.
uments shall be provided
x Edita
x The date of subm
mission of drawing docu
uments shall be considerred as the ddate of subm
mission of
pes whicheve
er is later.
hard and soft cop
he drawings shall
s
be prep
pared on com
mputer auto cad
c and othe
er documentss (like datash
heet etc.)
x All th
on M
MS office soft
ftware. Bidde
er not compl ying to the requirement
r
shall not bee considered. For the
execution of the contract
c
regu
ular meeting (generally once
o
in 15 da
ays or as perr project requ
uirement)
quired.
is req
x Vend
dor to come
e for meeting with the concerned dealing
d
pers
sons as perr BHEL or customer
c
requiirement in a short notice.
x Bidde
er to submitt instrument schedule, ccable schedu
ule and valve schedule in MS- Exce
el format
durin
ng detailed en
ngineering.
x Bidde
er to also furnish
f
the auto
a
cad co
opy/MS-Exce
el/MS-word (as applicabble) of the following
documents after award of co
ontract. Howe
ever any oth
her auto cad
d copy/MS-E
Excel/MS-worrd of any
a per the in
nsistence of BHEL and customer
c
will also be subbmitted by th
he bidder
otherr document as
witho
out any delive
ery and commercial impl ication to BH
HEL and custtomer.
P&ID.
Equipme
ent lay out of the DM Plan
nt area.
Equipme
ent Cable tray
y layout for D
DM Plant are
ea.
Equipme
ent earthing la
ayout for DM
M Plant area.
Civil scop
pe drawings..
Piping layy out drawing
g for DM Pla
ant area and yard piping layout.
l
Valve sch
hedule
Instrument schedule
Cable Scchedule
ii) Otherr requirements
x Succcessful bidde
er shall furnish detailed erection ma
anual for each of the eqquipment as
s well as
comp
plete system
m supplied un
nder this con
ntract at leas
st 3 months before the sscheduled errection of
the cconcerned eq
quipment / component orr along with supply of co
oncerned equuipment / co
omponent
which
hever is earlier.
x Engin
neering for this project is being ca
arried out in
n 3D enviro
onment at B
BHEL end. Name
N
of
engin
neering platfo
orm on which
h BHEL is do
oing the project IS SmarttPlant Suite. This is being
g done to
have
e automated interface che
ecking and tthereby minimising rework at site. Heence bidder, in their
t prepare a
all layout dra
awings using
g 3D Modell ing software
e. These
own interest, is requested to
wings will also
o be made available
a
to B
BHEL in soft for checking
g interface w
with other agencies in
draw
consolidated layo
out drawings
s. Bidders in
nability to prrepare drawing using 3D
D Modelling software
not be criterio
on for evalua
ation of their b
bid.
will n
x Docu
ument appro
oval by custtomer unde r Approval category orr informationn category shall
s
not
abso
olve the vend
dor of their contractual obligations of completin
ng the work as per spe
ecification
ent shall be reported
r
by the vendor in
i writing
requiirement. Anyy deviation frrom specifie d requireme
and rrequire writte
en approval. Unless any change in sp
pecified requ
uirement hass been broug
ght out by
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
62
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
the vvendor durin

ng detail eng
gineering in writing whille submitting
g the docum
ment to custtomer for
appro
oval, approved documen
nt (with impliccit deviation) will not be cited
c
as a reaason for not following
the sspecification requirement.
ase vendor submits revised drawing a
after approva
al of the corrresponding ddrawing, any
y delay in
x In ca
appro
oval of revissed drawing shall be to vvendors acc
count and sh
hall not be uused as a re
eason for
exten
nsion in contract comp
pletion. How
wever, in ca
ase changes
s are necesssitated due
e to any
consttraints at cusstomer end, delay in reviiew/ approva
al of such rev
vised drawinng beyond on
ne month
will b
be to custome
ers account..
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
63
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
ANNEXUREIV

PA
AINTING
GSPECIFICATIO
ON

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
64
SPEC NO.
TCE.5750A-H-500-001

VOLUME II
SECTION C 13
SHEET 1 OF 14
PAINTING REQUIREMENTS
PAINTING
13.0
13.0.1
This section defines the technical requirements for surface preparation

selection and application of paints on equipment, vessels, machinery, piping,
ducts etc. However, manufacturers shall follow their standard procedures for
painting their equipment. The Bidder shall submit a detailed painting
procedure for approval of OWNER / OWNERS representative after the
award of contract.
13.0.2
The following surface and material shall require painting:

a)
All un-insulated carbon steel and alloy steel equipment like columns,
vessels, drums, storage tanks, heat exchangers etc.
b)
All un-insulated carbon steel and low alloy piping, fitting and valves
(including painting of identification marks)
c)
All pipe structural steel supports, walkways, platforms, hand rails,
ladders etc.
13.0.3
The following surfaces and material shall not require painting:

a)
Non-ferrous materials
b)
Austenitic stainless steel
c)
Plastic and / or plastic coated materials
d)
Insulated surface of equipment and pipes except colour coating
wherever required
e)
Painted equipment like blowers, pumps, valves, etc., with finishing
coats in good condition and with matching colour-code
13.1.0
Codes and Standards
13.1.0.1
Painting of equipment shall be carried out as per the specifications indicated

below and shall conform to the relevant IS specification for the material and
workmanship.
13.1.0.2
The following Indian Standards may be referred to carrying out the painting
job.
IS : 5
Colours for ready mixed paints and enamels
IS : 1303
Glossary of terms relating to paints
IS : 2379
Colour code for identification of pipelines.
IS : 1477
Code of practice for painting of ferrous

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metals in buildings (Parts I & II)

IS: 2524
Code of practice for painting of non-ferrous

metals in buildings (Parts I & II)
IS : 2395
Code of practice for finishing of concrete,

masonry and plaster surfaces (Parts I and II)
IS : 2338
Code of practice for finishing of wood and

wood based materials (Parts I & II)
IS : 158
Ready mixed paint, brushing, bituminous,

black, lead free, acid, alkali, water and heat
resisting
IS : 2074
Ready mixed paint, air drying, red oxide zinc

chrome, and priming.
IS : 104
Ready mixed paint, brushing, zinc chrome,

priming
IS : 2932
Enamel, synthetic, exterior

(a) undercoating
(b) Finishing.
13.2.0
SIS : 55900
Swedish standard for blasting
IS: 14506
Epoxy Red oxide Zinc Phosphate Wieldable

Primer, Two Component Specification
IS: 14209
Epoxy Enamel, Two Component, Glossy

Specification
IS: 14589
Zinc priming paint, Epoxy based, Two-packspecification
SURFACE PREPARATION
The surface shall be prepared in a manner suitable for coatings. Chemical derusters or rust converters shall not be applied. Acid cleaning is subject to
approval of PURCHASER / PURCHASERS representative.
13.2.1
Blasting
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The surface of the part / component shall be blasted before the coating
material is applied.
Unless otherwise specified in the documents, the surface shall satisfy the
following requirements after blasting:
Primer paint shall be zinc silicate of approved brand. Dry film thickness of
each primer coat shall be 15 25 m
13.2.2
Manual Rust Removal

Manual rust removal shall be allowed for welded zones and for touching up
installed components.
13.2.3
Cleaning
Removal of impurity
Impurity
Removal
(a)
Dust, loose deposits
Vacuum-cleaning, brushing
(b)
Adhesive deposits
Power brushing
(c)
Oils, greasy impurities
Wet blasting, use of detergent additives by

agreement
(d)
Salt deposits
Rinsing
Markings (e.g., felt tip pen)
Organic
solvents
to
manufacturers
specifications e.g., Trichloro- trifluoro -ethane
and solvents containing acetone (renew
solvent and rag frequently).
(e)
13.3.0
PROCESSING
13.3.1
General
13.3.1.1
Application Conditions
The primer shall be applied to properly prepared surfaces only. The
specifications of the coating material manufacturers shall be observed.
The minimum temperature shall be +50C and the relative humidity shall
not exceed 80%. The temperature of the work piece shall be at least 3
0
C above dew point.
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13.3.1.2
Application Procedure
The primer shall be applied by means of brush or by spray. The top
coats shall be applied by means of brush, roller or by spray.
At points where coating application is interrupted, the individual layers
shall be adequately stepped to ensure proper layer sequence when
coating operations are resumed
13.3.1.3
Touching Up
Before each layer is applied, previous coating shall be touched up where
necessary by way of rust removal and cleaning, according coating
MANUFACTURERS specifications. The final top coat shall be reapplied
completely, if required.
13.3.1.4
Uncoated Surfaces
Moving parts of machines (e.g., stems, shafts, sliding and locating
bearings), nameplates, instruments and sealing surface shall not be
coated. Welds shall be left free of coating up to a distance of 30 mm on
each side of the weld edge until erection and weld examinations, if any,
have been completed.
13.3.1.5
Bond Strength
The pull-off stress determined using the pull-off test method for adhesion
shall be not less than 1.5 N/mm2, according to ISO 4624.
13.3.1.6
Surface Conditions of Coating Surfaces

The coating surface shall have a uniform film thickness, shade and gloss
and shall be free from inclusions, sags and wrinkles.
13.3.1.7
Coating Systems
13.3.1.7.1
General Requirements for Coating Systems

Coating materials according to SSPC, BS 5493 or DIN 55 928 shall be
used. Intermediate coats are to be pigmented with micaceous iron oxide.
The materials shall be matched with each other so that they are
compatible. Coatings deviating from this specification shall be subject to
approval. Standards of surface preparation and painting shall give a time
to first maintenance of 10 years.
The colour and gloss of top coats shall be in accordance with sub-clause
suggested colour codes for painting (Sub-clause 13.10).
13.3.1.7.2
Standard Coating System (External Coatings)

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a)
Steel Structures
i.
ii.
iii.
iv.
v.
b)
All steel structures shall receive two primer coats and two finish
coats of painting. First coat of primer shall be given in shop after
fabrication before dispatch to erection site after surface
preparation as described below. The second coat of primer shall
be applied after erection and final alignment of the erected
structures. Two finish coats shall also be applied after erection.
Steel surface which is to painted shall be cleaned of dust and
grease and the heavier layers of rust shall be removed by
chipping prior to actual surface preparation. The surface shall be
abrasive blasted to Sa-2 finish as per SIS05-5900. Primer paint
shall be zinc silicate of approved brand. Dry film thickness of each
primer coat shall be 40 microns.
Finish paint shall be 2 coats of High built epoxy finish of approved
brand. Dry film thickness of each finish coat shall be 90 microns.
The undercoat and finish coat shall be of different tint to
distinguish the same from finish paint. The total dry film thickness
shall be 300 microns. All paints shall be of approved brand and
shade as per the OWNERS requirement.
Joints to be site welded shall have no paint applied within 100
mm of welding zone. Similarly where Friction grip fasteners are to
be used no painting shall be provided. On completion of the joint
the surfaces shall receive the paint as specified.
Surfaces inaccessible after assembly shall receive two coats of
primer prior to assembly. Surfaces inaccessible after erection
including top surfaces of floor beams supporting gratings or
chequered plate shall receive one additional coat of finish paint
over and above number of coats specified before erection.
Portion of steel member embedded / to be encased in concrete
shall not be painted.
Galvanised iron and steel requiring paint finish at site

At site
Surface Treatment
Mechanical cleaning from contaminants by means of washing or steam
jetting and sweep blasting with fine sand or etching (T-Wash).
Touch-up mechanical damages:
De rusting St 3 and application of high build epoxy primer DFT 80 m.
Finish coating:
Analogous to standard painting scheme
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13.3.1.7.2.1
Painting of indoor components such as valves, pumps, motors,

electrical parts, tanks etc.
a)
At works
Surface preparation:
Blasting according to SIS 055900: grade SA 2 . Depending on
production flow, a weldable, inorganic ethyl zinc silicate shop primer dry
film thickness 15 25 m, may be used.
Prime coat:
Two (2) layers of zinc phosphate epoxy, total dry film thickness 75 m.
b)
At site
Thorough cleaning to remove oil, grease, dirt and any other
contaminants. De-rusting of all mechanical damages according to SIS
055900 Grade ST3. Touch up with dry film thickness 50 m.
Finish coat:
Application of two finishing coats of Chlorinated rubber paint in approved
shades at 30-40 microns DFT each coat in approved shades.
13.3.1.7.2.2
Remarks:
Equipment coated with a standard application system can be accepted if
the quality of this application system is corresponding with the quality of
the above mentioned system.
13.3.1.7.2.3
Painting of Outdoors equipment (external surfaces) such as piping,

valves, pumps, motors, electrical parts, tanks etc.
Weather exposure, weather resistance, temperature up to 1200C as per
13.7.1 and 13.7.3.
Surface Preparation:
Blasting according to SIS 055900: grade Sa 2 . Depending on
production flow, a weldable, inorganic ethyl zinc silicate shop primer dry
film thickness 15-25 m, may be used.
Prime Coat:
Two (2) layers of zinc phosphate epoxy, total dry film thickness 75 m.
Intermediate Coat:
One (1) layer 2 pack high build epoxy polyamide Mio, dry film thickness
100 m.
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Finish Coat:
Application of two finishing coats of Chlorinated rubber paint in approved
shades at 50 microns DFT each coat in approved shades.
13.3.1.7.2.4
Special Coating System (External Coatings)

Parts exposed to temperatures above 1200C, up to 2000C, not
insulated
a)
At works
Blasting according standard SIS 55900 Grade Sa 21/2 and ISO 8501-1:
1988. Depending on production flow, a weldable, inorganic ethyl zinc
silicate shop primer, dry film thickness 15-25 m, may be used
Prime coat
Inorganic ethyl zinc silicate, dry film thickness 75 m.
b)
At site
Pre-treatment:
De-rusting of all mechanical damages, according to ISO 8501-1: 1989,
grade St 3 Touch-up with 1 pack inorganic ethyl zinc silicate, dry film
thickness 50 m.
Removal of all decontaminants from prime coat.
Intermediate Coat:
1 pack silicon acrylic, dry film thickness 35 m.
Final coat
1 pack silicon acrylic, dry film thickness as 35 m.
Total system dry film thickness 145 m.
Final coat according to colour code.
Parts exposed to temperatures above 2000C, up to 4000C, not
insulated
At works
Blasting according to ISO 8501-1: 1988 grade Sa 21/2. Depending on
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production flow, a weldable, inorganic ethyl zinc silicate shop primer, dry
film 15-25 m, shall be used.
Prime coat:
Inorganic ethyl zinc silicate, dry film of thickness 75 m.
At site
Pre-treatment:
De-rusting of all mechanical damages, according standard Sa 21/2 to
ISO 8501-1: 1988. Touch-up with coating system according to
MANUFACTURERS recommendations.
Insulated Parts, continuously exposed to condensing water or parts
exposed to temperatures
a)
For parts that are provided with insulation on site.

Insulated parts, exposed to condensing water
At works
Surface Preparations:
Blasting according standard Sa 21/2 to ISO 8501-1: 1988. Depending on
production flow, a weldable, inorganic ethyl zinc silicate shop primer, dry
film thickness 15-25 m shall be used.
Prime coat:
Inorganic ethyl zinc silicate, dry film thickness 75 m.
b)
Insulated parts exposed to temperatures

Parts, exposed to temperatures up to <4000C at works
Blasting according to standard Sa 21/2 to ISO 8501-1: 1988. Depending
on production flow, a weldable, inorganic ethyl zinc silicate shop primer,
dry film thickness 15-25 m shall be used.
Parts, exposed to temperatures above 4000C at works (Steam pipes,
pressure tubes and parts for the HRSG, such as heating surfaces,
heaters and super heaters reheaters, etc.)
Surface preparation:
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Blasting according standard Sa 21/2 to ISO 8501-1: 1988.

Temporary primer:
Varnish.
c)
Intermittent exposure due to condensing water / chemicals (Indoors)

At works
Blasting according to standard Sa 21/2 to ISO 8501-1: 1988. Depending
on production flow, a weldable, inorganic ethyl zinc silicate shop primer,
dry film thickness 15-25 m may be used.
Prime Coat:
Two layers of zinc phosphate epoxy primer total dry film thickness
greater than or equal to 75 m.
At site
Pre-treatment:
De-rusting of all mechanical damages, according standard Sa 3 to ISO
8501-1: 1988, touch-up with 2 pack high build epoxy with volume solid
content of more than 85%, 75 m.
Intermediate Coat:
2 pack high build epoxy, dry film thickness 80 m.
Finish coat:
2 pack epoxy according to colour appearance, dry film thickness of 50
m.
When exposed to weathering, weather resistance finish coat shall be
applied.
d)
Water exposure
Surfaces permanently or predominantly in contact with water.
At site / works
Pre-treatment:
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SHEET 10 OF 14

Removal of all welding pearls.

Blasting according standard Sa 3 to ISO 8501-1: 1988.
Coat:
4 coats 2 pack coal-tar-epoxy, dry film thickness 125 m each.
Touch-up after erection as required.
13.3.1.7.2.5
Buried / underground piping system (except for sea water piping)

Where pipelines are buried, underground protection shall be provided for
the piping system as indicated in any one of the methods given below:
Coal tar primer, coal tar enamel, inner wrap of fibre glass, final outer
wrap of enamel impregnated fibre glass. Total thickness of coating shall
not be less than 4.0 mm.
With anti-corrosive tape of minimum 4 mm thick conforming to
IS-10221 and AWWA C 203-93.
Pipe surfaces shall be cleaned by shot or sand blasting before

application.
Tests to be carried out after application
Bond / Adhesion test
Holiday test
13.3.1.7.3
INTERNAL COATINGS
13.3.1.7.3.1
Tanks (Internal Surfaces) as specified in relevant sections of

specification
Industrial, deionised, demineralised and potable water up to 60 0C pH
range: 4.5 9.5.
Blasting according to ISO 8501-1: 1988, grade Sa 21/2.
Prime coat:
Two layers of zinc phosphate epoxy primer total DFT greater than or
equal to 75 m.
Pre-treatment:
De-rusting of all mechanical damages, according to standard Sa 3 to ISO
8501-1:1998, touch up with 2 pack high build epoxy with volume solid
content of more than 85%, 75 m.
Intermediate coat:
2 pack high build epoxy, dry film thickness 80 m.
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Finish coats:
2 pack solvent free epoxy paint dry film thickness 150 m per coat.
In case of service or potable water tanks, the coating material selected
shall not taint the water.
QA / QC procedure, including pinhole inspection, for shall be submitted
for approval by Owner / Owners Representative.
13.3.1.7.3.2
Rubber Lining of Pipes, Valves and Tanks as specified in relevant

sections.
At works
Pre-treatment:
Blasting according standard 21/2 to ISO 8501-1: 1988.
Rubber lining:
Hard-rubber 5mm for DM water applications, thickness greater than or
equal to 3 mm for others. In case of failure of rubber lining for both pipes
and vessels, the rubber lining shall be replaced by COROCOAT
13.4.0
13.4.1
Painting for Electrical Items

All the steel work shall be thoroughly cleaned of rust, scale, oil, grease,
dirt and scarf by pickling, emulsion cleaning, etc. The sheet steel shall be
phosphated / oven dried and then painted with two coats of zinc rich
primer paint. After application of the primer, two coats of finishing
synthetic enamel paint shall be applied. The colour of the finishing coats
inside shall be glossy white and exterior of the treated sheet steel shall
be shade 631 of IS-5 / RAL 7032 for all switchboard/MCC/ Distribution
boards, control panels, etc.
13.4.2
All electrical equipment shall be given tropical and fungicidal treatment

and outdoor equipment shall be provided with rain hood to prevent entry
of rain water into the equipment.
13.5.0
Painting for I & C equipment: Epoxy coating required for all I&C
equipment.
Suggested Colour Codes for Painting
13.5.1
Sl. No.
Item / Service
Colour
IS5
Colour
(Band)
IS
-5
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13.5.1
Structures, platforms, galleries,

ladders and handrails.
Dark
Admiralty
Grey
632
13.5.2
Boiler casing, ducting
Nut Brown
413
13.5.3
Crane
(a)
Crane structure
Golden
Yellow
356
Black
(b)
Trolley and hook
Crimson
540
13.5.4
Pump motors, compressors
Light Grey
631
13.5.5
Tanks (without insulation and

cladding)
(a)
Outdoor
Aluminium
(b)
Indoor
Light Grey
631
13.5.6
Vessels and all other proprietary Light Grey

equipment (without insulation and
cladding)
631
13.5.7
Switchgear
Light Grey
631
13.5.8
Control and relay panels
Light Grey
631/
7078 of
IS1650
13.5.9
Turbines
Light Grey
631
13.5.10
Generators and exciter
Light Grey
631
13.5.11
Transformers
Aluminium
13.5.12
Machinery guards
Signal red
13.5.13
Piping (Without insulation and

cladding)
(a)
Water System
537
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SHEET 13 OF 14
(i)
(ii)
(iii)
(iv)
(v)
Boiler feed
Condensate
DM Water
Soft Water
Bearing cooling water
Sea Green
Sea Green
Sea Green
Sea Green
Sea Green
217
217
217
217
217
Light Brown
Light Orange
French Blue
French Blue
410
557
166
166
(vi)
(vii)
(viii)
(ix)
Potable and filtered water

Service and clarified water
Cooling water
Raw water
Sea Green
Sea Green
Sea Green
Sea Green
217
217
217
217
French Blue
French Blue
French Blue
White
166
166
166
-
(b)
(i)
Air system
Station air
Sky Blue
101
(ii)
Control air
Sky Blue
101
White
(c)
(i)
Oil system
Light oil (HSD)
Light
Brown
410
French blue
166
(ii)
Lubricating oil
410
Light grey
631
(iii)
Transformer oil
Light
Brown
Light
Brown
410
Light Orange
557
(d)
(i)
Gas system
Fuel gas (Re-gassified LNG)
(ii)
Carbon dioxide
309
Light grey
631
(iii)
Hydrogen
309
Signal red
537
(e)
Fire Services
Fire red
536
(f)
Effluent pipes
Black
(g)
Vacuum pipes
Sky Blue
101
Black
(h)
Drainage
Black
Canary
Yellow
Canary
Yellow
Canary
Yellow
NOTES
1.
This colour code basically refers to IS: 2379 for piping with necessary
modifications.
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2.
Where band colour is specified, same shall be provided at 10 metre intervals on

long uninterrupted lines and also adjacent to valves and junctions.
Note: Bidder shall furnish his painting specification to suit corrosive atmosphere of
coastal area along with the bid. The specification shall in general be in line with
the above requirements.
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ANNEXURE-V
2x 660 MW RVUNL SURATGARH TPS UNIT - 7 & 8 PROJECTS
LIST & QUANTITY OF MANDATORY SPARES
S.NO.
DESCRIPTION
TOTAL QUANTITY INCLUDED
LT Motors(AC/DC)
a
b
c
d
Motor
Bearings
Space heaters (if applicable)
Cooling fan
Field Instruments/
Elements/Equipment(Gauges,
Switches, transmitters etc.) (AS
APPLICABLE)
Local gauges
Field Switches
Transmitter
10 % For each type,size and range or

minimum 2 No. whichever is higher.
Temperature Element(RTD) with

Thermowell

Temperature Element(T/C) with

Thermowell

Air filter Regulator

Junction Box

Flow Elements

i
j
I/P Conterter
Position Transmitter
Not Applicable
k
l
Mass Flow Meter

Positioner for control valve/Pneumatic
power cylinders
Not Applicable
Air lock relay for control

valves/pneumatic poer cylinders
Solenoid valves for control
valve/Pneumatic power cylinders
Not Applicable
3
a
PLC System (AS APPLICABLE)

Power Supply modules/ Cards
I/O Cards (Each type)
1
1
1
3
No of each type
Set of each type
No of each type
Nos. of each type
10 %For each type,size and range or


10 % for each type and rating but

minimum 1 No.
10 % for each type and range but
minimum 2 No.
79

c
SER Cards
Electronic modules of each type for

processor,controller, bus
communication, operator station,
memory module etc.
Network Cards/Switches
10 % for each type but minimum 2 No.
Communication Interface Cards
10 % for each type but minimum 1 No.
g
h
i
j
Optical Disk Drive

Optical Disk
DVD (R&W)
Hard Discs for servers & work station
2
10
100
k
l
m
n
o
p
q
r
Servers
Operator Stations
Printer Cartriges
SMPS for Printers
SVGA cards for printers
Data Bus cable
Data Bus Controller
Fibre Optic Cable Converter/Deconverter Unit(applicable if remote
I/O module is supplied)
VDU Monitor
Keyboard & Mouse/Track Ball with
connecting cable and plugs
Interposing Relay
2
4
10
2
2
2
2
4
Nos.
Nos.
Nos.
10 % of each type, size or minimum 2
Nos. whichever is higher.
No. of each type of server
Nos.
Nos. of each type
No of each type, rating
No. of each type
No. full length
No.
Nos.
2
4
No.
Nos. of each type
s
t
u
a
b
c
d
5
Clarified water pumps, Backwash

pumps, Filtered water pumps,
Regeneration pumps, Service &
Potable water pumps, sludge pumps,
neutralizing pit transfer pumps,UF/RO
pumps, wherever applicable
(Following spares are to be supplied
for each type of pump)
Bearings
Gland seals/mechanical seals
Couplings
Coupling pads/bushings
Spare RO memberanes
6
a
Valves (AS APPLICABLE)

Bonnet / cover gaskets
Gland Packings
Valve stems for size 50 mm NPS and

smaller
Valve stems for size 65mm NPS and

larger
10 % for each type and range but

minimum 1 No.
10 % for each type and but minimum 1
No.
10 % of total quantity
2
1
1
1
1
Sets
Set
Set
Set
10 % of total in each type
1 each for every set of 4

valves/specialities or part thereof,
subject to a maximum of 10,for each
size and type of valve/speciality.
1 set per valve/ speciality for each size
and type.
2 per set of 15 valves or part thereof,
subject to a maximum of 25, for each
size and type of valve.
1per set of 10 valves or part thereof,
subject to a maximum of 5, for each size
and type of valve.
80

e
Disc or Disc seat, as applicable for

Gate, Globe and safety valves and
Disc with Hinge pin for check valves
1per set of 10 valves or part thereof for

each size and type of valve.
Body seat ring for Gate, Globe and

Check valves
Yoke Bushing for Gate and Globe
valves
1per set of 25 valves or part thereof for

each size and type of valve.
1per set of 25 valves or part thereof
subject to a maximum of 5, for each size
and type of valve.
1per set Disc and seat for every 15 or
part thereof, subject to a maximum of 50
sets, for each size and type.
1 set of Bucket, Lever and Guide pin per
set of 10 traps or part thereof subject to
a maximum of 10, for each size and type
of trap.
1 per set of 6 traps or part thereof,
subject to a maximum of 10, for each
size and type of trap.
Sets of Control units per expansion joint.
Trap Disc and Seat
Bucket, Lever and Guide pin for

bucket traps
SS Screen for Traps with integral

strainers
Control units for Expansion Joints
81
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00

DATTASHEEETA

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
82
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
1.0
1.1
1.2
1.3
1.4
1.5
1.6
a
b
c
1.7
1.8
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
M PLANT SU
UPPLY PUMPS
DM
N
Number
S
Service
T
Type
D
Design Temp
perature
S
Suction Cond
dition
M
Material of Co
onstruction
C
Casing
Im
mpeller
sshaft
C
Capacity and
d head
L
Location
DU
UAL MEDIA FILTER
Tyype
Nos. required
Lo
ocation
D
Design Flow/D
DMF (Net)
D
Design Surface Flow Rate
e
a
at design flow
w
B
Backwash flo
ow rate
Supporting Ma
aterial for the
e
fill
2.8
Filter media
2.9
2.10
0
2.11
1
2.12
2
2.20
0
Supporting Be
ed
M
Minimum Bed
d Depth
S
Shell & Dish End Material
Thickness
T
Thickness
to
olerance/Allo
owance
In
nternal Paintting
E
External Pain
nting
M
Manhole
H
Hand hole
S
Sight Window
w
In
ntervals betw
ween two
ssuccessive ba
ackwash
D
Design code
2.21
1
D
Design presssure
2.22
2
2.23
3
D
Design Temp
perature
Free board (M
Minimum)
2.24
4
Filter Media Trap

T
2.13
3
2.14
4
2.15
5
2.16
6
2.17
7
2.18
8
2.19
9
2.25
5
3.0
3.1
3.2
3.3
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
3X
X70%
Co
ontinuous
Ve rtical centrifu
ugal
60 deg for mec
chanical design
Flo
ooded
2.5
5% Ni CI as per
p IS 210 FG
G 260
SS
S 316
SS
S 410
To suit net DM Plant outputt per stream of 70 cum/hr and Head to
t
eet the system requireme
ent.
me
Ne
ear DM Clariffied Water Sttorage Tank
Ve rtical Cylindrrical with dish
hed ends
3X
X70%
Ou
utdoor
To suit net DM Plant outputt per stream of 70 cum/hr
aximum 15 M3/Hr/M2
M
Ma
Min
nimum 2.5 tim
mes the design inlet flow
w rate
As per manufac
cturer standa
ard
Gra
aded Quartz
z Sand (free from
f
carbonaates & other foreign mattter)
and
d anthracite
Ro
ounded and graded
g
grave
el free from cclay & limesto
one
100
00 mm (excluding supporting bed)
CS
S :- SA516 Gr.70
Sh ell: 6 MM (m
minimum), Dis
shed end: 8M
MM (minimum
m)
As per the code
e requiremen
nt
Sh all be as perr customer approved painnting schedu
ule
ule
Min
nimum 2 nos
s., each of minimum 500m
mm dia
Min
nimum 1 no. of minimum 150mm dia
Min
nimum two nos
n
18 hrs
As per IS 2825 /ASME Sec. VIII Div I/Eqquivalent
Sh ut-off head of
o DM Plant supply
s
pumpp + Static Head (minimum
m 10
h
m) +5% overalll margin or 10Kg/cm2, whhichever is higher.
60 deg for mec
chanical design
75%
% of total be
ed depth
Sh all be provided at filter ou
utlet and bacckwash wate
er outlet of ea
ach
er.
filte
Suspended so
olids &
turrbidity at the
< 2 ppm and < 2 NTU respe
ectively
ou
utlet
A
AIR BLOWER
R FOR DUAL
L MEDIA FIL
LTER (DMF))
Number
Two (2X100%) [C
Common for all DMF].
Typ
pe
Rota
ary twin lobe oil free
Inter mittent
Duty
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
83
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
3.4
3.5
3.6
3.7
Ca
apacity & Hea
ad
Ma
aterial of consstruction
De
esign Temperrature
E
External Pain
nting
3.8
Acccessories Re
equired
4.0
4.1
4.2
4.3
AC
CTIVATED CARBON
C
FIL
LTER
T
Type
N
Nos. required
d
D
Design Flow//ACF (Net)
D
e
a
at design flow
w
S
Supporting Bed
4.4
4
4.5
4.6
F
Filter Media
4.7
4.8
S
T
Thickness
T
Thickness
to
olerance/Allo
owance
E
External Pain
nting
M
Manhole
H
Hand hole
S
Sight Window
w
In
ntervals betw
ween two
ssuccessive ba
ackwash
D
Design code
4.9
4.10
4.11
4.12
4.13
4.14
4.15
D
Design presssure
4.16
4.17
4.18
D
Design Temp
perature
M
Minimum Bed
d Depth
F
Free board (m
minimum)
F
Filter Media Trap
T
4.19
4.21
4.22
F
Free residuall chlorine,
ccolour & orga
anics at the
A
ACF outlet
L
Location
U
Under Drain System
S
T
Type
M
Material of Co
onstruction
4.20
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
As re
equired
CI ass per IS 210 Gr FG 260
60 de
eg C for mec
chanical design
ule
Moto rs, V belt witth guard, Flexible Couplinng, Discharg
ge Snubber, Suction
S
V
Instruments, comm
mon base pla
ate etc.
Filterr, Silencer, Valves,
hed ends
3X
X70%
aximum 20 M3/Hr/M2
M
Ma
Ro
ounded and graded
g
grave
el free from cclay & limesto
one
Gra
anular activa
ated carbon as
a per AWW
WA 8604 Dechlorination
gra
ade (Iodine number
n
should be minimuum1000)
The
e media shall work contin
nuously withoout any reac
ctivation or
rep
placement for minimum 1 year.
CS
S :- SA516 Gr.70
Sh ell: 6 mm (m
minimum), Dis
shed End: 8 mm (minimu
um)
As per the code
e requiremen
nt
ule
Min
nimum 2 nos
mm dia
Min
Min
nimum two nos
n
18 hrs
Sh ut-off head of
o DM Plant supply
s
pumpp + Static Head (minimum
m 10
m) +5% overalll margin or 10 kg/cm2 whhichever is higher.
60 deg C for mechanical de
esign
100
00 mm (excluding supporting bed)
75%
% of total be
ed depth
Sh all be provided at filter ou
utlet and bacckwash wate
er outlet of ea
ach
er.
filte
No
ot detectable (nil)
Ind
door
He
eader Lateral or strainer on
o plate, dessigned to avo
oid any nonuniiform flow.
Forr header late
eral, Header MSEP and laateral PP/PV
VC
Forr strainer on plate, plate MSEP and sstrainer PP/P
PVC
FIL
LTERED WA
ATER TANK
5.0
5.1
5.2
Number
Purrpose
5.3
Capacity
5.4
5.5
6.0
6.1
Typ
pe
Ma
aterial
DM
MF & ACF BA
ACKWASH PUMPS
Purrpose
For b
backwashing
g ACF and DMF.
One
e (1) no.
Forr backwashin
ng ACF and DMF.
D
Bacckwashing water
w
requirem
ment for onee DMF and on
ne ACF + 20
0%
marrgin
Verrtical cylindric
cal
PVC
C/HDPE.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
84
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
0
7.11
1
7.12
2
7.13
3
7.14
4
7.15
5
7.16
6
7.17
7
7.18
8
7.19
9
7.20
0
7.21
1
7.22
2
7.23
3
A
7.24
4
A
7.25
5
A
B
8.0
8.1
8.2
8.3
8.4
8.5
8.6
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
Qu
uantity
2X10
00%
Ca
apacity
To su
uit the system
m requireme
ent
Typ
pe
Horizzontal Centrifugal
He
ead
To su
uit the system
m requireme
ent
MO
OC of casing
SS 3
316
Imp
peller
SS 3
316
Shaft
SS 3
316 / SS 410
Seal
Mech
hanical Seal
ST
TRONG ACID
D CATION EXCHANGER
E
R (SAC)
Tyype
hed ends
Nos. required
3X7
70%
D
Design Flow/S
SAC (Net)
D
e
ot more than 40 M3/Hr/M2
2
No
a
at design flow
w
S
Service cycle
e
18 hrs.
CS
S :- SA516 Gr.70 with Rubber Lining ((3x1.5mm thk RL of
S
sho
ore hardness
s 65 + 5 Scale A)
T
Thickness
6M
MM (minimum
m) for Shell & 8 MM (minnimum) for Diished Ends
T
Thickness
As per the code
e requiremen
nt.
to
olerance/Allo
owance
E
External Pain
nting
ule
M
Manhole
Min
nimum 2 nos
mm dia
H
Hand hole
Min
S
Sight Window
w
Min
nimum two nos
n
R
Resin Type
Org
ganic monos
sphere/gel [H
H] form.
R
Regeneration
n
By Hydrochloric
c acid (HCL, as per IS 2665)
M
Mode of rege
eneration
Co
ountercurrentt
M
Minimum Ressin Bed Deptth
1.0
0M
D
Design code
D
Design presssure
10 kg/cm2
D
Design Tempe
erature
60 d
deg C for me
echanical design
Two
o nos- one at
a service outtlet and otherr at backwas
sh and rinse
R
Resin trap pro
ovided
outle
et.
Free board
50 % of total be
ed depth for SAC
S
D
Derating facto
or to be
co
onsidered on
n selected
10%
%
Exchange Capacity
R
Regenerant Distributor
D
M
Material of Co
onstruction
MS RL Header with
w PP/PVC
C laterals com
mplete with PP
P Strainer
In
nterface Colle
ector
M
Material of Co
onstruction
MS RL Header with
w PP/PVC
C laterals com
mplete with PP
P Strainer
Under drain System
S
He
oid any nonTyype
uniiform flow.
Forr header late
eral, Header MSRL and laateral PP/PV
VC
M
Material of Co
onstruction
Forr strainer on plate, plate MSRL and sstrainer PP/P
PVC
D
DEGASSER TOWER
T
Numbers Req
quired
3X7
70%
Service Cycle
e
18 h
hours
Tyype
Cou
unter Flow,
C
Capacity of to
ower (each)
Suittable to hand
dle 120% of the water floow from SAC on upstream
m.
Normal Flow Rate
R
per
To ssuit net DM Plant output per stream oof 70 cum/hrr
tow
wer
Fill Material
Polyypropylene Rasching
R
ring
gs/Pall Ringss.
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
85
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
8.7
8.8
8.9
8.10
0
8.11
1
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
10.2
2
Nott more that 5 ppm as CO2

IS 8
803
Atm
mospheric
60 d
deg C for me
echanical design.
CS:: SA 516 Gr. 70
Rub
bber, 4.5 mm
m thick (in thrree layers) ass per IS 4682 Part I Shorre
In
nternal Lining
g
Ha
ardness A 65+/-5
External Paintting
Sha
all be as per customer ap
pproved painnting schedule
Non
n Clogging, No
N corrosive type. All inteernals fittings
s, water
In
nternal Distrib
butors
disstribution tray
y and hand holes for loadding and rem
moval of packking
gs shall be provided.
p
ring
D
DEGASSED WATER
W
STO
ORAGE TAN
NK
Tyype
Horrizontal Cylin
ndrical
Numbers Req
quired
One
e (1X100%) (common for all the threee streams)
CS:: SA 516 Gr. 70 with rubb
ber lining (4.55 mm) in thre
ee layers as per
M
Material
IS 4
4682, Part-I. Shore Hardn
ness A 65+/--5
External Paintting
Sha
all be as per customer ap
pproved painnting schedule
Size
ed for one re
egeneration requirement
r
of all SAC units with 20%
%
Useful Capacity of each ta
ank
ma
argin.
D
Design code
IS 8
803.
D
Design pressu
ure
Atm
mospheric.
Thickness
Nott less than 8 mm.
DE
EGASSED AIR
A BLOWER
R
To
otal Six (2X1
100% per degasser toweer)
No
os. supplied
C
Centrifugal, oil free type
Typ
pe
10.3
3
Duty
C
Continuous
10.4
4
10.5
5
10.6
6
Ca
apacity & Hea
ad
Ma
De
esign Temperrature
A
As required
10.7
7
Acccessories Re
equired
8.12
2
8.13
3
8.14
4
9.0
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
10.0
0
10.1
1
11.0
0
11.1
1
11.2
2
11.3
3
11.4
4
11.5
5
11.6
6
11.7
7
11.8
8
11.9
9
11.1
10
12.0
0
12.1
1
12.2
2
12.3
3
12.4
4
12.5
5
12.6
6
C
CO2 content in
n effluent
D
Design Code
D
Design Pressu
ure
D
Design Tempe
erature
Shell Material
CI IS
S 210 FG 260
0
60 de
eg C for mec
chanical design
Moto
ors, V belt with guard, Fle
exible Coupli ng, Discharg
ge Snubber,
Suct ion Filter, Sillencer, Valve
es, Instrumennts, etc.
DE
EGASSED WATER
W
PU
UMPS
Qu
uantity
3X70
0%
Typ
pe
Horizzontal centriffugal
Conttinuous
Op
peration
Ca
apacity & Hea
ad
To su
uit net DM Plant output per
p stream off 70 cum/hr & TDH as req
quired
Suction Conditiions
Flood
ded
Ma
Ca
asing
AISI--316
Imp
peller
AISI--316
Shaft & shaft slleeve
AISI--316
Packing Seal
Mech
hanical Type
e
WE
EAK BASE ANION
A
EXCHANGER (W
WBA)
Tyype
Ve rtical Shell Type
T
with dished ends
Nos. required
3X
X70%
D
Design Flow/u
unit (Net)
De
esign Surface
e Flow Rate at
a
No
dessign flow
Service cycle
18 hrs.
CS
S
sho
ore hardness
s 65 + 5 Scale A)
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
86
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
12.7
7
12.8
8
12.9
9
12.1
10
12.1
11
12.1
12
12.1
13
12.1
14
12.1
15
12.1
16
12.1
17
12.1
18
12.1
19
12.2
20
12.2
21
12.2
22
12.2
23
A
12.2
24
A
12.2
25
A
B
13.0
0
13.1
1
13.2
2
13.3
3
13.4
4
13.5
5
13.6
6
13.7
7
13.8
8
13.9
9
13.1
10
13.1
11
13.1
12
13.1
13
13.1
14
13.1
15
13.1
16
13.1
17
13.1
18
13.1
19
13.2
20
13.2
21
13.2
22
S
Shell thicknesss
T
Thickness
to
olerance/Allo
owance
E
External Pain
nting
M
Manhole
H
Hand hole
S
Sight Window
w
R
Resin Type
R
Regeneration
n
M
Mode of rege
eneration
M
Minimum Ressin Depth
D
Design code
D
Design presssure
D
Design Tempe
erature
R
Resin trap pro
ovided
Free board
D
Derating facto
or to be
co
onsidered on
n selected
Exchange Capacity
R
D
M
Material of Co
onstruction
In
nterface Colle
ector
M
Material of Co
onstruction
Under drain System
S
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
6M
MM (minimum
As per the code
e requiremen
nt
ule
Min
nimum 2 nos
mm dia
Min
Min
nimum two nos
n
Org
ganic monos
sphere/gel tertiary aminne
By Sodium Hyd
droxide (NaO
OH as per IS 252)
Co
ountercurrentt
1.0
0M
As per IS 2825 / ASME SEC
C VIII DIV I/E
Equivalent
10 kg/cm2
60 d
deg C for me
echanical design
One
e at service outlet
o
and on
ne at backwaash and rinse
e outlet.
75 % of total be
ed depth for SBA
S
10%
%
MS RL Header with
w PP/PVC
C laterals com
mplete with PP
P Strainer
MS RL Header with
w PP/PVC
C laterals com
mplete with PP
P Strainer
He
Forr header late
VC
M
Material of Co
onstruction
PVC
ST
TRONG BAS
SE ANION EX
XCHANGER
R (SBA)
Tyype
T
with dished ends
Nos. required
3X
X70%
D
Design Flow/u
unit (Net)
De
esign Surface
e Flow Rate at
a
No
dessign flow
Service cycle
18 hrs.
CS
S
sho
ore hardness
s 65 + 5 Scale A)
S
Shell thicknesss
6M
MM (minimum
T
Thickness
As per the code
e requiremen
nt
to
olerance/Allo
owance
E
External Pain
nting
ule
M
Manhole
Min
nimum 2 nos
mm dia
H
Hand hole
Min
S
Sight Window
w
Min
nimum two nos
n
R
Resin Type
Org
ganic monos
sphere/gel [O
OH] form, Typpe I.
R
Regeneration
n
By Sodium Hyd
droxide (NaO
OH as per IS 252)
M
Mode of rege
eneration
Co
ountercurrentt
M
1.0
0M
D
Design code
C VIII DIV I/E
Equivalent
D
Design presssure
10 kg/cm2
D
Design Tempe
erature
60 d
deg C for me
echanical design
R
Resin trap pro
ovided
One
e at service outlet
o
and on
ne at backwaash and rinse
e outlet.
Free board
50 % of total be
ed depth for SBA
S
D
Derating facto
or to be
10%
%
Tyype
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
87
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
13.2
25
co
onsidered on
n selected
Exchange Capacity
R
D
M
Material of Co
onstruction
In
nterface Colle
ector
M
Material of Co
onstruction
Under drain System
S
Tyype
M
Material of Co
onstruction
14.0
0
14.1
1
14.2
2
14.3
3
M
MIXED BED UNIT
Tyype
Nos. required
D
Design Pressu
ure
D
Design Tempe
erature
D
Design Flow/u
unit (Net)
Service cycle
D
e
a
at design flow
w
13.2
23
A
13.2
24
A
14.4
4
14.5
5
14.6
6
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
MS RL Header with
w PP/PVC
C laterals com
mplete with PP
P Strainer
MS RL Header with
w PP/PVC
C laterals com
mplete with PP
P Strainer
He
Forr header late
eral, Header MSEP and laateral PP/PV
VC
Forr strainer on plate, plate MSEP and sstrainer PP/P
PVC
T
with dished ends
3X
X70%
10K
Kg/cm2
60 d
deg C for me
echanical design
18X
X5 hrsi.e, 90
0 hrs.
2
No
CS
sho
ore hardness
s 65 + 5 Scale A)
6M
MM (minimum
14.7
7
S
14.8
8
14.1
10
14.1
11
S
Shell thicknesss
T
Thickness
to
olerance/Allo
owance
E
External Pain
nting
M
Manhole
14.1
12
R
Resin Type
14.1
13
14.1
14
14.1
15
14.1
16
14.1
17
14.1
18
H
Hand hole
S
Sight Window
w
R
Regeneration
n
M
D
Design code
R
Resin trap pro
ovided

ule
Min
nimum 2 nos
mm dia
MB
B Resins: Org
ganic monos
sphere
Ine
ert resin: Ads
sorbent inert resin / Activee Resin (if ap
pplicable)
Min
Min
nimum two nos
n
By NaOH & HCL
H
1 M (excluding inert resin, iff applicable)
C VIII DIV I/E
Equivalent
On
ne at service outlet and one at backwaash and rinse outlet.
14.1
19
F
Free board
100
0 % of total bed
b depth for MB
14.9
9
14.2
23
D
Derating facto
or to be
considered on
o selected
E
Exchange Ca
apacity
R
D
M
Material of Co
onstruction
In
nterface Colle
ector
M
Material of Co
onstruction
Under drain System
S
Tyype
M
Material of Co
onstruction
14.2
20
14.2
21
A
14.2
22
A
15.0
0
15.1
1
15.2
2
15.3
3
15.4
4
As per code req

quirement
10%
%
MS RL Header with
w PP/PVC
C laterals com
mplete with PP
P Strainer
MS RL Header with
w PP/PVC
C laterals com
mplete with PP
P Strainer
He
Forr header late
VC
PVC
A
AIR BLOWER
R FOR MIXE
ED BEDS
Number
Two (2X100%) [C
Common for all MB].
Typ
pe
Rota
ary Twin Lobe
e
Inter
mittent
Duty
Ca
apacity & Hea
ad
As re
equired
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
88
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
15.5
5
15.6
6
Ma
De
esign Temperrature
15.7
7
A
Accessories Required
R
15.8
8
16.0
0
16.1
1
16.2
2
16.3
3
E
External Pain
nting
DE
ESCRIPTION
N FOR
CH
HEMICAL UN
NLOADING
PU
UMP
Numbers Requ
uired.
Typ
pe
Service.
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
CI IS
S 210 FG 260
0
60 de
eg C for mec
chanical design
Moto rs, V belt witth guard, Flexible Couplinng, Discharg
ge Snubber, Suction
S
V
Instruments, etc.
Filterr, Silencer, Valves,
ule
ACID
D UNLOADIN
NG PUMPS
ALK
KALI UNLOA
ADING PUMP
PS
2X10
00%
2X1000%
Inter mittent
Interrmittent
16.4
4
Ca
apacity & Hea
ad
Min. 20 m3/hr an
nd 10 MWC
ectively
respe
Min. 10 m3/hr an
nd 10 MWC
respeectively
16.5
5
Liq
quid to be handled
30-33
3 % HCL
48 % alkali
16.6
6
Suction Conditiion
Flood
ded
Floodded
16.7
7
Suction Straine
er
Y Tyype strainer shall be prov

vided
(MOC
C-PP).
Y T
Type strainer shall be provvided
(MOC
C-SS).
16.8
8
Ma
Co
ondition
16.9
9
Ca
asing and Imp
peller
PP
CI foor Casing & SS316

S
for Im
mpeller
16.1
10
We
earing rings
PP
SS
16.1
11
Base plate
Carb
bon Steel
Carbbon Steel.
16.1
12
Shaft
EN8+
+PP
BS:9970 EN8
16.1
13
Shaft sleeve
Cera
amic
SS3116 with flexib

ble coupling
16.1
14
Typ
pe of Shaft Sealing
S
Mech
hanical Seal
Mechhanical Seal
16.1
15
Op
perating Rang
ge
20 120 % of de
esign capacity
20 120 % of de
esign capacitty
16.1
16
Acccessories Re
equired for pump
Coup
pling guard, drain
d
plug, vent
valve
e, Y-Strainer
Couppling guard, drain plug, vent

v
valvee, Y-Strainerr
Flexiible coupling
Flexiible coupling
g
Appl icable
Appl icable
16.1
17
16.1
18
Typ
pe of couplin
ng between
mo
otor & pump
He
eliflex hoses with
w coupling
g&
iso
olation valvess
16.1
19
No
o. required
Two (2)
Two (2)
16.2
20
Sizze (mm)
80 m
mm dia
50 m
mm dia
16.2
21
Len
ngth
10 M
10 M
16.2
22
Ma
aterial
Helifflex
Helifflex
D STORAGE
E TANKS
ACID
ALK
KALI STORA
AGE TANKS
Two (2)
As pe
er BSEN 122
285-2:2005
Outd
door
50T e
each
Horizzontal cylindrical with dished
end, Atmospheric
c
Two (2)
As pper BSEN 122
285-2:2005
Outddoor
25T each
Horizzontal cylindrical with disshed
end, Atmospheric
17.1
1
17.2
2
17.3
3
17.4
4
DE
ESCRIPTION
N FOR
CH
HEMICAL ST
TORAGE TA
ANK
Qu
uantity (nos.)
De
esign Code
Loccation
Ca
apacity
17.5
5
Typ
pe & Pressure Class
17.0
0
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
89
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SEC
CTION: C1
REV
V NO: 00
17.6
6
De
esign Temperrature
60 de
eg C for mec
chanical design
17.7
7
17.8
8
Ma
aterials of Co
onstruction
Pro
otection / Lin
ning
FRP made of bis

sphenol resin
60 deeg C for mec

chanical design
(Thicckness minim
mum 8 mm)
SA5116 Gr.70 + 3x1.5mm
3
thk RL
17.9
9
Ou
utside
17.1
10
Shal l be as per customer

c
oved painting schedule
appro
30 33 %
17.1
12
17.1
13
17.1
14
17.1
15
18.0
0
18.1
1
18.2
2
Co
oncentration
Vent, overflow seal pots, drrain
d.
Shal l be provided
& ssample connection
Ma
anhole, stair-case, platforrm
Shal l be provided
d.
Fume absorberr
Shal l be provided
d.
CO
O2 absorber
N/A
Pro
ovision of 1 Spare
S
Nozzle
e
Shal l be provided
d.
AL
LKALI TRAN
NSFER CUM RECIRCUL
LATION PUM
MPS
Numbers Requ
uired.
2X10
00%
Typ
pe
Shal l be as per customer

c
app
proved
e
paintting schedule
48 % lye or flake
es
18.3
3
Co
oncentration of
o working media
m
4-50 %
18.4
4
Service
Inter mittent
18.5
5
Ca
apacity & Hea
ad
Min. 10 m3/hr an
nd 10 MWC respectively
r
18.6
6
Suction Conditiion
Flood
ded
18.7
7
Ma
18.8
8
Ca
asing
SS-3
316
18.9
9
Imp
peller
SS-3
316
18.1
10
Shaft
SS-4
410
18.1
11
Shaft sleeve
SS
18.1
12
Stu
uffing Box
SS
18.1
13
Suction Straine
er
Y-typ
pe in each Pump (MOC-S
SS)
19.0
0
TA
ANKS
CH
HEMICAL
HA
ANDLING/PR
REP
AR
RATION
ACID MEASURIN
NG TANK
19.1
1
Qu
uantity
Five nos.
n
(2 for SA
AC, 2 for MB
B
& 1 fo
or N.Pit).
Typ
pe
Vertic
cal Cylindrica
al with top
coverr hinged & fla
at bottom.
The ta
ank shall be fitted with
vent, drain, fume
w seal pots
absorrber, overflow
etc.
17.1
11
19.2
2
Shal l be provided
d.
N/A
Shal l be provided
d.
Shal l be provided
d.
ALKALI PREPN.
FOR
TANK (F
ALKALI
S)
FLAKES
One no
(Commo
on for
SBA, WB
BA and
MB).
Vertical
cal with
Cylindric
top cove
er hinged
& flat bottom.
k shall be
The tank
fitted with vent,
drain, CO
O2
absorber,
w seal
overflow
pots, dissolving
baskets, etc.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
90
Shal l be provided
d.
A
ALKALI MEA
ASURING TANK
T
F
Five nos. (2 for
f SBA & WBA,
W
2
ffor MB and 1 for N.Pit).
V
Vertical Cylin
ndrical with to
op
ccover hinged
d & flat bottom
m. The
ttank shall be
e fitted with vent,
ddrain, CO2 absorber,
a
ove
erflow
sseal pots, dis
ssolving baskkets,
eetc.
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
19.3
3
Useful Capacityy
(for each individ
dual
nk)
tan
19.4
4
Ma
aterials and
thicckness
19.5
5
Extternal Protecction
19.7
7
Vent, Overflow,
ain connectio
on
dra
Disssolving Basket
19.8
8
Agitator provide
ed
20.0
0
20.1
1
DO
OSING PUMP
PS
Qu
uantity
20.2
2
Ca
apacity & Hea
ad
(for each individ
dual
dossing pumps)
20.3
3
Ma
aterials of
Co
onstruction
19.6
6
21.0
0
21.1
1
21.2
2
21.3
3
21.4
4
21.5
5
21.6
6
21.7
7
21.8
8
21.9
9
SEC
CTION: C1
REV
V NO: 00
F
For SBA & WBA:
W
To holld
aadequate chemical equal to 120
% of one reg
generation
rrequirement for SBA & WBA
W
uunits.
F
For MB: To hold adequa
ate
cchemical equ
ual to 120 % of one
rregeneration
n requirement for
M
MB units.
F
For N.Pit: To
o hold adequ
uate
cchemical equ
ual to 120 % of
nneutralization
n requiremen
nt for
ttotal wastes of N.Pit.
S
To hold
d adequate
For SAC:
chemical equal to 120 % of
egeneration requirementt
one re
for SA
AC units.
For MB:
M To hold a
adequate
egeneration requirementt
one re
for MB
B units.
For N.Pit:
N
To hold
d adequate
alization requ
uirement for
neutra
total wastes
w
of N.P
Pit.
To hold
adequate
chemical equal
to 120 % of one
regenera
ation
requirem
ment for
SBA, WB
BA and
MB units
s
FRP made
m
of bisp
phenol resin
SA516 Gr.70
G
+
3x1.5mm
m thk RL
(thicknes
ss not
less thatt 6 mm)
S
SA516 Gr.70 + 3x1.5mm thk RL
(tthickness not less that 6 mm)
Shall be as per cu
ustomer
oved painting
g schedule
appro
Shall be as per
er
custome
approved
d
painting
e
schedule
S
Shall be as pe
er customer
aapproved pain
nting schedu
ule
Required
Not re
equired
d
R
Required
Required
SS 316
S
SS 316
Motor drriven
M
Motor driven stirrer
s
of SS 316
stirrer off SS 316
ACID
ALKALI
A
3 sets
s of Two (1W
W+1S); Total=
=6
3 sets of Twoo (1W+1S); Total=6
T
For SAC:
S
Capabl e of meeting
g
For
F SBA & W
WBA: Capab
ble of meetin
ng
regen
neration requ
uirement of SAC
S
units.
regeneration
r
n requiremen
nt of SBA & WBA
W
Head as required..
units.
u
Head aas required.
M Capable of meeting
For MB:
For
F MB: Cappable of mee
eting regenerration
regen
neration requ
uirement of MB
M units.
requirement
r
of MB units. Head as req
quired.
Head as required..
For
F N.Pit: C
Capable of me
eeting
N
Capablle of meeting
g
For N.Pit:
neutralization
n
n requiremen
nt for total wa
astes
neutra
alization requ
uirement for total
of
o N.Pit. Heaad as require
ed.
waste
es of N.Pit. H
Head as required.
SS-316
S
PP
AC
CTIVATED CARBON
C
FIL
LTER FOR A
ALKALI
T
Type
Vertical Cylindrical with dished endds
N
Nos. required
d
One no
D
Design Flow//ACF (Net)
10 cum/hrr
D
e at
Maximum 20 M3/Hr/M
M2
d
design flow
S
Supporting Bed
Rounded and graded gravel free frrom clay & limestone
Granular activated
a
carrbon as per A
AWWA 8604
4
F
Filter Media
Dechlorina
ation grade (Iodine
(
numbber should be
e
minimum1
1000)
S
CS :- SA5
516 Gr.70
T
Thickness
Shell: 6 mm
m (minimum
m), Dished Ennd: 8 mm (minimum)
T
Thickness tollerance/Allow
wance
As per the
e code requirrement
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
91
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
21.1
10
21.1
11
21.1
12
21.1
13
21.1
15
E
External Pain
nting
M
Manhole
H
Hand hole
S
Sight Window
w
In
ntervals betw
ween two
ssuccessive ba
ackwash
D
Design code
21.1
16
D
Design presssure
21.1
17
21.1
18
21.1
19
D
Design Temp
perature
M
Minimum Bed
d Depth
F
Free board (m
minimum)
F
Filter Media Trap
T
21.1
14
21.2
20
21.2
22
21.2
23
F
Free residuall chlorine, co
olour &
o
organics at th
he ACF outle
et
L
Location
U
Under Drain System
S
T
Type
21.2
24
M
Material of Co
onstruction
21.2
21
22.0
0
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
Shall be as
a per custom
mer approvedd painting sc
chedule
Minimum 2 nos., each of minimum
m 500mm dia
Minimum 1 no. of minimum 150mm
m dia
Minimum two nos
18 hrs
As per IS 2825 /ASME
E Sec. VIII Diiv I/Equivalent
Shut-off head of DM Plant
P
supply ppump + Static Head
cm2 whichevver
(minimum 10 m) +5% overall marggin or 10 kg/c
is higher.
60 deg C for mechanic
cal design
1000 mm (excluding supporting beed)
75% of tottal bed depth
h
Shall be provided
p
at fillter outlet an d backwash water outlett of
each filterr.
Not detecttable (nil)
Indoor
Header La
ateral or strainer on platee, designed to avoid any
non-uniforrm flow.
For heade
er lateral, Header MSEP and lateral PP/PVC
P
For straine
er on plate, plate
p
MSEP aand strainer PP/PVC
HO
OT WATER TANK
T
22.1
1
22.2
2
Qu
uantity
Typ
pe
22.3
3
Typ
pe of Heaterr/ Capacity
22.4
4
22.5
5
Temperature off alkali to be heated

Burn Out Prote
ection
22.6
6
Ma
aterial of Con
nstruction of tank
t
22.7
7
22.8
8
E
External Pain
nting
M
Manhole
NE
EUTRALISAT
TION PIT
23.0
0
SPE
EC NO: PE-TS-3392-163A-A001
24.0
0
Ne
eutralization Pit
25.0
0
Airr blowers fo
or Neutraliza
ation Pit
26.0
0
Efffluent Dispo
osal Pumps
One
Vertical, cylindrical with dished endss
Electric Hea
ater with 2 X 50 % electriccal heating coil
c / 120 % of
o
water requirred for regen
neration SBA
A, WBA, MB units
u
and N.P
Pit
To obtain te
emp of 50O C at alkali ejeector outlet within
w
2.5 hou
urs.
Shall be Pro
ovided
Shell CS to
t IS 2062 Gr.B, Dished E
End CS to IS 2062 Gr. B
Inside lined with Natural rubber (8 m
mm thick in six
s layers) suitable
perature of 70
7 deg C.
up to a temp
Shall be as
s per custom
mer approvedd painting sch
hedule
Minimum 2 nos., each of minimum
m 500mm dia
One (1) no. RCC with ac

cid-alkali resiistant tiling / equiv
20% of maxim
mum daily inffluents (DM + CPU).
Capacity: 12
CPU waste to
t be conside
ered minimuum 350 cum per regenera
ation.
No. of compartments: 2
Free board : 350 mm
A
Accessories : Panel mou
unted pH ind icator cum re
ecorder on
pump discha
arge recircula
ation headerr
2x100% Cen
ntrifugal, CI IS 210 FG2660
Capacity & Head:
H
As req
quired.
A
Accessories Required: Motors,
M
V bellt with guard,, Flexible Coupling,
Discharge Snubber,
S
Suc
ction Filter, S
Silencer, Valv
ves, Instrume
ents,
etc.
4
4x100% horizontal centrifugal pumpss, SS316
pty the entire
e pit in 4 hou rs + 10% ma
argin
Cap : to emp
TDH : As req
quired
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
92
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
27.0
0
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
DM
M REGENER
RATION PUM
MPS
27.1
1
27.2
2
Numbers Requ
uired.
Typ
pe
27.3
3
Ca
apacity (each
h)
27.4
4
He
ead
As Required
d.
27.5
5
Suction Conditiion
Flooded
27.6
6
Ma
27.7
7
Ca
asing
SS 316
27.8
8
Imp
peller
SS 316
27.9
9
Shaft
SS-410
27.1
10
Shaft sleeve
SS-410
27.1
11
Typ
pe of Shaft Sealing
S
Mechanical Seal
27.1
12
Pump Speed
As per syste
em requirement
28.0
0
29.0
0
29.1
1
29.2
2
29.3
3
29.4
4
29.5
5
29.6
6
29.7
7
29.8
8
29.9
9
30.0
0
30.1
1
30.2
2
30.3
3
30.4
4
30.5
5
30.6
6
30.7
7
30.8
8
30.9
9
31.0
0
31.1
1
31.2
2
31.3
3
31.4
4
31.5
5
31.6
6
31.7
7
31.8
8
31.9
9
32.0
0
Two (2), (1 working

w
+ 1 stand-by).
Horizontal centrifugal.
c
As required to regeneratte WBA, SBA
A, MB units and
a N.Pit+20
0%
margin.
UL
LTRAFILTER
RATION SYS
STEM
UF
F feed Pump
ps
Qu
uantity
Ca
apacity
Typ
pe
He
ead
MO
OC of casing
Imp
peller
Shaft
Seal
De
esign Temperrature
UF
F fast flush pumps
p
Qu
uantity
Ca
apacity
Typ
pe
He
ead
MO
OC of casing
Imp
peller
Shaft
Seal
De
esign Temperrature
UF
F backwash pumps
Qu
uantity
Ca
apacity
Typ
pe
He
ead
MO
OC of casing
Imp
peller
Shaft
Seal
De
esign Temperrature
UF
F Skid
3X70%
To suit the system
s
requirement
Horizontal Centrifugal
C
To suit the system
s
requirement
SS 316
SS 316
SS 316
Mechanical Seal
60 deg C for mechanical design.
2X100% (co
ommon for all the three sstreams)
To suit the system
s
requirement
C
To suit the system
s
requirement
SS 316
SS 316
SS 316 / SS
S 410
Mechanical Seal
2X100% (co
ommon for all the three sstreams)
To suit the system
s
requirement (min imum 70m3//hr each)
C
To suit the system
s
requirement
SS 316
SS 316
SS 316 / SS
S 410
Mechanical Seal
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
93
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
32.1
1
Ultra Filtration Units

U
32.2
2
MO
OC (Membrane)
32.3
3
32.4
4
32.5
5
32.6
6
32.7
7
32.8
8
32.9
9
33.0
0
33.1
1
33.2
2
33.3
3
33.4
4
33.5
5
33.6
6
33.7
7
Backwash Freq
quency
Typ
pe
Mo
olecular weig
ght cut off
No
o. of UF Modu
ules
Ho
ousing
Chemical Dosin
ng System fo
or UF
De
esign Temperrature
UF
F Feed tank
Ca
apacity
Position
Qu
uantity
MO
OC
De
esign Code
Thickness
Acccessories
34.0
0
SA
AFETY EQUIIPMENTS
35.0
36.0
36.1
Ma
aterial of Co
onstruction
PIP
PING
De
emineralized water
Insstrument air
36.2
2
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
3X70%
Polysulfone (60 inch in size)
s
/ As perr manufacturrers
dation.
recommend
As per manufacturers re
ecommendattion
Hollow Fibe
er
1,00,000
As per System Requirem
ment
UPVC
As per PID of DM PLAN
NT (PE-DG-3392-163A-A001)
To meet the
e system requirement
Vertical cylin
ndrical Atmospheric with flat bottom
1X100%
SA 516 Gr 70
7 with 4.5 mm
m rubber linning.
IS 803
Shell Plate: 8mm, Bottom
m Plate: 8mm
m, Roof Plate: 6mm
Platform, lad
dder, handra
ail, overflow, drain, CO2 absorber,
a
etcc.
Two sets of safety equip
pment comprrising PVC protection suits with
ber boots, fac
ce visors andd thick PVC gauntlets
g
sha
all also
hoods, rubb
be provided. A personne
el water drennch safety sh
hower and eyye bath
shall be provided near acid
a alkali un loading/hand
dling area.
Stainless stteel to ASTM

M A 312 TP 3304L (ERW) for all sizes
CS Galvanized as per IS
S 1239 Gr.B
B Galvanized
36.3
No
ormal service
e
ASTM A53 Gr.B
Co
orrosive Servvice (except DM
D
36.4
4
SS/MSRL
Wa
ater)
36.5
Accid and alkali service
CSRL for Acid
A
Service and
a SS304 fo
for alkali serv
vice
Efffluent dispossal piping from
m
36.6
HDPE as pe
er IS 4984 PN10
P
N-pit to Blow down Tank
Notte: All SS Pip
pes shall be of minimum Schedule 10
0S.
37.0
VA
ALVES
Notte: All valvess shall be dou
uble flanged type. The tyype of valves shall be as per the type shown in P&
&ID only.
x
x
x
37.1
37.2
2
No
on return valvve
Ebo
onite lined diaphragm vallves for corro
osive service
es
Elastomer lined butterfly vallves for norm
mal services
All automatic op
perated valvees shall be solenoid assissted
eumatic actuated.
pne
These valve
es shall be swing check ttype or dual plate type
Swing chec
ck type (non corrosive
c
appplication)
Body and disc : Cast iro
on
a door/disc
c pin: Cast stteel ASTM A216 Gr.WCB
B
Hinge pin and
Disc facing ring: stainles
ss steel
r
Stainles
ss steel
Body Seat ring:
c
waater (DM water, decationised
For applicattion of lime, corrosive
/deanionise
ed water), and air,thebodyy,cover and disc shall be
e lined
with naturall rubber,PTFE or Viton. B
Bolting shall be stainless steel.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
94
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
For acid services, the va

alves shall bbe of lined co
onstruction ass
bove and bod
dy/disc facin gring shall be
b of resilientt
specified ab
materials su
uch as natura
al rubber,PT
TFE or Viton.
For alkali se
ervice, the co
omplete valvve shall be sttainless steel
construction
n.
PUM
MPS AND PIIPE SELECT
TION CRITERIA.
Pu
ump and Pip
peline carry
ying water and
a
chemic
cals shall generally be sized on th
he following
g velocities
s.
Ho
owever wherever minim
mum pipe siz
zes are defi ned in the drawing/data
d
asheets, thee selected size
s
shall no
ot
be
e less than the specified
d size.
VELOCITY
V
IN
N m/sec.
BELOW 30
30-130 MM
200 MM AND
D ABOVE
MM.
Pu
ump Suction for water
-----1.2-1.5
1.2-1.8
Pu
ump discharg
ge for water
1.2-1.8
8
1.8-2.4
2.1-2.5
He
eader for watter
-------
1.5-2.4
1.8-2.4
Pu
ump Suction for chemicall
1.0-1.2
2
1.1-1.3
------solution
Pu
ump discharg
ge for chemiccal
1.2-1.4
4
1.3-1.5
-------solution
Grravity flows
1.0 (maxim
mum).
No
ote 1- TDH o
of all pumps
s shall be de
ecided assum
ming the following C values
v
in Haazen & Willia
ams
eq
quation for c
calculation of
o friction lo
oss.
a) Carbo
on steel pipe
es 100
b) C.I pip
pes 100
c) Rubbe
er lined stee
el pipe 120
0
d) PVC/H
HDPE pipes 120
gin shall be taken
t
over the
t pipe fric
ction losses for calculatting the pum
mp head.
10% marg
GUARA
ANTEE PARA
AMETERS
quality of DM water at the
t outlet off mixed bed units at des
sign flow raate shall be
The q
guarranteed by the bidder as
s follows:
x
x
x
x
x
x
x
x
x
put per stream

m between re
egeneration: Rated
Outp
ductivity at 20
0 Deg C: Not exceeding 0.1 micro mh
ho/cm
Cond
Reacctive silica: Not
N exceeding
g 0.01 ppm a
as SiO2
Totall silica: Not exceeding
e
0.0
02 ppm as S
SiO2
Totall hardness: Less
L
than 0.0
05 ppm
Chlorrides: Nil
Iron a
as Fe (max):: Nil
Totall dissolved so
olids: Less th
han 0.05 ppm
m
pH: 7 + 0.2
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
95
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00
o, the followiing parametters need to

o be guarantteed by the bidder:
Also
x
x
x
et of SAC units: 1 ppm Na as CaCO3

3
Outle
Outle
et of degasse
er units: 5 pp
pm CO2
Outle
et of SBA units: 0.1 ppm Silica as SiO
O2 and condu
uctivity< 6 micromho/cm
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
96
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C1
REV
V NO: 00

P
P&ID
D

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
97
98
99
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C2
REV
V NO: 00
S
SECTION
N C2
SPEC
CIFIC TEC
CHNICAL SPECIFICATIO
ON
E
ELECTR
RICAL
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
100

TITLE:
SPECIFICATION NO.
ELECTRICAL EQUIPMENT SPECIFICATION
FOR
DM PLANT
2X660 MW SURATGARH TPS, UNIT-7&8
VOLUME NO. :
II-B
SECTION:
C
REV NO. : 00 DATE: 20/09/2013
SHEET: 1 OF
1
SPECIFIC TECHNICAL REQUIREMENTS: ELECTRICAL

1.0
SCOPE OF ENQUIRY
General technical requirement of LT motors are indicated in specification no. PE-SS999-506-E101_Rev00. Project specific technical requirement for motors are listed
in customer specification for motor & actuators. Stipulations of Customer
Specifications (inclusive of Datasheet-A for motors & actuators) shall prevail, in case
of conflicts between Customer specification and General technical requirements for
LT Motors.
2.0
a)
b)
EQUIPMENT & SERVICES TO BE PROVIDED BY BIDDER:

Services and equipment as per Electrical Scope between BHEL and Vendor.
Any item/work either supply of equipment or erection material which have not been
specifically mentioned but are necessary to complete the work for trouble free and efficient
operation of the plant shall be deemed to be included within the scope of this specification.
The same shall be provided by the bidder without any technical, commercial, delivery
implications to BHEL/Customer.
c)
d)
e)
f)
g)
h)
i)
j)
3.0
Supply of mandatory spares as specified in the specifications of mechanical equipments.

Erection and commissioning spares.
Erection & Maintenance tools & tackles.
Electrical load requirement for DM PLANT.
All equipment shall be suitable for the power supply fault levels and other climatic conditions
mentioned in the enclosed project information.
Bidder to furnish list of makes for each equipment at contract stage, which shall be subject
to customer /BHEL approval without any commercial and delivery implications to BHEL.
Various drawings, data sheet as per required format, quality plans, calculations, Type test &
Routine test reports & certificates, operation and maintenance manuals, Complete technical
literature with catalogues etc shall be furnished as specified at contract stage. All documents
shall be subject to customer /BHEL approval without any commercial implications to BHEL.
The sub-vendor list for various electrical items is subject to BHEL/Customer approval without
any commercial implications.
EQUIPMENT & SERVICES TO BE PROVIDED BY PURCHASER FOR ELECTRICAL &
TERMINAL POINTS:
Refer Electrical Scope between BHEL and Vendor.
4.0
DOCUMENTS TO BE SUBMITTED ALONG WITH BID
4.1 Bidder shall confirm total compliance to the electrical specification without any deviation
from the technical/ quality assurance requirements stipulated. In line with this, the bidder
as technical offer shall furnish two signed and stamped copies of the following:
a)
A copy of this sheet Electrical Equipment Specification for DM PLANT and sheet
Electrical Scope between BHEL and Vendor with bidders signature and company
stamp.
b)
List of Erection and Commissioning spares.
c)
List of Erection & Maintenance tools & tackles.
d)
Electrical load requirement.
4.2
No technical submittal such as copies of data sheets, drawings, write-up, quality plans, type
test certificates, technical literature, etc, is required during tender stage. Any such
submission even if made, shall not be considered as part of offer.
101

TITLE:
SPECIFICATION NO.
ELECTRICAL EQUIPMENT SPECIFICATION
FOR
DM PLANT
2X660 MW SURATGARH TPS, UNIT-7&8
5.0
VOLUME NO. :
II-B
SECTION:
C
REV NO. : 00 DATE: 20/09/2013
SHEET: 1 OF
1
LIST OF ENCLOSURES
5.1 Electrical scope between BHEL & Vendor

5.2 General Technical requirements for LV motors (PE-SS-999-506-E101_Rev00)
5.3 Customer Technical specification for motor & actuator along with data sheet A of
motor & actuator.
5.4 Electrical Load data format
5.5 Datasheet-C of Motors & Actuators (to be filled by Vendor)
5.6 QP for motors
102
Local Push Button Station (For motors)

Power cables, control cables and screened control cables
for
a) both end equipment in BHELs scope
b) both end equipment in vendors scope
c) one end equipment in vendors scope
Any special type of cable like compensating, co-axial,

prefab, MICC, fibre optical etc.
Cable trays, accessories & cable trays supporting system
Cable glands and lugs for equipment supplied by Vendor
Conduit and conduit accessories for cabling between

equipments supplied by vendor
2
3
5
6
415V MCC
DETAILS
S.NO
PROJECT :
Vendor
BHEL
Vendor
103
PAGE 1 OF 3
Vendor
BHEL
Vendor
Vendor
BHEL
Vendor
BHEL
BHEL
BHEL
BHEL
Vendor
BHEL
BHEL
SCOPE E&C
BHEL
BHEL
SCOPE
SUPPLY
1. Double compression Ni-Cr plated brass cable glands

2. Solder less crimping type heavy duty tinned copper lugs for power
cables
3. Solder less crimping type heavy duty copper lugs for control cables.
Conduits shall be medium duty, hot dip galvanised cold rolled mild steel
rigid conduit as per IS: 9537. Makes of conduits shall be subject to
1. 415 V AC/240 V AC (3 phase , 3 wire) supply shall be provided by BHEL

based on load data provided by vendor at contract stage for all equipment
supplied by vendor as part of contract including power supply equipment
(battery charger etc) required for the PLC/control panel (as applicable) for
the system supplied by vendor.
2. Interposing relays (RE 302 of Jyoti make or equivalent), if required for
PLC and microprocessor based systems, shall be provided by BHEL in
MCCs. Requirement of these relays shall be furnished by vendor during
detailed engineering stage.
3. 3. Single phase supply (if required by vendor) to be
arranged by vendor only.
Located near the motor.
1. Sizes and quantity of cables required shall be informed by vendor at
contract stage (based on inputs provided by BHEL). Finalisation of cable
sizes shall be done by BHEL. Vendor shall provide lugs & glands
accordingly.
2. Termination at BHEL equipment terminals by BHEL.
3. Termination at Vendor equipment terminals by Vendor.
REMARKS
2X660MW SURATGARH STPS , STAGE-V, UNIT 7 & 8
REV : 01 DATE : 05.11.13

ANNEXURE I TO SECTION C : STANDARD ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR
PACKAGE : DM PLANT PLANT
Lighting
Equipment grounding & lightning protection
Below grade grounding
LT /HT Motors with base plate and foundation hardware
Mandatory spares
Recommended O & M spares, E & C spares, erection &
maintenance tools & tackle.
Any other equipment/material/service required for
completeness of system but not specified above (to
ensure trouble free and efficient operation of the system).
a) Input cable schedules (C & I)
b) Cable interconnection details for above
c) Cable block diagram
Equipment layout drawings
Electrical Equipment GA drawing
8
9
10
11
12
13
17
16
15
14
DETAILS
S.NO
Vendor
Vendor
Vendor
Vendor
104
PAGE 2 OF 3
Vendor
Vendor
Vendor
BHEL
BHEL
BHEL
Vendor
-
SCOPE E&C
BHEL
BHEL
BHEL
Vendor
Vendor
Vendor
SCOPE
SUPPLY
Cable listing for C & I systems for vendor supplied equipment shall be
furnished during detail engineering by vendor in soft copies in the BHEL
cable schedule format.
1. For ensuring cabling requirements are met, vendor shall furnish
layout drawings (both in print form as well as in AUTOCAD) of the
complete plant (including electrical area) indicating location and
identification of all equipment requiring cabling, and shall
incorporate cable trays routing details marked on the drawing as
per PEM interface comments. Electrical equipment layout drawing
shall be subjected to BHEL/ customer approval.
2. Layout drawing preparation wherever in vendors scope: the
cabling arrangement of the same (wherever overhead cable trays,
trenches, cable ducts etc) shall be decided during contract stage,
and the arrangement philosophy/ approval of the same shall be
subject to BHEL/Customer approval without any commercial implications
to BHEL.
For necessary interface review.
Makes shall be subject to customer/ BHEL approval at contract stage.

Vendor to quote as per specification.
As per specification
customer/ BHEL approval at contract stage.
REMARKS
REV : 01 DATE : 05.11.13

DETAILS
SCOPE
SUPPLY
SCOPE E&C
REMARKS
105
PAGE 3 OF 3
1. Make of all electrical equipments/items supplied shall be reputed make & shall be subject to approval of BHEL/customer after award of contract.
2. All QPs shall be subject to approval of BHEL/customer after award of contract without any commercial implication.
3. For skid mounted system, 2 nos. (1W+1S) supply feeders of 415 V, 3 phase, 3 wire AC shall be provided by BHEL. Complete skid including changeover between
feeders/starters/LCP/ inter-locks/protection devices /any other supply etc. shall be in bidders scope only. Bidder to also provide 24 V AC supply and suitable
arrangement for switching it on automatically for heating of motor stator winding during motor's idle time.
NOTES:
S.NO
REV : 01 DATE : 05.11.13

NOTES:
NAME
PLATE
MAX.
CONT.
DEMAND
(MCR)
UNIT (U)/STN (S)

4
VOLTAGE CODE*
7
FEEDER CODE**
8
CONT.(C)/ INTT.(I)
EMER. LOAD (Y)

9 10
11
STARTING TIME
>5 SEC (Y)
12
LOCATION
13
BOARD
NO.
14
SIZE
CODE
15
NOs
CABLE
16
17
CONTROL
CODE
18
REMARKS
LOAD DATA
(ELECTRICAL)
2. ABBREVIATIONS
(cc): G=220 V, H=110 V, J=48 V, K=+24V, L=-24 V
19
LOAD No.
ELECTRICAL
GAS CHLORINATION PLANT
2X660 MW SURATGARH 7&8
ORIGINATING AGENCY
NAME
SIGN.
SHEET 1 OF 1
REV. 00
PEM (ELECTRICAL)
DATA FILLED UP ON
DATA ENTERED ON
DES SIGN. & DATE
JOB NO.
PROJECT TITLE
SYSTEM / S
DEPTT. / SECTION
: ** FEEDER CODE (8):- U=UNIDIRECTIONAL STARTER, B=BI-DIRECTIONAL STARTER, S=SUPPLY FEEDER, D=SUPPLY FEEDER (CONTACTER CONTROLLED)
: * VOLTAGE CODE (7):- (ac) A=11 KV, B=6.6 KV, C=3.3 KV, D=415 V, E=240 V (1 PH), F=110 V
1. COLUMN 1 TO 12 & 18 SHALL BE FILLED BY THE REQUISITIONER (ORIGINATING AGENCY); REMAINING COLUMNS ARE TO BE FILLED UP BY PEM (ELECTRICAL)
LOAD TITLE
RUNNING
Nos.
STANDBY
RATING (KW / A)
BLOCK CABLE
DRG. No.
SCOPEMATRIXFORCONTROLOFSWITCHGEARBREAKERSFROMPLCFOROFFSITEAREAS
CONTROL
REV
SYSTEM
Sno.
OFFSITESYSTEM/
PACKAGE
Switchgeartobecontrolledfrom
Vendor'sPLC
Totalno.ofbreakers
No.ofoutgoingtie
No.of
tobecontrolledfrom
No.ofIncomer&
breakers(Otherthan
switchgearsto
PLC(Otherthan
Buscouplerbreakers
motorfeeder)
becontrolled
motorfeeder)
TYPE
EffluentTreatment
1.ETPMCC
Plant
PLC
1.ElectroChlorinationMCC,
ElectroChlorination
2.AdminMCC&
Plant
3.CanteenMCC
PLC
CompressedAir
system
1.ElectricalMCC
PLC
1.DMPlantMCCand
2.FilterwaterMCC
12
PLC
1.CPUMCC
PLC
1.PTPlantMCC
1.HydrogenPlantMCCand
2.STPMCC
PLC
PLC
4 DMWaterPlant
Condensate
5
PolishingUnit
6 PreTreatment
7 HYDROGENPLANT
Tentativeno.ofsignalstobe
consideredfor"eachbreaker"
Nos.
Approx.No.ofBinaryInputs:
Approx.No.ofBinaryOutputs:
Approx.No.ofAnalogInputs:
40
8
5
Remarks:
DetailsoftheswitchgeartobecontrolledfromrespectivePLCisgiveninscopematrixabove.Tentativenumberofsignalsperbreaker(Tobeconsideredforeach
1 breakerseperately)isalsoprovidedabove.
MimicforSingleLineDiagramoftheswitchgearlocatedinoffsiteareashallbeprovidedbyPLCvendorintheOWES.Itshallbepossibletoprovideclose&open
2 commandstotheapplicablebreakersoftheswitchgearapartfrommotorfeeders.SLDinputforthemimicshallbeprovidedduringdetailengineering.
PLCshallprovidethestatusindications,metering&AlarmsignalsfortheswitchgearlocatedintheoffsiteareaaspertheTCEspecificationVolumeIVsectior:D9
3 sheet13to15.
4 PLCshallalsoprovidestatusindications&alarmannunciationsfortransformerslocatedintheoffsitearea.
5 PLCvendorshallprovidedrawingspertainingtoelectricalcontrolsystemforreview&approvalduringdetailengineering.
107
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110
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: C3
REV
V NO: 00
S
SECTION
N C3
SPEC
CIFIC TEC
CHNICAL SPECIFICATIO
ON
CO
ONTROL
L & INSTR
RUMENT
TATION
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
111
C & I SPECIFICATIONS
FOR
DM PLANT
(PLC BASED)

;0:683(5&5,7,&$/736685$7*$5+67$*(981,7
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5(900
-2%12392
'$7(24.10.13
112
'(6*
&+.
$33'
AW
6./ATy
%6
1.0.0
SCOPE OF WORK
113

PROJECT TITLE
FOR DM PLANT (PLC BASED)
2 X 660 MW SURATGARH TPS
Bidder'sScopeforC&IforDMPlant
1.ThecontrolsforDMplantshallberealizedinPLCbasedcontrolsystem.PLCshallbeinBidder's
scope&specificationofPLCshallbeasperPart2.2.0oftheC&Ispecification.
2.TherequirementsgivenbelowaretobereadinconjunctionwithdetailedTechnicalspecification
enclosedinthespecification.Furtherincaseofanydiscrepancyintherequirementwithinthesame
sectionnotedbythebidderinthespecification,thesamewillbebroughttothenoticeofBHELinthe
formofprebidclarification.Inabsenceofanyprebidclarification,themorestringentrequirementas
perinterpretationofcustomershallprevailwithoutanycommercialimplication.
3.BiddershallprovidePLCSystemtrainingforhardware&softwaretoCustomerfor1weekfor2
persons.
4.AlltheInstrumentationasshowninP&IDshallbeinbidder'sscope.AllPrimaryandSecondary
Instrumentsforthepackageshallbesupplied,alongwithaccessorieslikeimpulsepipe,fittings&valve
manifoldsetcasperInstallationdiagram.(Part2.4.0ofC&ISpecification)Necessaryracksrequiredfor
mountingoftheseinstrumentsshallbesuppliedbybidder.
5.InadditiontoPLCbasedsystem,Biddershallprovide2nos.OWES,keyboard,mouse&2nos.A3
ColourlaserjetprintersinDMplantlocalcontrolroom.OWES,Keyboard,ColourlaserjetPrintershallbe
asspecifiedinPart2.2.0oftheC&Ispecification.
6.Plantschematicformonitoring&operationshallbeavailableonalltheOWES.Biddertofurther
submitlistofsignals(inBHELformatenclosedinPart5.0.0ofC&Ispecification)alongwithapplicable
schematicformonitoringinDCS.
7.TimesynchronizationofPLCwithMasterClockSystemistobecarriedout.Biddertoprovide
necessarysoftware/hardwareforthesameatPLCend.
8.RedundantBidirectionalOPCcommunicationlinkwithEthernetTCP/IPProtocolshallbeprovidedby
BidderbetweenPLC&DCSthroughOFCforControl&monitoring.
9.BiddershallprovidespareI/Ochannels:AlltypesofI/Omodulesshallbeprovidedwith10%Spare
channels.Sparechannelsshallbewiredandshallbedistributedamongthecontrolprocessors,10%hot
spareI/Omodules(installed)shallbeprovided,10%spareslotsforI/Omodulesdistributedamongthe
controlprocessors.
10.EachPLChastobeaccompaniedbyaLIU(LightInterfaceUnit/Fibrepatchcord,converter)which
hasmultimodeSCcouplers/adapters.
114

PROJECT TITLE

11.Allbidirectionaldrivesarenonintegralstartertype,typicalHookUpdiagramofdrivesisincluded
forreference(subjecttoCustomerapproval).
12.Biddertoprovide230VUPSforDMplantsystemPLC&itsassociatedHMIasperUPSsingleline
diagram&UPSspecificationenclosedinPart2.2.0ofC&Ispecification.Further24VDCrequiredfor
operationofanyinstrument/equipment/systemshallbederivedbyBidderfrom230VUPS.
13.Allinstruments/drivesshallbeterminatedonJB/PanelbyBidder.Instruments/Drives,JB/Panel,
Connectinginstrumentcable&controlcableareinBidder'sscope.
14.ThescopeofcableshallbereferredinElectricalscopesplitsheetinElectricalportionofthe
specification.
16.Biddershallprovidethenecessarycushionedrevolvingindependentlyadjustableseat/backchairs
andGlasstopTeakwoodtablesforeachLocalOperatorstation(2Nos.OWES)andPrintertableforeach
printer(2nos.printers)inLocalcontrolrooms.
17.BiddertoprovideTemperaturetransmittersalongwithitscompensatingcable,JB/rack&other
erectionhardware.
18.415VACsupplyshallbeprovidedbyBHELatasinglepoint,furtherdistributiontovarious
instruments/EquipmentsoftheDMplantsystemshallbeinBidder'sscope.Biddertoincludethe
necessarypowerdistributionboardinhisscope.Anypowersupplyotherthantheabove,ifrequiredfor
anyinstrument/equipmenthastobederivedfromtheabovesupply&allthenecessaryhardwarefor
thesameshallbeinBidder'sscope.
19.BiddertoperformtestsofC&Iitems/instruments/systemsasperPart3.0.0oftheC&Ispecification.
20.BiddertonotethatallthetransmitterssuppliedbyBiddershallberackmounted.Thetransmitter
racksshallbeinBidder'sscope.Alsonoinstruments/analyzers&JBs/Racksshouldbeprotrudingonthe
walkway.
21.Biddertoprovidesystemcabinets&marshallingcabinetsforallthesystemsinBidder'sscope.
22.InstrumentinstallationandaccessoriesrequiredforthesameshallbeinBidder'sscopeandshallbe
aspertheattachedinstrumentinstallationdiagrams.Howeveranyinstrument/analyzerinstallationnot
coveredinspecification,thesameshallbesubjecttocustomerandBHELapprovalduringdetailed
engineering.
115

PROJECT TITLE

23.AlltemperaturesensorsprovidedbyBiddershallbeDuplextypeandBiddershallprovidefield
mountedtemperaturetransmitters(SMARTTYPE)foralltemperaturemeasurementapplications.Direct
wiringofRTDorT/CtoPLCisnotacceptable.
24.Cablesizeforinstrumentationcableshallbe0.8sq.mm.andforControlcable,cablesizeshallbe1.5
sq.mm.
25.BiddertofollowMeasurement&ControlPhilosophy(Part2.5.0ofC&ISpecification)fordesigning
logics.Redundancyofsensors(tobeprovidedbyBidder)shallalsobeasperMeasurement&Control
philosophy.
26.DMplantPLC(inDMplantbidder'sscope)istobehardwiredinterfacedwithPTplantPLCforcontrol
&monitoring.Allthenecessaryhardware&softwarerequiredforthesameatDMplantPLCendshall
beinDMplantBidder'sscope.Tentativeno.ofI/Ostobeexchangedshallbe20(Analog/Binarytobe
decidedduringdetailedengineering).Also,Cableschedule&interconnectionforthesignalexchange
betweenDMplantPLC&PTplantPLCshallbefurnishedbyDMplantbidder.Erection&commissioning
ofcables,whereoneendisinDMplantbidder'sscopeistobedonebyDMplantBidder.Thisinterfacing
requirementisinadditiontointerfacingofDMplantPLCwithDCS(asmentionedatS.No.8).
Note:
1.Allequipmentitemsshallbeoflatestdesignwithprovenontrackrecord.
2.Theabovegivenscopeisminimum.Anyitem/equipmentnotindicatedabovehoweverrequiredfor
thecompletenessofthesystemistobesuppliedbybidderwithoutanytechnical,commercialand
deliveryimplicationtoBHEL.
116
DM Plant Instrumentation
The plant instrumentation shall be as per following:
x
x
x
x
x
x
x
x
x
x
x
x
x
Inlet and outlet pressure indicators for vessels and discharge pressure indicators for
various pumps.
Inlet (rate of) flow indicators and outlet flow totalizers.
Conductivity transmitter at outlet of each ion exchange unit. Conductivity
comparators & online sodium analyzers shall be provided for SAC units.
Flow transmitters at outlet of each ion exchange unit
Differential pressure switches
Residual chlorine analyzers (Online) at outlet of ACFs
pH recorders and transmitters
Pressure switches
Flow switches at filter outlet.
Outlet silica analyzer cum recorder at outlet of Anion & MB units with multipoint
recorder.
Density indicators for regenerant chemical solutions.
Tanks including filtered water tank, degassed water storage tank and UF feed tank level indicators and level switches with protection interlocks for associated pumps.
Instrumentation & control cables and erection hardware.
Note: Please note that the details given above are minimum requirements, however the requirements of
P&ID, Datasheet-A and the technical specification to be fulfilled completely. In addition to above any
other instruments required to complete the system requirement, shall be provided by bidder without any
technical, commercial and delivery implications to BHEL and customer.
117
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D
REV
V NO: 00

SEECTIOND

G
GENERA
ALTECH
HNICALREQUIR
REMEN
NT

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
118
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00

SEC
CTIOND1

GEENERALLTECHN
NICALR
REQUIR
REMENT
TMECCHANICA
AL

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
119
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00

TECHNICALSSPECIFICATION
NFOR

&STOR
RAGEVE
ESSEL
PRESSSURE&

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
120

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s&%\)
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!#$&*&ia*)\*
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("
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#$*`*)*)%&*s&\)c$s&)**`gc)
)+a)a&*)+&%&)+a)a&*)+&\)
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134
%& '# &(

SPEC NO.
TCE-M4-185-25
MINIMUM INSPECTION REQUIREMENTS FOR

DEAERATOR/PRESSURE VESSELS/PRESSURE FILTERS
SECTION : D
SHEET 1
OF 2
INSPN
CATEGORY
1.
2.
PLATES FOR
SHELL, ETC.
DISHED ENDS
Mechanical properties,
Chemical Composition
Review of test
certificates
UT on plates
100%
Mechanical Properties,
Review of test
certificates
UT on plates before dishing
100%
Heat treatment chart review
Dimensional checks after dishing
MT/PT on knuckle portion and

weld edges
100%
Mechanical testing of test coupon

after heat treatment
3.
4.
NOZZLES
ASSEMBLY
RT on all butt joints if any after

dishing
100%
Mechanical Properties,
Review of test
certificates
UT & MT on Nozzle forgings
100%
RT of longitudinal and
circumferential butt joints
100%
RT/UT on final closing seam
100%
MT/PT of attachment welds
100%
RT of nozzle to flange butt joints and

long seam butt joints in nozzles
fabricated from plates
100%
RT/UT & MT/PT on nozzle to shell

welds when nozzle size exceeds
100mm NB & 19mm thick.
100%
All other nozzle welds
100% MT/PT
ISSUE
R3
TCE FORM 329 R3
135

SPEC NO.
TCE-M4-185-25

DEAERATOR/PRESSURE VESSELS/PRESSURE FILTERS
SECTION : D
SHEET 2
OF 2
INSPN
CATEGORY
4.
ASSEMBLY
Heat treatment chart review
Pneumatic Test of Reinforcement

Pad welds
Mechanical Testing of Production

test coupons
Hydro Test
Visual and Dimensional check
Filter media/quantity and

specification for pressure filters
NOTES:
(A) INSPN CATEGORY :
A - WITNESSED BY TCE/PURCHASER
B - WITNESSED BY TCE/PURCHASERS DISCRETION
C - CERTIFICATES REVIEW BY TCE/PURCHASER
(B) ACCEPTANCE NORMS:
(1) MATERIALS
: As per applicable material specifications
(2) WELDING
: As per ASME Section-IX
(3) NON DESTRUCTIVE

TESTING & OTHER TESTS
: As per ASME Section-V/Section-VIII Div 1

requirements, BS 5500, IBR/HEI
(C) PT - LIQUID PENETRANT TESTING

MT - MAGNETIC PARTICLE TESTING
UT - ULTRASONIC TESTING
RT - RADIOGRAPHIC TESTING
D) Deaerator [Header, Storage tank] welds shall be Post weld Heat treated for all thickness. Soaking
time and temperature shall be as per ASME Sec VIII Div I.
ISSUE
R3
TCE FORM 329 R3
136

SPEC NO.
TCE-M4-185-49
SECTION : D

ATMOSPHERIC TANKS
SHEET 1 OF 2
INSPN
CATEGORY
1.0
RAW MATERIALS:
PLATES, SECTIONS,
BARS, FORGINGS,
PIPES, BOLTS,
NUTS
2.0
a) Chemical Composition & Mechanical

Properties
b) UT for plates t 25 mm thick and
forgings > 50 mm diameter
100%
c) Hydro test for pipes (if not done at mills)
a) Welding procedure & welders

performance qualification
IN PROCESS
INSPECTION:
WELDING
b) Butt welds over 25mm thick

- 10% of total vertical seam length plus
all T joints, 2% of total horizontal
seam length
RT
RT
RT
10% RT
c) Butt welds over 13mm upto 25mm thick

- 10% of total vertical seam length (Half
of the radiographs to include T joints),
2% of total horizontal seam length
d) Butt welds upto 13mm thick
- 1% of total vertical seam length, 1%
of total horizontal seam length
e) Annular plates
3.0
FINAL INSPECTION
a) Water fill test
b) Roof & Bottom - Vacuum/Pneumatic

Test
c) Dimensional inspection
ISSUE
R3
TCE FORM 329 R3
137

SPEC NO.
TCE-M4-185-49

ATMOSPHERIC TANKS
SECTION : D
SHEET 2 OF 2
NOTES:
(A) INSPN CATEGORY:
A - WITNESSED BY TCE/PURCHASER
B - WITNESSED BY TCE/PURCHASERS DISCRETION
C - CERTIFICATES REVIEW BY TCE/PURCHASER
(B) ACCEPTANCE NORMS:
(1) MATERIALS
: As per applicable material specifications
(2) WELDING
: As per Section-IX
(3) NON DESTRUCTIVE TESTING
: As per ASME Section-V requirements
(C) PT - LIQUID PENETRANT TESTING

MT - MAGNETIC PARTICLE TESTING
UT - ULTRASONIC TESTING
RT - RADIOGRAPHIC TESTING
ISSUE
R3
TCE FORM 329 R3
138
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
TE
ECHNICAL SPECIFICA
ATION FOR
R
PR
RESSURE & STORAG
GE VESSEL
L
(CONTINUED)
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
139
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
1.00.00
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
GENE
ERAL
The following
f
prrincipal presssure and atmospheric vessels ffor the systtem has
been covered in this part of specificatio
on.
1.
Dual Med
dia Filter
2.
Degassed Water Sto

orage Tank
3.
Regenera
ation Vesse
els
4.
Mixed Be
ed
5.
Alkali dilu
uent Heating
g cum Stora
age Vessel.( hot waterr tank)
6.
Activated
d carbon filte
er
7.
Alkali Pre
eparation Ta
ank
8.
Alkali Day
y/Measuring
g Tank
9.
Acid Mea
asuring Tan k.
1.01.00
ese, the ite

ems specifie
ed from S.N
No 1 to 6 shall
s
be dessigned as pressure
p
Of the
vesse
els and the rest shall be
e atmosphe
eric vessels.
1.01.01
All otther vessells, not spe

ecifically listed here, but
b requireed for the Bidders
system shall also
o meet the g
general req
quirements of
o this speccification.
1.01.02
Proce
ess requirem
ments of th
hese vessels shall be governed
g
bby the requirements
of the
e DM Plant System, wh
hich will dettermine their design coonditions. Following
sectio
ons only ind
dicate some
e of the min
nimum requ
uirements w
which must be met,
and the
t
actual design
d
of tthese vesse
els shall be
e better thaan these, if that is
requirred from pro
ocess cons iderations.
2.00.00
GENE
ERAL DESIGN FEATU
URES
2.01.00
Desig
gn
2.01.01
Desig
gn of all pressure
p
vvessels sha
all conform
m to ASME
E Section VIII or
accep
ptable equivalent interrnational sttandard. Design
D
presssure shall be the
maxim
mum expec
cted pressu
ure to which
h the vesse
els may bee subjected to plus
10% additional margin.
m
Ma
aximum exp
pected pres
ssure for veessels place
ed in the
discharge line off pumps sha
all be based on the sh
hut-off headd of the pum
mps plus
static head at pumps suctiion if any. Design pre
essure of alll pressure vessels
shall be at least 10 Kg/cm ((g).
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
140
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
2.01.02
Desig
gn of all ve
ertical cylind
drical atmo
ospheric sto
orage tankss containing
g water,
acid, alkali and other
o
chemiccals shall conform to IS
S: 803.
2.01.03
Desig
gn of all horizontal cyl indrical atm
mospheric storage
s
tankk containing
g water,
acid, alkali and other
o
chemiccals shall conform to BS
B EN122855-2:2005.
2.01.04
Desig
gn temperatture of all p
pressure vessels and storage
s
tankks shall be 10 deg.
C hig
gher than th
he maximu
um tempera
ature that any
a part of the vessel/tank is
likely to attain du
uring operattion.
2.01.05
s
to
o vacuum; the
t same sh
hall be takeen care in de
esigning
In casse, tank is subjected
the ta
ank.
2.02.00
All ve
essels / tank
ks without i nside rubbe
er lining sha
all have a ccorrosion allowance
of min
nimum 2 mm
m and mill allowance (minimum 0.3 mm) foor shell and
d dished
ends. Thinning allowance of 2 mm (m
minimum) shall
s
be connsidered for dished
end. Vessel ends shall b
be of dishe
ed design and consttructed by forging,
presssing or spin
nning proce
ess. Conica
al or flat ends shall noot be accep
pted. All
dished ends shall be stress relieved.
2.03.00
All th
he atmosph
heric tanks shall have
e sufficient free boardd above the
e Level
High/Normal Le
evel as the
e case may
y be. The overflow
o
levvel shall be
e kept at
least 20 cm or 10% of vesssel height above
a
the L
Level High/Normal Le
evel for
all the
e tanks. Fu
urther, a miinimum 100
0 mm free board
b
shall be provided above
the to
op of overflow level to
o the top of the tank. Wall
W thickneess of atmo
ospheric
tanks shall not be less than 6 mm.
2.04.00
Vesse
els coming under previiew of IBR shall
s
be des
signed accoordingly.
2.05.00
Interio
or surfaces
s of all tankks shall be
e clear of stiffeners
s
a nd other structural
suppo
orts. Tanks
s shall be re
einforced an
nd stiffened externally aas required.
2.06.00
All we
elds on inner tank surrface shall be free of voids,
v
gapss craters, pits,
p
high
spots, sharp edg
ges, abrupt ridges and
d valleys or undercut eedges. High spots,
irregu
ularities and
d sharp ed
dges shall be remove
ed by grindding. Insid
de weld
seam
ms shall be ground flu
ush and sm
mooth applicable for corrosion resistant
r
coatin
ng or lining.
2.07.00
All intternal baffle

es, wear pla
ates, pipes etc.
e shall be
e continuouusly welded on both
sides at all conta
act points w
with full fillet welds whic
ch shall be ffree of voids, gaps,
craterrs, high sp
pots, sharp edges, an
nd undercuttting. Shaarp edges shall
s
be
groun
nd to a 3 mm
m minimum radius.
2.08.00
Weld splatter sha

all be removved.
2.09.00
All we
elding shall be perform
med by ASM
ME qualified
d welders uunder Section-IX of
ASME
E Boiler and
d Pressure Vessel cod
de and weld
ding electroddes shall be
e as per
releva
ant Codes/S
Standards vviz. AISC Se
ection 1.17 etc.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
141
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
2.10.00
The plates
p
for cy
ylindrical tan
nks shall be
e accurately
y formed in bending rollls to the
diame
eters called for, and th
he complete
ed shells be
e concentricc and plump
p. Plates
shall be cold-rolled by platte bending machine in
n a numberr of passes
s to true
curva
ature and joiined by wel ding.
2.11.00
Vesse
els seam shall
s
be so
o positioned
d that they do not paass through
h vessel
conne
ections.
3.00.00
MATE
ERIAL OF CONSTRUC
C
CTION
3.01.00
Pleasse refer DAT

TA SHEET--A.
4.00.00
APPU
URTENANC
CES
4.01.00
Manh
holes
4.01.01
All the pressure vessels an

orage tankss shall be provided
p
nd horizonttal type sto
with manhole of 500 mm d
diameter minimum
m
siz
ze, preferabbly at the to
op head,
comp
plete with co
over plate, lifting hand
dle, davit ca
ap, nuts, boolts, gaskets
s etc. to
ensurre leak tighttness at the
e test pressu
ure.
4.01.02
The vertical
v
type
e storage ta nks shall be
e provided with
w a manhhole of 500 mm dia
on the
e top coverr, if the diam
meter of the
e tank is 12
200 mm or more. For the DM
waterr storage tan
nks, manho
oles shall be
e provided as
a per IS:8003.
4.01.03
All the vessels and

a tanks sshall be norrmally provided with a six inch gasketed
g
handh
hole located
d near the b
bottom of th
he straight side.
s
4.01.04
The required
r
lin
ning/coating
g for the in
nside surface of the manhole/ha
andhole,
nozzle and cove
er plate of tthe manhole/handhole shall be ssame as tha
at of the
respe
ective vesse
el/tank.
4.01.05
Sightt Glasses
All the
e vessels mentioned
m
sshall be prov
vided with pad
p type sigght glasses on their
verticcal sides. Lo
ocations of tthese sight glasses sha
all be as folllows:
4.01.06
One with
w the centre line att the norma
al level of th
he bed top,, and one near
n
the
bottom
m of the straight side, ffor each of these vesse
els.
4.01.07
In addition, item
m no. 1.00.0
00 shall be
e provided with sight glasses, with
w
their
cente
er lines at ea
ach of the n
normal sepa
arated resin interfaces.
4.02.00
Liftin
ng Lungs
All vessels
v
of diameter 12 00mm or greater
g
shall be provideed with a minimum
m
of 4 liftting
lug
gs. Smallerr vessels sh
hall be provided with att least 2 lifting lugs.
4.03.00
Vesse
els Supporrts
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
142
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
Adequate suppo
orting arrang
gements lik
ke straps, saddles,
s
skkirt rings, orr legs of
steel shall be pro
ovided to tra
ansfer all lo
oads to the respective
r
sskid structures.
4.04.00
Vesse
el Internals
s
The in
nternals forr pressure V
Vessels sha
all be design
ned for a loow pressure
e drop to
promo
ote uniform
m distribution
n and flow through
t
the
e vessels annd to withsttand the
full de
esign pressure of the vvessel in both directions.
Speciification req
quirements ffor vessel in
nternals are
e as follows :
4.05.00
Inlet water
w
and Regeneran
nt Distributtors
Hub and
a laterals
s with diffusser splash plates or he
eader and perforated laterals.
Materrial of consttruction sha
all be type 316
3 stainless
s steel, exccept for acid
d service
which
h shall be off Hastelloy B
B.
4.06.00
Unde
erdrains
Same
e as above
e with scre
eened laterrals with in
nternal perfforated pipes, and
rubbe
er-lined false
e bottom.
4.07.00
For lined vessels

s, they sha
all also be lined in the same mannner as the internal
surfacces of thes
se vessels. For the ca
austic dilue
ent heating//storage tan
nk, they
shall be of type 304
3 stainlesss steel con
nstruction.
4.08.00
nal Fastene
ers
Intern
All in
nternal faste
eners shalll be of typ
pe 316 sta
ainless steeel and hea
avy duty
locknuts shall be
e used throu
ughout.
4.09.00
ng Connecttions
Pipin
All lin
ned vessel connection
ns and con
nnections in
n unlined vvessels 25 NB and
largerr shall be to
o minimum ANSI 300 lb class. Flat face flannges shall be used
throug
ghout. Nozz
zle materia
al shall be ASTMA-106
A
6. Grade B.. schedule 80 pipe.
All fla
anged connections sh
hall be supplied com
mplete with matching counter
flange
es, nuts, bo
olts and full--face gaskets.
4.10.00
All ve
essel conne
ections in un
nlined tanks
s smaller than 25 NB sshall be scrrewed to
ANSI 2.1 for sch
hedule 80 p
pipe.
5.00.00
SPEC
CIFIC DETA
AILS
5.01.00
Alkali Diluent Heating Sttorage Tan

nk (Hot water tank)
This vessel sha
all be sized
d to hold a minimum of 5000 lliters of 80
0 deg C
demin
neralised water
w
requirred for the regeneratio
on of condeensate poliisher. In
sizing
g this vesse
el, preheatin
ng of the anion resins shall not bbe considerred as a
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
143
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
requirrement. The
e cold wate
er feed line shall enterr the tank thhrough or near
n
the
top he
ead and ex
xtend down ward to witthin 15 cm of the tankk bottom. Recovery
R
time shall
s
not exceed 4 to 5 hours.
All tank internals
s, including the inlet water
w
tail pip
pe, shall bee fabricated
d of type
304 stainless
s
ste
eel.
5.02.00
Atmo
ospheric Ta
anks
Wall thickness
t
off these tankks shall not be less tha
an 6mm.
5.04.00
Chem
mical preparation and day tanks
These
e shall be
e vertical ccylindrical tanks. The
ey shall bee of carbo
on steel
fabriccation, lined
d and provvided with full
f
height level gaug es right up
p to the
overfllow levels.
The alkali
a
prepa
aration tankk shall be provided
p
witth a dissolvving baskett of type
316 stainless
s
ste
eel construcctions, and a motorize
ed slow speeed stirrer mounted
m
eccen
ntrically to the
t
tank byy a brackett fixed to th
he side waall. The stirrrer shall
have impellers of type 316 sstainless ste
eel.
The alkali
a
day tank shall b
be provided
d with an airtight
a
coveer complete
e with a
breath
her arrangement, to prevent absorption
a
of carbon dioxide frrom the
atmossphere by the alkali so
olution conta
ained in it. The overfloow connectiion shall
also be
b provided with a suita
able seal fo
or this purpo
ose.
The tanks
t
for ammonia
a
s olution (if applicable) shall alsoo be provid
ded with
simila
ar arrangem
ments to pre
event escape of ammon
nia vapor too outside.
5.05.00
LININ
NG
All intternal lining
g of vesselss provided under
u
this specificationn shall be off natural
rubbe
er, meeting the followin
ng minimum
m requirements.
5.05.01
Hardn
ness
Lining
g used may
y be soft ru bber having
g a shore durometer
d
rreading or 4070
4
on
the D scale, or semi-hard
s
ru
ubber havin
ng a durometer readingg of 4570 on
o the D
scale. Variations
s in hardnesss of the rub
bber lining between th e different areas
a
of
a spe
ecific tank sh
hall be with in +/-5 duro
ometer read
ding.
5.05.02
Chem
mical Resis
stance
The lining
l
mate
erial shall b
be suitable for prolon
nged servicce in the chemical
c
enviro
onment des
scribed belo
ow:
a)
Hydrochlo
oric acid, 2 to 8% concentration, at temperatture from 10 deg C
to 50 deg
g C.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
144
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
b)
Sodium hydroxide,
h
1 to 4% con
ncentration, at temperaature from 30
3 deg C
to 50 deg
g C.
c)
100 to 50
00 mg /l of sulphuric and
a hydroch
hloric acid ccombined. Ratio of
concentra
ation of the
ese two acid
d 1 : 5 to 5 : 1 and tem
mperatures from 10
deg C to 40 deg C.
d)
1 to 10m
mg/l of sodiu
um hydroxide at temp
perature froom 10 deg C to 40
deg C.
b subjected
d to the con
ndition (a) or
o (b) for inteermittent pe
eriods of
The liinings will be
appro
oximately one
o
hour o
out of eigh
ht hours, and
a
to connditions (c)) or (d)
remaiinder of the time.
5.05.03
Thick
kness
The lining shall be applied in three layers, resultting in a tottal thicknes
ss of not
less than
t
4.5 mm
m anywhere
e on the intternal surfa
aces of the vessels. Th
he lining
shall extend ove
er the full face of all flanged connections and shall have a
minim
mum thickne
ess of 3 mm
m in all such
h external arreas.
5.05.04
Surfa
ace Prepara
ation
Prior to rubber lin
ning all surffaces must be prepared in he folloowing mann
ner.
5.05.05
a)
Degrease
e surface prrior to blasting.
b)
The surfa
ace is to be blasted witth steel grit or sharp sillica sand to
o a white
and brigh
ht metal surf
rface.
c)
All traces
s if grit and dust shoulld be remov
ved with a vacuum cle
eaner or
by brushing. Care m
must be take
en to avoid contaminati
c
ing the surfa
ace.
d)
Immediattely after bla

asting and removal of grit, the firsst coat of primer
p
or
cement shall
s
be app
plied and allowed to dry
y.
ection
Prote
After the lining is
s completed
d the vessels shall not be subjecteed to any prrolonged
expossure to dire
ect sunlightt in course of its transportation eerection, ettc. They
shall not also be stored in d
direct sunlig
ght. No furth
her welding or burning shall be
carrie
ed out on the vessel, affter applicattion of the lining.
All lin
ning projectting outside
e of the ves
ssel, shall be
b protecteed adequate
ely from
mech
hanical damages during
g shipment,, handling, storage
s
etc..
Suitab
ble warning
g, indicating
g the specia
al care that must be ta ken with re
espect to
these
e lined vesse
els, shall be
e stenciled on their outtside surfacces with the letter at
least 12mm high.
mple:
Exam
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
145
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SEC
CTION: D1
REV
V NO: 00
Warn
ning Tank
k is lined
Do not
n weld or Burn
B
Do not
n Store in Direct Sunl ight etc.
6.00.00
ES AND ST
TANDARDS
S
CODE
The design,
d
man
nufacture, s hop testing, site fabrica
ation and eerection, testing and
comm
missioning of
o the presssure and sto
orage vessels shall coonform to th
he latest
revisions of the following sstandards, in addition to
t other staandards me
entioned
elsew
where in the
e tender doccument sub
bject to any modificatioon and requirement,
as specified here
e in after.
a)
IS: 803
Code off practice for designn, fabrication and

erection of Vertical Mild Steel cylindrical welded
oil storag
ge tanks.
b)
IS: 816
Code of practice forr use of meetal arc welding for

general construction
c
n in mild steeel.
c)
IS: 817
Code of practice forr training a nd testing of

o metal
arc welde
ers.
d)
IS: 822
Code of procedure
p
for
f inspectioon of welds..
e)
IS:1363
Black hex
xagonal bolts, nuts andd locknuts (dia 6 to
39 mm) and black hexagon screws (dia to 24
mm).
f)
IS:1367
Technica
al
fasteners
s.
g)
IS:2062
Specifica
ation for weld able strucctural steel.
h)
IS:2002
Steel pla
ates for pres
ssure vesseels for interrmediate
and High
h temperature service inncluding bo
oilers.
i)
IS:2825
Code of unfired
u
pres
ssure vesseels.
j)
IS:3133
Manhole and inspe

ection opeening for chemical
c
equipmen
nt.
k)
IS:4049
Specifica
ation for fo
ormed endds for tan
nks and
pressure vessels.
l)
IS:4682
Code off practice for lining of vesse

els and
equipmen
nt for chemical processses Rubberr Lining.
m)
BS:2594
Specifica
ation for ca
arbon steel welded ho
orizontal
supply
conditionns
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
146
for
threaded
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
cylindrica
al storage ta
anks.
n)
ASME
Boiler and pressure vessel Secction VIII cod

de.
o)
ASTM
American
n Society for Testing annd Materials.
7.00.00
FABR
RICATION
7.01.00
The vessel
v
ends
s for storage
e tanks of vertical
v
type shall have dished end
ds at top
& botttom. Howe
ever, the en
nds of horiz
zontal storag
ge tanks, aand all the pressure
p
vesse
els shall be dished dessign of Tori-s
spherical ty
ype designeed.
7.02.00
The plates
p
to be
e used for fa
abrication shall
s
prefera
ably have a minimum width of
1500 mm.
7.03.00
All the joints (circumferent ial / longitu

udinal) shall be continnuous butt welded,
inside
e and outside. Connecction shall be flush with inner suurface of tanks and
welde
ed continuo
ously on b
both sides of shell. Sharp
S
insidde edges shall
s
be
round
ded to a min
nimum 3 mm
m radius.
7.04.00
Weldiing sequen
nce shall b
be adopted in such a way so aas to minim
mize the
distorrtion due to
o welding sshrinkage. Bidder shall indicate in his draw
wing the
seque
ence of wellding propo sed by him
m which should meet prrior approva
al of the
BHEL
L and custo
omer. Weld
ding shall no
ot be carrie
ed out whenn the surfac
ce of the
parts to be welde
ed are wet from any cause
c
and during
d
perioods of rain and
a high
windss unless the
e welder and
d work are properly shielded.
7.05.00
All prressure ves

ssels and storage tanks exceptt Demineraalised water (D.M.)
shall be fabricated comple
ete and tes
sted at manufacturerss works to ensure
betterr workmans
ship.
7.06.00
Tank Connectio
ons
7.06.01
er shall furrnish all pi pe materia

al required for tank cconnection for the
Bidde
proce
ess requirem
ment. In ad
ddition to the
ese, additional connect
ctions, if required by
the BHEL and cu
ustomer forr the inter-c
connection of
o their pipinng, instrumentation
etc. shall
s
also be
e provided. Such addittional requirement will be intimate
ed to the
succe
essful Bidde
er later and Bidder sha
all provide these fittingss to match with the
BHEL
L and custtomers item
ms. Adeq
quate pipe support aattachments
s in the
extern
nal surface of the tank//vessel sha
all be provided for Own ers pipes fo
or all the
vesse
els/tanks. All lined vesssels connec
ctions shall be conform
m to minimu
um ANSI
300 lb
b class. Noz
zzle materia
al shall be ASTM-106
A
Grade
G
B, Scchedule 80.
7.06.02
All fla
anged conn
nections sh
hould be su
upplied com
mplete withh matching counter
flange
es, nuts bo
olts and gassket materiials. The flange
f
desi gn, (thickne
ess and
drilling etc.) shall match with
h the interco
onnected piiping flangees.
Bolts and nuts to
o be used e
externally to
o the vesse
els shall be of hexagon
nal head
confo
orming to IS
S:1367. Ho
owever, inte
ernal fasten
ners if any, shall be of IS:316
/SS-3
304 or Hasta
alloy-B as p
per the duty
y conditions.
7.06.03
7.06.04
Gaskets shall be
e of full face
e type.
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
147
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
7.06.05
Sight glasses shall

s
be prrovided for the tanks
s/vessels ass specified
d in the
stand
dard specifiication. T he materia
al for sight glass shaall be high
h quality
transp
parent PLEXIGLASS o
of sufficient thickness to
t withstandd the test pressure.
The sight
s
glass shall
s
be pro
ovided with suitable gaskets and bbolts to ensure leak
tightn
ness at the test
t
pressurre.
7.07.00
Vesse
els Supporrting Lifting
g Lugs
7.07.01
Adequate supporting arrang

gements like
e straps, sa
addles, skirtt boards, pilllars etc.
shall be provided to transfe
er all loads to civil foundation. A
All foundatio
on bolts,
insertts etc. shall also be pro
ovided.
7.07.02
All ve
essels of intternal, diam
meter of 1200 mm or greater
g
shaall be provid
ded with
minim
mum four (4
4) lifting lug
gs for safe
e and effective handlinng during erection.
e
Smalller vessels shall be pro
ovided with at least two
o (2) lifting l ugs.
7.07.03
Materrial of construction for these vess

sel supports
s, saddles, lugs shall conform
to IS:2
2062 of tested quality.
7.08.00
Special Accessories Stora

age Tanks
7.08.01
el internals wherever rrequired sha

all be provid
ded as detaailed out els
sewhere
Vesse
in the
e specificatio
on.
7.08.02
All the pressure

e vessels a nd tanks shall
s
be pro
ovided with drain conn
nections
along
g with drain valves of suitable siz
ze. Furthe
er all the attmospheric storage
tanks shall be prrovided with
h over flow connection designed ffor the filling
g rate of
the re
espective ta
ank.
7.08.03
All the pressure and tanks shall be provided

p
witth the vent connection
ns. The
design shall be as to offer adequate area for ve
enting. Vennting area shall be
such that over pressure/va
p
acuum is not created in the tankk during maximum
m
filling//drain-off ra
ate. The ma
aximum dra
aw off rate for
f the DM storage tan
nks shall
be inttimated late
er to the succcessful bidder.
7.08.04
Various instrume
entation and
d the fittings
s required for
f the sam
me shall be supplied
s
as ela
aborated in data sheetss.
7.08.05
The vent
v
and ov
verflow line
es of alkali preparation
n /measurinng / day tanks and
vent line of DM storage
s
tankks shall be provided with Carbon ddioxide abs
sorber of
prove
ontaminatio
en design to
o prevent co
on from atm
mospheric aair. Carbon
n dioxide
absorrber shall preferably
p
b
be located at
a ground level. The vent and overflow
o
lines of Acid measuring ta
anks shall be provide
ed with fum
me absorbe
er using
suitab
uch as pall rings/raschig rings.
ble packing material, su
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
148
PIPING &
VALVES

*
149

SPEC. NO.
TCE.5750A-H-500-001

RRVUNL, 2x660 MW, Super-Critical TPS, StageV
PART B
VOLUME: III
SECTION: D7
SHEET 1 OF 22
POWER PLANT PIPING & VALVES
This Section covers the basic requirements for the all the piping systems,
valves and specialties and thermal insulation to be provided for the power
plant.
1.0
LINE SIZING
1.1
Sizes of pipelines shall be selected such that the velocity of fluid in pipes
does not exceed the following limits under conditions of maximum
possible volumetric flow:
Steam
Saturated steam
Wet steam/Exhaust steam
40 m/s
30 m/s
Water
Pump suction
Pump delivery
Service/Potable water
1.5 m/s
3.0 m/s
1.5 m/s
Oil
LDO
HFO
2.0 m/s
1.5 m/s
Gas
Compressed air
15 m/s
1.2
Lower values of velocities than those stated above shall be used to

determine line size if dictated by considerations of pressure drop, NPSH,
surges, water hammer, etc.
1.3
The design flows considered in line sizing shall not be less than the rated
capacities of equipment to which the piping is connected such as pumps,
blowers, compressors, valves, flow limiting orifices, etc., or, the system
heat and/or mass balance diagrams.
1.4
Sizes of Boiler feed pump suction piping shall be selected to meet the
NPSH requirements of the pumps under transient conditions prevailing
on loss of steam supply to feed water tank. Similarly for all pumps,
NPSH requirements shall be satisfied in line sizing.
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FILE NAME: F329R5.DOC

150

SPEC. NO.
TCE.5750A-H-500-001

PART B
VOLUME: III
SECTION: D7
SHEET 2 OF 22
2.0
MATERIALS
The material specifications of pipelines of various systems shall be as
specified in Data Sheet - A attached to this specification.
3.0
WALL THICKNESS
3.1
The calculation of wall thickness required for pipelines subject to internal

and/or external pressure shall be based on the formulae and
recommendations as given in the applicable codes.
Adequate
allowances shall be made towards thinning due to bending, weakening at
branch connections, threading, commercial tolerances on pipe wall
thickness, corrosion and erosion, etc. and the same shall be subject to
approval by ENGINEER. In any case a minimum corrosion allowance of
1.0 mm shall be considered while selecting the thickness.
3.2
In case of carbon steel materials, the nominal wall thickness of pipeline

shall be not less than the minimum acceptable values given below:
--------------------------------------------------------------------------------------------------------NB mm
15
20 25
32
40
50
65
80 100 125
(4)
(5)
(inch)
(1/2) (3/4) (1) (11/4) (11/2) (2) (21/2) (3)
--------------------------------------------------------------------------------------------------------Min.
3.2
3.2 4.0
4.0
4.0
4.5 4.5
4.8
5.4 5.4
thickness,
mm
---------------------------------------------------------------------------------------------------------NB mm
150
200
250
300
350
400 450 500
600
(inch)
(6)
(8)
(10)
(12)
(14)
(16) (18) (20) (24)
---------------------------------------------------------------------------------------------------------Min.
5.4
6.3
6.3
6.3
7.1
7.1
7.1
8.0
8.0
thickness,
mm
---------------------------------------------------------------------------------------- NB 600 mm to NB 950 mm - 10.00 mm
NB 950 mm to NB 1200 mm - 12.00 mm
Sizes of NB 32(11/4), NB 65(21/2), and NB 125(5) shall not be used in
the piping system.
4.0
FLEXIBILITY ANALYSIS
4.1
Formal flexibility analysis calculations shall be carried out in case of

pipelines subjected to restrained thermal expansions or contractions.
The following piping systems shall be analyzed:
(a)
Pipelines with a maximum operating temperature equal to or

greater than 150 C
(b)
Regardless of their operating temperatures, all pipelines
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VOLUME: III
SECTION: D7

PART B
SHEET 3 OF 22

connected to sensitive rotating equipment such as turbines,
feed pumps etc. for which limiting values of pipe reaction have
been specified by the equipment manufacturer
(c)
Any other pipeline which in the opinion

OWNER/ENGINEER requires a formal analysis.
of
the
4.2
If it is deemed necessary by the boiler or turbine vendor, a surge analysis

shall be carried out by the Contractor to evaluate the effect of closure of
valves that are hydrostatically or pneumatically actuated. The pressure
rise in the pipeline, additional forces and moments at terminal points and
additional stresses shall be calculated. If the stresses or the forces and
moments exceed the allowable value, suitable shock absorbers shall be
provided by the Contractor.
5.0
LAYOUT AND DETAILING
5.1
All pipelines with size greater than NB 50 mm are considered as shop

fabricated piping and detailed piping layout drawings shall be prepared
for all such pipelines. The drawings shall be to scale and shall be
prepared as plan & sections and shall carry the following minimum
details:
5.1.1
Fully dimensioned layout with locating dimensions referred to plant axes

and coordinates
5.1.2
Details of all stub connections and other welded attachments as required

for anchors, restraints, hangers supports, etc.
5.1.3
Slope, drains and vents
5.1.4
Edge preparation details of weld ends
5.1.5
Mounting and orientation of valves and specialties and maintenance

space requirements
5.1.6
Location and tag numbers of hangers, supports, restraints, anchors, etc.
5.1.7
Location and magnitude of cold cuts, if any
5.1.8
Pipe sizes, materials,

requirements
5.1.9
Insulation details
5.1.10
Tolerances, if any
5.1.11
Any specific requirements on shop fabrication and/or field erection
5.1.12
Any other detail considered necessary by the ENGINEER.
design
parameters,
shop
and
field
test
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PART B
VOLUME: III
SECTION: D7
SHEET 4 OF 22

5.2
Pipelines with a size of NPS 50 mm or smaller are regarded as field

routed. CONTRACTOR shall however indicate any specific requirements
he may have in regard to the routing of these pipelines.
5.3
Detailed bill of material shall be prepared for all piping systems. In case
of shop fabricated piping, the bill of material shall correspond to the
layout drawing prepared.
5.4
While routing piping, the following requirements shall be taken into

account:
5.4.1
All piping shall be routed so as to avoid interference with other pipes and
their hangers and supports, electrical cable trays, ventilation ducting,
structural members, equipment, etc. Adequate clearances shall be
ensured with respect to the above to accommodate insulation and pipe
movements.
5.4.2
All piping shall be grouped where practicable and shall be routed to

present a neat and aesthetic appearance.
5.4.3
The piping shall be arranged to provide clearance for the removal of

equipment requiring maintenance and for easy access to valves and
other piping accessories required for operation and maintenance. Layout
drawings shall indicate valve orientations and availability of access to
valves and specialties. Layout of all piping shall ensure that all valves
including motor operated valves are located as to be accessible
conveniently for operation. Valves for operation and maintenance shall
have 1.0 m clear approach space. If any of the valves are not accessible,
suitable access platform shall be provided by the CONTRACTOR.
5.4.4
Piping shall generally be routed above ground but where specifically

indicated/approved by the ENGINEER the pipes may be arranged in
trenches or buried. Pipes at working temperatures above the ambient
shall however not be buried.
5.4.5
Where steel piping is required to be buried, the pipe work shall be

protected from soil corrosion by suitable anti-corrosive treatment as
specified.
5.4.6
Overhead piping shall have a minimum vertical clearance of 2.3 meters

above walkways and working areas and 7.5 meters above roadways
unless otherwise approved by the ENGINEER.
5.4.7
Drains shall be provided, at all low points and vents at all high points as
per actual layout regardless of whether the same have been shown in the
flow diagrams or not. Pipelines shall be sloped towards the drain points.
5.4.8
Besides at low points, tell tale drains shall be provided at other points as
necessary to remove on-line valves and specialties from piping for repair
and replacement. Wherever spray water is introduced into steam piping,
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PART B
VOLUME: III
SECTION: D7
SHEET 5 OF 22

At a suitable location downstream, drain pots shall be envisaged along
with motor operated drain valves and high and low level switches. The
drain valves shall be interlocked with the level switches for automatic
operation. For operating temperatures of greater than 400oC, drip leg
with drains, operated by a motor operated valve shall be provided. At all
other drain locations (operating temperatures less than 400oC) traps shall
be provided. All traps shall be provided with strainers, isolating, bypass
and free blow valves. Traps shall be thermodynamic type.
5.4.9
Provision shall be made while preparing piping layout to accept control

valves, flow measurement element and any other on-line specialty or
equipment. Sufficient upstream and downstream lengths shall be
provided for flow measuring devices, control valves, de-superheaters and
other specialties as required by the respective equipment manufacturer.
5.4.10
At all the screwed valves and screwed connections on equipment, unions

shall be provided to facilitate disassembly. Likewise, unions shall also be
provided at suitable points on straight length of screwed pipelines.
5.4.11
At all points where pipes pass through concrete floors or brick or other
walls, suitable floor collars or wall boxes shall be provided. The
CONTRACTOR shall design and furnish the details of the floor collars to
the ENGINEER/OWNER.
5.4.12
In the case of flanged pipe work, boxes shall be large enough to permit
the passage of the flange.
5.4.13
All pipe racks shall be provided with walkways of 750 mm wide.
5.4.14
Edge preparation shall be as per fig. 4, 5 or 6 of ASME B 16.25 based on

the thickness of pipe.
5.5
Hangers and Supports
5.5.1
All piping supports, guides, anchors, turnbuckles, rod hangers, spring

hangers, rollers, with incidental structural sub-framing shall be designed
by the CONTRACTOR.
5.5.2
The hangers and supports shall be spaced in accordance with standard

engineering practice as outlined in applicable codes and standards.
5.5.3
No welded attachments shall be made on the critical piping systems viz.

Main steam, Hot reheat, cold reheat, HP / LP Bypass and feed water
systems.
5.5.4
The CONTRACTOR shall ensure that the location of the hangers and
supports shall not increase the forces and moments on the equipment
beyond their allowable values.
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PART B
VOLUME: III
SECTION: D7
SHEET 6 OF 22

5.5.5
If severe vibration of piping is encountered in systems over which the

CONTRACTOR has control or if the piping system is to be subjected to
shock loading, hangers shall be supplemented by vibration-control
equipment of an approved design.
5.5.6
At locations where lateral or axial movement is expected, the hangers

shall be provided with suitable linkages to permit swing. All hangers shall
be designed to be vertical in the hot position unless otherwise approved
by the ENGINEER.
5.5.7
In order to minimize any horizontal force components of the dead weight

or any binding of the pin or rocker joints used on the hangers, the hanger
rods should be as long as possible. In critical piping systems, the length
of the hanger assembly capable of swinging shall not be less than 20
times the maximum expected pipe movement in the horizontal plane at
the hanger location. It is recommended in case of main steam piping to
provide for a hanger rod length of at least 5-6 meters wherever feasible.
5.5.8
Constant support type of hangers shall be adopted at all locations on

critical piping excepting where the smallness of vertical movements of
pipe justifies the use of variable spring hangers.
5.5.9
As far as practicable, connections of hangers to supporting structure shall

be achieved without welding to structural members. If welding is
inevitable, adequate factor of safety shall be considered in the design and
specification of the weld.
5.5.10
The attachment of support brackets to brick walls shall be avoided as far

as possible and where this is not possible, details of the attachment shall
be furnished to the ENGINEER for his approval. Under unavoidable
circumstances, when medium or heavy brackets are bolted to walls, back
plates of adequate size and thickness shall be furnished to distribute the
load against the wall. Where the use of a back plate is not practical, the
brackets shall, be fastened to the wall in an approved manner.
5.5.11
Diameter of hanger rods for piping NB 50 mm and smaller shall not be

less than 10 mm and for piping with size NB 65 mm and larger shall not
be less than 13 mm.
5.5.12
All components for hangers such as turn buckles, clamps, etc. shall be of
forged steel.
5.6
Fittings and Flanges
5.6.1
Branch connections in piping shall be made by the use of wrought or

forged seamless fittings such as tees, laterals and crosses. Small stubs
as may be required for instrument, drain and vent connection may be
provided in the form of weld outlet fittings or forged couplings.
Intersection welds are acceptable only in the event of non-availability of
fittings.
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TCE.5750A-H-500-001

PART B
VOLUME: III
SECTION: D7
SHEET 7 OF 22
5.6.2
Wherever pipe bends are employed for change of direction the same
shall be to a radius of 5 times the pipe diameter.
5.6.3
Mitred bends may be adopted for piping systems upto a design pressure
10 bar (g) only. Mitre angle shall not exceed 22.5 degrees.
5.6.4
Slip-on type of flanges may be only upto a maximum pressure rating of

ANSI 300 lbs. In case of higher pressure ratings, weld-neck type of
flanges shall be employed.
For critical piping such as main steam, cold reheat, hot reheat, HP / LP
Bypass, boiler feed discharge etc, only wrought fitting shall be used.
Fabricated fittings are not acceptable.
5.6.5
5.7
Dimensional Standards
5.7.1
Uniform dimensional standards for all piping components shall be

employed to ensure compatibility with each other.
5.7.2
Nominal pipes sizes and pipe outside diameters shall generally be as per
ANSI B36.10. In case of deviation CONTRACTOR shall bring it to the
specific attention of ENGINEER for prior approval stating reasons for the
deviation.
5.8
Instrument Connections
5.8.1
Unless otherwise called for by OWNER all thermowell stubs shall have
an internal threading to M33 x 2.
5.8.2
All stubs for pressure or flow measurement for pipelines with a maximum
working pressure equal to or above 62 bar (g) or with a maximum
working temperature equal to or above 350 C shall be NPS 25 mm and
double root valves shall be used.
5.8.3
Stubs for pressure or flow measurement on pipelines with a maximum

working pressure less than 62 bar (g) and a maximum working
temperature less than 350 C shall be of NPS 15 mm size and single root
valves can be used.
5.8.4
Measurement stubs on fuel oil lines shall be of NPS 25 mm size and

provided with two root valves.
5.9
Drain and Vent Connections
5.9.1
Drain and vent connections on pipelines shall be at least of NPS 25 mm

size.
5.9.2
For pressure and temperature conditions as defined in Clause 5.8.2,

double isolating valves shall be used on drain and vent lines. For
pressure and temperature conditions as defined in Clause 5.8.3, single
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PART B
VOLUME: III
SECTION: D7
SHEET 8 OF 22

isolating valves are considered adequate. Where with single root valve,
instrument and root valve are not accessible, double root valve shall be
provided with one root valve near the tap off and the second root valve
with instrument at accessible point. For fuel oil drain and vent lines
double isolation valves shall be provided irrespective of the pressure and
temperature.
6.0
WELDING AND HEAT TREATMENT

All heat treatment, welding, post and pre weld temperatures shall be as
per the code ASME B31.1.
7.0
INSPECTION & CLEANING
7.1
All pipes shall be hydro tested at shops for pressures as per standards
and all erected piping shall be tested 1.5 times the design pressure. All
other inspection requirements shall be as per the enclosed data sheet
A1.
7.2
All hot bent, forged formed, fabricated and straight pipes shall be
chemically cleaned, pickled or wire brushed and purged with air blast or
shot/grit blast to remove all sand and scale from the inner surface as
applicable.
7.3
The Contractor shall carryout the following cleaning after hydro test.
(a)
(b)
(c)
(d)
(e)
(f)
All piping shall be mass flushed, in addition to the specific

cleaning operations as described below, as required.
Main steam, cold and hot reheat piping and HP & LP bypass
piping shall be steam blown.
Extraction steam, condensate, boiler feed suction and
discharge, heater drains and vents shall be alkaline flushed.
Auxiliary steam piping and associated steam lines, heavy fuel
oil piping shall be steam blown.
Compressed air piping shall be blown by air.
Turbine lubricating oil piping shall be pickled
8.0
PAINTING AND CORROSION ON PROTECTION
8.1
All un insulated piping systems, hangers and supports shall have two
coats of red oxide Zinc Chromate primer (conforming to IS 2074) with
minimum dry film thickness (DFT) of 25 microns per coat and two coats of
finish paints using enamel paint to give a minimum total DFT of 100
microns (after two coats of primer and two coats of finish paint). Shades
shall be as per IS 5 or as indicated by Owner /Engineer. Service of the
pipe/line designations shall be painted on all pipes at visible locations.
ISSUE
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157

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PART B
VOLUME: III
SECTION: D7
SHEET 9 OF 22

8.2
Before application of paint, Contractor shall clean the pipes of all mill
scale, dirt dust, soot, grease, rust etc.
8.3
All pipelines, piping components shall be adequately protected against

corrosion during manufacture, fabrication, shipment and storage by
appropriate protective paint.
9.0
UNDERGROUND PROTECTION
9.1
Where pipelines are buried, underground protection shall be provided for

the piping system as indicated any one of the methods given below:
(a)
Coal tar primer, coal tar enamel, inner wrap of fibreglass, final
outer wrap of enamel impregnated fibreglass. Total thickness of
coating shall not be less than 4.0 mm.
(b)
With anti-corrosive tape of 4 mm thick conforming to IS-10221

and AWWA C 203-93.
9.2
Pipe surfaces shall be cleaned by shot or sand blasting before

application.
9.3
Tests to be carried out after application

(a)
Bond/Adhesion test
(b)
Holiday test
10.0
SPECIFIC REQUIREMENTS OF PIPING SYSTEMS
11.0
These shall be as detailed out in data Sheet A1

THERMAL INSULATION
11.1
CONTRACTOR shall provide thermal insulation for all hot piping and
equipment with fluid temperatures greater than 60 C.
11.2
Specific requirements of thermal insulation are detailed out in Data

Sheet-A2. Further, the insulation thickness indicated in Data Sheet - A2
shall be regarded as minimum acceptable thickness. These minimum
acceptable thickness are OWNERs estimate based on use of mineral
wool blankets as insulating material with a surface temperature of 60 C
or less over the insulation finish and Contractor is advised to ensure that
the thickness envisaged by OWNER are adequate to guarantee a surface
temperature measured over the finish of not greater than 60 C. In case
the Contractor estimates that higher insulation thickness are required, the
same shall be included and clearly indicated in the offer under the
Schedule of Technical Deviations of this specification.
11.3
Contractor shall submit with his offer a schedule of insulation thickness

proposed by him along with supporting calculations. The calculations
ISSUE
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PART B
VOLUME: III
SECTION: D7
SHEET 10 OF 22

shall be based on thermal conductivity values certified and guaranteed by
the insulation supplier who shall base his guarantee on actual tests
conducted by recognized test houses. Calculation of insulation shall be
based on standard BS 5970/IS 3677. No credit would be claimed by the
insulation manufacturer over and above those actually recognized by
international standards. However, if the CONTRACTOR is offering
insulation material with superior thermal conductivity this value shall be
suitably substantiated by tests.
11.4
CONTRACTOR shall demonstrate to the OWNER/ENGINEER the

surface temperature of the insulation at site. For indoor piping, the
temperature shall be measured at the middle of one segment of pipe run
at different points. These temperatures shall be taken as representative
temperatures for that length of piping. If the temperature measured is
higher than that guaranteed, the whole length shall be replaced or
additional thickness added to meet the surface temperature. Two
measurements shall be taken at the measuring points (one at the top and
another at the bottom).
12.0
VALVES
12.1
DESIGN AND CONSTRUCTION FEATURES

The following design and construction features of valves shall be
complied with.
12.1.1
All gate and globe valves shall be of rising stem, outside screw and yoke
type. The design of valves shall ensure a streamlined passage and gate
valves shall have low pressure drop. The seats and discs shall be easily
renewable and/or shall be suitable for easy refracting and grinding. Valve
discs shall be of such design as to keep the seats tight when the valve
body is subjected to pressure, temperature variations and piping
stresses. Gate valves shall close in both flow directions.
12.1.2
All globe valves shall be capable of being closed against pressure.
12.1.3
All valves end details shall be as specified in Data Sheet-A3. In the case
of all end-welded valves, the stub ends of the valves shall project from
the valve body a sufficient amount to ensure that the welding process will
not distort the valve body and internal parts.
12.1.4
Valves for regulating duties shall be of the globe type with tapered plug
type disc.
12.1.5
Hardness of disc seating surface shall be minimum of 350 BHN and a

minimum differential hardness of 50 BHN shall be provided between disc
and seat to prevent galling. This is not applicable for stellited seats.
12.1.6
Check valves of sizes 400 mm NB and larger shall have dash pot
arrangement.
ISSUE
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PART B
VOLUME: III
SECTION: D7
SHEET 11 OF 22
12.1.7
All gate and globe valves shall have back-seating arrangement to

facilitate easy replacement of packing with the valve in service.
12.1.8
All valves shall be so designed that the hand-wheel moves in a clockwise

direction to close the valve. The face of the hand-wheel shall be clearly
marked with the words 'OPEN' and 'CLOSE' and an arrow to indicate the
direction for opening. All hand-wheels shall be fitted with nameplate.
12.1.9
Piston lift check valves shall have accurately guided pistons so that the
pistons are cushioned in their cylinders as they move up.
12.1.10 All gate, globe, Y-type and angle valves intended for manual operation
and falling under the following categories shall be equipped with a gear
operator for ease of operation and to ensure fast and tight closure:
ANSI PRESSURE RATING
----------------------------------Class 300 and below
Class 600 and above
--------------------------------------12.1.11
All gate valves falling in the following categories shall be provided with
integral bypass valve. Bypass size shall conform to MSS-SP-45 as a
minimum standard unless otherwise specified in Data Sheet-A3. The
bypass valve shall be hand operated unless otherwise specified in Data
Sheet-A3. Pipe for bypass shall be at least Schedule 80 seamless and
of a material of the same nominal chemical composition and physical
properties as that used for the main line. Orientation of bypass
arrangement shall be subject to the approval of OWNER/ENGINEER.
ANSI PRESSURE RATING
VALVE SIZES FOR WHICH

BYPASS IS REQUIRED
----------------------------------------200 mm and larger
350 mm and larger
-----------------------------------------
-----------------------------------Class 600 and over

Class 300 & 150
-----------------------------------12.1.12
12.1.13
12.1.14
VALVE SIZES FOR WHICH GEAR

OPERATOR IS REQUIRED
---------------------------------------------350 mm and larger
200 mm and larger
-----------------------------------------------
All gate valves of ANSI pressure-rating class 150 and 300 shall have
solid or flexible wedge and ANSI pressure rating class 600 and above
shall have flexible or parallel slide type of wedge.
Valves with flexible wedge shall have provision for relieving the pressure
in the neck of the valve when the valve is in the closed position.
All valves of ANSI pressure rating upto class 600 shall have bolted
bonnet construction and class 900 and above shall have bonnet
construction of the pressure seal type. Pressure seal valves shall have
ISSUE
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160

SPEC. NO.
TCE.5750A-H-500-001

PART B
VOLUME: III
SECTION: D7
SHEET 12 OF 22

stainless steel inlay in the gasket area and silver-plated gaskets or other
acceptable proven features.
12.1.15
All carbon steel valves of ANSI pressure rating upto class 150 and 300
shall have stainless steel trim (13% Cr) unless otherwise specified in
Data Sheet and ANSI pressure rating class 600 and above shall have
stellited trim.
12.1.16
All alloy steel valves shall have stellited seats.
12.1.17
All valves of ANSI pressure rating upto class 900 and higher shall have
yoke with anti-friction bearing arrangement.
12.1.18
Valves that are to be kept in full OPEN/'CLOSE' position shall be

provided with a non-detachable locking arrangement. The locking
arrangement provided shall be subject to approval by the OWNER.
12.1.19
Valves operating under vacuum conditions shall have glands with water
sealing. The inlet and outlet connections shall be NB 15mm. The
CONTRACTOR shall indicate the maximum and minimum sealing water
pressure and the required flow rate.
12.1.20
Motor actuators for motor operated valves shall meet requirements

indicated elsewhere in the specification.
12.1.21
Edge preparation of valves shall be as per fig. 4, 5 or 6 of ASME B 16.25

based on the connecting pipe thickness.
12.2
CLEANING
Prior to factory inspection, all manufacturing waste, such as metal chips
and filings, welding rods and stubs, rags, debris and all other foreign
matter shall be removed from the interior of each valve. All mill scale,
rust, oil, grease, chalk, crayon, paint marks and other deleterious
material shall be removed from the interior and exterior surfaces. At the
time of shipment, valves shall be clean inside and outside.
12.3
INSPECTION AND TESTS
12.3.1
Inspection and tests shall be as per the Quality Assurance requirements.
12.3.2
Defects in excess of acceptance standards shall be removed by suitable

means. If removal of surface defects does not result in reduction in wall
thickness below 5% of intended thickness of metal at that location, the
area shall be blended smoothly into the surrounding surface. Where
defect removal results in a wall thickness below the above, resultant
cavity may be repaired by welding. The procedure and operator shall be
qualified as per applicable standards. Major weld repairs shall be stress
relieved or heat treated in accordance with ASME Section VIII Division IUCS 56.
ISSUE
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PART B
VOLUME: III
SECTION: D7
SHEET 13 OF 22

12.3.3
The required area shall be re-examined and the acceptance standards

shall be as in the original examination.
12.3.4
Weld repairs made as a result of radiographic examination shall be

radiographed after welding. Repairing a particular area more than 2
times is not permitted and the component shall be rejected. The
acceptance standards for welds shall be as per ASME Boiler and
Pressure Vessel Code, Section VIII, Division I, UW - 51.
12.3.5
Prior approval shall be obtained from the OWNER/ENGINEER before

taking up major weld repairs (major weld repair - when depth of repair
exceeds 20% of thickness or 1 inch whichever is smaller). Mapping of
major weld repairs is also required.
12.3.6
All valves shall be tested hydrostatically for strength, tightness of seats

and tightness of back seating at the pressures indicated in Data Sheet-,
in accordance with MSS-SP 61, and Hydrostatic Testing of Steel
Valves". Water used for hydrostatic testing of valves with stainless steel
components shall not have chloride content exceeding 20 ppm. Clean
potable water may be used for testing of all other valves.
12.3.7
All valves except check valves shall be tested for seat tightness by air at
a pressure of 6-bar (g) on both sides of seat.
12.3.8
All check valves shall also be hydro tested at 25% of the seat hydro test
pressure.
12.3.9
All valves shall be checked for correctness in respect of specified end

details as per applicable standards.
12.4
PAINTING AND CORROSION PROTECTION

Two coats of primer of thickness 35 microns for each coat shall be
applied to all steel and cast iron exposed surfaces as required to prevent
corrosion, after release has been given for painting and before despatch.
The use of grease or oil, other than light grades mineral oil, for corrosion
protection is prohibited. Bores of all valves shall be covered immediately
after testing, draining and drying with suitable plastic end covers to avoid
ingress of foreign materials.
ISSUE
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SPEC. NO.
TCE.5750A-H-500-001
VOLUME: III
SECTION: D7

PART B
SHEET 14 OF 22

DATA SHEET A
SPECIFIC REQUIREMENTS FOR PIPING
SL.NO.
SIZES
PIPES
FITTINGS
FLANGES
GASKETS
LINE
JOINT
HOSES FOR
HFO TANKER
HEATING
(STEAM/
CONDENSATE)
ALL
CARBON
STEEL
ELECTRO
ZINC
PLATED
NA
NA
NA
NA
HOSES FOR
FUEL
OIL UNLOADING
ALL
NEOPRENE
NA
NA
NA
NA
> NB65
ASTM A106
Gr.B
ASTM A
234 WPB
ASTM
A105
SPIRAL
WOUND
SS
BW
< NB50
ASTM A106
Gr.B
ASTM
A105
ASTM
A105
SPIRAL
WOUND
SS
SW
> NB65
ASTM A106
Gr.B
ASTM A
234 WPB
ASTM
A105
SPIRAL
WOUND
SS
BW
< NB50
ASTM A106
Gr.B
ASTM
A105
ASTM
A105
SPIRAL
WOUND
SS
SW
SERVICE
STEAM LINES
CONDENSATE
LINES
FUEL OIL
UNLOADING
LINES
FUEL OIL PUMP

DISCHARGE
LINES
ALL
ASTM A 234
IS1239 PT-1
WPB
FOR < NB 150/
(FOR >
IS3589
NB65)
FABRICATED
FROM IS 2062 ASTM A 105
PLATES FOR
(FOR <
> NB65
NB50)
ASTM
A105
BW FOR
> NB65
GRAPHOIL
SW FOR
< NB50
> NB65
API 5L Gr.B
(ERW)
ASTM A
234 WPB
ASTM
A105
GRAPHOIL
BW
< NB50
API 5L Gr.B
(ERW)
ASTM
A105
ASTM
A105
GRAPHOIL
SW
ISSUE
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163

SPEC. NO.
TCE.5750A-H-500-001

PART B
VOLUME: III
SECTION: D7
SHEET 15 OF 22
INSTRUMENT
AIR &
POTABLE
WATER
DEMINERALISE
D WATER
(Refer Note:6)
CONDENSER
COOLING /
AUXILIARY
COOLING
WATER AND
SERVICE
WATER
SYSTEM
(FRESH WATER
APPLICATION)
> NB65
< NB50
ASTM A
IS1239
234 WPB
GALVANISED
GALV.
ASTM
IS1239
A105
GALVANISED
GALV.
ASTM
A105
GALV.
ASTM
A105
GALV.
TEFLON
(Asbestos
free)
TEFLON
(Asbestos
free)
TEFLON
ASTM A 182 ASTM A 182
(Asbestos
F304
F304
free)
TE
SE
NB 50 &
BELOW
ASTM A312
TP 304
(ERW)
NB 65 TO
NB 150
ASTM A312
TP 304
(ERW)
ASTM A 403 ASTM A 240 TEFLON

WP 304
TP 304
(Asbestos
free)
BW
NB 200 &
ABOVE
ASTM A312
TP 304
(ERW)
SAME AS
PIPE
BW
UPTO NB
150
IS 1239 PT-1
HEAVY
GRADE
IS 1239 PT-1 ASTM A105

HEAVY
GRADE
NB 200 TO
NB 350
IS 3589
(ERW)
ASTM A
234 WPB
ASTM A 105 TEFLON

(Asbestos
free)
BW
400 NB &
ABOVE
IS3589
PLATE
FORMED
ASTM A
234 WPB
OR
MITRES
ASTM A 105
BW
ASTM A 240 TEFLON

TP 304
(Asbestos
free)
SW
BW
Notes:
1.
All pipes shall be preferably shop fabricated. However large dia pipes (> 500
mm) shall be site fabricated.
2.
Each length of pipe shall be hydro-tested at shop as per the Codes/Standards.
3.
Blind flanges on SS Pipe lines shall be to ASTM A 240 TP 304. Stub ends shall
be used at flanged connections.
4.
All branch connections shall be wrought (seamless) or forged steel based on

the size and availability based on ASTM Standards.
5.
All gaskets shall be asbestos free type.
6.
Cast iron valves shall be provided for water system and cast steel valves shall
be provided for compressed air system.
ISSUE
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164

SPEC. NO.
TCE.5750A-H-500-001

PART B
VOLUME: III
SECTION: D7
SHEET 16 OF 22

7.
Ball valves or Plug valves shall be provided for oil and air system.
8.
All painting with primer coats (2 coats each) shall be provided for the piping and
all hangers.
ESSENTIAL SPARES FOR PIPING SYSTEM
1. Pipes
: 5% of total straight length for each size

and material grade of pipe
2. Gaskets
: 100% total requirement of gaskets
3. Fasteners (Flanges, Unions, etc.,) and

fittings
: 10% of total requirement of fasteners
4. Hangers and supports
: 5% spare spring box assembly for each

type and rating of spring provided
5. Pipe clamps
: 20% spare pipe clamp / attachment for

each size & category.
ISSUE
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165

SPEC. NO.
TCE.5750A-H-500-001

PART B
VOLUME: III
SECTION: D7
SHEET 19 OF 22
Temp
51100
PIPE DIA
SCHEDULE OF THICKNESS FOR THERMAL INSULATION

101151201251301351401150
200
250
300
350
400
450
INSULATION THICKNESS (IN mm)
451500
501550
551575
15 mm (1/2)
25
25
40
40
50
65
80
90
100
115
125
20 mm (3/4)
25
25
40
50
50
65
80
90
100
125
125
25 mm (1)
25
40
40
50
65
80
90
100
115
125
140
32 mm (1-1/4)
25
40
40
50
65
80
90
100
115
140
140
40 mm (1-1/2)
25
40
40
50
65
80
90
115
125
140
150
50 mm (2)
25
40
40
50
65
80
100
115
125
150
165
80 mm (3)
25
40
50
50
80
90
100
125
140
165
170
100mm (4)
40
50
50
65
80
90
115
125
150
165
190
150 mm (6)
40
50
50
65
80
100
115
140
165
190
200
200 mm (8)
40
50
50
65
80
100
125
140
165
190
215
250 mm (10)
40
50
50
65
90
115
125
150
175
200
215
300 mm (12)
40
50
65
75
90
115
140
150
190
215
225
350 mm (14)
50
65
75
75
90
115
140
165
190
215
225
400 mm (16)
50
65
75
75
90
115
140
165
190
215
240
450 mm (18)
50
65
75
75
90
115
140
165
190
215
240
500 mm (20)
50
65
75
100
115
115
140
165
200
225
240
600 mm (24)
50
65
75
100
115
115
140
175
200
240
250
625 mm (25)
50
65
75
100
115
115
140
175
200
240
250
650 mm (26)
50
65
75
100
115
115
150
175
200
240
250
700 mm (28)
50
65
75
100
115
115
150
175
215
240
300
800 mm (32)
50
65
75
100
115
125
150
175
215
240
300
900 mm (36)
50
65
75
100
115
125
150
175
215
240
300
950 mm (38)
1000 mm (40)
& above flat
surfaces
50
65
75
100
115
125
150
175
215
240
300
50
65
75
100
115
140
170
215
250
300
350
INSULATION THICKNESS IS CALCULATED CONSIDERING ALUMINIUM SHEATHING FOR THE

0
0
AMBIENT TEMPERATURE OF 30 C. SURFACE TEMPERATURE 60 C.
ISSUE
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TCE FORM NO. 329 R5

166
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
TECHN
NICAL SPECIF
FICATION FO
OR
PIPIN
NG, VALVES & FITTINGS
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
167
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
1.00.00
0
CO
ODE & STANDARDS
0
1.01.00
Th
he Design, ma
anufacture, sh
hop testing, errection, testing
g and commisssioning of pip
ping and valve
es
sh
hall conform to
o the latest re
evisions of the
e following co
odes and Indiaan Standards
s, in addition to
t
otther standards
s mentioned e
elsewhere in the tender do
ocuments subjject to any modification
m
an
nd
re
equirement as specified here
einafter.
IS
S : 778
G unmetal gate,, globe and ch

heck valves forr general purp
pose.
IS
S : 1239
Mild steel tubes

s and fittings - Part I & II.
M
IS
S : 1536
entrifugally ca
ast (spun) iron pipes for wate
ter, gas and se
ewage.
Ce
IS
S : 1537
Ve
ertically cast iron pressure pipe
p
for water,, gas and sew
wage.
IS
S : 1538
Ca
s for pressure pipes for watter, gas and se
ewage.
ast iron fittings
IS
S : 1703
Ba
all valves (ho
orizontal) plung
ger type incluuding floats fo
or water supply
pu
urposes.
IS
S : 2379
Co
dentification of pipe line.
olour for the id
IS
S : 2685
Co
ode of practic
ce for erection
n, installation,, and mainten
nance of sluicce
va
alves.
IS
S : 14846
Slluice valve forr water works purposes (1500 to 1200 mm).
IS
S : 3042
Siingle faced slu

uice gates (200 to 1200 mm
m).
IS
S : 3589
Ellectrically weld
ded steel pipe
es for Water ggas & sewage
e (200 to 200
00
m
mm).
IS
S : 4038
Fo
oot valve for water
w
works pu
urposes.
IS
S : 4984
Hiigh Density po
olyethylene pip
pes.
IS
S : 4985
Un
nplasticised PVC
P
Pipes.
IS
S : 5312
Sw
wing check type reflux (non-return) valve Part-I.
IS
S : 458
oncrete pipes (with and with

Co
hout reinforce ment).
IS
S : 3952
Ca
ast Iron butterrfly valves for general purpooses.
AS
STM-A 106
G r.C Seamless
s carbon steel pipe.
AS
STM - 53
Se
eamless carbo
on steel.
AW
WWA-C-504 - Standard fo
or butterfly valve.
BS
S : 5156
IS
S : 554
Sttandard for Diaphragm valve.

Piipe thread for pressure tightt joints.
IS
S : 1363
Bllack hexagon bolts, nuts and lock nuts.
IS
S : 1364
Prrecision and semi-precision hexagon boolts, screws, nuts and locck

nu
uts.
IS
S : 2062
Sttructural steel fusion welding quality.
IS
S : 4736
Ho
ot dip zinc coa
ating on steel tubes.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
168
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
IS
S : 2825
Co
ode of unfired
d pressure ves
ssels.
IS
S : 2712
G askets.
IS
S : 4192
art-I Rubber lining.

Pa
IS
S : 3006
Accid resistant SWG

S
Pipe.
IS
S : 783
Co
ode of practice for laying RC
CC pipes.
IS
S : 3114
ode of practice for CI Pipes.

Co
BS
S : 5142
Cll globe valve.
AN
NSI:B 16.5
Stteel pipe flang

ges and flange
ed fittings.
AN
NSI:B 31.1
Po
ower Piping co
ode.
2.00.00
0
DE
ESIGN, CONS
STRUCTION AND ERECT
TION ((Please
e note that th
he details giv
ven below arre
ge
eneral require
ements, howe
ever the requ
uirement of Datasheet-A
D
to
o be fulfilled completely)
0
2.01.00
Piiping and Fitttings (Genera

al)
2.01.01
De
esign
Alll piping systems shall be ccapable of withstanding the maximum prressure in the correspondin
ng
lin
nes at the rele
evant temperattures. The minimum thickne
ess for pipes aand fittings sh
hall be adhere
ed
to. Higher thick
kness in equivvalent materia
al is acceptab
ble. However,, no credit will be given fo
or
hig
gher thickness
s.
2.01.02
2
Alll the piping sy

ystems, fitting
gs and access
sories supplied
d under this paackage shall be designed to
t
op
perate withoutt replacement and with norm
mal maintenan
nce for a plantt service life of 25 years, an
nd
sh
hall withstand the operating
g parameter flu
uctuations and
d cycling whicch can be normally expecte
ed
du
uring this perio
od.
3
2.01.03
Alll piping syste

ems shall be properly designed to take
e care of hyddraulic shocks
s and pressurre
su
urges which may arise in
n the system during operation. Bidderr should prov
vide necessarry
prrotective arran
ngement like anchor block
ks/anchor bollts, etc. for thhe safeguard
d of the pipin
ng
syystems under above mentio
oned condition
ns. External and internal atttachments to piping shall be
b
de
esigned so as
s not to cause
e flattening of pipes, excess
sive localised bending stres
sses or harmfu
ul
thermal gradien
nts in pipe wal ls.
2.01.04
4
manufactured
Piiping and fittin
ngs shall be m
d by an appro
oved firm of reepute. They should
s
be truly
cyylindrical of cle
ear internal dia
ameter speciffied, of uniform
m thickness, ssmooth and strong, free from
m
de
ents, cracks and
a
holes and
d other defectts. They shall allow ready cutting, chipp
ping or drilling
g,
we
elding etc.
5
2.01.05
Alll rubber lined pipes shall be

e seamless orr bead remove
ed ERW pipes .
6
2.01.06
Inspection hole
es shall be prrovided at suitable location
ns for pipes 8800 mm NB and above as
a
re
equired for perriodic observattions and insp
pection purpos
ses.
2.01.07
7
Material of cons
struction for piipes carrying various
v
fluids shall be as beelow: -
--------------------------------------------------------------------------------------------------------------------S..No. Servic
ce
Material
M
-------------------------------------------------------------------------------------------------------------------1.
Raw water
w
Carboon Steel
2.
Clarifie
ed water/Filterred Water
Carboon steel
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
169
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SEC
CTION: D1
REV
V NO: 00
3.
Acidic Water
Rubbeer lined Steel
4.
Demin
neralised Wate
er
Stainleess Steel - 304
5.
Acid (h
hydrochloric)
Rubbeer lined Steel
6.
Alkali (Sodium
(
Hydrroxide)
a)
Strong (5%
% and above)
b)
Dilute
(b
below 5%)
7.
S
ensions
Lime Solution/Suspe
Galvannized Steel
8.
Air
Galvannized
Waste effluent from N Pit
0.
10
Resin water slurry
Steel to
39
IS 123
HDPE
e-304
Stainleess steel Type
8
2.01.08
he isolation valves of pipe lines conveyinng flushing wa

Th
he portion dow
wnstream of th
ater shall be of
o
the material & ty
ype as that off the chemical pipelines whic
ch is being fluushed.
2.01.09
9
Piipelines carryiing water, che

emicals, air etc. shall be siized generallyy on the follow
wing velocitiess.
Ho
owever where
ever minimum
m pipe sizes are defined in the tende r drawing /da
ata sheets th
he
se
elected size shall not be le
ess than the specified
s
size. The velocityy in the resin transfer line is
sp
pecified elsewhere in the sp
pecification.
--------------------------------------------------------------------------------------------------------------------Piipe Size
Velocity in
n m/sec.
Below
w 50 mm
50-150 mm
m
200 mm
m &
above
e
--------------------------------------------------------------------------------------------------------------------1.2 - 1.8
a))
Pump suction
1.2 - 1.5
1
b))
Pump discharge
c)
Heade
er
d))
1.2
1 - 1.8
1.8 - 2.4
2.1 - 2.5
2
1.5 - 2.4
2.1 - 2.4
2
15
1 - 20
20 - 30
25 - 35
5
20
2 - 30
25 - 40
35 - 45
5
Comprressed air
below 2 Kg/cm2(g)
e))
Comprressed air
2 Kg/c
cm2 & above
7-8
Suction to compresssor/
Blowerrs
-------------------------------------------------------------------------------------------------------------------f)
2.01.10
0
Piipeline under gravity flow sshall be restric

cted to a flow velocity of 1 m/sec genera
ally. Channels
un
nder gravity flo
ow shall be sizzed for a maxiimum flow velocity of 0.6 m//sec.
2.01.11
Th
he following " C" Value sha
all be used in WILLIAM & HAZEN
H
formuula for calculating the frictio
on
losss in piping sy
ystems.
I)
Carbon
n Steel pipe
100
ii)
C.I Pip
pe / Ductile Iro
on
100
iii))
Rubbe
er lined steel p
pipe
120
BHEL PS- PEM-PPE

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170
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SEC
CTION: D1
REV
V NO: 00
iv))
PVC / HDPE pipes
140
v)
e
Resin Transfer Pipe
100
or calculating the pump hea

ad, at least 10%
% margin shall be taken oveer the pipe fric
ction losses.
Fo
2.02.00
0
Material & Dim

mensional Sta
andards for Piping
2.02.01
standing the maximum

m
presssure and tem
mperature in th
he
Alll piping system shall be ca pable of withs
co
orresponding line.
2
2.02.02
Th
he Steel pipes
s (Welded typ
pe) for the se
ervices of raw
w water/clarifieed water/Filterred water sha
all
co
onform to the following
f
stand
dard or codes
s.
i)
ii)
iii))
Pipes up to 150 NB
a)
IS:1239 Pa
art-I
b)
ASTM-A-53
3 Grade B
Type-E
(Heavy
vy grade-Black
k)
(Welded),
Sch 800 up to 2 inch

nominnal size.
h
Sch 400 above 2 inch
nominnal size.
Pipes 200 NB and a

above
a)
IS:3589 - G
Grade 410
b)
ASTM - A5
53, Type-E Gra
ade B (Welded) - Sch. 40
Pipe 500
5 NB and ab
bove-In this case pipes sha
all be rolled annd butt welded. These pipe
es
may be
b fabricated by the bidde
er at site. The
e plates connforming to IS
S:2062 (Teste
ed
quality
y) or SA-285 G
Gr.C. or equiva
alent.
Howev
ver, condense
er polisher pip
pelines shall be
b of seamlesss carbon stee
el ASTM A 10
06
Gr.B all
a welded consstruction with minimum 300 lb flange connnection.
3
2.02.03
Piipes for the Air

A Service sha
all conform to
o the above clause 2.02.022 and shall be
e galvanized to
t
IS
S:4736.
4
2.02.04
Piipes to be use
ed for the rub
bber-lined con
nstruction shall conform thee above claus
se 2.02.02 an
nd
insside surface shall
s
be complletely de-bead
ded and made suitable for linning.
2.02.05
5
Otther piping ma
aterials shall cconform to the
e following stan
ndards.
6
2.02.06
i)
IS:498
84 - Class-5-H igh density po
olyethylene pip
pes.
ii)
IS:498
85 - Class-4 - P
PVC Pipes.
iii))
ASTM A-106, Gr. C,, Schedule 80

0 - Seamless carbon
c
steel piipe.
iv))
ASTM A-312 Grade TP-316 Sche

edule 40s - Sta
ainless Steel ppipes.
v)
ASTM A-312 - Gra

ade TP-316 Schedule
S
40
Seamless)
- Stainlesss Steel pipe

es ( ERW OR
Fittings
(a
a)
Fittings
s to be used w
with carbon ste
eel pipes shall conform to IS
S:1239 Part-II (Heavy grade
e)
for size
es up to 150 N
NB.
(b
b)
For siz
zes 200 NB & above steel fittings shall conform to ASTM A 234
2
Gr. WPB
B.
Howev
ver for sizes above 350 NB
N fabricated fittings (meteer bends etc) may be used
d.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
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171
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
Forged
d elbows of lo ng radius shall be used.
(cc)
Howev
ver inside surfface of all the fittings used fo
or the rubber llined applicatiion shall be de
ebeaded and made ssuitable for rub
bber lining.
(d
d)
For Ga
alvanized pipe
e application all
a the fittings shall
s
be galvannized as per IS
S:4736.
(e
e)
Fittings
s to be used
d in other ty
ype of piping shall conforrm to relevan
nt IS/BS ANS
SI
Standa
ards and in co
onformity with the parent pip
pe standard.
(f))
Unless
s otherwise sh
hown eccentric
c reducers sha
all be installedd with straight side at the to
op
of pipin
ng connection
n.
0
2.03.00
De
esign of Pipin
ng Systems
2.03.01
F water, air and other serrvices where steel pipes arre used, jointss of this size range shall be
For
b
sccrewed/flanged
d type.
2.03.02
2
Alll unlined stee

el pipes 65 NB
B and above (other than Cl pipes and airr service pipes
s) shall be join
nt
byy butt-welding.
2.03.03
3
Alll rubber lined pipes shall ha

ave flanged joints.
2.03.04
4
Stteel pipe flang

ges shall be ge
enerally slip on flat face type. Weld neckk flanges shalll be used whe
en
fla
ange follows immediately a
after a butt-w
welding or whe
ere it is requiired with resp
pect to servicce
co
onditions. Wh
hen weld neckk or socket weld flanges are
e used, their bbore must be made
m
the sam
me
ass that of the pipe
p
being we
elded to. Socket welded orr threaded flannges may be used, with th
he
ap
ppropriate pipiing system forr connection of
o pipe to the fllanged equipm
ment.
5
2.03.05
Alll the piping fla

anges and cou
unter flanges & their drilling shall conform
m to ANSI B 16.5 of relevan
nt
is involved wiith the Owners
prressure & tem
mperature classs. However wherever
w
the interferences
i
pipe, the flange
e/interconnecttion details sh
hall be designed to match tthe piping and
d the details of
o
wh
hich will be in
ntimated later.. Flanges sha
all conform to ANSI B.16.5 class 150 (m
min.) for servicce
otther than cond
densate polish
her pipelines.
6
2.03.06
Fo
or easy handling & remova
al of equipmen
nts, valves etc
c. and for mainntenance purp
pose, break up
u
fla
anges for 65 NB
N and above
e sizes and su
uitable type of compression flexible coupling for flange
ed
joints of 50 NB and below sizze shall be pro
ovided. The over
o
ground ppiping whereve
er routed insid
de
bu
uilding, shall have
h
a clear he
ead room of minimum
m
2.1 meter
m
from opeerating floor.
2.03.07
7
Piipes shall gen

nerally be routted above gro
ound but wherre specificallyy indicated/spe
ecified the pip
pe
may be laid in trenches
t
or bu
uried. Buried piping
p
shall be
e generally insstalled so that the top of pip
pe
is 1.0 metre below the groun
nd level unless
s otherwise sp
pecifically menntioned. Full le
ength of burie
ed
piping shall be provided
p
with 100 mm thick
k sand bed.
8
2.03.08
Bu
utt-welding ed
dge preparatio n shall be don
ne as per ANS
SI B 16.25.
9
2.03.09
Meter bends will not be acce

epted for steel pipes of 350 NB and below
w. For sizes above 350, th
he
meter bends sh
hall conform to
o BS:534. The bend radius
s shall be useed for all pipes
s 1.5 times th
he
no
ominal pipe dia
ameter.
0
2.03.10
Ha
angers and su
upports shall b
be capable of carrying the sum
s
of all con currently actin
ng loads. The
ey
sh
hall be design
ned to provide
e the required
d supporting effects
e
and alllow pipeline movements as
a
ne
ecessary. All guides, anch
hors, braces, dampener, expansion
e
joinnt and structu
ural steel to be
b
atttached to the building/strructure, trenches etc. sha
all be provideed. Type off hangers an
nd
co
omponents forr all piping sha
all be selected
d and approval obtained from
m the ENGINE
EER.
2.03.11
Fo
or rubber lined
d pipe, lining should be applied in two (2
2) layers, givinng a total thic
ckness not lesss
than 3 mm. Surrface hardnesss of rubber lining shall be 65
5 r 5o Shore A
2.03.12
2
Piipe coming un
nder purview of IBR should meet its req
quirements annd getting the
e IBR approva
al
sh
hall be under Vendors
V
scope
e.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
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172
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
3.00.00
0
VA
ALVES & GA
ATES (Please
e note that the
t
details given
g
below aare general requirements
s,
ho
owever the re
equirement o
of Datasheet-A to be fulfilled and typess of valves shall
s
be as pe
er
P&
&ID)
0
3.01.00
Va
alves will be used
u
to start/sttop or control flow. Gates will
w be primarilyy used for isolation of flow in
i
op
pen channels although thesse should be capable
c
of thro
ottling the flow
w too. Sample
e valves will be
b
ussed in sample collection line
es.
0
3.02.00
(a
a)
All valves, shall be suitable for service

s
condittions i.e. flow
w, temperature
e and pressurre
under which they arre required. All
A the valves shall
s
be of staandard pressure rating of th
he
relevan
nt design stan
ndard.
(b
b)
All the
e actuators off the valves shall be desiigned to handdle the maxim
mum expecte
ed
pressu
ure differentiall across the valves
v
and to overcome fririction forces and
a
unbalancce
forces due to the flo w through valve.
0
3.03.00
Va
alves in Raw water, Clarifiied & Filtered
d water applic
cation
3.03.01
Eiither Butterfly type or sluice//gate valves shall

s
be used for
f isolation puurposes.
2
3.03.02
Slluice/gate valv
ve shall confo
orm to IS 1484
46 of rating PN 1.6 (min.). Stem, seat ring and wedg
ge
facing ring shalll be of stainle
ess steel cons
struction. Oth
her parts shalll be as per IS
S:780. Flange
es
hall be designe
ed as per ANS
SI B 16.5 Cl. 300
3 (min.) to meet
m
with the piping flanges
s. Valves sha
all
sh
be
e of outside sc
crew and rising
g stem type.
Slluice valves fo
or sizes below
w 50 NB and below shall conforms
c
to I S:778 Class-2
2/ANSI B16.3
34
straight, rising stem;
s
without sside screw.
3
3.03.03
Slluice valves sh
hall be provide
ed with the following access
sories in additiion to the stan
ndard items.
a))
Hand wheel
w
b))
Manua
al Gear reducttion unit opera
ator for valves 250 NB and aabove.
c)
Bypass valve for vallve of sizes 35

50 NB and abo
ove.
d))
Drainin
ng arrangeme
ent wherever re
equired.
e))
Arrow indicating flow

w direction.
f)
on indicator.
Positio
3.03.04
4
Slluice Valves shall be provid

ded with back seating bush to facilitate glaand renewal during
d
full ope
en
co
ondition.
5
3.03.05
Bu
utterfly valves
s shall be of d
double flanged
d type of low leakage rate confirming to AWWA-C-50
04
cla
ass 300 (min.) or BS:5155 P
PN 10 (min.)
3.03.06
6
Th
he various com
mponents of b
butterfly valves
s shall be of th
he following
i)
Body
Cast Iron
I
- ASTM A 48 Cl.40; BS:1452 Gr.220 SG Iron BS:2789. Cast Iron IS:210 Gr.FG2260
Cast Steel
S
- ASTM. A 216 GR. W
WCB; BS:1504 Eq.Gr.
Fabric
cated Steel as per ASTM A5515 Gr.60/80
IS:206
62, Gr.B/IS:2002.
ii)
Disc.
Cast Iron IS:210, Gr.260; Cast Iron - ASTM

M A 48 Cl.40
0;
BS:1452, Gr.220, SG Iron - BS:27789.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
173
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
Cast Steel
S
- ASTM A 216 Gr. WC
CB; BS:1504 Eq.Gr.
E
Fabric
cated Steel as per ASTM A5515 Gr.60/80
IS:206
62, Gr.B/IS:2002.
iii))
Shaft
ASTM. A 296 Gr. CF8M/AISI

C
3166: AISI 420; BS
B 970 Gr.316
6;
BS:970 Gr.420 S45.
iv))
Seat riings
M (Ethylene prropylene rubber)

Nitrile rubber, EPDM
7
3.03.07
Bu
utterfly valves
s shall be fitte
ed with sleeve
e type bearing such as PTF
FE. Valves of
o size 350 NB
an
nd above shall be provided with one or tw
wo thrust beariings to hold thhe disc secure
ely in the centrre
off valve seat without hydraul ic or external axial shaft loa
ads. Sleeve aand other bea
arings fitted intto
the valves body shall be off self lubricate
ed materials that do not hhave any effe
ect on the fluiid
andled and oth
her componen
nts of the valve
es.
ha
8
3.03.08
Alll the butterfly valves shall b

be provided with Hand whee
el or lever as pper the require
ements.
or larger sizes
s i.e. 150 NB a
and above hand wheel shall be provided . For lever/wrrench operate
ed
Fo
ded for positiv
va
alves, means shall be provid
vely holding th
he disc in not less than thre
ee intermediatte
po
ositions.
Manually operated valves sha
all be provided with reductio
on gear unit foor valves of size 250 NB an
nd
ab
bove. Valve provided
p
with m
motorized or pneumatic
p
actuator shall bee provided with
h a hand whee
el
for manual operration.
Alll the valves shall
s
be equipp
ped with adjus
stable mechanical stop-limiiting devices to
t prevent ove
er
tra
avel of the va
alve disc in th e open and closed
c
positions. The valve
ve operators (Hand wheel or
o
Gear reduction
n unit or Mottor actuator etc.)
e
shall be designed ass per relevan
nt Internationa
al
Sttandard.
9
3.03.09
Alll the butterfly

y valves shalll be provided
d with an ind
dicator to shoow the positio
on of the discc.
Flanges shall co
onform to ANS
SI B 16.5 Cl.300 (min.)
3.03.10
0
Ba
all valves or Globe
G
Valves may also be provided for the
t applicationn of Raw/ Cla
arified / Filtere
ed
wa
ater services for
f sizes 40 N B and below conforming
c
to the following specifications
s.
a))
Ball Valves
i)
andard
Design Sta
BS:53351 Class 300 (min.)
ii)
Type
nds; Full bore

e:
Weldeed/Flanged en
Split Body & Se
eat supporte
ed
constrruction.
iii)
on
Material off Constructio
Body
Carboon Steel/Cast Iron
Ball
Stainleess steel ANS

SI 420
Seat ring
PTFE
Stem
Stainleess steel AISI 420
Seats
Nitrile rubber; PTFE

E.
iv)
Valves sha
all be designed
d to be directly
y operatable bby a wrench / Hand
H
lever.
v)
Suitable sto
ops shall be provided
p
for bo
oth the fully oppen & close co
ondition.
vi)
All the valvves shall be prrovided with an

a indicator fo r showing the
e position of th
he
ball port.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
174
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
b))
SEC
CTION: D1
REV
V NO: 00
Globe Valves 50 NB
B and Below
i)
Design Sta
andard
IS:7788 Class-2
ii)
Type
Straighht, rising stem

m, with outsid
de
screw..
iii)
on
Material off Constructio
i)
eaded Tin Broonze conLe

fo
orming IS:318 Gr.2
ii)
Body, Bon
nnet,
stuffing Bo
ox
& seat ring
gs
Stem
Sttainless Steel,, AISI-316
iii)
Disc
SI-316
IS
S:318 Gr. 2/AIS
For sizes above 50

0 NB
iv)
v)
vi)
vii)
3.03.11
i)
Design Sta
andard
IS
S:780/IS:2906 rating PN
1.0 min. or E
Equivalent/BS 5150 PN 10
0.
(m
min.)
ii)
Type
Double Flangeed or wafer body, outsid

de
crew and risingg stem type.
sc
iii)
Material o
of constructio
on
Body
Cast iron : IS:2110 Gr. FG

60/BS:1452 G
Gr.14.
26
Stem
Sttainless steel A
AISI 410/
13
3% chrome steeel.
Disc
Cast iron IS:2100 Gr.260/

S:1452 Gr.14..
BS
Packing
PT
TFE
at rings
Seat & sea
13
3% chromium steel
Gland & glland nut
AISI 420
Hand whee
el
Cast iron or Maalleable iron.
Ba
ack seat shall be provided o
on the stem orr on the disc.
Ren
newable disc assembly
a
shalll consist of disc holder, disc
c, disc guide, check nut and
d disc retainin
ng
n with washe
nut
er.
D of globe va
Disc
alve may be p
provided with renewable
r
rub
bber seating ri ng.
Ha
and wheels sh
hall be marke
ed with the wo
ord. OPEN or SHUT with aarrow to indica
ate direction of
o
o
opening
or clos
sing.
Ho
owever, valve
es in the flusshing water lines shall be
e of type andd material sp
pecified for th
he
ch
hemicals which is being flusshed by the line.
0
3.04.00
Va
alves for Dem
mineralised w
water applicattion
3.04.01
Bu
utterfly valves
s or Saunderrs patented diaphragm va
alves shall bee used for th
he services of
o
de
emineralised water
w
applicatiion for isolatio
on purposes.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
175
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
SEC
CTION: D1
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
3.04.02
2
Th
he diaphragm valves shall cconform to the
e following requirements.
a))
Design
n Standard
BS:5156 or equivalent of require

ed
ating/class. (m
minimum rating of valve
es
ra
sh
hould be PN 110).
b))
Type
Fllanged and lined body ends, seale

ed
bo
onnet, weir paattern, tight shut off type.
c)
Materiial of Constru
uction
Body/B
Bonnet
3.04.03
3
0
3.05.00
REV
V NO: 00
I)
Cast Iron IS:2100 Gr.FG.260 or

o equivalent.
II)
Cast steel AST M A-216 Gr. WCB.

W
Body lining
oft Natural rubbber, Ebonite polypropylene

e,
So
PV
VDF.
Diaphrragm
Reinforced rubbber, hypalon/a

app. equal.
Hand wheel
w
Comprressor
Stem & Bush
:
:
:
Cast Iron
Sttainless Steel
Sttainless Steel
d))
Flange
es shall conforrm to ANSI B 16.5 Cl.300 and shall be caast/integral witth the body.
e))
Hand wheels
w
shall b
be marked with
h the direction
n of closure.
f)
Valves
s shall be provvided with a po
osition indicato
or to show thee open and clo
osed condition
n.
g))
Valves
s provided wiith pneumatic
c actuators sh
hall be providded with a hand
h
wheel fo
or
manua
al operation. T
The valves op
perators shall be designed as per relevant Internationa
al
Standa
ard.
Th
he butterfly valves
v
shall cconform to Cl.3.03.05 to Cl.3.03.09
C
aboove except to
o the followin
ng
re
equirements.
a))
Body shall
s
be lined ((minimum 3 mm)
m with naturral rubber, eboonite,
polypro
opylene or PV
VDF.
b))
Disc sh
hall be lined w
with PVDF, polypropylene, or
o natural rubbber.
c)
Seat riings shall be o

of Nitrile rubbe
er or Hypalon.
Va
alves for Acid
d & Alkali Serrvices
Va
alves shall be
e saunders p
patented diaph
hragm type. The valves sshall conform to Cl. 3.04.0
02
ab
bove except to
o the following
g requirements
s.
a))
Diaphrragm shall be of reinforced teflon, EPDM

M/Black Butile//appd. eqv. fo
or acid service
es
and reinforced Neop
prene/Hypalon
n/app eqv for alkali
a
servicess.
0
3.06.00
Va
alves for Lime Slurry / Sollutions
3.06.01
Pllug valves sha

all be used for the applicatio
on of lime slurrry /lime solutioons.
3.06.02
2
Th
he plug valves
s shall conform
m to the follow
wing requireme
ents.
a))
Design
n Standard
b))
Type
BS:5353 Class
C
300 or
Equivalent.
:
Fllanged and noon lubricated,
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
176
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SEC
CTION: D1
REV
V NO: 00
re
egular pattern,, plug valves.
c)
0
3.07.00
Material of Construcction
i)
Body
B
Cast Iron IS:2100 Gr FG 260

orr Equivalent
Sttainless Steel AISI 316
ii)
Plug
P
iii)
Body
B
Sleeve orr Seat :
PTFE
iv)
Seat
S
PT
TFE
v)
Gland
G
AISI 304 / AISI 316
vi)
Cover
C
Cast Steel AST

TM A216 Gr WCB
W
vii) Gland
G
Nut
AISI :304 / AISII 316
d))
Valves
s shall be ope
erated by perm
manently fitted
d wrench or H
Hand lever. Wrench
W
shall be
b
mounted so that the
ey are parallel to the valve bore axis whhen the valve is in fully ope
en
conditiion.
e))
All valv
ves shall be p
provided with an
a indicator for the position oof the plug pa
art.
f)
Suitable stops shall be provided fo

or the fully open and fully cllosed positions of the valve.
g))
Valves
s of size of 250
0 NB and abo
ove shall be provided with a suitable reduc
ction gear unitt.
Re
esin Transferr Line
In resin transfe
er line in CPU
U two way eccentric
e
plug valve as maanufactured by
b De Zurik or
o
pproved equal shall be use
ed. Ball valve may also be used
u
for this aapplication. The valves sha
all
ap
ha
ave type 316 stainless stee
el body and bearings,
b
resilient faced plug and flan
nged ends. Fo
or
se
ervice vessel area pressurre rating shou
uld be in line with system
m requirement. All automatic
va
alves shall be provided with
h double actin
ng pneumatic cylinder actuuators controlled by solenoiid
va
alves, manual over ride featture & local po
osition indicato
ors.
0
3.08.00
Bu
utterfly valves in the conden
nsate polisherr service vesse
els.
3.08.01
Th
hey shall be lu
ugged wafer tyype.
2
3.08.02
Th
he material of construction sshall be as be
elow:
i)
Body
Cast Steel
S
(Please
e refer note wrritten below)
ii)
Disc
SS-316
iii))
Shaft
SS-316
iv))
Seal
Teflon
v)
Seat
Teflon with Titanium

m back-up ringgs
No
ote: - the bod
dy material sh all be SS 316
6 for all the butterfly valvess coming at th
he outlet of th
he
se
ervice vessels.
3
3.08.03
Flan
nges shall corrrespond to AS
SA 300 lb clas
ss (min).
4
3.08.04
Alll automatic va
alves shall be
e provided with
h double actin
ng pneumatic cylinder actua
ators controlle
ed
byy solenoid valv
ves, manual o
over ride feature & local position indicatorss.
0
3.09.00
Va
alves for Air pipe line app
plication
3.09.01
Fo
or Air services
s, globe valvess or Ball valve
es may be used for sizes 50 NB and below
w.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
177
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
SEC
CTION: D1
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
REV
V NO: 00
3.09.02
2
Fo
or sizes higher than 50 NB, either Butterfly valve or Ball valves shall be used.
3
3.09.03
Globe valves sh
hall generally cconform to Cl. 3.03.10 (b) above.
a
4
3.09.04
Ba
all valves shall conform to tthe requireme
ents stipulated
d in Cl.4.03.100 (a) above. However,
H
Bod
dy
material shall be
e leaded Tin B
Bronze (IS:318
8 Gr.2) or stainless steel (A
AISI:304/316).
3.09.05
5
Bu
utterfly valves
s shall conform
m to the Cl.3.0
03.05 to 3.03.09 of this secction. Howev
ver, the body &
Diisc shall be either
e
cast iro
on lined with elastomer such as PVDF or PTFE or stainless stee
el
co
onstruction (AIISI 304/316).
3.10.00
0
No
on-return valves (Check v
valves)
3.10.01
No
on return valves shall be of swing check (reflux) type or dual plate tyype.
2
3.10.02
Th
he valves shall conform to t he following specifications.
s
i)
Design
n Standard :
IS:5312, BS:1868, BS:5153

B
API 5594/
API 60 or Eqvt.
E
ii)
Type
iii))
Material of Construcction (For non corrosive app

plication)
Swing chec
ck Type and F
Flanged ends.
a)
Body
B
& Cover
Hinge
H
Disk/Do
oor
Cast iron IS:2100 Gr.FG 260/o

or
Cast Iron BS:14452 Gr.220 orr Eqvt.
b)
Hinge
H
Pin and
Door/Disc
D
Pin
Cast steel AST M A 216 Gr.

WCB.
W
High tensile Braass IS:320 HT
T 2 or BS:287
72
eq
qvt.
c)
Disc
D facing rin g
Sttainless steel
d)
Body
B
Seat ring
g
Sttainless steel
e)
Bearing
B
bushe
es
Le
eaded Tin Broonze IS:318 Gr.2
f)
Bolts
B
Carbon Steel
iv))
For the
e application o
of lime, corro
osive water (D
DM water), andd air, the body
y, cover & Dissc
shall be
b lined with na
atural Rubberr, PTFE or Vito
on. The Hingee, Hinge Pin & Disc Pin sha
all
be coa
ated with PVD
DF, or suitable elastomer. The bearing buushes shall be
e PTFE or Eqvvt.
material. Bolting sshall be of stainless steel. In the abssence of linin
ng/coating, th
he
comple
ete valve sh all be of sta
ainless steel construction (AISI 316) for the abovve
applica
ation.
v)
For ac
cid services, th
he valves sha
all be of lined construction aas specified in
n (iv) above, or
o
of Has
stalloy B consstruction and Body/Disc
B
facing ring shall bbe of resilient materials succh
as natu
ural rubber, P
PTFE or Viton.
vi))
For alk
kali services, tthe complete valve
v
shall be stainless steeel construction
n (AISI-316).
3
3.10.03
Flanges shall conform

c
to A
ANSI B 16.5 Cl.300
C
to match with the piping flange
es as specifie
ed
elssewhere.
3.10.04
4
Bo
ody shall be permanently
p
m
marked with an
n arrow inscrription indicatiing the directio
on of motion of
o
the fluid for all the check valvves.
5
3.10.05
Ch
heck valves fo
or Raw / Clariffied / Filtered water may be
e offered in Guun metal cons
struction & witth
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
178
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: II-B
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SEC
CTION: D1
REV
V NO: 00
threaded ends for

f sizes 50 N B and below conforming
c
to IS:778 or Equuivalent.
0
3.11.00
Th
he safety valves / relief valvves at the dow
wnstream of po
ositive displaccement type metering
m
pump
ps
sh
hall be of the
e standard tyype manufactu
ured by the pump manufaacturer and the
t
material of
o
co
onstruction sha
all suit to the ffluid handled.
0
3.12.00
Gates
3.12.01
esign standard
d for gates sh all be IS:3042
2 or Eqv.
De
2
3.12.02
Th
he gates shall be rectangu
ular or square sluice, risin
ng spindle typpe conforming
g to class-1 of
o
IS
S:3042.
3.12.03
3
Material of Construction
3.12.04
4
i)
e and Door
Frame
ii)
Spindles, bolts & nu

uts
iii))
Face & seat rings
Cast Iron IS
S:210 Gr. 20
:
M.S.
M to IS:20622
Gun metal (as per IS:30442).
All the parts of ga

ates shall be a
applied with th
he coats of hea
avy duty bitum
mastic paint.
3.12.05
5
Ea
ach of the gate
es shall be pro
ovided with ha
and wheel, and a position inndicator.
3.12.06
6
Th
he gates for DM
D plant drainss shall be rubb
ber lined to a minimum thickkness of 4.5 mm.
m
0
3.13.00
ST
TRAINERS
3.13.01
Ba
asket Straine
ers
a))
2
3.13.02
Basket strainers of simplex desig

gn shall have the following materials of construction
c
fo
or
raw/cla
arified/filtered water applica
ation.
i)
Bo
ody
m steel : IS:22062 (Tested quality)

q
Fabricated mild
ii)
Strrainers
Wire shall be stainless ssteel (AISI:316

6 18 BWG 30
3
bly reinforcedd. Reinforce
ement materia
al
mesh suitab
shall also be of stainless stteel construction.
iii)
Drrain Plug/Nuts
Gun metal
b))
Inside and outside of basket bod

dy shall be protected with one coat of high build zin
nc
hate primer an
nd three coats
s of Chlorinate
ed rubber painnt to a total th
hickness of 20
00
phosph
micron
ns.
c)
Suitable Vent and drrain valves sh

hall be provided for the strainners.
d))
Screen
n (strainer) flo
ow area shall be
b at least fou
ur times pipe ssectional area
a. Flow area in
i
any po
ortion of Baskket strainer as
ssembly shall not be less thhan the pipe cross
c
sectiona
al
area.
e))
Pressu
ure drop in cle
ean condition shall
s
not be more than 1.0 M
MWC.
f)
Basket Strainer shalll be provided with lifting lug

gs and suitablee mounting arrrangement.
g))
For DM
M water serviice, body sha
all be rubber lined to minim
mum 4.5 mm thickness (so
oft
rubberr of shore Hard
dness 65 5A).
Y--Type Straine
er
a))
Y-Type
e strainer for w
water application shall be co
onstructed of ffollowing mate
erials :
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
179
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
i)
Body
Cast Irron IS:210 Gr.. FG 260
ii)
Strainers
Wires of stainless ssteel AISI-316

6, 18 BWG 30
3
Reinforcemen
nt
mesh suitably reeinforced.
material shall alsso be of stainless
s
stee
el
construction.
iii)
Drain Plug//Nuts
Gun metal
m
(threadedd construction
n)
b))
Y-Type
e strainers sha
all also conforrm to Cl. 3.14.01 (b), (d), (e)) and (f).
c)
Body of
o the Y-type
e strainers of alkali, and de
emineralised water shall be
b of Cast Iro
on
(IS:210
0, Gr.FG 260)) and lined with soft or hard rubber to a thhickness of 4.5
5 mm.
d))
For ac
cid services, ap
part from the rubber
r
lined body material, the screen ma
aterial, shall be
b
Polyprropylene or HD
DPE wire cloth
h of suitable mesh
m
and thickkness.
3.14.00
0
Ge
eneral Requirements for V
Valves, Gates
s, Strainers
3.14.01
Alll the equipm

ments shall be
e of proven design
d
for the
e duty condittions and the
e contractor or
o
manufacturer shall have suffficient experie
ence in using the above eq uipments in water
w
treatmen
nt
pplication in th
he plants supp
plied earlier by
y them.
ap
2
3.14.02
In case owner desires, the e

experience lis
st/feedback fro
om the userss shall be mad
de available to
t
ow
wner for any or
o all the equip
pments during the detailed engineering
e
phhase.
3
3.14.03
Va
alves coming under the purv
rview of IBR if any shall mee
et its requirem
ments and the approval of th
he
e contractor.
sa
ame shall be obtained
o
by the
3.14.04
4
Siizes of the valves shall be ssame as that of the interconnected pipe sizes exceptt for the contro
ol
va
alves.
5
3.14.05
Th
he various equipments sha
all be installed so that they are easily appproachable fo
or the operatin
ng
an
nd maintenanc
ce personnel. Generally Va
alves shall be located aboutt 1.2 meter to 1.5 meter from
m
the operating platform and allso they shall not be located
d below the grround level su
uch as beneatth
the trenches ettc. In such ca
ases, extende
ed spindle sha
all be provideed with chain operating from
m
perating floor. Valves whicch are installed below the ground
g
floor s hall be provid
ded with a floo
or
op
mounted pedes
stal at the top of the operatiing floor. The position indica
cator for such valves shall be
b
alsso provided along with the sstand.
6
3.14.06
Ho
owever valves
s which are p
provided (in th
he burried pipe line) with a valves cham
mber shall havve
manual operato
or/Hand whee
el inside the valve
v
chamber. The valvee chamber sha
all be provide
ed
dders/staircase
es and sufficiient operating space withinn the chamber shall also be
b
wiith built in lad
prrovided for eas
sy operation o
of such valves.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
180
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00

TECHN
NICAL S
SPECIF
FICATION FOR
H
HORIZO
ONTAL C
CENTRIFUGAL
L PUMPS
S
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
181
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
1.0
00.0
SCOPE
1.0
01.0
Th
his specifica
ation covers the design, material, co
onstruction fe
eatures, mannufacture, inspection,
te
esting the pe
erformance at
a the Vendo rs/Sub-Vend
dors Works and deliveryy to site of Horizontal
H
Centrifugal Pu
umps.
2.0
00.00
C
CODES AND
D STANDARDS
2.0
01.0
Th
he design, material, construction,
c
manufacturre inspectio
on and perfformance te
esting of
Horizontal Centrifugal Pum
mps shall com
mply with all currently ap
pplicable stattutes, regulattions and
afety codes in the loc
cality where the Equipm
ment will be installed. Nothing in these
sa
sp
pecifications shall be co
onstrued to rrelieve the Vendor
V
of this responsibbility. The Eq
quipment
su
upplied shalll comply with
h the latest a
applicable In
ndian Standa
ards listed bbelow. Other National
Sttandards are acceptable, if they a
are establish
hed to be equal
e
or su perior to the Indian
Sttandards.
2.0
02.0
L
List of Applica
able Standarrds.
1
IS
S : 1520
C
Pumps
P
for cleear cold fresh
h water.
IS
S : 5120
AP
PI : 610
Technical re
equirements of roto dynaamic special purpose
pumps.
Centrifugal pumps for general refineery service.
IS
S : 5639
Pumps Han
ndling Chemiicals & corroosion liquids.
IS
S : 5659
Pumps for process

p
wate
er.
HIIS
Hydraulic In
nstitute Stand
dards, USA
AS
STM-1-165-6
65
Standards Methods
M
for Liquid Penettration Inspe
ection.
2.0
03.03
In
n case of anyy contradictio
on with afore
esaid standa
ards and the stipulationss as per the technical
sp
pecifications as specifie
ed hereinafte
er the stipulations of th
he technicall specificatio
ons shall
prrevail.
3.0
00.00
D
DESIGN REQUIREMEN
NTS
3.0
01.00
Th
he Pump shall be cap
pable of devveloping the
e required to
otal head aat rated cap
pacity for
co
ontinuous op
peration. Als
so the pump
ps shall be capable of be
eing operatedd to give satisfactory
pe
erformance at
a any point on the HQ ccharacteristics curve ove
er the operaating range of
o 40% to
12
20% of the duty
d
point. Th
he maximum
m efficiency of
o pump shalll be preferabbly be within
n +/- 10%
off the rated de
esign flow as
s indicated in
n the data sheets.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
182
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
3.0
02.00
Th
he total hea
ad capacity curve
c
shall b
be continuou
usly rising frrom the opeerating point towards
sh
hut-off withou
ut any zone of instability and with a minimum
m
shu
ut-off head oof 15% more than the
de
esign head.
3.0
03.00
Pumps of a pa
articular cate
egory shall be
e identical and shall be suitable
s
for pparallel opera
ation with
qual load divvision. The head Vs cap
pacity and BHP Vs capa
acity characteeristics shou
uld match
eq
to
o ensure eve
en load sharing and troub
ble free operation throug
ghout the rannge. Compo
onents of
identical pump
ps shall be in
nterchangeab
ble.
3.0
04.00
Pumps shall run smoothly without und ue noise and

d vibration. Peak
P
to peakk vibration lim
mits shall
e restricted to the followin
ng values du
uring operatio
on:
be
Anttifriction Be
earing
Sleeeve Bearin
ng
75.0
0 micron
75..0 micron
SPEED
1500 rpm and
a below
3.0
05.00
Th
he noise levvel shall nott exceed 85
5 dBA. Ove
erall sound pressure levvel reference
e 0.0002
m
microbar (the standard prressure refe rence for airr sound mea
asurement) aat a distance
e of 1 M
fro
om the equip
pment.
3.0
06.00
Th
he pumps shall be capa
able of startiing with disc
charge valve
e fully open and close condition.
c
M
Motors shall be selected to suit to th
he above re
equirements. Continuouss Motor ratin
ng (at 50
de
eg.C ambien
nt) shall be atleast ten p
percent (10%
%) above the
e maximum load deman
nd of the
pu
ump in the entire
e
operating range to take care off the system frequency vvariation and
d no case
le
ess than the maximum po
ower require
ement at any condition off the entire ccharacteristic
c curve of
th
he pump.
3.0
07.00
Th
he kW rating
g of the drive
e unit shall be
e based on continuously
c
quipment
driving the cconnected eq
fo
or the condittions specifie
ed. Howeve
er, in cases where para
allel operatioon of the pu
umps are
sp
pecified, the actual motor rating is to be selected by the Bidder considerinng overloading of the
pu
umps in the event
e
of tripp
ping of opera
ating pump(s
s).
3.0
08.00
Pumps shall be
b so design
ned that pum
mp impellers and other accessories
a
oof the pumps
s are not
amaged due to flow reversal.
da
3.0
09.00
Th
he Contracto
or under this specification
n shall assum
me full respo
onsibility in thhe operation of pump
an
nd motor as a unit.
4.0
00.0
D
DESIGN CO
ONSTRUCTION
4.0
01.00
DESIGN AND
D CONSTRU
UCTION OF
F VARIOUS COMPONE
ENTS OF T
THE PUMPS
S SHALL
T THE FO
OLLOWING GENERAL SPECIFICA
ATIONS. F
FOR MATER
RIAL OF
CONFORM TO
TION OF THE
E COMPONE
A SHEETS SHALL
S
BE R
REFERRED TO.
T
CONSTRUCT
ENTS, DATA
4.0
02.0
Pump Casin
ng
4.0
02.01
Pump casing shall have axially or radi ally split type

e constructio
on. The casiing shall be designed
d
o withstand the maxim
mum shut-offf pressure developed by the pum
mp at the pumping
to
te
emperature.
4.0
02.02
Pump casing shall be prov

vided with a vent connec
ction and piping with fittinngs & valves. Casing
e provided ccomplete with
h drain valve
es, piping annd plugs. It shall be
drrain as required shall be
prrovided with a connectio
on for suction
n and discha
arge pressurre gauge as standard fe
eature. It
sh
hall be struccturally sound
d to provide
e housing forr the pump assembly
a
annd shall be designed
d
hyydraulically to minimum radial
r
load att part load op
peration.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
183
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
4.0
03.00
Im
mpeller
4.0
03.01
Im
mpeller shall be closed, semi-closed
d or open typ
pe, and it sh
hall be desiggned in confformance
w
with the detailed analysis of
o the liquid b
being handle
ed.
4.0
03.01
Th
he impeller shall be se
ecured to th
he shaft, an
nd shall be retained aggainst circum
mferential
m
movement by keying, pinn
ning or lock rings. On pumps with overhung
o
shaaft, impellers
s shall be
se
ecured to th
he shaft by a lockout o r cap screw
w which tighttness in thee direction of
o normal
ro
otation.
4.0
04.00
Im
mpeller/Cas
sing Wearing Rings
4.0
04.01
R
Replaceable type
t
wearing
g rings shal l be provide
ed at suitable locations of pumps. Suitable
m
method of loccking the we
earing ring s hall be used
d. Wearing rings shall bbe provided in pump
ca
asing and/or impeller as per manufaccturers stand
dard practice
e.
4.0
05.00
Shaft
4.0
05.01
Th
he critical sp
peed shall be
e well away ffrom the ope
erating speed
d and in no ccase less than 130%
off the rated sp
peed.
4.0
05.02
Th
he shaft sha
all be ground
d and polish
hed to final dimensions
d
and
a shall bee adequately sized to
w
withstand all stresses
s
from
m rotor weigh
ht, hydraulic loads, vibrattion and torq ues coming in during
peration.
op
4..06.00
Shaft Sleeve
es
4.0
06.01
R
Renewable tyype fine finish
hed shaft sle
eeves shall be
b provided at the stuffinng boxes/me
echanical
eals. Length
h of the shaftt sleeves mu st extend be
eyond the outer faces of ggland packin
ng of seal
se
en
nd plates so
o as to distinguish betwe
een the leaka
age between
n shaft and sshaft sleeve and that
pa
ast the sealss/gland.
4.0
06.02
Shaft sleeve shall

s
be faste
ened to the sshaft to preve
ent any leaka
age or looseening. Shaft and
a shaft
entric rotation
n.
sleeve assembly should ensure conce
4.0
07.00
B
Bearings
4.0
07.01
Heavy duty bearings,

b
ade
equately dessigned for th
he type of service
s
speciified in the enclosed
ump data sheet and for lo
ong, trouble free operatio
on shall be fu
urnished
pu
4.0
07.02
Th
he bearings offered shall be capable of taking bo
oth the radial and axial thhrust coming into play
du
uring operattion. In cas
se, sleeve b
bearings are
e offered add
ditional thrusst bearings shall be
prrovided. Anttifriction bearrings of stand
dard type, if provided, sh
hall be selectted for a minimum life
16
6,000 hrs. off continuous operation at maximum axial and radial loads andd rated speed
d.
4.0
07.03
Proper lubrica
ating arrange
ement for the
s
be prov
vided. The ddesign shall be such
e bearings shall
hat the bearin
ng lubricating
g element do
oes not conta
aminate the liquid pumpeed. Where there
t
is a
th
po
ossibility of liquid enterin
ng the bearin
ngs suitable arrangement in the form
m of deflectors or any
otther suitable arrangemen
nt must be prrovided ahea
ad of bearings assembly.
4.0
07.04
Be
earings shalll be easily accessible
a
w
without disturrbing the pum
mp assemblyy. A drain plug
p
shall
be
e provided att the bottom of each bea rings housing.
4.0
08.00
Stuffing Box
xes
4.0
08.01
Sttuffing box design

d
should
d permit repl acement of packing without removingg any part other than
th
he gland.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
184
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
4.0
08.02
Sttuffing boxess of packed ring construcction type sh

hall be provided whereveer specified. Packed
rin
ng stuffing boxes
b
shall be properly lubricated and
a
sealed as
a per servicce requirements and
m
manufacturers standards.. If external gland sealin
ng is required
d, it shall be done from the
t pump
diischarge. The
T
Bidder shall
s
provide
e the necess
sary piping valves,
v
fittinggs etc. for the gland
ealing conne
ection.
se
4.0
09.00
M
Mechanical Seals
4.0
09.01
W
Wherever spe
ecified in pum
mp data shee
et, mechanic
cal seals sha
all be provideed. Unless otherwise
o
re
ecommended
d by the ten
nderer, mech
hanical seals shall be of
o single typpe with eithe
er sliding
ga
asket or bello
ows between
n the axially moving face
e and shaft sleeves or anny other suita
able type.
Th
he sealing fa
aces should be highly la
apped surfac
ces of materrials known ffor their low frictional
co
oefficient and
d resistance to corrosion against the liquid being pumped.
4.0
09.02
Th
he pump supplier shall coordinate w
with the sea
al maker in establishing
e
amber of
the seal cha
circulation rate
e for maintaiining a stable
e film at the seal face. The
T seal pipiing system shall
s
form
n integral pa
art of the pum
mp assemblyy. For the seals
s
under vacuum serv
rvice, the sea
al design
an
m
must ensure sealing agaiinst atmosph
heric pressure even whe
en the pumpps are not operating.
o
Necessary provision for seal
s
water ssupply along with comple
ete piping fi ttings and valves
v
as
equired shall form integra
al part of pum
mp supply.
re
4.1
10.00
Pump Shaftt Motor Sha

aft Couplin
ng
4.1
10.01
Th
he pump and motor sha
afts shall be connected with
w an adeq
quately sizedd flexible co
oupling of
prroven design
n with a spac
cer to facilita
ate dismantling of the pu
ump without disturbing th
he motor.
Necessary coupling guard
ds shall also b
be provided..
4.1
11.00
B
Base Plate
4.1
11.01
A common ba
ase plate mou
unting both ffor the pump and motor shall
s
be provvided. The ba
ase plate
hall be fabriccated steel and
a of rigid construction, suitably rib
bbed and reiinforced. Ba
ase plate
sh
an
nd pump supports shall be so consstructed and the piping unit so mouunted as to minimize
m
misalignment caused by mechanical forces such as normal piping strainn, internal differential
th
hermal expan
nsion and hydraulic pip ing thrust. Suitable dra
ain troughs aand drip lip shall be
prrovided.
4.1
12.00
A
Assembly and Disman
ntling
4.1
12.01
Asssembly and
d dismantling
g of each pu
ump with driv
ve motor sha
all be possibble without disturbing
d
th
he grouting base plate or alignment.
4.1
13.00
D
Drive Motorr (Prime Mo
over)
4.1
13.01
Th
he kW rating
g of the drive
e shall be ba
ased on conttinuously driv
ving the connnected equip
pment for
th
he conditionss specified. In case, w
where paralle
el operation of the pumpps are specified, the
acctual motor rating
r
is to be
b selected b
by the tende
erer considering overloadding of the pumps
p
in
th
he event of trripping of ope
erating pump
ps.
5.0
00.00
TESTING FO
OR HORIZO
ONTAL CEN
NTRIFUGA
AL PUMPS
Th
he manufactturer shall co
onduct all tessts required to ensure th
hat the equippment furnish
hed shall
co
onform to th
he requireme
ents of this sspecification
n and in com
mpliance withh the require
ement of
ap
pplicable Co
odes and Sta
andards. Th
he particulars
s of the prop
posed tests sshall be submitted to
th
he Owner for approval be
efore conductting the tests
s.
5.0
01.00
Hydrostatic Tests
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
185
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
All pressure parts

p
shall be
e hydraulicallly tested at 200%
2
of pum
mp rated headd or at 150%
% shut off
he
ead whichevver is higher. The test p
pressure sha
all be mainta
ained for 1/22 hr. and no
o leakage
sh
hall be permitted. While arriving at tthe above prressure, the maximum suuction head specified
in
n Data Sheet shall be take
en into accou
unt.
5.0
02.00
Performance Tests
5.0
02.01
All the pumps shall be tested in the Ma

s Works at ra
ated speed foor capacity, efficiency
e
anufactures
an
nd brake ho
orse power. Pumps sha
all be given running test over the enntire operatin
ng range
co
overing from
m the shut offf head to the
e maximum flow. The duration
d
of teest shall be minimum
m
on
ne (1) hour.. A minimu
um of seven
n readings approximatel
a
y equidistannt shall be taken
t
for
pllotting the cu
urves with on
ne point at de
esign flow. Testing
T
of pu
umps shall bbe in accorda
ance with
nstitute Stand
dards or as applicable
a
eq
quivalent
sttipulations off Hydraulic In
5.0
02.02
Th
he test shall be preferablly conducted
d with the acttual motor be
eing furnisheed.
5.0
02.03
O
Only those pumps
p
shall be subjeccted to strip
p down exa
amination viisually to check for
m
mechanical da
amages after testing at sshop in case abnormal no
oise level an d excessive vibration
is observed du
uring the perrformance te
est. Otherwise strip down examinationn is limited to
o bearing
nspection only.
in
5.0
02.04
Th
he pump acccessories e.g
g. the thrust bearing, cou
uplings etc. shall
s
be subjjected to tests as per
m
manufacturers standards.
5.0
03.00
M
Mechanical Balancing
All rotating components
c
of the pum
mps shall be statically balanced. IIn addition to static
ba
alancing, rottating compo
onents of th
he pumps sh
hall be balan
nced dynam
mically at or near the
op
perating speed. Tendere
er shall furnissh acceptanc
ce norm for this test.
5.0
04.00
V
Visual Inspe
ection
Pumps shall be
b offered forr visual inspe
ection by the
e bidder before shipment.. The compo
onents of
he pumps sha
all not be painted before inspection.
th
5.0
05.00
NPSH Test
NPSH test sha
all be conducted with wa
ater as mediu
um if required. NPSH shhall not be mandatory
m
n case type te
est certificate
es are furnish
hed for the similar
s
rating of pumps.
in
5.0
06.00
Noise and Vibration

V
Measuremen
nt
Noise and vibration shall be
b measured
d during the performance
p
e testing at shhop as well as
a during
he site test.
th
5.0
06.01
Th
he noise levvel shall nott exceed 85
5 dBA. Nois
se level measurement w
will be made
e as per
ap
pplicable internationally acceptable standard. The
T
measurrement shalll be carried out with
ca
alibrated inte
egrating sou
und level me
eter meeting the require
ement of IEC
C:651 or BS
S:5969 or
IS
S:9779. Sou
und pressurre level will be measure
ed all round
d the pump and motor set at a
diistance of on
ne meter from the neare
est surface of
o the machin
ne and at a height of 1.5
5 m from
he floor leve
el. A minim
mum of six (6) points should
s
be covered
c
for measurement. The
th
m
measurementt shall be don
ne with a slo
ow response on the A-weighted scalee. The average of the
A--Weighted sound
s
press
sure measurrements exp
pressed in decibels
d
to a reference
e 0.0002
m
microbars sha
all not exceed
d the specifie
ed value.
Th
he tests shall be carried out on the m
machine operrating at rate
ed speed andd as near as possible
to
o the rated power. Co
orrections forr backgroun
nd noise and
d correctionn on accoun
nt of test
en
nvironment will
w be cons
sidered in li ne with app
plicable stan
ndard. For this purpose all the
ad
dditional data
a required sh
hould necesssarily be colle
ected during the test.
BHEL PS- PEM-PPE
EI: NOIDA, SEC
CTOR 16A, UP--201301
186
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
5.0
06.2
Vibration checck will also be done as per HIS. Vibration

V
wou
uld be checkked at thrustt bearing
ocations on horizontal,
h
ra
adial and ve
ertical direction. The acceptance lim
mits would be
b as per
lo
HIS. The insstrument use
ed would be
e IRD 308 or equivalent with velocitty pick-up. Vibration
mits to be specified as pe
er the speed of the pump
p.
lim
5.0
07.00
M
Material Tes
st Certificatte
5.0
07.01
M
Material of th
he various pump
p
compo
onents shall be tested in accordancce with the relevant
sttandards. Te
est certificate
es for these sshall be furnished for the Owners ap proval.
5.0
07.02
W
Where stage inspection is desired b
by BHEL/cus
stomer all material
m
test certificates shall be
co
orrelated and
d verified witth the actuall material used for construction beforre starting fa
abrication
byy BHEL/custtomers inspe
ector who w
will stamp the
e material. In
n case mill ttest certificatte for the
m
material are not
n available, the supplie
er shall carry
y out physica
al and chem
mical tests att his own
co
ost from a te
esting agenc
cy, approved by BHEL/Customer, as per the requuirement of specified
m
material stand
dard. The sa
ample for phyysical and ch
hemical testing shall be ddrawn up in presence
p
off BHEL/Customers inspe
ector who sh all also witne
ess the testin
ng.
5.0
08.00
Non Destruc
ctive Testin
ng
(a)
UT shall be ca
arried out on shafts of dia
ameter more than 50 mm
m.
(b)
o on shaft a
and impeller..
DP tests shall be carried out
(c)
N
No weld repa
air shall be allowed on ca st iron.
5.0
09.00
Field Testing
5.0
09.01
Affter installatiion, the pum

mps offered shall be ope
erated to prove satisfacctory perform
mance as
in
ndividual equ
uipment as well
w as a sysstem run. Iff the perform
mance at sitee is found not
n to the
equirements then the equ
uipment sha ll be rectified
d or replaced
d by the Venndor, at no extra
e
cost
re
to
o the Owner. The proced
dure of the a
above testing
g will be muttually agreedd between th
he Owner
an
nd the contra
actor. Noice and vibration
n tests shall also be repe
eated at site.
5.0
09.02
Ba
ased on obsservation of the trial op
peration, if modifications
m
sary, the
and repairss are necess
sa
ame shall be
e carried out by the contrractor to the full satisfacttion of the e ngineer and then the
pe
erformance and guaran
ntee tests to
o be repeatted at site as per releevant clauses of the
sp
pecification.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
187
TITLE: TECHN
NICAL SPECIF
FICATION FOR
CONDEN
NSATE POLISH
HING UNIT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
TECHN
NICAL S
SPECIF
FICATION FOR
METERING PUMPS
P
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
188
TITLE: TECHN
NICAL SPECIF
FICATION FOR
CONDEN
NSATE POLISH
HING UNIT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
1.0
00.0
G
GENERAL
1.0
01.01
Specification cover
c
the de
esign, materia
al, constructtion features,, manufacturre, inspection
n, testing
he performan
nce at the ve
endor's/sub-vvendor's works, delivery to site, erecction, comm
missioning
th
an
nd testing of metering pu
umps.
2.0
00.0
G
GENERAL DESIGN
D
FE
EATURES
2.0
00.01
Pumps shall be
b simplex positive displa
acement hyd
draulically op
perated diaphhragm desig
gn, driven
ugh suitable speed reduc
ction unit. Maaximum pum
mp stroke
byy squirrel cage induction motor throu
sp
peed shall no
ot exceed 10
00 per minute
e.
2.0
00.02
Th
he stroke shall be continuously adjusstable to give
e a capacity variation 0-1100% range while the
pu
ump is running or stopp
ped. Adjustm
ment of capa
acity shall be
e done by m
manual control facility
(m
micrometric adjusting
a
type
e) to be provvided locally for each of the pump.
2.0
00.03
Th
he stroke shall be continuously adjusstable to give
e a capacity variation 0-1100% range while the
pu
ump is running or stopp
ped. Adjustm
ment of capa
acity shall be
e done by m
manual control facility
(m
micrometric adjusting
a
type
e) to be provvided locally for each of the pump.
2.0
00.04
Capacity varia
ation may be
e effected byy changing eccentricity
e
of
o the drivingg crank or by
y suitable
uit. Pump acc
curacy shall be industry standard
s
1% of capacitty setting.
hyydraulic circu
2.0
00.05
Pumps shall be
b provided with
w an integ
gral relief valv
ve, spring op
perated to reelease pressu
ure when
elivery line blockage occurs.
de
2.0
00.06
Crankcase shall be constrructed of hig h quality cas

st iron, which
h will also hoouse the gea
arbox and
uides of crosss head.
gu
2.0
00.07
G
Guided, contro
olled travel, double-ball ccheck valves
s or equivale
ent, shall be provided both on the
uction and diischarge side
e.
su
2.0
00.08
M
Material of co
onstruction off the variouss parts shall be as per th
he details fu rnished else
ewhere in
th
he specification. However all parts co
oming in con
ntact with acid shall be oof Haste alloy 'B' and
fo
or alkali it sho
ould be of SS
S-316 only.
2.0
00.09
Suitable gland
d seal shall be
b provided tto prevent lea
akage.
2.0
00.10
Electric drive motor

m
particu
ulars should follow enclosed electrica
al chapters.
3.0
00.00
TESTING
3.0
01.00
Te
esting and
d Inspection
n at Manufa
facturer's Works
W
3.0
01.01
Th
he manufaccturer shall conduct
c
all tests require
ed to ensurre that the eequipment furnished
f
co
onforms to th
he requireme
ents of this S
Specification and is in com
mpliance withh requiremen
nts of the
ap
pplicable cod
des. The particulars of th
d tests and the procedurres for the te
ests shall
he proposed
be
e submitted to
t Owner forr approval be
efore conduc
cting the tests
s.
3.0
01.02
Th
he Owner's representativ
ves shall be given full access to all tests for wh ich the Manufacturer
sh
hall inform the Owner allowing a
adequate tim
me so that if the Ownner so des
sires, his
re
epresentative
es can witnes
ss the test.
3.0
01.03
All materials and

a castings used for the
e equipment shall be of te
ested qualityy. The test ce
ertificates
sh
hall be made
e available to
o Owner.
BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
189
TITLE: TECHN
NICAL SPECIF
FICATION FOR
CONDEN
NSATE POLISH
HING UNIT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D1
REV
V NO: 00
3.0
01.04
Th
he pump casing shall be
e hydraulica lly tested at 200% pump
p operating ppressure or 150% of
de
esign pressu
ure whicheve
er is higher. The test pre
essure shall be maintainned at least for an
ho
our.
3.0
01.05
Th
he rotating parts
p
of pump
p drive shall b
be subjected
d to static balancing.
3.0
01.06
All pumps sha

all be tested
d at the sho
op for capaciity, volumetrric accuracy,, repetitive accuracy,
a
po
ower and volumetric effic
ciency. The ttests are to be
b done according to thee requiremen
nts of the
"H
Hydraulic Insstitute" of U.S
S.A. and India
an Standards as applicab
ble.
3.0
01.07
Th
he pump acccessories e.g
g. gear box, speed reduc
ction unit etc. will be subjjected to tes
sts as per
m
manufacturer's standards. The test ressults shall be
e furnished to
o the Owner..
3.0
01.08
Th
he combined
d variation of
o the pump and motor should
s
be re
estricted withhin limits spe
ecified by
Hydraulic Institute Standard, USA whe
en the pump operated sin
ngly or in parrallel.
3.0
01.09
All pumps sha

all be subjectt to strip dow
wn examinatiion visually to check for m
mechanical damages
d
affter performa
ance testing at
a shop.
3.0
01.10
Diaphragm of the metering

g pump shalll be type testted as per ap
pplicable codde/standard.
3.0
01.11
Pe
erformance test
t
shall be carried out ffor the setting
g of pressure
e relief valvee.
3.0
01.12
Te
est reports and
a certificate
es of all the a
above-mentioned tests to
o ensure sattisfactory ope
eration of
th
he system sh
hall be submitted to the O
Owner for app
proval before
e dispatch.
3.0
02.00
Te
est at Site
Affter erection
n at site pum
mps as deta
ailed under different gro
oups shall bee operated to prove
sa
atisfactory pe
erformance as
a individual equipment as
a well as a system.
s
If thee performance at site
is found to be
e not to the re
equirementss, then the eq
quipment shall be rectifieed or replace
ed by the
endor at no extra
e
cost to the Owner.
Ve

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
190
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D2
REV
V NO: 00

SEC
CTIOND2

G
GENERA
ALTECH
HNICALREQUIREMEN
NTELE CTRICA
AL

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
191

TITLE :
GENERAL TECHNICAL REQUIREMENTs
SPECIFICATION NO.
PE-SS-999-506-E101
VOLUME NO. :
II-B
FOR
REV NO. : 00 DATE : 29/08/2005
SHEET : 1 OF 1
LV MOTORS
GENERAL TECHNICAL REQUIREMENTS
FOR
LV MOTORS
SPECIFICATION NO.: PE-SS-999-506-E101 Rev 00
192

TITLE :
FOR
LV MOTORS
1.0
SPECIFICATION NO.
PE-SS-999-506-E101
VOLUME NO. :
II-B
SECTION
:
D
REV NO. : 00 DATE : 29/08/2005
SHEET : 1 OF 4
INTENT OF SPECIFIATION
The specification covers the design, materials, constructional features, manufacture, inspection and
testing at manufacturers work, and packing of Low voltage (LV) squirrel cage induction motors
along with all accessories for driving auxiliaries in thermal power station.
Motors having a voltage rating of below 1000V are referred to as low voltage (LV) motors.
2.0
CODES AND STANDARDS

Motors shall fully comply with latest edition, including all amendments and revision, of following
codes and standards:
IS:325
IS : 900
IS: 996
IS: 4722
IS: 4691
IS: 4728
IS: 1231
IS: 8789
IS: 13555
IS: 2148
IS: 5571
IS: 12824
IS: 12802
IS: 12065
IS: 12075
Three phase Induction motors

Code of practice for installation and maintenance of induction motors
Single phase small AC and universal motors
Rotating Electrical machines
Degree of Protection provided by enclosures for rotating electrical machines
Terminal marking and direction of rotation rotating electrical machines
Dimensions of three phase foot mounted induction motors
Values of performance characteristics for three phase induction motors
Guide for selection and application of 3-phase A.C. induction motors for
different types of driven equipment
Flame proof enclosures for electrical appliance
Guide for selection of electrical equipment for hazardous areas
Type of duty and classes of rating assigned
Temperature rise measurement for rotating electrical machnines
Permissible limits of noise level for rotating electrical machines
Mechanical vibration of rotating electrical machines
In case of imported motors, motors as per IEC-34 shall also be acceptable.

3.0
DESIGN REQUIREMENTS
3.1
Motors and accessories shall be designed to operate satisfactorily under conditions specified in data
sheet-A and Project Information, including voltage & frequency variation of supply system as defined
in Data sheet-A
3.2
Motors shall be continuously rated at the design ambient temperature specified in Data Sheet-A and
other site conditions specified under Project Information
Motor ratings shall have at least a 15% margin over the continuous maximum demand of the driven
equipment, under entire operating range including voltage & frequency variation specified above.
3.3
Starting Requirements
3.3.1
Motor characteristics such as speed, starting torque, break away torque and starting time shall be
properly co-ordinated with the requirements of driven equipment. The accelerating torque at any
speed with the minimum starting voltage shall be at least 10% higher than that of the driven
equipment.
3.3.2
Motors shall be capable of starting and accelerating the load with direct on line starting without
exceeding acceptable winding temperature.
193

TITLE :
FOR
LV MOTORS
SPECIFICATION NO.
PE-SS-999-506-E101
VOLUME NO. :
II-B
SECTION
:
D
REV NO. : 00 DATE : 29/08/2005
SHEET : 2 OF 4
The limiting value of voltage at rated frequency under which a motor will successfully start and
accelerate to rated speed with load shall be taken to be a constant value as per Data Sheet - A during
the starting period of motors.
3.3.3
The following frequency of starts shall apply

i)
Two starts in succession with the motor being initially at a temperature not exceeding the
rated load temperature.
ii)
Three equally spread starts in an hour the motor being initially at a temperature not exceeding
the rated load operating temperature. (not to be repeated in the second successive hour)
iii)
Motors for coal conveyor and coal crusher application shall be suitable for three consecutive
hot starts followed by one hour interval with maximum twenty starts per day and shall be
suitable for mimimum 20,000 starts during the life time of the motor
3.4
Running Requirements
3.4.1
Motors shall run satisfactorily at a supply voltage of 75% of rated voltage for 5 minutes with full load
without injurious heating to the motor.
3.4.2
Motor shall not stall due to voltage dip in the system causing momentary drop in voltage upto 70% of
the rated voltage for duration of 2 secs.
3.5
Stress During bus Transfer
3.5.1
Motors shall withstand the voltage, heavy inrush transient current, mechanical and torque stress
developed due to the application of 150% of the rated voltage for at least 1 sec. caused due to vector
difference between the motor residual voltage and the incoming supply voltage during occasional auto
bus transfer.
3.5.2
Motor and driven equipment shafts shall be adequately sized to satisfactorily withstand transient
torque under above condition.
3.6
Maximum noise level measured at distance of 1.0 metres from the outline of motor shall not exceed
the values specified in IS 12065.
3.7
The max. vibration velocity or double amplitude of motors vibration as measured at motor bearings
shall be within the limits specified in IS: 12075.
4.0
CONSTRUCTIONAL FEATURES
4.1
Indoor motors shall conform to degree of protection IP: 54 as per IS: 4691. Outdoor or semi-indoor
motors shall conform to degree of protection IP: 55 as per IS: 4691and shall be of weather-proof
construction. Outdoor motors shall be installed under a suitable canopy
4.2
Motors upto 160KW shall have Totally Enclosed Fan Cooled (TEFC) enclosures, the method of
cooling conforming to IC-0141 or IC-0151 of IS: 6362.
Motors rated above 160 KW shall be Closed Air Circuit Air (CACA) cooled
4.3
Motors shall be designed with cooling fans suitable for both directions of rotation.
194

TITLE :
FOR
LV MOTORS
4.4.
4.5
SPECIFICATION NO.
PE-SS-999-506-E101
VOLUME NO. :
II-B
SECTION
:
D
REV NO. : 00 DATE : 29/08/2005
SHEET : 3 OF 4
Motors shall not be provided with any electric or pneumatic operated external fan for cooling the
motors.
Frames shall be designed to avoid collection of moisture and all enclosures shall be provided with
facility for drainage at the lowest point.
4.6
In case Class F insulation is provided for LV motors, temperature rise shall be limited to the limits
applicable to Class B insulation.
In case of continuous operation at extreme voltage limits the temperature limits specified in table-1 of
IS:325 shall not exceed by more than 10qC.
4.7
Terminals and Terminal Boxes
4.7.1
Terminals, terminal leads, terminal boxes, windings tails and associated equipment shall be suitable
for connection to a supply system having a short circuit level, specified in the Data Sheet-A.
Unless otherwise stated in Data Sheet-A, motors of rating 110 kW and above will be controlled by
circuit breaker and below 110 kW by switch fuse-contactor. The terminal box of motors shall be
designed for the fault current mentioned in data sheet A.
4.7.2
unless otherwise specified or approved, phase terminal boxes of horizontal motors shall be positioned
on the left hand side of the motor when viewed from the non-driving end.
4.7.3
Connections shall be such that when the supply leads R, Y & B are connected to motor terminals A B
& C or U, V & W respectively, motor shall rotate in an anticlockwise direction when viewed from the
non-driving end. Where such motors require clockwise rotation, the supply leads R, Y, B will be
connected to motor terminals A, C, B or U W & V respectively.
4.7.4
Permanently attached diagram and instruction plate made preferably of stainless steel shall be
mounted inside terminal box cover giving the connection diagram for the desired direction of rotation
and reverse rotation.
4.7.5
Motor terminals and terminal leads shall be fully insulated with no bar live parts. Adequate space
shall be available inside the terminal box so that no difficulty is encountered for terminating the cable
specified in Data Sheet-A.
4.7.6
Degree of protection for terminal boxes shall be IP 55 as per IS 4691.
4.7.7
Separate terminal boxes shall be provided for space heaters.. If this is not possible in case of LV
motors, the space heater terminals shall be adequately segregated from the main terminals in the main
terminal box. Detachable gland plates with double compression brass glands shall be provided in
terminal boxes.
4.7.8.
Phase terminal boxes shall be suitable for 360 degree of rotation in steps of 90 degree for LV motors.
4.7.9
Cable glands and cable lugs as per cable sizes specified in Data Sheet-A shall be included. Cable lugs
shall be of tinned Copper, crimping type.
4.8
Two separate earthing terminals suitable for connecting G.I. or MS strip grounding conductor of size
given in Data Sheet-A shall be provided on opposite sides of motor frame. Each terminal box shall
have a grounding terminal.
4.9
General
195

TITLE :
FOR
LV MOTORS
SPECIFICATION NO.
PE-SS-999-506-E101
VOLUME NO. :
II-B
SECTION
:
D
REV NO. : 00 DATE : 29/08/2005
SHEET : 4 OF 4
4.9.1
Motors provided for similar drives shall be interchangeable.
4.9.2
Suitable foundation bolts are to be supplied alongwith the motors.
4.9.3
Motors shall be provided with eye bolts, or other means to facilitate safe lifting if the weight is 20Kgs.
and above.
4.9.4
Necessary fitments and accessories shall be provided on motors in accordance with the latest Indian
Electricity rules 1956.
4.9.5
All motors rated above 30 kW shall be provided with space heaters to maintain the motor internal air
temperature above the dew point. Unless otherwise specified, space heaters shall be suitable for a
supply of 240V AC, single phase, 50 Hz.
4.9.6
Name plate with all particulars as per IS: 325 shall be provided
4.9.7
Unless otherwise specified, the colour of finish shall be grey to Shade No. 631 and 632 as per IS:5 for
motors installed indoor and outdoor respectively. The paint shall be epoxy based and shall be suitable
for withstanding specified site conditions.
5.0
INSPECTION AND TESTING
5.1
All materials, components and equipments covered under this specification shall be procured,
manufactured, as per the BHEL standard quality plan No. PED-506-00-Q-006/0 and PED-506-00-Q007/2 enclosed with this specification and which shall be complied.
5.2
LV motors of type-tested design shall be provided. Valid type test reports not more than 5 year shall
be furnished. In the absence of these, type tests shall have to be conducted by manufacturer without
any commercial implication to purchaser.
5.3
All motors shall be subjected to routine tests as per IS: 325 and as per BHEL standard quality plan.
5.4
Motors shall also be subjected to additional tests, if any, as mentioned in Data Sheet A.
6.0
DRAWINGS TO BE SUBMITTED AFTER AWARD OF CONTRACT

a)
b)
c)
OGA drawing showing the position of terminal boxes, earthing connections etc.
Arrangement drawing of terminal boxes.
Characteristic curves:
(To be given for motor above 55 kW unless otherwise specified in Data Sheet).
i)
ii)
iii)
iv)
Current vs. time at rated voltage and minimum starting voltage.

Speed vs. time at rated voltage and minimum starting voltage.
Torque vs. speed at rated voltage and minimum voltage.
For the motors with solid coupling the above curves i), ii), iii) to be furnished for the
motors coupled with driven equipment. In case motor is coupled with mechanical
equipment by fluid coupling, the above curves shall be furnished with and without
coupling.
Thermal withstand curve under hot and cold conditions at rated
voltage and max. permissible voltage.
196
MOTORS
& ACTUATORS
197
Efficiency class IE2 as per latest revision of IS 12615 along with amendments ( 2nd
IE*rev:2011).
efficiency
class will be IE3 for these motors.
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SPEC.NO.
TCE.5750A-H-500-001
VOLUME IV
SECTION: D13
RRVUNL, 2 x 660 MW, Super-Critical TPS, StageV, Units 7 & 8, at Suratgarh, Rajasthan
SHEET 4 OF 7
PART B
MOTOR & ACTUATOR

output drive. The hand wheel shall be clearly marked with an arrow and the word
CLOSE.
2.1.5. The hand wheel shall automatically disengage when the power to the motor is
restored i.e. power drive shall have a preference over manual drive.
2.1.6. The manual effort should not exceed 400 N (push / pull). A top bevel gear set
(side mounted hand wheel) shall be employed to reduce the manual effort.
2.1.7. Each actuator shall have a local mechanical position indicator. It should be
suitable to indicate 0 - 100% position of the valve (continuous type).
2.1.8. In order to minimise the amount of spare parts required, parts and subassemblies limit / torque switches, limit switch counter gear assembly, torque
switch drive assembly, mechanical position indicator assembly etc. individually
interchangeable / replaceable throughout the models selected.
2.1.9. The actuator shall be painted with corrosion resistant epoxy resin paint. Paint
shade shall be Grey (Shade 631) as per IS-5.
2.1.10. In order to prevent condensation, a space heater shall be provided in the switch
compartment, suitable for continuous operation. Actuator mounting dimensions
shall be according to ISO-5210. For rising stem applications, the design must
allow the removal of actuator from the output drive without disturbing the function
of valve.
2.2.
LIMIT AND TORQUE SWITCHES
2.2.1. Independent torque and limit switches shall be provided in the actuator. A
minimum of two position limit switches and two torque switches, one each for
each direction of travel, having 4 NO + 4 NC potential free contacts, shall be
supplied. If called for in the data sheet, two additional limit switches shall be
provided for intermediate positions.
2.2.2. Torque switch dial shall be graduated directly in kg-m for easy setting to desired
value within the range specified. Separate dials shall be provided for CLOSE and
OPEN torque switches.
2.2.3. Two additional limit switches with 2NO + 2NC contacts, each adjustable at any
intermediate position, shall be provided in the actuator.
2.2.4. The rating of both torque and limit switches shall be 240 V AC, 5 Amps. The
switches shall individually be enclosed to a minimum of IP-64 protection class.
2.2.5. Torque and limit switches shall have only stainless steel flaps for better
protection against environmental condition.
2.2.6. Limit switches shall be operated by gear driven cams, which are mechanically
linked to the driving devices. The counter gear used for counting and tripping the
limit switches shall be of metallic construction like brass etc. No plastic gearing
shall be allowed.
ISSUE
R1
TCE FORM 329 R5
201
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228

OF
CONDUITS AND PIPES
SPECIFICATION NO. PES-507-27
REV 0
229

1.0
GENERAL
1.1
This specification covers the manufacture, inspection & testing at vendors works and delivery to site of conduits,
pipes and their fittings for electrical installation.
2.0
CODES AND STANDARDS
2.1
The material, constructional features and various processes involved in manufacture shall comply with currently
applicable Indian Standards.
2.2
The following Indian Standards shall be applicable, in general. However if Data Sheet A specifies conformance to
other international standards, the equivalent IEC/BS/other standards shall be considered.
3.0
a) IS:9537 (All Parts)
Conduits for electrical installation.
b) IS:3480
Flexible steel conduits for electrical wiring.
c) IS:6946
Flexible non-metallic conduits for electrical installation.
d) IS:1239
Mild steel tubes, tubulars and other wrought steel fittings.

(for size above 63mm dia of rigid conduits)
e) IS:2667
Fittings for rigid steel conduits for electrical wiring.
f) IS:3837
Accessories for rigid steel conduits for electrical wiring.
g) IS:3419
Fittings for rigid non-metallic conduits.
h) IS:6005
Code of practice for phostating iron & steel.
i) IS:2629
Recommended practice for hot dip galvanizing on iron and steel.
j) IS:4759
Specification for hot dip zinc coatings on structural steel and allied
products.
k) IS:6745
Methods for determination of mass of zinc coating on zinc coated iron

and steel articles.
DESIGN REQUIREMENTS AND CONSTRUCTIONAL FEATURES

The conduit and conduit accessories shall include conduit plugs & caps, gaskets and box cover etc in addition to
any specific requirement given in Data Sheet A. The diameter of conduits and accessories shall be uniform
throughout the length.
3.1
Rigid Conduits and Fittings
3.1.1
Rigid conduits shall generally conform to the requirements of IS:9537 (Part I & Part II). However conduits above
63mm diameter shall conform to the requirements of IS:1239. Unless specified otherwise in Data Sheet A, all
conduits and pipes shall be of medium duty.
230
3.1.2
The rigid conduits shall be hot dip galvanized inside and outside. Weight of zinc shall be as per IS:4759. Conduits
shall be thoroughly cleaned and pretreated, conforming to IS:6005.
3.1.3
Conduits shall be supplied in approximate length as specified below

a)
Rigid Conduits
5 metres
b)
Flexible Conduits 10 - 30 metres
3.1.4
Each end of conduit length shall be threaded. The ends of conduits shall be sealed with protective caps to prevent
damage to threaded portions and entrance of moisture and foreign material.
3.1.5
The inside surface of all conduits shall be smooth and suitable for pulling insulated cables and wires without
damage.
3.1.6
Conduit fittings shall be made out of tube or cast to the shape as to match with corresponding conduit sizes and
meet their purpose without any special adjustment.
3.1.7
All fittings shall be screwed type and hot dip galvanized inside and outside.
3.2
Flexible Metallic Conduits and Fittings
3.2.1
Flexible metallic conduits shall generally conform to the requirements of IS:3480.
3.2.2
Flexible conduits shall be made of strip steel which shall be of cold rolled mild steel. The strip shall be of uniform
width and thickness throughout.
3.2.3
The strip shall be electro galvanized to a minimum thickness of 25 microns as specified in IS:3480. The surface of
the strip shall be thoroughly cleaned before application of protective coating. Pretreatment, before galvanization,
shall conform to IS:6005.
3.2.4
The strip for making flexible conduit shall be wound tightly and so overlapped in subsequent helicals that no
openings are seen in normal position.
3.2.5
Flexible conduits shall be lead coated for application in high temperature zones, if specifically mentioned in Data
Sheet A.
3.2.6
The conduit shall have uniform diameter throughout its length. The internal surface of all conduits shall be smooth
and suitable for pulling insulated cables and wires without damage.
3.3
PVC Conduits
3.3.1
PVC conduits shall generally conform to the requirements of IS:9537(Part I & Part III).
4.0
INSPECTION
4.1

4.1.1
The following stages of manufacture shall be stage inspected by Purchaser or his duly authorized representative.
4.1.2
Inspection of packing material and procedure.
Inspection of manufacturing processes such as shearing, punching, bending, welding, galvanizing etc.
231
4.1.3
Inspection of finished product.
4.2
The inspection will be carried out as per agreed quality plan.
5.0
TESTING
5.1
Rigid Conduits
a)
b)
5.2
- as per IS:9537 Part 1 & 2 upto 63mm OD

- as per IS:1239 above 63mm OD
i)
Dimension checks
ii)
Bending test (below 32mm OD)
iii)
Compression test
Special Tests (as acceptance test) as applicable to galvanizing.
Flexible Steel Conduits

a)
b)
5.3
Acceptance Tests
Acceptance Tests
- as per IS:3480
i)
Dimension checks
ii)
Linear breaking test
iii)
Test for flexibility
iv)
Bend fracture test
v)
crushing test
Special Tests (as acceptance test) as applicable to galvanizing.
PVC Conduits
a)
Type Tests
- as per IS : 9537 (Part 1 & 3)
i)
Dimension checks
ii)
Bending test
iii)
Compression test
iv)
Impact test
v)
Collapse test
vi)
Resistance test
vii)
Resistance to burning
232
viii)
b)
Electrical Characteristics
Acceptance tests - as per IS:9537 (Part 1 & 3)

i)
Dimension checks
ii)
Bending test
iii)
Compression test
iv)
Collapse test
v)
Resistance to burning
vi)
Electrical characteristics
5.4
Sampling for the tests shall be done as per applicable standards mentioned above.
5.5
The testing shall be carried out as per agreed quality plan.
6.0
PACKING
6.1
The material shall be packed as per manufacturers standard. Packing procedure shall be to the purchasers
approval.
7.0
DRAWING, DATA AND DOCUMENTS REQUIRED
7.1
The following information shall be furnished within two weeks of award of contract, for purchasers approval.
7.3
a)
Manufacturing drawings/details.
b)
Recommended Field quality plan covering site handling, storing, laying etc.
c)
Final quality plan.
The following information shall be furnished after testing and inspection

Type Test, routine test and special test certificates in bound volume in requisite number.
233
DATASHEET A
1.0
APPLICABLE STANDARDS:
2.0
RIGID STEEL CONDUITS & STEEL PIPES
3.0
4.0
a)
Material:
b)
Applicable standard
IS:9537,IS: 1239, IS:3480
Cold rolled mild steel to IS:226
i) Upto 63mm OD:
IS:9537 Part I & II
ii) Above 63mm OD:
IS:1239
c)
Surface treatment:
Hot dip galvanizing inside & outside as per

IS:2629
d)
Wt. of zinc:
as per IS 4759
e)
Duty:
Medium
f)
Fittings:
Screw type as per IS:2667
FLEXIBLE CONDUITS:
a)
Material:
Strip steel cold rolled and annealed
b)
Standard applicable:
IS: 3480
c)
Surface treatment:
Electro galvanized as per IS: 3480
d)
Whether lead coated:
YES
e)
Minimum thickness:
of zinc coating
25 microns
PVC CONDUITS
a)
Material:
PVC
b)
Applicable standard:
IS: 9537 (Part I & III)

234
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D2
REV
V NO: 00

QUALIT
TY PLAN
N (MOTORS)

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
235
236
237
238
239
240
241
242
243
244
245
246
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: II-B
SEC
CTION: D3
REV
V NO: 00

SE CTION D3
HNICAL REQUIR
GENER
RAL TECH
REMENT
CON
NTROL & INSTRU
UMENTAT
TION

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
247

2.0.0
MEASUREMENT&CONTROLSPECIFICATION

2.1.0GENERALTECHNICALREQUIREMENTS
2.2.0SPECIFICATIONOFPLCSYSTEM&UPS
SYSTEM
2.3.0MEASURINGINSTRUMENTS
2.4.0INSTRUMENTSTUBDETAILS&INSTALLATION
DIAGRAMS
2.5.0MEASUREMENT&CONTROLPHILOSOPHY
2.6.0CODES&STANDARDS
248

2.1.0

GENERALTECHNICALREQUIREMENTS
249
FORM NO. PEM-6666-0
SPECIFICATION NO.:
SPECIFICATION FOR
CONTROL & INSTRUMENTATION FOR AUX
PACKAGES
VOLUME
SUB SECTION
REV. NO.
SHEET
DATE :
OF
GENERAL REQUIREMENT
1.0 Bidder shall provide complete and independent control & instrumentation system with all
accessories, auxiliaries and associated equipments for the safe, efficient and reliable operation of
auxiliary systems.
2.0 The quantity of instruments for auxiliary system shall be as per tender P &ID wherever provided
of the respective system as a minimum, for bidding purpose. However, Bidder shall also include
in his proposal all the instruments and devices that are needed for the completeness of the plant
auxiliary system/ equipment supplied by the bidder, even if the same is not specifically appearing
in the P & ID. During detail engineering if any additional instruments are required for safe &
reliable operation of plant, bidder shall supply the same without any price implication.
3.0 Measuring instruments/equipment and subsystems offered by the bidder shall be from reputed
experienced manufacturers of specified type and range of equipment, whose guaranteed and
trouble free operation has been proven. Further all the instruments shall be of proven reliability,
accuracy, and acceptable international standards and shall be subject to employers approval. All
instrumentation equipment and accessories under this specification shall be furnished as per
technical specification, ranges, makes/ numbers as approved by the employer during detail
engineering.
4.0 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve manifold and
all the other accessories required for mounting/ erection of these local instruments shall be
furnished, even if not specifically asked for, on as required basis. The contacts of equipment
mounted instruments; sensors, switches etc for external connection including spare contacts shall
be wired out to suitably located junction boxes.
5.0 The customer specification attached as Specific Technical Requirement will supercede the Data
sheets, if there is any mismatch.
250

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 16 OF 55

DESIGN, PERFORMANCE AND FUNCTIONAL
REQUIREMENTS
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
14.0
EHTC
HPBP
LPBP
ATRS-1
ATRS-2
ATRS-3
TSE/TSI
ATT
Misc turbine integral controls
Generator auxiliaries
Stream-A equipment IDF, PAF,FDF,APH, etc.
Stream-B equipment IDF, PAF,FDF,APH, etc.
Coordinated master control
SH/RH/FW controls
Stream-A equipment of CEP, BFP, ACWP, CWP, etc.
Stream-B equipment of CEP, BFP, ACWP, CWP, etc.
Stream-C equipment of CEP, BFP, ACWP, CWP, etc.
Electrical system-A
Electrical system-B
Common system
Common system
BASIS FOR PROVISION OF INSTRUMENTS / TAPPING POINTS

Instrumentation and control system shall be supplied in accordance with the various
sections of the specification including the following. Redundancies in sensors shall be
considered as specified elsewhere:
14.1
14.2
Pressure indicators shall be provided wherever indicating type Pressure transmitters are
not envisaged. The applications include:
(a)
Suction and discharge lines of pumps / fans, including on header section, if two
or more pumps / fans are employed for the same service.
(b)
All input and output lines of process equipments.
(c)
Inlets and outlets of heat exchangers (both the fluid media) and desuper
heaters.
Pressure Switches shall be avoided as far as possible and in place, smart pressure
transmitters with soft limit value monitoring in DCS/PLC shall be provided. Pressure
Switches applications will include the following:
(a)
On all process lines / Equipments where parameter abnormality / status

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FILE NAME: SEC D5.3.DOC

251

SPEC.NO.
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Package: EPC
VOLUME V
SECTION : D5.3
SHEET 17 OF 55

REQUIREMENTS
including pre trips alarms to be communicated to the operator in control room.
14.3
14.4
(b)
For all permissives and protection conditions governed by safety operation of

the equipments. e.g. pr. adequate, pr. very high / very low conditions.
(c)
For all interlock conditions, governing starting of standby equipment or

subsequent equipments for safety operation of the system.
(d)
Inlet and outlet of filters / strainers.
(e)
Discharge lines of pumps / fans.
Differential Pressure Switches (indicating type) shall be provided for the following
applications:
(a)
Across filters/strainers for remote monitoring
(b)
Across condenser for remote monitoring and interlocks.
SMART Pressure Transmitter shall be provided for following applications :. Pressure

stubs with isolating valves shall be provided for mounting Pressure Transmitters.
(a)
For all control/monitoring applications
(b)
Discharge headers of pumps / fans,
14.5
SMART Differential Pressure Transmitter shall be provided for all the requirements of
Diff. pressure, flow, level measurement. Pressure stubs with isolating valves shall be
provided for mounting differential Pressure Transmitters.
14.6
Temperature indicators (Thermometers) shall be provided
14.7
(a)
On all process lines where local indication is warranted by the system either for
monitoring or testing.
(b)
On the inlet/outlet equipments such as desuper-heaters, Heat Exchangers &

Coolers for both the fluid media.
(c)
Differential temperature
and discharge service.
indicator
shall
be provided across BFP suction
Temperature Elements/Temperature Transmitters:.

(a)
All thermocouples and RTDs as required for implementation of control &

monitoring in Bidders system, shall be supplied. RTDs are recommended for
applications upto 200 deg C.
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252

SPEC.NO.
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Package: EPC
VOLUME V
SECTION : D5.3
SHEET 18 OF 55

REQUIREMENTS
(b)
Thermocouples / RTDs shall be provided for casing metal temperature

monitoring, winding and bearing temperature monitoring of 6.6 kV
drives/motors
(c)
The elements shall be duplex type with integral thermowell (except for metal
thermocouples). K Type Thermocouples shall be used. For metal
thermocouples suitable MS pads, clamps, flexible extension lengths etc. shall
be provided. Temperature elements in boiler and air ducts shall be in protective
tubes.
(d)
All temperature elements shall be supplied with associated junction box.
(e)
Compensating cable shall be provided with all thermocouples.
(f)
SMART Temperature transmitters shall be provided for all the Thermocouples /

RTDs except for bearing and winding RTDs.
14.8
Level gauges shall be provided on all tanks and the maximum length of one gauge glass
shall not exceed 1 meter. The gauge glasses shall be stacked to cover the complete
height of the tanks including over flow level. There shall be an overlap of minimum
100mm, when more than one level gauge is required.
14.9
Level switches: The instrument shall be provided for the following applications:
14.10
(a)
On all equipments (storage vessel) where parameter abnormality/status has to

be communicated to the operator in the control room.
(b)
All permissive, interlock and protection conditions governed by the safety

operation of the equipment.
(c)
The instrument shall be external cage type with SW connection with isolation
facility for surface mounted tanks and top mounted with still pipe for all sumps.
Still pipes shall be provided with adequate supports.
(d)
Conductivity type level switches shall be used for all heaters and drain pots.
(e)
Radar type level switches shall be used for bulk material bunkers.
(f)
Displacer type level switches shall be provided for level measurements of the
vessel under vacuum or low pressure applications viz for condensate and feed
water system.
Level Transmitters Stubs with impulse pipes, root valves for mounting Level transmitters
shall be provided on process equipments where continuous remote monitoring and/or
control of level is envisaged. Wherever necessary standpipes or float chambers shall be
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253

SPEC.NO.
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Package: EPC
VOLUME V
SECTION : D5.3
SHEET 19 OF 55

REQUIREMENTS
provided and also makeup line for filling up the constant level vessel shall be provided.
14.11
(a)
The instrument shall be Radar type for all low pressure and vacuum
applications involving two phase media viz: condenser, hotwell and LP heaters
level measurements.
(b)
The instrument shall be differential pressure type or Ultrasonic type for other
applications.
(c)
Radar type level transmitter shall be used for fuel oil storage tanks.
(d)
Admittance or Radar type shall be for sludge and slurry applications.
Flow Glasses shall be provided at the outlet of the pipe lines of cooling water side of
coolers / heat exchangers and shall meet the following requirements:
(a)
The instrument shall be rotary type with glass mounted for indication
(b)
Upto 6 inch on-line flow glasses shall be supplied and above 6 inch bypass
type flow glasses shall be provided.
14.12
Speed Measurement shall be provided, where variable speed drives are to be

controlled from remote (e.g. BFPs, feeders, ID fans etc).
14.13
Flow elements shall be provided as required.
14.14
Digital Display Unit (DDU) shall be provided for main steam pressure, temperature, fuel
flow, MW Export, MW Target, MVAR and frequency, condenser vacuum, Instrument air
pressure, GPS Time, Weather Report (Room Temperature, Humidity, Barometer, Air
purity etc).
14.15
Pneumatically Operated Control Valves
14.15.1
Pneumatically Operated Control Valves shall be provided for all control application. If
the process demands any other control, then control valves shall be provided for those
applications also. Where a single control valve can not meet the turn down ratio as
dictated by the process, control valves with split range application shall be provided.
All bypass valves of control valves shall be motor operated valves suitable for
inching operation provided with position transmitters. All integrated bypass valves
shall be motor operated. Electro-pneumatic positioners shall be used for all pneumatic
control valves.
Pressure test points & drains shall be provided across each control valve .
14.15.2
In case during detailed engineering, pneumatic control elements get converted to

electrically operated items, thyristor reversing unit based electronic power positioner
(EPP) are in Bidders scope. In case, for these EPPs, power supply other than what is
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254

SPEC.NO.
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Package: EPC
VOLUME V
SECTION : D5.3
SHEET 20 OF 55

REQUIREMENTS
available if required, the same shall be supplied, by the Bidder.

14.15.3
The pneumatically operated control valves shall be provided with Smart Positioners,
diagnostics and HART compatibility. Control Valve diagnostics shall be transmitted
through this HART Protocol to DCS/PLC.
14.16
Solenoid Valves shall be provided for all pneumatic control valves hooked up with
process
interlock requirements and where direct tripping is involved. All solenoid
valves shall be uniformly rated for 24VDC. The number of ways for solenoid valve shall
be provided as indicated below :
(a)
On line two (2) way solenoid valves shall be provided, where process line
of less than 2 inch with low pressure & temperature application is involved.
(b)
Three (3) way solenoid valves shall be provided commonly, where the
pressure is admitted or exhausted from a diaphragm valve or single acting
cylinder. E.g.: Pneumatic operated spray water block valve.
(c)
Four (4) way solenoid valves shall be provided for operating double acting
cylinders. If applicable. E.g.: Pneumatically operated on-off type dampers.
(d)
Dual coil, latch/unlatch type Solenoid valves shall be supplied for equipment
trips/critical applications.
(e)
Five-way, dual coil solenoid valves shall be used for Oil guns.
14.17
Position Transmitters shall be provided for all motorised inching valves .Position
transmitters shall be 24 VDC, 2 wire, non-contact type.
14.18
Electro-Pneumatic positioners shall be provided for all pneumatically operated control

valves, power cylinders etc., for converting controller output of 4-20 mA to appropriate
pneumatic signal.
14.19
Air Filter Regulators along with gauges shall be provided in each of the:
14.20
(a)
Air supply line to valve positioners /power cylinders
(b)
Air supply line to pneumatic interlocked block valves
(c)
Transmitter Racks
Interposing relay (To be mounted in Control room cabinet) for interface to the following:
(a)
Solenoid valve (two relays per valve) - Relays with contact rating of 2 Amps.
(b)
DC Starter(two relays per drive) - Relays with contact rating of 0.2Amps.

ISSUE
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255

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 21 OF 55

REQUIREMENTS
(c)
14.21
14.22
Hardwired signal exchange as required.
Analytical Instruments-Withdrawable Type Conductivity Analyser;

(a)
Provision for mounting the above analyzer shall be made at the condenser hot
well along
with
necessary
mounting
arrangements/ accessories as
required.
(b)
For other analytical measurements, the sampling tapping points as called for,
shall be provided.
Centralised Vibration Monitoring & Analysis system: (Unit-wise):

Refer TABLE-13.
14.23
Junction Boxes/Field termination cabinet:
14.23.1
All JBs /FTCs shall be SS. Junction Boxes shall be provided for
14.23.2
14.24
(a)
Termination of all sensors located equipment wise.
(b)
Termination of Duplex Thermocouples / RTDS
(c )
Termination of limit switch, torque switch, position transmitter and control

demand, independently for each valve.
FTCs shall be provided for:

(a)
Connecting group of JBs area wise.
(b)
FTC shall be designed to provide multiple units in Boiler and Turbine areas.
FTCs reduce the number of cables entering the control room. Depending on
the size of the multi core cable, one or two cables shall link to marshalling
cabinet in the control room.
Instrumentation & control cables

treatment shall be supplied to:
and
Prefabricated Cables with Anti-Rodent
(a)
Connect field instruments to field junction boxes/Local Panels. For switches,

both the SPDT contacts of switches shall be wired upto the J.B.
(b)
Connect limit switches, torque switches and position transmitters to their

respective field junction boxes.
(c)
Compensating cable shall be supplied for connection between the element and
ISSUE
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TCE FORM 329 R5

256

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 22 OF 55

REQUIREMENTS
the respective junction boxes / system cabinets as per guidelines.
14.25
(d)
Prefabricated cable for connecting between system cabinets, marshalling

cabinet to system cabinet, system cabinet to Relay Rack, system cabinets
to Operator work stations , system cabinets to Engineering work stations etc.
shall be in Bidders scope.
(e)
Entire I&C cable within the battery limits.
(f)
All cables between Bidders equipment and Others supplied equipment from
where signals have been specified to be acquired / provided by/from Bidder
for processing in his system.
Auxiliary Power Supply System (APSS)

The power supply system shall conform to the requirements indicated in Electrical
portion of this specification. The power requirements of the various systems in the scope
shall be consolidated and power supply shall be envisaged.
A list indicating the loads to be connected to different voltages shall be furnished. Bidder
shall distribute the power for his I&C system. All power supply in the cabinets shall
be redundant and have auto change over facility or diode auctioneering.
14.26
Instrument Air Supply System

Dry instrument air shall be distributed to various equipments of I&C system like control
valves, Analyzer purging, Transmitter racks, pneumatic On-Off dampers. The Bidder
shall supply total Instrument air requirement Calculations, and design of Air compressor
system along with the Bid.
14.27
Impulse pipes/tubes & fittings

Impulse pipes, fittings and air supply and signal piping/tubing shall be supplied for
all the instruments under the scope of this specification. Instrument piping shall be
designed for maximum design pressure and temperature of the process. Pressure
measurement connection shall be or 12mm pipe connection. Instrument on Vacuum
system at CEP inlet should have vent lines connected to high point in the condenser.
Instrument air tubing shall be copper, PVC coated to avoid oxidation at the surface of
the tubing.
14.28
Instruments for Performance Testing

All instruments required for performance testing to prove the guaranteed performance of
the plant shall be supplied by the BIDDER for the Performance Test. These test
instruments shall have test certificates from reputed test house, valid for the duration of
the performance test.
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TCE FORM 329 R5

257

SPEC.NO.
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VOLUME V
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REQUIREMENTS
14.29
System cabinets & marshalling cabinets shall be provided for all the systems in Bidders
scope.
14.30
Stand pipes required for hot well, deaerator, heaters, GSC, drain pot, etc. shall be
provided by Bidder.
14.31
CABLE TRAY GROUPING
14.31.1
Separate cable tray shall be provided for instrumentation cables extension cables, flame
scanner cables, pre fabricated cables etc. Instrumentation cables shall run through the
top most cable tray
14.31.2
Minimum distance of 500mm to 1000mm must be maintained between the

instrumentation cable tray in the high heat zones where the temperature is 200 deg.C
and above.
14.31.3
Maximum two Layers of cables shall be laid in each cable tray.
14.31.4
Inside the control room the PLC system cables and Bus cables shall run only through
cable trays or conduits. Also the PLC cables through the false flooring shall also be
through dedicated closed cable trays and conduits.
14.32
All the control room cabinets, field JBs /FTCs etc. shall have bottom Cable entry.
15.0
SELECTION OF RANGES FOR INSTRUMENTS
15.1
The ranges of the instruments shall be selected based on the following philosophy
indicated below:
15.2
For pressure and draft measurements, the maximum operating pressure will be within
70 to 80% of the maximum scale range. All pump suction measurement and steam
pressure measurements in extraction steam and in heaters will cover the negative
pressure range also and all draft gauges will cover the negative pressure as well as the
positive pressure as the case may be.
15.3
For temperature measurement, the maximum operating temperature will be within 80

to 90% of the maximum scale range.
15.4
For pressure switches and temperature switches, the set points shall fall within 40% to
70% of the scale range selected.
15.5
For level measurement, the maximum of the range will cover the overflow point or six
inches from the top of the vessel and the minimum of the range will be six inches above
the bottom of the vessel. Also, the gauge glasses will be stacked with overlap to cover
permissive, alarm and trip levels.
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REQUIREMENTS
15.6
For flow measurement, the maximum range shall be fixed at about 10 to 15% above
the maximum operating flow.
15.7
For electro-chemical measurements (conductivity, pH, dissolved O2, Silica etc.), the
maximum range will be around 10 to 15% higher than the recommended alarm
settings.
15.8
For gas analysers (if included in scope), the maximum range will be around 10 to 15%
higher than the recommended alarm settings.
16.0
PG TEST POINTS
16.1
Pressure, temperature and flow test points shall be provided in line with latest
performance test code requirements.
16.2
In addition, pressure and temperature test points shall be provided for the following
services:
(a)
At the discharge of all pumps and fans
(b)
At the inlet and outlet of the heat exchangers for the fluid media involved
(c)
Adequate number at the Combustor at different zones
(d)
At the inlet and outlet of each control valve
16.3
Pressure test points shall be complete with root valves and shall terminate with a
nipple.
16.4
Temperature test points shall be provided with thermowell with a cap and chain.
17.0
SIZE OF TAPPING POINT STUB, NO. AND SIZE OF ROOT VALVES FOR
DIFFERENT TYPE OF MEASUREMENTS
Sl. No
Qty. Of Root Stub & Root Valve Service Conditions

Valves
Size
A. Pressure & Differential Pressure Measurement

(i)
25 NB
>=62 bar OR 425 degree C
(ii)
15 NB
< 62 bar AND425 degree C.
B. Level Measurement
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REQUIREMENTS
B1-Level Gauge And Switch

(i)
25 NB
(ii)
15 NB
< 62 bar AND 425 degree C.
B2-Level Transmitter (Displacement Type)

(i)
40 NB
(ii)
40 NB
B3-Standpipe For Level Measuring Instrument

(i)
80 NB
(ii)
80 NB
C-Flow Measurement
(i)
25 NB
(ii)
25 NB
D. Sampling System Measurement (Steam & Water Service)

(i)
25 NB
(ii)
25 NB
18.0
CONTROL ROOM LAYOUT
18.1
Central control room shall be common for both the units. However, each unit shall have
its own separate area/ desk for control & monitoring of SG, STG & BOP auxiliaries i.e
control room shall have distinct sections, one for each unit though not physically
separated but clearly distinguishable.
18.2
The control room shall be partitioned to different rooms to house the following
equipment:
(a)
Unit Control Desk (UCD) and Unit Control Panel in the main control room.
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REQUIREMENTS
diagram ,along with Tag numbers, functional description of the signals ,control loop
references for both OLCS and CLCS , Legend etc.,.Also bidder shall indicate all Field
mounted, Local Panel monted, and DCS/PLC displayed Measurements using Standard
symbols along with alarm, protection, interlock and control functions based on the
Redundancy Philosophy mentioned in the specification.
30.17
Bidder shall include all the measurements necessary for the safe, efficient, reliable and
fully automatic operation of the entire plant including all fail-safe requirements and
recommendations of each equipment manufacturer.
31.0
31.1
The general engineering and calculations shall be made as per prevailing Indian,
International standards acceptable to Owner / Project Manager. Wherever such
standards are not available, they shall be as per the best practice in India and abroad.
31.2
All measurements shall be in metric units
31.3
All the electronic circuitry shall be built-up with plug in modules providing maximum
flexibility and easy servicing.
31.4
Anti-vibration mountings and shock absorbers shall be provided for cabinets, desk and
panels.
31.5
The cabinets surface shall be thoroughly degreased, smoothed, filled and painted with
rust resistant primer to present a smooth and flat finish. Front of cabinets shall be
primed and filled as required at least two coats of primer and minimum two coats of
final colour above the primer coating to present a smooth and mat finish.
31.6
SS Legend plates shall be provided on the cabinet front and back, desk face, unit
control panel, local panels, junction boxes, transmitter racks, FTCs, Remote I/O rack,
instruments, Control valves etc., for all items supplied to identify the equipment. Overall
dimensions of the nameplates shall be decided by the text of legend, maintaining
overall consistency and clarity and avoiding size variations.
31.7
The cabinets shall be upright; floor mounted, front open type with removable door and
shall have ventilation with steel mesh. The outside colour of all instrumentation
cabinets, control desks, consoles, local cabinets, marshalling cabinets, system
cabinets, junction boxes, Transmitter racks, FTCs etc. shall be of light grey shade no.
631 of IS: 5, 1978 or equivalent international code. The inside colour of all these
cabinets shall be brilliant white. This shall hold good for instrumentation cabinets of all
auxiliary units also.
31.8
The cabinets shall be made from CRCA Steel sheet with a minimum thickness of 2
mm. Removable eye lifting lugs shall be furnished and installed on all cabinets.
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REQUIREMENTS
31.9
For all HT drives alarm and trip signals for bearing and winding temperatures shall be
considered through soft LVM from temperature element signal only. No temperature
transmitters are required for these signals.
31.10
All Critical control valves shall be provided with anti-cavitation trim. Control valves /
dampers shall be supplied with all accessories including non-contact type position
transmitters and E/P Positioners. Combination of I/P + Pneumatic positioner is not
acceptable. All inching valves shall be supplied with position transmitters integral with
the valve positioner.
31.11
All transmitters shall be SMART type with integral local LCD indication and HART
protocol.
31.12
All Temperature sensors shall be Duplex type and field mounted temperature
transmitter shall be provided for all temperature measurement applications. Direct
wiring of RTD or T/C to DCS or PLC is not preferred. (Except for Winding and bearing
temperature sensors ).
31.13
Switches (pressure, temperature, level & flow etc.) shall be provided only for critical
equipment trip such as BFP/ CEP trip etc. Wherever possible, transmitters shall be
provided with required redundancies for all other purposes.
31.14
Similar make and model shall be provided for same type of I&C system equipment.
This shall specifically apply for field transmitters, control valves etc.
31.15
Smart positioners shall be provided for all control valves/ dampers.
31.16
Where multiple functions like monitoring /control/alarm etc. are sought to be performed
based on a parameter value, in minimum dual sensor shall type be provided.
31.17
All outdoor field equipment shall be provided with epoxy painting.
31.18
Individual continuous purging shall be provided for all Air and Flue gas transmitters.
The tap points for these services shall be Y shaped. The purging line shall be
connected near the root valve only and not at the Transmitter end.
31.19
All local cabinets / utility plant control panels with bottom cable entry shall be provided
with suitable pedestals for easy cabling. The panels shall be designed for ease of
operation of operating hardware and monitoring the indicators.
31.20
All local panel indicating lamp/indicating type Push button should be of cluster LED
type only. All local panels shall be of double door type instead of double leaf type to
avoid ingress of dust in dust prone areas.
31.21
All motorised bypass valves shall be inching type and shall be provided with position
transmitters of non-contact type.
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REQUIREMENTS
31.22
When floor openings are considered for LP heaters and HP heaters, the corresponding
stand pipe and level transmitter dimensions (along with impulse piping and root valve)
shall be added radially. The standpipe and mounted instruments should not foul with
the civil structures or any mechanical system part.
31.23
Conductivity type dedicated level switches shall preferably be used for heater level
applications.
31.24
Spring-loaded terminals shall be used for termination of instrumentation cables at field

JBs, FTCs and local panels.
31.24
Instrumentation cables shall be laid in separate cable trays.
31.25
Cable number tags and markings will be provided at every 30 meters along the entire
length of cable.
31.26
Instrumentation cable trays will be run on the top in the cable gallery.
31.27
All JBs, FTCs and similar equipment in Boiler, STG and other areas shall not have top
entry to avoid dust entry. No equipment shall have top entry for cables.
31.28
All the switches, wherever provided shall be provided with 2nos. changeover contacts
and both shall be wired upto Junction Boxes.
32.0
STATION BLACKOUT
Availability of all equipment, drives, emergency power supplies, controls, logics
required for the protection/safe operation of the Boiler/Turbine and auxiliaries during
Emergency blackout shall be ensured. All the related drives shall operate automatically
on the occurrence of blackout. All such drives required during emergency and blackout
shall be 220 V DC (solenoid operated) to ensure availability and shall be designed for
fail-safe mode. All the required controls shall be available as the system to be powered
from UPS. The UPS sizing shall consider this requirement.
33.0
CODES AND STANDARDS
33.1
All equipment, systems, software and services covered under this specification shall
comply with all currently applicable statutes, regulations and safety codes in the locality
where the equipment will be installed.
All codes and standards referred in this
specification shall be understood to be the latest version on the date of offer made by
the Bidder, unless otherwise specified. If such standards are not existing for any
equipment or system, the same shall comply with the applicable recommendations of
the following professional institutes:
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SPECIFICATIONOF PLC SYSTEM & UPS SYSTEM
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SHEET 1 OF 5
Package: EPC
INSTRUMENTATION AND CONTROL

EQUIPMENT
PLC SYSTEM REQUIREMENTS
SI. No.
DESCRIPTION
1.0
1.1
Programmable Logic Controller

Offered PLC System
Latest system available/ being
supported in the market by the
Vendor/collaborator with minimum 3
years of proven performance record.
Make/Model
Bidder to specify
Control processor
Control processor with 32 bit processor , RISC based
floating point arithmetic
capability
Capacity of RAM
Min. 32MB
Battery backup for RAM
Required
Duration of battery backup Min. 72 Hrs
for RAM
Capacity of Non-volatile Min. 64 MB
Memory
Redundancy
Requirements
Processor
1:1 redundant hot stand-by
Communication
Dual redundant hot stand-by
Power Supply
Dual redundant both at CPU and I/O
Rack level
Synchronization between
Primary and Secondary
CPU
Program changes
Automatic
Forced Bit update
Automatic
Auto switchover time to Instantaneous and bump-less
backup/redundant at
Processor level
Bidder to specify
Communication level
Bidder to specify
Power supply level
Bidder to specify
Response times:
Scanning rate of analog Maximum 1 sec for measurement
signals
Scanning rate of digital Maximum. 100 ms
signals
Scanning rate of pulse Max. 100 ms
signals
Loop execution time for Maximum 250 ms (For all Loops)
CLCS
Loop execution time for Maximum 100 ms (For all Loops)
OLCS
Controller output update Every 250 ms (For all CLCS Loops)
for CLCS
Controller output update Every 100 ms (For all OLCS Loops)
1.2
1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.4
1.4.1
1.4.2
1.4.3
1.5
1.5.1
1.5.2
1.6
1.6.1
1.6.2
1.6.3
1.7
1.7.1
1.7.2
1.7.3
1.7.4
1.7.5
1.7.6
1.7.7
REQUIREMENT
BIDDER RESPONSE
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EQUIPMENT
SI. No.
1.7.8
1.7.9
1.7.10
1.7.11
1.7.12
1.7.13
1.8
1.9
1.10
1.11
1.11.1
1.11.2
1.11.3
1.11.4
1.11.5
1.11.6
1.11.7
1.11.8
1.11.9
1.12
1.13
1.14
1.15
1.16
1.17
DESCRIPTION
for OLCS
Updating rate of Analog
display
Updating rate of Analog
display
Updating rate of Digital
value
Updating rate of Digital
value
Time for display in VDU
screen
Keyboard
command
execution time
Control processor loading
considering spare I/O
channels and future I/O
modules to be located in
the spare I/O slots
Data Bus Loading
Overall system availability
Self diagnostics
Processor
Module
diagnostics
I/O Module diagnostics
Open-wire circuit detection
Short-circuit detection
Reverse polarity detection
Processor
changeover
indication
Communication
bus
changeover indication
Power supply changeover
indication
Any other channel level
diagnostics
Module replacement
Output status on power
supply failure
Status indication for each
channel in DI/ DO card
Power supply healthiness
status in all modules
Optical Isolation for DI/ DO
Galvanic isolation for AI/
AO
REQUIREMENT
BIDDER RESPONSE
Max. 2 seconds (for measurement)

Max. 1 second for OLCS/CLCS
Max. 1 second (for measurement)
Max. 1 second for OLCS/CLCS
Max 1-2 seconds on demand
Max. 1 sec
Max. 60 %
Max. 50 %
99.7 %
Required
Required
Required
Required
Required
Alarm in HMI Required
Bidder to indicate
All modules shall be replaceable Online online under power-up condition
Configurable for switching to fail safe
mode
LED indication required
LED indication required
Channel to channel & channel to
ground isolation required
Channel to channel & channel to
ground isolation required
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EQUIPMENT
SI. No.
DESCRIPTION
REQUIREMENT
1.18
Fuse protection and fuse

failure for I/O channels
Contact monitoring for
Non-coincidence
Output status on controller
failure
Output status on power
supply failure
Output status on loss of
I/O
communication link
with processor
Modular expansion facility
for I/O system
Open loop control ( Logic ,
Protection & Interlock) &
Close loop control
Maximum
number
of
channels in I/O modules:
Analog I/O modules
RTD, Thermocouple
Digital I/O modules
Remote I/O cabinets (If
applicable)
Redundant I/O bus
to
interface
remote
I/O
modules and controller
Environmental
conditioning for Remote
I/O cabinets
Power supply to the field
transmitters
Individual for each signal
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.25.1
1.25.2
1.25.3
1.26
1.26.1
1.26.2
1.27
1.28
1.29
1.30
1.31
Interrogation voltage for

Digital signals
Digital outputs
Interposing Relays for DO

(Not applicable for DO for
motor drives)
Power Supply
BIDDER RESPONSE
Required in digital input cards

Configurable in Engineering station
mode
mode
Required
Redundant I/O modules
8 Channels
8 Channels
16 Channels
Bidder to specify
Required
Required
Sourced from AI module for 2 wire

transmitters
Separate power supply for 4 wire
transmitters
24 V DC (to be derived from UPS AC
supply in PLC panel)
For Motor drives Potential (wet)
type with 24 VDC to energize
interposing
relay
part
of
MCC/Switchgear
For others Potential free (dry)
contact type with min. rating of 3 VA
at 24V DC.
24 V DC with free wheeling diode
across the coil.
Relay contact
rating- 5A at 240VAC.
230 V AC, 1, 50 Hz dual redundant
UPS feeding to a common bus bar
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EQUIPMENT
SI. No.
DESCRIPTION
REQUIREMENT
1.32
Any other voltage required

for the CPU and I/O rack
and field instrumentation
like 24 V DC etc.
1.33
1.33.1
Communication
Communication
between CPU
Modules
Communication
processor and
station
and
processors
Communication
PLC and DCS
1.33.2
1.33.3
1.34
1.35
from which outgoing feeders to

different services to be provided.
Shall be derived from 230 VAC UPS.
Derived
voltages
shall
have
redundant power supply (SMPS)
arrangements with diode o-ring
change over circuit.
speed
and I/O
2 MBPS
between
Operator
across
Redundant Ethernet TCP/IP based

protocol with transmission rate of
100 Mbps
between
Redundant Ethernet TCP/IP network

based OPC AE (alarms and events)
protocol for time stamped data
transfer.
Bidder to specify
Time stamping protocol

required for PLC from
GPS master clock system
Earthing Requirement
Separate panel earthing and isolated

signal earthing that shall be
connected to the station earth grids
to separate earth pits.
2.0
2.1
2.2
2.3
Operator / Engineering Work Station PC

Quantity
2
Make & Model
Bidder to specify
Operating System
Windows XP Professional or Latest
proven Windows OS
2.4
2.4.1
Hardware Requirements:
Processor
Core i7 Processor, 3.2 GHz or
better
RAM
4 GB DDR2 RAM
Mother board
Intel Express chipset
Graphics
Onboard with min 512 MB Video
Memory
Hard Drives
1 no. x 500 GB SATA HDD @
7200 RPM or Higher
DVD R/W
1 no. 52X CD RW & 16X DVD
RW IDE Combo
Ethernet Card
2 nos. x 10/10/1000MB
Network Controller
1 GbE NIC upgradable to 10 GbE
Serial Port (RS232)
2 nos.
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.4.8
2.4.9
BIDDER RESPONSE
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EQUIPMENT
SI. No.
DESCRIPTION
REQUIREMENT
2.4.10
2.4.11
2.4.12
Parallel Port
USB Port
Peripherals
1 no.
4 nos.
1 no. USB Optical Mouse
1 no. USB Multimedia QWERTY
Keyboard
1 no. 21 Colour TFT/LCD
Monitor
2.5
Software Licenses
2.6
2.7
2.8
Alarm Annunciation
Hierarchical protection for
operator
&
engineer
functions
Displays on HMI monitor
Individual original licences for OES,

SCADA Software, PLC Programming
Software, Antivirus, and any other
software loaded for the proper
functioning of the System.
Part of operator station
At least 3 levels of security is
required
2.9
Min. configurable
2.10
Time activated logs
BIDDER RESPONSE
Process Mimic displays, trend

displays, system status, alarm
display, logs/reports etc.
Mimics-50
Real time trend(current and last 5
min)-50
Historical trends-50
Current alarms-100
Logged alarms-300
Periodic logs, shift report, daily
report, status change log, Control
system fault log
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SPECIFICATION FOR INSTRUMENTATION &

CONTROL EQUIPMENT
2.2
(p)
USB Port
4 nos
(q)
Peripherals
1 no. USB/ PS2 Optical Mouse

1 no. USB/PS2 Multimedia Keyboard
1 no. 21/22 Colour TFT/LCD Monitor
(r)
Operating System
Latest Proven Windows Server
USER/WORK/OPERATOR/ENGG STATION HARDWARE SPECIFICATION

(a)
Processor
Core i7 Processor, 3.2 GHz or better
(b)
RAM
4 GB DDR2 RAM
(c)
Mother board
Intel Express chipset
(d)
Graphics
Onboard with min 512 MB Video Memory
(e)
Hard Drives
1 no. x 500 GB SATA HDD @ 7200 RPM or Higher
(f)
DVD R/W
1 no. 52X CD RW & 16X DVD RW IDE Combo
(g)
Ethernet Card
2 nos. x 10/10/1000MB
(h)
Network Controller
1 GbE NIC upgradable to 10 GbE
(i)
Serial Port (RS232) 2 nos.
(j)
Parallel Port
1 no.
(k)
USB Port
4 nos.
(l)
Peripherals
1 no. USB Optical Mouse

1 no. USB Multimedia QWERTY Keyboard
1 no. 21 Colour TFT/LCD Monitor
(m)
Operating System
Windows XP Professional or Latest Proven Windows OS.
2.3
Keyboard
2.3.1
Keyboard for OS
Qwerty type Keyboard shall be provided for operator interface with process for plant
control and display functions to access plant data in conjunction with Operator station
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CONTROL EQUIPMENT
VDUs. Assignable function keys shall be provided for execution of most frequenctly used
displays...
2.3.2
Keyboard for ES
Qwerty type Keyboard shall be provided to enable the maintenance engineer to develop
graphic displays, control system software and system configuration for the DCS. It shall
be possible to perform OS functions from VDU of ES. Assignable function keys shall be
provided for execution of command, program etc. Pass- word protection facility shall be
provided to set ES in engineer or operator mode.
2.4
Printers
2.4.1
Dot-matrix Character Printer:
132 column width with minimum speed 400 cps for printing operator requested functions
and graphics. Print colours shall be black and red. The operator shall be able to direct
logs, reports etc. to any printer assigned to his console. The interface shall be either
RS232C or RS422A. All printers shall be of A3 size. Noise levels for the Printers at 1
meter distance shall be < 45 dB
2.4.2
Colour Laser Printer:

Shall serve as a hard copy device to copy graphics/diagrams from the Operator Station/
Engineering Station for documentation and graphic diagram development functions.
Printer shall be of 600 DPI with minimum 16 colours. Printer shall be connected to
network to facilitate printing of graphics from any of the OS / ES VDUs and accordingly
suitable network interface card shall be provided. All printers shall be of A3 size. Noise
levels for the Printers at 1 meter distance shall be < 45 dB.
3.0
TIME SYNCHRONISATION EQUIPMENT
3.1
Time synchronisation equipment shall be complete with all hardware and software to
receive the synchronising signals from remote satelite and provide outputs to synchronise
plant wide all programmable control systems like DCS system equipment, SER, all utility
plant control systems PLCs, Boiler & Turbine protection system and any other control
systems to ensure a common time reference.
3.2
The system shall be based on Global Positioning system reference and shall include GPS
antenna, GPS receiver, signal processing unit etc. Time accuracy shall be 1 PPM.
3.3
Global Positioning System to which the Master Clock gets synchronised, shall be an
absolute system to provide continuously 3 dimensional position fixing, velocity
measurement and Time reference generation.
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CONTROL EQUIPMENT
(a)
The display controller shall have scalable display control unit.
(b)
In an industrial 19 rack mounted casing based on P IV 3 Ghz (Min.).
(c)
The min. memory of 256MB expandable upto 1 GB.
(d)
The unit shall be equipped with a 48X or better CD ROM, 3.5 Floppy Drive.
(e)
The hard Disk shall be of 60 GB, 7200 rpm.
(f)
Shall have 10/100 MBPS Ethernet port for LAN connection.
(g)
Supplied with a Keyboard and mouse with adequate cable extension.
(h)
Min. 4 Digital Graphics Output to be connected to 4 rear projection modules.
8.15
The system shall have future expansion possibilities.
9.0
QUALITY ASSURANCE
Bidder shall furnish a detailed Quality Assurance / Quality Control Plan (QA/QC) for each
Instrument/System covered under this specification for OWNER/ Consultant review and
approval.
10.0

This system shall consist of a standalone redundant microprocessor based PLC system
incorporating the functions of Measurement, Control, Interlock & Protection and
Annunciation System for automatic sequential start-up, interlocks, protection and control
of each packages as mentioned in earlier sections. The PLC system shall meet the
specific requirements mentioned in Table-15 in addition to the requirements listed below.
10.1
PROGRAMMABLE LOGIC CONTROLLER (PLC)
10.1.1
The PLC system shall comprise of the processor, I/O cards, communication modules,
power supply modules, racks, mounting accessories fully wired and tested. The system
shall have the specified redundancies.
10.1.2
The PLC hardware shall include all electronics required to perform signal conditioning
functions required to process the various types of input / output signals such as 4-20 mA,
RTD & T/C inputs, etc. It shall also be capable of implementing closed and open loop
controls.
10.1.3
The PLC system features shall include but not be limited to the following:
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i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
10.1.4
The PLC system shall have system monitoring features but not be limited to the following:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
10.1.5
Scan time for digital and pulse inputs not greater than 250msec.
Scan time for all analog inputs not greater than 500msec.
Execution time not greater than 120msec.
Max. system loading of 60% under worst loading conditions.
Independent measurement circuit for each measurement.
Grouping of signals in each card is subject to approval at the time of detailed
engineering.
Failure of one logic shall not result in failure of the other logics.
Overall accuracy of measurement signals shall be 0.5%.
Extensive self diagnostic alarms and power supply failure alarm.
Each subsystem failure alarm.

Earth fault alarm for each subsystem.
Power failure alarm.
Battery back-up low alarm.
Isolation facility for ground detection at subsystem without removing any
hardware (power supply isolation).
Isolation facility for ground detection of individual signal without removing field
wiring (isolation of signal at both terminals).
MTBF & MTTR (supporting data for calculations shall be furnished).
Power supply monitoring.
LEDs for fault indication on each type of card.
LED for watch dog timer failure.
Fuse protection and fuse failure.
Communication monitoring.
Self checking features.
Critical faults to freeze the final control element to change to
manual with
alarm.
The PLC system shall support the following design features for hardware:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
Optical isolation for all digital inputs and outputs.

Galvanic isolation / optical isolation for all analog inputs and outputs.
24VDC power supply to transmitters from internal power pack.
Contact interrogation voltage shall be 24VDC.
Cold junction compensation for thermocouples.
Detection of open circuit for thermocouples and RTDs.
Inrush current limiter.
Circuits shall be short circuit proof and voltage surge proof.
Modular type of cards.
Plug in type PCB with gold plated contacts at both plug and socket.
Card type or function designation to be inscribed on each card.
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xii.
xiii.
xiv.
xv.
xvi.
xvii.
10.1.6
The PLC system processor shall support the following functions and capabilities:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
10.1.7
All cards shall be tropicalised.

Filters for noise rejection.
Signal distribution of input signals to various devices within the PLC system
shall be through multiplication.
Non volatile memory is required to store programs, standard software to
perform logic functions, data acquisition and diagnostic features.
The internal power pack shall be redundant and accept two (2) nos. of feeders
of 230VAC. The internal power packs shall generate all the different voltages
required by the system and a bus shall be formed for each of these voltages at
the outlet of the internal power pack. Each power pack shall be rated to 110%
of the max. requirements.
All card replacements shall be possible on power on conditions.
Data acquisition.
Logic functions.
Closed loop control functions.
Generation of boolean functions.
Self diagnostic functions.
Monitoring of ADC / DAC performance and alarming for analog inputs.
Digital filtering.
Validation of all inputs and outputs.
Point identification by 8 character long tagno.
Point description with min. 24 character long identification.
Redundant communication with all I/O modules.
Redundant communication with all MMI equipment.
Communication control and monitoring.
Battery back-up of not less than 72 hrs.
Minimum 32 bit processor with floating point capability.
Volatile memory to store dynamic plant data, control programs and self
diagnostic routines.
The following general design and construction requirements shall be fulfilled by the PLC
system:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
Proven design.
Reputed make.
Shock proof design.
Vibration proof design.
Maximum interchangeability of parts.
Use of components which have higher rating than required for operation
conditions.
Design of equipment to avoid overheating of electronic components.
Ruggedness of equipment / components.
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ix.
10.1.8
The following concept for I/O assignment shall be followed:

i.
ii.
iii.
iv.
v.
vi.
10.2
PLC system shall perform satisfactorily under max. temperature of 50 deg C

and relative humidity of 95%.
No two identical / similar equipment shall be grouped in the same I/O module.
Any one card shall have I/O related to only one equipment and auxiliaries. If
any equipment and auxiliaries requires more than one card, I/O related
auxiliaries shall be different cards.
Inputs and Outputs shall not be combined in a single module.
Whenever, 2/3 logic is involved, each of these inputs shall be connected to
different input cards and all the corresponding conditioned outputs shall be
taken to one processor or more than one processor depending on the grouping
for performing 2/3 logic.
I/O assignment shall be identical for similar / redundant equipment, i.e., if
Pump-A run is assigned to channel 4 of a card, Pump-B run shall be
assigned to channel 4 of another card. Also, these cards shall be located in
identical slots in different racks.
I/O modules of one equipment and associated auxiliaries shall be located in
the same rack, in different racks or even in different cabinets to increase
availability.
DATA BUS SYSTEM (DBS)

Data bus system shall have cubicle bus, communication controller and main bus to
transfer the data between the various cards and the MMI equipment. The data bus
system shall include for control level and MMI level communications as also the
communication between these two levels. The data bus system at all levels shall be
redundant. Coaxial or fibre optic data bus redundant in hot back-up mode with a min.
transmission rate of 2 Mbaud shall be provided for cyclic transmission. The type of
communication protocol shall be token passing / master less. Both the buses shall be
active and in the even to failure of one bus, the same shall be annunciated and the other
bus shall be capable of meeting the functional requirement.
10.3
The operator station shall serve as operator and engineering station and shall have
independent electronics and shall have the following functions: The operator and
engineering functions can be combined in a single stations
i.
ii.
iii.
Plant control displays to facilitate normal plant operations. These displays shall
be organised in the form of plant displays, individual I/O point displays and
logic function displays. It shall be possible to perform open loop and closed
loop controls from these screens. Auto / manual selection, local / remote
selection etc. shall be possible from these screens.
Plant schematics.
Alarm notifications / actions.
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iv.
v.
vi.
vii.
viii.
ix.
x.
Alarm display functions.

Alarm summaries shall be provided for existing alarms, bad input points, points
out of scan, C&I faults, system faults and shall be printed out on alarm or on
demand in chronological order.
Individual point data information on the screen.
Trend plot features.
X-Y plots with a facility of upto 4 variables on the vertical axis against one
variable on the horizontal axis.
Logs and reports.
Equipment operating history.
10.4
SOFTWARE AND MMI/PHERIPHARLS:
10.4.1
The Real Time operating System (RTOS) supplied shall be proven, able to support all the
equipment/peripherals execute the entire task as stipulated in this specification. The
background executive shall enable software development in time sharing mode by two or
more programme simultaneously and shall run/Test any program without making it into an
online program.
10.4.2
The data acquisition, processing and alarm monitoring/ reporting software resident in
each DPU shall enable processing of raw process data including Engineering unit
conversion and process alarm time checking. The control software resident in each DPU
shall enable the execution of both modulating and sequential control without interrupts to
ensure security of controls software for performing mathematical function
routines/algorithms and logic functions for control loops as specified. The generation of
control software shall be based on logic blocks and ladder diagrams and no programming
knowledge is necessary.
10.4.2
Utilities like report and display generation, data base management, file handling unit,
communication, online system back up, on line diagnosis, `screen editor, soft ware
development, on line debugger and down loader, man machine interface software, log
generator, data transfer from magnetic tape to disk and vice versa, test and maintenance
program, anti virus vaccine/detection utility, full scale steam/water property routines
conforming to ASME 1967 steam table and software for information management system
shall be supplied. Licensed copies of operating system and system software shall be
supplied.
10.4.4
For all Software supplied by main Bidder or Sub Bidders shall provide access to
Purchaser at all levels.
10.4.5
The workstation hardware shall meet the specification under clause 2.0 above.
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10.5
ANNUNCIATION SYSTEM
10.5.1
Annunciation system shall be standalone system. The system shall be implemented

using ISA sequence sequence. The no of annunciation windows shall be as required.
Approximately around 40 nos per LCP.
10.5.2
A set of annunciation push buttons (Sound Cancel, Reset, Acknowledge, Lamp Test etc.)
shall be provided on Local Control panel. The alarm response shall be less than 30 m
sec. The no of windows required for the electrical system in the main control room shall
be around 180 nos.
10.5.3
System features of Annunciation System: ISA sequence for non first up with time delay
adjustable for each point, reflash facility and auxiliary output.
10.5.4
Audible Devices: One hooter for first up alarm points, second hooter for mains supply
failure, buzzer for non first up alarm points. Audible devices shall be redundant with
selector switches.
10.5.5
Push buttons for sound cancel (Silence), acknowledge (first up), acknowledge (Non first
up), reset, lamp test, system test, earth test, reset (main supply failure alarm), test (main
supply failure alarm) and four sets of first four push buttons and one set of balance push
buttons shall be provided.
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STANDARD TECHNICAL REQUIREMENTS

Form No. PEM-6666-0
TITLE:
SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER SYSTEM
VOLUME
II-B
SECTION D
REV. NO. 02
SHEET
1
DATE: July 19, 2008

OF
9
1. SCOPE
This specification covers the Design, Manufacture, Assembly, Inspection and Testing at
manufacturers works, proper packing and delivery to site, erection and commissioning
of the PLC Control & Monitoring System comprising PLC Control panel/Remote I/O
panel (housing Processors, I/O cards, power supply packs etc.), Operator
workstations(OWS), Printers, Annunciation system, UPS, cables and all other
equipments and accessories required for completeness of the system as mentioned in
different sections of this specification.
2. GENERAL
2.1.
The PLC shall perform protection logic, interlock and sequential control functions
such as binary logic operation, set/reset operation, timers, counters, logic blocks,
math functions, input quality checking engineering unit conversion, Boolean
functions & PID control (Analog logic function).
2.2.
The system shall be redundant in processor, power supply and communication

interfaces unless otherwise specified. The system shall have self-diagnostic
features. The control of all drives and equipment shall be effected through the
keyboard/mouse / panel mounted push button / control switches as per Data
sheets-A&B.
2.3.
The system shall have facility for connecting to Main Plants Distributed control
system (DCS) using hardware / software interface for two-way transfer of signals.
2.4.
The mimic shall be displayed on the OWS screen and may also be provided on the
control desk/panel (as per Data sheets).
2.5.
In case OWS is provided, HMI functions like Trends, Curves, Bar charts, Historical
storage of Data, Logs and reports etc. shall be provided in addition to Plantschematics. The necessary catalogue / literature elaborating the features of HMI
shall be supplied along with the bid.
2.6.
It shall be possible to use the same OWS as programming station.
2.7.
The PLC system shall be sized to meet process/system requirements as per the
approved P&IDs and Control write-up.
2.8.
The PLC system shall be designed to ensure that no single device failure should
result in failure of any other device.
2.9.
Signal multiplication where required shall be done in PLC. Use of relays for
multiplication of contacts (for control, monitoring and alarm) is not acceptable. The
control/ monitoring components on the control panel/ desk shall be driven through
I/O modules.
3. TECHNICAL REQUIREMENTS
Details of various PLC system components shall be inclusive of but not limited to the
following:
3.1. CODES AND STANDARDS
3.1.1. The equipment covered under this specification shall meet the requirements of
latest edition of all applicable codes and standards like ANSI, NEMA, IEEE, IEC,
NEC & IS.

278

Form No. PEM-6666-0
TITLE:
SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER SYSTEM
VOLUME
II-B
SECTION D
REV. NO. 02
SHEET
2
DATE: July 19, 2008

OF
9
3.1.2. PLC shall conform to IEC: 1131

3.1.3. The offered PLC shall comply with safety standards as per Data sheet-A&B.
3.2. CONTROL PANEL
3.2.1. PLC control panel shall be freestanding type with provision for mimic display, pushbutton stations, control switches, indicating lamps, metering instruments like
Indicators, ammeters etc. and facia windows for critical alarms.
3.2.2. The salient features of construction shall be:
Sheet material: Cold rolled sheet steel
Frame thickness: Not less than 3.0mm
Enclosure thickness: Not less than 2.0 mm for load bearing sections
(mounted with instruments) and Not less than 1.6 mm for others
Gland plate thickness: 3.0mm
Base channel: ISMC 100 with anti-vibration mounting & foundation bolts.
3.2.3. Each panel shall be identified by a name plate, which shall be of non-rusting metal
or three ply lamicold, with engraved lettering.
3.2.4. 25 x 6 mm Copper ground bus to be provided for each panel.
3.2.5. 240V AC single phase, thermostatically controlled space heaters shall be provided.
Each free standing panel shall have a door switch operated fluorescent lamp and a
240V AC plug point.
3.2.6. Painting treatment shall be as per IS: 6005. Two coats of lead oxide primer shall be
followed by powder coating. Paint shade shall be as specified in the Data sheet for
PLC system-Data Sheet-A&B.
3.2.7. The annunciation system shall be facia window type, driven by the PLC. Audible
alarm, Acknowledge, Reset and lamp test facility shall be provided as per ISA
sequence S18.1, M.

279

Form No. PEM-6666-0
TITLE:
SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER SYSTEM
VOLUME
II-B
SECTION D
REV. NO. 02
SHEET
3
DATE: July 19, 2008

OF
9
3.3. PROCESSORS
3.3.1. The microprocessors shall be 32 bit, and Hot redundant.
3.3.2. Hot redundancy: PLC shall be provided with two processors (Main processing unit
and memories) one for normal operation and one as hot standby. In case of failure
of working processor, there shall be an appropriate alarm and simultaneously the
hot standby processor shall take over the complete operation automatically. This
transfer from main processor to standby processor shall be bump less and shall not
cause any disturbance whatsoever. In the event of both processors failing, the
system shall revert to fail safe mode. It shall be possible to keep any of the
processor as master and other as standby.
3.3.3.
An authorized forcing facility shall be provided for changing the status of inputs and
outputs, timers and flags to facilitate fault finding and other testing requirements.
3.3.4. The standby processor shall be updated automatically in line with the changes
made in the working processor.
3.3.5. In the event of any replacement of the processor, synchronization of the replaced
processor shall be automatic upon live insertion.
3.3.6. The cycle time for input scanning, execution of logics, overheads and output scan
shall not exceed 120 m sec.
3.3.7. The processor & memory shall be loaded up to 50% at normal conditions and
maximum up to 60% under worst loading conditions.
3.3.8. The memories shall be field expandable.
3.4. INPUT / OUTPUT Modules
3.4.1. Input/output card assignments shall be modular i.e. no single card shall be assigned
with more than one drive of a particular sub-system. The maximum number of
channels per I/O module shall be as follows.
x
Analog Input Module: 16
Analog Output Module: 16
Binary Input Module: 32
Binary Output Module: 32
Analog Input/output combined: 16
Binary Input/output combined: 32
3.4.2. On line I/O replacement: All I/O cards shall have quick disconnect terminations
allowing for card replacement without disconnection of external wiring and without
switching off the power supply.
3.4.3.
10% spare capacity shall be ensured in each card channel assignment. Overall
minimum 20% spare channels shall be provided.

280

Form No. PEM-6666-0
TITLE:
SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER SYSTEM
VOLUME
II-B
SECTION D
REV. NO. 02
SHEET
4
DATE: July 19, 2008

OF
9
3.4.4. Output command to MCC/Switchgear shall be through coupling relays, whose

mounting location shall be as per Data sheet A & B for PLC System. In case
coupling relays are located in PLC Panel, the same shall be in PLC vendors scope
of supply.
3.4.5. Status feedback from MCC shall be in the form of potential free contact.
3.5. DATA BUS/ I/O BUS
3.5.1. The Data bus connecting PLC and HMI work stations shall be TCP/IP on Ethernet.
3.5.2. The Data bus and I/O bus communication medium shall be twisted pair shield
copper conductor for indoor locations and those areas not subjected to induced
signals. Repeaters/signal amplifiers shall not be used. Copper conductor cable used
shall be Category-5 or better. The communication medium shall be Fibre optic cable
in the event any portion of communication cable run is in outdoor or where
distances are beyond 500 meters.
3.6. OPERATOR WORK STATION (OWS)
3.6.1. The OWS and Keyboard shall be desktop mounted and shall be used for
controlling, monitoring and programming function.
3.6.2. Colour CRT(s) with keyboard and mouse shall be as per Data Sheet-A&B. CRT
shall have graphic display facility.
3.6.3. The OWS shall be with Windows based operating system having necessary
Engineering/Configuring software.
3.7. PRINTER
Printers shall be provided as per Data Sheet-A&B.

281

Form No. PEM-6666-0
TITLE:
SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER SYSTEM
VOLUME
II-B
SECTION D
REV. NO. 02
SHEET
5
DATE: July 19, 2008

OF
9
3.8. COMMUNICATION WITH PLANT DCS

3.8.1. The PLC system shall be provided with hardwired/serial interface for communication
with plant DCS.
3.8.2. Serial communication to / from DCS where provided shall be engineered to ensure
that signal communication time from / to DCS shall not exceed 1 seconds for control
/ feedback.
3.8.3. Serial communication to DCS shall be OPC (Data access 2.0), Ethernet based
TCP/IP Protocol. Alternatively the serial communication shall be MODBUS protocol
on RS 485 network.
3.8.4. Data transmitted from PLC to DCS shall include all information necessary for the
DCS graphic displays to monitor and control the process equipment and PLC. Such
data may include pertinent analog and digital status information, interlock, alarms
and maintenance conditions. Data transmitted from DCS to the PLC shall include
necessary signals to provide operator control interface from DCS for the process/
equipment being controlled by PLC.
3.8.5. Bidder to include Light interface units, converters, Ethernet switch, accessories at
PLC end for connectivity to other system. The bidders terminal point shall be
Ethernet port in case of copper medium connection to DCS or LIU in case of Fiber
optic medium for connectivity with plant DCS. In case distance between PLC & DCS
is greater than 1.8 Km, single mode of optical fiber cable with compatible
accessories shall be used. For distance less than 1.8 Km multimode optical fiber
ports shall be used.
3.9. POWER SUPPLY Scheme
3.9.1. PLC Panel and I/O Cabinets: PLC system shall be provided with 2x100% UPS fed
from Two Nos. redundant 415V, 3-ph feeders, as per the scheme PE-DG-392-145I004, sh-02 of 02. Each UPS shall have 60 minutes back up. Input feeder failure
shall be monitored in the PLC system. Necessary redundant power pack and
transformers shall be provided (in the PLC panel) to derive the power supply for
control desk, PLC panel and input / output cabinets etc
3.9.2. Remote I/O panels: Similar power supply arrangement as for PLC panels shall be
provided if it is not possible to extend the power cable form UPS of PLC panels.
3.9.3.
Each OWS and associated HMI peripherals shall be provided with a feeder from
either one of the UPS
4. DRAWING/DOCUMENT AND DATA TO BE FURNISHED AFTER AWARD OF THE

CONTRACT:
4.1. For Approval:
x
x
x
x
x
x
x
x
PLC system configuration drawing along with functional write-up.

Input/Output signal list.
BOM of PLC
List of PLC controlled devices
Control panel/control desk GA drawings.
Control desk/panel component layout drawing.
Control panel/control desk Foundation detail and cutout drawings
Power distribution scheme.

282

Form No. PEM-6666-0
TITLE:
SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER SYSTEM
x
x
x
x
x
x
x
x
x
VOLUME
II-B
SECTION D
REV. NO. 02
SHEET
6
DATE: July 19, 2008

OF
9
Block logic diagrams.

Annunciation list.
PLC control room layout drawing.
List of soft signal exchange with Plant DCS.
List of mandatory spares
Quality plan
Data Sheet-C
CRT display
Power supply scheme for PLC system, HMI & peripherals, Remote I/O etc.
4.2. For Information:

x
x
x
x
x
x
x
Cable schedule and cable interconnection drawing( in BHEL approved format)

Between Field and PLC
Between Field and MCC
Between MCC and PLC
Electronic earthing requirements.
Panel Heat dissipation data
Product/component catalogues.
Operation & Maintenance Manual on CDs.
Softcopy of Final/As-built drawings on CDs.
Calculation for Processor, Memory & Data bus loading
The above list is the minimum requirements. Additional documents/calculations required

shall be finalized during contract stage.
5. DRAWINGS AND DOCUMENTS TO BE SUBMITTED ALONG WITH THE BID
x
x
x
Proposed PLC system configuration drawing with write-up

Product catalogues and specifications for PLC as well as HMI application.
Proposed power supply schemes for PLC system, peripherals, and Remote I/O
panels.
6. TESTING AND INSPECTION

6.1. The bidder shall adopt suitable quality assurance program to ensure that the
equipments offered will meet the specification requirements in full.
6.2. BHELs standard Quality Plan for PLC is enclosed with the specification. The bidder
shall furnish his acceptance to BHELs QP and submit the signed and stamped
copy of QP along with the offer.
6.3. The complete PLC system, including all instrument and devices shall be subjected
to standard factory tests (i.e. Type Tests and Routine Tests) as per relevant IS,
NEMA, IEEE, IEC.
6.4. Factory Acceptance Test-FAT (Functional Tests) shall be performed prior to
shipment and Owner/Purchaser shall be notified 15 days before the schedules
dates of the test.
6.5. The certificates for following type tests, as per IEC Standard, shall be submitted: x
x
x
Surge protection test as per IEC-225-4

Dry heat test as per IEC-68-2-2
Damp Heat test as per IEC-68-2-3

283

Form No. PEM-6666-0
TITLE:
SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER SYSTEM
x
x
x
x
VOLUME
II-B
SECTION D
REV. NO. 02
SHEET
7
DATE: July 19, 2008

OF
9
Vibration Heat test as per IEC-68-2-6

Electrostatic discharge test as per IEC-801-2 or equivalent
Radio frequency Immunity test as per IEC-801-6 or equivalent
Electromagnetic Immunity test as per IEC-801-3 or equivalent
7. SPARES AND CONSUMABLES

7.1. Commissioning Spares and consumables
The bidder shall supply all commissioning spares and consumables as required
during Start-up, as part of the main equipment supply.
7.2. Mandatory Spares
The bidder shall offer alongwith main offer, the Mandatory Spares as specified
elsewhere in the specification. The Mandatory Spares offered shall be of the same
make and type as the main equipment.
7.3. Recommended Spares
The bidder shall furnish a list of Recommended Spares indicating the normal
service expectancy period and frequency of replacement; quantities recommended
for 3 years operation alongwith unit rate against each item to enable BHEL/BHELs
Customer to place a separate order later, if required.
7.4. Special Tools & Tackles
The bidder shall supply all Special Tools & Tackles as required during Start-up and
further maintenance of the system, as part of the main equipment supply.
7.5. Spares, Service support
Bidder shall provide availability of spares and service support for minimum 10 years
after guarantee period.
8. MARKING AND PACKING
8.1. Marking:
A stainless steel name-plate shall be permanently fixed on each equipment giving
its Tag/serial Number and salient technical specification.
8.2. Packing:
All equipment/materials shall be suitably packed and protected for the entire period
of dispatch, storage and erection against impact, abrasion, corrosion, incidental
damage due to vermin, sunlight, high temperature, rain, moisture, humidity, dust,
sea-water spray (where applicable) as well as rough handling and delays in transit
and storage in open.
9. PERFORMANCE AND GUARANTEE

284

Form No. PEM-6666-0
TITLE:
SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER SYSTEM
VOLUME
II-B
SECTION D
REV. NO. 02
SHEET
8
DATE: July 19, 2008

OF
9
The PLC system shall be guaranteed to meet the performance requirement as

specified and also for trouble-free continuous operation for 12 months from the date
of commissioning or 18 months from the date of delivery at site whichever is later
unless specified otherwise in Vol-IIB Section - B or Section - C.
10. APPLICABLE DATA SHEET FORMS
This document shall be read with the following data sheet forms :
- Data Sheet A & B for PLC system - PE-DC-999-145-I036-1
- Data Sheet C for PLC system
- PE-DC-999-145-I036-2

285
286

)250123(0
63(&,),&$7,2112
92/80(,,
DATA SHEET FOR PLC SYSTEM
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288

VOLUME IV
SPEC.NO.

SECTION: D11
TCE.5750A-H-500-001
RRVUNL, 2 x 660 MW, Super-Critical TPS, Stage- V,

Units 7 & 8, at Suratgarh, Rajasthan
PART B
SHEET 1 OF 4
UNINTERRUPTIBLE POWER SUPPLY SYSTEM
1.0
SPECIFIC REQUIREMENTS
1.1.
The Uninterruptible power supply system (UPS System) shall cater to the complete
DM plant instrumentation and control system loads and
PLC system loads.
The UPS shall be sized considering full load plus spare loops plus
25% margin. The output shall confirm to stringent requirements in respect of
voltage & frequency regulation, harmonic content & transient recovery.
1.2.
The UPS shall be of parallel redundant with static bypass to regulated supply
type with 2 x 100% chargers and inverters and 2X100% battery bank, bypass line
transformer and voltage stabiliser, AC distribution board, other necessary
protection devices and accessories. UPS shall derive power from auxiliary
switchgear as shown in the UPS Single Line Diagram.
UPS Battery shall be of Plante Type with 60 min back up.
1.3.
The UPS shall include AC distribution board with air break switch, fuses, current
transformers, meters, alarm and indications. It shall incorporate complete circuit
protection against all types of abnormal conditions, the system is likely to
encounter while in service.
1.4.
Requirement of the 24V DC or any other voltage level system for PLC and other
system if any shall be derived from the UPS supply. The UPS shall be sized for
the same. A separate 24V DCDB shall be provided for distributing feeders to the
24V DC system.
1.5.
The UPS system offered shall be suitable for normal operation, emergency
operation with required protections for Thyristor, Automatic synchronisation etc.
The UPS system shall be provided with necessary meters (accuracy class 1.0 or
better), mimic diagram, status of operation, indications and alarms. Group alarms
and analog parameters of each branch of parallel redundant UPS shall be made
available on PLC. The UPS shall be suitable for PC connectivity and necessary
hardware and software shall be included.
1.6.
The UPS system shall be based on latest generation technology having proven
performance of satisfactory operation for similar applications.
2.0
SYSTEM REQUIREMENTS
2.1.
The UPS system shall be of the static type, composed of static inverters, static
switches for added protection and transfer of loads with no break or with minimum
interruption of the order of a fraction of a cycle during undervoltage condition to the
healthy inverter or to standby regulated supply. The components of UPS shall
isolate power line voltage transients, frequency variations and high/low voltage
conditions from the critical load and act as a line filter and voltage regulator, apart
from providing no-break power at constant frequency during normal power
outages.
ISSUE
R1
TCE FORM 329 R5

289

VOLUME IV
SPEC.NO.

SECTION: D11
TCE.5750A-H-500-001

PART B
SHEET 2 OF 4

2.2.
Suitable isolation transformers shall be provided at the inputs to prevent switching

transients entering the 415 V system from the UPS.
2.3.
Mode of Operation
2.3.1. The system shall have a combination of two inverters (UPS modules) operating in
synchronism, each having isolating facility from the critical bus by a static switch.
Power supply to UPS shall be as shown in the sketch for UPS Single Line
Diagram.
2.3.2. In addition to the two inverter systems, a back-up from a regulated AC supply
through transformer and voltage stabilizer derived from a standby AC supply shall
be provided. The system shall have a selector switch. In the `Normal' position,
both the inverters share 50% load each, with output of both inverters being
automatically synchronized with each other. If one inverter fails, the healthy
inverter shall supply the full 100% load by the operation of the static switch. When
any one of the UPS is under maintenance, the selector switch shall be suitably
changed and the branch circuit supplying 100% load shall be synchronised with
the frequency of the standby source.
2.3.3. If the frequency of the standby source is beyond the preset limit, the inverter
frequency control shall get disconnected from the standby synchronising signal.
The operating inverter shall continuously monitor the frequency of standby source
and upon restoration of proper frequency of the standby source, the inverter shall
use the frequency of the standby source as the synchronising signal.
2.3.4. When the selector switch is in bypass position the standby source shall cater
100% load, isolating both inverters from the critical load bus.
2.3.5. The output of the UPS shall feed all the essential loads through the ACDB. The
connection from the UPS to ACDB shall be through a switch and fast acting
semiconductor fuses, trip fuses and micro switch with alarm contacts. The feeders
shall be designed by the Contractor to suit the load requirements.
2.4.
Inverter
2.4.1. Inverter shall be of the CVT (Constant Voltage Transformer) or PWM (Pulse Width
Modulation) type, adequately designed to meet the requirements as specified.
2.5.
Static Transfer Switch
2.5.1. Inverter output shall be connected to the AC bus through a static switch and fast
acting fuses. The static switch comprises an interrupter and transfer switch,
enabling loads to be connected to the standby regulated AC supply.
2.5.2. Automatic initiation of the transfer from a faulty branch circuit to the standbyregulated source shall be accomplished during following conditions:
a)
Loss of inverter square wave/inverter failure
b)
Loss of inverter AC output
ISSUE
R1
TCE FORM 329 R5

290

VOLUME IV
SPEC.NO.

SECTION: D11
TCE.5750A-H-500-001

PART B
SHEET 3 OF 4

Note: Retransfer to the inverter circuit shall be manual.
2.6.
Regulated Stand-by AC Supply
2.6.1. Regulated standby AC supply shall be derived from standby supply through a stepdown transformer of appropriate rating and a servo controlled voltage stabiliser
with isolation transformer and power conditioning equipment viz., spike arrester,
etc.
2.7.
Protection
2.7.1. The UPS system components and assemblies shall be provided with the
necessary protection associated with all components.
3.0
UPS PANEL CONSTRUCTION DETAILS
3.1
UPS shall be of unitized construction, free standing, floor mounted, indoor type,
dust and vermin proof.
3.2
Forced Cooling
3.2.1
Forced ventilation of panel, if provided, shall be supplemented by 100%

redundant fans. In normal operation, normal fans will be in service and on
failure reserve fans shall start automatically. The power supply for the fans shall
be tapped from the inverter output. Alarms & contacts for fan failure shall be
provided.
3.2.2
The panel enclosure shall confirm to IP-32 degree of protection. The panels
shall be provided with illumination lamps, door switches, space heaters and
power sockets.
4.0
UPS DISTRIBUTION BOARD
4.1
Sheet steel enclosed AC distribution board shall be provided as part of the

complete UPS package. The distribution board shall be floor mounted, fixed
type with compartmentalised construction, having horizontal and vertical bus
bars. All bus bars shall be PVC sleeved. It shall be possible to operate the
switches without opening the doors. Switches shall be provided with door
interlock. Vertical cable alley shall be provided for the termination of outgoing
cables. Suitable supports shall be provided for supporting incoming and
outgoing cables
4.2
The enclosure cold rolled steel thickness shall be 2.0 mm minimum for load
bearing and 1.6 mm for other non-load bearing members and enclosure class
protection shall be IP 54.
4.3
The DB shall have two sections with sectionalising switch (ACB/MCCB) & shall
be protected by semiconductor fuses with fuse monitoring device, bus healthy
lamps, Voltmeters & Ammeters. Each load shall be fed by two independent
feeders. Each feeder shall have double pole isolation switches & semiconductor
fuse (on both phase & neutral side) and feeder ON LED indication with glass
fuse.
ISSUE
R1
TCE FORM 329 R5

291

VOLUME IV
SPEC.NO.

SECTION: D11
TCE.5750A-H-500-001

PART B
SHEET 4 OF 4

4.4
Incoming to ACDB from static switch shall be MCCB or ACBs of draw out
module.
4.5
All outgoing switches shall be air insulated load break type with suitable LED
indications. Cable entry shall be decided during detail engineering stage. The
gland plate of the distribution board shall be non-magnetic type.
4.6
UPS distribution board shall be provided with individual feeders for each load.
25% spare feeder of each type and rating shall be provided for purchasers use.
4.7
Interposing relays / transducers / potential free contacts required for PLC

system shall be mounted on the UPS distribution board.
4.8
AC source of supply to UPS shall be as follows:

a)
Inverter-1 from Normal source of Unit-7
b)
Inverter-2 from Normal source of Unit-8
c)
Bypass from Normal Emergency switchgear
5.0
TESTS
5.1
Type and routine test certificates for all components made use in the UPS
system shall be furnished. Tests for components shall be as per relevant
standards.
5.2
Tests on the following equipment shall as per the relevant standards.

a)
AC Distribution Board
5.3
System tests shall be performed on the completely assembled UPS system at

vendors works. System tests shall include frequency regulation, voltage
regulation, current limiting feature and harmonic content tests in addition to the
tests to prove the functional requirements such as transfer of static switch for
conditions of loss of square wave, overload and under voltage conditions.
5.4
Routine tests covered under clause 7.3 of IEC-60146-4 shall be conducted on

the UPS system in addition to the system tests. Certificates of type tests shall
be submitted for review.
5.5
Endurance test on static switches shall be performed for not less than 10
transfer/ retransfer cycles at full load.
5.6
The complete assembled UPS system shall be operated at rated load under
relevant ambient conditions for not less than 96 hours continuously prior to
release for shipment.
6.0
For technical particulars refer datasheet-A.
ISSUE
R1
TCE FORM 329 R5

292

SPEC. NO.
VOLUME IV
TCE.5750A-H-500-001
SECTION: D11

SHEET 1 OF 5
PART B
DATA SHEET-A
Sl. No.
Description
1.0
Type
Parallel redundant UPS with static

bypass to regulated supply.
2.0
Application
Uninterruptible Power supply for

loads of auxiliary system loads.
3.0
Number required
4.0
Ambient temperature
5.0
Output Voltage
6.0
Output rating at 0.8 p.f lagging load.
7.0
Degree of protection
IP 32
8.0
Cable entry
Will be decided during detail

engineering stage
9.0
Input Supply Voltage
415V, 3 Phase, 3 wire, 50Hz

supply
10.0
Installation / paint shade
Indoor, natural ventilated, shade

631 of IS-5.
11.0
Material of Enclosure
2.0mm thick Cold rolled sheet

steel
12.0
Inverters
12.1.
Type
Static
12.2.
Number required
Two per unit
12.3.
Suitable for parallel operation
Yes
REV. NO.
PPD. BY :
CKD. BY :
R0
UM
MSVM
R1
SK
MSVM
DATE
NOV2009
JUN2012
Unit
Specification Requirement
1 nos. UPS unit
50
230V, 1phase
kVA
JOB NO.
TCE 5750A
CLIENT : RRVUNL
PROJECT : 2 x 660 MW, Super-Critical TPS,
Stage- V, Units 7 & 8, at Suratgarh, Rajasthan
TCE FORM NO. 329 R5
293

SPEC. NO.
VOLUME IV
TCE.5750A-H-500-001
SECTION: D11

SHEET 2 OF 5
PART B
DATA SHEET-A
12.4.
Service
Indoor
12.5.
Output rating of each
12.6.
Output Voltage
230V A.C. 50 Hz, Single phase
12.7.
Voltage regulation
Combined Voltage regula-tion

2% from 0 to 100% load at 0.8
power factor within 50 milli
seconds
12.8.
Frequency regulation
5% for 0 to 100% load variation

(continuous or step load change)
and full range of input variation
a) Transient voltage regulation on

application or removal of 100%
load
8%
12.9.
50
b)
Time to recover from
transient- to normal voltage
ms
12.10.
Total harmonic content
5% RMS maximum with not more

than 3% distortion in any single
harmonic
12.11.
Duty
Continuous
12.12.
Overload capacity
125% for 15 minutes at 0.8 p.f,

150% for 10 sec.
12.13.
Short time rating
1 second for short circuit at

inverter output terminals
12.14.
Short circuit current withstandability
Shall be capable of withstanding

short circuit current for the largest
fuse to clear the fault in less than
cycle
12.15.
Efficiency
Not less than 80% at rated load
REV. NO.
PPD. BY :
CKD. BY :
R0
UM
MSVM
R1
SK
MSVM
DATE
NOV2009
JUN2012
JOB NO.
TCE 5750A
CLIENT : RRVUNL
TCE FORM NO. 329 R5
294

SPEC. NO.
VOLUME IV
TCE.5750A-H-500-001
SECTION: D11

SHEET 3 OF 5
PART B
DATA SHEET-A
12.16.
Cooling
Natural air cooled
12.17.
Synchronization with alternate

source required
Yes
13.0
Static Transfer Switch
13.1.
Capacity Continuous
Make and carry full load current

of inverter at 0.8 p.f
13.2.
Type
Make before break
13.3.
Voltage
230V, single phase
13.4.
Short time rating
Short circuit rating of the inverter

for 1 second and 150% of full
load current for 2 min.
13.5.
Frequency
13.6.
Transfer time
Less than 5 mili sec.
13.7.
Retransfer
Automatic retransfer shall occur

after approximately 2 sec time
delay during which normal source
voltage must remain at 240V
2%
13.8.
Indication protection / Annunciation
Hz
13.9.
13.10.
50
I.
Indicating lamp for static

switch in normal position.
Indicating lamp for static

switch connected to alternate
source.
Protection of all
semiconductor devices
against short circuit and
transients.
iv) Annunciations for the

following conditions.
13.11.
REV. NO.
PPD. BY :
CKD. BY :
R0
UM
MSVM
R1
SK
MSVM
DATE
NOV2009
JUN2012
JOB NO.
TCE 5750A
CLIENT : RRVUNL
TCE FORM NO. 329 R5
295

SPEC. NO.
VOLUME IV
TCE.5750A-H-500-001
SECTION: D11

SHEET 4 OF 5
PART B
DATA SHEET-A
a) Static switch connected to
alternate source
5
Alternate source voltage

deviation greater than 2%
from nominal.
14.0
Bypass Switch
14.1.
Capacity Continuous
14.2.
Type
14.3.
Short time rating
15.0
Standby AC supply with isolation transformer and servo controlled voltage

stabilizer
15.1.
Number
15.2.
Rating
15.3.
Single or poly phase unit
15.4.
Type
15.5.
Voltage ratio at no load
15.6.
Type of cooling
15.7.
Winding insulation class
15.8.
Location
15.9.
Voltage regulation
15.10.
System fault level on 415 V side
15.11.
Output voltage setting range
5% of nominal voltage
15.12.
Output frequency regulation
1% of nominal freq.
Make and carry full load current

of inverters at 0.8 p.f
Make before break
Short time rating of the inverter
for 1 second and 150% of full
load current for 2 minutes.
One for each unit

Same as UPS rating
*
Dry type double wound
*
Natural Air cooled
Class-H
Indoor
REV. NO.
PPD. BY :
CKD. BY :
R0
UM
MSVM
R1
SK
MSVM
DATE
NOV2009
JUN2012
2% from 0 to 100% load at 0.8

p.f
kA
JOB NO.
TCE 5750A
50
CLIENT : RRVUNL
TCE FORM NO. 329 R5
296

SPEC. NO.
VOLUME IV
TCE.5750A-H-500-001
SECTION: D11

SHEET 5 OF 5
PART B
DATA SHEET-A
15.13.
Synchronising between inverter and

standby supply
16.0
ACDB
16.1.
Fully drawout/ Semidraw out/ fixed
16.2.
Dimensions of the board
16.3.
17.0
BATTERIES
17.1.
Type
17.2.
Capacity
17.3.
Rated Voltage
17.4.
Back up time
17.5.
Redundancy
Required Within 2.5 Hz
**
**
IP52
Lead acid Plante

AH
*
*
60 mins
2 X 100%
* indicated above shall be filled by the Contractor.

** Contractor shall furnish the data after placement of order.
REV. NO.
PPD. BY :
CKD. BY :
R0
UM
MSVM
R1
SK
MSVM
DATE
NOV2009
JUN2012
JOB NO.
TCE 5750A
CLIENT : RRVUNL
TCE FORM NO. 329 R5
297

VOLUME IV
SPEC.NO.
SECTION:D11
TCE.5750A-H-500-001

PART B
SHEET 1 OF 7
DATA SHEET B
UPS
ENQUIRY/SPECIFICATION NO.:
BIDDER:
S.NO
.
ITEM
BIDDER
1.0
GENERAL PARTICULARS
1.1
Name / Manufacturer
1.2
Quantity Offered
1.3
Type of UPS
1.4
Output Rating at 0C Ambient
kVA
1.5
Mains Input . at load PF 0.8
kVA
1.6
Mains Tolerance Range
Nos.
Voltage
Frequency
Combined
1.7
Environment
1.7.1
Design Ambient Temperature Range
1.7.2
For Operation
For Storage
Relative Humidity
C
C
SIGNATURE OF BIDDER & DATE
NOTES TO BIDDER
1
.
ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.
2
.
THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY

SHALL BE ENCLOSED WITH EACH COPY OF THE BID.
ISSUE
R1
TCE FORM NO. 294 R3

298

VOLUME IV
SPEC.NO.
SECTION:D11
TCE.5750A-H-500-001

PART B
SHEET 2 OF 7
DATA SHEET B
UPS
BIDDER:
S.NO
.
1.7.3
BIDDER
Installation Altitude range without derating
2.0
ENCLOSURE
2.1
Sheet Thickness / Material
2.2
Degree of protection as per IS 13947
2.3
Mode of Cooling
2.4
Earth Bus material & size
2.5
Cable Entry
ITEM
m
mm
From Top / Bottom

2.6
Dimensions of
LxDxH
(mm)
Rectifier/ Inverter Panel

Bypass Transformer Panel
Automatic Voltage stabiliser Panel
Battery CB Panel
System Output Assembly Panel
AC Distribution Board
2.7
Mimic Diagram
a) Graphic LCD display

b) Mimic diagram with event
NOTES TO BIDDER
1
.

2
.

ISSUE
R1
TCE FORM NO. 294 R3

299

VOLUME IV
SPEC.NO.
SECTION:D11
TCE.5750A-H-500-001

PART B
SHEET 3 OF 7
DATA SHEET B
UPS
S.NO
.
BIDDER:
BIDDER
ITEM
indication LED
2.8
Accoustic Noise Level
2.9
Colour of Paint
dBA
Exterior
Interior
2.10
Weight of each Panel
kg
3.0
RECTIFIER
3.1
Ripple
3.2
Harmonics at the point of connection to

source
a) THD (Voltage)
b) THD ( Current)
3.3
Whether Soft Start Feature Incorporated
3.4
Type of Rectifier Bridge Circuit
3.5
Rectifier Efficiency
% rms
Yes / No
( At Half Rated Load of the System

a
)
NOTES TO BIDDER
1
.

2
.

ISSUE
R1
TCE FORM NO. 294 R3

300

VOLUME IV
SPEC.NO.
SECTION:D11
TCE.5750A-H-500-001

PART B
SHEET 4 OF 7
DATA SHEET B
UPS
S.NO
.
BIDDER:
BIDDER
ITEM
( At Full Rated Load of the System
b
)
3.6
Input Power factor range
4.0
INVERTER SYSTEM
4.1
PWM / any other
4.2
Type of Power Switching Devices
4.3
Output Rating at 0.8 Pf Lag at 0C
kVA
4.4
Input Nominal DC Voltage and Range
V DC
4.5
Output
4.5.1
Voltage
4.5.2
Voltage adjustment range
+%
4.5.3
Steady state output voltage regulation

from no-load to full load for input line
variations
+%
( For balanced loads

a
)
( For 20% unbalanced loads in 3-PH
b system
)
NOTES TO BIDDER
1
.

2
.

ISSUE
R1
TCE FORM NO. 294 R3

301

VOLUME IV
SPEC.NO.
SECTION:D11
TCE.5750A-H-500-001

PART B
SHEET 5 OF 7
DATA SHEET B
UPS
S.NO
.
BIDDER:
BIDDER
ITEM
4.5.4
Transient voltage regulation for 100% load

application
+%
4.5.5
Transient recovery time to regulating band
ms
4.6
Frequency
4.6.1
Nominal frequency
Hz
4.6.2
Frequency deviation range
+%
4.6.3
Synchronising adjustable range
+ Hz
4.6.4
Slew rate of synchronising adjustable

range
Hz/Sec.
4.7
Overload Capability
- for 10 min.
% full
load
- for 10 secs.
% full
load
5.0
BATTERY
5.1
No. of 100% capacity batteries
Nos.
5.2
Battery backup time
Min.
5.3
Type of battery cells
5.4
No. of battery cells
Nos.
NOTES TO BIDDER
1
.

2
.

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SPEC.NO.
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PART B
SHEET 6 OF 7
DATA SHEET B
UPS
BIDDER:
S.NO
.
ITEM
BIDDER
5.5
Battery cell / Rack dimensions
6.0
STATIC SWITCH
6.1
Rating of basic SCR used
6.2
Load Transfer
7.0
STAND-BY REGULATED SUPPLY
7.1
Servo controlled Voltage Stabiliser with

isolation transformer provided
Yes / No
7.1.1
Input volts with percentage variation

allowed
V+%
7.1.2
Output volts
7.1.3
Voltage regulation for line variation of +

10% and 0 to 100% load variation and PF
0.8 to 1.0 range
+%
7.1.4
Output voltage setting range
+%
7.1.5
Stabiliser continuous rating
kVA
7.1.6
Isolation transformer on output side
Yes / No
LXWXH
A
Bidder to furnish a detailed write
up on load transfer /. Switching
arrangement
NOTES TO BIDDER
1
.

2
.

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PART B
SHEET 7 OF 7
DATA SHEET B
UPS
S.NO
.
BIDDER:
BIDDER
ITEM
provided
9.0
DISTRIBUTION BOARD
9.1
Single front or double front
SF /DF
9.2
Modular construction
Yes / No
9.3
Type of outgoing feeder protection
9.4
Total dimension of each complete

switchgear L x W x D
NOTES TO BIDDER
1
.

2
.

ISSUE
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304
305
2.3.0
MEASURING INSTRUMENTS
306

SPEC.NO.
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Package: EPC
VOLUME V
SECTION : D5.4
SHEET 1 OF 42

CONTROL EQUIPMENT
1.0
SPECIFICATIONS FOR INSTRUMENTS TO BE SUPPLIED ARE AS FOLLOWS.
1.1
Pressure Indicators/DP indicators

Direct reading, pipe mounted Pressure gauges of die-cast aluminium body, with 6
inch(150mm) phenolic dial (white dial with black numerals), 316 SS/304 SS Bourdon
tube for high pressure application and 316SS Diaphragm/bellow for low pressure
applications, AISI 304 movements and micrometer type adjustable aluminium pointer
an accuracy of +/-1.0% of span including accessories like siphons for steam
services, snubbers for pump discharge applications and chemical diaphragm for
corrosive and oil services and name plate, etc. Material of accessories shall be SS.
IP65 or equivalent degree of protection for enclosure. Over range protection shall be
50% above maximum pressure. Armoured capillary of 10 M shall be provided as
required. Process connection shall be NPT (F).
1.2
Pressure Switches/DP Switches

Non indicating type, field mounted Pressure Switches of aluminium casing (epoxy
coated), and 316 SS element and repeatability of +/-1% of span, including
accessories like siphons for steam services, snubbers for pump discharge applications
and chemical diaphragm for corrosive and oil services, name plate & mounting
brackets. Material of accessories shall be SS. Auto reset micro switch with internal
adjustment for set values with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or
equivalent degree of protection for enclosure. Over range protection 50% above
maximum pressure. Scale for setting shall be provided. Piston actuated for high
pressure applications and diaphragm/bellows for low pressure/vacuum. Process
connection NPT (F).
1.3
Pressure Transmitters/DP Transmitters/Flow transmitters(DP type/Level transmitters/DP

type (SMART)
Micro-processor based 2 wire indicating type (LCD display), rack mounted with
accuracy of +/-0.075% of span, external zero and span adjustment, self diagnostics,
temperature sensor for compensation. Power supply 24 V DC; output signal of 4-20 mA
DC. IP 65 or equivalent degree of protection. Aluminum housing with epoxy coating,
Accessories like snubbers for pump discharge applications and chemical diaphragm. 10
m PVC covered SS armoured capillary for corrosive and oil services, three way manifold,
nameplate etc. Material for accessories shall be SS. Turn down ration 30:1. Load
impedance 700 ohm (min).Process connection-1/2NPT (F). 2 valve manifold for
absolute pressure, 3 valve manifold for gauge/vacuum and 5 valve manifold for
DP/level/flow measurements. For HFO, LFO applications, SS capillary with ANSI RF
flanged ends shall be provided.
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SHEET 2 OF 42

CONTROL EQUIPMENT
1.4
Thermometers
Bimetallic below 80 deg.C. and inert gas actuated for above 80 deg.C. of SS bulb and
capillary. Body material-Die-cast aluminium. Dial size-150 mm with white dial and black
numerals and process connection-1/2NPT (F). Accuracy-+/- 1% of span. IP 65
protection class. Accessories include nameplate, mounting brackets and SS Thermo
well. Process connection- M33 x 2 thread /1 Socket welded/ 1 flanged.
1.5
Thermo wells
Pipe/equipment mounted temperature test wells of 316 SS with a process connection of
M33x2 thread /1 socket welded/ 1 flanged. Accessories like name plate, plug with
chain, etc. shall be provided. Material of accessories shall be SS. Thermowell shall be
hex head of barstock assembly. In case flanged wells are required for any specific
application, the same shall be supplied as required. The thermo well construction shall
meet the ANSI 19.3 (latest) requirements. Thermo well shall be designed such that the
resonant frequency is above the exciting frequencies generated by vortex shedding in
the process fluid. All Test thermo well shall have the plug of SS316.
1.6
Thermocouple Assembly
Duplex, K Type, 16 AWG or R type, 24 AWG with accuracy as per ANSI-C-96.1/IEC
60584, ungrounded type depending on operating temperature range. Response time of
2 to 6 sec, Spring loaded mineral insulated thermocouple assembly with 316 SS
thermo well housed aluminium casing (epoxy coated) having a process connection
of M33 x 2 thread / 1 Socket welded. Material of accessories (name plate, etc.) shall be
SS. IP 65 or equivalent degree of protection for enclosure. Thermo well with hex
head (with screwed cover & SS chain) bar stock assembly with ungrounded junction. For
metal temperature measurement, thermocouple pads weldable to M.S pipes shall be
provided with 15 m thermocouple extension wires. Element size shall be 18 AWG.
Insulation resistance at 540 Deg C shall not be less than 5 M ohms. Temperature
devices provided with thermo wells shall be calibrated with the associated thermo well as
an assembly. The thermo well construction shall meet the ANSI 19.3 (latest)
requirements. All pent house thermocouples shall be supplied with 15mts flexible
extension length.
1.7
Resistance Temperature Detectors (RTD)

Duplex type, PT 100, with accuracy of +/-0.5% of span as per IEC-60751, response
time 1-2 seconds; Spring loaded mineral insulated three(3) wire RTD assembly with
316 SS Thermo well housed in aluminium casing (epoxy coated) having a process
connection of M33 x 2 thread /1 Socket welded/ 1 flanged. IP 65 or equivalent degree
of protection for enclosure. Material of accessories (name plate, etc.) shall be SS.
Thermo well with hex head with screwed cover & SS chain, barstock assembly. Element
lead size shall be 18 AWG. The insulation resistance at 540 Deg C shall not be less
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CONTROL EQUIPMENT
than 5M ohms. Repeatability over full range shall be better than 0.02%. RTDs shall be
ungrounded. RTD shall be supplied as an assembly complete with thermo wells meeting
ANSI 19.3 (latest) requirements.
1.8
Level Gauges
Tubular type level gauges for low pressure upto 7 kg /sq.cm & reflex type for high
pressure water & steam services & vacuum services with automatic ball check
valves, illuminator (240 AC), pyrex/ tempered toughened borosilicate glass, mica
shield, brass guard rods & brass holders. Body material: Forged carbon steel/304SS.
Accuracy- +/- 2% with vertical scale.4 Material of accessories (name plate, etc.) shall be
SS. Tubular glass OD shall be 5/8. Vent & drain valves shall be provided. Connection
shall be screwed or flanged (ANSI class 150 RF).
1.9
Level Switches
External cage magnetic float operated level switches for tanks and vessels and top
mounted level switches for sumps and underground tanks. The top mounted level
switches shall be supplied with still tubes to suit the requirement. Micro switch with 2
SPDT contacts rated for 0.2 A, 220 V DC. Material of float & float chord shall be 316 SS
& cage material shall be fabricated steel and the material of accessories shall be SS.
IP65 or equivalent degree of protection for enclosure.
Accessories like name plate, drain valve for external case type level switches,
mating flange, gaskets (asbestos), fasteners, bolts & nuts, etc. shall be supplied.
Conductivity type electronic Probe type level switches shall be supplied for Drain pots.
The required pressure vessel assembly for mounting probes are included in the scope.
1.10
Level Transmitter
Ultrasonic type level transmitters top mounted with integral local LCD indicator, IP-65
protection; 2 wire type transmitter with 4-20mA output with HART protocol; Accuracy
0.25%; Resolution 1mm; Repeatability 0.1%; Linearity 1%; Response time 150ms;
Beam angle <12; Auto false echo-suppression; Accessories like integral cable between
sensor and transmitter unit with connectors on both side, gasket and cable gland, digital
panel meter, name plate & metal tag; the material of accessories will be SS.
Radar type level transmitters top mounted with LCD indicator,IP-65 protection; 2 wire
type transmitter with 4-20mA output with HART protocol; Accuracy 1%; Resolution
1mm; Repeatability 1 mm; Linearity 0.01%; Beam angle <20; Accessories like
integral cable between sensor and transmitter unit with connectors on both side, gasket
and cable gland, digital panel meter, name plate & metal tag; the material of accessories
will be SS.
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SECTION : D5.4
SHEET 4 OF 42

CONTROL EQUIPMENT
1.11
Flow Glasses
Online flow glasses for pipe size up to 6 with a rotary wheel (not a flapper type)
suitable for installation on vertical or horizontal pipelines, material Pyrex tempered
glass. Body material shall be carbon steel, rotor & wetted parts shall be bronze. The
material of accessories shall be SS. IP 65 or equivalent degree of protection for
enclosure. Upto 50 Nb size, connection shall be screwed & above 50 mm Nb size it
shall be flanged - ANSI, 150 RF. Accessories like name plate, mating flanges with
gaskets (neoprene), bolts & nuts, etc. shall be supplied.
1.12
Flow Switches
Indicating, Differential pressure, flapper type on line flow switches for line sizes up to
80 mm with an accuracy of +/-0.5% of span and dial size of min. 50 mm having 316
SS flapper/SS 316 bellows housed in die cast aluminium. Micro switch with adjustable
range with 2 SPDT contacts rated for 0.2 A, 220 V DC. IP 65 or equivalent degree
of protection for enclosure. The material of accessories shall be SS. Repeatability
shall be
+/-0.5% of span. Over range protection shall be 50% above maximum flow. Setting
shall be tamper proof external adjustment & scale shall be provided for setting.
Range spring & orifice plate shall be SS 316 for DP type. NPT for sizes below 2 & for
sizes above 2 ANSI 150 RF shall be provided. Accessories like nameplate, mating
flanges with gaskets, bolts & nuts, pipe assembly with orifice plate, etc. 5 way manifold,
pipe, fittings (DP type), etc. shall be supplied.
1.13
Flow Elements
316 SS long radius, welded type flow nozzles as per ASME PTC 19.5 or BS-1042 for
all steam and feed water services with D and D/2 pressure tappings; 316SS
concentric orifice plate assembly as per ASME PTC 19.5 or BS-1042 for all water
services with flange tap connections. Beta ratio of 0.34 to 0.7 for orifice and around 0.7
for flow nozzles.. The material of accessories shall be SS. Refer to Table-5 for provision
of flow elements. All the flow elements shall have 3 pairs of differential pressure
tappings complete with root valves. Orifice plate shall be3 mm thick for nominal pipe
diameter upto 300 mm & 6 mm thick for pipe diameter > 300 mm. The thickness of the
flow nozzle shall be as per the application. The flow elements shall be supplied as
assemblies with High/low pressure tappings, root valves as required. Performance
Guarantee flow elements shall be provided separately. Butt welded edges shall be
prepared as per ANSI 16.25 & flanged connections shall be as per ANSI 16.5
standards. Orifice assembly complete with nipples & valves to be supplied by Bidder
shall be one meter long with ANSI class 150 RF SS flanges at the ends including
gaskets, bolts & nuts. Isolating valves shall have SW end connection. Accessories
like nameplate, gaskets, bolts & nuts, reservoirs (condensing chambers), 6 nos. shut
off valves per assembly, nipple, welding adapters, etc. shall supplied. Bidder shall
submit assembly drawing and flow vs DP curve for each flow element.
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CONTROL EQUIPMENT
1.14
Magnetic Flowmeter
Inline type with indicating top mounted transmitter with flange connection. Accuracy:
0.5% of flow rate or volume flow. Repeatability 0.1% of flow rate/volume flow.
Transmitter shall be smart with LCD display and superimposed HART on 4-20mA DC
output. Data storage shall be in EEPROM. Shall have diagnostic capabilities. Touch
control facility on the indicator for checking the rate/volume and diagnostic messages.
Material: Case-Al.alloy with corrosion resistant, flow tube and extension pipe- Stainless
steel (SS 304) and Lining-fluro carbon.
The flow rate shall be available in DCS/PLC and flow integration shall be implemented in
DCS/PLC to indicate volume flow.
1.15
Anubar ( Impact Head Type)

Element shall be tubular, insert type with minimum four impact ports facing upstream
direction, located precisely for measurement of average flow velocity. The material of the
sensor shall be SS 316. Accuracy shall be +/ - 1% of the actual value or better.
Repeatability shall be + /- 0.1 of actual value or better. Online retracting facility and
flushing arrangement shall be provided. The sensor shall be supplied with complete
mounting hardware and support plugs and valve manifolds ( NPT) for DP transmitter
connection. The specification of DP transmitter is specified elsewhere.
1.16
SWAS system (Wet Panel and dry panel)

Sampling racks include sample filtering, primary and final sampling cooling and
temperature control. Pressure regulating device shall be capable of regulating the output
pressure, irrespective of upstream fluctuations. Flow rate control shall be with glass tube
purge rotometer with built in regulating valve. The system shall have the following
features: automatic temperature compensation in the range of 0-100deg.c,flow
indicators, sample coolers, flow and pressure regulators and gauges, SS tubing and
fittings within the system, Isolation and drain valves. Provision for Grab sample shall be
provided for all sample streams. A backpressure regulator shall be used before the grab
sample valve to ensure priority flow to analysers. The wet panel shall be open frame
freestanding type construction. The sheet steel shall be 2mm thick. All internal piping,
tubing and system components shall be shop installed and tested prior to shipment. The
piping material shall be as follows:
Sample tubing: SS, ASTM A 213,type 316 20 SWG tubing
Blow down header: SS, ASTM A 312,Type 316,Sch-80
Various drains and Cooling water headers: Carbon Steel, ASTM A 106,Gr.A sch-40
Dry panel shall house analysers whose output shall include continuous monitoring of
various parameters using indicators with isolated 4-20mA DC to moniyo from DCS.
All the analysers shall be from a single vendor and should work with sample temperature
of 40-45 deg.c. without chilled water requirement.
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CONTROL EQUIPMENT
coloured LCD or fluorescent tube with user selectable span; programmability (selection
of input & scan/storage rate) shall be through Front panel keyboard; the recorder shall
have the capability of being drawn out from the front side of the housing for maintenance
and shall have electrical connection of plug-in type; material of casing shall be die-cast
aluminium with epoxy coating and with a non-glare shatter proof Glass; enclosure shall
be IP32 The quantity of Hybrid recorders shall be 4 nos.
1.21
Pressure and Differential Pressure Transmitter Racks

Open type transmitter racks to mount all pressure, differential pressure and flow
transmitters with vibration dampener: air supply lines and header shall be provided with
bulk head fittings to receive impulse lines; Also provided with blow down/drain header.
The material of accessories shall be SS. Drains shall be connected upto suitable
Owner / Project Managers drain header. The quantity shall be as required for the
specified Pressure and Diff. Pressure transmitter.
1.22
Junction Boxes (JB)

All JBs shall be Galvanised. Wall/column mounted junction boxes having 32 (2x16)
terminals and cable entry only at the bottom and sealed with fireproof compound;
Screwed terminal type; IP 65 or equivalent degree of protection for enclosure.
Separate terminal blocks shall be used for analog and digital signal and also for
signals with different voltages. Removable gland plate shall be supplied. JB shall
have single lockable door with gasket, able to open side ways, with common keys.
Painting inside shall be glossy white & outside - IS-5 shade 631. Shield bus for screw
connection shall be provided. Terminal size shall be suitable for 0.5 sq.mm to 2.5
sq.mm wire. Terminal blocks shall be vertical. JB shall have provision to add 10%
additional terminals. Accessories like metal tag (SS), clamps, fixtures, bolts (SS), nuts
(SS), gaskets (neoprene), lock & key, fireproof compound for sealing, etc. shall be
supplied. The grouping of instruments in JBs is subject to Owner / Project Managers
approval. All the field Junction boxes shall have single doors and provision for locking.
The doors shall not have screwed type of locking, but turnable hinge based. The JBs are
subject to approval prior to manufacturing All JBs shall be provided with individual
canopies to avoid ingress of water.
All the TBs used shall be 6.6polymide to withstand corrosion and the metallic portion
shall be coated against rust / corrosion.
1.23
Programmable Logic controller (PLC)-Refer Cl.no. 9.0 & Table-15
1.24
Interposing Relays (IPR)

Electro magnetic
type
IPRs
with
plug-in
type connections, suitable for
channel/rail mounting in cabinets; coil rating 24V D.C; 2 set of silver plated Change
over contacts rated for 0.2A 220 V DC. Freewheeling diode across relay coil (copper)
and self reset type status indicator flag (electronic) shall be provided. All relays
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CONTROL EQUIPMENT
shall be mounted in IPR cabinet & relay base (silver plated) internally wired to the
external cabling termination block in IPR cabinet. Wiring connection shall be cageclamp & termination shall be suitable for 0.5 sq.mm to 2.5 sq.mm size wiring. Facility to
simulate relay operation manually shall be provided. Relays of different contact
interrogation voltages shall be separated by a barrier in IPR cabinet. Accessories like
name plate (SS) with tag & service inscription, relay base mounting rail/channel, nuts
& bolts, etc. shall be supplied.
In each cabinet, a DC Voltmeter shall be provided to check the Field Interrogation
voltage.
1.25
System Cabinets
These cabinets shall house signal-conditioning cards, input/output cards, processor
cards & associated power supply units. Indoor located, free standing vertical type
system cabinets with IP-32 enclosure and with 2 mm thick sheet metal of cold rolled
steel; double doors with neoprene gaskets; ant vibration pads of 15 mm thick; blower
& louvers in each cabinet with brass mesh; fire proof compound (50 mm thickness) for
sealing cable entry (bottom); fire detector for each cabinet. The racks in system cabinets
shall have provision along with plug in sockets/back plane to house accommodate the
spare slots/modules as specified elsewhere. The colour of the cabinets shall be
indicated at detailed engineering stage. Doors shall have concealed type of hinges and
swing of 100o. to, on the side to help the operator. Power supply distribution shall be
provided on per cabinet basis with all associated MCBs, protections, etc. The system
cabinets, racks in system cabinets, slots in the racks & the terminals shall have
identification numbers. A stainless steel metal tag (plate) shall be fixed to the inside of
the door & the layout of the racks, slots & details of the card type/service shall be
inscribed on this metal tag. Each cabinet shall be provided with one each 3 pin
receptacles for 240 V, 1P, 50 C/S and receptacles for +24V DC. Cabinet shall be
delivered totally wired. All electronics shall be mounted & wiring connections at these
hardware shall be terminated by Bidder. Quantity shall be as required. One of the doors
shall be provided with folder to keep the relevant engineering document of the cabinet.
All cabinets shall have common key for the locks.
In each cabinet, a 24 VDC Voltmeter shall be provided to check the Field Interrogation
voltage.
1.26
Marshalling Cabinets
Indoor located, free standing vertical type marshalling cabinets with IP-32 enclosure and
with 2 mm thick sheet metal of cold rolled steel; single/double door with neoprene
gaskets; anti vibration pads of 15 mm thick; fluorescent lighting; blower & louver in
each cabinet with brass mesh; fire detection for each cabinet; fire proof compound (50
mm thick) for sealing cable entry (bottom, front, rear). The colour of the cabinets shall
be indicated at detailed engineering stage. The type of terminal shall be Phoenix / Weid
ueller / WAGO. The terminal blocks shall be cage clamp type. Fused terminal blocks
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hinged at one end to facilitate easy isolation shall be provided wherever necessary. All
cabinets shall be provided with spare terminals for the spare inputs/outputs as specified
else where in the specification.. The type of terminals for terminations from
cabinets/panels shall match with the pre fabricated cables and pins supplied. The
terminals for field cables shall be arranged in a logical order of equipment/system
wise and shall be worked out by Bidder, subject to approval by Owner / Project
Manager/ Consultant. Door shall have concealed type hinges and swing of 180
Degree & lockable. The doors shall be provided both on the front and rear. Channels,
bolts & nuts shall be zinc plated and passivated. Two coats of premier paint and
black colour paint shall be applied. Fluorescent lamp of 40W shall be provided and
shall be operated by the door switches as well as by manual switches. The
marshalling cabinets, the terminal blocks, the terminals and the electronic hardware if
any, shall have identification numbers. Each cabinet shall be provided with one each 3
pin receptacles for 240 V AC, 1Ph, 50 c/s and receptacles for +24V DC. A system
cabinet and associated cabinets shall be supplied on a skid to avoid outside
interconnecting cables. Cabinet
shall
be delivered totally wired. Preparation of
interconnection schedule (ICS) between marshalling cabinets & JBs/FTCs and JBs to
Instruments is in Bidder scope. The format of Interconnection Cable Schedule (ICS) shall
be submitted by the Bidder during detailed engineering stage for approval by Owner /
Project Manager.
All cabinets shall have common key for the locks.
All the terminals shall have no screws and the cables shall be gripped by spring. Each
terminal shall have LED indication with fuses to indicate and isolate earth faults.
1.27
Local Panels
1.27.1
Indoor/Outdoor located, free standing vertical type local panels with 2 mm thick sheet
material of cold rolled steel; ant vibration pads of 15 mm thick; fluorescent lighting;
Double doors with neoprene gaskets at every 1.5 m; blower & louvers in each section
with brass mesh; fire proof compound (50 mm thick) for sealing cable entry (bottom);
fire detector for each section; space heater with thermostatic control for each section
(strip type). IP-52 degree of protection for enclosure for outdoor and IP-32 for indoor.
Removable cover plates with locking facility shall be provided along the bottom of the
front desk continuously to facilitate maintenance work. The length of each cover plate
shall not exceed 1 m. Fluorescent lamp of 40 W shall be provided from one end of the
panel to the other end at continuous length and shall be operated by the door switches
as well as by manual switches. Nameplates shall be provided for all instruments/inserts
with Tag. No. & short description of service engraved. These shall be phenolic
overlays (1.6 mm thick), black background with white lettering & shall be fixed to the
panel by stainless steel screws (counter sunk). Each section of the panels shall be
provided with one each 3 pin receptacles for 240V AC, 1P, 50 c/s &. Panel shall be
delivered totally wired. All instruments, inserts and annunciation windows shall be
mounted & wiring connections at these hardware shall be terminated at site by
Bidder.
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CONTROL EQUIPMENT
1.27.2
All the Terminal Blocks shall be rust proof and corrosive resistant for outdoor mounted
panels. Terminal Blocks housing material shall be 6.6 polyamide and metallic portion
shall be coated against rust/corrosion.
1.27.3
In each Local Panel, a 24 V DC Voltmeter shall be provided to check the Field

Interrogation voltage.
1.28
Vibration Monitoring And Analysis System

Refer TABLE-13.
1.29
230 V AC Distribution Board

The function of the 230V AC distribution is sub distribution of 230V AC power
supply from UPS to all the utilities viz., system cabinets, HMI and peripherals.
Redundant feeders shall be provided for each utility. The cabinets shall be free
standing vertical cabinets, designed for indoor location. Material of construction shall
be 2mm thick CRCA. Fluorescent lighting, fire detector and space heater shall be
provided for each cabinet. Isolating switches and HRC cartridge fuses shall be
provided for individual feeder isolation. Ammeter and voltmeter shall be provided for
incoming feeders to the distribution boards.
Each terminal shall have LED indication with fuses to indicate and isolate earth faults.
1.30
Control Valves
1.30.1
Multistage, anti-cavitation, balanced, modulating, globe type, cage guided, single

ported, diaphragm type of actuator with hand wheel, SMART positioner, air filter
regulator, air lock device, solenoid valve as applicable, limit switches and position
transmitters completely tubed with junction box. Smart positioner shall be suitable for
accepting 4-20mADC signal. Pneumatic (PVC coated copper) tubing complete with
accessories, fittings, If any up-gradation of the offered system is envisaged before
completion of the job to meet the specified requirements, the same shall be incorporated
in the system, with the approval of the OWNER without any additional cost. Positioner
shall be provided with input/output/bypass gauges. Local position indicator & Noncontact type position transmitter with 2 wire, 4-20mA DC output. All limit
switches/position transmitters, E/P converter signals etc., shall be wired out to external
block of actuator and respective junction boxes.
1.30.2
Control valves shall be sized to have an opening of 15% at minimum flow condition
and 85% at maximum flow condition. Noise level shall not exceed 85 dB at a
distance of about 1.5 M from the valve. In case of predicted noise level above 85dBA,
suitable low noise trim shall be provided. Noise reduction shall be achieved through an
inherent Trim design and not through external means.
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CONTROL EQUIPMENT
1.30.3
All control valves shall have a leakage class of V and tight shut off application class VI
shall be provided.
1.30.4
Either extended type bonnet or cooling fin type bonnet shall be provided for service
above 200 Degree C and for other service the bonnet type shall be standard.
1.30.5
The end connections shall be socket welded for sizes below 50 NB and butt welded
for sizes 50 NB and above. Flanged connection shall be provided for DM water
services, with suitable rubber lined interfaces.
1.30.6
Water seal shall be provided for valves that could be subjected to below atmospheric
conditions.
1.30.7
Generally stem and guide material(trim) shall be SS 316 stellited, and plug and seat
material shall be 17-4 PH SS, except for specific applications like DM water, HP
bypass services. Refer to mechanical section of this specification for selection of
control valve body material and actuator type.. The trims supplied shall be suitable for
quick changing. Actuator housing shall be of pressed steel construction.
1.30.8
Trim shall be designed such that trim exit velocity shall be limited to avoid cavitation.
1.30.9
The action of valves on failure of operating media shall be determined by the process
requirements with regard to safe operation and emergency shut down requirements.
1.30.10
Control valve sizing shall be accompanied with data sheets. Following size calculation
details shall be furnished for Control valves:
1.31
Pneumatic block valves

Balanced, on off, plug type, single ported, gate valve. End connection socket welded
for sizes 50 NB and below & butt welded for sizes above 50 NB and flow direction
shall be horizontal.
For body and bonnet material refer mechanical section of this specification.
Packing material GRAFOIL.
Trim : Cage guided, metal seated with flow characteristic of quick opening with
stem, plug, seat and guide material of SS 316.
Actuator : Diaphragm (Nitrile) type with handwheel & travel indicator and adjustable
stop. It shall be sized for shut off differential pressure.
Accessories like air filter regulator, solenoid valve, limit switch with Nema4
enclosure, etc. shall be supplied. Actuators & accessories requiring tubing shall be
mounted and tubed.
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1.32
Control Damper Drives

Pneumatic actuator type, located in flue gas/air area with damper shaft bearings
mounted externally. Bearings are grease lubricated. Blades(SS) shall be linked together.
Accessories like position transmitters (2 wire) with 4-20mA DC output, Local Position
indicator, position locks, limit/torque switches, etc. shall be supplied, after integrating,
calibrating & testing at works. Smart Positioners with all required accessories, required
for the positioning of control damper drives shall be provided. Spare cams for
accommodating any change in characteristic to achieve better process control during
commissioning shall be supplied as required.
All the field mounted Damper accessories ( position indicator, limit switches etc.,) shall
comply to IP 65.
1.33
SMART Positioners of Control Valves.
1.33.1
Positioner shall be microprocessor based with digital communication by means of HART

protocol. Positioner has to be 2-wire, 4-20 mA loop powered by the control system and
capable of split ranging operation.
1.33.2
The SMART positioner shall be suitable for both single acting and double acting
actuators. The SMART positioner shall be fully modular in construction with
Encapsulated printed wiring board and pressure gauges inside the positioner cover to
protect from transit/site damage.
1.33.3
SMART positioner shall preferably be of the same make as the Control Valve, to ensure
repeatability in Calibration, serviceability and proper maintenance of the Control System.
1.33.4
The SMART positioner shall have pressure sensors to measure the pneumatic outputs
to the actuator.
1.33.5
The control algorithm for the positioner shall use feedback signal from the motion of the
pneumatic relay beam instead of pressure feedback to minimize pneumatic related
effects and for stable and smooth response of the control valve. The SMART positioner
shall have user adjustable tuning sets to identify the optimum tuning for the total valve
assembly. SMART Positioner with HART Communication facility shall communicate all
the valve diagnostics to DCS.
1.33.6
The electrical housing shall be designed to meet NEMA 4X,IEC 60529 IP66.
1.34
Void
1.35
Void
1.36
Void
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1.37
Air Filter Regulator (AFR)

Constant bleed type AFR with an accuracy of +/-0.1%, inlet pressure range of 5-8 kg
/sq.cm and suitable spring ranges (AFR) for use with positioners in control valves,
control damper, E/P converters and shut off valves, transmitter purging lines etc;
Filtering particles above five microns having phosphor bronze filter element. Material of
accessories shall be SS. Built in blow down valve shall be provided. AFR shall have
automatic drain feature. All accessories shall be supplied. Degree of protection shall be
IP65.
1.38
Position Transmitters
24VDC operated Non contact LVDT type with 4-20 mA DC 2 wire system with an
accuracy of 1%; range adjustment and zero adjustment to be provided; IP65 degree of
protection for casing. The output shall be linear. All accessories shall be SS.
1.39
Solenoid Valves
Direct operated solenoid valves, pilot operated for higher sizes with shut off class
(leakage) VI, body material of bronze, plunger material of 316 SS rated for continuous
duty. IP 65 class for enclosure. Insulation class of 'F' for the solenoid. Body ratings shall
suit the pressure and temperature conditions.
1.40
Void
1.41
Bunker level monitoring system:

Radar type shall be provided. 230V UPS shall be utilised for the instruments. The
system shall provide 4-20mA for connecting to DCS and CHS PLC.
1.42
Furnace Temperature Probe

Duplex k-type thermocouple with mineral insulation & SS sheath located in furnace
below SH panels; minimum of 2 nos. Probe housing shall be weather proof &
corrosion resistant. Accuracy shall be +/-0.5% of span. The junction shall be
ungrounded with response time of 2 to 5 seconds. Starter box shall be provided
with IP65 enclosure & 3 mm thick sheet. Electric motor with chain drive shall be
provided for the lance. The traverse of the probes from opposite sidewalls shall cover
the full cross section of the furnace. Automatically controlled cooling system shall be
provided for the lance. Loss of cooling water shall be detected & provided as a contact.
Accessories like limit/torque switches position transmitters, etc. shall be provided.
All the field mounted accessories (limit switches etc.,) shall comply to NEMA-4
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Online reading shall be provided at Main Plant Control room.

1.43.6
Particulate Emission Analyser

Optical Trans receiver type or TRIBO ELECTRIC METHOD type microprocessor based/
solid state system with an accuracy of + 2% of FS, response time of 90% with in 5
seconds having features like auto zero calibration and correction, auto span calibration
and window check. IP65 or equivalent degree of protection for enclosure. Output shall be
isolated 4-20 mA DC linear signal. Air purge system with air blower shall be provided.
The analyser shall be located at Chimney at elevation as per Pollution board norms.
Online reading shall be provided at Main Plant Control room
1.44
STEAM AND WATER ANALYSERS
1.44.1
Conductivity Measurement
Solid state/micro-processor based, single stream with an accuracy of +/-1 %FSD, auto
temperature compensation, auto calibration, zero check and integral indicator having
gate valve insertion type (with drawable) cell for hot well conductivity measurements and
flow line (screwed) type cell for other services. Housing for cell and analyser shall be
weather and waterproof. Output shall be isolated 4-20 mA DC linear signal. Dual channel
analyser with independent output signal for each channel of measurement can be used
(if required).
Movable type for Hot well and flow through, single stream, type for other applications,
with an accuracy less than +/- 1%, response time less than 1 sec for 90% of full scale
change and range of 0-1,0-10,0-100 microsiemens/cm for specific conductivity and 0-1
microsiemens/cm log scale for cation conductivity. Dual cation exchange shall be
provided for cation conductivity. Analyser shall have features like auto zero & span
calibration, ambient temperature compensation, and integral indicator etc. Fault
diagnosis data shall include faults in analog/digital circuits, faults in calibrated valves,
power supply failure and sample failure. Analyser housing shall be weather and
waterproof. Output shall be isolated 4-20 mA DC linear signal. Dual channel analyser
with independent output signal for each channel of measurement can be used (if
required).
1.44.2
pH Measurement
Solid state/micro processor based system with system accuracy of 0.02 pH, auto
temperature compensation, auto zero check, manual zero and span calibration, integral
indicator, automatic ultrasonic cleaner, iso potential adjustment having flow type cells.
Housing for electrode and analyser shall be IP65. Output shall be isolated 4-20 mA DC
linear signal. Accessories shall include preamplifier, screened junction box for electrode.
Dual channel analyser with independent output signal for each channel of measurement
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can be used (if required).

1.44.3
Dissolved Oxygen Measurement

Continuous flow through sample single stream with an accuracy of +/-5%, having
features like auto temperature compensation, auto zero & span calibration and integral
indicator. Fault diagnosis data shall include faults in analogue/digital circuits, faults in
calibrated values, power supply failure and sample failure. Housing for cell and analyser
shall be IP54 or equal. Output shall be isolated 4-20 mA DC linear signal. The range of
measurement shall be 0-20/0-200 ppb.
1.44.4
Silica Analyser
Continuous colourimetric with an accuracy of +/-5%, response time better than 10 min
for 90% change including sample switching, six number of sample streams with sample
shut-off solenoid valve having features like auto zero & span calibration, ambient
temperature compensation and integral indicator. Self diagnostic features shall include
alarm for no reagent, calibration fault and silica concentration low/high. Analyser housing
shall be weather and waterproof. Output shall be isolated 4-20 mA DC linear signal.
Range shall be 0-50/0-500 ppb.
1.44.5
Hydrazine Analyser
Continuous electrochemical single stream type with an accuracy of +/-5% FSD,
response time better than 2 min for 90% of full scale having features like auto zero &
span calibration, ambient temperature compensation, and integral indicator etc. Fault
diagnosis data shall include faults in analog/digital circuits, faults in calibrated valves,
power supply failure and sample failure. Analyser housing shall be weather and
waterproof. Output shall be isolated 4-20 mA DC linear signal. The range shall be 050/0-100 ppb.
1.44.6
Sodium Analyser
Continuous flow through sample, multi stream type with accuracy less than +/-10% ,
response time less than 2 min and range of 0-20/0-200 ppb . Analyser shall have
features like auto zero & span calibration, ambient temperature compensation, and
integral indicator etc. Fault diagnosis data shall include faults in analog/digital circuits,
faults in calibrated valves, power supply failure and sample failure. Analyser housing
shall be weather and waterproof. Output shall be isolated 4-20 mA DC linear signal.
1.45
Void
1.46
Void
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1.47
Cables
1.47.1
Individual pair shielded & overall shield twisted pair copper cables shall be used for
analog signals & overall shielded cables shall be used for digital signals. All these
cables shall be armoured. All the insulation including overall sheath shall be FRLS
quality. The wire size shall be 0.5 sq.mm. Ferruling indicating terminal numbers on
termination side shall be followed. Colour coding shall be approved by Owner / Project
Manager. Only sleeve type ferruling with printed terminal numbers shall be used. Cross
ferruling shall be adopted.
1.47.2
Instrumentation Cables
Instrumentation cables shall be 600VAC grade, stranded high conductivity annealed,
tinned copper, twisted pair (with min. 20 twists for meter) extruded PVC insulated with
overall and / or individual screening, extruded PVC inner sheathed, galvanized steel wire
armoured, extruded outer sheathed with FRLS PVC compound. The conductor size
shall be minimum 0.8 sq.mm. Triplex cables similar to instrumentation cables can be
used for RTDs. Instrumentation cables carrying digital signals shall have overall
screening along with drain wire and analogue signal carrying cables shall have each pair
screening and overall screening along with each pair drain wire and overall drain wire.
The Fire survival cable shall conform to IEC 331 standard.
1.47.3
Control Cables
Control cables shall be 1100V AC grade, multicore, minimum 1.5 sq.mm cross section,
stranded copper conductor having 7 strands, PVC insulated, inner FRLS PVC sheathed
of type ST-1, galvanized steel wire armoured and outer sheath made of FRLS PVC
compound of type ST-1. In situations where accuracy of measurement or voltage drop in
control circuit, warrant, higher cross sections as required shall be used. For all the CT &
PT cables, minimum 2.5 sq.mm cables shall be used. Solenoid valve Power supply
cables shall be minimum 2.5 sq.mm. The Fire survival cable shall conform to IEC 331
standard.
1.47.4
Compensating Cables
1.47.4.1
All Compensating cables shall be single or multicore cable (ANSI type KK) twisted and
multiple shielded thermocouple extension compensating cable and shall be of Flame
Retardant Low Smoke type (FRLS). All Compensating cable ( Chromel - Alumel) of
FRLS type shall conform to additional test to Prove the FRLS Characteristics as
mentioned in the FRLS Instrument Cable specifications
1.47.4.2
Compensating Cable:
(a)
Reference
ANSI MC (96.1)
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(b)
Conductor
16 SWG shield alloy
(c)
Insulation
Insulated with heavy duty, self extinguishing type,

PVC, cores colour coded, extruded PVC sheathing,
insulation of each wire with high grade 0.6mm, 105
deg C PVC, Voltage grading of 1100V.
(d)
Lay
Twisted pair with 75 mm maximum lay.
(e)
Shielding
Shielding shall be single pair-cable assembly only,

Multiple pair-each pair and cable assembly
2.35MIL, Thick combination Aluminium Mylar tape
and 7 strand 20 SWG tin coated copper drain wire.
Insulation, coverage shall be 100% and total shield
isolation shall be such as to isolate from all other
fields.
Thermocouple Extension Cable

1.47.5
1100V AC, twisted pair (20 twist/meter), 1.5 sq.mm dia. Thermocouple
extension
wires,
PVC insulated, aluminium Mylar tape shielded/PVC jacketed/ armoured &
overall PVC jacketed/FRLS. Features such as colour coding, thermo electric
characteristics, etc. shall be as per ANSI MC 96.1, 1975. Alternatively thermocouple
extension wires with 1100 V AC twisted pair ,1.5 sq.mm, PTFE insulated copper braiding
& PTFE outer jacket , shall be considered for turbine area.
1.47.6
Fibre Optic cables
1.47.6.1
Mono mode type fibre optic cable shall have following parameters:
(a)
Wavelength band optimized : 850nm / 1300nm / 1550nm

Mode field diameter : 9-10m + 10% of nominal value
Cladding diameter : 125m + 3
Non-concentricity core/cladding : not more than 2m
Non-circularity of cladding : not more than 3m
Cut-off wavelength : 1200mm
(b)
Mode field diameter : 9-10m + 10% of nominal value
(c)
Cladding diameter : 125m + 3
(d)
Non-concentricity core/cladding : not more than 2m
(e)
Non-circularity of cladding : not more than 3m

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1.47.6.2
(f)
Cut-off wavelength : 1200mm
(g)
Attenuation : less than 0.3-0.4 dB/km at 1300nm, less than 0.15-0.25 dB/km at
1550nm
Fibre Optic Network Cable- minimum Specification :

(a)
Cable Type
Multi-mode Dual Fibre
(b)
Core / cladding diameter
62.5 / 125 m
(c)
Jacketing Material
Halogen Free, Flame Retardant, Low Toxicity
(d)
Attenuation @ 850 nm
Length (m) x 0.0035 db/m+2db maximum
(e)
Outside Diameter
8.10 mm (0.324 in)
(f)
Minimum Bend Radius
12.5 cm (5 in)
(g)
Minimum
Bend
(Long term)
(h)
Cable Assembly Tensile 300 N (66 lb) maximum

Load
for
attenuation
increase <0.5 db
(i)
Tensile Load at Installation
1776 N (400 lb) max.
(j)
Connector Tensile Load
MIC : 133 N (30lb)
(k)
Minimum Crush Resistance
46 N /cm (250 lb /in)
(l)
Maximum Cable Weight
46 kg/1 km ( 31 lb/1000ft)
(m)
Maximum Cable length
1 km
Radius 7.5 cm (3 in)
1.48
Wiring, Termination and Accessories
1.48.1
All the cables are to be treated with anti-rodent treatment properties, voltage grade shall
be 1100V.
1.48.2
Prefabricated Cable :
Used for interconnection between system/marshalling cabinets. Used for panel external
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wiring, tinned copper conductor of 0.5 sq.mm cross section with seven strands
twisted pair with 20 twists/meter. Insulation material shall be PVC, heat resistant
with flame retarding properties with thickness not more than 0.5 sq.mm. Voltage
grade shall be 1100V AC. Each prefabricated cable shall have a minimum of 5 cores
as spares and these shall not be connected to end connectors.
1.48.3
Terminal Block (TB):

Cage clamp type , 600V V AC grade, vertically mounted, size of 0.5 sq.mm to 1.5
sq.mm for instrument wires and 100V AC 1.5 sq.mm to 2.5 sq.mm for control wires.
Clearance between TBs shall be 150 mm and between TB and bottom plate shall be
250 mm, flame
resistant,
non-hygroscopic, decarbonised. Insulation between
adjacent terminals or between terminals & framework shall be 2 KV RMS for 1 minute .
Power supply and signal TB shall be separate. Signals shall be grouped in TBs in the
same order as that in field junction box so as to provide neat cable layout and wiring.
High voltage and low voltage signals shall be provided on separate TBs, which are
mounted separately.
TBs housing material shall be 6.6 polyamide and metallic portion shall be coated against
corrosion. There shall be no double decker terminals.
1.49
Electromatic Relief Valve (EMRV) Controller

Electronic/relay based type with pressure high & low switches. One no. for each
EMRV. Man/Auto/Off selection with lamps for auto/manual positions shall be provided.
IP65 or equivalent degree of protection for enclosure. Enclosure material will be
epoxy coated die cast aluminum. Power supply will be 220 V DC & output signal will be
pressure high potential free contact for solenoid valve energisation. One no. solenoid
valve (for each EMRV) of 220 V DC single coil with limit switches shall be supplied.
Other features of solenoid valve shall be in line with that specified under Solenoid
Valves in this section. Terminals in terminal block of the controller & solenoid shall
accept cable of 0.5 to 2.5 Sq.mm. Switch contact rating shall be boosted using
relays.
1.50
Electronic display board

Electronic display board with Super bright red LED display for alphanumeric letters of
size 9 x 7,gap between two lines 25mm,weather proof IP 65, with canopy. Power
supply 240VAC. Seven lines of display as following:
i.
Name of company
ii.
Date and Day
iii.
Stack emission parameters with units
iv.
Ambient air quality parameters with units
v.
Meteorological parameters
vi.
Provision for additional line
vii.
Provision for additional line
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2.4.0
INSTRUMENTSTUB DETAILS &

INSTALLATION DIAGRAMS

325
PE-DG-392-145-I101
00
326
PE-DG-392-145-I101
PE-SC-367-145-I101
00
327
PE-DG-392-145-I101
PE-SC-367-145-I101
00
328
PE-SC-367-145-I101
PE-DG-392-145-I101
00
[PROCESS PRESSURE EQUAL/> 40 Kg/Cm2 (g)]

329
PE-DG-392-145-I101
PE-DG-392-145-I101
PE-DG-392-145-I101
PE-SC-367-145-I101
00
[PROCESS PRESSURE < 40 Kg/Cm2 (g), TEMP < 400C]

330
PE-DG-392-145-I101
PE-DG-392-145-I101
PE-DG-392-145-I101
PE-SC-367-145-I101
00
331
PE-DG-392-145-I101
PE-SC-367-145-I101
PE-DG-392-145-I101
00
332
333
334
335
336
337
338
339
340
341

2.5.0
MEASUREMENT &&21752/3+,/2623+

'5,(&21752/3+,/2623+
02725,6('$/($&78$7OR'$7$6+((7
1
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Package: EPC

REQUIREMENTS
1.0
DESIGN REQUIREMENTS
1.1
GENERAL
1.1
The offered I&C system shall be based on State of the art practices prevailing in the
field of Control & Instrumentation for Thermal Power Stations, designed to have a fully
automated plant control using Group level control concept to achieve START to
SYNCHRONIZE in automatic sequence with selective minimum manual interventions.
1.1.1
The Instrumentation and Control equipment system called for in this specification
consists of a functionally distributed microprocessor based system for carrying out the
functions of measurement system, control system, protection and interlock system,
Sequence of events recording and Annunciation system, Condition Monitoring system,
operating system and communication system. The system shall be complete with
hardware and software along with the Man Machine Interface (MMI) capable of
operating together as an integrated system along with panels, cables, unit control desk,
cabinets, field instruments and erection hardware, control elements and devices to
perform the various functions of the above systems as specified. The system shall be up
gradable, evolutionary in both hardware and software. Manufacturers shall provide
evidence on such upgrades in similar plants, along with the bid.
2.0
INSTRUMENTATION AND CONTROL SYSTEM PHILOSOPHY
2.1
MEASUREMENT SYSTEM (MS)
2.1.1
The measurement system consist of primary sensors, various function modules,

processors, VDUs and peripherals, back up panel hardware and power supply racks
integrated together to perform monitoring function of non-controlled variables and
interact with other parts of DCS/PLC. All analogue parameters will be displayed. For all
drives, status indication will be displayed. The system requirements are specified
subsequently. All the transmitters shall be SMART type using HART protocol and with
remote calibration station including configuration and Diagnostic software.
2.1.2
The MS shall have the following features:

(a)
Linearisation for temperature measurement i.e. mv Vs Deg. C
(b)
Square root extraction for flow measurement, where the measurement is in

differential pressure.
(c)
Integration for totalising the flow measurement, whenever applicable.
(d)
Compensation for variation in pressure or temperature or density for flow / level

measurement. E.g.: Feed water flow / Boiler drum level.
(e)
Limit value monitor for generation of contacts for alarm/interlock purpose. E.g.:
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REQUIREMENTS
Boiler Tube metal, Bearing, winding temperature measurements
(f)
2.2
Each of the analog transmitters shall be Smart type with the following
(i)
4-20mA DC signal with 24V DC interrogation.
(ii)
HART protocol based digital communication
(g)
All these Transmitters shall be hooked up to a PC based Centralised Calibration

system, which shall have Diagnostic and Configuration software.
The
transmitters that are part of the OEMs integral systems especially used for
critical control and protections that are not recommended to be connected to
central STMS for safety reasons then at least 2 nos. of Hand held calibrators
shall be supplied for each make and model of the transmitters used in the
system,
(h)
All contact inputs shall be interrogated with 24 V DC.
CONTROL SYSTEM-DESIGN FEATURES

(a)
No single random fault in the entire automation and control system will cause a
load loss, forced outage or unit trip.
(b)
No two simultaneous faults shall lead to or potentially cause damage to plant
(c)
Safety related instrumentation and control shall be designed with a fail- safe
mode.
(d)
No single fault shall jeopardise the functioning of the entire system.
(e)
The control and automation system and the field instruments and actuators as
well as its support systems, power supplies and data networks shall be immune
to the electromagnetic interference and shall conform to the internationally
accepted standards.
(f)
To meet the operational and safety requirements, the control system hardware
and software shall conform to a modular, hierarchical architecture.
2.3
CONTROL SYSTEM PHILOSOPHY
2.3.1
In order to minimise the burden on the unit operator, all control functions within the
operational load range shall be fully automated. The control system shall be structured
in accordance with a well-defined control hierarchy to permit operator intervention at
appropriate levels during abnormal modes of operation.
2.3.2
The automation shall meet the following objectives as minimum:

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REQUIREMENTS
(a)
Consistent start-up, shut down and running of the plant under all operational
condition
(b)
Achieve minimum run-up and loading time
(c)
Maximise fuel economy during start-up, shut down and normal on load
operation cycle
(d)
Maximise plant life expectancy
(e)
Contribute to power grid during normal and disturbance condition
(f)
To meet the operational and safety requirements, the control system hardware
and software shall conform to a modular, hierarchical architecture. The system
hierarchy shall be at four levels. The closed loop (i.e. modulating) functions and
open loop (i.e. sequence or on/off) functions shall form separate elements at
each of the hierarchical level.
2.4
DIFFERENET LEVELS OF CONTROLS
2.4.1
Drive Level
2.4.1.1
The first and lowest level shall cover all the modulating, sequence and protection control
functions directly associated with all remotely controlled plant items. It shall also
incorporate all necessary interlocks, initiations and trip functions for starting and stopping a
main drive motor.
2.4.1.1
Control at this level shall either be initiated directly from the remote manual control
interface or automatically by the next hierarchical level.
2.4.2
Subgroup Level
2.4.2.1
The second level shall coordinate the control of all first level drives, both closed loop
and open loop, associated with a particular functional subgroup. In the case of a pump
subgroup, for instance, the permissive checks, the coordination of the operation of the
suction and discharge valves, the main drive initiations and the basic modulating control
loops shall be executed at this control level. The major monitoring functions (e.g. turbine
supervisory measurements) shall also be identified with this level.
2.4.2.2
Typical control functions associated with this level are:

(i)
Auto- Start and stop initiation or set point guidance from the next higher control
level.
(ii)
Start-stop- Normal initiation of the auxiliary start and stop sequence.

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(iii)
Auto Standby-Start initiation in the event of duty item failure.
2.4.2.3
A functional group consists of different units, which individually represent and control a
part of the complete plant and can be divided into two or more groups. Every sub group
is controlled by an independent sub group control, which controls the operation of
various drives. Once a start signal issued by a functional group, the sub group control
brings the sub group from one state into another operating condition by issuing
command signals in a programmed sequence. It brings the sub group from a shut down
state into a working condition and vice-versa. The functional group instrumentation and
control system co-ordinates the entire sub group controls belonging to one functional
group.
2.4.3
Group Level
2.4.3.1
The third and penultimate level shall coordinate the individual subgroup control function
(both modulating and sequence controls) within the main functional groups of the system.
2.4.3.2
The group co-ordinate the sub group of a functional group. Its main function is to deliver
start-up or shutdown command signals to the sub-group and change over from a faulty
subgroup to the reserve sub group, the group co-ordination control supervises the actual
and the required position of the switchgear in the sub group and then decides whether
the sub group shall be switched ON or OFF..
2.4.3.3
The aforesaid concept of functional group control is independent of the control

techniques-freely programmable.
2.4.4
Unit Co-Ordination Level
2.4.4.1
The fourth level, which stands at the apex of the hierarchical triangle, shall perform the
overall unit coordination. It shall incorporate, for example, the master load control
function which should regulate the load generated by the generator to the demand set
point value. In general for automatic start-up and shutdown control, the sequential
initiations of the functional group sequences should be generated at this level.
2.4.4.2
The typical sequence control functions to be implemented at this level would include:
(a)
The sequential initiation of the subordinate functional group sequences for

automatic start up and shutdown.
(b)
The sequential initiation of the subordinate functional group sequences for

automatic start up and shutdown of a part/full.
(c)
The sequential transition to the various combination of subordinate functional

groups.
ISSUE
R1
TCE FORM 329 R5

346

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 5 OF 55

REQUIREMENTS
2.4.4.3
The modulating control functions to be implemented at this level would include the
following:
(a)
Unit load control with frequency regulation incorporating load balancing (remote
set point adjustment from the CCR shall be provided).
(b)
Station load demand and demand rate limiting.
2.4.4.4
In general the operator shall have direct access to all four control levels where these are
identified, through the operator control interface located in the LCR.
2.4.4.5
Communication links shall be provided between the various control systems to allow for
access to the system from any of the operators interface stations.
2.5
CONTROL SYSTEM-LEVEL OF AUTOMATION
2.5.1
The unit control and monitoring shall be performed from unit control room by means of
an CRT operation interface mounted on unit control desk, through a microprocessor
based distributed Digital control monitoring and information system.
2.5.2
The unit shall be remotely controlled, but a fully automatic system of the plant shall be
provided, i.e. all valves, motors, final control elements and other equipment that have to
be operated during start up, operation and shut down, belonging to the Main Systems,
shall be remotely controllable from unit control room by the operator through Distributed
digital control monitoring and Information system.
2.5.3
Subordinated drives belonging to one main aggregate shall be managed by means by

sub group control systems. Automatic open/closed loop controls shall be installed
wherever it is possible to lighten the work of the operation.
3.0
CLOSED LOOP CONTROL SYSTEM (CLCS)
3.1
The CLCS shall control the process variables automatically both under steady state and
dynamic conditions with in the limits specified under guarantee clauses over the entire
operational range of the equipment/system.
3.2
The CLCS shall have the following features:

(a)
Provision of predictive and/or adaptive controls in addition to PID controls as

required by the system like Super-heater control, Re-heater control, etc.
(b)
Set point adjustments and indication from operating CRTs for process variables
which need to be changed during load changes, start-up, shutdown, normal or
under any other emergency conditions.
(c)
Fixed set point at the software level/hardware level (only changeable by the
ISSUE
R1
TCE FORM 329 R5

347

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 6 OF 55

REQUIREMENTS
maintenance engineer) and indication for those process variables which need not
be changed with respect to load or otherwise.
(d)
Bias adjustment with indication where a single controller is controlling more than
one final control element (control valve, control damper, speed drive etc.) to
maintain the same process variable.
(e)
Auto and manual control facility shall be transferable in both directions without
bump of the value of the process variable to control the parameter during manual
operation. Both master Auto Manual station and Auto / Manual station for
individual control element shall be provided in CRTs. Manual control facility will
include operation from Back Up Control Panel also in addition to operation from
operator station.
(f)
Characterisation of final control element to suit the various applications with

respect to load or otherwise as dictated by the process.
(g)
Function generator to provide necessary characterisation or variation of set points

with respect to load, speed or any other requirement.
(h)
Soft Auto /Manual station interlocks to drive the final control elements to a
suitable position for safe plant operation in the event of process/equipment
abnormal conditions.
(i)
Blocking/Interlocking function as dictated by process/equipment.
(j)
Monitoring of loop failures or any hardware failure in the loops.
(k)
Fail safe operation of final control elements in case of failure of motive power or
signal.
4.0
OPEN LOOP CONTROL SYSTEM (OLCS)
4.1
Protection, interlock and sequence controls constitute OLCS. This system shall enable
the operator for safe start up and shutdown and carryout normal operation both from
control room and local areas. Protection and Interlock shall be provided for all the
equipment and system to safeguard the equipment against abnormal conditions which
may result in the failure and less utility of the equipment and protect the operating
personnel. Controls shall be provided to start/shutdown various systems and/or any
equipment with associated auxiliaries and to operate the Unit on line with optimum
number of operations and higher safety.
4.2
The OLCS shall have the following features as a minimum:
4.2.1
Features-General Requirements
ISSUE
R1
TCE FORM 329 R5

348

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 7 OF 55

REQUIREMENTS
4.2.2
4.2.3
(a)
The logic and sequence control shall be Digital distributed microprocessor based
and programmable.
(b)
Enable the operator to start/stop various unidirectional motors, to open/close

various valves and dampers and carry out inching operation of bypass valves or
any other similar equipment both from control room and local areas.
(c)
The system shall be designed based on the philosophy of command to energise a

relay or solenoid valve.
(d)
Where there is more than one pump or fan for the same service (say 2 pumps),
auto standby features shall be provided to select the standby unit and this
standby unit shall start automatically on failure of running pump or on applicable
process criteria (say low discharge pressure) with an annunciation.
(e)
All the contacts of the sensors used in protection circuit shall be monitored.
(f)
Triple redundant sensors shall be provided when used in protection circuits for
major critical equipment and 2 out of 3 logic shall be derived for further use in
protection circuit
Features-Interlock Requirements
(a)
Permissive conditions for a equipment start shall be provided. The permissive

conditions within the equipment are bearing temperature normal, winding
temperature normal, adequate suction pressure, bearing vibrations normal,
bearing lubrication oil pressure normal, switchgear in service, switchgear not in
test, no protection trip command persisting (as applicable) etc.
(b)
The permissive conditions from a process system related equipment are

establishment of free path for the flowing medium under all start-up, emergency
and shutdown conditions, closure of discharge valve for the starting of first of the
identical pumps/fans and then opening the valve after the operating condition is
established etc.
(c)
Selection of standby equipment and starting the equipment automatically on the

tripping of running equipment and/or desired process parameter conditions (say
loss of discharge pressure or low level in the discharge tank etc.)
(d)
Isolation of the tripped equipment from the main process.
(e)
Any other conditions for safe starting and shutting down the equipment.
Features-Sequence Control Requirements

ISSUE
R1
TCE FORM 329 R5

349

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 8 OF 55

REQUIREMENTS
Sequence control shall be provided to start and stop the equipment and the associated
auxiliaries. The sequence control shall have the following features:
4.2.4
(a)
Once the start-up or shutdown of an equipment is initiated either manually or

automatically from the system, the control of associated auxiliaries shall be
automatic with facility for manual operation at each stage (step).
(b)
Criteria check up for each stage of operation with monitoring and displaying.
(c)
Bypass facility for each criteria when only the feedback signal/display is incorrect
but the actual condition is fulfilled. This activity shall be logged and annunciated
in control system (DCS/PLC).
(d)
Adequate time delay between the steps as dictated by the process to establish
an operating parameter or healthiness of an equipment.
(e)
Normally, the auxiliaries of the standby equipment should be running (as

applicable) so that the standby equipment is started without loss of time.
Features-Protection Control Requirements

The following minimum protection shall be provided for the various equipment/system as
applicable to trip the equipment.
(a)
Any condition which endangers the safety of the plant personnel
(b)
Any of the permissive conditions becoming abnormal thereby producing a

dangerous condition in operating the equipment.
(c)
The conditions from process such as dry flow conditions, flashing conditions or
any other conditions that may create cavitation.
5.0
SPECIFIC INSTRUMENTATION REQUIREMENTS FOR STEAM GENERATOR
5.1
Redundant speed sensor shall be provided with each coal feeder and shall provide an
output to the feeder speed control. All feeder speed sensor tachometer-feedback circuits
shall be suitably shielded from any electrical and mechanical interference.
5.2
A no-coal flow detector complete with amplifier and pick-up located at the outlet of each
coal feeder shall be provided to detect no-coal flow.
5.3
Coal flow measurement with the help of conveyor speed and active load cells shall be
provided for each feeder. The coal flow rate along with the integrator shall be made
available in plant DCS.
ISSUE
R1
TCE FORM 329 R5

350

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 12 OF 55

REQUIREMENTS
7.5
The Contractor shall submit a brief write up on CLCS function for all SG, TG and
balance of plant controls along with the bid.
8.0
OPEN LOOP CONTROL SYSTEM FOR SG & TG AND ITS AUXILIARIES
8.1
The open loop controls shall be provided as per system requirement.
8.2
The open loop control system shall be provided as per the guidelines given under
clause 4.0 of this section.
8.3
The Contractor shall submit a brief write up on OLCS function for all SG, TG and
balance of plant controls along with the bid.
9.0
REDUNDANCY AND AVAILABILITY REQUIREMENTS
9.1
Measurement system (MS), Closed Loop Control System (CLCS) and Open Loop
Control System (OLCS) shall all be configured with redundancy at processor modules,
communication modules, data bus and power supply modules.
9.2
Both CLCS & OLCS shall be configured with Redundant I/O channels for each
sensor/signals. Where redundant sensors are provided redundant I/O channels shall be
provided for each sensors/signals. (For eg. If two sensors are provided for a particular
service, then totally 4 input channels are required.). All the outputs from the CLCS and
OLCS shall be dual redundant.
.
9.3
Boiler protection system & Turbine Protection system shall be with SIL3 certification for
each unit.
9.4
Redundant sensors shall be provided for all control applications.
9.5
For all important and critical controls (CLCS) triple redundant sensors shall be provided.
This will include sensors provided for compensation also. Similarly for critical protection
logic requirements triple redundant sensors for 2 out of 3 logic shall be provided to avoid
spurious tripping. For all other control application dual redundant sensors shall be
provided. Critical closed loop controls are detailed in Clause 12.0 of this section.
10.0
SENSOR REDUNDANCY- PHILOSOPHY
10.1
Two out of three measurements philosophy shall be adopted for the control of all critical
closed and open loop variables for reliability of operation. The control system shall
select the median value for the normal control purpose.
10.2
In case of deviation of one transmitter output from the other two, the same shall be
automatically isolated and average output of the remaining transmitters shall be fed to
the control and measurement system and the control loop in this case shall be
ISSUE
R1
TCE FORM 329 R5

351

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 13 OF 55

REQUIREMENTS
maintained on auto, with an alarm on the operators monitor as well as maintenance

engineers monitor. In case of failure of the two remaining transmitters in circuit,
deviation of one transmitter output is more than the preset limit compared to the other
transmitter, there shall be automatic bump less transfer and changeovers shall have
suitable alarms.
10.3
For all other control parameters the number of sensors / transmitters shall be two. One
out of two selection logic and selection of average value of the two signals shall be
followed.
10.4
In the event of excessive deviation between two signals control system shall trip to
manual and it shall be annunciated to bring operators attention and operator has facility
to select any of the transmitters through VDU operation.
10.5
In the event of failure of one of the two transmitters, it shall automatically select a
healthy transmitter but control system shall remain in auto mode.
10.6
Separate transmitters shall be used for measurement avoiding signal tapping from
control loop/ control transmitter.
10.7
For signal compensations, separate signals from separate transmitters shall be used for
measurement and control.
10.8
Sensor Redundancy For OLCS
10.8.1
All sensors for the following causes of trips shall be triple.
10.8.2
10.8.3
(a)
Unit trips,
(b)
Boiler trips,
(c)
Turbine trips
(d)
Trip of any auxiliary which will lead to substantial (50%) loss of unit availability.
All sensors for the following causes of trips shall be dual (requirement specified at
Clause 10.8.1 will have priority of application).
(a)
All HT equipment trips.
(b)
All LT equipment trips.
Single sensors shall be provided for the following:

(a)
Alarm
ISSUE
R1
TCE FORM 329 R5

352

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.3
SHEET 14 OF 55

REQUIREMENTS
(b)
Permissive
(c)
Measurement
10.9
Sensor Redundancy For CLCS
11.0
CONTROLS INCLUDED IN DCS
11.1
Steam Generators (SG) soot blowing controls, Fans, blowers (if applicable) controls for
boiler and auxiliaries. All SG closed loop controls like combustion control (fuel flow / air
flow), temperature & pressure, air flow, SA/PA pressure, SH/ RH steam temperature,
furnace draft, drum level (if applicable) etc..
11.2
All turbine analog controls including EHTC for TD BFP(except turbine integral system
analog controls)
11.3
Co-ordinated Master Control
11.4
Regenerative cycle controls like heater drain, deaerator level, deaerator pressure,
hotwell level, CEP controls, BFP controls, Hotwell makeup, Vacuum Bkr.vlv gland seal
water pressure control.
11.5
Balance of plant controls like auxiliary steam, CW & Circulating cooling water system,
Emergency cooling water system (if applicable), etc.
12.0
CRITICAL CONTROL LOOPS

Following CLCS loops are considered critical, for which triple redundant sensors shall
be provided for all involved parameters involved in the loop. Parameters involved will
also include parameters used for compensation. For the balance control loops, only dual
redundant sensors shall be provided.
(a)
Furnace draft
(b)
PA Flow Control,
(c)
SA Pressure control
(d)
SA Flow control
(e)
O2 correction control
(f)
Steam Temperature Control
(g)
Turbine Governor control

ISSUE
R1
TCE FORM 329 R5

353
PLC
PLC
354
PLC
PLC
355
PLC
PLC
356
PLC
PLC
357
PLC
PLC
358

)250123(0
63(&,),&$7,2112PE-SS-999-145-I007
SPECIFICATION
FOR
MOTORISED VALVE ACTUATOR
92/80(,,
%
6(&7,21'
5(912

6+((7
2)
'$7(

Data Sheet A & B

'$7$6+((7$

'$7$6+((7%
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GENERAL*
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)250123(0
63(&,),&$7,2112PE-SS-999-145-I007
SPECIFICATION
FOR
92/80(,,
%
6(&7,21'
5(912

6+((7
2)
'$7(

Data Sheet A & B

'$7$6+((7$

'$7$6+((7%
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)250123(0
63(&,),&$7,2112PE-SS-999-145-I007
SPECIFICATION
FOR
92/80(,,
%
6(&7,21'
5(912

6+((7
2)
'$7(

Data Sheet A & B

'$7$6+((7$

'$7$6+((7%
72%(),//('83%<%,''(5
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TRANSMITTER
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NOTES

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PREPARED BY
CHECKED BY
APPROVED BY
VENDOR COMPANY SEAL
1$0(
0$0D
3DD-D
6.'DD
1$0(
6,*1$785(
6,*1$785(
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127(6 72%(),//('%<03//($'$*(1&<# 72%(),//('%<(668%-(&772$33529$/2)'5,9(&21752/3+,/2623+<
361
362
NOTE: THE WIRING DIAGRAM SHALL BE MODIFIED FOR LIMIT SWITCHES & TORQUE SWITCHES FOR 4 NO + 4 NC CONTACTS
4 NO + 4 NC
4 NO + 4 NC
4 NO + 4 NC
4 NO + 4 NC

2.6.0
CODES AND STANDARDS

363

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SECTION :TABLE 5

Package: EPC
SHEET 1 OF 1

CODES AND STANDARDS
Instrumentation Symbols and identification.

Binary Logic Diagrams for Process Operation
Graphic symbols for DCS, shared display inst. logic & Comp. System
Annunciator sequences and spec.
Environmental Conditions
Control Valve Sizing
Control Valve Procedure Capacity Test
Uniform Face Two Face Dimensions for Flanged Globe Style CV Bodies
Diagrams, Charts, Tables
Industrial Process Control Valves
Graphical Symbols for Diagrams, Binary Logic Elements
Operating Conditions for Industrial Process Meas. & Control Equipment.
Electromagnetic Compatibility for Industrial Process Measurement
Preparation of Function Chart for Control System
Industrial Measurement & Control Terms & definition
Vibration, Axial Position & Bearing Temperature Monitoring Systems
Plain End Steel Tubes, Welded & Seamless General Table Dimensions
& Masses / Length
Measurement of Fluid Flow by Means of Orifice Plates & Nozzles
Pipe Threads
Quality Control Standard for Control
Valves Seat Leakage
Thermocouples
Measurement & Control, Electrical sensors, Elec. Position sensors & Sig.
Converters for IS two wire DC systems.
Industrial Platinum. RTD
Air Purge System
Measurement of Fluid Flow by Meter Run
Temperature Measurement
Degree of Protection by Enclosure
Electrical Apparatus for Explosive Gas
Standards for Cables
Process control security requirements
ISA S 5.1
ISA S 5.2
ISA S 5.3
ISA S 18.1
ISA S 71.04
ISA S 75.01
ISA S 75.02
ISA S 75.03
IEC 113
IEC 534
IEC 617-12
IEC 654
IEC 801
IEC 848
IEC 902
API 670
ISO 4200
ISO 5167
ANSI B 2.1
ANSI FCI 70.02
ANSI B 16.104
ISA MC 96.1 /
ASTM E 23003/DIN 43710/IEC
60584
DIN 19243
DIN 43760/ IEC
751
ISA S 12.4 / NFPA
496
ISO 5167
ANSI MC 96.1 /
IEC 751
IEC 529
IEC
IEC
IEC 62443
ISSUE
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364

3.0.0
QUALITY ASSURANCE, QUALITY PLANS,

INSPECTION & TESTING PROCEDURE

365
SPECIFIC TECHNICAL REQUIREMENT

SPEC.NO.
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VOLUME V
SECTION : TABLE14

SHEET 1 OF 13
Package: EPC

EQUIPMENT
TESTS
PART-A: TESTS FOR I&C EQUIPMENT
SL. NO
INSTRUMENT /
EQUIPMENT
TESTS TO BE CONDUCTED
1.
Pressure indicators
Calibration Hydro test (1.5 times max. Pr.)
2.
Pressure switches
Calibration test /Hydro test/Contact rating test/ Accuracy test

/ Repeatability Test
3.
Pressure
Transmitters
Calibration test /Hydro test/Leak test/Over range test /

Accuracy test /Repeatability test.
4.
Differential Pressure
Indicators
Calibration test /Hydro test/Leak test/Over range test /

Accuracy test/Repeatability test.
5.
Switches
Calibration test /Hydro test/Leak test/Over range test/

6.
Transmitters
Calibration test /Hydro test/Leak test/Over range test/

7.
Thermometers
Calibration test /Material test//Accuracy test/Bore

concentricity : 5% of wall thick/Hydrostatic test for TW (1.5
times max. pr.).
8.
Temperature switch
Calibration test/Material test//Accuracy test/Bore

concentricity : 1.5% of wall thick/Hydrostatic test for TW (1.5
times max. pr.)/Contact rating test.
9.
Resistance
temperature detector
assembly
Calibration/Material test/Accuracy test/Bore concentricity

test/Insulation test (<500 M at 500 V, DC) as per ISA, Hydro
test for TW.(1.5 times max. pr.). Bore concentricity : 5% of
wall thick, Accuracy test
10.
Thermocouple
assembly
Calibration/Material test/Insulation test (<500 at 500 V, DC)

as per ISA, Hydro static test for TW.(1.5 times max. pr.)
More concentricity 5% of wall thick
11.
Temperature
transmitters
Calibration test/Accuracy test/Ambient temperature error test
12.
Thermowells
Material test /Bore concentricity : 5% of wall thick/

Hydrostatic test for TW (1.5 times max.pr)
ISSUE
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EQUIPMENT
TESTS
SL. NO
13.
INSTRUMENT /
EQUIPMENT
Interposing relay
14.
Level gauges
Hydrostatic test/Material test/Seat leakage test / Ball check

test
15.
Level switches
(magnetic)
Material test/Contact rating test/Hydro test / Calibration test
16.
Level gauges (Probe)
Material test /Contact rating test /Hydro test / Calibration test
17.
Flow switch
Material test / Hydro test/ (1.5 time max. pr) / function test
18.
Flow glasses
Material test /Hydro test/ (1.5 time max. pr) / function test
19.
Variable are flow

metes
Calibration test / Material test / Hydrostatic test (1.5 time

max. pr)
20.
Flow element
100% Radiography test / Hydro test / Calibration test / IBR

certificate
21.
Control valves
(a)
(b)
Functional test/temperature rise test/high voltage test/ limits

of operation test/insulation test.
(c)
(d)
(e)
(f)
(g)
IBR certificate Form III C

Hydrostatic test : IBR/MSS-SP-61/ANSI B 16.34
(Note 1)
Seat leakage test : As per ANSI B 16-104 (Note-1)
CV test : As per ISA procedure (Note 1)
Magnetic particle test : As per ANSI B 16.34 special
class (applicable for pr.> 70 bar & tem < 4000C
Liquid penetration test : As per ANSI B 16.34
special class (applicable for pr > 70 bar & temp <
4000C
Calibration and Hysteresis test (Note-1)
NOTE-1: These tests shall be witnessed by PURCHASER /

CONSULTANT
22.
Pneumatic Block
Valves:
(a)
(b)
(c)
(d)
Hydrostatic test : ANSI B 16.34 (Note 1)

ISSUE
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EQUIPMENT
TESTS
SL. NO
INSTRUMENT /
EQUIPMENT
(e)
(f)
(g)
(h)
(i)

4000C
Radiography test : As per ANSI B 16.34 special
class
Actuator leakage test (Note-1)
Note-1: These tests shall be witnessed by PURCHASER /

CONSULTANT
23.
Pressure Regulating
Valves
(a)
(b)
(c)
(d)
(e)
Hydrostatic test : ANSI B 16.34 (Note 1)

4000C
Radiography test : As per ANSI B 16.34 special
class
Actuator leakage test (Note-1)
(f)
(g)
(h)
(i)
Note-1: These tests shall be witnessed by PURCHASER /

CONSULTANT
24.
Position Transmitters
Calibration/ Hysteresis and Accuracy test
25.
I/P Converters
Calibration test/Accuracy Test
26.
Solenoid Valves
Hydro test/Seat leakage test/CV test/Coil insulation test
27.
Air Filter Regulators
Calibration test/Accuracy test
28.
Junction Boxes
Test for degree of protection/Material test
ISSUE
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EQUIPMENT
TESTS
SL. NO
29.
INSTRUMENT /
EQUIPMENT
Transmitter Racks
30.
Transmitter Racks
Verification of degree or protection. Test for enclosure type,

Type tests & routine tests as per relevant Indian standards.
31.
Compensating cable
Thermo-emf characteristic/Continuity test/Measurement on

capacitance, inductance and loop resistance / insulation
resistance /high voltage test as per latest IS/Tensile and
elongation test/Oxygen index test /Any other test applicable
32.
Local Panels
Verification of degree of protection / Electrical tests as

detailed under Wiring, Terminations & Accessories/Type
tests & routine tests as per relevant Indian standards.
33.
Marshalling Cabinets

34.
System cabinets

35.
Wiring Termination
and Accessories
35.1
Routine test
Conductor resistance test (*) / High voltage test (*)/Impulse

dielectric test/Insulation test/Humidity test/Temperature rise
tests on power circuits/Short time current tests on power
circuits.
35.2
Type test
Annealing test (*) / Test for insulation and sheath (*)/Flame

retardance test (a) Oxygen index, (b) Flammability/Test for
acid gas generation/Test for water absorption (*)/Wet
dielectric test.
Note (*) As per IS-1554
35.3
Test for terminal

blocks
Test for moulding for flame resistant, Non-hygroscopic and

Decarbonised / Insulation test between terminals / Insulation
between terminal block and frame
Hydro test, Air leak test for tubing/Piping & fittings, IBR
certificate required for impulse pipes, tubes and fittings of all
steam & water services
ISSUE
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EQUIPMENT
TESTS
SL. NO
INSTRUMENT /
EQUIPMENT
36
DCS / PLC SYSTEM
36.1
Measurement &
Control System
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
Simulated Functional test for the complete system

(As per FAT procedure. Note-1)
System performance & tests for monitoring
functions (As per FAT procedure. Note-1)
Surge withstand capability test as per ANSI C37.9A
/ IEEE 4721 BE MMA 219 or equivalent.
Damp heat cycling test as per is 2106, part 1I- 1962
or equivalent.
Dielectric strength test (high pot tests as per NEMA
ICSI. part ICS-109) ANSI C39.51/UL 508 or
equivalent,
Radio frequency interference test as per SAMA
PMC 33.1 or equivalent.
Immunity to noise test as per IEEE SWC test 587 or
equivalent.
Burn in test & temperature rise test for 120 hrs.
Continuity test & short circuit test for current limiters.
Under voltage and over voltage test (Note-1).
Note-1: Test to be witnessed by Owner or Owners

representative.
36.2
Data bus system
(a)
(b)
(c)
Functional test for the complete system (Both

hardware & software) simulating worst condition (As
per FAT procedure. Note-1).
Noise test-surge withstand capability test as per
IEEE or equivalent.
Quality assurance and tests shall be as per latest
BS-5750 and ESS-1980 or equivalent.

representative.
36.3
Central Processing
Unit for Man Machine
Interface
(a)
(b)
Main memory test of 12 hours duration to

demonstrate the capability of memory Read-Write
function under worst pattern at various voltage
levels
Main memory parity detection test of 12 hours
ISSUE
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EQUIPMENT
TESTS
SL. NO
INSTRUMENT /
EQUIPMENT
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
duration to demonstrate that parity detection feature

performs properly to the Owners satisfaction
Logic tests for 12 hours duration to demonstrate the
hardware commands, interrupt structures and
hardware failure detection
Count down registers and pulse counter test of 8
hours duration to demonstrate the accuracy of all
time count down registers
Bulk memory Data transfer test of 36 hours duration
to demonstrate possible combinations of transfer
from/to bulk memory including checks for illegal
writing, reading and wrong transfer indications
Voltage and speed variation checks
Bulk memory parity detection test of 12 hours
duration to demonstrate the proper functioning of
parity detection feature
Functional test for complete system (Both hardware
and software) simulating worst conditions (As per
FAT procedure. Note-1).
Noise test-surge withstand capability test as per
IEEE or equivalent.
Quality assurance and tests shall be as per latest
BS-5750 and ESS-1980 or equivalent.
Design, construction, components, materials,
finishes and testing of electronic equipment as per
EES - 1980 (General specification of electronic
equipment) or equivalent.

representative.
37
Colour Graphic Video

Display Unit (VDU)
(a)
Functional tests (As per FAT procedure. Note-1).
(b)
Test for capabilities of VDU including error detection

for the complete system (Both Hardware &
Software) simulating worst conditions
Noise test
Surge withstanding capacity as per IEEE or
equivalent
Quality assurance as governed by BS 5750 or
equivalent.
(c)
(d)
(e)
ISSUE
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EQUIPMENT
TESTS
SL. NO
INSTRUMENT /
EQUIPMENT
(f)
Design, construction, components, finishes and

testing of electronic equipment as per EES-1980
(General specification of electronic equipment) or
equivalent.

representative.
38
Keyboard
(a)
(b)
(c)
Test for satisfactory operation of keyboard controls,

push buttons and all associated functions (As per
FAT procedure. Note-1).
Quality assurance as governed By BS5750 or
equivalent for functional test for the complete
system simulating worst conditions
Design, construction, components Materials finishes
and testing of electronic equipment as per EES1980 (General specification for electronic
equipment) or equivalent

representative.
39
Printers
(a)
(b)
(c)
(d)
40
Floppy/Tape Drive
Unit / Bulk Memory
Unit / CD drive Unit /
DAT Drive
Noise level test for the printer

Test of interlock performance and error detection
feature,
equivalent
equivalent
(a)
Noise test
(b)
Surge withstanding capacity as per IEEE or

equivalent
equivalent
(c)
(d)
ISSUE
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EQUIPMENT
TESTS
SL. NO
INSTRUMENT /
EQUIPMENT
(e)
41
Vibration Monitoring
& Analysis System

equivalent
Test of Control unit and drive for all features, Date
checking features.
(a)
Simulated Functional test (Note-1)
(b)
Tests for Server, VDU, Printer, Keyboard

representative.
42
Flame Monitoring &

Analysis System
(a)
(b)

representative.
43
PADO System
(a)
(b)


representative.
44
CMMS System
(a)
(b)


representative.
45
MIS System
(a)
(b)


representative.
46
Boiler Tube Leak

Detection System
(a)
(b)
ISSUE
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EQUIPMENT
TESTS
SL. NO
INSTRUMENT /
EQUIPMENT

representative.
47
Smart Transmitter
Maintenance Station
(a)
(b)

representative.
48
Smart Soot Blower

Control
(a)
(b)

representative.
ISSUE
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EQUIPMENT
TESTS
PART-B: GUIDELINES FOR FACTORY ACCEPTANCE TEST (FAT) FOR DCS/ PLC
1
GENERAL REQUIREMENTS
Factory acceptance test (Fat) procedure : Ref. Note -1 & 2
TEST REQUIREMENTS
(a)
Test shall be performed with the completely assembled system and also
with complete i&c software and performing all functions expected out while
in actual service and with system configuration as finalised.
(b)
Process input / output conditions and other load on the system to be

stimulated either by hardware / software.
(c)
All system software & application software to be loaded and operational on

the system prior to fat refer relevant sections.
TEST DOCUMENTS / DRAWINGS

(a)
(b)
Total system configuration drawings

Fat procedure consisting of :
(i)
Test equipment
(ii)
Test environment
(iii)
Test configuration
(iv) Test procedure
(v)
Test schedule
(vi) Test venue
(vii) Test reports- specimen copies
(c)
Function design specification for each equipment / system
PRELIMINARY CHECKS
(a)
(b)
(c)
(d)
(e)
(f)
(g)
General appearance check & bill of mateirals check

Construction check as per over all general arrangement drawings
Dimensional check
Labelling, terminal arrangement and equipment identification check
Power supply voltage level check & power 'leds - on check
Cooling fan operation check
Grounding network check
SYSTEM HARDWARE CHECKS
ISSUE
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EQUIPMENT
TESTS
(a)
(b)
(c)
(d)
(e)
(f)
6
CONTROLLER ENGINEER FUNCTIONAL CHECK

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)
(q)
(r)
(s)
(t)
(u)
(v)
(w)
(x)
(y)
Power supply under voltage and over voltage check ( 10%)

Processor & main data bus network redundancy check ,
Communication coupler redundancy check
Communication module of the controller to network redundancy check,
Power supply redundancy check
Hardware on-line maintainability check ,
Closed loop control simulation check

Open loop control simulation check
Control loop response check
Bump less auto manual transfer check
VDU graphic overview check
VDU- trend check
VDU- real time trend check
VDU- mimics check
VDU- check for operating control directly from mimics
VDU- analog control display check
VDU- sequence control display check
VDU- operator guidence message check
VDU/ backpanel operation priority check
VDU- alarm management function check
VDU logging function check
VDU / response / updating check
Keyboard lock function check
VDU interchangebility & assignability check
Printer assignability & back-up function check
Floppy disk / compact disk / optical disk unit storage & retrieval check
VDU assignability check for hard copier function
Plant performance calculation check
Communication interface to others system simulation check
Ser interface data dump function check
Data bus distance building check (refer note- 3)
MAINTENANCE ENGINEER FUNCTION CHECK

(a)
(b)
(c)
(d)
(e)
(f)
Graphic display building function check

Closed loop control system modification check
Open loop control system modification check
Alarm display prioritisation check
System security check
System alarm check
ISSUE
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Package: EPC

EQUIPMENT
TESTS
(g)
(h)
(i)
(j)
8
SYSTEM PERFORMANCE REQUIREMENTS

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
System diagnostic function check

Point detail configuration check
Control loop tuning check
System self documentation check
System response time

Controller responsiveness
Input off - normal detection responsiveness
Operator crt responsiveness
Command initiation
Command formatting
Command execution and data display for monitoring
Printer responsiveness
System accuracy requirements
AUTHORISATION TO SHIP TEST

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
Includes all features of operation tests

Simulation of inputs / outputs: to verify conversion accuracy, scan rates,
operator panel functions, correctness of calculations.
Operation test : to verify that the system performs all operations specified
Power consumption test
Power failure test : to observe the consequence of total power failure
Accuracy and repeatability test :
Function test :
Format test : to verify printouts and display formats
Manual & auto switch over from master to standby
All disgnostic and s/w debug tests shall be performed in the presence of
the owner / project manager / consultant representative with the system
fully assembled and all parts interconnected together with simulated anolog
/ digital inputs.
Surge withstand capacity test as per relevant standard
Management information system function check
NOTES:
1
The intent of the fat is to demonstrate and ensure that the I&C system meets all
the functional requirements as intended in the specification / contract. A
completed integrated test of the system shall be carried out at vendor's works
in the presence of owner / project manager / consultant, on completion of
integration/manufacturing of the system. The shipment of i&c equipment to site
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EQUIPMENT
TESTS
will be effected only after the fat has been accepted by the owner / project
manager / consultant.
2
Fat procedure shall be prepared by vendor and to be submitted for owner /

project managers / consultant's approval well in advance prior to the
commencement of fat
Fat shall be conducted with the distance between the processor and other
supporting peripherals as per the final layout in the control room.
Duration of fat shall be minimum three (3) weeks. the fat procedure shall be
subject to owner / project managers approval.
For closed loop controls vendor shall also demonstrate the performance using
simulation software to cover the relative performance of the boiler parameters
and turbine parameters.
During the course of fabrication the owner / project manager shall have access
to the plant for inspection. at all times, the owner / project manager / consultant
shall have the right to inspect for quality control.
Preshipment inspection
The complete system shall be examined at the factory for workmanship,
assembly and fat, mechanical safety, materials, wiring, connections, parts, finish,
operation and strict conformance to this specification and approved design
layouts and detail drawings . All tests including functional tests shall be
conducted as per is and this specification.
ISSUE
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SPEC.NO.
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Package: EPC
VOLUME V
SECTION : D5.5
SHEET 1 OF 5

TESTS AND INSPECTION
1.0
TESTS AND INSPECTION FOR INSTRUMENTS
1.1
After Manufacturing, all instruments shall be tested and calibrated at Factory.

CONTRACTOR shall be responsible in obtaining test certificates related to
calibration of all the Instruments and submit for Owner/Engineers approval.
CONTRACTOR shall allow despatch of these instruments only after passing
applicable Factory Acceptance test and approved by Owner/Engineer. The details of
the tests to be carried out for the different instruments / field equipments/ Systems
shall be as indicated in the TABLE-14 and any other tests as required by the
Standards and Codes.
2.0
TESTS AND INSPECTION FOR DCS/PLC
2.1
Tests for DCS/PLC system will include the following:

(a)
Factory Acceptance Test (FAT):

To be carried out at DCS/PLC system CONTRACTORs / Sub-Vendors
works and witnessed by Owner/Engineer, successful completion of which
will be the basis for Authorisation for Shipment to Site. FAT shall be
preceded by a pre-FAT inspection/test by Vendor.
(b)
Site Acceptance Test (SAT):

Involves tests for site commissioning, guarantee tests for system
performance & availability to be conducted in the presence of Owner.
2.2
Factory Acceptance Test (FAT)
2.2.1
FAT shall be a complete integrated test of the DCS/PLC system and carried out at
CONTRACTORs / Sub-Vendors works on completion of manufacturing of the
system. The test shall be performed with the completely assembled system and
performing all the functions, it is expected to perform while in actual service. The
various tests to be performed for DCS/PLC system equipment / total system
together with the guideline for Factory acceptance test (FAT) procedure are detailed
in TABLE-14. The CONTRACTOR shall submit a detailed "Factory Acceptance Test
Procedure" in line with the above specified guidelines for Owner / Consultant
approval.
2.2.2
FAT shall be preceded by a Pre- FAT Inspection/ Test to be carried out by

Contractor/ Vendor. Pre-FAT inspection / test shall be carried out as per approved
FAT procedure detailed above and shall submit Pre- FAT Inspection/ Test report for
Owner/Consultants review and approval. Owner/ Consultant shall witness the actual
FAT on the basis of successful completion of Pre- FAT Inspection/ Test.
ISSUE
R1
TCE FORM 329 R5

379

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.5
SHEET 2 OF 5

2.3
Site Acceptance Test (SAT)
2.3.1
Tests to be conducted at site will involve the following:

(a)
Site Pre-commissioning Tests comprising the following to be conducted by

Contractor at site:
(i)
Calibration of monitoring and control equipment
(ii)
Integrated loop test wiring, Simulation input from site
(b)
Trial Operation of the DCS/PLC system functioning.
(c)
Performance Guarantee Test for I&C systems
(d)
Availability Guarantee Test for DCS system
3.0
Trial Operation Of The DCS/PLC System
3.1
Trial operation test of DCS/PLC system shall be conducted on completion of

installation as per specification requirements, checking and satisfactory precommissioning tests detailed at 2.3.1 (a) above.
3.2
Test shall be conducted at site by Contractors personnel in the presence of the

Owner / Consultant.
3.3
Test shall be a Total Integration Test of the whole DCS/PLC System including the
testing of communication links.
3.4
Test duration shall be of 14 days out of which 72 hours shall be continuous

operation performing all the specified functions.
3.5
The trial operation shall be considered successful provided that each item of
equipment can operate continuously at the specified characteristics for the period of
trial operations. During this period, any modifications / repairs as required shall be
carried out. If the total interruption period (outage time) is more than 4 hours, the trial
operation duration shall be extended by the period of interruption.
3.6
Total interruption period (system outage time) shall be calculated as detailed in 5.4
below.
4.0
PERFORMANCE GUARANTEE TEST FOR I&C SYSTEM
4.1
After successful trial operation, the OWNER shall conduct performance guarantee
test for a period of 14 days in the presence of CONTRACTORs commissioning
engineer. During the test, the system shall run with 100% availability. Contractor
ISSUE
R1
TCE FORM 329 R5

380

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.5
SHEET 3 OF 5

shall also furnish the guaranteed process parameters and the acceptable deviations
before conducting the performance test.
4.2
Following tests to be performed during the PG test:
4.2.1
Redundancy checks for processor, communication, power supply and 1/O modules.
This check shall be conducted in a sequence as mutually decided between the
Client and the contractor. During each redundancy check, the plant operation shall
not be disturbed and the control loops shall continue in auto mode. The trending of
control parameters shall be in service during these checks and the over shoot /
under shoot of the controlled parameters shall be less than 1%. These checks shall
be logged (removal and relocation of modules/cables) in the system in addition to
being made available to the operator in operator station.
4.2.2
Response time for each type of update as per the specification shall be checked on
line by suitably recording each activity.
4.2.3
Guaranteed parameters shall be checked and established as per Schedule of

Performance Guarantees furnished by the contractor. The stability tests for the
control loops shall be checked for other load conditions viz. 75%, 50% and 25% and
the variation in the process parameters shall be within the limits specified.
4.2.4
Checking of the time activated and on demand reports.
4.2.5
Functional inter-changeability of the Operator Stations and printers shall be

checked.
4.2.5
Time synchronisation with master clock shall be tested.
4.2.6
Specified serial links shall be established and proven.
4.2.7
The calculations / documents earlier furnished for establishing the specified system
availability, shall be demonstrated with due consideration for the running plant.
4.2.8
The specified MIS functions, Performance Calculations etc., shall be checked.
4.3
PG Test Methodology
4.3.1
If the performance of the system deviates from the specification requirements, the
contractor shall be given a maximum period of 3 days depending on the gravity of
the defect as mutually agreed, to carryout the modification without disturbing the
plant operation.
4.3.2
Contractor shall declare the system fit for checking after completing the modification
/ rectification. The specific test shall be repeated for proper functioning.
ISSUE
R1
TCE FORM 329 R5

381

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.5
SHEET 4 OF 5

4.3.3
Contractor shall be given maximum of three attempts each not exceeding 3 days for
any subsequent defects found. After 3 tests for each activity, if the system still
deviates from the specified requirements, the warranty period may be extended
depending on the gravity of the defect, during which period, the contractor shall
rectify / modify the system to meet the specified requirements.
4.3.4
During the test, any modules / equipment fails, the contractor immediately within four
hours shall replace the faulty module / equipment and the test shall be repeated
after extended continuous running of 96 hrs.
4.3.5
The total duration for the site acceptance tests i.e site pre-commissioning tests and
Trial operation test together shall not exceed 30 days including the repetition of tests
and duration for replacement / rectification.
4.3.6
During all the above tests, Contractor shall ensure that the disturbance to the
process is minimum.
4.4
PG Test Result Interpretation
4.4.1
The failure of any one of the hard or soft copy device shall not be taken as nonavailability of the system. However, the mean time to repair shall not exceed that
specified by the CONTRACTOR. Any other failure shall be considered as system
reliability / availability failure as defined in Section D5.3.
4.4.2
The PG test shall be repeated if the test results deviate from the guaranteed values.
All the special equipment, tools and tackles required for the successful completion of
the PG test shall be provided by CONTRACTOR as part of the total scope of
services. Ready stock of all types of modules / PC boards shall be available as part
of the total scope of services for immediate replacement during the period.
4.5
The DCS/PLC System PG test shall be carried out to Owners satisfaction. The last
5% of the total supply payment will be released only after successful completion of
DCS/PLC system PG test.
5.0
AVALABILITY GUARANTEE TEST FOR DCS/PLC SYSTEM
5.1
The test shall demonstrate the specified guaranteed availability of 99.7% for
DCS/PLC system & 99.9% for SIL3 certified BMS & Boiler Protection system,
Turbine protection system for a continuous period of 6 months as specified in
Section D5.3 or as agreed for the project.
5.2
The test period shall be a continuous period of 6 months.
5.3
DCS/PLC system availability shall be computed as specified in Section D5.3.
5.4
During the test period, the Owners engineer shall keep the log of total outage period
ISSUE
R1
TCE FORM 329 R5

382

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION : D5.5
SHEET 5 OF 5

in a pre-determined format mutually agreed between Owner and Contractor.

Equipment repair shall be carried out by Contractors engineer by using the spare
and as per trouble shooting procedure furnished by DCS/PLC System Vendor.
5.5
The Contractor shall depute their representative/ engineer for the total duration of
Availability Guarantee Test covering 24 hrs. of the day.
5.6
If the accrued downtime exceeds 0.3% (considering guaranteed availability of

99.7%) of the test duration of 6 months, then a new 6 months test run shall start
from the time the system is fully available again.
5.7
The DCS/PLC System Availability Guarantee Test shall be carried out to Owners
satisfaction. The last 5% of the total supply payment will be released only after
successful completion of DCS/PLC system Availability Guarantee Test.
6.0
TESTS AND INSPECTION FOR SPECIAL I&C SYSTEMS
6.1
Special I&C systems refers to any I&C system other than DCS/PLC system and
detailed in TABLE-13. Tests and inspection requirement for the same shall be as
detailed in TABLE-14.
ISSUE
R1
TCE FORM 329 R5

383
384

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Norms
Format
of
Records
5(912

6(&7,21'
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,%
92/80(,

DK
I
HFHH
H
)IDH
H
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Reference
documents
3 $JHF3HIJKH7H
: $JHF:HJKH7H
9 $JHF9HIJKH7H
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of
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operation
1.0
Sl.
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gory
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documents
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9 $JHF9HIJKH7H
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of
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67$1'$5'48$/,7<3/$1
)25
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0$ 0DFKDDFHF

0, 0FKDDFHF
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5.0

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Component /
operation
4.0
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No.
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Format
of
Records

6(&7,21'
6+((7
,%
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Agency
2)
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Remarks
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48$/,7<3/$112PE-QP-999-145-I029
397
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Routine Test
3.0
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9D
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Extent
of
Check
G
G
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2)

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7H

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Acceptance
Norms
Format
of
Records
5(912

6(&7,21'
6+((7
,%
92/80(,

DK
I
HFHH
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)5HIH
H
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Remarks
'$7(
48$/,7<3/$112PE-QP-999-145-I028
Reference
documents
3 $JHF3HIJKH7H
: $JHF:HJKH7H
9 $JHF9HIJKH7H
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Cate
gory
Type/Method
of
Check
67$1'$5'48$/,7<3/$1
)25
/(9(/*$8*(6

0$ 0DFKDDFHF

0, 0FKDDFHF
Assembly
%G&H,H
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2.0
Material /
Components
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operation
1.0
Sl.
No.
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Cate
gory
0$9
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Extent
of
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G
$HGGJ
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documents
3 $JHF3HIJKH7H
: $JHF:HJKH7H
9 $JHF9HIJKH7H
Type/Method
of
Check
67$1'$5'48$/,7<3/$1
)25
/(9(/*$8*(6

0$ 0DFKDDFHF

0, 0FKDDFHF
Packing
5.0

Painting
Component /
operation
4.0
Sl.
No.
3(0& ,
5(912
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G
,HF
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$HGGJ
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Acceptance
Norms
Format
of
Records

6(&7,21'
6+((7
,%
92/80(,

Agency
2)
$

Remarks
'$7(
48$/,7<3/$112PE-QP-999-145-I028
399
1.1
1.0
Sl.
No.
LEGEND:
CR
MA
MI
Body & Bonnet

casting / forgings,
plug, stem.
MATERIAL
Component /
operation
PEM :: C&I
- Critical characteristics
- Major characteristics
- Minor characteristics
MA
MA
MA
MA
MA
Cate
gory
*
Type/Method
of
Check
MT/PT
2.
100%
100%
100%
100%
Each H.T.
One/
Heat(HT
Batch)
Extent of
Check
MT- Magnetic Test
PT Dye penetrant Test
Hyd. Test
Visual
1.
RT for Body &

UT for
Bonnet(NDT)
Review of H.T.
Chart
Physical,
Chemical tests
RT- Radiographic Test

UT Ultrasonic Test
Pressure test for shell
5.
Internal quality of castings
3.
Surface Quality
Heat Treatment
2.
4.
Physical, Chemical
properties
1.

FOR
CONTROL VALVE (PNEUMATIC)
ISA-S-75.19/
ASME B 16.34
ASME B 16.34
MSS-SP-55
ASME B 16.34
Approved drg. /
data sheet /
BHEL specn.
Approved drg. /
data sheet /
BHEL specn.
3/2
3/2
3/2
---
---
2,1
2,1
For Body &

Bonnet after
machining
After
Machining on
machined
surface only
Applicable for
Body
and
Bonnet only.
For
Lower
rating only if
called for in
specification.
Only for
rating ANSI
900 and
above.
IBR
Certification
(if applicable)
to be verified
by BHEL
Remarks
DATE: 24.07.2010
6
Agency
OF
1 - BHEL
2 - Vendor
3 - Sub-vendor
Test
Certificate
Test
Certificate
Test
Certificate
Test Report
/ FILM
Test
Certificate
Test
Certificate
Format
of
Records
REV. NO.
SHEET
Acceptance
Norms
D
05
1
SECTION
P - Agency Performing the Test.

W - Agency Witnessing the Test.
V - Agency Verifying the Test.
ISA-S-75.19/
ASME B 16.34
ASME B 16.34
MSS-SP-55
ASME B 16.34
Approved drg. /
data sheet /
BHEL specn.
Approved drg. /
data sheet /
BHEL specn.
Reference
documents
IIB
VOLUME
QUALITY PLAN NO.: PE-QP-999-145-I 006
400
LEGEND:
CR
MA
MI
Routine Test
1.
2.
MA
MA
MA
MA
MA
MA
MA
MA
Cate
gory
*
Type/Method
of
Check
One / type
One
sample/
Lot
3. Cyclic test
(Endurance)
4. Dimension
(Measurement)
One
sample /
type
MT- Magnetic Test
IP/NEMA
Tests
100%
100%
2. Scragging
HV, IR,
Continuity
function
100%
One
sample/
Heat
One
sample/
Heat
One /
Type
100%
100%
Extent of
Check
1. Stiffness
ratio
Mech. Test
ChemicalAnalysis
Cyclic test
10,000 cycles
Measurement
Visual

UT Ultrasonic Test
Performance
3.
Mech. Properties
2.
Endurance / Life cycle
3.
Composition
Hardness
2.
1.
Surface Quality
1.
Electrical items [Limit

switches, Solenoids,
Position Transmitter(if
provided externally)]
Spring
1.3
1.4
Diaphragm
Component /
operation
1.2
Sl.
No.
PEM :: C&I

FOR
Approved Data
sheet
Approved Data
sheet

Rele. Standards
Appd Drg
Material spec. /
Mfr. standard
Material spec. /
Mfr. standard
Rele. Standards
Mfr. standard
10,000 cycles
Material spec. /
Mfr. standard
Material spec. /
Mfr. standard
Material spec. /
Mfr. standard
Material spec. /
Mfr. standard
Material spec. /
Mfr. standard
Material spec. /
Mfr. standard
No damage
Mfr. standard
Mfr. standard
3/2
3/2
3/2
---
---
---
---
---
---
---
---
---
---
2,1
2,1
2,1
2,1
2,1
2,1
2,1
2,1
2,1
2,1
2,1
In case TC is
not available,
Actual test
shall be
conducted
Remarks
DATE: 24.07.2010
6
Agency
OF
1 - BHEL
2 - Vendor
3 - Sub-vendor
Test
Certificate
Test
Certificate
Record
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Format
of
Records
REV. NO.
SHEET
Acceptance
Norms
D
05
2
SECTION
Material spec. /
Mfr. standard
10,000 cycles/
Mfr. standard.
Mfr. standard
Mfr. standard
Reference
documents
IIB
VOLUME
401
IN PROCESS INSPECTION
Body & Bonnet after

machining, Plug with
actuator stem
2.1
OPERATION TEST
ON COMPLETED
VALVE (Final
inspection)
4.0
CR
MA
MI
Seat leakage test for

completed valve
3.3
Body
3.2
LEGEND:
Actuator Chamber
3.1
Opening/Closing time
2.
MA
Valve Travel
1.
Type/Method
of
Check
100%
100%
100%
100%
100%
MT- Magnetic Test
REV. NO.
SHEET
Approved drg. /
data sheet
Approved drg. /
data sheet
FCI-70.2
No Leakage
No Leakage
Proper Physical
Contact
Mfr. Standard
Mfr. Standard
ASME B 16.34
Mfr. standard
Mfr. Standard
---
---
---
---
---
2,1
2,1
Refer Note-4
Refer Note-4
Refer Note-4
Refer Note-4
Refer Note-4
Butt weld
ends shall be
included.
Remarks
DATE: 24.07.2010
6
Agency
OF
1 - BHEL
2 - Vendor
3 - Sub-vendor
Test Report
Test Report
Test
Certificate
Test
Certificate
Test
Certificate
Test
Records
Records
Records
Test
Records
Records
Test
Certificate
Format
of
Records
D
05
3
SECTION
Acceptance
Norms
IIB
VOLUME

Approved drg. /
data sheet
Approved drg. /
data sheet
FCI-70.2
ISA - S-75.19
Mfr. Standard
------
Mfr. Standard
One
sample/lot
Mfr. Standard
100%
ASME B 16.34
Mfr. standard
Mfr. Standard
Reference
documents
One
sample/Lot
100% (on
accessible
surfaces)
100%
100%
Extent of
Check
Measurement
Measurement
Pneumatic Test
Hydro test
Pneumatic test
Blue Matching
Hardness
Measurement
Measurement
Visual &
MT/PT
Visual
Review of
calibration
certificates

UT Ultrasonic Test
MA
MA
MA
MA
MA
MA
MA
MA
MA
MA
Cate
gory
Seat Leakage
Leakage and Pressure test

(Body Mount Leakage)
Leakage & Strength
TESTS ON COMPLETED VALVE
3.0
Machining surface contact
Hard facing (wherever

applicable)
3.
Lapping
Dimensional checks
2.
2.2
Surface flaws
1.
Marking
2.
2.0
Performance
1.
Pressure Gauges
1.5
Component /
operation
Sl.
No.
PEM :: C&I

FOR
402
Sl.
No.
LEGEND:
CR
MA
MI
Component /
operation
PEM :: C&I
MA
MA
MI
MA
MA
MA
MA
MA
MA
MA
Cate
gory
*
Type/Method
of
Check
100%
100%
100%
MT- Magnetic Test
Visual and
dimensional
Visual
Visual and
dimensional
100%
One per
type
iMeasurement
(Press. vs.
discharge and
discharge vs.
opening 0100% in steps
of 10%)
Function
100%
100%
100%
100%
100%
Extent of
Check
Measurement
Measurement
Measurement
Measurement
Measurement

UT Ultrasonic Test
Cleanliness, painting,
stamping (for direction of
flow), Tag No.
12.
Pre defined valve position

in case of air failure
Control Valve
characteristics / CV Test
8.
11.
Accuracy (Overall)
7.
Overall dimensions
Sensitivity
6.
10.
Hysteresis
5.
Operation of limit switch &

solenoids and other
accessories
Repeatability
4.
9.
Linearity/cam
characteristic
3.

FOR
As per specs/
Approved drg. /
data sheet
As per spec &

Appd drg
As per specs/
Approved drg. /
data sheet
As per specs/
Approved drg. /
data sheet
As per specs/
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
--
Refer Note-4
On
assembled
valve
Refer Note-4
iSize = Body
& port size Or
Body size &
CV for non
std port.
Refer Note 1.
Refer Note-4
Refer Note-4
Refer Note-4
Refer Note-4
Refer Note-4
Remarks
DATE: 24.07.2010
6
Agency
OF
1 - BHEL
2 - Vendor
3 - Sub-vendor
Test
Certificate
Test
Certificate
Records
Test Report
Test
Certificate
Test Report
Test Report
Test Report
Test Report
Test Report
Format
of
Records
REV. NO.
SHEET
Acceptance
Norms
D
05
4
SECTION

Approved drg. /
data sheet
As per spec &

Appd drg
Approved drg. /
data sheet
Approved drg. /
data sheet
As per specs/
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
Reference
documents
IIB
VOLUME
403
Electronic position
transmitter(not
applicable if provided
integral to smart
positioner)
Current to Pneumatic
converter(not
applicable for smart
positioner)
5.4
5.5
Physical Verification
Make/Model
Degree of Protection
Linearity
Hysterisis
1.
2.
3.
4.
Type/Method
of
Check
100%
100%
Each
type
100%
100%
100%
100 %
Each
type
100 %
Extent of
Check
MT- Magnetic Test
Measurement
Measurement
IP/NEMA test
Visual
Operation
Leakage test
Visual (soap
solution)
Measurement
Leak Test (in

the steady state
input signal)

UT Ultrasonic Test
CR
CR
MA
MA
MA
Accuracy
1.
MA
MA
Overall leakage
2.
MA
MA
Cate
gory
Performance Test
Normal air consumption
1.
Overall leakage after assembly

including Nozzles leakage
Air lock relay
5.3
CR
MA
MI
Air filter regulator
5.2
Positioner
5.1
LEGEND:
AUXILIARY ITEMS
Component /
operation
5.0
Sl.
No.
PEM :: C&I

FOR
P
Inspection
Report
Inspection
Report
Approved drg. /
data sheet /
BHEL specn.
Approved drg. /
data sheet /
BHEL specn.
---
---
---
---
---
---
---
---
2,1
2,1
On completed
valve
Overall
leakage
including
tubing
Remarks
DATE: 24.07.2010
6
Agency
OF
1 - BHEL
2 - Vendor
3 - Sub-vendor
3/2
3/2
3/2
3/2
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Relevant
Standard
Approved drg. /
data sheet
Approved data
sheet /
No leakage
No leakage
No leakage
No leakage
Format
of
Records
REV. NO.
SHEET
Acceptance
Norms
D
05
5
SECTION

Approved drg. /
data sheet /
BHEL specn.
Approved drg. /
data sheet /
BHEL specn.
Relevant
Standard
Approved drg. /
data sheet
Approved data
sheet /
Mfr. Standard
Mfr. Standard
Mfr. Standard
Mfr. Standard
Reference
documents
IIB
VOLUME
404
LEGEND:
2.
3.
4.
5.
6.
1.
PACKING
7.0
NOTES:
PAINTING
Calibration with Hand

Held Communicator
5.
MA
CR
MA
Hysterisis
4.
CR
Soundness of Packing against

transit damage
Linearity
3.
MA
MA
Degree of Protection
2.
MA
Cate
gory
Soundness of Painting
Physical Verification
Make/Model
1.
Visual
Visual and
Measurement
Measurement
Measurement
Measurement
IP/NEMA test
Visual
Type/Method
of
Check
100%
100%
Each
type
100%
100%
Each
type
100%
Extent of
Check
Mfr. Standard
BHEL specn. /
Mfr. Standard
Approved data
sheet / Mfr.
Standard
Approved drg. /
data sheet /
BHEL specn.
Approved drg. /
data sheet /
BHEL specn.
Relevant
Standard
Approved drg. /
data sheet
Reference
documents
REV. NO.
SHEET
Mfr. Standard
BHEL specn. /
Mfr. Standard
Approved data
sheet / Mfr.
Standard
Approved drg. /
data sheet /
BHEL specn.
Approved drg. /
data sheet /
BHEL specn.
Relevant
Standard
Approved drg. /
data sheet
Inspection
Report
Inspection
Report
Inspection
Report
Test
Certificate
Inspection
Report
Test
Certificate
Test
Certificate
Format
of
Records
D
05
6
SECTION
Acceptance
Norms
IIB
VOLUME
---
---
---
---
---
---
---
2,1
2,1
Refer Note-3
Refer Note-2
CR
MA
MI

UT Ultrasonic Test
MT- Magnetic Test

1 - BHEL
2 - Vendor
3 - Sub-vendor
Remarks
DATE: 24.07.2010
6
Agency
OF
Cv test will be conducted if Test Certificate for a similar Model / Size / Cv is not available. Validity of the certificate considered as last 3 years. Cv test conducted
at IIT/FCRI/any govt. approved laboratory shall not be witnessed by BHEL.
In the absence of BHEL spec. for painting, vendor to obtain BHELs approval on their painting specification / procedure.
Sea worthy packing, if applicable.
The quantum of check shall be 100% for manufacturer and 10% for BHEL/BHEL nominated inspection agency.
IBR certificates in Form III-C shall be submitted if called for in the specification/datasheet.
Copies of all TCs(Test Certificates) for materials duly correlated with Heat Nos., TCs for electrical items and mechanical tests(Leak/Operation) shall be
submitted to BHEL for verification and acceptance.
Smart Positioner
(As Applicable)
Component /
operation
6.0
5.6
Sl.
No.
PEM :: C&I

FOR
405
1.2
MA
MI
* CR
Dimensions
2.
Calibration
Painting
3.
MA
Visual
Performance
Test
Visual
MA
MA
Measurement
Penetrant test
Visual
Measurement
Measurement
Chem & Mech

UT test
Measurement
Physical,
Chemical
Tests
MA
MA
MA
MA
MA
MA
MA
MA
Cate
gory
Type/Method
of
Check
100%
One per
type
100%
100%
100%
100%
100%
100 %
Sample
100%
One /
Plate
OR
One/
Heat
Extent
of
Check
IR - Inspection Reports
DS Data Sheet
TC - Test Certificates
SP Tech. Spec.
AP Approved Drawings/doc
Marking, Tag no.

Direction of flow
2.
Surface flaw on
machined surface
3.
Overall dimensions
Surface finish
2.
1.
Dimension
1.
Dimensions
Chemical,Mech Properties,
UT & Heat Treatment
Physical, Chemical
properties
1.
ASSEMBLY and
FINAL INSPECTION
3.0
LEGEND:
IN PROCESS
Machine
2.0
Machining
Flanges
A. Forgings
B.
MATERIAL
Orifice Plate
Component /
operation
1.0
1.1
Sl.
No.
PEM :: C&I
Reference
documents
AP / DS / SP
IR / MR
TC
IR
IR
IR / TC
-------
IR
IR
MTC,UT
cert,HT cert
IR
Lab Report
3/2
3/2
3/2
3/2
3/2
3/2
3/2
3/2
3/2
3/2
3/2
-----
1
2
3
IBR
certification
(if
applicable)
to be
verified by
BHEL
Remarks
- BHEL
- Vendor
- Sub-vendor
---
2,1
----
DATE: 30.05.13
2,1
----
---
---
Agency
OF

SP / MS
SP
AP / DS
AP
No surface flaw
Mirror Finish
AP
AP / DS
ANSI B 16.34
AP
Format
of
Records
05
REV. NO.
1
SECTION
SHEET
IIB
D
VOLUME
Acceptance
Norms
MR- Manufacturer records

MS- Manufacturer standards
SP / MS
------------
AP / DS
AP
ASTM 165 /
IS:3658
------------
AP
AP / DS
Material Spec
as per ASTM
A 388 for UT
AP
AP / DS / SP

FOR
FLOW ORIFICE PLATE ASSEMBLY
QUALITY PLAN NO.: PE-QP-999-145-I024
406
4.0
Sl.
No.
MA
MI
* CR
IR - Inspection Reports
DS Data Sheet
TC - Test Certificates
SP Tech. Spec.
AP Approved Drawings/doc
MR- Manufacturer records

MS- Manufacturer standards
----
3/2
----
Refer Note
4
Remarks
- BHEL
- Vendor
- Sub-vendor
----
DATE: 30.05.13
1
2
3
Agency
OF

Sea Worthy packing, if applicable.
LEGEND:
CALIBRATION Test to be carried out at IIT-DELHI / FCRI or BHEL approved laboratory.
SP / MS
4.
SP / MS
3.
100%
Acceptance
Norms
Minimum 2 coats of primer paint to be applied before dispatch.
Visual
Reference
documents
Format
of
Records
2.
MA
Cate
gory
Extent
of
Check
All test reports & dimension reports shall be verified by BHEL wherever verification is by BHEL at the time of Final Inspection.
Soundness of Packing
against transit damage
Type/Method
of
Check
05
REV. NO.
2
SECTION
SHEET
IIB
D
VOLUME
1.
NOTE:
PACKING
Component /
operation
PEM :: C&I

FOR
FLOW ORIFICE PLATE ASSEMBLY
407
Terminal Head
Thermowell
1.3
1.4
MA
MI
* CR
Protective Sheath
1.2
LEGEND:
Raw Material /
Component
Resistance sheath
1.0
1.1
Component /
operation
Sl.
No.
PEM :: C&I
Leak Test
4.
Visual
CR
Thread
matching
P
W
V
Measurement
Chemical
composition
Chemical
testing
Chemical
testing
Chemical
testing
MA
MA
CR
MA
MA
CR
Cate
gory
- Minor characteristics; Mfd std - Manufacturers standard
(Hyd. test at 1.5 times design press)
3.
Chemical properties
Dimensions (wall thickness

concentrity of bore, OD &
length)
Threading
2.
1.
Material composition
Type/Method
of
Check
Approved drg.,
BHEL Spec.
Approved drg.,
BHEL Spec.
1
2
3
Approved drg.,
BHEL Spec.
Approved drg.,
BHEL Spec.
Approved drg.,
BHEL Spec.
Relevant
material std.
Approved drg. /
data sheet
Approved drg.,
BHEL Spec.
Relevant
material std.
Relevant
material std.
Relevant
material std.
Acceptance
Norms
- BHEL
- Vendor
- Sub-vendor
Inspection
Report
Inspection
Report
Inspection
report
Test
Certificate
Test
Certificate
Test
Certificate
Test
Certificate
Format
of
Records
P
3,2
3,2
3,2
3,2
3,2
01
REV. NO.
1
SECTION
SHEET
IIB
VOLUME
Approved drg. /
data sheet
Approved drg. /
data sheet
Approved drg. /
data sheet
Reference
documents
- Agency Performing the Test.

- Agency Witnessing the Test.
- Agency Verifying the Test.
100%
100%
100%
One
Sample
from
each lot
One
Sample
from
each lot
Extent
of
Check

FOR
RESISTANCE TEMPERATURE DETECTOR WITH THERMOWELL
1**
2,1i
1i
---
---
---
---
Agency
OF
$
2/1
2,1
2,1
2,1
2,1
**10% of
total quantity
with minimum
of 2 random
piece/type &
size
IBR
certificate
wherever
specified to
be verified.
iBHEL to
witness 25%
Samples
compliance
certificate to
be verified.
kRelevant
Remarks
DATE: 21.03.2012
408
LEGEND:
Packing
3.0
MA
MI
* CR
Routine Tests
2.2
Type Test
Final Inspection
RTD Assembly
2.0
2.1
2.3
Component /
operation
Sl.
No.
PEM :: C&I
Thermal Response time
3.
MA
CR
CR
MA
CR
MA
MA
MA
Cate
gory
Visual
Verification
P
W
V
Measurement
Electrical
Measurement
Measurement
Visual
Visual
- Minor characteristics; Mfd std - Manufacturers standard
Soundness of packing
Enclosure protection test
Insulation Resistance
2.
Dimensions
3.
Calibration (Resis Vs. Temp.)
Marking
2.
1.
Workmanship
1.
Type/Method
of
Check
Mfd std.
Mfd std.
1
2
3
Approved drg. /
data sheet
IS:2848
IS:2848
Approved drg. /
data sheet
IS:2848
IS:2848
Approved drg. /
data sheet
- BHEL
- Vendor
- Sub-vendor
Inspection
Report
Test
Certificate
Test
Certificate
Test Report
Test Report
Inspection
Report
Format
of
Records
P
----
3/2
----
----
----
Agency
OF
3/2
01
REV. NO.
2
SECTION
SHEET
IIB
VOLUME
Acceptance
Norms
IS:2848
IS:2848
Approved drg. /
data sheet
Reference
documents
- Agency Performing the Test.

- Agency Witnessing the Test.
- Agency Verifying the Test.
100%
Each
type
One
Sample
from
each
type
100%
100%
100%
100%
100%
Extent
of
Check

FOR
RESISTANCE TEMPERATURE DETECTOR WITH THERMOWELL
$
---
1*
---
---
1k
1k
1k
*Type Test
Certificate
(not more
than 5 year
old) to be
verified
Visual
Remarks
DATE: 21.03.2012

4.0.0
DOCUMENTSTOBEPROVIDED AT BIDDING STAGE

409
ThefollowingdocumentsshallbesubmittedbyBidderat
Biddingstage:

1.Signed&StampedPLCsystemconfigurationdrawingwith
writeup
2.Signed&StampedpowersupplyschemesforPLCsystem,
peripherals,andRemoteI/Opanels.
3.Signed&StampedcopyofQAPs&FATforPLC
4.FilledDatasheetBforPLC
5.Earthingrequirement
410

5.0.0
LIST OF DOCUMENTS TO BE SUBMITTED AFTER
AWARD OF CONTRACT

411
LIST OF DELIVERABLES OF PEM - C&I DEPARTMENT FOR DM PLANT (2 X 660 MW SURATGARH PROJECT)
DOCUMENT NUMBER
Sl.No. DRAWING NO.
PE-GL-163A-145-I100
DRAWING/DOCUMENT TITLE
SHEET
CATEGORY CUSTOMER FROM
1 of 1
USER REMARKS
INSTRUMENTATION
11
PE-V9-392-163A-I910
PE-V9-392-163A-I911
INSTRUMENT DATA SHEETS

INSTRUMENT SCHEDULE
INSTRUMENT HOOK UP
FIELD JB TERMINATIONS
QUALITY PLANS (CV,FE, Tx and Analyser)
TRANSMITTER RACK GROUPINGS
DRIVE LIST/SOLENOID/ACTUATOR VALVE LIST
WITH LOCATION DATA
CONTROL VALVE DATASHEET WITH VALVE AND
ACTUATOR SIZING CALCULATION
CONTROL VALVE NOISE CALCULATION(BOTH
HYDRO-STATIC & HYDRO-DYNAMIC)
FLOW ELEMENT DATA SHEET WITH SIZING
CALCULATION
THERMOWELL SIZING CALCULATION
1
2
3
PE-V9-392-163A-I912
PE-V9-392-163A-I913
PE-V9-392-163A-I914
PLC PANEL
PLC CONFIGURATION DRAWING
PLC PANEL GA (INTERNAL & EXTERNAL)
CONTROL SCHEMES (BLOCK LOGIC)
PE-V9-392-163A-I915
PLC INPUT / OUTPUT SIGNAL LIST
VENDOR
C&I
PE-V9-392-163A-I916
UPS BATTERY CHARGER/ BATTERY DATASHEET
$$
VENDOR
C&I
Refer Notes Below
6
7
8
9
10
PE-V9-392-163A-I917
PE-V9-392-163A-I918
PE-V9-392-163A-I919
PE-V9-392-163A-I920
PE-V9-392-163A-I921
UPS SIZING CALCULATIONS

BATTERY SIZING CALCULATIONS
CONTROL DESK LAYOUT / GA DRAWING
PLC-OWS/PRINTER FURNITURE BOM
PLC CONTROL ROOM LAYOUT DRAWING
I
I
A
A
A
VENDOR
VENDOR
VENDOR
VENDOR
VENDOR
C&I
C&I
C&I
C&I
C&I
IF APPLICABLE
11
PE-V9-392-163A-I922
PLC CATALOGUE, OWS & PRINTER CATALOGUES,
VENDOR
C&I
12
PE-V9-392-163A-I923
VENDOR
C&I
13
PE-V9-392-163A-I924
PLC QUALITY PLAN & FAT PROCEDURE

LIST OF SIGNAL EXCHANGE WITH DDCMIS & PT
PLANT PLC (BOTH HARDWIRED & SERIAL
INTERFACE IN BHEL FORMAT)
VENDOR
C&I
14
PE-V9-392-163A-I925
PROCESS GRAPHIC MANUSCRIPTS PLC
VENDOR
C&I
15
PE-V9-392-163A-I926
PROCESS GRAPHIC MANUSCRIPTS FOR DDCMIS
VENDOR
C&I
16
PE-V9-392-163A-I927
CABLE SCHEDULE & INTERCONNECTION
VENDOR
C&I
17
PE-V9-392-163A-I928
PANEL & ELECTRONIC EARTHING REQUIREMENT
VENDOR
C&I
18
19
20
21
22
23
24
25
PE-V9-392-163A-I929
PE-V9-392-163A-I930
PE-V9-392-163A-I931
PE-V9-392-163A-I932
PE-V9-392-163A-I933
PE-V9-392-163A-I934
PE-V9-392-163A-I935
PE-V9-392-163A-I936
PANEL HEAT DISSIPATION DATA

MANDATORY SPARES BILL OF MATERIAL
PLC O & M MANUAL
ANNUNCIATION LIST & SER LIST
I/O ASSIGNMENT INCLUDING NEST LOADING
LIST OF SET POINTS
LIST OF LOGS WITH POINT ASSIGNMENTS
MARSHALLING PHILOSOPHY
HISTORICAL STORAGE AND RETRIEVAL(HSR)
SYSTEM DETAILS
PLC CONTROLLER LOADING UNDER WORST
LOADING CONDITION CALCULATION
SER(SEQUENCE OF EVENT RECORDER)/
ANNUNCIATION & EVENTS CONFIGURATION
DIAGRAM/LIST
WIRING DIAGRAMS FOR PANEL,LOCAL
PANELS,JBs,ACTUATORS etc.
UPS BOM,SLD & GA DRAWING
LIST OF SOFTWARES INCLUDED
I
A
I
A
A
I
I
A
A
-
VENDOR
VENDOR
VENDOR
VENDOR
VENDOR
VENDOR
VENDOR
VENDOR
C&I
C&I
C&I
C&I
C&I
C&I
C&I
C&I
1
2
3
4
5
6
7
8
9
10
PE-V9-392-163A-I901
PE-V9-392-163A-I902
PE-V9-392-163A-I903
PE-V9-392-163A-I904
PE-V9-392-163A-I905
PE-V9-392-163A-I906
PE-V9-392-163A-I907
PE-V9-392-163A-I908
PE-V9-392-163A-I909
26
PE-V9-392-163A-I937
27
PE-V9-392-163A-I938
28
PE-V9-392-163A-I939
29
PE-V9-392-163A-I940
30
31
PE-V9-392-163A-I941
PE-V9-392-163A-I942
32
PE-V9-392-163A-I943
33
34
A
I
A
I
A
I
A
A
I
A
I
A
A
A
VENDOR
VENDOR
VENDOR
VENDOR
VENDOR
VENDOR
C&I
C&I
C&I
C&I
C&I
C&I
VENDOR
C&I
VENDOR
C&I
VENDOR
C&I
VENDOR
VENDOR
C&I
C&I
A
-
VENDOR
VENDOR
VENDOR
C&I
C&I
C&I
VENDOR
C&I
VENDOR
C&I
VENDOR
C&I
VENDOR
C&I
A
I
VENDOR
VENDOR
C&I
C&I
CONFIRMATION CERTIFICATE FOR THE LATEST

VERSION OF SOFTWARE AND HARDWARE USED
VENDOR
C&I
PE-V9-392-163A-I944
DETAILED MANUFACTURER'S CABLE

SPECIFICATION FOR OFFERED CABLE
VENDOR
C&I
PE-V9-392-163A-I945
EQUIPMENT WISE VENDOR'S DETAILS INCLUDING

ADDRESS, CONTACT PERSON, TELEPHONE NOS.
VENDOR
C&I
35
PE-V9-392-163A-I946
36
37
38
PE-V9-392-163A-I947
PE-V9-392-163A-I948
PE-V9-392-163A-I949
39
PE-V9-392-163A-I950
TRAINING METHODOLOGY, SCHEDULE,TRAINING

MANUALS & ASSESSMENT CRITERIA
UPS QAP
UPS INSTRUCTION MANUALS
HARDWARE & SOFTWARE DESIGN MANUALS
UPS TYPE TEST REPORTS ON COMPONENTS
CHOSEN
VENDOR
C&I
I
I
A
VENDOR
VENDOR
VENDOR
C&I
C&I
C&I
VENDOR
C&I
OTHER DOCUMENTS
1
PE-V9-392-163A-I951
LIST OF I&C SPARE PARTS
VENDOR
C&I
PE-V9-392-163A-I952
LIST OF I&C DRAWINGS/DOCUMENTS
VENDOR
C&I
PE-V9-392-163A-I953
VENDOR
C&I
PE-V9-392-163A-I954
ESSENTIAL & START-UP SPARES LIST

DETAILED IMPLEMENTATION SCHEDULE FOR I&C
SYSTEM
VENDOR
C&I
PE-V9-392-163A-I955
VENDOR
C&I
I&C SYSTEM DESIGN BASIS REPORT

INCORPORATING CONTROL
PHILOSOPHY/OPERATION PHILOSOPHY/DESIGN
PHILOSOPHY/REDUNDANCY PHILOSOPHY
Notes:
$$
- Approval by BHEL if Vendor BBU Item

Approval by Customer if Customer BBU Item
412
413
Group No
1
2
3
4
1
2
3
Tag No
OPC Name in Server
Description
R/W
OPC Server IP Address

OPC Server Name
Type of Signal Engg Unit
Range
Enter only Numbers under Group No and Tag No in ascending order

OPC Name is reference name by which client will access data
Description is details of a tag
R/W is read or Write or both Function
Type of signal is information type
Ex Process Parameter( Analog value) etc
or Process Status ( Digital Value )
Engg units if applicable
Range if applicable
Provide Technical Manual
Reqd. Contents : This document must provide an overview of the device including its intended
use(a general technical,communication & electrical details)
Remote Registration File - File to be sent

and also to be copied in OPC PC under c:\custom\opc
one file for each OPC device to be interfaced
OPC DATA INPUT FORMAT ( FORMAT FOR SOFT SIGNAL EXCHANGE BETWEEN PLC & DDCMIS)

6.0.0
ERECTION,TESTING & COMMISIONING REQUIREMENTS

414

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION :TABLE 6
SHEET 1 OF 7

ERECTION, TESTING AND COMMISSIONING
REQUIREMENT
1.0
GENERAL
1.1
The erection of instrumentation system shall be carried out generally conforming to

sound engineering practices. However, the Bidder shall select and adopt methods and
procedures for equipment erection to suit the nature of equipment and erection,
involved according to the best modern practice and his own experience.
2.0
SCOPE OF WORK FOR ERECTION
2.1
The Bidder shall be required to erect all cabinets, consoles, desks, all cables,
conduits, instruments etc. required for complete I&C system covered in this
specification.
2.2
The Bidder shall provide all supervisory, skilled, semiskilled and unskilled labours
including instrument tube fitters, licensed cable jointing mechanics etc., tools and
tackles, consumable, erection materials required for the complete installation,
transport vehicles, hydraulic jacks, welding sets, mobile cranes, blowers and other
necessary equipment for timely efficient erection and testing.
2.3
The Bidder shall maintain proper record of the materials at the place of storage for
quick identification as and when required.
2.4
The Bidder shall carry out all repairs to damages that might have suffered during
transit or in subsequent storage and replacement of all lost parts.
2.5
The Bidder shall furnish a detail erection schedule, which shall be finalised along with
the offer keeping in view the overall erection and commissioning schedule. The
erection schedule as agreed with the PURCHASER shall be strictly adhered to by the
Bidder.
2.6
The erection work shall include but not limited to the following:
(a)
(a)
(b)
(c)
(d)
Unloading the material received at site, transporting to stores at site, storing,

unpacking, delivery from stores whenever necessary and transportation to
erection site. This service shall include for all the equipment covered in this
specification.
Handling of the tested and calibrated equipment to the place of installation
without any damage.
Installation of DCS/PLC equipment as per bill of material and as per relevant
approved G.A and disposition drawing.
Installation of the necessary cable and racks with posts, brackets, and
fasteners.
Installation and termination of electrical, measuring, control, power supply,
and signal lines, from the available / to be erected marshalling cabinets to I/O
cabinets System cabinets as per relevant interconnecting and terminating
drawings prepared by the successful Bidder. This includes laying of all control
ISSUE
R1
TCE FORM 329 R5

415

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION :TABLE 6
SHEET 2 OF 7

REQUIREMENT
(e)
(f)
(g)
cables, compensating cables etc.

Supply, fabrication and erection of structural steel plates, angles, pipes
required for supporting cable trays complete with bolts and nuts.
Providing identification of cable by engraved Aluminium tag plates at both
ends inside the cabinets, consoles as per cable schedule.
Preparation of separate earthing pits as recommended by the DCS/PLC
system supplier, laying and connection of the earthing cables from different
equipment to the respective earthing pit.
2.7
Supply of structural steel like clamps, bolts, nuts, etc. to fabricate hangers and
supports and other accessories required to install all the equipment supplied under this
contract.
2.8
Supply of all consumables like welding rods, drill bits, tapes, grease, lubricants etc. as
required.
3.0
ERECTION
3.1
Cabinets and desk
3.1.1
The Bidder shall arrange for the transportation and handling of cabinets and desks
from stores to work site suitably without any damage. If any damage is observed
before handling, this shall be brought to the notice of the PURCHASER.
3.1.2
Before installation of cabinets and desks, the necessary openings and inserts required
to be made on the floor by the Bidder shall be checked and then after proper
alignment, the cabinets and desks shall be installed on the floor by the Bidder. All
necessary civil work to be carried out for this shall be in Bidders scope of supply.
3.1.3
The cabinets and desks shall be cleaned by blowing air to remove dust or foreign
particles.
3.1.4
The Bidder's scope of work and supply shall also include tightening of wires,
replacement of broken items and retouching of damaged painted surface of cabinets
those has taken place during transport from store to work site and during installation.
3.1.5
The Bidder's scope of work and supply shall also include tightening of wires,
replacement of broken items and retouching of damaged painted surface of cabinets
those has taken place during transport from store to work site and during installation.
3.2
Cables, cables trays and conduits
3.2.1
All electrical work shall conform to the rules and regulations of Indian Electricity Act.
3.2.2
All cables shall be tested for insulation level. Cable ends shall be properly cleaned.
ISSUE
R1
TCE FORM 329 R5

416

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION :TABLE 6
SHEET 3 OF 7

REQUIREMENT
3.2.3
The entry to and exit from pipes shall be smooth and free from burr where cables are
run through pipes. Cable shall be pulled into the pipes in such a way that there shall
be no damage to the cables.
3.2.4
Flexible conduits shall be provided wherever necessary.
3.2.5
Cable in hot areas shall have proper heat protection.
3.2.6
A minimum distance of 400 mm shall be kept between instrument / signal cables and
power cables.
3.2.7
Each tray shall be filled with a maximum of two layers for instrument and control
cables and one layer for power cables providing 20% spare space in the number of
layers specified.
3.2.8
Instrument Cable Trays, shall be erected vertically as far as possible to avoid dust
accumulation.
3.2.9
All the cables laid shall be tied individually to the Tray.
3.2.10
Thermocouple cables shall be run completely independent of all other cables with
minimum separation as per relevant standard and with cross over at right angles.
3.2.11
The cabling accessories shall include cage-clamp type terminal blocks, splicing
materials, crimping tools, cable support grips, insulating tapes, GI flexible conduits,
conduit fittings, GI perforated covered trays, supports, accessories, and cadmium
plated trays & cable glands.
4.0
SPECIFIC REQUIREMENTS FOR ERECTION, TESTING, CALIBRATION AND

COMMISSIONING
4.1
ERECTION REQUIREMENTS
4.1.1
The installation details given in the specification are the guide lines and the installation
shall be done as per the standards. The exact routing of impulse pipes/ tubes will be
decided at site during erection by the Bidder depending upon the location of tap points.
PURCHASER/ ENGINEER reserve the right to approve the suitable location of field
mounted junction boxes.
4.1.2
The Bidder shall prepare isometric drawing for installation and routing of impulse pipes
from the tapping point location to each instrument and device supplied by him. The
BIdder shall furnish as installed drawing to the PURCHASER/ENGINEER.
4.1.3
The actual location of transmitter racks, junction boxes and other instruments shall be
decided by the Bidder depending on the site conditions considering the layout and
maintenance aspects.
ISSUE
R1
TCE FORM 329 R5

417

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION :TABLE 6
SHEET 4 OF 7

REQUIREMENT
4.1.4
The Bidder shall get prior approval as per approved quality assurance plan of the
Purchaser / Purchasers Representative before any installation work starts. If any
work is carried out by the Bidder before prior approval from Purchaser / Purchasers
Representative and modification is sought by Purchaser / Purchasers Representative
later, then the work shall be redone by Bidder without any cost / material implications
to the Purchaser / Purchasers Representative.
4.1.5
Impulse / sample piping, air supply and pneumatic tubing, cable trays and equipment
shall be supported rigid enough to prevent vibration and anchored sufficiently to
prevent strains on equipment installed. Supporting clamps shall be provided atleast at
every one metre distance for better rigidity. Impulse / sampling piping shall be
provided with adequate slope, (preferably 1:10). Hanger and supports shall be so
installed as not to interfere with free expansion and contraction of the piping and
tubing between anchors. Suitable vibration dampners, etc., shall be provided
wherever necessary. In addition, care shall be taken that the arrangement of impulse
/ sampling piping, air supply and pneumatic tubing from detrimental sagging,
mechanical injury, abuse due to unusual service conditions from sources other than
those due to pressure, temperature and vibrations. All impulse lines of joints shall be
welded type unless otherwise specified. Argon arc welding shall be employed.
4.1.6
All the panels, desk, cabinets supplied by the Bidder shall be welded or bolted to the
floor channel.
4.2
TESTING REQUIREMENTS
4.2.1
The Bidder shall set up his own instrument laboratory. The calibration equipment shall
cover complete range and shall have the desired accuracy of not less than 0.1%. All
the calibration equipment shall have the certification from National Physical Laboratory
(NPL) or IDEMI for the duration of Contract Period.
4.2.2
The Bidder shall follow the standard procedures for calibration of various instruments
and as set by the manufacturer of instruments and as instructed by the Purchaser
including any requirements of field calibration. First, the calibrations shall be carried
out independently by the Bidder and later in the presence of Purchaser who shall
certify the same. Proper documentation in this regard shall be maintained and handed
over to the Purchaser.
4.2.3
All the instruments shall be calibrated for the entire range of the instrument for which it
is designed. Calibration shall include test for repeatability. After first commissioning,
the instruments shall be tested for calibration again to check whether the instrument
maintains its zero and maximum of the range.
4.2.4
All instruments and control equipment shall be calibrated to read correctly to the
satisfaction of equipment supplier / Purchaser.
ISSUE
R1
TCE FORM 329 R5

418

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION :TABLE 6
SHEET 5 OF 7

REQUIREMENT
4.2.5
All switches shall be tested for the actuation of both normally open and normally
closed contacts at the desired set points and also for the fixed / differential settings.
4.2.6
All the float operated level switches shall be tested for the movement of the float and
linkages to make to break the switch contacts by filling up with water before
installation. For such tests, necessary testing set up required shall be arranged by the
Bidder. All the conductivity type probes and switches shall be tested for performance
before installation.
4.2.7
Air leak tests shall be performed on all flue gas impulse / sample lines, air supply and
pneumatic lines. Necessary equipment such as portable compressor, connecting
pipes, materials, cables and test gauges shall be provided by the Bidder.
4.2.8
Hydro test shall be performed for all other impulse lines / sampling lines. Necessary
equipment such as hydro test pumps and temporary piping to the required point, fill
pump etc., materials such as temporary gaskets, miscellaneous fasteners, etc. tools
and tackles including test pressure gauges, etc. are to be provided by the Bidder.
4.2.9
For all electrical actuators of the valves, functioning, setting and performance of limit
switches / torque switches of various positions shall be checked before and after
installation of the actuators. The position transmitters for inching applications shall
also be calibrated.
4.2.10
Pneumatic actuators shall be calibrated at site.
4.3
COMMISSIONING REQUIREMENTS
4.3.1
Prior to taking the instruments in service, all impulse lines, sampling lines and air
supply lines shall be blown as required with the establishment of adequate line
pressure and temperature conditions to keep the lines thoroughly clean.
4.3.2
On-line i.e., without removing control valves from the pipe, calibration of the
positioners and stroking of control valves / control dampers shall be carried out as
required during control system tuning.
4.3.3
Pre-commissioning checks, individuals loop checks, power initialisation, verification of

system functioning, trouble shooting final solutions to application and / or instrument
problems, etc., is Bidders responsibility. All the required software and hardware
changes shall be incorporated as required for successful commissioning to
Purchasers satisfaction.
4.3.4
Any other tests as may be directed by the Purchaser/Purchasers Representative.
4.3.5
After delivery of the equipment, the Bidder shall locate all the equipment including
electronic cards in its final position, check all the power wiring, grounding and
interconnection cables, all in accordance with manufacturers recommendations. The
ISSUE
R1
TCE FORM 329 R5

419

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION :TABLE 6
SHEET 6 OF 7

REQUIREMENT
Bidder shall perform initialisation of system power, field loading of system

configuration / software and data base, demonstration of system functionality to verify
conformance with manufacturers instructions and specifications, tuning of control
loops, implementation of any configuration changes including hardware, software and
additional tappings / instruments, cabinets as required and providing general trouble
shooting and final solutions to application and / or instrument problems.
4.4
LOOP TESTING
4.4.1
The action of the controller is set as prescribed. Controller settings for various modes
of operation (Proportional band, reset and rate action) are at nominal value.
4.4.2
For current signals, 4 20 mA shall be injected and checked the loop for 0%, 25%,
50%, 75% and 100% of full scale inputs.
4.4.3
For temperature loops with thermocouples, a known milli volt signal shall be injected
and the output display shall be checked for input signals of 0%, 25%, 50%, 75% and
100%.
4.4.4
For temperature loops with RTDs, a known resistance shall be injected in the control
cable through decade resistance box and output display shall be checked for 0%,
25%, 50%, 75% and 100%.
4.4.5
For field mounted switches for alarms / interlocks, the action shall be simulated by
disconnecting the wires / shorting the terminals and the function of the associated
system shall be checked.
4.4.6
Any equipment required by the Bidder for testing, calibration and commissioning shall
be brought by the Bidder at site. The list of such equipment shall be furnished along
with the offer.
5.0
COMMISSIONING
5.1
The Bidder shall take care to complete all pre-commissioning activities and simulation
tests after erection to suit the over all start up of respective plant equipment.
5.2
The pre-commissioning activities of the system shall be completed at least two (2)
days in advance as per the schedule of plant start-up.
5.3
The controllers shall be tuned as per the process requirement. The list of set points,
alarms / interlocks, settings for the controllers shall be furnished in the standard format
and handed over to the PURCHASER.
5.4
Control loops shall be put in auto mode as per the operational requirement of different
phases.
ISSUE
R1
TCE FORM 329 R5

420

SPEC.NO.
TCE.5750A-H-500-001

Package: EPC
VOLUME V
SECTION :TABLE 6
SHEET 7 OF 7

REQUIREMENT
5.5
Bus Worst loading conditions calculation shall be proved at the time of commissioning.
5.6
Before taking over of the plant by the PURCHASER, all the system and auto control
loops shall run satisfactorily for at least one month at varying loads without disturbing
any adjustment. During this period, supervision and maintenance of the system shall
be the scope and responsibility of the Bidder.
5.7
The performance test shall be carried out for the system offered and certificates to
these effects shall be approved by the PURCHASER.
6.0
Safety
6.1
The entire works will be carried out with necessary precautions to meet the rules of
local statutory authorities to have the utmost protection to men and material. The use
of safety equipment like safety belts, helmets, safety shoes, safety glasses etc. will be
enforced. All the rigging and lifting equipment will be tested for reliability and for safe
operation. A full fledged safety engineer will be provided by the VENDOR to be in
charge of the supervision of safety requirements at site. It is the VENDORS
responsibility to provide safety to his personnel and equipment.
6.2
Construction water and construction power will be made available by the

PURCHASER at one point in the plant. Further connections required from this point
onwards shall be included by the BIDDER in his scope. The BIDDER will be charged
for consumption of power @ Rs 3 per kWh. Construction water will be supplied free of
cost.
6.3
Erection of all equipments/instruments shall be in a manner to avoid inconvenience to

operation and maintenance activities. Approach ways and platforms for maintenance
shall be provided.
ISSUE
R1
TCE FORM 329 R5

421
SPEC. NO. PE-TS-392-163A-A001
TITLE: TECHNICAL SPECIFICATION FOR

DM PLANT
2X660 MW Suratgarh Super Critical TPS, Stage-V Unit
7 & 8 at Suratgarh, Rajasthan
VOLUME
III
REV. NO. 00
VOLUME-III
BHEL PS- PEM-PPEI: NOIDA, SECTOR 16A, UP-201301
422
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: III
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
REV
V NO: 00

SCHED
DULE OF CL
LARIFICATIO
ON

All clarification from the Technica
al Specificatiion shall be filled
f
in by the
t
BIDDER
R clause by
y clause
in this fformat only.
VOLUME
SECTION
CLAU
SE
NO.
PAGE
NO.
SP
PECIFICATIO
ON
RE
EQUIREMEN
NT
CLARIFICATION

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
423
REASONS
R
FOR
CATION
CLARIFIC
SPE
EC NO: PE-TS-3392-163A-A001
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
VOL
LUME: III
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
REV
V NO: 00
SCHEDU
ULEOFD
DEVIATIO
ONS
S. No.
V
Volume /
S
Section
Page
P
No.
Clau
use
No
o.
T
Technical
Sp
pecification
De
eviation
Cost off withdrawal

(**)

Bid
dder shall indicate quoted in cost of wi thdrawal column of schedu
ule of technicaal deviation along with theirr

tecchnical offer.
n along with price
Bid
dder shall furn
nish priced sch
hedule of tech
hnical deviatio
p
bid in seaaled envelope
e.
Co
ost of withdraw
wal prices shall be submittted without ta
axes, duties, freight
f
and othher taxes as applicable forr
pro
oject.

(**) Bidder tto note the following:

x
x
x
PA
ARICULARS OF
O BIDDER / AUTHORISE
ED REPRESENTATIVE
NAME
DESIGNA
ATION
SIGN
DATE

BHEL PS- PEM-PPE

EI: NOIDA, SEC
CTOR 16A, UP--201301
424
CO
OMPANY SEAL
TITLE: TECHN
NICAL SPECIF
FICATION FOR
DM PLANT
SPE
EC NO: PE-TS-3392-163A-A001
VOL
LUME: III
2X660 MW Suratgarh
h Super Critica
al TPS, Stage-V
V Unit 7
REV
V NO: 00
ANN
NEXUREI
SCHEDULE
E OF GUARA
ANTEED CH
HEMICAL CO
ONSUMPTIO
ON 33% HC
Cl per annum
m AND
48
8% NaOH pe
er annum

GAURANTEED 33%
% HCl CONSU
UMPTION PER
R
NNE)
ANNUM FOR DM PLANT (IN TON
GAURANTEED 48%
% NaOH CON SUMPTION
PER ANNUM
A
FOR DM
D PLANT (IN
N TONNE)
___TONNE
___TONNE
uaranteed chemical
c
con
nsumption (33% HCl pe
er annum an
nd 48% NaO
OH per
Bidder tto submit gu
annum)) in a sealed
d envelope.

PART
TICULARS OF BIDDER
B
/ AUTH
HORISED REPR
RESENTATIVE
NAME
D
DESIGNATION
SIG
GNATURE
425
DATE
E
COMPA
ANY SEAL
FORM NO PEM 6040-1

SPECIFICATION NO. PE-TS-392-163A-A001
TECHNICAL SPECIFICATION FOR

DM PLANT
VOL III
2X660 MW Suratgarh Super Critical TPS, Stage-V Unit 7 & 8 at

Suratgarh, Rajasthan
* SCHEDULE OF DECLARATIONS
DECLARATIONS
I ..certify that all the technical data and

information pertaining to this specification are correct and are true representation of the equipment/system
covered by our format proposal number Dated .. and there is no deviation to the
specification.
I hereby certify that I am duly authorized representative of the Bidders company whose name appears
above my signature.
Bidders Company Name
Authorized representatives
Signature
..
Name
Bidders Name
with
The bidder hereby agrees to fully comply

the requirements and intent of this
specification for the price indicated
PARTICULARS OF BIDDER / AUTHORISED REPRESENTATIVE

NAME
DESIGNATION
SIGNATURE
DATE
426
COMPANY SEAL
PROJECT: 2X660 MW Suratgarh Super Critical TPS,

Stage-V Unit 7 & 8 at Suratgarh, Rajasthan
SUGGESTIVE PRICE SCHEDULE
DM PLANT
THE PRICES SHOULD BE SUBMITTED IN THE ENCLOSED
PRICE SCHEDULE FORMAT ONLY. FOLLOWING PRICE
SCHEDULE FORMATS ARE ENCLOSED
ANNEXURE A : LUMP SUM PRICES AND MAJOR
BREAK-UP OF PRICES
Bidder shall furnish this price schedule in his price offer only
Particulars of bidder / authorised representative
Name
Designation
Signature
427
Date
Company
seal

SUGGESTIVE PRICE SCHEDULE (ANNEXURE-A)
ANNEXURE -A
1
a)
b)
Total lump sum firm price for design, engineering, manufacture,

fabrication, assembly, inspection and testing at vendor's & subvendors works, painting, mandatory spares, erection &
commissioning spares, forwarding, proper packing, shipment and
delivery at site, unloading, handling & transportation at site,
Erection & Commissioning, trial run, preparation & submission of
As Built drawings, Performance and guarantee testing at site
inclusive of all prevailing taxes, duties and other levies and
handover to customer for DM PLANT complete with all accessories
for the total scope defined as per BHEL tender technical
specification (PE-TS-392-163A-A001) for project 2X660 MW
Suratgarh Super Critical TPS, Stage-V Unit 7 & 8 at Suratgarh,
Rajasthan.
Bidder to note that total price indicated above at 1 shall be
considered for evaluation and hence should be complete in all
respect for the full scope defined and considering all terms and
conditions agreed.
In case, price indicated above does not match with item wise breakup given at 2, the highest price so calculated shall be considered for
evaluation but in case of order, the same shall be placed at the
lowest price.
MAJOR BREAK-UP OF PRICES GIVEN IN 1 ABOVE
2.1
Total lumpsum firm price for design, engineering, manufacture,

fabrication, assembly, inspection and testing at vendor's & subvendors works, painting, erection & commissioning spares,
forwarding, proper packing, shipment and delivery at site, inclusive
of all taxes & duties for the complete scope of supply (except
mandatory spares) of DM PLANT defined as per tender technical
specification (PE-TS-392-163A-A001).
2.2
Total lump sum firm price for all services including unloading,
handling & transportation at site , Erection & Commissioning, trial
run, preparation & submission of As Built drawings, etc, required
for completion of DM PLANT as per tender technical specification
(PE-TS-392-163A-A001).
2.3
Mandatory Spares as per tender technical specification (PE-TS-392163A-A001).
2.4
Price for PG test and handing over the plant to the customer.
Bidder shall furnish this price schedule in his price offer only
Particulars of bidder / authorised representative
Name
Designation
Signature
428
Date
Company
seal

DM Plant

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TENDER

Design, engineering, manufacturing, supply, erection

BHARAT HEAVY ELECTRICALS LIMITED

2X660 MW Suratgarh Super Critical TPS, Stage-V Unit 7 & 8 at

VOLUME: II B & III

SPECIFICATION NO.: PE-TS-392-163A-A001

BHARAT HEAVY ELECTRICALS LIMITED

TITLE: TECHNICAL SPECIFICATION FOR

SPEC NO: PE-TS-392-163A-A001

SPECIFIC TECHNICAL REQUIREMENTS

SPECIFIC TECHNICAL REQUIREMENTS (MECHANICAL)

GENERAL TECHNICAL REQUIREMENT

GENERAL TECHNICAL REQUIREMENT (MECHANICAL)

PS-PEM-MAX PPEI BUILDING, SECTOR 16A NOIDA

ntractor shall be respon

It is not the intent to specify here

While alll efforts havve been made to make th

In case all above req

Unless sspecified othe

BHEL PS- PEM-PPE

BHEL PS- PEM-PPE

THIS IS A PART OF TECHNICAL SPECIFICATION PE-TS-392-163A-A001

TATA CONSULTING ENGINEERS LIMITED

GENERAL PROJECT INFORMATION

Rajasthan Rajya Vidyut Utpadan

TATA Consulting Engineers Ltd.

Location of the plant

Prabat Nagar, Suratgarh

Latitude and longitude

Latitude : 29 deg. 10 min. N

Elevation above mean sea level

Mean of daily max.

32.8 deg.C (in the month of May)

Temperatures : Annual basis

Highest temperature recorded

Lowest temperature recorded

(-) 2.8 deg.C

Varies between 21% and 81%

Annual average rain fall

Annual mean wind speed :

THIS IS A PART OF TECHNICAL SPECIFICATION PE-TS-392-163A-A001

TATA CONSULTING ENGINEERS LIMITED

GENERAL PROJECT INFORMATION

Calculations for wind effect shall be in accordance with IS:875-1987(Part-3)

Designs & design coefficients shall be based on IS 1893:2002

Auxiliary power supply:

415V AC, 3-phase, 3-wire effectively

b) For motors rated above 160 kW

6600V AC, 3-phase, 3-wire, 50 Hz, noneffectively earthed

For motors rated above 1500kW

11000V AC, 3-phase, 3-wire, 50 Hz,

d) For motor control centres

415V AC, 3-phase, 3/4-wire effectively

e) DC motor starters, DC solenoids,

220 V DC, 2-wire unearthed

110 V 1 phase, 50Hz, 2 wire AC supply.

AC control & protective devices

g) Uninterrupted power supply

230 V, 1-phase, 50 Hz, 2-wire, AC

THIS IS A PART OF TECHNICAL SPECIFICATION PE-TS-392-163A-A001

TATA CONSULTING ENGINEERS LIMITED

GENERAL PROJECT INFORMATION

supply (For all instrumentation and