Tech Spec of Cpu - Ennore

TAMILNADU GENERATION AND DISTRIBUTION
CORPORATIONLIMITED (TANGEDCO)
2X660 MW ENNORE SEZ

SUPERCRITICAL THERMAL POWER PROJECT
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VOLUME – II – B
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TECHNICAL SPECIFICATION
FOR
CONDENSATE POLISHING UNIT
*********************************************************
SPECIFICATION NO. PE-TS-412-155A-A001, R0
************************************************
BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR
PROJECT ENGINEERING MANAGEMENT
NOIDA, INDIA
TITLE SPECIFICATION NO: PE‐TS‐412‐155A‐A001
2X 660 MW ENNORE SEZ STPP VOLUME: II B
TECHNICAL SPECIFICATION FOR REV 00
CONDENSATE POLISHING UNIT SHEET

INDEX

VOLUME – IIB

SECTIONS TITLE PAGE NO.
SECTION‐A INTENT OF SPECIFICATIONS 1‐3

SECTION‐B PROJECT INFORMATION WITH WIND AND SEISMIC 4‐16
DESIGN CRITERIA
SECTION‐C SPECIFIC TECHNICAL REQUIREMENT
SECTION‐C1 – A SCOPE OF SUPPLY & SERVICES, EXCLUSION AND 19‐38
TERMINAL POINTS ETC.
SECTION‐C1 – B GENERAL REQUIREMENT 39‐104
SECTION‐C1 – C FUNCTIONAL / PERFROMANCE / DEMOSTARTION 105‐109
GUARANTEE
SECTION‐C1 ‐ D QUALITY ASSURANCE 110‐183
SECTION‐C1 ‐ E PAINTING SPECIFICATION 184‐199
SECTION‐C1 ‐ F DATASHEET – A 200‐209
SECTION‐C2 TECHNICAL SPECIFICATION FOR ELECTRICAL 210‐227
SECTION‐C3 TECHNICAL SPECIFICATION FOR CONTROL AND 228‐245
INSTRUMENTATION
ANNEXURES
i) ANNEXURE‐I: LIST OF MAKES 246‐265

ii) ANNEXURE‐II: MANDATORY SPARE LIST 266‐286
iii) ANNEXURE‐III: RAW WATER ANALYSIS AND CLARIFIED 287
WATER ANALYSIS
iv) ANNEXURE‐IV: LIST OF TOOLS & TACKLES 288‐289
v) ANNEXURE‐V: DRAWING / DOCUMENT SUBMISSION 290‐295
SCHEDULE
vi) ANNEXURE‐VII: MAIN DRAWING LIST WITH SCHEDULE OF 296‐300
SUBMISSION
vii) ANNEXURE‐VIII: FORMAT FOR OPERATION AND 301‐304
MAINTENANCE MANUAL
x) ANNEXURE‐IX: SITE STORAGE AND PRESERVATION 305‐319
xi ANNEXURE‐X: INPUT DRAWING 320‐325
SECTION‐D STANDARD TECHNICAL SPECIFICATIONS
SECTION D1 STANDARD TECHNICAL SPECIFICATION FOR MECHANICAL 327‐463
SECTION D2 STANDARD TECHNICAL SPECIFICATION FOR ELECTRICAL 464‐481
SECTION D3 STANDARD TECHNICAL SPECIFICATION FOR CONTROL 482‐671
AND INSTRUMENTATION


VOLUME‐III

S. NO. TITLE PAGE NO.
1 LIST OF DOCUMENTS TO BE SUBMITTED WITH BID 673
2 COMPLIANCE CUM CONFIRMATION CERTIFICATE 674‐675
3 PRE BID CLARIFICATION SCHEDULE 676
4 SCHEDULE OF TECHNICAL DEVIATION 677
5 SUGGESTIVE PRICE FORMAT 678‐680

SECTION - A
INTENT OF SPECIFICATIONS
Page 1 of 680
1.0 SCOPE:
1.1 CONDENSATE POLISHING UNIT

This specification is intended to cover design, engineering, manufacture, fabrication, assembly,
inspection & testing at manufacturer’s works, painting, forwarding, supply and delivery at site
including start up and commissioning spares, mandatory spares, properly packed for
transportation, loading/unloading / handling and storage at site, in site transportation, assembly,
erection and commissioning, trial run ,preparation and submission of “As Built” drawings, site
testing, carrying out performance guarantee tests at site and handover of CPU PLANT as per
details elaborated in different sections / volumes of technical specification (PE-TS-412-155A-
A001) for 2X660 MW ENNORE SEZ STPP.
The bidder’s scope shall also include any other services, etc. if called for in the succeeding
sections of the specification.
2.0 GENERAL TECHNICAL INSTRUCTIONS
2.1 The bidder shall be responsible for providing all material, equipment & services, which are required
to fulfil the intent of ensuring operability, maintainability, reliability and complete safety of the
complete work covered under this specification, irrespective of whether it has been specifically
listed herein or not. Items though not specifically mentioned but needed to make the system
complete as stipulated under these specifications are also to be furnished unless otherwise
specifically excluded.Omission of specific reference to any component / accessory necessary for
proper performance of the equipment shall not relieve the vendor from the responsibility of
providing such facilities to complete the supply and erection & commissioning of condensate
polishing unit.
2.2 It is not the intent to specify herein all the details of design and manufacture. However, the
equipment shall conform in all respects to high standards of design, engineering and workmanship
and shall be capable of performing the required duties in a manner acceptable to purchaser who
will interpret the meaning of drawings and specifications and shall be entitled to reject any work or
material which in his judgment is not in full accordance herewith.
2.3 The extent of supply under the contract includes all items shown in the drawings, notwithstanding
the fact that such items may have been omitted from the specification or schedules. Similarly, the
extent of supply also includes all items mentioned in the specification and /or schedules,
notwithstanding the fact that such items may have been omitted in the drawing.
2.4 The general term and conditions, instructions to tenderer and other attachment referred to
elsewhere are made part of the tender specification. The equipment materials and works covered
by this specification are subject to compliance to all attachments referred in the specification. The
bidder shall be responsible for and governed by all requirements stipulated herein.
2.5 While all efforts have been made to make the specification requirement complete & unambiguous,
it shall be bidders’ responsibility to ask for missing information, ensure completeness of
specification, to bring out any contradictory / conflicting requirement in different sections of the
specification and within a section itself to the notice of BHEL and to seek any clarification on
specification requirement in the format enclosed under VOL-III of the specification. In absence of
any such clarifications, in case of any contradictory requirement, the more stringent requirement as
per interpretation of Purchaser / Customer shall prevail and shall be complied by the bidder without
any commercial implication on account of the same. Further in case of any missing information in
the specification not brought out by the prospective bidders as part of pre-bid clarification, the
same shall be furnished by Purchaser/ Customer as and when brought to their notice either by the
bidder or by purchaser/ customer themselves. However, such requirements shall be binding on the
successful bidder without any commercial & delivery implication to BHEL / Customer.
Page 2 of 680

2.6 Deviations along with cost of withdrawal (positive or negative), if any, should be very clearly
brought out clause by clause in the enclosed schedule; otherwise, it will be presumed that the
vendor's offer is strictly in line with tender specification & there is no deviation.( Price to be given in
sealed envelope only.)
2.7 In case all above requirements are not complied with, the offer may be considered as incomplete
and would become liable for rejection.
2.8 Unless specified otherwise, all through the specification, the word contractor shall have same
meaning as successful bidder / vendor and Customer / Purchaser / Employer will mean BHEL and
/or TAMILNADU GENERATION AND DISTRIBUTION CORPORATION LIMITED (TANGEDCO),
HYDERABAD and /or DESEIN (customer’s assigned consultant).
2.9 The equipment covered under this specification shall not dispatch unless the same have been
finally inspected, accepted and shipping release issue by BHEL/Customer.
2.10 BHEL’s/Customer’s representative shall be given full access to the shop in which the equipments
are being manufactured or tested and all test records shall be made available to him.

Page 3 of 680

SECTION - B
PROJECT INFORMATION WITH WIND AND SEISMIC DESIGN CRITERIA
Page 4 of 680
THIS IS A PART OF TECHNICAL SPECIFICATION NO. PE-TS-412-155A-A001
CHAPTER 1
PROJECT SYNOPSIS
1.0 GENERAL BACKGROUND AND SALIENT FEATURES
1.1 Introduction
Tamilnadu Generation and Distribution Corporation owns the proposed

green-field 1320 MW (2 units of 660 MW each) Coal Based Thermal Power
Station at Katupalli. This is an expansion of North Chennai Thermal Power
Station (NCTPS) and located on some portion of the ashdyke of NCTPS.
1.2 Location
The proposed site for main power plant is located near Ennore port (approx 5
kms).
The nearest Railway station is at Athipattu Pudunagar (approx 5 kms)
All weather road from Pattamandri on the Thiruvottiyur-Ponneri district

highway is the nearest road access.
The nearest airport is at Chennai at a distance of 60 km.
1.3 Type of Plant
The proposed 2x660 MW Super-Critical Power Project consists of coal fired

steam generator connected to a reheat type steam turbine generator along
with all the required auxiliaries. Circulating cooling water system is envisaged
for condenser cooling.
The description and salient technical data of the Steam Generator, Steam
Turbine Generator, Auxiliary systems, Electrical, Control & Instrumentation,
Civil etc. are explained elsewhere in the specification:
1.4 PROJECT INFORMATION
Project Title : 2 x 660 M W E nnore S EZ C oal B ased

Supercritical T hermal P ower Project at Ash
Dyke of NCTPS
Page 5 of 680
Owner : TAMIL N ADU GENERATION AND DI STRIBUTION

CORPORATION (TANGEDCO)
LOCATION
The site is located near Vayalur Village, Ennore

Latitude : 13017’ N to 13018’ N
Longitude : 80018’ E to 80019’ E
Distance from Chennai City : 35 km
Nearest Airport is at Chennai at a
Distance of : 60 km
Nearest Seaport is : Ennore
Nearest Railway Station is : Athipattu Pudunagar (approx 5 kms)
Meteorological Condition
Climate : Tropical ,very dry and hot summer, dry and cold
winter and good rain-fall in monsoon
accompanied with strong wind.
Climatological data : Ambient temp. (0C)

Annual Maximum Mean Temp 41.5(0C)
Annual Minimum Mean Temp 24(0C)
Design Ambient temperature 35(0C)
Relative Humidity
Maximum 100%
Minimum 36%
Design 75%
Annual Rainfall
Maximum 2540 mm
Average 1600 mm
Minimum 1175 mm
Prevailing Wind Direction

Nov to Jan – From NW & NE
Page 6 of 680
Feb to Mar – From East & SE

Apr to May – From South & SE
June – From SW
July to Aug – From NW
Sept to Oct – From SE & SW
Wind Speed 11.8 kmph (avg)
50 kmph (max)
Seismic Zone III as per
IS:1893-2002
1.5 Access to Site
Site is well connected to all weather road from Pattamandri on the Thiruvottiyur
– Ponneri district highway. Site is located adjacent to the Chennai – Howrah
broad gauge line and thus well connected by rail also.
1.6 Plant Rating, Capacity, Availability, PLF
Each of the two units shall have a Turbine maximum continuous rating
(TMCR) of 660 MW at generator terminals based on the following site
conditions.
 Ambient air temperature

 Condenser cooling water inlet temperature of 33°C and 9°C
temperature rise across the condenser.
 Generator power factor of 0.85.
 Fuel specification as given elsewhere.
 Design temperature for electrical equipment is 50°C.
The VWO capacity of the steam turbine shall not be less than 105% of TMCR
flow at rated parameters. Boiler maximum Continuous Rating (BMCR) will be
established to match the steam flow at VWO conditions, but BMCR flow shall
not less than 108% of TMCR flow.
The capacity of the unit is selected so as to deliver the rated output even after
ageing that will occur between overhauls, as a result of deposition of salts in
turbine blades, wear and tear etc.
The plant load factor (PLF) being considered is 85%.
1.7 Power Evacuation
Power will be evacuated from the proposed thermal power station at 400 KV
voltage level through 400 KV transmission lines . The power evacuation lines
would be double circuit 400 KV lines which will act as Line in & Line out
circuit.
Page 7 of 680
1.8 Site Selection
The following factors which influence the project site selection have been
found very favourable to establish and operate the project.
a. Availability of fuel.
b. Existing power plant
c. Availability of adequate cooling water.
d. Availability of adequate land for locating the power plant with
approach roads.
e. Suitability of land from topographical and geological aspects
f. Proximity of National Highways, Ports & Transport of fuel &
heavy equipment.
g. Facility for interconnection with transmission and distribution
system for evacuation of power.
h. Environmental aspects.
Total land required for the project is 500 acres which is under the possession
of TANGEDCO.
1.9 Fuel
1.9.1 Source of Fuel
Domestic coal requirement for the power plant will be sourced from Kalinga
block of Talcher coal fields, Mahanadi and IB valley coal fields in the state of
Orissa. Coal will be transported by sea. The port of dispatch and port of
receipt for domestic coal would be Paradip port and Ennore port respectively.
Imported coal shall be sourced from foreign countries through sea to Ennore
port.
Coal can be transported from coal mines to Ennore port by sea and unloaded
at proposed coal berth-III. Further the coal can be transported to the
proposed power plant through pipe conveyor which shall have a system
capacity of 2 x 2000TPH.
The steam generator shall be designed for the following conditions :
• Best Coal – 100% Imported Coal

• Design Coal – 70% Imported & 30% Domestic Coal
• Worst Coal – 50% Imported & 50% Domestic Coal
The analysis of fuel is given below :
1.9.2 Coal Analysis:
Coal Quality Parameters
SL.NO DESCRIPTION DOMESTIC COAL IMPORTED COAL

1. HIGHER HEATING 2800 (GCV as 6250 ( GCV Air
Page 8 of 680
VALUE received basis) dried basis)

-As Fired basis given 5642 (as received
Kcal/kg basis)
2. TOTAL MOISTURE % During rainy 16.5%
season
20% ( inherent +
surface)
3. HGI 45 to 55 51
Abrasiveness expected Average 52
YGP 50 to 70 mg/kg
Shale and sand stone 20% max.
content upto 50 mm.
Feed coal size
DOMESTIC COAL
Sr. No. Particulars Units Parameters

A. Proximate Analysis
1. Moisture % 16.00
2. Volatile Matter % 19.00
3. Ash % 45.00
4. Fixed carbon % 20.00
Total % 100
B. ULTIMATE
ANALYSIS, % ( As
received)
1. Carbon % 27.70
2. Hydrogen % 2.60
3. Nitrogen % 0.52
4. Oxygen % 7.26
5. Sulphur % 0.50
6. Ash % 45.00
7. Moisture % 16.00
8. Carbonates % 0.38
9. Phosphorous % 0.04
10. Others % -
Total % 100.00
C. Ash f usion deg C
temperature
1. Initial deformation, IT deg C 1100
2. Spherical, ST deg C 1200
3. Hemispherical, HT deg C 1300
4. Fluid, FT deg C -
D. Ash Analysis, %
1. Sio2 % 59.54
2. Al 2 O3 % 29.00
3. Fe2O3 % 6.42
4. CaO % 1.50
5. Na2O % 0.08
Page 9 of 680
Sr. No. Particulars Units Parameters

6. K2O % -
7. TiO2 % 1.60
8. SO3 % 0.25
9. P2O5 % 0.51
10. MgO % 0.50
11. Others % 0.60
12. Total 100.00
E Resistivity of fly ash Ohm - cm 1.73x 10^12
IMPORTED COAL
Sr. Particulars Units Parameters

No.
A. Proximate Analysis
(As received)
1. Moisture % 16.50
2. Volatile Matter % 36.45
3. Ash % 6.62
4. Fixed carbon % 40.43
5 Total % 100.00
B. ULTIMATE ANALYSIS,
% (As received)
1. Carbon % 60.12
2. Hydrogen % 4.38
3. Nitrogen % 1.48
4. Oxygen % 10.37
5. Sulphur % 0.53
6. Ash % 6.62
7. Moisture % 16.5
8. Carbonates % -
9. Phosphorous % -
10. Others % -
Total % 100.00
C. Ash f usion deg C
temperature
1. Initial deformation, IT deg C 1230
2. Spherical, ST deg C 1270
3. Hemispherical, HT deg C 1320
4. Fluid, FT deg C -
D. Ash Analysis, %
1. Sio2 % 36.00
2. Al 2 O3 % 13.90
3. Fe2O3 % 14.80
4. CaO % 12.70
5. Na2O % 0.70
6. K2O % 1.70
7. TiO2 % 0.80
Page 10 of 680
Sr. Particulars Units Parameters

No.
8. SO3 % 10.60
9. P2O5 % 0.20
10. MgO % 8.60
11. Others % -
12. Total % 100.00
The plant should be suitable to accept imported coal sourced from any
country. The limiting parameters of imported coal are furnished below :
S. Particulars Unit Parameter

No.
1 Total Moisture (ARB) % Up to 23 (Max)
2 Ash (ADB) % Up to 20 (Max)
3 Gross Calorific Value Kcal / Kg 5800 - 6500
(ADB)
4 Sulphur (ADB) % Up to 1 (Max)
5 Fixed Carbon (ADB) % 30-50
6 Volatile Matter (ADB) % 25-45
7 HGI 45-60
8 IDT (Under Reducing Deg C 1100-1250
Atmosphere)
9 Size mm < 50
Note: ADB stands for “As dried Basis” and ARB for “As Received Basis”
1.9.3 Specification of LDO
Specific gravity @ 15° C 0.8348
Gross calorific value, Kcal/kg 10400
Pour point “°C” max. 12
Flash point “°C” min. 66
Sulphur % “T” max. 0.5
K. Viscosity in Centistokes @ 50° C max. 7.5
Ash by wt. % 0.01
Water & sediment Vol. Max. % 0.25
1.9.4 Specification of HFO
Flash point “°C” min. 66
K. Viscosity in Centistokes @ 50° C max. 370
Page 11 of 680
Ash by wt. % 0.1
Water content by volume % max 1
Sediment by weight % max 0.25
Total Sulphur by weight % max 4.5
Gross calorific value, Kcal/kg 10800
1.9.5 Fuel Linkage
TANGEDCO has approached Ministry of Coal through Ministry of Power for

the long term linkage of Coal from the coal sources of Talcher or Mahanadi in
Orissa.
The coal requirement has been worked as under:-

Coal required at MCR per hr. (Blended) 872 tonnes
Per day 20928 tonnes.
Annual 6.5 MTPA for 85% PLF
1.9.6 Fuel Transportation
The coal shall be received at Ennore port. The coal will be transported by
pipe conveyor from coal berth 3 in Ennore Port and then through 2 x 2000
TPH pipe conveyor to the bunker directly or to stockyard.
1.10 Source Of Water
1.10.1 Source
The raw water intake shall be from the existing cooling water forebay of
NCTPS PHASE-II.
1.10.2 Chemical analysis of Sea Water:
As given in Annexure-1, Volume III, Chapter- 3.
1.10.3 Requirement
The requirement of water for the plant will be for meeting the requirement of
make up for the re-circulating cooling water system, dust suppression system
in coal handling plants, ash disposal system and the RO/ D.M. water plant
which will be supplying the power cycle make up requirements, etc. In
addition the water requirements will be for drinking and service purposes.
Water requirement is estimated as approx. 15523 m3/hr.
Page 12 of 680
1.11 Source of Equipment
The proposed plant will be supplied, erected and commissioned on Single

EPC basis.
1.12 Power Evacuation Plan
Power will be evacuated from the proposed thermal power station at 400 KV
voltage level through 400 KV transmission lines . The power evacuation lines
would be double circuit 400 KV lines.
1.13 400 KV GIS Switchyard
The 400 KV Switchyard is proposed to have one and a half bus arrangement and
will comprise following bays/circuits :
♦ 2 – Generator transformer bays

♦ 1– Start up transformer bay
♦ 4 – Line Bays
♦ 2 – Bus VT’s
♦ 2 – Bus Reactor Bays
♦ 2 – Spare bay (Equipped)
♦ 1 – Equipped bay for future GT
♦ 2 – Equipped bays for future lines
The switchyard will be complete with galvanized steel structures, lightning surge
arrestors, OPGW Equipment, CTs, PTs of suitable VA burden and accuracy
class as required for measurement protection and communication, insulators,
bus-bars clamps & hard wares etc. The switchyard will be controlled by
computerized control and data acquisition (SCADA) system.
1.14 Average Yearly Generation
The average yearly generation is calculated considering the following.
• The expected plant load factor is 85 %. With this PLF the average
yearly generation will be around 11914 Million units.
1.15 INFORMATION FOR ENVIRONMENTAL APPRAISAL
1.0 GENERAL IN FORMATION

ABOUT THE PROJECT
1.1 Name / Title of the Project : 2 x 660 MW Ennore SEZ Coal

Based Supercritical Thermal Power
Project at Ash Dyke of NCTPS
1.2 Name of Owner : Tamilnadu Generation and

Distribution Corporation
(TANGEDCO)
Page 13 of 680
1.3 Location of the Project : Near Vayalur Village, Ennore,

Tamil Nadu
1.4 Site where proposed plant is : Ash dyke of NCTPS

to be located
1.5 Capacity of the project under : 2x 660MW

consideration
1.5.1 Govt. land / Private land / : TANGEDCO land

others
1.5.2 Topographical feature, : Site has differential levels and

demographic profile & require filling to maintain the
physiography desried grade level of +10.00
meter above MSL
1.5.3 Nature of soil : Clayey soil
1.5.4 Distance from the nearest : Chennai -35 km

town / city / major human
settlements
1.5.5 Population to be displaced : Nil
1.5.6 Distance from water source : Approx. 5 km (from Cooling Water

Forebay of NCTPS Stage II)
1.5.7 Area of forest land, if involved : Nil
1.5.8 Distance of forest from the site : N.A
1.6 Is this an extension? : No

If so indicate capacity of
existing plant
1.7 What is the ultimate capacity : 2x660 MW

envisaged
2.0 GENERAL
ENVIRONMENTAL
INFORMATION
2.1 Area of the land proposed to : Refer Plot Plan Land already
be acquired acquired
i. Area required for plant : 500 Acres
ii. Ash disposal : 100 % dry fly ash disposal and
Page 14 of 680
100% wet bottom ash disposal is

envisaged to existing ash pond.
iii. Plant facilities : The area is adequate for locating

all the required systems for 2x660
MW.
2.2 Area proposed to be built-up : Power station will be built-up in

or developed the proposed site as indicated in
the plot plan.
2.3 Specify site characteristics : Site is close to Buckingham Canal

River basin/ estuarine /
coastal / others
2.4 Is the site situated in the : No
forest area? Give following
details
2.4.1 Area : N.A
2.4.2 Type of forests : N.A
2.5 Is site situated near to the : N.A.

forests? Give the distance
from the site.
2.6 Give a description of the flora :

within 25 km of your plant
site under the following
heads
a. Crops :
b. Forest : Refer details in the specification
elsewhere.
c. Grass land :
d. Endangered species :
e. Others (Specify) :
2.6.2 Give details of the following :

features, if they exist, within
a radius of 25 km of the
proposed site?
i. Fisheries :
ii. Sanctuary / natural :
park biosphere
reserve
iii. Lakes / ponds / :
reservoir
iv. Stream / river : Buckingham canal is close to the
site
v. Estuary / sea : Bay of Bengal is 5 km from site
Page 15 of 680
vi. Hills / mountains :

vii. Historic / cultural / :
tourist /
archaeological scenic
sites / defence
installations
2.7 Human settlement :
2.7.1 Total number of persons :

proposed to be employed
i. During construction : 2500
450(0.75person/MW) TANGEDCO
ii. During operation : direct employees
Page 16 of 680
TITLE SPECIFICATION NO : PE‐TS‐412‐155A‐A001

SECTION – C
SPECIFIC TECHNICAL REQUIREMENTS
SECTION – C1: SPECIFIC TECHNICAL REQUIREMENTS FOR MECHANICAL
SECTION – C2: SPECIFIC TECHNICAL REQUIREMENTS FOR ELECTRICAL
SECTION – C3: SPECIFIC TECHNICAL REQUIREMENTS FOR CONTROL AND

INSTRUMENTATION
Page 17 of 680

SECTION – C1
SPECIFIC TECHNICAL REQUIREMENTS FOR MECHANICAL
SECTION C1 – A – SCOPE OF SUPPLY & SERVICES, EXCLUSION AND TERMINAL POINTS ETC.
SECTION C1 – B – GENERAL REQUIREMENT
SECTION C1 – C – FUNCTIONAL / PERFORMANCE / DEMONATRATION GUARANTEE
SECTION C1 – D – QUALITY ASSURANCE
SECTION C1 – E – PAINTING SPECIFICATION
SECTION C1 – F – DATASHEET A
Page 18 of 680
SECTION C1 – A
SCOPE OF SUPPLY & SERVICES, EXCLUSION AND TERMINAL POINTS ETC.
Page 19 of 680
1.0 GENERAL
This specification is intended to cover design, engineering, manufacture, fabrication, assembly,

inspection & testing at manufacturer’s works, painting, forwarding, supply and delivery at site including
start up and commissioning spares, mandatory spares, properly packed for transportation,
loading/unloading / handling and storage at site, in site transportation, assembly, erection and
commissioning, trial run ,preparation and submission of “As Built” drawings, site testing, carrying out
performance guarantee tests at site and handover of CPU PLANT as per details elaborated in different
sections / volumes of technical specification (PE-TS-412-155A-A001) for 2X 660 MW ENNORE SEZ
STPP.
The Condensate polishing plant with regeneration system and associated accessories shall conform to
the technical specification (PE-TS-412-155A-A001) of 2X 660 MW ENNORE SEZ STPP.
2.0 DESIGN CONDITIONS FOR CONDENSATE POLISHING UNIT
There shall be three service vessels (3X50%) for each 660 MW unit each polishing 50% of the condensate
flow corresponding to VWO (valve wide open) condition at 1% make up (Flow through each service vessel
indicated in the data sheet) & all HP heaters out of service condition.
3.0 BRIEF DESCRIPTION OF THE SYSTEM
The proposed condensate plant shall treat the entire condensate of the turbine generator of each unit of
power station. The proposed schematic arrangement of the condensate polishing plant and its
regeneration facility shall be as per the enclosed P&I Diagram. Arrangement of piping, valves and
instruments shown in the P&ID are bare minimum. The bidder shall include the complete system
including regeneration facility as elaborated in this specification meeting the contractual requirements.
The condensate polisher service vessels shall be located in the TG hall of corresponding units. The
resins shall be transferred to and from the common regeneration facility by sluicing through a pipeline
hydraulically / hydro pneumatically.
The regeneration process offered by the bidder shall be of proven design and shall essentially be the
same process by virtue of which the bidder is qualified and shall give resin-separation compatible with
the desired effluent quality.
4.0 SCOPE OF SUPPLY (MECHANICAL)
Broad scope of supply (mechanical) for this package is detailed below and as indicated in relevant
portion of this specification shall be in bidder’s scope.
A. SERVICE VESSEL FACILITY
1) There shall be three service vessels (3X50%) for each 660 MW unit each polishing 50 % of the
condensate flow.
2) Each Condensate polisher vessels shall be complete with condensate inlet and outlet connections,
connections for resin transfer to and from the vessels, bed support-cum-under drain system, inlet
water distributors, air distribution arrangement for resin mixing, all fittings and appurtenances etc. as
specified and as required.
3) One no External resin traps at the outlet of each of the polisher vessel outlet & rinse outlet, designed
for in-place manual back flushing facility.
4) Condensate inlet and outlet headers for each installation with pipe connections to the condensate
polisher vessels.
5) Resin transfer headers and pipe lines connecting the common external regeneration facilities to the
Page 20 of 680
condensate polisher vessels of each installation.
6) Rinse water outlet headers from condensate polisher vessels of each installation up to the
condenser hot well. Rinse water outlet headers from condensate-polisher vessels shall be provided with
a pressure reducing valve and orifice plate, suitably designed to enable the water entry to the condenser
hot well under all operating condition of condenser.
7) All necessary valves, and fittings for the installations with actuators necessary for their remote operation
from CP System Control Panel of each 660 MW Unit. These shall include suitable foolproof arrangement
to prevent accidental over pressurization of the resin transfer pipeline and regeneration facilities
connected to it, which are designed for pressure much lower than that of the Condensate Polisher Mixed
Beds / Condensate Polisher Service vessels.
8) A drain header for the condensate polisher service vessels .All necessary drains, vents and sampling
points, with valves as required.
9) Gland sealing water piping for the Gland sealing valves in the rinse water line & other lines.
10) Sample cooling line piping for sample cooling for all analyzers.
11) Two nos. (1W + 1S) per unit oil free type air blowers with electric motor drives for each unit for
supplying air required for mixing the resins in the service vessels. Each blower shall be complete
with motor, V-belt drive with belt guard, inlet filter, silencer, flexible couplings and discharge snubber,
acoustic hood, relief valve etc all mounted on a single base.
12) Complete Instrumentation and Control for automatic operation.
13) Emergency bypass between the condensate influent and effluent headers. Each Condensate polisher
service unit shall be provided with an automatic bypass for the condensate polisher on the condensate
inlet and outlet headers of the unit with a modulating butterfly type control valve along with Butterfly
isolation valves (resilient material seated, to ensure bubble-tight shut off) on the upstream and
downstream sides of the control valve. Either 2X50% capacity valves or 1X100% capacity control valve
shall be provided to achieve proper control under all operating conditions. Isolation valve shall be
provided with geared operators for manual operation. Complete instrumentation and controls for this
emergency by-pass system. Further all tubing, wiring air sets and other fittings required to complete the
system shall be provided.
14) The plant shall include resins for each condensate polisher service vessels along with one (1) spare
charge of resin in the mixed resin storage tank. Two (2) spare charge of resins per unit during
commissioning and one (1) spare charge of resins as mandatory spares. Total resin charges shall be
supplied for the project is twelve (12) nos. One resin charge shall be considered as resin required for one
service vessel i.e. cation resin, anion resin and inert resin ( if any) used for the project. Further one
Year's topping requirements or 10 % of first fill quantity, whichever is more shall be supplied by
bidder.
15) One no. Conductivity Analyzer at condensate inlet header, One no. Conductivity Analyzer at
condensate outlet header, One no. Conductivity Analyzer at outlet of each Condensate polishing
Mixed Beds / Condensate Polisher Service vessels.
16) One no. Cation Conductivity Analyzer at condensate inlet header, One no. Cation Conductivity
Analyzer at condensate outlet header, One no. Cation Conductivity Analyzer at outlet of each
Condensate polishing Mixed Beds / Condensate Polisher Service vessels.
17) One no. Conductivity Analyzer at condensate inlet header, One no. Conductivity Analyzer at
condensate outlet header, One no. Conductivity Analyzer at outlet of each Condensate polishing
Mixed Beds / Condensate Polisher Service vessels.
18) One no. pH Analyzer at condensate inlet header & One no. pH Analyzer at outlet of each
Condensate polishing Mixed Beds / Condensate Polisher Service vessels.
Page 21 of 680
19) One no. multichannel (consist of four channel & four sensor) sodium analyzer to measure
the values of common inlet and each service vessel outlet. Total number of multichannel sodium
analysers for both the units shall be two.
20) One no. multichannel (consist of four channel & four sensor) Silica analyzer to measure the values
of common inlet and each service vessel outlet. Total number of multichannel sodium analysers for
both the units shall be two.
21) One no. multichannel (consist of four channel & four sensor) chloride analyzer to measure the
values of common inlet and each service vessel outlet. Total number of multichannel sodium
analysers for both the units shall be two.
22) Complete instrumentation and controls for this system, including the differential pressure
transmitters, panel mounted indicating type controller with provision for remote manual operation,
actuator for the control valve with positioner etc. All tubing, wiring, airsets, and other fittings, required
to complete the system.
23) All the piping, valves, fitting, accessories etc. used in service vessel area shall be 300# class
minimum and this area shall be considered as high pressure side.
24) Minimum instrumentation required as per P & ID included in this tender specification.
25) All butterfly valves MOC used in service vessel area in condensate inline line shall be (body :WCB
Disc:CF8M/SS316) and condensate outlet line will be (Body & Disc both :CF8M/SS316)
B. REGENERATION SYSTEM
The regeneration system shall be common to polisher of both the units and shall be external. The CPU
regeneration system will be located near DM plant area. Regeneration area shall be considered as low
pressure area. Complete regeneration facility as mentioned below shall be in Bidder’s scope:
I. One common facility for regeneration of the resins from the condensate polishers of all the TG units
shall be provided by the bidder and consisting of following:
1) One no Resin Separation & Cation Regeneration Vessel.
2) One no Anion resin regeneration vessel.
3) One no. Mixed resin storage vessel
4) All internals, fittings and appurtenances for these vessels.
5) Common waste effluent header with one resin trap designed for in place manual backwashing.
6) The type of vessels indicated above (s.no 1, 2 and 3) shall be as per supplier process requirement.
7) Resin Make up/injection hopper complete with water ejector system for resin make up. Resin Make
up/injection hopper shall be sized to handle up to minimum 150 liters of as received new resins per
single injection.
8) Two (2) nos. (1W+1S) oil free type air blowers with electric motor drives, for supplying all the
process air required for cleaning of the resins and their regeneration processes. Each blower shall
be complete with motor, V-belt drive with belt guard, inlet filter, silencer, flexible couplings and
discharge snubber, acoustic hood, relief valve etc.as required and shall be mounted on a single
base.
9) Two (2) nos. CPU Regeneration cum Resin Transfer Pumps each with electric drive motor drives, one
normally operating and the other standby, for water supply for chemical preparation / dosing and transfer
of resin from service vessel to regeneration vessels & vice-versa, backwash & rinse activities shall be
provided. These CPU Regeneration cum Resin Transfer Pumps will take suction from DM water
storage tanks (DM water storage tanks not in bidder’s scope).
Page 22 of 680

10) All integral pipe works, valves, internals, fittings, hangers, supports and appurtenances etc. for these
vessels.
II. BULK ACID AND ALKALI UNLOADING AND DOSING FACILITY
The Acid and alkali unloading equipment for regeneration of condensate polishing resins shall
preferably be mounted on skid.
a) One (1) no. hose Station for Transfer of Hydrochloric Acid (30-33% HCl).The hose station shall consist
of one (1) no. of hose pipe. Hose size shall be of 80 mm /NB @ 20 m, provided along with coupling &
diaphragm type isolation valves.
b) One (1) no. hose station for transfer of Alkali (48% NaOH). The hose station shall consist of one (1) no.
of hose pipe. Hose size shall be of 80 mm /NB @ 20 m, provided along with coupling & diaphragm type
isolation valves.
c) Two (2) nos. Bulk Acid storage tanks complete with integral pipe works, valves, level transmitter, level
gauges, fume absorber cum overflow seal pot and all other accessories required. Further each of these
bulk acid storage tanks have One spare nozzles of min 65NB size along with one isolation valve for
chemical supply up to RO-DM plant by gravity.
d) Two (2) nos. Bulk Alkali storage tanks complete with integral pipe works, valves, level transmitter, level
gauges, CO2 absorber, over flow seal pot and all other accessories required. Further each of these bulk
alkali storage tanks have One spare nozzles of min 65NB size along with one isolation valve for
chemical supply up to RO-DM plant by gravity.
e) Two nos. (2X100%) Acid unloading pumps each complete with electrical drive motor and all other
accessories as required.
f) Two nos. (2X100%) Alkali unloading pumps each complete with electrical drive motor and all other
III. ALKALI PREPARATION FACILITY
In order to facilitate erection at site chemical dosing preparation equipment shall be mounted on
structural steel skids and assembled (including piping) at the manufacturer’s shop, to the maximum
extent possible, prior to shipping. The number of mechanical connections shall be minimised by the
use of pipe headers wherever possible. The bidder may also supply and install these equipment’s
independently instead of assembling the skids. Complete facility for preparing alkali solution from
alkali lye & flakes shall be included in Bidder’s scope. This will consist of the following:
a) One number alkali solution preparation tank. The tank shall consist of slow speed agitator driven by
motor, carbon dioxide absorber, overflow seal pot, dissolving basket, integral pipe works, valves and all
other required accessories. The tank capacity shall be equal to 120% of regeneration requirement of
one regeneration.
b) One (1) no. hot water tank for heating of alkali diluent water with (2X50%) electric heating coil,
adequately insulated of stainless steel construction shall be provided complete with integral pipe works,
valves, instrumentation and all other accessories required shall be provided. The capacity of tank shall
be minimum 20% higher than the maximum water demand. This tank shall be provided with burn out
protection, pressure relief valve, level switches, temperature indicator etc. The heaters shall be sized for
heating the water from a temperature of 15 to 50 deg. C in 5 hours at the outlet of ejector.
c) Two (2) nos. (1W+1S) alkali transfer cum recirculation pumps. These pumps shall be provided with a
pulsation dampener at the outlet header of each pump along with necessary valves & instrumentation &
d) One (1) no. Activated carbon filter for alkali complete with internals, integral pipe works, valves and all
other accessories as required. Activated Carbon Filter for alkali rated flow of the filter shall not be less
than the design capacity of the alkali unloading pump /alkali transfer cum recirculation pump (as
applicable), and the maximum velocity through the filter for this flow shall not exceed 12 meters/hour:
Depth of the filter materials shall not be less than 1 meter.
Page 23 of 680
e) One number Carbon trap shall be provided at the outlet line of Activated carbon filter. This
carbon trap shall have screen opening of 60 mesh.
f) All interconnecting piping, valves and fittings & instrumentation as required to complete the system.
IV. ACID AND ALKALI DOSING SYSTEM
The Acid and alkali dosing equipment for regeneration of condensate polishing resins shall preferably
be mounted on skid and shall be in bidder’s scope. All the equipment, piping etc. shall be assembled
on two structural steel skids one for acid and one alkali dosing equipment. The Acid and Alkali dosing
systems shall be skid mounted and shall consist of at least following equipment’s:
a) Two (02) numbers acid measuring tanks complete with fume absorbers, overflow seal pot, integral pipe
works, valves, instrumentation and all other accessories required. Each tank capacity shall be equal to
120% of regeneration requirement of one regeneration.
b) One (1) no. Alkali measuring (day) tank including slow speed agitator driven by motor complete with
carbon dioxide absorber, overflow seal pot , integral pipe works, valves, instrumentation and all other
accessories required. The tank capacity shall be equal to 120% of regeneration requirement of one
regeneration.
c) Two (02) numbers (1W+1S) Positive displacement type metering pumps for acid dosing with electric
motor drive, pulsation dampener & safety relief valve at the outlet header of each pump along with all
other required accessories.
d) Two (02) numbers (1W+1S) Positive displacement type metering pumps for alkali dosing with electric
motor drive, pulsation dampener & safety relief valve at the outlet header of each pump along with all
other required accessories.
e) Diluent water supply separately, for acid and alkali, each provided with an automatic on-off valve, a
throttling valve for setting of flow, a local flow indicator, and a mixing tee where the chemicals get
injected into the water stream.
f) All necessary suction and discharge piping for these pumps including all strainers, valves and fittings as
required, upto the mixing tee with the diluent water.
g) All the equipment, piping etc. shall be assembled on two structural steel skids one for acid and one for
alkali dosing equipment. The bidder shall supply all anchor bolts, foundation plates, sleeves, nuts,
inserts etc. to be embedded in concrete for these equipment skids. The length of the foundation bolts
shall be liberally sized to reach below the reinforcement level. Each equipment skid shall be provided
with suitable lighting lugs, eye bolts etc. to facilitate erection and maintenance.
C. NPIT AND NPIT DISPOSAL SYSTEM
a) One (1) no. Neutralization Pit of RCC construction (civil work not in bidder’s scope) with two (2)
compartments with acid and alkali resistant lining/tiling along with isolation gates shall be provided in the
CPU regeneration area. Each section shall have capacity to hold 150% of waste water generated from
CPU in one regeneration + 120% of waste generated from RO –DM plant in one regeneration (170 m3
considering margin) . Dosing of acid and alkali shall also be provided to neutralize effluents of CPU
regeneration waste before disposal.
b) One (1) no. Acid Measuring Tank for Neutralization- pit complete with fume absorbers, overflow seal pot,
integral pipe works, valves, instrumentation & all other accessories as required shall be supplied by
bidder.
c) One (1) no. Alkali Measuring Tank for neutralization-pit along with including slow speed agitator driven
by motor complete with carbon dioxide absorber, overflow seal pot, integral pipe works, valves,
instrumentation and all other accessories as required shall be supplied by bidder.
d) Two (2 x 100%) capacity Waste Recirculation / Disposal pumps of horizontal centrifugal type (rubber
lined) single stage with priming arrangement (two priming tanks for N-pit waste recirculation / disposal
pumps) each complete with electrical drive motor. These pumps shall be of horizontal centrifugal type
with priming arrangement and shall be supplied for waste recirculation and disposal to CMB of ETP.
Page 24 of 680
Each pump capacity shall be selected & designed to empty total volume of one section of the
neutralization pit in 2 hours. Proven agitation system like air agitation, venturi mixing etc. shall be
provided in addition to recirculation from pumps.
e) 2 nos. sluice gate will be provided at the inlet to each compartment of neutralization pit.
f) One no. pH Analyzer at effluent discharge header, shall be in the scope of bidder
g) Two (2) nos. Safety Shower with necessary accessories one in acid & alkali dosing facilities and one in
bulk acid & alkali storage area along with piping and isolation valve shall be in bidder’s scope.
h) All interconnecting piping, valves, instrumentation and fittings as required for the N-pit and N-pit disposal
system.
D. PIPING
All the piping as listed below shall be in bidder’s scope. The below indicated pipes shall be designed,
supplied, erected, laid and tested by the bidder. Elbows, tees, flanges Hangers and supports,
embedment plates with lugs etc. required for the below given piping shall also be provided by the
bidder.
i) Service vessel inlet header shall be SA 106 Gr-C (OD 457.2 X 12.7 mm thick)
j) Service vessel outlet header shall be SA 106 Gr C (OD 457.2 X 12.7 mm thick)
k) Rinse water outlet piping shall be SA 106 Gr-C (OD 168.3 x 7.11 mm). The distance between CPU
service vessel to condenser hot well shall be considered as 70 meter for each unit (Total 140 m) and
this piping shall be in bidder’s scope.
l) Resin transfer piping shall be minimum 80 NB and of ASTM A 312 Gr. TP 304 (SS 304) Sch 40
(minimum). One way distance for resin Transfer Piping between farthest service vessel and
regeneration area shall be 550m. In addition to that complete resin transfer piping shall be in bidder’s
scope which shall include the piping inside regeneration area equipments also.
m) Piping handling DM water shall be ASTM A 312 Gr. TP 304 (SS 304) Sch 40 (minimum). One way
distance for DM water piping between farthest service vessel and regeneration area shall be 600 m. In
addition to that complete DM Water piping shall be in bidder’s scope which shall include the piping inside
regeneration area equipments also.
n) N-Pit effluent piping from N-Pit to ETP of CMB shall be minimum 150 NB CPVC Sch. 40. The distance
between N-Pit and CMB (common monitoring basin) of ETP shall be 750 m and this piping shall be in
bidder’s scope.
o) Piping used for handling alkali (concentrated) and alkali solution shall be CPVC Sch. 40 minimum for
complete CPU regeneration area.
p) Piping handling acid service shall be CPVC Sch. 40 for complete CPU regeneration area.
q) Piping for air service shall be hot dip galvanized (heavy grade) steel as per IS 1239.
r) All piping within each of the above skids/equipment shall be in bidder’s scope.
s) Similarly DM water piping from each DM water storage tanks to CPU REGENERATION CUM RESIN
TRANSFER PUMPS (including re circulation lines connected to DM water storage tanks) along with their
isolation valves shall be in bidder’s scope.
t) Further DM water piping from each CPU REGENERATION CUM RESIN TRANSFER PUMPS to service
vessel area and regeneration area all equipments shall be in bidder’s scope.
u) Service water piping (used for cooling of condensate sample & other activities in regeneration area),
piping for gland sealed valve cooling, instrument air piping and service air piping, potable water piping
for eye wash 7 other applications etc. shall be in bidder’s scope.
Page 25 of 680
v) Similarly, all piping between the external regeneration facility and the skids for chemical
dosing and acid/alkali preparation, and acid & alkali storage shall also be designed, supplied, erected
and tested by the bidder. These shall include demineralized water piping to the chemical dosing, acid
/alkali piping from external bulk storage tanks to respective preparation skids, the alkali preparation
skids from the external regeneration facility, alkali solution from its preparation facility to the alkali dosing
skid, dilute chemical solution piping for acid and alkali from the dosing skids to the external regeneration
facility, piping to the preparation/dosing facilities, instrument air piping and power supply for immersion
heaters of the diluent water tank from the regeneration facility, and all instrumentation and control wiring
between these skids, etc.
w) In addition, any additional piping and associated accessories required to complete the system shall be in
bidder’s scope.
NOTE: There will be no price implication to BHEL/Customer from bidder’s side due to addition / deletion in
piping, when the piping quantity increases ± 10% from the specified quantity in the technical specification. Layout
and routing shall be finalized during detailed engineering. However system shall be designed to take care of any
increase or decrease in length of piping.
E. ADDITIONAL REQUIREMENT
1) Operating platforms, ladders, supports and other structural works for each vessel to facilitate
accessibility for operation and maintenance for all the condensate polisher mixed beds, regeneration
vessels, storage tanks, alkali and acid measuring tanks & preparation tanks and other equipment’s
etc. is also in bidder’s scope.
2) Initial charge of all lubricants & grease.
3) All special tools necessary for proper maintenance or adjustment of the equipment packaged in
permanent box. Finish paints for touch-up painting of equipment after erection at site in sealed
container.
4) Start-up and commissioning spares as required.
5) All required elbow, tee, pipe fittings etc. required for erection of the complete system including piping
shall be in bidder’s scope. Bidder to provide the detailed BOQ shall be derived during detail
engineering. Bidder to consider 10% margin over and above the BOQ requirement of all the fittings.
6) Wherever pipe racks are not available, pipes shall run on pedestals or below ground. All fixing items
such as U clamps, nuts, bolts etc. required to lay the pipes on pedestals shall be in bidder’s scope of
work. Coating, wrapping and protection required for buries pipes shall be in bidder’s scope of work.
7) Bidder shall consider 12 m static head + 10% margin in addition to the losses in straight and bend in pipes
and valves etc. while selection of pump head during detailed engineering.
8) The Bidder’s scope includes all the first fill and one year’s topping, requirements of consumables such as
oils, lubricants including grease, servo fluids, gases and essential chemicals etc. Consumption of all these
consumables during the initial operation or PG test of bidder’s supplied equipment (whichever is later)
and final filling after the initial operation OR PG test of bidder’s supplied equipment (whichever is later)
shall also be included in the scope of the Bidder. Bidder shall also supply a quantity not less than 10% of
the full charge of each variety of lubricants, servo fluids, gases, chemicals etc. used which is expected to
be utilised during the first year of operation. This additional quantity shall be supplied in separate
Containers. As far as possible lubricants marketed by the Indian Oil Corporation shall be used. The variety
of lubricants shall be kept to a minimum possible.
9) On completion of erection, a complete list of bearings/ equipment giving their location and identification
marks shall be furnished to the Owner along with lubrication requirements.
10) MCC, PLC control room & battery room shall be located in CPU regeneration area building. All
regeneration vessels and chemical dosing facilities shall be located in CPU regeneration building. Bulk
chemical storage tanks, unloading and transfer pumps shall be located open to sky. Further N-pit shall be
located in open area near CPU regeneration area. CPU regeneration cum resin transfer pumps shall be
located near DM water Storage tanks and shall have been provided with localised KNOPY arrangement
Page 26 of 680
on pump & motor and the same shall be in bidder’s scope.
11) Document approval by customer under Approval category or information category shall not absolve the
vendor of their contractual obligations of completing the work as per specification requirement. Any
deviation from specified requirement shall be reported by the vendor in writing and require written
approval. Unless any change in specified requirement has been brought out by the vendor during detail
engineering in writing while submitting the document to customer for approval, approved document (with
implicit deviation) will not be cited as a reason for not following the specification requirement.
12) In case vendor submits revised drawing after approval of the corresponding drawing, any delay in
approval of revised drawing shall be to vendor’s account and shall not be used as a reason for extension
in contract completion.
13) Bidders shall make Site visit in order to familiarize themselves with existing condition of site before
submitting the bid in order to make their offer complete. During detail engineering also, the successful
bidder shall be responsible for the correctness of details w.r.t. existing facility at site. Customer approval
on any drawing having details of existing facility shall not be cited by the successful bidder a valid reason
for any shortcoming in the work by them. BHEL shall also not entertain any cost implication for any lack of
input data with regard to site during detail engineering.
14) Successful bidder shall furnish detailed erection manual for each of the equipment as well as complete
system supplied under this contract at least 3 months before the scheduled erection of the concerned
equipment / component or along with supply of concerned equipment / component whichever is earlier.
15) Final Electrical Load list will be submitted by the successful bidder as per agreed drawing/ doc submission
schedule. Thereafter any change in the electrical load list shall be entertained only subject to its feasibility,
and BHEL reserves the right to debit the vendor cost of any changes necessitated in the switch
gear /MCC on account of changed loads.
16) Wherever CIVIL works is excluded from the bidder’s scope, successful bidder shall furnish civil
assignment / scope drawings. The corresponding CIVIL drawing prepared by BHEL / CIVIL agency,
based on civil assignment drawing of bidder will be furnished to the successful bidder for concurrence. In
case any modification is required in the civil work already carried out based on final civil inputs given by
vendor, BHEL reserves the right to debit cost of such rework to vendor”.
17) Ladder & platforms shall be provided for each tank for easy accessibility & maintenance purpose by
bidder.
18) All necessary valves and fittings for the installations with the actuators necessary for their remote
operation.
19) Embedment plates with lugs shall also be provided by bidder as per system requirement.
20) All channels & brackets, mounting plates as required for mounting of motors, pumps, stirrers, tank etc.
shall be in bidder’s scope.
21) Start-up and commissioning spares as required.
22) Mandatory spares as per attached Annexure to this technical specification.
23) All necessary structural steel for pipe supporting structure, platforms, walkways / pathways and access
stairs, mechanical plant and equipment, mechanical services and pipe work associated with DM Plant.
24) All Motorized valves with integral starter as per requirement and as indicated in the P&ID.
25) All handrails shall be of 32 mm nominal bore MS pipes (medium class) as per IS: 1161 galvanized using
750 gm/sq. m of zinc. Hand railing shall be a two-rail system with the top rail 1000 mm above the walkway
surface and the intermediate rail 450 mm below the top rail. Handrail post spacing shall be limited to 1500
mm as far as possible but can be proportioned to the length of the opening. In such a case spacing shall
not exceed 1850 mm centre to centre of posts. Hand railing shall be shop fabricated for specific locations
and field welded or bolted to the erected structural steel. Railings shall be provided with 100 mm wide and
8 mm thick MS strip at bottom as toe guard all along the length of railing in horizontal plane. For RCC
stairs, hand railing with 20 mm square MS bar balustrade with suitable MS flat and Aluminium / Teakwood
Page 27 of 680
handrail shall be provided, unless specifically mentioned otherwise.
26) Instrument hook up material shall be in bidder’s scope.
27) Permanent ladder (not rungs) for approaching the top of tanks, valves for All steel inserts with lugs, plates,
bolts, nuts, sleeves, edge angles and all other embedding components etc. as required to grout in civil
works and to support/hold the equipments being supplied under this specification for opening/maintenance
purpose.
28) Wrapping, coating and protection of the entire buried pipe shall be as per IS 10221 or AWWA C 203-93.
29) Any item/work either supply of equipment or erection material which have not been specifically mentioned
in but are necessary to complete the woks for trouble free and efficient operation of the plant shall be
deemed to be included within the scope of this specification and shall be in bidder’s scope without any
commercial, technical and delivery implication to BHEL.
30) If service air required by the bidder in the service vessel area ( for hydro-pneumatic resin transfer
operation etc.) then bidder to provide necessary compressors, valves, piping, fittings, flanges, instruments
etc. to meet the system requirement.
31) All other items are also included in scope of supply as specified in other part of the specification.
32) Bidder to use analysis given in Section –D1 of this technical specification under SALIENT DESIGN
INPUTS/ CRITERIA for NORMAL RUN & START-UP OR CONDENSER LEAK CONDITION for design
of condensate polishing plant.
33) Bidder shall perform the guarantee parameters as per specification requirement to the
satisfaction of owner. The exact modalities of verifying guarantee for the parameters indicated in the
specification shall be finally as agreed with the owner during detailed engineering & mutually agreed.
5.0 SCOPE OF SUPPLY (ELECTRICAL)

Complete electrical as per specification and details indicated in Section C2 (Specific Technical Requirement
Electrical) and D2 (General Technical Requirement Electrical).
6.0 SCOPE OF SUPPLY (C&I)

Complete C&I as per specification and details indicated in Section C3 (Specific Technical Requirement C&I)
and D3 (General Technical Requirement C&I).
7.0 SCOPE OF SUPPLY (CIVIL)

Total Civil is in BHEL’s Scope of work, however complete grouting for equipments, fixing and any concreting
inside the vessels, puddle pipe inside civil structure, nozzles, supporting plate/ structures & lining shall be in
bidder’s scope.
Also detailed Civil Input drawing shall be provided by bidder. Successful bidder shall furnish civil assignment
drawings. The corresponding CIVIL drawing prepared by BHEL / CIVIL agency, based on civil assignment
drawing of bidder.
8.0 SCOPE OF SERVICES
The bidder’s scope also includes following services for scope under this specification:
(i) Erection and commissioning, unloading, storage and handling at site.
(ii) Minor civil work like chipping of foundation, grouting below base plate for all structures, equipment,
grouting of anchor bolts wherever these are not placed in the foundation during casting of foundation
itself, excavation & filling of earth for buried pipes if and as required. To the extent possible, vendor
shall ensure to supply all foundation bolts timely so as to facilitate placement of these bolts while
casting the foundation. Wrapping, coating and protection of all the buried pipe shall be as per IS
10221.
Page 28 of 680
(iii) Pre- Commissioning work such as flushing, hydraulic testing etc. Necessary
consumables and instrumentation as required for inspection and testing at works as well as at site
including pre-commissioning activities shall be arranged by the successful bidder at their own cost.
(iv) Arrangement of all instruments, equipments, lab facilities, reagents, monitoring gadgets for
monitoring, pre-commissioning, carrying out trial run, commissioning, PG test & plant hand over.
(v) Monitoring gadgets, instruments and equipments required for maintenance.
(vi) During commissioning of PLC, bidder shall arrange his concerned PLC sub-vendor personnel at site
for commissioning of PLC at site, as and when required by customer / BHEL without any delay.
(vii) Complete grouting for equipment, fixing and any concreting inside the vessels and lining.
(viii) All personnel required during maintenance, Commissioning, trial run and PG test.
(ix) Trial run for requisite period.
(x) Performance guarantee testing.
(xi) Training of plant Owner’s personnel, O&M operators’ personnel on plant operation and maintenance.
(xii) All other facilities/ services as described in section on site services in specification and related to
CPU Plant scope of work.
(xiii) Relevant requirements as per GTR, GCC, ECC & SCC.
(xiv) Painting shall be as specified in ANNEXURE of this technical specification. However any variation in
the painting schedule as finally approved by BHEL & Customer shall be taken care by the bidder
without any commercial & delivery implication to BHEL & Customer.
(xv) Final touch up paint at site.
9.0 COMMISSIONING SPARES

All the necessary commissioning spares shall be supplied as a part of base offer. Bidder will submit the
list of commissioning spares for CPU plant along with the offer.
10.0 TERMINAL POINTS
10.1 CONDENSATE POLISHING PLANT - SERVICE VESSEL AREA
(i) Service vessel inlet – (OD 457.2 X 12.7 mm thick, SA 106 Gr-C) - Single piping connection near
service vessel area in BC bay for unit 1 & unit -2.
(ii) Service vessel outlet – (OD 457.2 X 12.7 mm thick, SA 106 Gr-C) - Single piping connection near
service vessel area in BC bay for unit 1 & unit -2.
(iii) Rinse water outlet- Rinse water outlet piping (OD 168.3 x 7.11 mm, SA 106 Gr-B) from the service
vessel outlet till condenser hot well for each unit is in the scope of bidder.
(iv) The DM water used for resin transfer operations from the Regeneration building to the Condensate
Polisher vessels shall be terminated by the bidder to the nearest drain trench through drain channel.
(v) 25 NB connection of Instrument air supply at 5 to 7 kg/cm2 (g) – At 5 meter distance from service
vessel area.
(vi) Gland sealing valves cooling water supply & analysers rack cooling water supply piping - Service
Page 29 of 680
water connection (25 NB) at 5 meter distance from service vessel area. Piping inside service
vessel area for mentioned services will be in bidder’s scope.
10.2 EXTERNAL REGENERATION AREA
(i) DM Water Supply –The DM water piping terminal point shall be from outlet nozzles to both DM water
storage tanks (DM water storage tanks not in bidder’s scope) & for recirculation line terminal point
shall be up to the recirculation nozzles to both DM water storage tanks. Piping from these terminal
points to the pump suctions (CPU regeneration cum resin transfer pumps) shall be in the scope of
bidder.
(ii) DM Pumps Recirculation Lines – Piping from CPU regeneration cum resin transfer pumps outlet
lines to DM water storage tanks recirculation nozzle shall also be in the scope of bidder.
(iii) Alkali (48% NaOH)- A spare connection of minimum 65 NB size shall be provided along with
isolation valve in both alkali storage tanks for drawing alkali for RO-DM plant .
(iv) Acid (30-33% HCL)- A spare connection of minimum 65 NB size shall be provided along with
isolation valve in both Acid storage tanks for drawing acid for RO-DM plant .
(v) 25 NB Instrument air supply at 5 to 7 kg/cm2 (g) – At 5 meter distance from the regeneration
building.
(vi) 25 NB Service air supply at 5 to 7 kg/cm2 (g) - At 5 meter distance from regeneration area. If service
air required is more than provided by BHEL, bidder to provide necessary compressors, valves,
piping, fittings, flanges, instruments etc. to meet the system requirement.
(vii) Drinking/potable water (25 NB) and service water (50 NB) - At 5 meter distance from the
regeneration building. However distribution and piping inside regeneration area will be in bidder’s
scope.
(viii) N Pit effluent piping (150 NB) from N Pit up to CMB OF ETP shall be in bidder’s scope. The piping
distance to be considered shall be 750 m.
(ix) RO-DM plant regeneration waste – RO DM plant regeneration waste shall be terminated by the RO-
DM plant bidder near the neutralization pit inlet channel of CPU.
(x) In addition to that detailed terminal points shall be as per the P&ID for CPU plant (BHEL Drg. No.:
PE-DG-412-155A-A001) enclosed with the technical specification.
11.0 PG TEST
Functional Guarantees and liquidated damages shall be as per Section C1C of this specification. Bidder
shall perform the guarantee parameters as per the specification requirement to the satisfaction of Owner.
The exact modalities of verifying guarantee for the parameters indicated in the specification shall be finally as
agreed with the Owner during detailed engineering & mutually agreed. The Bidder shall arrange all the
Monitoring gadgets / instruments / equipment required for performing guarantee parameters (returnable after PG
test).
12.0 EXCLUSIONS
12.1 All civil works including foundation of equipment. However complete grouting for equipment, fixing
and any concreting inside vessels and lining shall be in the scope of the bidder. But civil works
including operating / maintenance platforms and interconnection platforms (if any) with ladders /
stairs & handrails, structural supports and hangers for pipes / cables / ducts, crane rails, all
embedment and inserts with lugs including anchor fasteners, bolts etc., dressing of foundations,
Page 30 of 680
grouting of pockets and underpinning of base plates for equipment / structures and fixing
supports, filling and finishing of openings in walls, floors, cladding, roof and trenches shall be in
vendor’s scope.
12.2 Main pipe trestles interconnecting CPU regeneration building and Service vessel Pipe trestle.
However, auxiliary structure, hanger/support components for all the piping (CPU regeneration area,
in acid/alkali handling area, interconnecting acid/alkali storage area ,CPU service vessels, DM water
piping, resin transfer piping, instrument air piping, service air piping and effluent disposal piping etc.)
are in bidder’s scope.
12.3 Instrument air & service air up to terminal points.
12.4 All chemicals except reagents, monitoring gadgets required for pre- commissioning, commissioning,
trial run and PG test.
12.5 Air conditioning, ventilation & firefighting facilities.
12.6 Other exclusions are mentioned in the respective electrical & C&I portion of this specification.
12.7 Drinking water and service water & DM water up to terminal points.
13.0 QP AND SUB VENDOR APPROVAL
13.1 Minimum QP requirements are specified as C1 D. However any additional comments as given by
BHEL/Customer shall be adhered by the bidder without any commercial & delivery implication to
BHEL.
13.2 Requirement of detailed QP, inspection checklist, certificate of conformance etc. for each equipment
and sub-vendor shall be finalized during detailed engineering stage; decision of BHEL/customer
shall be binding on vendor in this regard. Any changes/additional tests insisted upon by Owner
during approval of QAP’s shall be accepted by bidder without any commercial and delivery
implication to BHEL/Customer. Bidder shall submit the quality plans in BHEL format during detailed
engineering stage. Bidder to note further that during detailed engineering all the QAP’s/check lists
etc. shall be submitted to Customer/BHEL for approval. All inspection & testing etc. shall be carried
out accordingly.
13.3 The sub vendor list (as per Annexure-I) enclosed elsewhere in this specification is indicative only
and is subject to BHEL and Customer approval during detailed engineering stage without any
commercial & delivery implication to BHEL.
13.4 Bidder to propose sub vendor list with following back up documents within 4 weeks of placement of
LOI/LOA. Thereafter no request for additional sub-vendor shall be entertained. The sub vendor list
shall subject to BHEL and Customer approval during detailed engineering stage without any
13.5 Bidder to assess the capability of their proposed sub-vendors in terms of preparation of drawings,
calculations, documents, quality assurance, supply of material etc. as per project schedule before
placing the order on them.
13.6 Dealers are not acceptable for any item of the package. Bidder shall procure all items including
plates, structural, flanges; counter flanges etc. from approved sub vendor only.
13.7 PLC should be procured/ sourced from original manufacturers only; PLC from system house shall
not be acceptable.
14.0 DESIGN/ CONSTRUCTION
In addition to the requirements of Section C & D the following shall also be complied under scope of
this specification.
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The P&I diagram is enclosed herein in this section for bidders compliance.
The material of construction specified in data sheet-A are minimum requirements and material of
construction for other components not specified shall be similarly selected by the bidder for intended
duty which shall be subject to BHEL / Customer approval during detail engineering without any
15.0 DRAWING/DOCUMENTS REQUIREMENT
After award of LOI, following minimum drawing/documents shall be submitted by the bidder for BHEL
and Customer approval. However any additional drawing/document if found necessary for
completion of the engineering, the same shall be submitted by bidder without any commercial &
delivery implication to BHEL.
For the Drawings/Documents Submission Procedure, please refer Annexure elsewhere specified in
this specification. The bidder has to submit the revised drawing/document along with the compliance
sheet indicating enumerate reply to all BHEL and customer comments or observations. Without
compliance sheet the submission of the drawings/documents will not be considered and the delay on
this account will be solely on bidder’s side only. Bidder to comply with the observations of the BHEL
and CUSTOMER without price & delivery implication.
For the Drawings/Documents distribution Procedure, please refer attached Annexure-V. Bidder has
to submit the revised drawing/document along with the compliance sheet indicating enumerate reply
to all BHEL and customer comments or observations. Without compliance sheet the submission of
the drawings/documents will not be considered and the delay on this account will be solely on
bidder’s side only. The numbers of soft copies & hard copies of drawing/documents to be submitted
by the bidder shall be as per enclosed Annexure-V.
After award of LOI/LOA, drawing/documents to be submitted by the bidder for BHEL/Customer

approval has been indicated in Annexure VI. However any additional drawing/document if found
necessary for completion of the engineering, the same shall be submitted by bidder without any
Bidder to note that the successful bidder, during detail engineering, will submit the drg/doc through
web based Document Management System in addition to hard copies to be submitted as per the
Annexure III of this specification. Bidder would be provided access to the DMS for drg/doc approval
and adequate training for the same. Detailed methodology would be finalized during the kick-off
meeting.
Bidder to confirm drawings submission schedule as follows:
 Drawing/documents submission schedule: First submission of basic drawings/ documents –

(Process Design & Sizing Calculation, Resin Data Sheet & curves and P&ID shall be within 4
weeks from the date of LOI and Operation & Control Philosophy along with Control System
Configuration Diagram, and Equipment Layout within 6 weeks from the date of LOI.)
 Every revised submission incorporating comments – within 7 working days.
 Bidder further confirmed that drawings submitted shall be complete in all respects with revised
drawing submitted incorporating all comments. Any incomplete drawing submitted shall be treated
as non-submission with delays attributable to bidder’s account. . Engineering meeting shall be held
fort nightly, for which the bidder shall depute his concerned engineer along with project manager to
BHEL PEM office or at customer office. The meeting can also be held at site.
 Bidder to also provide the auto-cad copy of the all drawings (i.e. P& ID, Equipment Layout, Civil
assignment drawing, cable tray/trench layout drawings, piping layout drawings) & Excel files of
documents ( i.e. Process design & sizing calculation, pressure drop calculation, valve schedule,
instrument schedule etc.) for checking of the document during detail engineering stage.
Page 32 of 680

Bidder to ensure following requirements at their end for engineering drawing/ document submissions:
 Internet explorer version – Minimum Internet Explorer 7

 Internet speed – 2 mbps (Minimum preferred)
 Pop ups from our external DMS IP (124.124.36.198) should not be blocked
 Vendor’s Internal proxy setting should not block DMS application’s link
(http://124.124.36.198/wrenchwebaccess/login.aspx)”
 DMS user manuals to be used by BHEL PEM vendors for uploading, viewing, revising,
commenting and tracking documents on PEM’s DMS have been uploaded on PEM internet
website (www.bhelpem.com) under the Vendor session.
 For quick access bidder may refer the link http://bhelpem.com/DMSManuals/DMSManuals.html
16.0 SPARES
The Bidder shall include in his scope of supply all the necessary Mandatory spares, start up and
commissioning spares as indicated in the relevant sections of specifications. The general
requirements pertaining to the supply of these spares is given below:-
16.1 MANDATORY SPARES
i) All the Mandatory spares for the equipment under the contract provided by the vendor will strictly
conform to the specifications and documents and will be identical to the corresponding main
equipment/components supplied under the contract.
ii) The list of mandatory spares which is to be considered by bidder in their scope are indicated in
respective Annexure-II mentioned elsewhere in this specification.
iii) Whenever the quantity is mentioned in "sets" the bidder has to give the item details and prices of each
item.
iv) All mandatory spares shall be delivered at site at least two months before scheduled date of initial
operation of the first unit. However, spares shall not be dispatched before dispatch of corresponding
main equipments.
v) Wherever quantity is specified both as a percentage and a value, the Bidder has to supply the higher
quantity until and unless specified otherwise.
vi) Inspection of mandatory spares shall be in line with the approved quality plans for the respective
items/equipments. The inspection categorisation of mandatory spares shall also be in line with the
approved Categorisation plan for the respective items/equipment.
16.2 RECOMMENDED SPARES
Bidder shall also provide a list of recommended spares for 3 years of normal operation of the
Condensate polishing plant.
16.3 START-UP & COMMISSIONING SPARES
i) Start-up and commissioning spares are those spares which are required during the start-up and
commissioning of the equipment/system. All spares used till the plant is handed over to the
BHEL/Customer shall come under this category. The Bidder shall provide for an adequate stock of
such start up and commissioning spares to be brought by him to the site for the plant erection and
commissioning. They must be available at site before the equipments are energized. The unused
spares, if any, should be removed from there only after the issue of Taking Over certificate. All start up
spares which remain unused at the time shall remain the property of the Bidder.
Page 33 of 680
Notes:
1) The Bidder shall indicate the service expectancy period for the spares parts (mandatory) under
normal operating conditions before replacement is necessary.
2) All spares supplied under this contract shall be strictly inter changeable with the parts for which
they are intended for replacements. The spares shall be treated and packed for long storage under
the climatic conditions prevailing at the site e.g. small items shall be packed in sealed transparent
plastic with desecrator packs as necessary.
3) All the spares (mandatory) shall be manufactured along with the main equipment components as a
continuous operation as per same specification and quality plan.
4) Each spares part shall be clearly marked or labelled on the outside of the packing with its
description. When more than one spares part is packed in a single case, a general description of
the content shall be shown on the outside of such case and a detailed list enclosed. All cases,
containers and other packages must be suitably marked and numbered for the purposes of
identification.
5) All cases, containers or other packages are to be opened for such examination as may be
considered necessary by BHEL / Customer.
6) The Bidder will provide the BHEL/Customer with all the addresses and particulars of his sub
suppliers while placing the order on vendors for items/components/equipments covered under the
contract and will further ensure with his vendors that the BHEL/Customer, if so desires, will have
the right to place order for spares directly on them on mutually agreed terms based on offers of
such vendors.
7) The Bidder shall warrant that all spares supplied will be new and in accordance with the contract
Documents and will be free from defects in design, material and workmanship.
8) The bidder to provide datasheets/assembly drawings of the manufacturer/ any other relevant
document showing Bill of Material(s), Make, Model Number, Part Number etc. through which the
mandatory spares to be supplied can be uniquely identified.
9) The bidder shall guarantee the long term availability of spares to the BHEL/Customer for the full life
of the equipment covered under the contract. The Bidder shall guarantee that before going out of
production of spares parts of the equipment covered under the Contract, He shall give the
BHEL/Customer at least 2 years advance notice so that the latter may order his bulk requirement
of spares, if he so desires. The same provision will also be applicable to sub-vendors. Further, in
case of discontinuance of manufacture of any spares by the Bidder and/or his sub-vendors, bidder
will provide the BHEL/Customer, two years in advance, with full manufacturing drawings, material
specifications and technical information including information on alternative equivalent makes
required by BHEL /Customer for the purpose of procurement of such items.
10) Wherever quantity has been specified as percentage (%), it shall mean percentage (%) of the total
population of the item in the station (project), unless specified otherwise and the fraction will be
rounded off to the next higher whole number.
11) Wherever the quantities have been indicated for each type, size, thickness, material, radius, range
etc. these shall cover all the items supplied and installed and the break up for these shall be
furnished.
12) In case spares indicated in the list are not applicable to the particular design offered by the bidder,
the bidder should offer spares applicable to offered design with quantities.
Page 34 of 680
13) Identification: Each spare shall be clearly marked and labelled on the outside of the
packing with its description. When more than one spare part is packed in single case, a general
description of the contents shall be shown on the outside of such case and a detailed list enclosed.
All cases, containers and other packages must be suitably marked and numbered for the purpose
of identification.
Any other documents submitted by bidder except as asked in the bid’s specification shall not be evaluated
& considered as null & void.
17.0 MISCELLENEOUS REQUIREMENT
I. Bidders is advised to visit the site in order to familiarize themselves with existing condition of site
before submitting the bid in order to make their offer complete. During detail engineering also, the
successful bidder shall be responsible for the correctness of details wrt existing facility at site.
Customer approval on any drawing having details of existing facility shall not be cited by the
successful bidder a valid reason for any shortcoming in the work by them. BHEL shall also not
entertain any cost implication for any lack of input data with regard to site during detail engineering.
II. The complete system shall be proven and necessary design documentation in support of
proveness shall be submitted by the successful bidder in support of the systems, if asked by the
customer without any price and delivery implication to BHEL and customer.
III. System to be designed to meet all the statutory requirements. Preparation of all necessary
drawings/data/ documents for obtaining necessary Approval of statutory authorities like CCOE ,
IBR , Weight & Measures Department and any other agency/ competent authority ,on behalf of the
customer, related to installation of CPU plant (if required) is included in bidder’s scope. All
expenses required to obtain the approval shall also be borne by the successful bidder. Successful
bidder shall inform customer well in advance requirement of authority letter along with format for
the same. After issuance of authority letter by customer, it will be vendor’s responsibility to
regularly follow up with the concerned authorities to obtain timely approval from these authorities.
Any delay on account of the same, unless any specific information related to above approval to be
furnished by customer is delayed by customer, shall be to vendor’s account and shall not be used
as a reason for extension in contract completion.
IV. Vendor to attend regular engineering meeting with BHEL and customer fortnightly in BHEL or
customer office as decided during detail engineering. Vendor will depute all his concerned
engineering representative along with the project manager for discussion and approval. Meeting
can be held at site also.
V. In case of any conflict and repetition of clauses in the specification, the more stringent
requirements among them are to be complied with.
VI. Latest version of all codes and standards to be followed.
VII. CPU regeneration facilities (except bulk acid & alkali storage and Neutralisation pit which area kept
in open) shall be housed in RCC Building. Control room, battery room & MCC room for CPU plant
shall be shall be housed shall be located in RCC building. RCC building shall have toilet blocks for
ladies and gents.
VIII. Bidder to submit BBU during detailed engineering after approval of Basic documents. BBU shall be
equal to BOQ for the package and there shall be no price and delivery implication is applicable to
BHEL / customer for the same. None of the items supplied for the project as non-billable.
Incomplete BBU shall not be review by BHEL.
IX. Any statutory requirement / clearance required for the package from government / local body shall
be in bidder’s scope.
Page 35 of 680
X. All interconnecting piping, valves, fittings including dosing piping, drain piping from
tanks to nearby drain, flushing lines from nearest available water source, valves, fittings and
accessories is also in bidder’s scope.
XI. All the vertical pumps shall be self-lubricating type.

XII. Document approval by customer under Approval category or information category shall not
absolve the vendor of their contractual obligations of completing the work as per specification
requirement. Any deviation from specified requirement shall be reported by the vendor in writing
and require written approval shall be taken from BHEL. Unless any change in specified
requirement has been brought out by the vendor during detail engineering in writing while
submitting the document to customer for approval, approved document (with implicit deviation) will
not be cited as a reason for not following the specification requirement.
XIII. KKS numbering if required, as per BHEL/Customer requirement shall be provided by the Bidder
during detailed engineering stage without any commercial/delivery implication to BHEL.
XIV. Any item/work either supply of equipment or erection material which have not been specifically
mentioned but are necessary to complete the works for trouble free and efficient operation of the
plant shall be deemed to be included within the scope of this specification. The bidder without any
extra charge shall provide the same.
XV. Buried piping shall be protected as under (as per IS-10221).

Surface cleaning by wire brush, power tool cleaning etc.
Apply one coat of coaltar/primer/enamel.
Apply one layer of tape comprising of coaltar. Application of tape shall conform to AWWA C-
203/IS 10221 (appendix-B) with Minimum thickness of tape as 4MM +10%
XVI. All drawings/documents shall be approved by BHEL/Customer during detailed engineering stage.
Successful Bidder shall comply with the comment of the customer/BHEL without price & delivery
implication.
XVII. Successful bidder shall furnish detailed erection manual for each of the equipment as well as
complete system supplied under this contract at least 3 months before the scheduled erection of
the concerned equipment / component or along with supply of concerned equipment / component
whichever is earlier.
XVIII. Final Electrical Load list will be submitted by the successful bidder as per agreed drawing/ doc
submission schedule. Thereafter any change in the electrical load list shall be entertained only
subject to its feasibility, and BHEL reserves the right to debit the vendor cost of any changes
necessitated in the switch gear /MCC on account of changed loads.
XIX. Wherever CIVIL works is excluded from the bidder’s scope, successful bidder shall furnish civil
assignment / scope drawings. The corresponding CIVIL drawing prepared by BHEL / CIVIL
agency, based on civil assignment drawing of bidder will be furnished to the successful bidder for
concurrence. In case any modification is required in the civil work already carried out based on
final civil inputs given by bidder, BHEL reserves the right to debit cost of such rework to bidder.
XX. In case vendor submits revised drawing after approval of the corresponding drawing, any delay in
approval of revised drawing shall be to vendor’s account and shall not be used as a reason for
extension in contract completion.
XXI. Bidders shall make Site visit in order to familiarize themselves with existing condition of site
before submitting the bid in order to make their offer complete. During detail engineering also, the
successful bidder shall be responsible for the correctness of details w.r.t. existing facility at site.
Customer approval on any drawing having details of existing facility shall not be cited by the
successful bidder a valid reason for any shortcoming in the work by them. BHEL shall also not
entertain any cost implication for any lack of input data with regard to site during detail engineering.
Page 36 of 680
18.0 PAINTING
Painting shall be C1 E of technical specification. Internal painting of the equipments shall be suitable
for withstanding effect of effluent. Outer painting shall be as per technical specifications. Supporting
documents shall be furnished in support of suitability of the lining offered for the duty conditions by
bidder during detailed engineering.
19.0 HOIST AND TROLLEYS WITH MONORAILS
For items weighing 300 kg and above, hoists and trolleys along with monorails shall be provided
throughout the plant where crane cannot be utilized. For items weighing less than 1000 kg, manual
hoists shall be provided. For items weighing 1000 kg and more, electric hoists (lift & travel) shall be
provided. In case the lifting height is more than 10m, electric hoist (lift & travel) shall be provided
irrespective of the weight. All hoists shall be provided with trolleys.
19.1 CAPACITY OF CRANES & HOISTS

Capacity of cranes & hoists shall be selected considering a minimum margin of 25% over the
maximum weight of the heaviest equipment / component to be handled by the Crane/Hoist.
19.2 ELECTRICAL REQUIREMENTS
Electrical equipment shall be adequately rated to permit simultaneous operation of nay combination
of motions of the crane for it duty service.
19.2.1 Motor ratings shall be 25% (at least) over the maximum power requirement. The hoist motors
shall be rated to lift 125% of the design load at rated speed.
19.2.2 Motors shall suit the duty class S4, cyclic duration factor 60% and 300 starts per hour and shall
be suitable for VVF operation. Motor pull out torque shall not be less than 2.75 times/ rated
torque. Motor shall have class F insulation temperature rise limited to class B and enclosures
shall conform to the degree of protection IP-55.
19.2.3 All motors shall be capable of the following:
• Operating satisfactorily at full load for 5 minutes without injurious heating with 75% rated voltage
at motor terminals.
• Withstand 120% of rated speed for two minutes.
• Current shall not exceed 6 times full load current for creep speed motor.
• Withstanding the stresses imposed if started at 110% rated voltage.
• Start with rated load and accelerate to full speed with 80% rated voltage at motor terminals.
• The locked rotor motor withstand time under hot condition at 110% rated voltage shall be more
than motor starting time at minimum permissible voltage by at least 3 seconds for motors upto
20 seconds starting time.
• Maximum torque shall not be below 200% of full load torque.
19.2.4 Each motor more than 30 KW rating shall be provided with space heater. All electrical equipment
accessories and wiring shall have tropical protection.
19.2.5 The VVF drive control shall be used for control of each motion. The VVF drive shall be equipped
at least with 1024 pulse incard, droop control for synchronization and crane software. The rating
of VVF shall be decided considering 250% of full load current of respective drive motor based on
in panel rating with derated at 50 Deg C ambient temperature.
The crane(s) shall be furnished complete with all electrical equipment, accessories, like drive
motors with VVF drives, conductors, insulators, protective & operating devices, cables, current
collectors, all protective devices, anti-collision limit switches, mechanical overload and protection
for electrical faults etc.
Page 37 of 680
19.3 DSL
19.3.1 DSL shall meet the following requirements:
• Shrouded bus bar type.

• Minimum 20% allowance for wear and tear shall be considered during sizing.
• Voltage drop for all conductors and cables/ wires shall be limited to 3% of rated voltage between
the main disconnect witch and motor terminals.
19.4 LIMIT SWITCHES
The limit switches shall be totally enclosed type IP-55. Each hoist shall be furnished with two (2)
limit switches meeting the following requirements:
• A screw type limit switch with self-resetting features which will act in case of over hoisting.
• A gravity operated hand reset type limit switch as a backup protection against over hoisting.
Track type limit switches shall be provided on the bridge and trolley to prevent over travelling in
either direction.
19.5 Trailing cable shall be 1100 V grade, tinned copper, heat resistant, with EPR insulation and as per
Class – 5 of IS-8130. Also should have inner PCP sheath and outer CSP sheath with nylon chord
reinforcement & heat resistant, oil resistant and flame retardant heavy duty FRLS type.
19.6 CONTROL & INSTRUMENTATION REQUIREMENTS
19.6.1 Necessary start/stop and emergency controls shall be provided. Automatic reset type limit
switches shall be provided to prevent over-travel for-
a) Over hoisting and lowering motions of the hook.

b) Long travel motion
c) Cross travel motion
19.7 OPERATING SPEEDS FOR MISCELLANEOUS HOISTS

a. Hoist : 3 m/min
b. Trolley travel : 6 m/min
c. Long travel : 10 m/min
d. Creep speed : 10% of full speed (as applicable)
e. Crane runway rails : Rails to suit
Notes:
1. Area, type, capacity mentioned are minimum requirement and shall be finalized during detail
engineering without any commercial implication.
2. Travel and Lift are layout dependent and shall be finalized during detail engineering without any
commercial implication.
3. Additional electric/manual hoist required during detail engineering shall be provided as per
design criteria given above without any commercial implication.
20.0 MINIMUM IMPORTED ITEMS
i) Resins.
Page 38 of 680

SECTION C1 – B
GENERAL REQUIREMENT
Page 39 of 680
CHAPTER – 3
GENERAL TECHNICAL REQUIREMENTS
1.00.00 INTRODUCTION
This part covers technical requirements, which will form an integral part of the
Contract. The following provisions shall supplement all the detailed technical
requirements brought out in the Technical Specifications and the Technical
Data Sheets.
2.00.00 BRAND NAME
Whenever a material or article is specified or described by the name of a

particular brand, manufacturer or vendor, the specific item mentioned shall be
understood to be indicative of the function and quality desired, and not
restrictive; other manufacturer's products may be considered provided
sufficient information is furnished to enable the Owner to determine that the
products proposed are equivalent to those named.
3.00.00 BASE OFFER & ALTERNATE PROPOSALS
The Bidder's proposal shall be based upon the use of equipment and material
complying fully with the requirements specified herein. It is recognized that
the Bidder may have standardized on the use of certain components,
materials, processes or procedures different than those specified herein.
Alternate proposals offering similar equipment based on the manufacturer's
standard practice may also be considered, provided the base offer is in line
with technical specifications and such proposals meet the specified design
standards and performance requirement and are acceptable to the Owner.
Sufficient amount of information for justifying such proposals shall be
furnished to Owner along with the bid to enable the Owner to determine the
acceptability of these proposals.
4.00.00 COMPLETENESS OF FACILITIES
4.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant shall be engineered and
designed in accordance with the specification requirement. All engineering
and associated services are required to ensure that a completely engineered
plant is provided.
4.02.00 All equipment furnished by the Bidder shall be complete in every respect, with
all mountings, fittings, fixtures and standard accessories normally provided
with such equipment and/or those needed for erection, completion and safe
operation & maintenance of the equipment and for the safety of the operating
personnel, as required by applicable codes, though they may not have been
specifically detailed in the respective specifications, unless included in the list
of exclusions.
Page 40 of 680
All similar standard components/ parts of similar standard equipment

provided, shall be interchangeable with one another.
5.00.00 CODES & STANDARDS
5.01.00 In addition to the codes and standards specifically mentioned in the relevant
technical specifications for the equipment / plant / system, all equipment
parts, systems and works covered under this specification shall comply with
all currently applicable statutory regulations and safety codes of the Republic
of India as well as of the locality where they will be installed, including the
following:
(a.) Bureau of Indian Standards (BIS)
(b.) Indian electricity act
(c.) Indian electricity rules
(d.) Indian Explosives Act
(e.) Indian Factories Act and State Factories Act
(f.) Indian Boiler Regulations (IBR)
(g.) Regulations of the Central Pollution Control Board, India
(h.) Regulations of the Ministry of Environment & Forest (MoEF),

Government of India
(i.) Pollution Control Regulations of Department of Environment,

Government of India
(j.) State Pollution Control Board.
(k.) Rules for Electrical installation by Tariff Advisory Committee (TAC).
(l.) Any other statutory codes / standards / regulations, as may be

applicable.
5.02.00 Unless covered otherwise by Indian codes & standards and in case nothing to
the contrary is specifically mentioned elsewhere in the specifications, the
latest editions (as applicable as on date of bid opening), of the codes and
standards given below shall also apply:
(a.) Japanese Industrial Standards (JIS)

(b.) American National Standards Institute (ANSI)
(c.) American Society of Testing and Materials (ASTM)
(d.) American Society of Mechanical Engineers (ASME)
Page 41 of 680
(e.) American Petroleum Institute (API)

(f.) Standards of the Hydraulic Institute, U.S.A.
(g.) International Organisation for Standardization (ISO)
(h.) Tubular Exchanger Manufacturer's Association (TEMA)
(i.) American Welding Society (AWS)
(j.) National Electrical Manufacturers Association (NEMA)
(k.) National Fire Protection Association (NFPA)
(l.) International Electro-Technical Commission (IEC)
(m.) Expansion Joint Manufacturers Association (EJMA)
(n.) Heat Exchange Institute (HEI)
5.03.00 Other International/ National standards such as DIN, VDI, BS, etc. shall also
be accepted for only material codes and manufacturing standards, subject to
the Owner's approval, for which the Bidder shall furnish, alongwith the offer,
adequate information to justify that these standards are equivalent or superior
to the standards mentioned above. In all such cases the Bidder shall furnish
specifically the variations and deviations from the standards mentioned else
where in the specification together with the complete word to word translation
of the standard that is normally not published in English.
5.04.00 As regards highly standardized equipment such as Steam Turbine and

Generator, National /International standards such as JIS, DIN, VDI, ISO, SEL,
SEW, VDE, IEC & VGB shall also be considered as far as applicable for
Design, Manufacturing and Testing of the respective equipment. In addition,
these standards shall be referred for the design of machine foundations,
wherever specifically mentioned in the specifications. However, for those of
the above equipment not covered by these National / International standards,
established and proven standards of manufacturers shall also be considered.
5.05.00 In the event of any conflict between the codes and standards referred to in
the above clauses and the requirement of this specification, the requirement
of Technical Specification shall govern.
5.06.00 Two (2) English language copies of all-national and international codes and/or
standards used in the design of the plant, equipment, civil and structural
works shall be provided by the Bidder to the Owner within two calendar
months from the date of the Notification of Award.
5.07.00 In case of any change in codes, standards & regulations between the date of
bid opening and the date when vendors proceed with fabrication, the Owner
shall have the option to incorporate the changed requirements or to retain the
original standard. It shall be the responsibility of the Bidder to bring to the
notice of the Owner such changes and advise Owner of the resulting effect.
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE
Page 42 of 680
6.01.00 The Equipment and Auxiliaries shall be capable of continuous operation in

frequency range of 47.5 to 51.5 Hz.
6.02.00 The functional guarantees of the equipment under the scope of the Contract
is given elsewhere in the technical specification. These guarantees shall
supplement the general functional guarantee provisions covered under
General Conditions of Contract.
6.03.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the
performance and guarantee tests shall be assessed and recovered from the
Bidder as specified elsewhere in this specification.
7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY

CONSIDERATIONS
7.01.00 Design of Facilities
All the design procedures, systems and components proposed shall have
already been adequately developed and shall have demonstrated good
reliability under similar conditions elsewhere.
The Bidder shall be responsible for the selection and design of appropriate
equipment to provide the best co-ordinate performance of the entire system.
The basic requirements are detailed out in various clauses of the Technical
Specifications. The design of various components, assemblies and
subassemblies shall be done so that it facilitates easy field assembly and
dismantling. All the rotating components shall be so selected that the natural
frequency of the complete unit is not critical or close to the operating range of
the unit.
7.02.00 Maintenance and Availability Considerations
Equipment/facilities offered shall be designed for high availability, low

maintenance and ease of maintenance. The Bidder shall specifically state the
design features incorporated to achieve high degree of reliability/ availability
and ease of maintenance. The Bidder shall also furnish details of availability
records in the reference plants stated in his experience list.
Bidder shall state in his offer the various maintenance intervals, spare parts
and man-hour requirement during such operation. The intervals for each type
of maintenance namely inspection of the furnace, inspection of the entire hot
gas path and the minor and major overhauls shall be specified in terms of
fired hours, clearly defining the spare parts and man-hour requirement for
each stage.
Lifting devices i.e. hoists and chain pulley jacks, etc. shall be provided by the
Bidder for handling of any equipment or any of its part having weight in
excess of 500 Kgs during erection and maintenance activities.
Page 43 of 680
Lifting devices like lifting tackles, slings, etc. to be connected to hook of the
hoist / crane shall be provided by the Bidder for lifting the equipment and
accessories covered under the specification.
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY BIDDER
8.01.00 Each of the plant and equipment shall be fully integrated, engineered and
designed to perform in accordance with the technical specification. All
engineering and technical services required ensuring a completely
engineered plant shall be provided in respect of mechanical, electrical, control
& instrumentation, civil & structural works as per the scope.
The Bidder shall furnish engineering data/drgs. in accordance with the

schedule of information as specified in Technical Specification and data
sheets.
8.02.00 The number of copies/prints/CD-ROMs/manuals to be furnished for various

types of documents is given in Annexure-I attached with Chapter 3.
8.03.00 The documentation that shall be provided by the Bidder is indicated in various
sections of specification. The documentation shall include but not be limited to
the following:
Basic Engineering Documentation
Prior to commencement of the detailed engineering work, the

Bidder shall furnish a Plant Definition Manual within 4-6 weeks from
the date of the Notification of Award. This manual shall contain the
following as a minimum:
i. System description of all the mechanical, electrical, control &

instrumentation & civil systems.
ii. Technology scan for each system / sub-system & equipment.
iii. Selection of appropriate technology / schemes for various systems/

subsystems including techno-economic studies between various
options.
iv. Optimization studies including thermal cycle optimization.
v. Sizing criteria of all the systems, sub-systems including various

piping systems/ equipment/ structures/ equipment foundations
along with all calculations justifying and identifying the sizing and
the design margins.
vi. Schemes and Process & Instrumentation diagrams for the various
systems/ sub-system with functional write-ups.
vii. Operation Philosophy and the control philosophy of the Main Plant
and other plants.
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viii. General Layout plan of the power station incorporating all facilities
in Bidder's as well as those in the Owner's scope. This drawing
shall also be furnished in the form of floppy discs to the Owner for
engineering of areas not included in Bidder's scope.
ix. Basic layouts and cross sections of the main plant building (various
floor elevations), boiler, fuel oil area and other areas included in the
scope of the Bidder.
x. Documentation in respect of Quality Assurance System as listed out

elsewhere in this specification.
xi. The successful bidder shall furnish within three (3) weeks from the
date of Notification of Award, a list of contents of the Plant Definition
Manual (PDMs) including techno-economic studies, which shall
then be mutually discussed & finalised with the Owner.
xii. After approval of Plant Definition Manual / Design Basis Report,

Bidder shall furnish detailed technical specification of all system /
packages of the Plant.
i. Layouts, general arrangements, elevations and cross-sections

drawings for all the equipment and facilities of the plant.
ii. Flow diagrams, Process & Instrumentation Diagrams alongwith

write-up and system description.
iii. Start-up curves for turbine, boiler and both turbine and boiler
combined together as a unit for various start-ups, viz. cold, warm
and hot start-up.
iv. Piping isometric, composite layout and fabrication drawings.
v. Piping engineering diagrams, pipe and fittings schedules, valve

schedules, hanger and support schedules, insulation schedules.
vi. Technical data sheets for all bought out and manufactured items.
Bidder shall use the specifications as a base for placement of
orders on their sub-vendors.
vii. Detailed design calculations for components, system/sub-system,,

piping etc., wherever applicable including sizing calculations for all
auxiliaries as per criteria specified elsewhere in specification.
viii. Boiler pressure part schedule and sizing calculations. Boiler

performance data and boiler design dossier.
ix. Transient, hydraulic and thermal stress analysis of piping and

system wherever applicable & input and output data alongwith
stress analysis isometrics showing nodes.
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x. Thermal cycle information (heat balance diagrams, boiler

performance calculations, condenser and heat exchanger thermal
calculations etc.).
xi. Characteristic Curves/ Performance Correction Curves. Hydraulic &

Mechanical design calculations for condensers & heaters.
xii. Comprehensive list of all terminal points which interface with

Owner's facilities giving details of location, terminal pressure,
temperature, fluid handled & end connection details, forces,
moments etc.
xiii. Power supply single line diagram, block logics, control schematics,
electrical schematics, etc.
xiv. Protection system diagrams and relay settings.
xv. Interconnection diagrams.
xvi. Cable routing plan.
xvii. Instrument schedule, measuring point list, I/O list, Interconnection &
wiring diagram, functional write-ups, installation drawings for field
mounted instruments, logic diagrams, control schematics, wiring
and tubing diagrams of panels and enclosures etc. Drawings for
open loop and close loop controls (both hardware and software).
Motor list and valve schedule including type of actuator etc.
xviii. Alarm and annunciation list and alarms & trip set points.
xix. Sequence and protection interlock schemes.
xx. Type test reports and power system stability study report.
xxi. Control system configuration diagrams and card circuit diagrams

and maintenance details.
xxii. Detailed software manuals & source software listing.
xxiii. Detailed flow chart for digital control system.
xxiv. Mimic diagram layout.
xxv. Civil Task drawings(for the Engineering by Owner),Design and

Drawings for the Civil & Structural works in the scope of the Bidder.
xxvi. Model study reports wherever applicable.
xxvii. Functional & guarantee test procedures and test reports.
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xxviii. Documentation in respect of Quality Assurance System as listed

out elsewhere in this specification.
xxix. Documentation in respect of commissioning as listed out elsewhere

in this specification.
xxx. The Bidder while submitting the above documents / drawings for
approval / reference as the case may be, shall mark on each copy
of submission the reference letter alongwith the date vide which the
submissions are made.
8.03.01 Instruction Manuals
The Bidder shall submit to the Owner, draft Instruction Manuals for all the
equipment covered under the Contract by the end of one year from the date
of his acceptance of the Letter of Award. The Instruction manuals shall
contain full details required for erection, commissioning, operation and
maintenance of each equipment. The manual shall be specifically compiled
for this project. After finalization and approval of the Owner the Instruction
Manuals shall be submitted as indicated in Annexure-I. The Contract shall
not be considered to be completed for purposes of taking over until the final
Instructions manuals have been supplied to the Owner. The Instruction
Manuals shall comprise of the following.
Erection Manuals
The erection manuals shall be submitted atleast three (3) months prior to the
commencement of erection activities of particular equipment/system. The
erection manual should contain the following as a minimum.
a) Erection strategy.
b) Sequence of erection.
c) Erection instructions.
d) Critical checks and permissible deviation/tolerances.
e) List of tool, tackles, heavy equipment like cranes, dozers, etc.
f) Bill of Materials
g) Procedure for erection.
h) General safety procedures to followed during erection/installation.
i) Procedure for initial checking after erection.
j) Procedure for testing and acceptance norms.
k) Procedure / Check list for pre-commissioning activities.
l) Procedure / Check list for commissioning of the system.
Page 47 of 680
m) Safety precautions to be followed in electrical supply distribution

during erection
Operation & Maintenance Manuals
i. The operating and maintenance instructions together with drawings

(other than shop drawings) of the equipment, as completed, shall be
in sufficient detail to enable the Owner to operate, maintain,
dismantle, reassemble and adjust all parts of the equipment. They
shall give a step by step procedure for all operations likely to be
carried out during the life of the plant / equipment including,
operation, maintenance, dismantling and repair including periodical
activities such as chemical cleaning of the generator. Each manual
shall also include a complete set of drawings together with
performance/rating curves of the equipment and test certificates
wherever applicable. The contract shall not be considered to be
completed for purposes for taking over until these manuals have
been supplied to the Owner.
ii. If after the commissioning and initial operation of the plant, the
manuals require any modification / additions / changes, the same
shall be incorporated and the updated final instruction manuals shall
be submitted to the Owner for records.
iii. A separate section of the manual shall be for each size/ type of
equipment and shall contain a detailed description of construction
and operation, together with all relevant pamphlets and drawings.
iv. The manuals shall include the following :
a) List of spare parts along with their drawing and catalogues and
procedure for ordering spares.
b) Lubrication Schedule including charts showing lubrication

checking, testing and replacement procedure to be carried daily,
weekly, monthly & at longer intervals to ensure trouble free
operation.
c) Where applicable, fault location charts shall be included to

facilitate finding the cause of maloperation or break down.
v. Detailed specifications for all the consumables including lubricant

oils, greases, chemicals etc. system/equipment/assembly/sub-
assembly - wise required for the complete plant.
vi. On completion of erection, a complete list of bearings / equipment

giving their location, and identification marks etc. shall also be
furnished to the Owner indicating lubrication method for each
type/category of bearing.
8.03.02 Plant Handbook
Page 48 of 680
The Bidder shall submit to the Owner a preliminary plant hand book
preferably in A-4 size sheets which shall contain the design and performance
data of various plants, equipment and systems covering the complete project
including
Design and performance data.
1.
Process & Instrumentation diagrams.
2.
Single line diagrams.
3.
Sequence & Protection Interlock Schemes.
4.
Alarm and trip values.
5.
Performance Curves.
6.
General layout plan and layout of main plant building and auxiliary
7. buildings.
Important Do's & Don't's

8.
The plant handbook shall be submitted within twelve (12) months
from the date of award of contract. After the incorporation of Owner's
comments, the final plant handbook complete in all respects shall be
submitted three (3) months before start-up and commissioning
activities.
8.03.03 Project Completion Report
The Bidder shall submit a Project Completion Report at the time of handing
over the plant.
8.03.04 Drawings
(a.) All documents submitted by the Bidder for Owner's review shall be in
electronic form (soft copies) along with the desired number of hard
copies as per Annexure-I. The soft copies to be supplied shall be
either in CDs, or through direct transfer via E-mail, etc. depending
upon the nature/volume/size of the document. The drawings submitted
for approval could be in the Image form.
(b.) Final copies of the approved drawings shall be submitted on CD-ROM

along with the requisite number of hard copies as per Annexure-I.
(c.) The completed plant documentation with equipment drawings, data

sheets, P&ID, BOQ, schematics, logic diagrams, test reports and
quality plan, etc. shall be furnished to Owner.
(d.) All documents/text information shall be in latest version of MS Office.
Page 49 of 680
(e.) All drawings submitted by the Bidder including those submitted at the
time of bid shall be in sufficient detail indicating the type, size,
arrangement, weight of each component for packing and shipment,
the external connection, fixing arrangement required, the dimensions
required for installation and interconnections with other equipment and
materials, clearance and spaces required between various portions of
equipment and any other information specifically requested in the
drawing schedules.
(f.) Each drawing submitted by the Bidder (including those of sub-

vendors) shall bear a title block at the right hand bottom corner with
clear mention of the name of the Owner, Consultant, name of the
Project, system designation, the specifications title, the specification
number, drawing/document number and revisions. If standard
catalogue pages are submitted the applicable items shall be indicated
therein. All titles, notings, markings and writings on the drawing shall
be in English. All the dimensions should be in metric units.
(g.) The Bidder shall also furnish a “Master Drawing List” which shall be a
comprehensive list of all drawings/ documents/ calculations envisaged
to be furnished by him during the detailed engineering to the Owner.
Such list should clearly indicate the purpose of submission of these
drawings i.e. “FOR APPROVAL” or “FOR INFORMATION ONLY”.
(h.) Similarly, all the drawings/ documents submitted by the Bidder during
detailed engineering stage shall be stamped “FOR APPROVAL” or
“FOR INFORMATION” prior to submission.
(i.) The furnishing of detailed engineering data and drawings by the

Bidder shall be in accordance with the time schedule for the project.
The review of these documents/ data/ drawings by the Owner will
cover only general conformance of the data/ drawings/ documents to
the specifications and contract, interfaces with the equipment provided
by others and external connections & dimensions which might affect
plant layout. The review by the Owner should not be construed to be a
thorough review of all dimensions, quantities and details of the
equipment, materials, any devices or items indicated or the accuracy
of the information submitted. The review and/ or approval by the
Owner / Project Manager shall not relieve the Bidder of any of his
responsibilities and liabilities under this contract.
(j.) After the approval of the drawings, further work by the Bidder shall be
in strict accordance with these approved drawings and no deviation
shall be permitted without the written approval of the Owner.
(k.) All manufacturing, fabrication and execution of work in connection with

the equipment / system, prior to the approval of the drawings, shall be
at the Bidder’s risk. The Bidder is expected not to make any changes
in the design of the equipment /system, once they are approved by the
Owner. However, if some changes are necessitated in the design of
the equipment/system at a later date, the Bidder may do so, but such
Page 50 of 680
changes shall promptly be brought to the notice of the Owner

indicating the reasons for the change and get the revised drawing
approved again in strict conformance to the provisions of the
Technical Specification.
(l.) Drawings shall include all installations and detailed piping layout
drawings. Layout drawings for all piping of 65 mm and larger diameter
shall be submitted for review/ approval of Owner prior to erection.
Small diameter pipes shall however be routed as per site conditions in
consultation with site authority/representative of Owner based on
requirements of such piping indicated in approved / finalized Flow
Scheme / Process & Instrumentation Diagrams and/or the
requirements cropping up for draining & venting of larger diameter
piping or otherwise after their erection as per actual physical condition
for the entire scope of work of this package.
(m.) Assessing & anticipating the requirement and supply of all piping and
equipment shall be done by the Bidder well in advance so as not to
hinder the progress of piping & equipment erection, subsequent
system charging and its effective draining & venting arrangement as
per site suitability.
(n.) As Built Drawings
After final acceptance of individual equipment/system by the Owner, the

Bidder will update all original drawings and documents for the equipment/
system to “as built” conditions.
(o.) Drawings must be checked by the Bidder in terms of its completeness,

data adequacy and relevance with respect to Engineering schedule
prior to submission to the Owner. In case drawings are found to be
submitted without proper endorsement for checking by the Bidder, the
same shall not be reviewed and returned to the Bidder for re-
submission. The Bidder shall make a visit to site to see the existing
facilities and understand the layout completely and collect all
necessary data/drawings at site which are needed as an input to the
engineering. The Bidder shall do the complete engineering including
interfacing and integration of all his equipment, systems & facilities
within his scope of work as well as interface engineering & integration
of systems, facilities, equipment & works under Owner’s scope and
submit all necessary drawings/ documents for the same.
(p.) The Bidder shall submit adequate prints of drawing/data/document for

Owner’s review and approval. The Owner shall review the drawings
and return one (1) copy to the Bidder authorizing either to proceed
with manufacture or fabrication, or marked to show changes desired.
When changes are required, drawings shall be re-submitted promptly,
with revisions clearly marked, for final review. Any delays arising out
of the failure of the Bidder to submit/rectify and resubmit in time shall
not be accepted as a reason for delay in the contract schedule.
Page 51 of 680
(q.) All engineering data submitted by the Bidder after final process
including review and approval by the Owner shall form part of the
contract documents and the entire works covered under these
specification shall be performed in strict conformity with technical
specifications unless otherwise expressly requested by the Owner in
writing.
8.04.00 Engineering Information Submission Schedule
Prior to the award of Contract, a Detailed Engineering Information

Submission Schedule shall be tied up with the Owner. For this, the bidder
shall furnish a detailed list of engineering information alongwith the proposed
submission schedule. This list would be a comprehensive one including all
engineering data / drawings / information for all bought out items and
manufactured items. The information shall be categorised into the following
parts.
(a.) Information that shall be submitted for the approval of the Owner
before proceeding further, and
(b.) Information that would be submitted for Owner’s information only.
The Engineering Information Schedule shall be updated monthwise.
The schedule should allow adequate time for proper review and incorporation
of changes/ modifications, if any, to meet the contract without affecting the
equipment delivery schedule and overall project schedule. The early
submission of drawings and data is as important as the manufacture and
delivery of equipment and hardware and this shall be duly considered while
determining the overall performance and progress.
8.05.00 Engineering Progress and Exception Report
8.05.01 Report giving the status of each engineering information including
(a.) A list of drawings/engineering information which remains unapproved

for more than four (4) weeks after the date of first submission
(b.) Drawings which were not submitted as per agreed schedule.
8.05.02 The draft format for this report shall be furnished to the Owner within four (4)
weeks of the award of the contract, which shall then be discussed and
finalized with the Owner.
8.06.00 Co-Ordination Meetings
8.06.01 The Bidder shall be called upon to organize and attend monthly Design/ Co-
ordination Meetings with the Owner/Owner’s representatives, Project
Consultant during the period of contract. The Bidder shall attend such
meetings at his own cost at mutually agreed venue as and when required and
Page 52 of 680
fully co-operate with such persons and agencies involved during the
discussions.
8.06.02 The Bidder should note that Time is the essence of the contract. In order to
expedite the early completion of engineering activities, the Bidder shall submit
all drawings as per the agreed Engineering Information Submission Schedule.
The drawings submitted by the Bidder will be reviewed by the Owner as far as
practicable within three (3) weeks from the date of receipt of the drawing .The
comments of the Owner shall then be discussed across the table during the
above co-ordination Meetings wherein best efforts shall be made by both
sides to ensure the approval of the drawing.
8.06.03 The Bidder shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these
meetings. The Bidder shall be equipped with necessary tools and facilities so
that the drawings/documents can be resubmitted after incorporating
necessary changes and approved during the meeting itself.
8.06.04 Should any drawing remain unapproved for more than six (6) weeks after it’s
first submission, this shall be brought out in the monthly Engineering Progress
and Exception Report with reasons thereof.
8.06.05 Any delays arising out of failure by the Bidder to incorporate Owner’s
comments and resubmit the same during the TCM shall be considered as a
default and in no case shall entitle the Bidder to alter the Contract completion
date.
8.07.00 Design Improvements
The Owner or the Bidder may propose changes in the specification of the
equipment or quality thereof and if the parties agree upon any such changes
the specification shall be modified accordingly.
If any such agreed upon change is such that it affects the price and schedule
of completion, the parties shall agree in writing as to the extent of any
changing the price and/or schedule of completion before the Bidder proceeds
with the change. Following such agreement, the provision thereof, shall be
deemed to have been amended accordingly.
8.08.00 Equipment Bases

A cast iron or welded steel base plate shall be provided for all rotating
equipment which is to be installed on a concrete base, unless otherwise
specifically agreed to by the Owner. Each base plate which support the unit
and its drive assembly, shall be of a neat design with pads for anchoring the
units, shall have a raised lip all around, and shall have threaded drain
connections.
8.09.00 Protective Guards

Suitable guards shall be provided for protection of personnel on all exposed
rotating and/or moving machine parts. All such guards shall be designed for
easy installation and removal for maintenance purpose.
Page 53 of 680
8.10.00 Lubricants, Servo Fluids and Chemicals
8.10.01 The Bidder’s scope includes all the first fill and one year’s topping,
requirements of consumables such as oils, lubricants including grease, servo
fluids, gases and essential chemicals etc. Consumption of all these
consumables during the initial operation and final filling after the initial
operation shall also be included in the scope of the Bidder. Bidder shall also
supply a quantity not less than 10% of the full charge of each variety of
lubricants, servo fluids, gases, chemicals etc. used which is expected to be
utilised during the first year of operation. This additional quantity shall be
supplied in separate Containers.
8.10.02 As far as possible lubricants marketed by the Indian Oil Corporation shall be
used. The variety of lubricants shall be kept to a minimum possible.
Detailed specifications for the lubricating oil, grease, gases, servo fluids,
control fluids, chemicals etc. required for the complete plant covered herein
shall be furnished. On completion of erection, a complete list of bearings/
equipment giving their location and identification marks shall be furnished to
the Owner along with lubrication requirements.
8.11.00 Lubrication
8.11.01 Equipment shall be lubricated by systems designed for continuous operation.

Lubricant level indicators shall be furnished and marked to indicate proper
levels under both standstill and operating conditions.
8.12.00 Material of Construction
8.12.01 All materials used for the construction of the equipment shall be new and
shall be in accordance with the requirements of this specification. Materials
utilized for various components shall be those which have established
themselves for use in such applications.
8.13.00 Rating Plates, Name Plates & Labels
8.13.01 Each main and auxiliary item of plant including instruments shall have
permanently attached to it in a conspicuous position, a rating plate of non-
corrosive material upon which shall be engraved manufacturer’s name,
equipment, type or serial number together with details of the ratings, service
conditions under which the item of plant in question has been designed to
operate, and such diagram plates as may be required by the Owner.
8.13.02 Each item of plant shall be provided with nameplate or label designating the
service of the particular equipment. The inscriptions shall be approved by the
Owner or as detailed in appropriate section of the technical specifications.
8.13.03 Such nameplates or labels shall be of white non-hygroscopic material with

engraved black lettering or alternately, in the case of indoor circuit breakers,
starters, etc. of transparent plastic material with suitably coloured lettering
Page 54 of 680
engraved on the back. The name plates shall be suitably fixed on both front
and rear sides.
8.13.04 Items of plant such as valves, which are subject to handling, shall be provided
with an engraved chromium plated nameplate or label with engraving filled
with epoxy. The name plates for valves shall be marked in accordance with
MSS standard SP-25 and ANSI B 16.34 as a minimum.
8.13.05 Hanger/ support numbers shall be marked on all pipe supports, anchors,
hangers, snubbers and restraint assemblies. Each constant and variable
spring support shall also have stamped upon it the designed hot and cold
load which it is intended to support. Suitable scale shall also be provided to
indicate load on support/hanger.
8.13.06 Valves, steam traps and strainers shall be identified by Owner’s tag number
of a metal tap permanently attached to non pressure parts such as the yoke
by a stainless steel wire. The direction of flow shall also be marked on the
body.
8.13.07 Safety and relief valves shall be provided with the following :
(a.) Manufacturer’s identification.
(b.) Nominal inlet and outlet sizes in mm.
(c.) Set pressure in Kg/cm2 (abs).
(d.) Blowdown and accumulation as percentage of set pressure.
(e.) Certified capacity in Kg of saturated steam per hour or in case of liquid

certified capacity in litres of water per minute.
8.13.08 All such plates, instruction plates, etc. shall be bilingual with Hindi inscription
first, followed by English. Alternatively, two separate plates one with Hindi and
the other with English inscriptions may be provided.
8.13.09 All segregated phases of conductors or bus ducts, indoor or outdoor, shall be
provided with coloured phase plates to clearly identify the phase of the
system
8.14.00 Tools and Tackles
The Bidder shall supply with the equipment one complete set of all special
tools and tackles and other instruments required for the erection, assembly,
disassembly and proper maintenance of the plant and equipment and
systems (including software). These special tools will also include special
material handling equipment, jigs and fixtures for maintenance and calibration
/ readjustment, checking and measurement aids etc. A list of such tools and
tackles shall be submitted by the Bidder alongwith the offer.
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The price of each tool / tackle shall be deemed to have been included in the
total bid price. These tools and tackles shall be separately packed and sent to
site. The Bidder shall also ensure that these tools and tackles are not used by
him during erection, commissioning and initial operation. For this period the
Bidder should bring his own tools and tackles. All the tools and tackles shall
be of reputed make acceptable to the Owner.
8.15.00 Welding
8.15.01 If the manufacturer has special requirements relating to the welding

procedures for welds at the terminals of the equipment to be per formed by
others the requirements shall be submitted to the Owner in advance of
commencement of erection work.
8.16.00 Colour Code for all Equipment/ Pipings/ Pipe Services
8.16.01 All equipment/ piping/ pipe services are to be painted by the Bidder in
accordance with Owner’s standard colour coding scheme, which will be
furnished to the Bidder during detailed engineering stage.
8.17.00 Protection and Preservative Shop Coating
8.17.01 Protection
All coated surfaces shall be protected against abrasion, impact, discoloration

and any other damages. All exposed threaded portions shall be suitably
protected with either metallic or a nonmetallic protection device. All ends of
all valves and piping and conduit equipment connections shall be properly
sealed with suitable devices to protect them from damage. The parts which
are likely to get rusted, due to exposure to weather, should also be properly
treated and protected in a suitable manner. All primers/paints/coatings shall
take into account the hot humid, corrosive & alkaline, subsoil or overground
environment as the case may be.
8.17.02 Preservative Shop Coating
All exposed metallic surfaces subject to corrosion shall be protected by shop

application of suitable coatings. All surfaces which will not be easily
accessible after the shop assembly, shall be treated beforehand and
protected for the life of the equipment. All surfaces shall be thoroughly
cleaned of all mill scales, oxides and other coatings and prepared in the shop.
The surfaces that are to be finish-painted after installation or require corrosion
protection until installation, shall be shop painted with atleast two coats of
primer.
Transformers and other electrical equipment if included shall be shop finished

with one or more coats of primer and two coats of high grade epoxy. The
finished colors shall be as per manufacturer’s standards, to be selected and
specified by the Owner at a later date.
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8.17.03 Shop primer for all steel surfaces which will be exposed to operating
temperature below 95 degrees Celsius shall be selected by the Bidder after
obtaining specific approval of the Owner regarding the quality of primer
proposed to be applied. Special high temperature primer shall be used on
surfaces exposed to temperature higher than 95 degrees Celsius and such
primer shall also be subject to the approval of the Owner.
8.17.04 All other steel surfaces which are not to be painted shall be coated with
suitable rust preventive compound subject to the approval of the Owner.
8.17.05 All piping shall be cleaned after shop assembly by shot blasting or other
means approved by the Owner. Lube oil piping or carbon steel shall be
pickled.
8.17.06 Painting for Civil structures shall be done as per relevant part of technical
specification.
9.00.00 QUALITY ASSURANCE PROGRAMME
9.01.00 The Bidder shall adopt suitable quality assurance programme to ensure that
the equipment and services under the scope of contract whether
manufactured or performed within the Bidder’s works or at his sub-Bidder’s
premises or at the Owner’s site or at any other place of work are in
accordance with the specifications. Such programs shall be outlined by the
Bidder and shall be finally accepted by the Owner/authorized representative
after discussions before the award of the contract. The QA programme shall
be generally in line with IS/ISO-9001. A quality assurance programme of the
Bidder shall generally cover the following:
(a.) His organization structure for the management and implementation of

the proposed quality assurance programme
(b.) Quality System Manual

(c.) Design Control System
(d.) Documentation and Data Control System
(e.) Qualification data for bidder’s key personnel.
(f.) The procedure for purchase of materials, parts, components and

selection of sub-Bidder’s services including vendor analysis, source
inspection, incoming raw-material inspection, verification of materials
purchased etc.
(g.) System for shop manufacturing and site erection controls including
process, fabrication and assembly.
(h.) Control of non-conforming items and system for corrective actions and
resolution of deviations.
(i.) Inspection and test procedure both for manufacture and field activities.
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(j.) Control of calibration and testing of measuring testing equipment.
(k.) System for Quality Audits.
(l.) System for identification and appraisal of inspection status.
(m.) System for authorising release of manufactured product to the Owner.
(n.) System for handling, storage and delivery.
(o.) System for maintenance of records, and
(p.) Quality plans for manufacturing and field activities detailing out the
specific quality control procedure adopted for controlling the quality
characteristics relevant to each item of equipment/component.
9.02.00 General Requirements - Quality Assurance
9.02.01 All materials, components and equipment covered under this specification
shall be procured, manufactured, erected, commissioned and tested at all the
stages, as per a comprehensive Quality Assurance Programme. An
indicative programme of inspection/tests to be carried out by the Bidder for
some of the major items is given in the respective technical specification.
This is, however, not intended to form a comprehensive programme as it is
the Bidder’s responsibility to draw up and implement such programme duly
approved by the Owner. The detailed Quality Plans for manufacturing and
field activities shall be drawn up by the Bidder and will be submitted to Owner
for approval. Schedule of finalisation of such quality plans will be finalised
before award. Monthly progress reports on MQP/FQP submission/approval
shall be furnished.
9.02.02 Manufacturing Quality Plan will detail out for all the components and
equipment, various tests/inspection, to be carried out as per the requirements
of this specification and standards mentioned therein and quality practices
and procedures followed by Bidder’s/ Sub-Bidder’s/ sub-supplier's Quality
Control Organisation, the relevant reference documents and standards,
acceptance norms, inspection documents raised etc., during all stages of
materials procurement, manufacture, assembly and final testing/performance
testing. The Quality Plan shall be submitted on electronic media e.g.
Compact Disc or E-mail in addition to hard copy, for review and approval.
After approval the same shall be submitted in compiled form on CD-ROM.
9.02.03 Field Quality Plans will detail out for all the equipment, the quality practices
and procedures etc. to be followed by the Bidder’s "Site Quality Control
Organisation", during various stages of site activities starting from receipt of
materials/equipment at site.
9.02.04 The Bidder shall also furnish copies of the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc., as referred
in Quality Plans along with Quality Plans. These Quality Plans and reference
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documents/standards etc. will be subject to Owner’s approval without which

manufacturer shall not proceed. These approved documents shall form a part
of the contract. In these approved Quality Plans, Owner shall identify
customer hold points (CHP), i.e. test/checks which shall be carried out in
presence of the Owner’s Project Manager or his authorised representative
and beyond which the work will not proceed without consent of Owner in
writing. All deviations to this specification, approved quality plans and
applicable standards must be documented and referred to Owner along with
technical justification for approval and dispositioning.
9.02.05 No material shall be despatched from the manufacturer’s works before the
same is accepted, subsequent to predespatch final inspection including
verification of records of all previous tests/inspections by Owner’s Project
Manager/Authorised representative and duly authorised for despatch by
issuance of Material Despatch Clearance Certificate (MDCC).
9.02.06 All material used for equipment manufacture including casting and forging etc.
shall be of tested quality as per relevant codes/standards. Details of results
of the tests conducted to determine the mechanical properties; chemical
analysis and details of heat treatment procedure recommended and actually
followed shall be recorded on certificates and time temperature chart. Tests
shall be carried out as per applicable material standards and/or agreed
details.
9.02.07 The Bidder shall submit to the Owner Field Welding Schedule for field welding
activities in the enclosed format No.: QS-01-QAI-P-02/F3. The field welding
schedule shall be submitted to the Owner along with all supporting
documents, like welding procedures, heat treatment procedures, NDT
procedures etc. at least ninety days before schedule start of erection work at
site.
9.02.08 All welding and brazing shall be carried out as per procedure drawn and
qualified in accordance with requirements of ASME Section IX/BS-4870 or
other International equivalent standard acceptable to the Owner.
All welding/brazing procedures shall be submitted to the Owner or its

authorised representative for approval prior to carrying out the
welding/brazing.
9.02.09 All brazers, welders and welding operators employed on any part of the
contract either in Bidder’s/sub-Bidder’s works or at site or elsewhere shall be
qualified as per ASME Section-IX or BS-4871 or other equivalent International
Standards acceptable to the Owner.
9.02.10 Welding procedure qualification & Welder qualification test results shall be
furnished to the Owner for approval. However, where required by the Owner,
tests shall be conducted in presence of Owner/authorised representative.
9.02.11 For all pressure parts and high pressure piping welding, the latest applicable
requirements of the IBR (Indian Boiler Regulations) shall also be essentially
complied with. Similarly, any other statutory requirements for the
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equipment/systems shall also be complied with. On all back-gauged welds

MPI/LPI shall be carried before seal welding.
9.02.12 Unless otherwise proven and specifically agreed with the Owner, welding of
dissimilar materials and high alloy materials shall be carried out at shop only.
9.02.13 No welding shall be carried out on cast iron components for repair.
9.02.14 All the heat treatment results shall be recorded on time temperature charts
and verified with recommended regimes.
9.02.15 All non-destructive examination shall be performed in accordance with written

procedures as per International Standards, The NDT operator shall be
qualified as per SNT-TC-IA (of the American Society of non-destructive
examination). NDT shall be recorded in a report, which includes details of
methods and equipment used, result/evaluation, job data and identification of
personnel employed and details of co-relation of the test report with the job.
All plates of thickness above 40mm & all bar stock/Forging above 40mm dia
shall be ultrasonically tested. For pressure parts, plate of thickness equal to
or above 25mm shall be ultrasonically tested.
9.02.16 The Bidder shall list out all major items/ equipment/ components to be
manufactured in house as well as procured from sub-contractors bought out
items (BOI). All the sub-Bidder proposed by the Bidder for procurement of
major bought out items including castings, forging, semi-finished and finished
components/equipment etc., list of which shall be drawn up by the Bidder and
finalised with the Owner, shall be subject to Owner's approval. The Bidder’s
proposal shall include vendor’s facilities established at the respective works,
the process capability, process stabilization, QC systems followed,
experience list, etc. along with his own technical evaluation for identified sub-
contractors enclosed and shall be submitted to the Owner for approval within
the period agreed at the time of pre-awards discussion and identified in
review category prior to any procurement. Monthly progress reports on sub-
Bidder detail submission / approval shall be furnished. Such vendor approval
shall not relieve the Bidder from any obligation, duty or responsibility under
the contract.
9.02.17 For components/equipment procured by the contractors for the purpose of the
contract, after obtaining the written approval of the Owner, the Bidder’s
purchase specifications and inquiries shall call for quality plans to be
submitted by the suppliers. The quality plans called for from the sub-Bidder
shall set out, during the various stages of manufacture and installation, the
quality practices and procedures followed by the vendor’s quality control
organisation, the relevant reference documents/standards used, acceptance
level, inspection of documentation raised, etc. Such quality plans of the
successful vendors shall be finalised with the Owner and such approved
Quality Plans shall form a part of the purchase order/contract between the
Bidder and sub-Bidder. With in three weeks of the release of the purchase
orders /contracts for such bought out items /components, a copy of the same
without price details but together with the detailed purchase specifications,
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quality plans and delivery conditions shall be furnished to the Owner on the
monthly basis by the Bidder along with a report of the Purchase Order placed
so far for the contract.
9.02.18 Owner reserves the right to carry out quality audit and quality surveillance of
the systems and procedures of the Bidder’s or their sub-Bidder’s quality
management and control activities. The Bidder shall provide all necessary
assistance to enable the Owner carry out such audit and surveillance.
9.02.19 The Bidder shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-Bidder’s and at site to ensure the
mechanical accuracy of components, compliance with drawings, conformance
to functional and performance requirements, identity and acceptability of all
materials parts and equipment. Bidder shall carry out all tests/inspection
required to establish that the items/equipment conform to requirements of the
specification and the relevant codes/standards specified in the specification,
in addition to carrying out tests as per the approved quality plan.
9.02.20 Quality audit/surveillance/approval of the results of the tests and inspection

will not, however, prejudice the right of the Owner to reject the equipment if it
does not comply with the specification when erected or does not give
complete satisfaction in service and the above shall in no way limit the
liabilities and responsibilities of the Bidder in ensuring complete conformance
of the materials/equipment supplied to relevant specification, standard, data
sheets, drawings, etc.
9.02.21 For all spares and replacement items, the quality requirements as agreed for
the main equipment supply shall be applicable.
9.02.22 Repair/rectification procedures to be adopted to make the job acceptable

shall be subject to the approval of the Owner/ authorised representative.
9.02.23 Burn in and Elevated Temperature Test Requirement for Electronics Solid
State Equipment
All solid state electronic systems/equipment shall be tested as a complete

system/equipment with all devices connected for a minimum of 168 hours (7
Days) continuously under energized conditions prior to shipment from
manufacturing works, as per the following cycle.
Elevated Temperature Test Cycle
During the elevated temperature test which shall be for 48 hours of the total
168 hours of testing, the ambient temperature shall be maintained at 50
deg.C. The equipment shall be interconnected with devices which will cause it
to repeatedly perform all operations it is expected to perform in actual service
with load on various components being equal to those which will be
experienced in actual service.
During the elevated temperature test the cubicle doors shall be closed (or
shall be in the position same as they are supposed to be in the field) and
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inside temperature in the zone of highest heat dissipating

components/modules shall be monitored. The temperature rise inside the
cubicle should not exceed 10 deg.C above the ambient temp. at 50 deg.C.
Burn in Test Cycle
The 48 hours elevated temperature test shall be followed by 120 hours of

burn in test as above except that the temperature shall be reduced to the
ambient temperature prevalent at that time.
During the above tests, the process I/O and other load on the system shall be
simulated by simulated inputs and in the case of control systems, the process
which is to be controlled shall also be simulated. Testing of individual
components or modules shall not be acceptable.
In case the Bidder/ sub-Bidder is having any alternate established procedure

of eliminating infant mortile components, the detail procedures followed by the
Bidder/ sub- Bidder along with the statistical figures to validate the alternate
procedure to be forwarded.
The Bidder/Sub-Bidder shall carry out routine test on 100% item at

Bidder/sub-Bidder’s works. The quantum of check/test for routine &
acceptance test by Owner shall be generally as per criteria/sampling plan
defined in referred standards. Wherever standards have not been mentioned
quantum of check/test for routine / acceptance test shall be as agreed during
detailed engineering stage.
9.03.00 QA Documentation Package
The Bidder shall be required to submit the QA Documentation in two hard

copies and two CD ROMs, as identified in respective quality plan with tick (?)
mark.
9.03.01 Each QA Documentation shall have a project specific Cover Sheet bearing
name & identification number of equipment and including an index of its
contents with page control on each document.
The QA Documentation file shall be progressively completed by the

Supplier’s sub- supplier to allow regular reviews by all parties during the
manufacturing.
The final quality document will be compiled and issued at the final assembly
place of equipment before despatch. However CD-Rom may be issued not
later than three weeks.
9.03.02 Typical contents of QA Documentation is as below:-
(a.) Quality Plan
(b.) Material mill test reports on components as specified by the

specification and approved Quality Plans.
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(c.) Manufacturer / works test reports/results for testing required as per

applicable codes and standard referred in the specification and
approved Quality Plans.
(d.) Non-destructive examination results /reports including radiography

interpretation reports. Sketches/drawings used for indicating the
method of traceability of the radiographs to the location on the
equipment.
(e.) Heat Treatment Certificate/Record (Time- temperature Chart)
(f.) All the accepted Non-conformance Reports (Major/Minor) / deviation,

including complete technical details / repair procedure).
(g.) CHP / Inspection reports duly signed by the Inspector of the Owner
and Bidder for the agreed Customer Hold Points.
(h.) Certificate of Conformance (COC) wherever applicable.
(i.) MDCC
9.03.03 Similarly, the Bidder shall be required to submit two sets (two hard copies and
two CD ROMs), containing QA Documentation pertaining to field activities as
per Approved Field Quality Plans and other agreed manuals/ procedures,
prior to commissioning of individual system.
9.03.04 Before despatch / commissioning of any equipment, the Supplier shall make
sure that the corresponding quality document or in the case of protracted
phased deliveries, the applicable section of the quality document file is
completed. The supplier will then notify the Inspector regarding the readiness
of the quality document (or applicable section) for review.
(a.) If the result of the review carried out by the Inspector is satisfactory,
the Inspector shall stamp the quality document (or applicable section)
for release.
(b.) If the quality document is unsatisfactory, the Supplier shall endeavor

to correct the incompleteness, thus allowing to finalize the quality
document (or applicable section) by time compatible with the
requirements as per contract documents. When it is done, the quality
document (or applicable section) is stamped by the Inspector.
(c.) If a decision is made despatch, whereas all outstanding actions

cannot be readily cleared for the release of the quality document by
that time. The supplier shall immediately, upon shipment of the
equipment, send a copy of the quality document Review Status signed
by the Supplier Representative to the Inspector and notify of the
committed date for the completion of all outstanding actions &
submission. The Inspector shall stamp the quality document for
applicable section when it is effectively completed. The submission of
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QA documentation package shall not be later than 3 weeks after the

despatch of equipment.
9.03.05 Transmission Of QA Documentation
On release of QA Documentation by Inspector, one set of quality document

shall be forwarded to Corporate Quality Assurance Department and other set
to respective Project Site of Owner.
For the particular case of phased deliveries, the complete quality document to
the Owner shall be issued not later than 3 weeks after the date of the last
delivery of equipment.
9.04.00 Project Manager’s Supervision
9.04.01 To eliminate delays and avoid disputes and litigation, it is agreed between the
parties to the Contract that all matters and questions shall be referred to the
Project Manager and without prejudice to the provisions of ‘Arbitration’ clause
in Section General Conditions of Contract, the Bidder shall proceed to comply
with the Project Manager's decision.
9.04.02 The work shall be performed under the supervision of the Project Manager.
The scope of the duties of the Project Manager pursuant to the Contract, will
include but not be limited to the following:
(a.) Interpretation of all the terms and conditions of these documents and
specifications:
(b.) Review and interpretation of all the Bidder’s drawing, engineering

data, etc:
(c.) Witness or his authorised representative to witness tests and trials

either at the manufacturer’s works or at site, or at any place where
work is performed under the contract :
(d.) Inspect, accept or reject any equipment, material and work under the
contract.
(e.) Issue certificate of acceptance and/or progressive payment and final

payment certificates
(f.) Review and suggest modifications and improvement in completion

schedules from time to time, and
(g.) Supervise Quality Assurance Programme implementation at all stages

of the works.
9.05.00 Inspection, Testing And Inspection Certificates
9.05.01 The word ‘Inspector’ shall mean the Project Manager and/or his authorized
representative and/or an outside inspection agency acting on behalf of the
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Owner to inspect and examine the materials and workmanship of the works
during its manufacture or erection.
9.05.02 The Project Manager or his duly authorized representative and/or an outside
inspection agency acting on behalf of the Owner shall have access at all
reasonable times to inspect and examine the materials and workmanship of
the works during its manufacture or erection and if part of the works is being
manufactured or assembled on other premises or works, the Bidder shall
obtain for the Project Manager and for his duly authorized representative
permission to inspect as if the works were manufactured or assembled on the
Bidder’s own premises or works.
9.05.03 The Bidder shall give the Project Manager/Inspector fifteen (15) days written
notice of any material being ready for testing. Such tests shall be to the
Bidder’s account except for the expenses of the Inspector’s. The Project
Manager/Inspector, unless the witnessing of the tests is virtually waived and
confirmed in writing, will attend such tests within fifteen (15) days of the date
on which the equipment is noticed as being ready for test/inspection failing
which the Bidder may proceed with test which shall be deemed to have been
made in the inspector’s presence and he shall forthwith forward to the
inspector duly certified copies of test reports in two (2) copies.
9.05.04 The Project Manager or Inspector shall within fifteen (15) days from the date
of inspection as defined herein give notice in writing to the Bidder, or any
objection to any drawings and all or any equipment and workmanship which is
in his opinion not in accordance with the contract. The Bidder shall give due
consideration to such objections and shall either make modifications that may
be necessary to meet the said objections or shall inform in writing to the
Project Manager/Inspector giving reasons therein, that no modifications are
necessary to comply with the contract.
9.05.05 When the factory tests have been completed at the Bidder’s or sub-Bidder’s
works, the Project Manager /Inspector shall issue a certificate to this effect
fifteen (15) days after completion of tests but if the tests are not witnessed by
the Project Manager /Inspectors, the certificate shall be issued within fifteen
(15) days of the receipt of the Bidder’s test certificate by the Project Manager
/Inspector. Project Manager /Inspector to issue such a certificate shall not
prevent the Bidder from proceeding with the works. The completion of these
tests or the issue of the certificates shall not bind the Owner to accept the
equipment should it, on further tests after erection be found not to comply with
the contract.
9.05.06 In all cases where the contract provides for tests whether at the premises or
works of the Bidder or any sub-Bidder, the Bidder, except where otherwise
specified shall provide free of charge such items as labour, material,
electricity, fuel, water, stores, apparatus and instruments as may be
reasonably demanded by the Project Manager /Inspector or his authorized
representatives to carry out effectively such tests on the equipment in
accordance with the Bidder and shall give facilities to the Project
Manager/Inspector or to his authorized representative to accomplish testing.
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9.05.07 The inspection by Project Manager / Inspector and issue of Inspection

Certificate thereon shall in no way limit the liabilities and responsibilities of the
Bidder in respect of the agreed Quality Assurance Programme forming a part
of the contract.
9.05.08 To facilitate advance planning of inspection in addition to giving inspection

notice as specified at clause no 9.05.03- of this chapter, the Bidder shall
furnish quarterly inspection programme indicating schedule dates of
inspection at Customer Hold Point and final inspection stages. Updated
quarterly inspection plans will be made for each three consecutive months
and shall be furnished before beginning of each calendar month.
9.05.09 All inspection, measuring and test equipment used by Bidder shall be
calibrated periodically depending on its use and criticality of the
test/measurement to be done. The Bidder shall maintain all the relevant
records of periodic calibration and instrument identification, and shall produce
the same for inspection by the Owner. Wherever asked specifically, the
Bidder shall re-calibrate the measuring/test equipment in the presence of
Project Manager/Inspector.
9.06.00 Associated document for quality assurance programme:
9.06.01 List of items requiring quality plan and sub supplier approval. (Annexure-III).
9.06.02 Status of items requiring Quality Plan and sub supplier approval. (Annexure-
IV).
9.06.03 Field Welding Schedule (Annexure-V).
9.06.04 Manufacturing Quality Plan (Annexure-VI).
9.06.05 Field Quality Plan (Annexure-VII).
10.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES
(a.) As soon as the facilities or part thereof has been completed

operationally and structurally and before start-up, each item of the
equipment and systems forming part of facilities shall be thoroughly
cleaned and then inspected jointly by the Owner and the Bidder for
correctness of and completeness of facility or part thereof and
acceptability for initial pre-commissioning tests, commissioning and
start-up at Site. The list of pre-commissioning tests to be performed
shall be as mutually agreed and included in the Bidder’s quality
assurance programme as well as those included elsewhere in the
Technical Specifications.
(b.) The Bidder’s pre-commissioning/ commissioning/start-up engineers,

specially identified as far as possible, shall be responsible for carrying
out all the pre-commissioning tests at Site. On completion of
inspection, checking and after the pre-commissioning tests are
satisfactorily over, the commissioning of the complete facilities shall
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be commenced during which period the complete facilities, equipment

shall be operated integral with sub-systems and supporting equipment
as a complete plant.
It will be the responsibility of the Bidder to assess and furnish a list of

all commissioning spares required for successful commissioning of all
the equipment covered under the contract. Such a list shall be
furnished by the Bidder within 12 months from the date of LOA,
separately for each equipment and shall be reviewed by the Owner
and discussed for mutual agreement. The commissioning spares will
be so identified as not to allow the trial operation to suffer for want of
such commissioning spares. The identification of commissioning
spares will not in any way relieve the Bidder of any of his
responsibilities of satisfactory performance under the provisions of
other conditions of contract. All the commissioning spares shall be
deemed to be included in scope of the Bidder as a part of the
respective equipment package at no extra cost to the Owner.
(c.) All piping system shall be flushed, steam blown, air blown as required
and cleanliness demonstrated using acceptable industry standards.
Procedures to accomplish this work shall be submitted for approval to
the Owner six months prior to the respective implementations. The
Owner will approve final verification of cleanliness.
(d.) The time consumed in the inspection and checking of the units shall
be considered as a part of the erection and installation period.
(e.) The check outs during the pre - commissioning period should be
programmed to follow the construction completion schedule. Each
equipment/system, as it is completed in construction and turned over
to Owner's commissioning (start-up) Engineer(s), should be checked
out and cleaned. The checking and inspection of individual systems
should then follow a prescribed commissioning documentation [SLs
(Standard Check List) / TS (Testing Schedule) / CS (Commissioning
Schedule)] approved by the Owner.
(f.) The Bidder during initial operation and performance testing shall
conduct vibration testing to determine the ‘base line’ of performance of
all plant rotating equipment. These tests shall be conducted when the
equipment is running at the base load, peak load as well as lowest
sustained operating condition as far as practicable.
(g.) Bidder shall furnish the commissioning organization chart for review &
acceptance of Owner at least eighteen months prior to the schedule
date of synchronization of 1st unit. The chart should contain :
(1.) Biodata including experience of the Commissioning Engineers.
(2.) Role and responsibilities of the Commissioning Organisation

members.
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(3.) Expected duration of posting of the above Commissioning

Engineers at site.
10.02.00 Initial Operation
a) On completion of all pre-commissioning activities / tests and as a part of

commissioning the complete facilities shall be put on 'Initial Operation'
during which period all necessary adjustments shall be made while
operating over the full load range enabling the facilities to be made ready
for the Guarantee Tests.
b) The 'Initial Operation' of the complete facility as an integral unit shall be

conducted for 720 continuous hours. During the period of initial operation
of 720 hours, the unit shall operate continuously at full rated load for a
period not less than 72 hours.
c) The Initial Operation shall be considered successful, provided that each
item/ part of the facility can operate continuously at the specified
operating characteristics, for the period of Initial Operation with all
operating parameters within the specified limits and at or near the
predicted performacne of the equipment/ facility.
d) The Bidder shall intimate the Owner about the commencement of initial
operation and shall furnish adequate notice to the Owner in this respect.
e) Any loss of generation due to constraints attributable to the Owner shall

be construed as Deemed Generation.
f) An Initial Operation report comprising of observations and recordings of

various parameters to be measured in respect of the above Initial
Operation shall be prepared by the Bidder. This report, besides
recording the details of the various observations during initial operation
shall also include the dates of start and finish of the Initial Operation and
shall be signed by the representatives of both the parties. The report
shall have sheets, recording all the details of interruptions occurred,
adjustments made and any minor repairs done during the Initial
Operation. Based on the observations, necessary modifications/repairs
to the plant shall be carried out by the Bidder to the full satisfaction of the
Owner to enable the latter to accord permission to carry out the
Guarantee tests on the facilities. However, minor defects which do not
endanger the safe operation of the equipment, shall not be considered
as reasons for with holding the aforesaid permission.
10.03.00 Guarantee Tests
a) The final test as to prove the Functional Guarantees shall be conducted

at Site by the Bidder in presence of the Owner. The Bidder's
Commissioning, Start-up Purchaser shall make the unit ready to conduct
such test. Such test will be commenced and completed as per schedule
indicated in Vol I GCC
b) These tests shall be binding on both the parties of the Contract to
determine compliance of the equipment with the functional guarantee.
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c) For performance/ demonstration tests instrumentations, of accuracy

class, to the approval of the Owner shall be used. The numbers and
location of the instruments shall be as per the specified test codes. In
addition the values of parameters shall be logged from the information
system provided under Owner's Distributed Digital Control Monitoring and
Information system. Test will be conducted at specified load points.
d) Any special equipment, tools and tackles required for the successful
completion of the Guarantee Tests shall be provided by the Bidder, free
of cost.
e) The Guarantee tests and specific tests to be conducted on equipment

have been brought out in detail elsewhere in the specification.
11.00.00 TAKING OVER
Upon successful completion of Initial Operations and all the tests other than
guarantee tests conducted to the Owner's satisfaction, the Owner shall issue
to the Bidder a Taking over Certificate as a proof of the final acceptance of
the equipment. Such certificate shall not unreasonably be with held nor will
the Owner delay the issuance thereof, on account of minor omissions or
defects which do not affect the commercial operation and/or cause any
serious risk to the equipment. Such certificate shall not relieve the Bidder of
any of his obligations which otherwise survive, by the terms and conditions of
the Contract after issuance of such certificate.
12.00.00 TRAINING OF OWNER'S PERSONNEL
12.01.00 The scope of service under training of Owner shall include a training module
in the areas of Operation & Maintenance.
Such training should cover the following areas as a minimum in order to

enable these personnel to individually take the responsibility of operating and
maintaining the power station in a manner acceptable to the Owner:
(a.) Training for Steam Generator Equipment
(b.) Training for TG and related equipment.
(c.) DDCMIS
(d.) Training for Electric Power Supply systems
(e.) Training for HT motor
(f.) Training for power cycle piping/critical piping.
The above training shall be provided taken by the EPC Bidder in one of the
reference power plant.
Page 69 of 680
12.02.00 The scope of services under training shall also necessarily include training of
Owner's Engineering personnel covering a training module of upto 52 man
months. This shall cover all disciplines viz, Mechanical, Electrical, C&I, & QA
etc. and shall include all the related areas like Design familiarization, training
on product design features and product design softwares of major equipment
and systems, engineering, manufacturing, erection, commissioning, training
on operating features of equipment, quality assurance and testing, plant visits
and visits to manufacturer's works, exposure to various kinds of problems
which may be encountered in fabrication, manufacturing, erection, welding
etc. An indicative module of the training requirement of Owner's Engineering
personnel is attached as Annexure-II.
Four (4) man month and two (2) man month training for Purchasers
Engineering Personnel on the offered CFD modelling code for SG & ESP
including alternative geometry modelling technique to be provided.
12.03.00 Bidder shall furnish in his offer, details of training module(s) covering above
requirements which shall be subject to Owner's approval. Consolidated
training period included above (i.e. 35 and 52 man months respectively for
O&M and Engineering) is indicative only. Owner reserves the right to
reappropriate the training period between O&M and engineering depending
upon the details of training module proposed by the Bidder.
12.04.00 Clause 12.02.00 & 12.03.00 shall be applicable for domestic bidders. For
foreign bidders refer Vol I GCC.
12.05.00 Exact details, extent of training and the training schedule shall be finalised
based on the Bidder's proposal within two (2) months from placement of
award.
12.06.00 In all the above cases, wherever the training of Owner's personnel is
arranged at the works of the manufacturer's it shall be noted that the lodging
and boarding of the Owner's personnel shall be at the cost of Bidder. The
Bidder shall make all necessary arrangements towards the same.
12.07.00 Take off prices (product wise) should be indicated by the Bidder in the Bid
Proposal Sheets. Owner reserves the right to include or exclude these
item(s) during place of Award. All expenses except travelling expenses shall
be borne by the contractor.
13.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION
In addition to the requirements given in Erection Conditions of Contract (ECC)

the following shall also cover:
(a.) Working platforms should be fenced and shall have means of access.
(b.) Ladders in accordance with Owner’s safety rules for construction and
erection shall be used. Rungs shall not be welded on columns. All
the stairs shall be provided with handrails immediately after its
erection.
Page 70 of 680
14.00.00 NOISE LEVEL
The equivalent 'A' weighted sound pressure level measured at a height of 1.0
m above floor level in elevation and at a distance of one (1) meter horizontally
from the nearest surface of any equipment / machine, furnished and installed
under these specifications, expressed in decibels to a reference of 0.0002
microbar, shall not exceed 85 dBA except for
(a.) Safety valves and associated vent pipes for which it shall not exceed
105 dBA.
(b.) Regulating drain valves in which case it shall be limited to 90 dBA.
(c.) TG unit in which case it shall not exceed 90 dBA.
(d.) For HP-LP bypass valves and other intermittantly operating control
valves, the noise level shall be within the limit of 85 dBA.
15.00.00 PACKAGING AND TRANSPORTATION
All the equipment & spares shall be suitably protected, coated, covered or
boxed and crated to prevent damage or deterioration during transit, handling
and storage at Site till the time of erection. Each spare shall be clearly
marked or labeled on the outside of the packing with its description. When
more than one spare part is packaged in a single case, a general description
of the contents shall be shown on the outside of such a case and other
packages must be suitably marked and numbered for the purpose of
identification. All cases, containers or packages, are liable to be opened for
such examination as may be considered reasonable by the Engineer.In case
of equipment supplied with grease/lubricants from imported origin, the
supplied shall clearly indicate the indigenous equivalent of the
grease/lubricant and source of supply so as to enable the Owner to procure
these items from indigenous sources. While packing all the materials, the
limitation from the point of view of the sizes of railway wagons available in
India should be taken account of. The Bidder shall be responsible for any loss
or damage during transportation, handling and storage due to improper
packing. The Bidder shall ascertain the availability of Railway wagon sizes
from the Indian Railways or any other agency concerned in India well before
effecting dispatch of equipment. Before dispatch it shall be ensured that
complete processing and manufacturing of the components is carried out at
shop, only restricted by transport limitation, in order to ensure that site works
like grinding, welding, cutting & pre-assembly to bare minimum. The Owner's
Inspector shall have right to insist for completion of works in shops before
dispatch of materials for transportation.
16.00.00 ELECTRICAL ENCLOSURE
All electrical equipment and devices, including insulation, heating and

ventilation devices shall be designed for ambient temperature and a
maximum relative humidity as specified elsewhere in the specification.
Page 71 of 680
17.00.00 INSTRUMENTATION AND CONTROL

All instrumentation and control systems/ equipment/ devices/ components,
furnished under this contract shall be in accordance with the requirements
stated herein, unless otherwise specified in the detailed specifications.
17.01.00 All instrument scales and charts shall be calibrated and printed in metric units
and shall have linear graduation. The ranges shall be selected to have the
normal reading at 75% of full scale.
All scales and charts shall be calibrated and printed in Metric Units as follows:
a) Temperature - Degree centigrade (deg C)
b) Pressure - Kilograms per square centimeter (Kg/cm2).
Pressure instrument shall have the unit
suffixed with 'a' to indicate absolute
pressure. If nothing is there, that will mean
that the indicated pressure is gauge
pressure.
c) Draught - Millimeters of water column (mm wc).
d) Vacuum - Millimeters of mercury column (mm Hg) or
water column (mm Wcl).
e) Flow (Gas) - Tonnes/ hour
f) Flow (Steam) - Tonnes/ hour
g) Flow (Liquid) - Tonnes / hour
h) Flow base - 760 mm Hg. 15 deg.C
i) Density Grams per cubic centimeter.
17.02.00 All instruments and control devices provided on panels shall be of

miniaturized design, suitable for modular flush mounting on panels with front
draw out facility and flexible plug-in connection at rear.
17.03.00 All electronic modules shall have gold plated connector fingers and further all
input and output modules shall be short circuit proof. These shall also be
tropicalized & components shall be of industrial grade or better.
18.00.00 ELECTRICAL NOISE CONTROL
The equipment furnished by the Bidder shall incorporate necessary

techniques to eliminate measurement and control problems caused by
electrical noise. Areas in Bidder's equipment, which are vulnerable to
electrical noise shall be hardened to eliminate possible problems. Any
additional equipment, services required for effectively eliminating the noise
problems shall be included in the proposal. The equipment shall be protected
against ESD as per IEC-801- 2. Radio Frequency interference (RFI) and
Electro Magnetic Interference (EMI) protection against hardware damage and
control system mal-operations/errors shall be provided for all systems.
19.00.00 INSTRUMENT AIR SYSTEM
Page 72 of 680
The instrument air supply system as supplied by the Bidder for various
pneumatic control & instrumentation devices like pneumatic actuators, power
cylinders, E/P converters, piping / tubing etc. shall be as per the details
furnished elsewhere.
Each pneumatic instrument shall have an individual air shut - off valve. The
pressure-regulating valve shall be equipped with an internal filter, a 50 mm
pressure gauge and a built-in filter housing blow down valve.
20.00.00 TAPPING POINTS FOR MEASUREMENTS
Tapping points shall include probes, wherever applicable, for analytical

measurements and sampling.
For direct temperature measurement of all working media, one stub with
internal threading of approved pattern shall be provided along with suitable
plug and washer. The Bidder will be intimated about thread standard to be
adopted.
The following shall be provided on equipment by the Bidder. The standard

which is to be adopted, will be intimated to the Bidder.
(a.) Temperature test pockets with stub and thermowell
(b.) Pressure test pockets
21.00.00 ELECTRONIC MODULE/COMPONENT DETAILS
The Bidder shall have to furnish all technical details including circuit
diagrams, specifications of components, etc., in respect of each and every
electronic card/module as employed on the various solid state as well as
microprocessor based systems and equipment including conventional
instruments, peripherals etc.
It is mandatory for the Bidder to identify clearly the custom built ICs used in
the package. The Bidder shall also furnish the details of any equivalents of
the same.
22.00.00 ENVIRONMENTAL MONITORING & CONTROL MEASURES
Bidder to note that MOEF has declared Manali area as critically polluted area
and also imposed certain restrictions on consideration of developmental
projects.
Concerned authorities have been addressed to have self monitoring system

(for Air, Water & Land) so as to ascertain the level of compliance of standards
prescribed by MOEF and also to furnish the action plan ie., for the
establishment of self monitoring system. It is also directed to undertake
Environmental Audit (EA) to ascertain the compliance level of standards
notified by MOEF.
Page 73 of 680
In this context it is to be noted that our proposed project is also located in the
said critically polluted cluster. Though environmental clearance for the said
project has been obtained the Controlling Authorities will be highly keen and
keep a tight vigil on the availability/provision of self monitoring system (for Air,
Water & Land) so as to ascertain the level of compliance of standards
prescribed by MOEF.
Environmental Clearance:
The environmental appraisal minutes are indicated below.
“Expert Appraisal Committee/MoEF has considered the project on 25th June

2012 and recommended issue of EC subject to TANGEDCO furnishing the
cumulative impact on air, water and soil considering the Industries located
15km radius from the Ennore SEZ Project Site. The same is being furnished.
Copy of Minutes of EAC is enclosed. Final Environmental Clearance yet to be
received. For Compliance of conditions stipulated by TNPCB under section 21
of the Air (Prevention and control of Pollution) Act 1981 as amended in 1987,
the following are included in the specification:
a) RCC chimney with designed height of 275mtrs included in the

specification.
b) High efficiency ESPs ( 99.9% efficiency) have been proposed to ensure
emission of particulate matter within 50 mg/Nm3..
c) Bag filters have been proposed for the coal crushers to collect suspended
particulate emission.
d) Dust suppression system has been proposed for the coal yard.
e) Equipment for continuous monitoring of Ambient Air Quality has been
proposed.
f) On line / automatic continuous stack monitor has been proposed.
g) Port holes in the chimney and sampling facilities for the stack for the
proposed Boiler, as per the Central Pollution Control Board guide lines.
h) The unit shall have suitable sufficient acoustic measures for Generator,
Turbine, Coal crusher and other sources including special anti vibration
Foundation for which all the heavy rotating equipments / machines shall
be erected over the Anti vibration foundations to reduce noise, vibration
etc.,
i) The unit shall have separate energy meter for the operation of the Electro
Static Precipitator, the Air pollution control equipment for the proposed
Boiler.
Page 74 of 680
j) Alternate power source will come into effect in case of power failure for
the operation of Air Pollution Control measures
k) laboratory for analysis of gaseous / particulate emissions
l) The coal shall be stored in a completely paved area with the provisions for
leach ate collection. The coal storage yard shall be provided with wind
barriers of sufficient height. The height of the coal piles shall be lower than
that of the wind barrier.
m) The location of wind barriers shall be based on the predominant wind
direction and shall be in consultation with TNPCB so as to avoid fugitive
dust emission.
n) Closed conveyors for coal transport and Bag filters in all the transfer
points to control dust emission have been proposed
o) Dust suppression system / water sprinklers to keep the stock pile
sufficiently wet all the time to avoid carryover of dust.
p) All the internal roads shall be well paved and be provided with water
sprinkling arrangement to avoid fugitive dust emission during vehicle
movement. The unit shall limit the speed of the vehicle to 10KM/hr. for
heavy vehicles within the plant premises to prevent the road dust
emission.
q) Burners have been designed for low NOx.
r) Space provision made for installation of FGD of requisite efficiency of
removal of SO2, if required at a later stage for which adequate space is
provided near the chimney.
s) The unit shall ensure that the velocity of the exit gas from the stack shall
be greater than 25 m/sec and the ratio of the exit gas to wind velocity shall
not be less than 1.5 to eliminate or reduce pollutant down wash.
t) The unit shall have on line/automatic continuous stack monitors with
computer recording arrangement for monitoring SPM, Sox and Nox in the
boiler emission.
u) Sewage Treatment Plant & Effluent Treatment Plant has been proposed.
v) Natural draft cooling tower has been included in the specification.
w) 100% Dry fly ash collection system and conventional wet bottom ash
disposal is included. However ash water recovery system is included in
this scope if ash slurry is disposed in the ash pond in emergencies.
Page 75 of 680
x) Ash slurry pipe lines and ash water recovery pipe lines of adequate
capacity and strength are proposed to be provided. However these pipe
lines will be used only during emergency, since 100% dry fly ash
collection is proposed.
Hence, it is stated that the implementation of Environmental measures

including self monitoring system (for air, Water and land) as per the EC
granted, especially in the following areas have to be ensured by the bidder
without any exception:
Continuous Air quality monitoring stations

Online monitoring system
Effluent Treatment plant
Sewage treatment plant
Optimum use of land area
100% Ash collection & utilisation
Green Belt Development.
Page 76 of 680
ANNEXURE-I
S. NO. DESCRIPTION OF MANUALS NO OF PRINTS NO. OF CD-

(sets) ROMs (sets)
1. PLANT DEFINITION MANUAL- - 3 CD-ROMs
2. Drawings "FOR APPROVAL" 10 Soft Copy
3. Drawings "FOR INFORMATION" 10 Soft Copy
4. Drawings "FINAL APPROVED 8 Soft Copy

DRAWING"
5. Drawings "AS BUILT " 8 3 CD-ROMs
6 DATASHEETS,DESIGNCALCULATI
ONS,PURCHASE
SPECIFICATIONS, etc. and Other
type of documents
i) For Approval 10 SOFT COPY
ii) FINAL 8 3 CD-ROMs -
iii) Analysis reports of equipment/
piping/ structures components/
systems employing software
packages as detailed
in the specifications
a) Input 10 SOFT COPY
b) Output 10 SOFT COPY
c) Drawings/ Sketches 10 SOFT COPY
7 Erection manual "FINAL" 8 3CD ROMS

8 Operation & Maintenance manual 10 3CD ROMS
9 Plant Hand Book "DRAFT" 6 SOFT COPY
10 Plant Hand Book "FINAL" 15 3CD ROMS
11 Commissioning and Performance 10 3CD ROMS
Procedure manual
12 Performance and Functional 6 3CD ROMS
Guarantees test report
13 Progress Reports 6 3CD ROMS
14 Project completion report 10 3CD ROMS
15 QA programme including 1
Page 77 of 680

(sets) ROMs (sets)
Organization for implementation and
QA system manual (with revision-
servicing)
16 Vendor details in respect of proposed 1
vendors including Bidder’s evaluation
report.
17 Manufacturing QPs, Field QPs, Field
welding schedules and their
reference documents like test
procedures, WPS, POR etc.
(i) For review/comment 3
(ii) For final approval 4 1 set CD ROMS
18 Welding Manual, Heat Treatment 4
Manuals,
Storage & preservation manuals
Final 4 2 CD ROMS
19 Monthly Vendor Approval 2 1 CD ROM
and QP approval status
20 QA Documentation Package for 2 2 CD ROMS
items / equipment manufactured and
dispatched to site
21 QA Documentation Package for field 2 2 CD ROMS
activities on equipment/systems at
site
Page 78 of 680
ANNEXURE-II
(Total within 52 man months)
PRODUCT AREAS OF TRAINING REQUIREMENT
Product Design Plant Visit Visit To Operation & Maintenance Of
Manufacturer’s Work Plant
STEAM Thermal design and hydraulic circulation Familiarization with various Manufacturing Control philosphy operation,
GENERATOR balance system and equipment processes of pressure notices, logic & protection
parts, and equipment schemes, O&M manual
familiarization O&M issues
Combustion and Air & gas weight Performance data collect- Welding process
calculation ion analysis and review
Pressure part calculation O&M feed back Testing facilities Familiarization of special
maintenance techniques.
Pressure part and strength calculation Operation history of various Product development Special tool and tackles
equipment and system in process familiarization
Tube metal temp. calculation and Failure analysis Future plan for
selection. technology induction
Performance calculation R&D work inprogress
Duct design.
Pressure part
Page 79 of 680

Equipment and system sizing and
selection of mills, fans, airpreheater, soot
blowers, dampers, valves heater, soot
blowers, dampers, valves, feeders,
burners startup system, fuel firing
system, draft plant
Flow scheme development of air & flue
gas, fuel oil, auxiliary steam, main and
reheat steam feed water.
Layout of over all plant, steam generator
area, pressure part arrangements,
platforms, equipment, piping and duct,
coal pipe, flue gas ducts, bunker
arrangement, valves and damper, ESP
area, cable & piping tressels etc.
Erection stretegies, erection procedures
Performance and demonstration tests.
MANDAYS 120 20 20 20
CFD model Familarisation of fundamentals and basis
development for the development of the CFD models.
and validation Solving of set of simple problems by Em-
for Steam ployer’s engineers with the help of
Generator trainer.
Page 80 of 680

Hands on experience on the
development of detailed/realistic CFD
models for the steam generator and
ESP. The Bidder/trainer shall develop
CFD models for SG & ESPas per the
Contract requirement with complete
association of the Owner’s engineers.
Validation of the above CFD model for
SG & ESPby Bidder in association with
the Owner’s Engineers.
MANDAYS 120 for SG and 60 for ESP - - -
Page 81 of 680

Product Design Plant Visit Visit To Manufacturer’s Operation &
Work Maintenance Of Plant
TURBINE Turbine cycle optimization and Familiarization of power plants Manufacturing processes of
GENERATOR AND turbine performance in off of various makes of turbines turbine
IT’S INTEGRAL design condition. for super critical units
AUXILIARIES
Rotor design and strength Collection of data for analysis Assembly of turbine
calculation of availability of turbines
Rotor dynamic behavior studies Comparative studies for Testing of turbines
wrt natural frequency, critical integral systems of turbine
speed, vibration etc.
Blade profile/root design and O&M history/problems related Product development in
blade strength design, blade to turbine process
vibration analysis
Casing & diaphragm design Failure analysis Future plan for technology
induction
Labyrinth seal selection & R&D work in progress
design for different turbine
configurations
Selection of turbine type (i.e.
Tandem vs cross compounding,
separate HP/IP vs combined
HP/IP, material of construction
etc.)
Page 82 of 680

Design principle for Up
rating/down rating of existing
design/ modules for the specific
project.
Selection of nos., type and
arrangement of bearings, load
calculation on bearings, bearing
oil flow calculation
Selection, design and control
principle for Turbine governing
system
Performance calculation
Steam path audit
Layout principle of various
equipment’s of TG and its
integral system
Latest technological
advancements
MANDAYS 45 10 10
Boiler Feed Pumps Techno-economic syudies for Familiarization of power plants Manufacturing process of
Selection of BFP Configuration of various makes of feed various components of BFP
and its drive pumps
Criteria for selection of boiler Data collection of BFP Assembly of BFP
Page 83 of 680

Feed Pump parameters parameters and configur ation
Rotor design, strength Collection of data for analysis Testing, capabilities of BFP
calculation and rotor dynamic of availability of BFP at works wrt performance,
behavior studies wrt critical NPSH, thermal shock, dry
speed, vibration etc run, visual cavitation, string
test, axial thrust
measurement
Impeller design and its hydraulic O&M history/problems related Product development in
behavior to BFP process
Role of critical parameters Comparative studies for Future plan for technology
such as NPSH(R), Suction various types of BFP& its induction
specific speed, running features
clearances, speed etc. in design
of feed pumps
Material selection of BFP R&D work in progress
components
Guiding factors for selection of
BFP seals
Computation of axial thrust
under various flows
Performance calculation
Transient analysis in pump
Page 84 of 680

suction piping wrt NPSH margin
Latest technological trends in
BFP design
MANDAYS 20 5 10
Condenser Selection of condenser type and Comparative studies of salient Manufacturing process of
its optimization wrt temp rise features various components of
across condenser, pressure condenser Assembly
drop in condenser, surface area
etc.
Techno economic studies for Collection of data for analysis Testing capability at works
Selection of condenser tube of availability of Condenser
material and other parts
depending on water quality
Condenser support selection & O&M history/problems related Product development in
design to condenser process
Sizing of condenser w.r.t. super Future plan for technology
critical units induction
Latest technological trends in R&D work in progress
condenser arrangement and
design
Condenser vacuum system
design
Page 85 of 680

MANDAYS 10 5 5
Feed Regenerative Thermal and mechanical design Comparative studies of salient Manufacturing process of
Equipment’s calculation of heaters features various components of
heaters
Basis of selecting Analysis of data Assembly
horizontal/vertical heaters
Selection of TTD and DCAs for O&M history/problems related Testing capability at works
various heaters, and their effect to heaters
on turbine heat rate
Configuration of HP heaters Product development in
(2x50% v/s100% capacity process
Sizing criteria for De- Future plan for technology
aerator/Heaters induction
Selection of tube & tube sheet R&D work in progress
material of heaters
Latest technological trends in
heaters design
MANDAYS 15 10 10
3-dimensional CFD CFD model develop ment and
modeling validation of design data for
steam turbine, BFP, CEP,
condenser, heaters etc.
Page 86 of 680

MANDAYS 20
Compressors Equipment Theory &
Maintenance Practice
MANDAYS 16 ----- 4
Ash Handling Equipment Theory &
System Maintenance Practice
MANDAYS 16 4 4
Coal Handling Equipment Theory &
System Maintenance Practice
MANDAYS 20 5 5
H 2 Plant Equipment Theory &
MANDAYS 10 3 3
Condensate Equipment Theory &
Polishing Unit Maintenance Practice
MANDAYS 15 5 5
Page 87 of 680

CONTROL &
INSTRUMENTATION
DDCMIS-Man Machine Hardware & Software Operational feedback
Interface - Hardware & organization of the system
Operating System Basis of selection of H/W
memory sizing
Operating system features,
interface with other system,
openness & inter- operability
Upgradability
System testing features
MANDAYS 24 6 16
DDCMIS-Man Machine Specific system customisation Operation feedback
Interface System Various system
Engineering &
Application Software modules & interface with OS
Database organization &
development
Development of mimics
Other application like
calculations, logs historical
storage functionalities & use
MANDAYS 40 6 8
Page 88 of 680

DDCMIS - Control Basic design features for system Operation feedback Manufacturing processes
System Hardware & its modules special attention to handling
of the modules
System capabilities & system Maintenance facilities
design techniques
Communication with MMI &
other system
MANDAYS 24 5 10
DDCMIS-Control Database structure Organisation Operational feedback System integration & System
system Application & interface between application capabilities testing
Software program & database
Application for implementation of
Control functions
Study of standard algorithms &
development of new algorithms
MANDAYS 18 4 4
DDCMIS - Control Loop General description of closed Specific operational
Study Loop Study loop controls of thermal power feedback
plant
Critical analysis of few control
loops e.g., TSCS Stress Control
boiler startup control etc.
Page 89 of 680

MANDAYS 12 4
DDCMIS-Burner Hardware logic, NFPA/ VDE Operational feedback Manufacturing procedure&
Management System requirements other safety precautions for handling the
standard system
Flame scanner location System testing facilities
MANDAYS 16 6 6 12
DDCMIS - EHTC, Basic design concept& features Operational feedback Manufacturing procedure &
Turbine stress control precautions for handling for
system, Turbine handling the system
protection system&
Logics of turbine stress control System testing facilities
ATRS
system
Implementation of failsafe
philosophy in turbine protection
system
MANDAYS 16 6 6 12
Furnace and Flame Theory & principle of operation Operational feedback
Viewing System.
Details of software & methods of
modification/ customisation
Misc. systems for
SG/TG C&I
Page 90 of 680

MANDAYS 6 3
BOP (DDCMIS) Hardware organization Manufacturing process of
PLC hardware
Operating system features Integration & testing facilities
Data base organization
Logic/loop algorithm
Development of control logic &
loop s/w & MMI application
development
MANDAYS 24 - 6
BOP Controller
System
1) Hard Ware Equipment Theory &
MANDAYS 30 10 10
2) Soft Ware Equipment Theory &
MANDAYS 30 10 10
VMS
1) Hardware Equipment Theory &
Page 91 of 680

MANDAYS 12 - 6
2)Vibration Analysis Equipment Theory &
MANDAYS 12 - 6
Analyser
Water & Gas Equipment Theory &
MANDAYS 20 - 8
PADO: Equipment Theory &
System Engineering
MANDAYS 6 3 3
PADO: Equipment Theory &
Operation & Analysis
MANDAYS 18 6 -
Actuators Equipment Theory &
MANDAYS 18 - 6
Simulator Equipment Theory &
Page 92 of 680

MANDAYS 16 - 4
Networking / MIS Equipment Theory &
MANDAYS 12 - 4
Electric Power Supply Theory & design features Manufacturing/assembly
System process
Testing methodology
MANDAYS 5 2
Page 93 of 680

Work Maintenance Of
Plant
(ELECTRICAL)
GENERATOR (a) Design aspects of the - Operational feed back (a) Manufacturing process
following areas for
- Insulation system - Familarisation with - Core
- Cooling medium & different sub-systems - Winding bars
arrangement
- Winding & core - Assembly
support systems
b) Design aspects of other (b) Testing facilities
auxiliary systems
MANDAYS 30 15 15
Generator Excitation Design features of various sub- - Operational feed back - Manufacturing
System including AVR. systems process& testing
Excitor - Familiarisation with facilities for various
various equipment equipment of excitation
PMG system
functioning at reference
Transformer plants
Controllers & different limiters
etc.
PSS & associated system studies
MANDAYS 30 15 15
Page 94 of 680

Boiler Feed pump Design Criteria for the Operational feed Manufacturing process & test
H.T. Motor back facilities
Stator core & wdg
Rotor core & wdg
Insulation system
Cooling arrangement
MANDAYS 20 5
POWER Equipment Theory &
TRANSFORMER Maintenance Practice
MANDAYS 12 - 4 4
UPS/BATTERY Equipment Theory &
CHARGER Maintenance Practice
MANDAYS 8 - 4 4
GIS Equipment Theory &
MANDAYS 24 4 12 24
SAS Equipment Theory &
MANDAYS 12 - 6 6
Page 95 of 680

CRITICAL PIPING & Design familiarization for critical Familiarization with Cold Setting of spring
POWER CYCLE piping of supercritical Plant feed back (in super hanger
PIPING critical plant) on
failure analysis and
vibration analysis of
piping.
Optimization study for sizing Study of Feed back Cyclic tests carried on
including pressure drop calculation regarding hanger spring hangers.
and selection of single or double lead setting strategies and
together with Owner’s engineers practice
Design and stress analysis of lines Cyclic tests carried on
with Expansion Joints together with expansion joints
Owner’s engineers
Design and stress analysis of piping Manufacturing process of
systems with two phase flow critical piping components
involving Owner’s engineers and appreciation of their
testing facilities at shop
Transient analysis and optimum
sizing of feed suction piping together
with Owner’s engineers.
Page 96 of 680

Static and dynamic analysis of critical
piping including siesmic and other
occassional load analysis (safety
valve blowing condition). A joint
activity together with Owner’s
engineers.
Study and collection of data
pertaining to special welding
requirements (pre and post weld heat
treat ment and electrode selection
criteria etc.) of materials used in high
temp piping system.
Study and collection of data on
special requirements in case of
welding dissimilar metals and
electrode selection criteria
MANDAYS 45 10 10
Page 97 of 680
ANNEXURE-III
Project : LIST OF ITEMS REQUIRING QUALITY PLAN DOC. NO.:
Stage : AND SUB-SUPPLIER APPROVAL REV. NO.:
Package : DATE :
Supplier : SUB-SYSTEM: PAGE : OF
Bidder No. :
S. Item QP/ Insp. QP No. QP Sub. QP Proposed Place Sub- Sub- Remarks
N. Cat. Schedule approval sub- suppliers supplier
schedule supplier approval Details
status/ submission
category schedule
LEGENDS
1. SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY the Owner)
A – For these items proposed vendor is acceptable to the Owner. To be indicated with letter “A” in the list alongwith the condition of approval, if any.
DR – For these items “Detailed required” for the Owner review. To be identified with letter “DR” in the list.
NOTED – For these items vendors are approved by Main Supplier and accepted by the Owner without specific vendor approval from the Owner. To
be identified with “NOTED.’
2. QP/INSPN CATEGORY:
CAT-I : For these items the Quality Plans are approved by the Owner and the final acceptance will be on physical inspection witness by the Owner.
CAT-II : For these items the Quality Plans approved by the Owner. However no physical inspection shall be done by the Owner. The final
acceptance by the Owner shall be on the basis review of documents as per approved QP.
CAT-III : For these items Main Supplier approves the Quality Plans. The final acceptance by the Owner shall be on the basis certificate of
conformance by the main supplier.
UNITS/WORKS : Place of manufacturing Place of Main Supplier of multi units/works.
Page 98 of 680
ANNEXURE-IV
Project : S STATUS OF ITEM REQUIRING QP& DOC. NO.:
Package : SUB-SUPPLIER APPROVAL REV. NO.:
Bidder : DATE :
Bidder No. : PAGE : OF
S. N. Item/ QP/ QP Date of Date of Status Proposed Place of Appro Sub-supplier Remarks
Service Insp. Sub. sub- commt Code Sub- manufacturi val detail
Cat. Schedule mission Appl. C/II/I suppliers ng works Status submission
Approval schedule
schedule
Page 99 of 680
ANNEXURE-V
Project : Stage : FIELD WELDING SCHEDULE DOC. NO.:
Bidder : (To be raised by the Bidder) REV. NO.:
Bidder No. : Welding Code: ……………………………………… DATE :
System : PAGE : OF
Sl. DRG No. for Weld Descrip Matl. Dimensi Process Type Electrod WPS. Min. Heat treatment NDT REF Re
No. Location and tion of Spec. ons of of e filler No. pre- method/ mar
Identification mark parts to welding Weld spec. heat Temp. Holdin Quantum Spec. ACC ks
welded g time No. Norm
Ref.
NOTES:
SIGNATURE
Page 100 of 680

ANNEXURE-VI
MANUFACTURER’S NAME MANUFACTURING QUALITY PLAN PROJECT :
AND ADDRESS ITEM : QP NO.:
PACKAGE :
REV.NO.:
MFGR.’s SUB-SYSTEM: DATE: CONTRACT NO. :
LOGO PAGE: …. OF…. MAIN-SUPPLIER:
TYPE QUANT REFERENC AGENCY
CHARACTERISTIC CLA ACCEPTAN FORMAT
SL. COMPONENT & OF UM E
S SS CE OF REMARKS
NO OPERATIONS CHEC OF DOCUMEN NORMS RECORD M C N
K CHECK T
1. 2. 3. 4. 5. 6. 7. 8. D 11.
9. ** 10.
*
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” ( DOC. NO.:

√ ) SHALL BE ESSENTIALLY INCLUDED BY REV…… CAT…..
SUPPLIER IN QA DOCUMENTATION.
** M: MANUFACTURER/SUB-SUPPLIER
MANUFACTURER/ MAIN- C: SUPPLIER/NOMINATED INSPECTION AGENCY, FOR
SUB-SUPPLIER SUPPLIER N: THE OWNER THE
Page 101 of 680

SIGNATURE P: PERFORM W: WITNESS AND V: OWNE REVIEWED APPROVE APPRO

VERIFICATION. AS APPROPRIATE, R BY D BY VAL
CHP: THE OWNER SHALL IDENTIFIED IN COLUM USE SEAL
“N”
Page 102 of 680

ANNEXURE-VII
SUPPLIER’S NAME AND FIELD QUALITY PLAN PROJECT :
ADDRESS ITEM : QP NO.: PACKAGE :
REV.NO.:
MFGR.’s SUB-SYSTEM : DATE: CONTRACT NO. :
LOGO PAGE: …. OF…. MAIN-SUPPLIER:
TYPE QUANT REFEREN
SL CHARACTERISTICS / CLASS#
ACTIVITY AND OF UM CE ACCEPTANCE FORMAT OF REMAR
. INSTRUMENTS OF
OPERATION CHEC OF DOCUMEN NORMS RECORD KS
NO CHECK
K CHECK T
1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (√) DOC. NO.:

SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN REV……
QA DOCUMENTATION.
LEGEND TO BE USED: CLASS #: A = CRITICAL,
MANUFACTURER/ MAIN- B=MAJOR, C=MINOR; FOR
SUB-SUPPLIER SUPPLIER THE
Page 103 of 680

SIGNATURE ‘A’ SHALL BE WITNESSED BY THE OWNER FQA, ‘B’ OWNE REVIEWED APPROVE APPROV
SHALL BE WITNESSED BY OWNER’S ERECTION / R BY D BY AL
CONSTRUCTION DEPTT. AND ‘C’ SHALL BE USE SEAL
WITNESSED BY ERECTION SUPPLIER (A & B CHECK
SHALL BE OWNER CHP STAGE)
Page 104 of 680


SECTION – C1-C
FUNCTIONAL / PERFORMANCE / DEMONSTRATION GUARANTEE
Page 105 of 680

FUNCTIONAL GUARANTEES, LIQUIDATED DAMAGES FOR SHORTFALL IN PERFORMANCE AND

GUARANTEE TESTS
(The term "Performance Guarantees" wherever appears in this Section shall have the same meaning and
shall be synonymous to "Functional Guarantees". Similarly the term "Performance Tests" wherever
appears in this Section shall have the same meaning and shall be synonymous to "Guarantee Test(s)".
The term "TMCR" (Turbine maximum continuous rating) appearing in the Technical Specification shall
mean 660 MW electrical power output at generator terminals (power at generator terminals as per clause
indicated in this section) under 0% cycle make-up and 76 mm Hg (abs) condenser pressure unless used in
conjunction with a different cycle make-up and/or a different condenser pressure.
1.00 PERFORMANCE GUARANTEES
General Requirements
1.01 The Bidder shall guarantee that the equipment offered shall meet the rating and performance
requirements stipulated for various equipment covered in this specifications.
1.02 The guaranteed performance parameters furnished by the bidder in his offer, shall be without
any tolerance values and all margins required for instrument inaccuracies and other
uncertainties shall be deemed to have been included in the guaranteed figures.
1.03 The bidder shall demonstrate all the guarantees covered herein during performance
guarantee/acceptance test. The various tests which are to be carried out during performance
guarantee/acceptance tests are listed in the specification. The guarantee tests shall be
conducted by the bidder at site in presence of BHEL / CUSTOMER on each unit individually.
1.04 All costs associated with the tests shall be included in the bid price.
1.05 In case during performance guarantee tests, it is found that the equipment/system has failed to
meet the guarantees, the bidder shall carry out all necessary modifications and/or replacements
to make the equipment/system comply with the guaranteed requirements at no extra cost to the
BHEL / CUSTOMER and re-conduct the performance guarantee test(s) with BHEL /
CUSTOMER’s consent. However if the specified performance guarantee(s) are still not met but
are achieved within the Acceptable shortfall limit specified in the specification, BHEL /
CUSTOMER will accept the equipment/system/plant after levying liquidated damages as
mention in the specification. If, however, the demonstrated guarantee(s) continue to be more
than the stipulated Acceptable Shortfall Limit, even after the above modifications/replacements
within ninety (90) days or a reasonable period allowed by the BHEL / CUSTOMER, after the
tests have been completed, the BHEL / CUSTOMER will have the right to either of the following:
a) For Category-I Guarantees
Reject the equipment/system/plant and recover from the bidder the payments already made.
OR
Accept the equipment/system/plant after levying liquidated damages as specified hereunder.
The liquidated damages, for shortfall in performance shall be levied separately for each unit.
The rates indicated are on station basis and per vessel basis respectively. The liquidated
damages shall be pro-rated for the fractional parts of the deficiencies. The performance
guarantees coming under this category shall be called ‘Category-I’ Guarantees.
b) For Category-II Guarantees
The performance guarantees under this category shall be called ‘Category-II’ Guarantees.
Conformance to the performance requirements under category-II is mandatory.
Page 106 of 680

c) For Category-III Guarantees
OR
Accept the equipment/system after assessing the deficiency in respect of the various ratings,
performance parameters and capabilities and recover from the contract price an amount
equivalent to the damages as determined by the BHEL/CUSTOMER. Such damages shall,
however be limited to the cost of replacement of the equipments/systems replacement of which
shall remove the deficiency so as to achieve the guarantee performance. These parameters /
capacities shall be termed as Category-III, guarantees.
2.00 GUARANTEES UNDER CATEGORY I
NIL
3.00 GUARANTEE UNDER CATEGORY –II
NIL
4.00 GUARANTEE UNDER CATEGORY –III
CONDENSATE POLISHING PLANT
5.00 Following shall be guaranteed by the Bidder in the relevant Guarantee Schedule of the Bid
Document and falls under “GUARANTEE UNDER CATEGORY –III”:
a. NORMAL OPERATING CONDITION:
i. Design Flow of each Service Vessel of Condensate Polishing Plant to be guaranteed.
ii. Guaranteed service length (Period between two successive regenerations) of each service
vessel shall be 30 days (720 hours).
iii. Bidder shall guarantee the number of hours of operation of each service vessel in hydrogen
cycle mode.
iv. Quantity of Chemicals (30% HCl & 48% NaOH) per regeneration of each service vessel shall
be guaranteed. Bidder to refer Technical Specification regarding minimum regeneration
level to be employed while furnishing the guaranteed chemical consumption figures.
v. Effluent Quality of Condensate:
 With specified Design Flow, influent quality, each CPU Vessel regenerated with
Guaranteed quantity of Chemical (Acid & Alkali) shall be guaranteed to maintain the
effluent quality as specified in technical specification throughout the cycle (i.e. period
between two successive regenerations) of 30 days (720 hours). No shortfall in guaranteed
effluent quality will be accepted by the BHEL / customer during the service cycle.
 Throughout the Service Cycle each Service vessel regenerated with guaranteed chemicals
(Acid & Alkali), shall treat the condensate with influent crud level of 50 ppb at its design
Flow and crud level of condensate at vessel outlet shall be guaranteed to be 5 ppb.
b. UNIT START UP CONDITION OR CONDENSER LEAK CONDITION
With Design Flow, influent quality, each Service vessel regenerated with guaranteed
chemicals (Acid & Alkali) shall be guaranteed to maintain the effluent quality as specified in
technical specification throughout useful service run of not less than 50 hours (i.e. period
Page 107 of 680

between two successive regenerations). No shortfall in guaranteed effluent quality

will be accepted by the BHEL / customer during the service cycle. Throughout the Service
Cycle of each CPU service vessel, total crud content in the effluent shall not exceed 150 ppb
considering an influent average crud level of 500 ppb in the condensate.
c. Pressure drop across the polisher service vessel (as defined elsewhere) in clean and dirty
condition of resin at rated design flow i.e.
i) At the design flow rate, the pressure drop between inlet and outlet flanges of the polisher
Condensate Polisher Mixed Beds with clean resin bed shall not exceed 2.0 bar (g).
ii) Maximum pressure drop under dirty conditions shall be restricted to about 3.5 bar (g) including the
pressure drop across effluent resin traps.
d. Vibration & parallel operation of all the pumps and blowers at the rated duty point shall be
demonstrated at site.
e. Noise level of all pumps and blowers at the rated duty point shall be demonstrated at site.
i) Noise: All the CPU plant pumps and blowers covered under this specification shall perform
continuously without exceeding the noise level over the entire range of output and operating
frequency specified in the technical specifications. Noise level measurement shall be carried out
using applicable and internationally acceptable standards. The measurement shall be carried out
with a calibrated integrating sound level meter meeting the requirement of IEC 651 or BS 5969 or
IS 9779. Sound pressure shall be measured all around the equipment at a distance of 1.0 m
horizontally from the nearest surface of any equipment/ machine and at a height of 1.5 m above the
floor level in elevation. A minimum of 6 points around each equipment shall be covered for
measurement. Additional measurement points shall be considered based on the applicable
standards and the size of the equipment. The measurement shall be done with slow response on
the A - weighting scale. The average of A-weighted sound pressure level measurements expressed
in decibels to a reference of 0.0002 micro bar shall not exceed the guaranteed value. Corrections
for background noise shall be considered in line with the applicable standards. All the necessary
data for determining these corrections, in line with the applicable standards, shall be collected
during the tests.
6.00 PERFORMANCE GUARANTEE / ACCEPTANCE TEST
6.1. General Requirements
a) It is the responsibility of the Bidder to perform the Performance Guarantee/Acceptance test as specified
in this Section. The performance tests will be performed using only the normal number of BHEL
/Customer supplied operating staff for monitoring of PG test. Bidder personnel shall be used for
instructional purposes or data collection and conducting the PG test at site. At all times during the
Performance Tests the effluents quality from the Plant shall not exceed the Guaranteed Effluent Limits.
b) The Bidder shall make their system ready for the performance guarantee tests.
c) All instruments required for performance testing shall be of the type and accuracy required by the code
and prior to the test, the Bidder shall get these instruments calibrated in an independent test Institute
approved by the TANGEDCO/BHEL. All test instrumentation required for performance tests shall be
supplied by the Bidder and shall be retained by him upon satisfactory completion of all such tests at site.
All costs associated with the supply, calibration, installation and removal of the test instrumentation shall
be included in the bid price. All calibration procedures and standards shall be subjected to the approval
of the TANGEDCO/BHEL. The protecting tubes, pressure connections and other test connections
required for conducting guarantee test shall conform to the relevant codes. Tools and tackles, thermo
wells (both screwed and welded) instruments/devices including flow devices, matching flanges, impulse
piping & valves etc. and any special equipment, required for the successful completion of the tests, shall
be provided by the Bidder free of cost.
Page 108 of 680


d) The Bidder shall submit for TANGEDCO/BHEL approval the detailed Performance Test procedure
containing the following:
(i) Object of the test.

(ii) Various guaranteed parameters & tests as per contract.
(iii) Method of conductance of test and test code.
(iv) Duration of test, frequency of readings & number of test runs.
(v) Method of calculation.
(vi) Correction curves.
(vii) Instrument list consisting of range, accuracy, least count, and location of instruments.
(viii) Scheme showing measurement points.
(ix) Sample calculation.
(x) Acceptance criteria.
(xi) Any other information required for conducting the test.
The Performance / Acceptance test shall be carried out as per the agreed procedure. After the
conductance of Performance test, the Bidder shall submit the test evaluation report of Performance
test results to TANGEDCO/BHEL promptly but not later than one month from the date of
conductance of Performance test. However, preliminary test reports shall be submitted to the
TANGEDCO/BHEL after completing each test run.
e) Test Interruptions:
In the event of a test interruption resulting from an Event of Force Majeure the interrupted
Performance Test must be started again and test data that were collected during the interrupted
test must be ignored.
Page 109 of 680


SECTION C1 – D
QUALITY ASSURANCE
Page 110 of 680


QUALITY PLAN FOR MECHANICAL ITEMS
Page 111 of 680

Page 112 of 680

10. Inspection / test / check requirements for pressure vessels other than service vessel are same as
for inspection / test / check requirements for service vessel as indicate in table given above.
11. For piping, vales, fillings in service vessel area quality requirements please also refer power cycle
piping quality plan.
12. Quality requirements specified here if contradicting as specified elsewhere in this chapter, then
stringent quality requirements shall be followed by the bidder for all items without any price and
delivery implications to BHEL/customer.
Page 113 of 680

SECTION - 5
QUALITY ASSURANCE PLAN
1.0. GENERAL REQUIREMENTS
a) Shop Tests
Shop t ests s hall i nclude a ll t ests t o be c arried o ut at Bidder's works, at w orks of hi s s ub-
contractor an d at works where r aw m aterial s upplied f rom manufacture of equ ipment i s
manufactured. Testing r equirement of major equi pment o ver and a bove t he r espective c ode /
standard r equirements ar e gi ven f or S T & A ux. including C ondenser, H P Bypass S ystem &
Vibration Isolating System.
b) Site Tests
The Bidder s hall pr epare an d s ubmit det ailed f ield quality plans b y s etting out t he qu ality
practice and procedures to be adopted by him for assuring quality for each equipment of material
at this specification f rom t he r eceipt of m aterial at s ite, d uring s torage erection,
precommissioning to final commissioning of the plant. These procedures shall necessarily
include all c hecks/tests c onducted at s ite f or pr eservation, assembly, a lignment, pos itioning of
the e quipment, f oundation pr eparation, welding/bolting he at t reatment, non -destructive
examination, hydraulic test, running test, performance test etc. The Bidder shall also furnish
detailed qu ality procedure proposed b y h im for storage, pr eservation, p ainting, ac id c leaning,
alkali boil out, steam blowing, hydraulic test air/gas tightness test etc. to the BHEL/TANGEDCO. The same
shall be discussed and finalised with the BHEL/TANGEDCO and six numbers of such finalised copies shall
be submitted.
2.0. STEAM TURBINE AND ASSOCIATED EQUIPMENT
2.1. High Pressure & Intermediate Enclosure
High pr essure Cast Steel Enclosures ( for ex ample H igh pr essure and I ntermediate P ressure
Inner and Outer Cylinders, Steam Chests and liner, Steam Inlet Pipes, nozzle boxes).
1) Test pieces fully representative of the material and condition of the casting shall be provided to
enable the properties of material to be determined.
Creep requirements:
a) Steels chosen for design metal temperatures less than 400°C are exempt from creep /stress
rupture testing.
b) Steels chosen for design metal temperatures between 400°C to 540°C and having less than
3% c hromium, s hall r equire 5 years per formance feedback ex perience in t he absence of
which, creep rupture test will be required to be carried out for maximum test duration of 1000
hrs/mutually agreed parameters for employer’s approval.
c) Steels c hosen f or d esign metal t emperatures ab ove 54 0°C and/or having m ore t han 3%
chromium, shall r equire 1 0 years per formance feedback ex perience O R ade quate s tress
rupture data, in the absence of which, creep rupture test will be required to be carried out for
maximum test duration of 1000 hrs/mutually agreed parameters for employer’s approval.
d) Unspecified alloying elements shall be controlled as per the applicable standard.
2) Each casting shall be subjected to m agnetic particle examination on the entire i nner and outer
surfaces after heat treatment.
Page 114 of 680

h) Shroud ba nds af ter punc hing an d af ter r ivet-ting s hall be s ubjected t o 1 00% D PT t o ens ure
freedom from harmful surface defects.
i) In case of cast blades, following testing shall be done:-
1. Chemical analysis/Mechanical testing per heat/heat treatment batch.
2. Rough machined and finish machined blade shall be subjected to MPI.
3. RT on blades.
4. Before starting mass productions, following technological tests shall be carried out on the first
lot of 10 to 15 blades :-
i. 100% radiography and 100% MPI on blades
ii. 100% hardness testing.
iii. Mechanical testing and metallurgical testing.
iv. Weld repair shall not be permitted unless prior approval of Employer is obtained.
In c ase of r epair i s allowed, m anufacturer s hall s ubmit WPS/PQR and def ectogram for
Employer's appr oval bef ore w elding. A fter w eld r epair, R T shall be c arried out on r epaired
area.
2.5. Diaphragms
a) Welded and fabricated Diaphragms
1) Concentricity checks shall be carried out on finally machined diaphragms to ensure that there
are no negative overlaps between guide and moving blades.
2) 10% Ultrasonic examination and 100% magnetic particle examination shall be carried out on
finished, stress relieved and machined welds.
b) Cast/Forged/Machined Diaphragms
1) Details of the results of the tests conducted to determine mechanical properties together with
chemical analysis, metallographic/ metallurgical examination, and heat treatment procedures
recommended and actually followed shall be recorded on certificates.
2) Concentricity, flatness, blade drop and area checks shall be carried out on finally machined
diaphragms to ensure that there are no negative overlaps between guide and moving blades
and port wall. Finish shall be to employer’s approval.
3) A 100% u ltrasonic ex amination s hall be c arried out on di aphragm materials. B lade j unction
areas with the side walls shall be checked by magnetic particle or dye penetrant testing.
c) Colour matching of all the diaphragms by putting two halves together, and feeler gauge
tightness check shall be carried out.
2.6. Stop, Control and bypass valves, actuators/servo-motors and steam strainers
a) Test pi eces s hall be pr ovided t o en able t he m echanical properties of v alve bodies, bonnets,
valve disc and seat, and valve spindle material to be determined.
Test Creep requirements:
Page 115 of 680

i. Steels chosen for design metal temperatures less than 400°C are exempt from creep /stress
rupture testing.
ii. Steels chosen for design metal temperatures between 400°C to 540°C and having less than
3% c hromium, s hall r equire 5 years per formance feedback ex perience in t he absence of
which, creep rupture test will be required to be carried out for maximum test duration of 1000
hrs/mutually agreed parameters for employer’s approval.
iii. Steels c hosen f or d esign metal t emperatures ab ove 54 0°C and/or having m ore t han 3%
chromium, shall r equire 1 0 years per formance feedback ex perience O R ade quate s tress
rupture data, in the absence of which, creep rupture test will be required to be carried out for
maximum test duration of 1000 hrs/mutually agreed parameters for employer’s approval.
iv. Unspecified alloying elements shall be controlled as per the applicable standard.
b) Dye penetrant checks shall be carried out on stellited / nitrided areas of components and stellite
components in t he f inish g round or ho ned c ondition. Hardness c heck s hall be carried o ut t o
ensure required hardness.
c) Valve b ody a nd bo nnet c astings/forgings s hall b e s ubjected t o 100% r adiography or 10 0%

ultrasonic ex amination. B ody and bo nnet s hall a lso be s ubjected t o 1 00% m agnetic par ticle
examination on en tire s urface. A ll pr essure c ontaining welds in bo dy and b onnet shall be
subjected to 100% RT/UT and MPI examination.
d) Wall thickness of the body and bonnet after finish machining shall be measured by ultrasonic
method and valve seat bore shall be checked for size and concentricity.
e) Bar stock for valve stem shall be subjected to ultrasonic examination and finish machined stem
shall be subjected to magnetic particle/Dye penetrant examination.
f) Each valve body and bonnet shall be hydraulically tested at minimum 1.5 times the maximum
working pressure after applying temperature corrections.
g) All the actuating cylinders/servomotors shall be performance tested.
h) Performance t esting s hall be c arried o ut o n v alve operators/ ac tuators t o c heck functional

requirements like trip closing and opening time, valve lift and hysterisis.
i) Colour matching of the valve disc and seat to ensure the required contact area is to be carried
out.
2.7. Cast and Forged Steel Components such as LP casing, in case of cast design, inlet &
extraction / ex haust c onnections, s haft s eal c overs and r ings, go vernor s haft, br each nu t,
threaded ring, angle ring, U-ring, servomotor parts such as body, piston, cover, yokes; turning
gear casing and other items which are not specifically covered elsewhere
Results of t ests c onducted t o d etermine m echanical pr operties, chemical a nalysis,

metallurgical/ m etallographic ex amination, a nd heat treatment pr ocedures r ecommended an d
actually followed shall be recorded on certificates.
Each pressure containing enclosure shall be subjected to a hydraulic pressure test at 1.5 times
the design pressure.
Each c asting/forging s hall be s ubjected t o s uitable non-destructive ex amination by

Radiographic or ul trasonic and m agnetic par ticle or d ye pe netrant ex amination methods t o
ensure freedom from harmful defects.
Page 116 of 680

b) Surface defect test shall be carried out on all the springs after coiling and heat treatment.
c) Surface cleaning shall be checked prior to painting and check for thickness of painting shall be
carried out.
5.0. Condenser air evacuation system for main turbine condenser and drive turbine
condenser (if offered)
5.1. Pumps
a) Vacuum pump shafts shall be subjected to ultrasonic test. After finish machining, shaft shall be
subjected to magnetic particle examination/dye penetration test.
b) Pump casings and impellers shall be subjected to magnetic particle/dye penetration test.
Finished pump rotor shall be subjected to dynamic balancing.
c) Pump casings shall be subjected to hydraulic test at 1.5 times the shut off pressure or twice the
maximum operating pressure, whichever is higher.
d) Each pump shall be tested at supplier's works at full speed and load conditions to demonstrate
successful operation and performance in accordance with the design requirements.
e) Supplier s hall d emonstrate b y c arrying out visual c avitation t est t hat p ump w ill be op erating
under all operating condition including blank off condition without cavitation.
f) Refer r elevant c lauses of the s pecification f or ot her items s uch as heat ex changers, f ilters,
piping, valves, etc. in this system.
5.2. The c omplete p ackage s hall be s ubjected t o h ydraulic pr essure an d l eakage t est and s hop
tested t o c heck interlocks and f unctional r equirements. T he one c omplete un it shall also be
subjected t o d emonstrate s uccessful oper ation and performance t esting, with s aturated air
conditions at condenser design vacuum point as well as vacuum pump design point with total
minimum three points The test should be conducted with the respective motors to be supplied.
The test shall include check for vibration and noise level.
6.0. FEED WATER HEATER, DRAIN COOLERS, GLAND STEAM CONDNSER, HEAT
EXCHANGERS & PRESSURE VESSELS / STORAGE TANKS
6.1. All raw materials used s hall ha ve co-related mill test certificate meeting mandatory and
supplementary checks of material specification.
6.2. Material f or T ube pl ates s hall be ultrasonically t ested. F inished plates s hall be s ubjected t o
suitable NDT. For cladded pl ates, bon ding s hall b e c hecked by UT. V endor shall f urnish t heir
practice r egarding m anufacturing & N DT f or s upply of c ladded pl ates f or E mployer's r eview.
Drilled Tube plates shall be checked for ovality of holes, ligaments, surface finish etc.
6.3. Dished ends s hall be s ubjected t o 100% M PI and RT/UT on w elded j oints. K nuckle por tion
shall be checked by MPI for surface defects and thinning shall be checked by UT.
6.4. Butt Welded / Full penetration joints shall be checked by suitable RT / UT. Fillet welds shall be
checked by MPI / DPT.
6.5. Tubes shall be tested as per the relevant codes / specification / standards.
6.6. Before tubes expansion in the tube sheets, the mockup test for expansions shall be carried out,
in c ase not don e ear lier. T orque s etting of expander s hall b e bas ed on m ock up t ests. J oints
shall be checked for tube thinning.
Page 117 of 680

6.7. Completed assemblies shall be pressure tested with working-fluid/ hydraulically/ pneumatically.
The heat exchangers shall be tested on both tube side and shell side. After hydrotest, the heat
exchangers shall be suitably dried and nitrogen capped. Atmospheric tanks shall be tested for
leakage by water fill test for atleast 12 hrs.
7.0. PIPING, BELLOWS AND THERMAL INSULATION FOR TURBINE & AUX SYSTEMS
7.1. Piping and Fittings
a) All raw materials used shall have co-related mill test certificate meeting mandatory and
b) All pipe lengths shall be subjected to 100% ultrasonic examination or hydraulic tests and UT/RT
on longitudinal welds at the tube mill.
c) All mother pipes used for fittings shall be subjected to a hydraulic test or an ultrasonic test at the
tube mill. Raw material of all forged fittings shall be ultrasonically tested. Forged fittings shall be
ultrasonically tested.
d) Welded and cast fittings, if any, shall be subjected to suitable NDT as per applicable standards.
However, as a minimum 100% RT shall be carried out on all alloy steel fittings and on carbon
steel fittings for use above 71 bar design conditions.
e) The edge preparation for shop and site welds shall be checked by MPI/LPI however edge
preparation in stainless steel alloy/ steel shall be subjected to a Dye penetrant check.
f) Thickness of pipe bends shall be checked by ultrasonic or other acceptable methods on sample
basis for high pressure applications. Outer surface of bends shall be subjected to magnetic
particle examination / LPI.
g) Non-destructive examination of welds shall be carried out after post weld heat treatment, if any.
h) Non-Destructive Examination of welds shall be carried out in accordance with the relevant
design/manufacturing codes. However, as a minimum, the following requirements shall be met
(except for oil piping). Further statutory requirement, wherever applicable shall also be complied
with
0
1) Temperature > 400 C and / or pressure exceeding 71 bar.
i. 100% RT/UT on butt welds and full penetration branch welds.
ii. 100% MPE.
2) Temperature > 1750C up to 4000C and / or pressure exceeding 17 bar and up to 71 bar.
i. 100% RT / UT on butt welds and full penetration branch welds for pipe dia more than 100
NB.
ii. 10% RT / UT on butt welds and full penetration branch welds for pipe dia up to 100 NB.
iii. 100% MPE.
3) Wherever SR/PWHT is envisaged, above NDTs shall be after SR/PWHT.
4) For all other pipes not covered above (except oil piping), shall be subjected 100% MPE / DPT
in case of under ground pipes and 10% MPE/DPT in case of piping above the ground.
Further, 10% of butt welds of underground piping shall be subjected to RT.
Page 118 of 680

5) Hardness survey of welds shall be carried out on alloy steel/stainless steel piping. (100%
Hardness survey of welds on P91, X20 & X22 material grade pipings).
6) For welds in P91, X20 & X22 materials, only induction type of heating shall be deployed for
heat treatment.
i) Oil piping shall be subjected to following NDT.
1) Butt welds of Oil piping shall be subjected to 10% RT and 10% DP Test. For Jacking oil lines
100% RT & 100% DPT shall be carried out on butt welds.
2) Fillet welds with load transfer shall be subjected to 100% MPE/DPT and fillet welds without
load transfer shall be subjected to 10% MPE/DPT.
j) Rubber lined pipes shall be hydraulically tested before rubber lining. All rubber lining is to be
subjected to following tests as per IS-4682 part-I or acceptable equivalent:
1) Adhesion test
2) Check for resistance to bleeding
3) Measurement of thickness
4) Shore hardness test
5) Visual examination and spark test at 5 kv/mm of thickness.
7.2. Metallic Expansion Bellows
a) Hydraulic pressure test shall be carried out on each pipe and expansion bellow.
b) Longitudinal butt weld on bellow shall be subjected to suitable NDT examination before forming,
and after forming MPE / DP test shall be carried out.
c) All welds shall be subjected to 100% magnetic particle/dye pentrant check and butt welds shall
be subjected to 100% radiographic testing.
d) All the bellows subjected to vacuum service shall be subjected to vacuum test.
e) The bellows shall be subjected to movement test to establish suitability to perform satisfactorily
in site conditions. During this test spring rate shall also be measured.
f) Life cycle test, meridional yield rupture test and squirm test to be carried out on a prototype /
expansion bellow as per Sec.D clause 3.2 of standards of Expansion joint Manufacturer
Association (EJMA). In case these tests have already been accepted by employer on a
prototype expansion bellow, as defined in Sec.D Clause 3.2 of Expansion Joints Manufacturers
Association (EJMA) test reports may be furnished by manufacturer for consideration and
approval of Employer.
7.3. Rubber Expansion Joint
a) Rubber compound test slab after valcanising shall be tested for tensile strength, elongation and
shore hardness. Tests on rubber compound shall also include hydrostability test as per ASTM
D-3137 and ozone resistance test as per ASTM D- 380.
Page 119 of 680

b) Fabric strength of synthetic fibre for reinforcement shall be checked, and test for rubber to fabric
adhesion as per IS:3400/ASTM D- 413, rubber to metal adhesion as per IS 3100/ASTM D-429
shall be carried out.
c) All expansion joints in assembled condition shall be subjected to vacuum test at 730 mm Hg
under conditions to ensure its suitability to withstand deflection in each axial transverse and
longitudinal direction. Duration of test shall be of minimum 10 minutes.
d) All bare bellows shall be subjected to hydraulic pressure test in normal condition at twice the
design pressure for a duration of 30 minutes.
e) Additionally, all bare bellows shall be subjected to deflection tests under pressure, pressure
being raised from zero to the design value in regular steps and deflection measured at each
step.
f) All expansion joints in assembled condition alongwith control rod assembly shall be subjected to
deflection test under design pressure. The details of test procedure shall be subjected to
approval by employer.
g) Either during the hydraulic test or during the vacuum test, change in circumference at the top
position of the arch shall not exceed 1.5% of measured circumference at normal position.
h) Twenty Four (24) hours after the above tests, the permanent set (variation in dimensions with
respect to its original dimension) shall be measured and recorded. The permanent set shall not
be more than 0.5%.
i) Life cycle test and burst test shall be carried out on bellows of each type, design and size. In
case these test have already been accepted by employer in earlier projects for the same type /
size /design, test certificate for the same may be furnished for approval of Employer.
7.4. THERMAL INSULATION
a) For mineral wool insulation, testing shall be carried out as per IS:3144.
b) For sprayed mineral wool, testing shall be carried out as per IS:9724.
c) Thermal conductivity (k value) shall generally be measured in line with IS:3346.
7.5. Hangers and Supports
a) Forged components such as clevis, turnbuckle, eyebolts, coupling etc. will be subjected to
material testing, hardness, MPE, proof load test etc.
b) Dampers with viscous fluids will be checked for viscosity of liquid used, damping resistance of
the damper, stiffness of the damper etc.
c) Springs used for variable constant load and spring hangers shall be checked for chemical,
mechanical and spring rate tests.
d) Complete variable and constant load spring cage will be subjected to performance test and
load/deflection test.
e) Complete hanger will be subjected to performance test and load test.
8.0. VALVES
8.1. Inspection and testing requirements for valves other than extraction line valves and butterfly
valves shall be as follows:-
Page 120 of 680

a) Pressure retaining parts of valves shall be subjected to NDT as per Table 1.
b) Bar stock/forging above 40mm diameter for valve trim shall be subjected to UT
c) Hardened / stellitted valve disc and seat are to be subjected to LPI and hardness check.
d) Colour matching of valve disc/plug and seat shall be carried out to ensure contact.
e) Hydraulic pressure test and seat leak test shall be carried out as per ANSI 16.34.
f) Air seat leak test shall be carried out as per applicable Standards/Codes.
g) Functional testing shall be carried out on each valve to check the following as per the approved
valve data sheet:
1) Smooth operation
2) Valve travel, closing and opening time.
3) Current drawn by actuators..
h) Springs for safety valves shall be tested with suitable NDT and for spring rate.
i) Safety and safety relief valves shall be tested for performance.
TABLE-1
NDT REQUIREMENTS FOR PRESSURE RETAINING COMPONENTS OF VALVES
Valve size NB in ANSI Class upto ANSI Class ANSI Class ANSI Class 900 &
mm 300 above 300 below above 600 below above & below
600 900 4500
Less than 50 Visual Visual Visual MPI
50 & above but Visual Visual MPI MPI & RT (on 10%
below 100 of valves on 100%
area)
100 & above but Visual MPI MPI & RT (on 10% MPI & RT on
less than 300 of valves on 100% area)
change of section
& weld ends)
300 and above MPI MPI MPI & RT (on MPI, RT (on 100%
change of sections area)
& weld ends)
Note:
i. For body and bonnet forgings UT with MPI may be adopted in place of RT. For austenitic steel
MPI may be replaced by LPI.
ii. Weld Edge Preparation shall be subjected to MPI/LPI
8.2. Extraction Line Valves
a) Surface crack examination and hardness check shall be carried out on all hard faced/stellieted
surfaces, if any.
Page 121 of 680

b) As a minimum requirement of castings for all valves on cold reheat and extraction lines shall be
subjected to 100% MPI on all areas and RT on Butt Weld ends and change of Section. For
forgings minimum requirement shall be 100% UT and 100% MPI.
c) Bar stock for valves stem shall be subjected to UT. Finish machined valve stem shall be
subjected to magnetic particle examination/dye penetration test.
d) Wall thickness measurement by ultrasonic for critical and highly stressed zones of the
casting/forging shall be carried out.
e) Colour matching of the valve disc and seat to ensure required contact area shall be carried out.
f) Hydraulic pressure tests shall be carried out on each valve to check body and bonnet strength.
Seat leakage and back seat leakage test (wherever applicable) shall be carried out. Air seat
leakage test shall also be carried out. Minimum test requirements of pressure shall be as per
ANSI B 16.34.
g) Functional testing shall be carried out on each valve to check for freedom of movement,
adherence to clearance, opening/ closing etc. Type tests for discharge co-efficient and pressure
drop co-efficient, shall be carried out. In case the type tests have been carried out in the past
and documents generated, the same shall be furnished to the Employer for approval.
8.3. Butterfly valves
a) Valve disc shall be checked for surface and sub-surface defects by magnetic particle
examination.
b) Stubs and driving shafts shall be tested for internal defects by ultrasonic method.
c) Dye penetration test shall be carried out on shafts, seat rings etc.
d) Test samples for rubber seal shall be subjected to tensile and hardness test for vulcanising and
after ageing. Hydraulic stability test and ozone crack reistance tests also be carried out.
e) Valve shall be subjected to hydraulic pressure test for body and air seat leakage tests as per
AWWA-C504
f) Proof of design tests for valves and actuator shall be carried out as per AWWA-C504. In case
the test has already been carried out on previous supplies, the contractor may submit the test
certification of same for approval of employer.
g) After complete assembly each valve with actuator will be subjected to performance test by
opening and closing the valve from fully closed to fully open position and the reverse, under no
flow for at least 25 cycles to check.
1) Smooth uninterrupted movement of valve.
2) Closing and opening time.
3) Current drawn by actuator.
4) Operation of tripping switch and position indicator.
h) After assembly, one valve of each size with respective actuator shall be shop operated over the
full range of movement in both the directions, with the body subjected to the full hydrostatic
pressure conditions, to demonstrate that the unit is in working order without any leakage
through the joints and torque switches/clutches, limit switches are operating satisfactorily.
During the test, hand wheel operation, opening/closing time and current drawn shall also be
Page 122 of 680

checked. The test shall be conducted for three consecutive cycles with valve shaft both in
vertical and horizontal planes.
9.0. MISC. ITEMS / EQUIPMENTS
9.1. FILTERS / STRAINERS
a) Filters / strainers shall be tested as per the requirements of relevant codes / standards.
b) Filters / strainer shall be performance tested for pressure drop, flow, particle size. If
performance test is earlier established, then records shall be reviewed.
9.2. BLOWERS/ EXHAUSTERS
a) Rotors shall be dynamically balanced. Leakage tests (if applicable) shall be carried out.
b) Performance tests including noise and vibration tests shall be carried out as per relevant
standards / codes.
9.3. LP CHEMICAL DOSING SYSTEM
a) Pumps of chemical doing system shall be performance tested as per relevant international
codes.
b) In case of diaphragm type of pumps, the life cycle test shall be done on pumps. If this test is
already conducted for same model in earlier projects of TANGEDCO, then TCs for same shall
be reviewed.
c) Dosing skid shall be subjected to leakage test and functional test.
10.0. Electrical and Control & Instrumentation:
Refer Electrical and Control & Instrumentation Sections.
11.0. SITE TEST:
Quality requirements for site activities shall be as a minimum, those specified for
corresponding shop activities.
11.1. Hydraulic Test of Pressure Parts :
On completion of erection of pressure parts of each steam turbine generator, the unit with its
fittings and mountings in position shall be subjected to hydraulic test pressure in accordance
with requirement of Indian Boiler Regulations. Water used for hydraulic test shall be made
alkaline by addition of suitable chemical. After the test, all parts shall be drained and suitably
preserved.
11.2. Condenser Assembly :
a) If the condenser sections calls for site assembly, care shall be taken in assembly of sections
and correctness of alignment and fit up shall be checked. Site welding shall be carried out as
per the procedure approved by the employer.
b) All weld seams shall be subjected to magnetic particle examination. At least 10% of butt welds
shall be subjected to radiographic examination.
c) All welds between condenser neck and LP turbine shall be subjected to 100% radiographic and
magnetic particle examination.
Page 123 of 680

d) Condenser tubes shall be visually examined for dents, mechanical damages or any other
defects prior to insertion. Both tube ends shall be thoroughly cleaned to a length of 100mm to
remove oil, grease etc. and shall be checked for freedom from burrs prior to insertion.
e) Tube expansion shall be carried out by electronic automatic torque control expanding unit,
which shall be calibrated before use. Tube wall thinning and length of expansion shall be
controlled and recorded.
f) Hydrostatic testing of condenser steam space shall be carried out after connecting all the pipes
with the condenser along with condenser vacuum systems by filling the steam space with water
upto the tip of the last stages of blades of LP cylinder.
g) Condenser water boxes shall be tested hydraulically at a minimum test pressure of 1.5 times
the design pressure.
11.3. TURBINE ASSEMBLY
Bidder shall clearly indicate the extent of assembly to be carried out at site. Accordingly, bidder
shall submit elaborate erection and assembly inspection programme of turbine for Employer's
approval.
12.0. CONDENSER ON LOAD TUBE CLEANING SYSTEM/DEBRIS FILTER FOR MAIN TURBINE
CONDENSER AND DRIVE TURBINE CONDENSER (IF OFFERED)
General Requirements
12.1. Ball Recirculation Pump
a) All rotating parts shall be dynamically balanced.
b) Pump casing shall be subjected to hydraulic test at 1.5 times the shut off head or twice the
maximum working pressure whichever is higher.
c) Complete pump assembly shall be subjected to shop performance test at supplier's works.
12.2. Ball Sorter / Fabricated Body (housing)
a) In the case of fabricated design, all butt welds shall be subjected to 10% radiographic/ultrasonic
examination. All welds shall be examined by 10% magnetic particle testing method to ensure
freedom from surface and subsurface defects.
b) Body shall be subjected to hydraulic pressure test at 1.5 times the design pressure.
c) Performance test shall be carried out on ball sorter assembly.
12.3. Strainer
a) Strainer mesh shall be checked for chemical composition and mesh size.
b) Strainer body shall be subjected to hydraulic pressure test at 1.5 times the design pressure.
c) Strainer assembly shall be checked for its function.
12.4. The complete system and the individual equipment shall be subjected to performance testing at
Site to demonstrate successful operation and performance to meet the design conditions. The
tests shall also include hydraulic test, function test, check for interlocks and sequential
Page 124 of 680

operation. Site test shall also include test to establish pressure drop across the strainer section,
proper functioning of DELTA-P system.
12.5. Piping and Fittings
Piping and fabricated fittings shall be subjected to following NDT.
a) Butt welds of piping shall be subjected to 10% RT and 10% DP Test. Butt welds of Segmental
flanges shall be checked by 100% RT and DPT.
b) Fillet welds with load transfer shall be subjected to 100% MPE/DPT and fillet welds without load
transfer shall be subjected to 10% MPE/DPT.
Wrought/ forged fittings shall be tested as per relevant code/ specification/ standard.
12.6. Coating / lining
12.7. Coating shall be checked for DFT and adhesion. Further, Contractor shall furnish his practice
for testing of coating to ensure the uniformity and freedom from pinholes.
12.8. Rubber lined items shall be hydraulically tested before rubber lining. All rubber lining is to be
subjected to following tests as per IS-4682 part-I or acceptable equivalent:
a) Adhesion test
b) Check for resistance to bleeding
c) Measurement of thickness
d) Shore hardness test
e) Visual examination and spark test at 5 kv/mm of thickness.
12.9. VALVES
Conventional gate/ globe/ check/ ball valves shall be tested as per relevant standard.
13.0. CONDENSATE EXTRACTION PUMPS AND DRIP PUMPS (IF OFFERED)
CONDENSATE EXTRACTION PUMP
INPROCESS TEST FINAL TESTS

Pressure Drop Test
TEST
Chemical Analysis
Mechanical Prop.
Performance test
Inclusion Rating
Strip Down Test

Heat Treatment
NPSH Test
Balancing
Hyd. Test
Vibration
Run out
D.P.T.
M.P.I.
Noise
U.T.
R.T
ITEM
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Pump Casing Y Y➀ - - - - Y - - Y -
Suction Bell Y Y➀ - - - - Y - - -
Shaft Y Y➀ Y Y Y - Y Y - Y
Impeller Y Y➀ Y - - - Y - Y -
Rotor - - - Y - - - - Y -
Page 125 of 680

16.0. LOW PRESSURE PIPING
Sl.No. Tests/Check
Functional/operati
Hydraulic / Water
Ultrasonic Test
All Tests as per

Material Test
Relevant Std
Assembly Fit
Performance
Dimensions
Other tests
WQS/PQR
Adhesion /
Pneumatic
Balancing
DPT/MPI
Remarks
on al Test
Fill Test
Spark
WPS/
Test
Test
Items /
up
Components
a b
1) Pipes & Fittings Y Y Y Y
and
Metered Bends
a 5 6
2) Diaphragm Y Y Y Y
Valves
3) Butterfly Valves
(Low Pressure)
a) Casted Butterfly
Valves
a b 7
(i) Body (Cast) Y Y Y Y Y Y Y
a b
(ii) Disc (Cast) Y Y
a c
(iii) Shaft Y Y Y
b) Fabricated Ref.
Butterfly Note14
Valves
a b c 5 8
4) Gate / Globe / Y Y Y Y Y Y Y
Swing Check
Valves
a b c 4
5) Dual Plate Check Y Y Y Y Y Y Y
Valves
a 3 1
6) Rolled & Welded Y Y Y Y Y
Pipes
2 2
7) Coating & Y Y
Wrapping of
Pipes
a b
8) Tanks & Vessels Y Y Y Y
a b 11
9) Strainers Y Y Y Y
Page 126 of 680

Sl.No. Tests/Check
Functional/operati
Hydraulic / Water
Ultrasonic Test
All Tests as per

Material Test
Relevant Std
Assembly Fit
Performance
Dimensions
Other tests
WQS/PQR
Adhesion /
Pneumatic
Balancing
DPT/MPI
Remarks
on al Test
Fill Test
Spark
WPS/
Test
Test
Items /
up
Components
a 12 13
10) Rubber Y Y Y Y
Expansion Joints
a b 9
11) Rubber Lining of Y Y Y Y Y Y Y
Pipes
a
12) Hangers & Y Y
Supports
a b
13) Fastners Y Y Y
1
14) Site Welding Y Y Y
Notes:
1. Weld Joints not subjected to hydraulic test shall be subjected to 100% RT.
2. Spark Test, Adhesion Test and Material Test for primer and enameled & Coal Tar Tapes as per AWWA-C-203-91
3. DPT on route run and after back gouging and on finish welds.
4. Dry Cycle Test (Spring Cycle Test) for one lakh Cycles shall be carried out as a type test..
5. Seat Leakage Test for Actuator Operated Valves, shall be done with by closing the valves with actuator.
6. Tests on rubber parts per batch of rubber mix such as hardness, adhesion, spark test, bleed test and flex test on diaphragm, type test for diaphragm for
50,000 cycles.
7. Hydraulic Test of Body, Seat and disc-strength shall be carried out in accordance with latest edition of AWWA-C-504 in presence of Employer’s
representatives. Actuator operated valves shall be checked for Seat Leakage by closing the valves with actuator. Seat Leakage Test shall be carried
out in both directions.
Page 127 of 680

8. Blue matching, wear travel for gates, valves, pneumatic seat leakage, reduced pressure test for check valves shall be done as per relevant standard.
Maximum allowable vacuum loss is 0.5 mm of Hg abs. for valves to be tested for vacuum operation for internal pressure 25 mm of Hg abs. for a period
of 15 minutes 9.
9. Hardness, Bleeding Test and Ozone resistance test shall be done on rubber material
10. 2% of welds shall be subjected to DPT.
11. Pressure drop across the strainer for each type and size as a special test shall be carried out
12. During hydraulic and vacuum tests at 25mm Hg abs in 3 positions, the change in the circumference of arch should not be more than 1.5%. 24 hrs after
the test permanent set in dimension should not exceed 0.5%.
13. Tests on rubber for tensile, elongation, hardness, hydraulic stability check as per ASTM D 471, ozone resistance test as per ASTM D 1149 aging test
and adhesion strength of rubber to fabric, rubber to metal adhesion shall be carried out.
14. For fabricated butterfly valves: UT as per ASTM A-435 on plates material for body and disc. 100% RT as per ASTM, Section-VIII, Division-I, on butt
joins of body and disc and post weld heat treatment as per ASME, Section-VIII, Division- I on butt joints of body and disc of thickness above 30mm shall
be carried out in addition to other tests indicated for cast butter fly valves.
a) One per heat/heat treatment batch/lot.
b) On machined surfaces only for castings and on finished butt welds.
For shaft/spindles > or = 50 m
Page 128 of 680

17.0 POWER CYCLE PIPING
17.1 H.P. PIPING FOR TURBINE AND AUX.
1. Piping & Fittings
a) All raw materials used shall have co-related mill test certificate meeting mandatory and
b) Raw material of all forged/formed fittings shall be ultrasonically tested. All mother pipes used for
fitting shall either be ultrasonically tested or hydraulic tested. Forged fittings shall be ultrasonically
tested and formed fittings shall be MPI tested.
c) All pipe lengths shall be subjected to 100 % ultrasonic examination or hydraulic tests and UT/RT
on longitudinal welds at the tube mill.
d) Welded and cast fittings if any shall be subjected to suitable NDT as per applicable standards.
However, 100 % RT shall be carried out on alloy steel fittings and on carbon steel fittings for use
above 71 bar design conditions.
e) The edge preparation for shop and site welds in stainless steel /alloy steel shall be subjected to a
dye penetrate check
f) Thickness of pipe bend shall be checked by ultrasonic or other acceptable methods on sample
basis for high pressure applications. Outer surface of bends shall be subjected to magnetic particle
examination/LPI.
g) Non-destructive examination of welds shall be carried out after post weld heat treatment, if any.
h) For welds in P91, X20 & X22 materials, induction type of heating shall be deployed for heat
treatment, or heat treatment can be carried out in furnace.
i) Non-destructive examination of welds shall be carried out in accordance with the relevant
design/manufacturing codes. However, as a minimum, the following requirements shall be met.
Further statutory requirement, wherever applicable shall also be complied with.
a) Temperature > 400 Deg, C and / or pressure exceeding 71 bar
i. 100% RT/UT on butt welds and full penetration branch welds.
ii. 100% MPE.
b) Temperature > 175 Deg, C upto 400 Deg. C and/or pressure exceeding 17 bar and upto 71 bar
i. 100% RT/UT on butt welds and full penetration branch welds for pipe dia more than 100 NB.
ii. 10% RT/UT on butt welds and full penetration branch for pipe dia upto 100NB.
iii. 100% MPE.
c) 100% UT & 100% MPI on all butt welds of P 91 and X22 UT shall be carried out by digital
recorded type.
Wherever SR/PWHT is envisaged, above NDTs shall be after SR/PWHT.
j) For all other pipes not covered above, shall be subjected 100% MPE/ DPT in case of underground
pipes and 10% MPE/DPT in case of piping above the ground. Further, 10% of butt welds of
underground piping shall be subjected to RT.
Page 129 of 680

k) Hardness survey of welds shall be carried out on alloy steel/stainless steel piping (100% Hardness
survey of welds on P91, X20 & X22 material grade piping) and 3% hardness survey on welds of
other alloy steel.
2. Hangers & Supports
a) All raw materials used shall have co-related mill test certificate meeting mandatory checks of
material specification.
b) Completed springs shall be tested for Scragging Test & Load vs Deflection Test and for dia. >
25mm MPI shall be carried out.
c) Butt Welds shall be tested for UT and fillet welds shall be tested for MPI.
d) Turn buckle/ pipe clamps/ Hangers of thickness > 25mm shall be checked by MPI/DPT on bent
portion.
e) Assembled Hangers shall be checked for Variation in deflection and Travel vs Load test.
3. Thermal Insulation & Lagging, Cladding
a) Light resign bound mineral wool:
LRB mattresses of Rockwool/Glasswool from approved manufacturing sources confirming to 8183,

tested as per relevant clauses of IS 3144. Wire mesh of diameter 0.71mm (min.) shall only be
used.
b) Lagging & Cladding
Aluminium sheeting confirming to ASTM B-203-1060 temper H14 from reputed manufacturer.
4. Valves
a) Pressure retaining parts of valves shall be subjected to (min.) NDT as per Table 2.
b) Hardened / stellitted valve disc and seat are to be subjected to LPI and hardness check.
c) Color matching of valve disc/plug and seat shall be carried out to ensure min. 80% contact and no
through passage.
d) Hydraulic pressure test and seat leak test shall be carried out as per ANSI 16.34/ IBR.
e) Air seat leak test shall be carried out as per applicable Standards/Codes.
f) Functional testing shall be carried out on each valve to check the following as per the approved
valve data sheet
i. Smooth operation
ii. Valve travel, closing and opening time.
iii. Current drawn by actuators.
g) Springs for safety valves shall be tested with suitable NDT and for spring rate.
h) Safety and safety relief valves shall be tested for performance.
Page 130 of 680

TABLE-2
Valve size NB in ANSI Class upto ANSI Class ANSI Class ANSI Class 900 &
mm 300 above 300 below above 600 below above & below
600 900 4500
Less than 50 Visual Visual Visual MPI
50 & above but Visual Visual MPI MPI & RT (on 10%
below 100 of valves on 100%
area)
100 & above but Visual MPI MPI & RT (on 10% MPI & RT on
less than 300 of valves on 100% area)
change of section
& weld ends)
300 and above MPI MPI MPI & RT (on MPI, RT (on 100%
change of sections area)
& weld ends)
NOTE:
For body and bonnet forgings UT with MPI may be adopted in place of RT.
For austenitic steel MPI may be replaced by LPI.
Page 131 of 680

MANUFACTURER’S NAME & ADDRESS : MANUFACTURING QUALITY PLAN PROJECT :
ITEM : Chain Pulley Block PACKAGE : CHAIN PULLEY BLOCKS
QP No.: PE-TS-XXX-XXX-A001
VOL IIB, SEC C
REV.:0, Date.:, PAGE: 1 OF 4
Sr. COMPONENT / CHARACTERISTICS CLASS TYPE OF QUANTU REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No. OPERATION CHECK M OF DOCUMENT NORMS OF
CHECK RECORD M C N
11.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
RAW MATERIAL & B/OUT
1 ITEMS:

1.1 HOOKS DIMENSIONS, MA One IS: 15560 IS: 15560 MTC P V V UT FOR SHANK
sample DIA 50MM AND
CHEMICAL MA LAB ANALYSIS PER LOT Material specification as per T.C. P V V ABOVE
COMPOSITION, approved drawings
MECHANICAL, PHYSICAL
PROPERTIES
IDENTIFICATION & MA 100% HOOK TC FROM COMPETENT IR P V V
COMPLIANCE WITH TC. VISUAL AUTHORITY
INTERNAL DEFECTS MA UT 100% ASTM A‐388 (REFER NOTE 1) TC P V V
PROOF LOAD TEST MA REVIEW 100% IS 15560 TC P V V
NDT AFTER PROOF LOAD MA DPT 100% ASTM E‐165 NO RELEVANT TC P V V
IDENTIFICATION
1.2 LOAD CHAIN ‐ DIMENSIONS MA MEASUREMENT 100 % IS: 6216 & IS: 6216 & IR P V V
‐ BREAKING MA ‐TENSILE TEST 1/LOT APPD. DRGS. APPD. DRGS. MTC P V V
STRENGTH MTC
‐ PROOF LOAD MA ‐TENSILE TEST 100% HT P V V
‐HEAT TREATMENT MA REVIEW 100% CHA P V V
‐GRADE MA REVIEW 1/BATCH RT
MTC P V V
1.3 RAW MATL. FOR GEAR/ CHEMICAL COMPOSITION, MA LAB ANALYSIS ONE MATERIAL MATERIAL MTC P V V TC or inspection
RATCHET PAWL / RATCHET MECHANICAL PROPERTIES SAMPLE SPECIFICATION SPECIFICATION report for
WHEEL PER LOT AS PER AS PER components
LEGEND: FOR CUSTOMER USE
** M : MANUFACTURER / SUB-CONTRACTOR
MANUFACTURER / CONTRACTOR C : BHEL / NOMINATED INSPECTION AGENCY.
N : CUSTOMER
SUB-CONTRACTOR INDICATE “P” PERFORM “W” WITNESS AND “V” VERIFICATION
SIGNATURE REVIEWED BY NAME & SIGN OF APPROVING AUTHORITY & SEAL
Page 132 of 680

VOL IIB, SEC C
CHECK RECORD M C N
11.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
APPROVED APPROVED shall be given.

DRAWING DRAWING
MA UT 10% ASTM A‐388 (REFER NOTE 1) IR P V V

INTERNAL DEFECTS
1.4. LOAD CHAIN WHEELS ‐ CHEMICAL MA CHEMICAL ONE APPD. DRG. APPD. DRG. P V V
COMPOSITION SAMPLE MTC
MECHANICAL PROPERTIES MA MECHANICAL PER LOT
PROPERTIES

1.5 BEARINGS MAKE, TYPE, CATALOGUE MA RANDOM APP DRG / APP DRG / IR P V V
NO. VISUAL MFR”S MFR”S
CATALOGUE CATALOGUE

1.6 HAND CHAIN WHEEL CHEMICAL MA CHEMICAL ONE AS PER AS PER MTC P V V
MECHANICAL PROPERTIES MECHANICAL SAMPLE DRAWING DRAWING
PROPERTIES PER LOT
1.7 HAND CHAIN GRADE/ DIMENSION MA GRADE 100 % AS PER AS PER MTC P V V
DIMENSION DRAWING DRAWING
1.8 TROLLEY GEARS, CHEMICAL & MECHANICAL MA LAB ANALYSIS, 100% APPVD DRGS APPVD DRGS IR/T P V V

PINION,WHEELS, AXLE C
2 IN PROCESS
2.1 RATCHET PAWL / ‐HARDNESS MA HARDNESS 100% IS:3832 / APPD IS:3832/ IR P V V
RATCHET WHEEL DRG. APPD. DRG.
N : CUSTOMER
Page 133 of 680

VOL IIB, SEC C
CHECK RECORD M C N
11.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
‐SURFACE CRACK MA DPT 100 % IR P V V

ASTM E165 NO DEFECT
2.2 GEARS AND PINIONS SURFACE HARDNESS MA HARDNESS RANDOM MFG MFG IR P V V
AFTER MACHINING HEAT TREATMENT, STANDARD STANDARD
SURFACE CRACK, HT CHART, DPT ASTM E
CASE DEPTH FOR SURFACE 165 FOR NO DEFECT IR P V V
CRACK DPT
3.0 FINAL INSPECTION

3.1 COMPLETE ASSEMBLY OVERALL DIMENSION MA MEASUREMENT 100 % IS:3832 /APPD IS:3832 /APPD IR P W V
DRG DRG
PROOF LOAD TEST CR 100% ‐DO‐ No cracks, flaws IR P W V
LOAD TEST & other defects
LIGHT LOAD TEST MA 100% IS 3832 IS 3832 IR P W V
LOAD TEST
HEIGHT OF LIFT MA MEASUREME NT 100% ‐DO‐ ‐DO – IR P W V

SWIVELING OF HOOK MA VISUAL 100 % ‐DO‐ ‐DO‐ IR P W V

EFFORT MA PULL ON CHAIN 100% ‐DO‐ ‐DO‐ IR P W V

3.2 PAINTING ‐CLEANING MA VISUAL AT APPROVED APPROVED IR ‐‐ ‐‐
RANDOM P
‐ SHADE & DFT OF PAINT MI VISUAL AT DRAWING/ DRAWING/ IR
(Blue / Black) RANDOM SPECIFICATION SPECIFICATION P W ‐

N : CUSTOMER
Page 134 of 680

VOL IIB, SEC C
CHECK RECORD M C N
11.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

3.3 NAME PLATE VERIFICATION MA VISUAL 100% IR P V ‐‐

3.4 PACKING ‐VERIFICATION MI VISUAL 100% SPECS. SPECS. IR P ‐‐ ‐

3.5 REVIEW OF QA VERIFICATION MA VISUAL 100% APPD. QP APPD. QP V V V
DOCUMENTATION

CR – CRITICAL, MA – MAJOR , MI – MINOR
NOTE 1: BACK WALL ECHO SHALL BE ADJUSTED TO 100% OF FULL SCREEN HEIGHT IN SOUND (DEFECT FREE) AREA. DEFECT ECHO HEIGHT MORE THAN 20% OF SCREEN HEIGHT SHALL BE
TREATED AS UNACCEPTABLE. BACK WALL ECHO SHALL NOT BE LESS THAN 80% OF SCREEN HEIGHT IN ANY CASE.
NOTE 2: RECORDS IDENTIFIED WITH TICK SHALL BE ESSENTIALLY INLCUDED IN QA DOCUMENTATION.
N : CUSTOMER
Page 135 of 680

MANUFACTURERS NAME & ADDRESS STANDARD QUALITY PLAN PROJECT
AS PER APPROVED VENDOR LIST ITEM: ELECTRIC QP NO PACKAGE WIRE ROPE ELECTRIC HOIST
WIRE REV 0 CONTRACT No
ROPE
DATE CONTRACTOR BHEL
PAGE 1 of 4
Sl.No COMPONENT & CHARACTERISTICS CATEGORY TYPE OF CHECK EXTENT REFERENCE DOCUMENT ACCEPTANCE FORMAT OF AGENCY REMARKS
OPERATIONS OF CHECK NORMS RECORD
D* M C N
1 2 3 4 5 6 7 8 9 ** 10 11
1.0 RAW-MATERIALS
1.1 a) STRUCTURAL MATERIAL MECH. , CHEM. PROPS MA CHEMICAL 1 / lot APPD. DRG./ DATA SHEET APPD. DRG./ Mill.s TC V V V Test shall be carried out in

b) RAW MATERIAL FOR COMPOSITION DATA SHEET absence of mill TC
HOIST AND GEAR BOX AND TENSILE
HOUSEING, TROLLEY PLATE STRENGTH
(AS APPLICABLE)
1.2 GEARS, SHAFT/AXLES, MECH , CHEM. PROPS MA CHEMICAL I / LOT APPD. DRG./ DATA SHEET APPD. DRG./ LAB. REPORT P V V In case the items are not

WHEELS COMPOSITION, DATA SHEET / / manufactured in-house,
HARDNESS IS:3938 MANUFACTUR the manufacturer's test
(DURING IN- ER'S TEST certificate shall be
PROCESS) CERTIFICATE submitted for chemical
U.T FOR DIA/THK > 50mm CR NDT 100% ASTM A 388 NOTE 4 INSPN. P V V

REPORT
1.3 WIRE ROPE Dimensional CHECK MI Dia. 100% APPD. DRG./ DATA SHEET APPD. DRG./ MFRS’ TEST P V V

DATA SHEET CERT.
BREAKING LOAD CR BREAKING 100% APPROVED DRG/DATA APPROVED MFRS’ TEST P V V

CAPACITY LOAD SHEET / IS:3938 / IS: 2266 DRG/DATA CERT.
SHEET AND /
IS:3938 /
1.4 HOOKS PHYS./ MECH. , CHEM. MA CHEMICAL I / LOT APPROVED DRG/DATA APPROVED MFRS’ TEST P V V

PROPS. COMPOSITION, SHEET / IS:3938 / DRG/DATA CERT.
HARDNESS IS:15560 SHEET / IS:3938
/ IS:15560
U.T IF SHANK DIA > 50mm CR NDT 100% ASTM A 388 NOTE 1 INSPN. P W V SHANK PORTION ONLY

REPORT
PROOF LOAD CAPACITY CR PROOF LOAD 100% APPROVED DRG/DATA APPROVED INSPN. P W V

TEST SHEET / IS:3938 / IS:15560 DRG/DATA REPORT
SHEET / IS:3938
/ IS:15560
DP AFTER PROOF LOAD CR NDT 100% ASTM E-165 NO CRACKS INSPN. P V/W V

REPORT
2.0 IN-PROCESS
2.1* WELDING PROCEDURE CORRECTNESS MA SCRUTINY 100% IS:7307 / ASME SEC IX IS:7307 / ASME FORMAT OF IS P V V
SPECIFICATION SEC IX / ASME SEC
IX
2.2* PROCEDURE & WELDER WEDLING PARAMETRES MA PHYS. TESTS/RT 100% IS:7310 / ASME SEC IX IS:7310 / ASME AS PER ASME P W W IN CASE OF LLOYDS /

QUALIFICATION SEC IX SEC IX EIL / TPL QUALIFIED
WELDERS AVAILABLE,
REQUALIFICATION OF
WELDER IS NOT
REQUIRED
LEGNDS
* RECORDS INDENTIFIED WITH 'TICK'(  ) SHALL BE ESSENTIALLY
INCLUDED BY CONTRACTOR IN QA DOCUMENTATION
** M: MANUFACTURER/SUBCONTRACTOR
MANUFACTURER/ SUB CONTRACTOR C: CONTRACTOR NOMINATED INSPECTION AGENCY(BHEL) N: CUSTOME
CONTRACTOR INDICATE 'P' PERFORM"W" WITNESS AND "V" VERIFICATION AS
SIGNATURE APPROPRIATE " CHP" CUSTOMER SHALL IDENTIFY IN COLUMN"N" REVIEWED BY NAME & SIGN OF APPROVING AUTHORITY &SEAL
Page 136 of 680

ROPE
PAGE 1 of 4
D* M C N
1 2 3 4 5 6 7 8 9 ** 10 11
2.3* WELD SET UPS DIMENSIONS MA MEAS. , VISUAL 100% WPS, APPD. DRG. WPS, APPD. INSPN. P V
DRG. REPORT
2.4* WELDMENTS –FINAL RUN SURFACE DEFECTS MA PT 100% IS:3658 / ASTME:165 ASME SEC. VIII INSPN. P V V

DIV. I REPORT
2.5 TRUNION / TROLLEY SURFACE & INTERNAL MA PT / UT 100% ASTME:165 NO LINEAR INSPN. P W V

WHEELS, GEARS PINION FLAWS (FOR DIA. / DEFECTS / NOTE- REPORT
THICKNESS >50MM) 4
2.6 NDT OF LOAD BEARING WELD QUALITY OF CR PT & RT 100% ASME SEC. VIII DIV. I ASME SEC. VIII INSPN. P V V FILMS TO BE REVIEWED

BUTT WELDS (IF ANY) a)Butt weld on tension DIV. 4 . CLUW-51 REPORT ND BY BHEL & Customer.
100% RT and 100% DPT FOR RT FILM DPT SHALL BE CHP FOR
b)Butt weld oncompression APPENDIX -8 FOR Customer & BHEL
10% RT and 100% DPT PT
c)Butt weld on rope drum
100% RT and 100% DPT
d) Fillet weld - Random 10%
DPT
2.7 GEAR BOXES
COMPLETE ASSEMBLY OVERALL DIMENSIONS MA MEAS. 100% MFG. DRG. MFG. DRG. INSPN. P V

REPORT
Gear shall be checked for CHECK FOR OIL MA NO LOAD 100% MFG. DRG. MFG. STD. - DO - P V V

reduction ratio, backlash & LEAKAGE, VIBRATION, RUNNING FOR
contact pattern. NOISE TEMP. RISE TWO HOURS
2.8 ELECTRICALS
1 MOTORS TYPE TESTS ( INCLUDING MA TYPE 1 / TYPE, IS:3938 IS:3938 MFRS’ TEST P V V

DEGREE OF PROTECTION) TESTS 100% CERT., INSPN
REPORT
ROUTINE TESTS ROUTINE TESTS 100% IS 325 IS 325 DO P V V


2 RESISTANCES (IF TEMPERATURE RISE MA VERTIFICATION 100% IS:3938, RELV. ISS IS:3938, RELV. MFRS’ TEST P V V

APPLICABLE) OF MNFRS’ TEST ISS CERT.
CERT.
3 CONTROLLER, LIMIT ROUTINE TESTS MA ROUTINE TEST 100% IS:6975/TECH. SPEC., IS:6875/TECH. MFRS’ TEST P V V Rating and make to be

SWITCHES (IF APPLICABLE) SPEC., CERT. verified.
4 BRAKES ROUTINE TESTS MA ROUTINE TEST 100% TECH. SPEC. / IS:15560 IS:3938/TECH. MFRS’ TEST P V V

SPEC. CERT.
5 BRAKE DRUM (IF VERIFICATION OF HT MA VISUAL, 100% APPD. DRGS./TECH. SPC. APPD. HT. CHART P V V

APPLICABLE) CHARTS, HARDNESS (IF HARDNESS DRGS./TECH. /INSPN.
APPLICABLE) TEST SPEC. REPORT
6 CONTACTOR ROUTINE TESTS MA ROUTINE TEST 100% IS:2959 AND TECH. SPEC., IS:2959 AND INSPN. P V V Rating and make to be

IS:6547 / IS:3938 TECH. SPEC., REPORT verified.
IS:6547 / IS:3933
7 CONTROL PANEL, PENDANT * FIXING OF MA VISUAL 100% APPD.DRG. WIRING APPD. DRG. INSPN. P V V BOUGHT OUT ITEMS AS

SWITCH COMPONENTS WIRING DIAGRAM, WIRING REPORT PER BHEL / CUSTOMER
MARKING CONTINUITY DIAGRAM, APPROVAL LIST
* FUNCTIONAL TEST
* IR & H.V. TEST
* IP - PROTECTION TEST
* PAINT SHADE,
THICKNESS, SHEET
THICHKNESS
LEGNDS
* RECORDS INDENTIFIED WITH 'TICK'(  ) SHALL BE ESSENTIALLY
Page 137 of 680
ROPE
PAGE 1 of 4
D* M C N
1 2 3 4 5 6 7 8 9 ** 10 11
8 CABLES TYPE AND ROUTINE TESTS MA TYPE & 100% AS PER TECH. SPEC. AS PER TECH. MNFRS’ TEST Ö P V V
ROUTINE TESTS IS:1554/IS:9968- PART - I / SPEC. CERT.
IS:694 / RELEVANT IS FOR IS:1554/IS:9968-
FRLS CABLES PART - I / IS:694
3.0 FINAL INSPECTION
3.1 COMPLETELY ASSEMBLED 1. COMPLETENESS, MA P W V
VISUAL, 100% APPD. DRG. APPD. DRG. MNFRS’ TEST 
HOIST CORRECTNESS, OVERALL MEAS CERT.
DIMENSIONS
3.2 ASSEMBLED HOIST 1. LOAD TEST CR LOAD TEST at 100% IS:6547 / IS:3938 IS:6547 / IS:3938 MNFRS’ TEST P W V

PERFORMANCE SWL CERT.
2. HOISTING & CR MEAS & VISUAL 100% IS:6547 / IS:3938, TECH TECH SPEC. P W V
MNFRS’ TEST 
LOWERING SPEED, SPEC. CERT.
PERFORMANCE OF
CONTROLLERS SWITCHES
CONTRACTORS, RELAYS
AND OTHER CONTROL
DEVICES CORRELATIONS
OF CIRCUITS AND
INTERLOCKS AND
SEQUENCES OF
OPERATION
3. OPERATION OF ALL CR VISUAL 100% TECH SPEC TECH SPEC. P W V

MNFRS’ TEST 
PROTECTIVE DEVICES CERT.
3.3 OVER LOAD TEST 1. OVER LOAD CR TEST AT 125 % 100% IS:6547/IS:3938 IS:6547/IS:3938 INSPN. P W V

OF SWL REPORT
4 PAINTING
1 PRIMER & FINISHING AND 1. TO RELEVANT IS MI CORRECTNESS EACH DRG. & DATA SHEET & DRG. & DATA MNFRS’ P V
SHADE OF MFG. TEST CONSIGN RELV. IS SPEC. SHEET & RELV. TEST CERT.
CERT. MENT IS SPEC.
NOTE:
* 1.0 Clause from 2.1 to 2.4 shall be applicable for load bearing welded joints.
2.0 Back Wall Echo shall be adjusted to 100% of Full Screen Height in sound (Defect Free) Area.
Defect Echo Height more than 20% of Screen Height shall be treated as unacceptable. Back Wall
Echo shall not be less than 80% of Screen Height in any case.
LEGNDS
* RECORDS INDENTIFIED WITH 'TICK'(  ) SHALL BE ESSENTIALLY
Page 138 of 680

CUSTOMER : PROJECT 2X 660 MW ENNORE SEZ STPP SPECIFICATION :

M/s TANGEDCO TITLE NUMBER :PE-TS-412-155A-A001
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION
VENDOR NUMBER PED-506-00-Q-006, REV-01 TITLE
SHEET 1 OF 2 SYSTEM ITEM AC ELECT. MOTORS BELOW 55KW (LV) SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 ASSEMBLY 1.WORKMANSHIP MA VISUAL 100% MANUF'S SPEC MANUF'S SPEC -DO- 2 - -
2.DIMENSIONS MA -DO- -DO- MFG. DRG./ MFG. DRG./ -DO- 2 - -

MFG. SPEC. MFG. SPEC.
3.CORRECTNESS MA VISUAL 100% MFG.SPEC./ MFG.SPEC. -DO- 2 - -

COMPLETENESS RELEVANT IS RELEVANT IS
TERMINATIONS/
MARKING/COLOUR
CODE
2.0 PAINTING 1.SHADE MA VISUAL SAMPLE MANUFR'S BHEL SPEC. LOG BOOK 2 - -
SPEC/BHEL SAME AS
SPEC./RELEVANT COL.7
STANDARD
3.0 TESTS 1.ROUTINE MA -DO- 100% IS-325/ SAME AS TEST 2 1 NOTE -1

TEST INCLUDING BHEL SPEC./ COL.7 REPORT &
SPECIAL TEST DATA SHEET NOTE-3
AS PER BHEL
SPEC.
2.OVERALL MA MEASUREMENT 100% APPROVED APPROVED INSPN. 2 1 - NOTE -1

DIMENSIONS & & DRG/DATA DRG/DATA REPORT &
ORIENTATION VISUAL SHEET SHEET NOTE-3
& RELEVANT IS
BHEL PARTICULARS BIDDER/VENDOR

NAME
SIGNATURE
DATE BIDDER'S/VENDORS COMPANY SEAL
Page 139 of 680


QUALITY PLAN
M/s TANGEDCO TITLE NUMBER : PE-TS-412-155A-A001
BIDDER/ : QUALITY PLAN SPECIFICATION :
VENDOR NUMBER PED-506-00-Q-006, REV-01 TITLE :
SHEET 2 OF 2 SYSTEM ITEM AC ELECT. MOTORS BELOW 55KW (LV) SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3.NAMEPLATE MA VISUAL 100% IS-325 & IS-325 & INSPN. 2 1 -

DETAILS DATA SHEET DATA SHEET REPORT
NOTES:
1 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. THE
SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON
2 WHERE EVER CUSTOMER IS INVOLVED IN INSPECTION, (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER.
3 FOR EXHAUST/VENTILATION FAN MOTORS OF RATING UPTO 1.5KW , ONLY ROUTINE TEST CERTIFICATES SHALL BE FURNISHED FOR SCRUTINY.
Legends for Inspection agency
1. BHEL/CUSTOMER
2. VENDOR (MOTOR MANUFACTURER)
3. SUB-VENDOR (RAW MATERIAL/COMPONENTS SUPPLIER)
P. PERFORM
W. WITNESS
V. VERIFY

NAME
SIGNATURE
Page 140 of 680


QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION :
SHEET 1 OF 9 SYSTEM ITEM: AC ELECT. MOTORS 55 KW & ABOVE (LV & MV) SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL & BOUGHT OUT
CONTROL
1.1 SHEET STEEL, PLATES, 1.SURFACE MA VISUAL 100% - FREE FROM LOG BOOK 3 - -
SECTION, EYEBOLTS CONDITION BLINKS,
CRACKS,
WAVINESS
ETC
2.DIMENSIONS MA MEASUREMENT SAMPLE MANFR'S MANFR'S -DO- 3 - -

DRG./SPEC DRG./SPEC
3.PROOF LOAD MA MECH. TEST -DO- -DO- -DO- INSPEC. 3 - 2

TEST (EYE REPORT
BOLT)
1.2 HARDWARES 1.SURFACE MA VISUAL 100% FREE FROM -DO- 3 - -

CONDITION CRACKS, UN-
EVENNESS
ETC.
2.PROPERTY MA VISUAL SAMPLES MANFR'S RELEVENT SUPPLIERS 3 - 2 PROPERTY CLASS

CLASS DRG./SPEC IS/SPEC. TC & LOG MARKING SHALL BE
BOOK CHECKED BY THE
VENDOR
1.3 CASTING 1.SURFACE MA VISUAL 100% FREE FROM LOG BOOK 3 - 2

CONDITION CRACKS,
BLOW HOLES
ETC.
2.CHEM. & MA CHEM & MECH 1/HEAT NO. MANFR'S RELEVENT SUPPLIER'S 3 - 2 HEAT NO. SHALL BE
PHY. PROP. TEST DRG./SPEC IS/ TC VERIFIED
3.DIMENSIONS MA MEASUREMENT 100% MANUFR'S MANUFR'S LOG BOOK 3 - 2

DRG. DRG.
1.4 PAINT & VARNISH 1.MAKE, SHADE, MA VISUAL 100% MANFR'S MANFR'S LOG BOOK 3 - 2
SHELF LIFE & CONTINUOUS DRG./SPEC DRG./SPEC
TYPE

NAME
SIGNATURE
Page 141 of 680


CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.5 SHAFT 1. SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - - VENDOR'S APPROVAL
(FORGED OR ROLLED) COND. VISUAL IDENTIFICATION SHALL BE
DEFECTS MAINTAINED
2. CHEM. & MA CHEM. & 1/HEAT NO. MFG. DRG. RELEVANT SUPPLIER'S 3 - 2
PHYSICAL PHYSICAL OR HEAT SPEC. IS TC
PROPERTIES TESTS TREATMENT
BATCH NO
3. DIMENSIONS MA MEASUREMENT 100% -DO- MANUFR'S LOG BOOK 3 - 2

DRG.
4.INTERNAL CR UT -DO- ASTM-A388 MANUFR'S -DO- 3 2 1 FOR DIA OF 55 MM &

FLAWS SPEC. ABOVE
BHEL SPEC.
1.6 SPACE HEATERS, CONNEC- 1. MAKE & MA VISUAL -DO- MANUFR'S MANUFR'S -DO- 3 - 2
TORS, TERMINAL BLOCKS, RATING DRG. SPEC. DRG. SPEC.
CABLES, CABLE LUGS,
CARBON BRUSH TEMP.
DETECTORS, RTD, BTD'S
2. PHYSICAL MA -DO- -DO- - NO PHYS. DAMAGE, -DO- 3 - 2

COND. NO ELECTRICAL
DISCONTINUITY
3.DIMENSIONS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S -DO- 3 - 2

(WHEREVER DRG./ SPEC. DRG. / SPEC.
APPLICABLE)
4.PERFORMANCE/ MA TEST 100% -DO- -DO- INSP. 3 - 2

CALIBRATION REPORT

NAME
SIGNATURE
Page 142 of 680


CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.7 OTHER INSULATING 1. SURFACE MA VISUAL 100% - NO VISUAL INSPT. 3 - 2

MATERIALS LIKE SLEEVES, COND. ETC. DEFECTS REPORT
BINDINGS CORDS, PAPERS,
PRESS BOARDS ETC.
2. OTHER
CHARACTERISTICS MA TEST SAMPLE MANUF'S MANUF'S LOG BOOK 3 - 2
SPEC. SPEC. AND OR
SUPPLIER'S
TC
1.8 SHEET STAMPING 1. SURFACE MA VISUAL 100% - NO VISUAL LOG BOOK 3 - -

(PUNCHED) COND. DEFECTS
(FREE FROM
BURS)
2.DIMENSIONS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S -DO- 3 - 2 FOR MV MOTOR INSULA-

INCLUDING BURS DRG. . DRG. TION/VARNISH THICKNESS
HEIGHT SHALL BE MORE THAN
THE BURS HEIGHT
3. ACCEPTANCE MA ELECT. & MECH -DO- MANUF'S RELEVANT SUPPLIER'S 3 - 2
TESTS TESTS SPEC./ IS TC
RELEVANT
IS
1.9 CONDUCTORS 1. SURFACE MA VISUAL 100% - FREE FROM LOG BOOK 3* - 2* * MOTOR MANUFACTURER TO
FINISH VISUAL CONDUCT VISUAL CHECK FOR
DEFECTS SURFACE FINISH ON RANDOM
BASIS (10% SAMPLE) AT HIS
WORKS AND MAINTAIN
RECORD FOR VERIFICATION
BY BHEL/CUSTOMER.
2.ELECT. PROP, & MA ELECT. & SAMPLES RELEVANT IS/ RELEVANT IS/ SUPPLIERS 3 - 2
MECH. PROP MECH.TEST BS OR BS OR TC &
OTHER OTHER VENDOR'S
STANDARDS STANDARDS INSPN.
REPORTS

NAME
SIGNATURE
Page 143 of 680


CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3.DIMENSIONS MA MEASUREMENT -DO- -DO- -DO- Log Book 3 - 2
MANFR'S DRG./ MANFR'S DRG./

1.10 BEARINGS 1.MAKE & TYPE MA VISUAL 100% APPROVED APPROVED -DO- 3 - 2
DATASHEET DATASHEET
2.DIMENSIONS MA MEASUREMENT SAMPLE BHEL DATA BHEL DATA -DO- 3 - 2

SHEET SHEET BEARING
MANUF'S
CATALOGUES
3.SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - 2

FINISH VISUAL
DEFECTS
1.11 SLIP RING 1.SURFACE MA VISUAL 100% - -DO- -DO- 3 - -

(WHEREVER APPLICABLE) COND.
2.DIMENSIONS MA MEASUREMENT SAMPLE MANUF'S MANUF'S -DO- 3 - -

DRG DRG
3.TEMP.WITH- MA ELECT.TEST -DO- MANUF'S MANUF'S -DO- 3 - 2

SPEC./ BHEL
STAND CAPACITY SPEC./ BHEL SPEC.
SPEC.
4.HV/IR MA -DO- 100% -DO- -DO- -DO- 3 - 2
1.12 OIL SEALS & GASKETS 1.MATERIAL OF MA VISUAL 100% MANUF'S MANUF'S -DO- 3 - -
GASKET DRG/SPECS DRG./ SPECS.
2.SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - -

COND. VISUAL
DEFECTS
3.DIMENSIONS MA MEASUREMENT SAMPLE MANUF'S MANUF'S -DO- 3 - -

DRG DRG

NAME
SIGNATURE
Page 144 of 680


CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.0 IN PROCESS
2.1 STATOR FRAME WELDING 1.WORKMANSHIP MA VISUAL 100% -DO- GOOD FINISH LOG BOOK 3/2 2 -
(IN CASE OF FABRICATED & CLEANNESS
STATOR )
2.DIMENSIONS MA MEASUREMENT -DO- MANUF'S MANUF'S -DO- 2 - -

DRG DRG
2.2 MACHINING 1.FINISH MA VISUAL 100% -DO- GOOD FINISH LOG BOOK 2 - -
2.DIMENSIONS MA MEASUREMENT -DO- MANUF'S MANUF'S -DO- 2 - -

DRG DRG
3.SHAFT SURFACE MA PT -DO- RELEVENT MANUFR'S -DO- 2 - 1

FLOWS SPEC./ SPEC./
ASTM-E165 BHEL SPEC./
2.3 PAINTING 1.SURFACE MA VISUAL 100% MANFR'S BHEL LOG BOOK 2 - -

PREPARATION SPEC/BHEL SPEC.
SPEC./ SAME AS
RELEVANT COL.7
STAND
2.PAINT THICKNESS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - -

(BOTH PRIMER & BY ELCOMETER
FINISH COAT)
3.SHADE MA VISUAL -DO- -DO- -DO- Log Book 2 - -
4.ADHESION MA CROSS -DO- -DO- -DO- Log Book 2 - -

CUTTING &
TAPE TEST

NAME
SIGNATURE
Page 145 of 680


CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.4 SHEET STACKING 1.COMPLETENESS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S Log Book 2 - -
SPEC. SPEC.
2.COMPRESSION MA MEASUREMENT 100% -DO- -DO- Log Book 2 - -

& TIGHTENING
3.CORE LOSS & MA ELECT.TEST -DO- -DO- -DO- Log Book 2 1* 1 (FOR MOTORS OF 2MW AND
HOTSPOT ABOVE)
* ON 10% RANDOM SAMPLE
2.5 WINDING 1.COMPLETENESS CR VISUAL 100% MANUFR'S MANUFR'S Log Book 2 - -
SPEC./BHEL SPEC./BHEL
SPEC. SPEC.
2.CLEANLINESS CR -DO- -DO- -DO- -DO- Log Book 2 - -
3.IR-HV-IR CR ELECT. TEST -DO- -DO- -DO- Log Book 2 - 1
4.RESISTANCE CR -DO- -DO- -DO- -DO- Log Book 2 - 1
5.INTERTURN CR -DO- -DO- -DO- -DO- Log Book 2 - -

INSULATION
6.SURGE WITH CR -DO- -DO- -DO- -DO- Log Book 2 - 1 FOR MV MOTOR
STAND AND
TAN. DELTA
TEST
2.6 IMPREGNATION 1.VISCOSCITY MA PHY. TEST AT STARTING -DO- -DO- Log Book 2 - -
2.TEMP. MA PROCESS CONTINUOUS -DO- -DO- Log Book 2 - -

PRESSURE CHECK
VACCUM
3.NO. OF DIPS MA -DO- -DO- -DO- -DO- Log Book 2 - 1 THREE DIPS TO BE
GIVEN

NAME
SIGNATURE
Page 146 of 680


SHEET 7 OF 9 SYSTEM ITEM: AC ELECT. 2X 660 MW ENNORE SEZ STPP SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
4.DURATION MA -DO- -DO- -DO- -DO- Log Book 2 - 1
2.7 COMPLETE STATOR 1.COMPACTNESS MA VISUAL 100% -DO- -DO- Log Book 2 - -
ASSEMBLY & CLEANLINESS
2.8 BRAZING/COMPRESSION 1.COMPLETENESS CR -DO- -DO- -DO- -DO- Log Book 2 - -

JOINT
2.SOUNDNESS CR MALLET TEST -DO- -DO- -DO- Log Book 2 1
& UT
3.HV MA ELECT. TEST -DO- -DO- -DO- Log Book 2 1
2.9 COMPLETE ROTOR 1.RESIDUAL CR DYN. BALANCE -DO- MFG SPEC./ MFG. DWG. Log Book 2 1 VERIFICATION FOR MV
ASSEMBLY UNBALANCE ISO 1940 MOTOR ONLY
2.SOUNDNESS CR ELECT. -DO- MFG. SPEC. MFG. SPEC. Log Book 2 1

OF DIE (GROWLER
CASTING TEST)
2.10 ASSEMBLY 1.ALIGNMENT MA MEAS. -DO- -DO- -DO- Log Book 2 - -
2.WORKMANSHIP MA VISUAL -DO- -DO- -DO- Log Book 2 - -
3.AXIAL PLAY MA MEAS. -DO- -DO- -DO- Log Book 2 - 1
4.DIMENSIONS MA -DO- -DO- MFG.DRG./ MFG. DRG/ Log Book 2 - -

MFG SPEC. RELEVANT IS
5.CORRECTNESS, MA VISUAL 100% MFG SPEC. MFG SPEC. Log Book 2 - -

COMPLETENESS RELEVANT IS RELEVANT IS
TERMINATIONS/
MARKING/
COLOUR CODE
6. RTD, BTD & SPACE MA VISUAL 100% MFG SPEC. MFG SPEC. Log Book 2 1
HEATER MOUNTING. RELEVANT IS RELEVANT IS

NAME
SIGNATURE
Page 147 of 680

CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3.0 TESTS 1.TYPE TESTS MA ELECT.TEST 1/TYPE/SIZE IS-325/ IS-325/ TEST 2 1* 1 * NOTE - 1
INCLUDING BHEL SPEC./ BHEL SPEC./ REPORT
SPECIAL DATA SHEET DATA SHEET
TESTS AS PER
BHEL SPEC.
2.ROUTINE MA -DO- 100% -DO- -DO- -DO- 2 1$ 1 $

NOTE - 2
TESTS INCLUDING
SPECIAL TEST
AS PER BHEL
SPEC.
3.VIBRATION & MA -DO- 100% IS-12075 & IS-12075 & -DO- 2 1$ 1 $

NOTE - 2
NOISE LEVEL IS-12065 IS-12065
4.OVERALL MA MEASUREMENT 100% APPROVED APPROVED INSPC. 2 1 -

DIMENSIONS & VISUAL DRG/DATA DRG/DATA REPORT
AND ORIENTATION SHEET SHEET &
RELEVANT IS
5.DEGREE OF MA ELECT. & 1/TYPE/ RELEVANT IS BHEL SPEC. TC 2 - 1 TC FROM AN INDEPENDENT

PROTECTION MECH. TEST SIZE AND DATA LABORATORY, REFER NOTE-3
SHEET
6. MEASUREMENT OF MA -DO- 100% -DO- -DO- -DO- 2 1$ 1 $
NOTE - 2
RESISTANCE OF RTD
& BTD
7. MEASUREMENT OF MA -DO- 100% -DO- -DO- -DO- 2 1$ 1 $

NOTE - 2
RESISTANCE, IR OF
SPACE HEATER
8. NAMEPLATE MA VISUAL 100% IS-325 & IS-325 & INSPC. 2 1$ 1 $

NOTE - 2
DETAILS DATA SHEET DATA SHEET REPORT
9.EXPLOSION MA EXPLOSION 1/TYPE IS-3682 IS-3682 TC 2 - 1 TC FROM AN INDEPENDENT

FLAME PROOF FLAME PROOF IS-8239 IS-8239 LABORATORY, REFER NOTE-3
NESS (IF TEST IS-8240 IS-8240
SPECIFIED)
10. PAINT SHADE, MA VISUAL & SAMPLE BHEL SPEC. BHEL SPEC. TC 2 1$ 1 SAMPLING PLAN TO BE
THICKNESS MEASUREMENT & DATA & DATA DECIDED BY INSPECTION
& FINISH BY ELKOMETER SHEET SHEET AGENCY
$
NOTE - 2

NAME
SIGNATURE
Page 148 of 680

CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
NOTES:
1 DEPENDING UPON THE SIZE AND CRITICALLY, WITNESSING BY BHEL SHALL BE DECIDED.
2 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES.
THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON.
3 IN CASE TEST CERTIFICATES FOR THESE TESTS ON SIMILAR TYPE, SIZE AND DESIGN OF MOTOR FROM INDEPENDENT LABORATORY ARE AVAILABLE,
THESE TEST MAY NOT BE REPEATED.
4 WHEREVER CUSTOMER IS INVOLVED IN INSPECTION, AGENCY (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER.
Legends for Inspection agency
1. BHEL/CUSTOMER
2. VENDOR (MOTOR MANUFACTURER)
3. SUB-VENDOR (RAW MATERIAL/COMPONENTS SUPPLIER)
P. PERFORM
W. WITNESS
V. VERIFY

NAME
SIGNATURE
Page 149 of 680

I.SPECIFICATION
FOR
QUALITY ASSURANCE
&
TESTING
Page 150 of 680

CHAPTER-14
QUALITY ASSURANCE AND TESTING AND GUARANTEES
14.01.00 GENERAL REQUIREMENT
14.01.01 All equipment furnished under this specification shall be subject to test by authorized
quality assu rance per sonnel of the B idder, representatives of the O wner during
manufacture, e rection a nd on co mpletion. B idder'’ quality assu rance pe rsonnel for
these shop and site tests shall be identified in advance and shall be acceptable to the
Owner. The app roval of t he O wner or passi ng of su ch i nspection o f t ests will not,
however, prejudice the right of the owner to reject the equipment if it does not comply
with the specifications when erected or fails to give complete satisfaction in service.
14.01.02 The Bidder shall furnish details of shop and si te tests proposed to be co nducted by
him at v arious stages to m eet the sp ecification r equirements for ea ch t ype of
instrument/system al ong w ith hi s proposal. B idder sh all al so f urnish d etails of hi s
proposed shop and site quality assurance organization for this contract
14.01.03 Bidder shall prepare a detailed shop and site ‘Quality Assurance Programme’ to meet
the requirements of these specifications for Owner’s approval. T his document shall
also contain the formats for reports and maintenance of test records specification of
test equipment to be used for site tests.
14.01.04 All eq uipment and sy stems furnished under t his sp ecification sh all be s ubjected t o
shop & site tests in accordance with the Quality Assurance Program approved by the
Owner and shall be adequate to ensure full compliance with these specification, all
applicable co des & st andards and det ailed en gineering dr awings and docu ments
approved by the Owner.
14.01.05 The Bidder shall provide all required test equipment and simulation devices for
performing al l shop and si te t ests. A ll t ests equipment sh all be of r eputed m ake,
required accuracy class and shall be recently calibrated. The record of calibration of
test equipment shall be made available to the Owner on demand.
14.01.06 The cost of all tests as per the requirements of this specification and approved quality
assurance programme shall be i ncluded in Bidder’s lump sum price for this package
and no ex tra price shall be pay able by the Owner for conducting any test as per the
intent and requirements of this specification.
14.01.07 All approval/Inspection are to be carried out by the Owner only.
14.02.00 SHOP TESTS
14.02.01 General Requirement
14.02.01.00 Shop tests shall include all tests to be carried out at Bidder’s works at of this sub-bidder and at works
where raw materials used for manufacture of equipment is produced.
Page 151 of 680

14.02.01.01 Individual co mponents, instruments and dev ices furnished i n acco rdance w ith
specification sheets, and I&C device list enclosed with these specifications shall be
shop t ested by m anufacturer pr ior t o sh ipment. T he m anufacturer sh all co nduct
these tests for certifying compliance with published specifications for the equipment
and pr ovide t est r esults t o t he O wner i n writing. T hese t ests and t est certificates
shall be in acco rdance w ith t he ag reed ' QA’ pr ogramme for m ajor
systems/equipments. However, manufacturer’s standard methods shall be followed if
details of tests for a ny eq uipment ar e no t co vered under t his agreed ‘ QA
Programme’.
14.02.01.02 Whenever t ested quality m aterial i s specified an d w herever ca lled upon by I ndian
Boilers Regulations or b y t he desi gn co de, the test pi eces ar e t o be p repared and
tested to Owner's satisfaction.
14.02.01.03 In the event of Owner being furnished with certified particulars of tests, which have
been ca rried ou t by t he su ppliers of material, t he O wner may, at hi s discretion,
dispense with these tests.
14.02.02 Material Tests
14.02.02.01 Whenever tested quality material specified and whenever called upon by Indian
Boilers Regulations or by design code, the test pieces, are to be prepared and tested
to Owner’s satisfaction.
been carried out by the suppliers of material, the Owner may, at his discretion,
14.02.03 Test at Manufacturer’s Works
14.02.03.01 Works tests are to include electrical, mechanical performance and hydraulic tests in
accordance with relevant IS, IBR or any other approved standard or any other tests
called f or by t he O wner under t hese sp ecifications to ensu re t hat t he equipment
being supplied fulfills the requirements of these specifications. For equipments not
covered by any IS or other approved standards, the tests to be carried out shall be in
accordance with Bidders’ quality assurance programme approved by the Owner.
14.02.03.02 Control sy stems, monitoring sy stems ,control panel s instrument encl osures ,and
power su pply sy stems shall be sh op t ested a ccording t o uni que requirements
specified in the applicable section of these specifications for each item and quality
assurance program approved by the owner.
14.02.03.03 All shop tests shall be performed prior to shipment and the Owner shall be given the
opportunity t o w itness these t ests. The B idder sh all not ify t he O wner r egarding
readiness for shop test at least 10 day s before the scheduled date if the tests to be
conducted within Indian and at least 60 days before the schedule date if the test is to
be conducted abroad.
14.02.04 Factory Tests
Page 152 of 680

14.02.04.01 Automatic Control and Monitoring system (DDCMIS, PLC & any other
microprocessor based control system) including alarm annunciation system furnished
as per t his specification sh all be su bject to shop and si te t ests as per t he
requirements of t his specification, appl icable c odes and O wner appr oved Q uantity
Assurance Program so as to demonstrate to the Owner that the equipment furnished
by t he B idder m eets the i ntent and requirement o f this specification. T hese t ests
shall include but shall not be limited to the tests indicated in the subsequent clauses.
14.02.04.02 Surge Protection Test for Solid State Equipment
All solid state equipment shall be able to withstand the noise and surge inherent in a Power House,
and shall strictly comply with SWC tests ANSI C 37.90A, 1974 for IEEE-472 (1974). C omplete
details of the features incorporated in electronic system to meet this requirement, the relevant test
carried out, and the test certificates shall be submitted along with the proposal.
14.02.04.03 Burn-in and Elevated Temperature Test
All solid state electronic equipment shall be t ested as a complete system/equipment

with all devices connected for a minimum of 168 hours continuously under energized
conditions prior to shipment from manufacturer’s works, as per the following cycle :-
During the first 48 hours of testing the ambient temperature shall be maintained at 50
deg.C and r elative humidity at 95%. T he equipment shall be i nterconnected with all
devices, which will ca use i t t o r epeatedly per form al l oper ations; i t i s supposed t o
perform in actual service, with load on various components being equal to those,
which will be experienced in actual service.
The 48 hours tests period shall be continuous but shall be divided into four 12 hours
segments. The input voltage during each 12-hour segment shall be nom inal voltage
for 11 hour s, followed by 110% o f no rmal v oltage for 30 minutes followed b y 90
percent of nominal voltage for 30 minutes.
The 48 hou rs elevated t emp t est sh all be followed by 120 hour s of bur n i n t est a s
specified in the above paragraphs except that the temperature is reduced to ambient
temperature prevalent at that time. Alternatively copy of type test certificate for burn-
in test shall be submitted.
14.02.04.04 The Bidder shall furnish full details regarding shop tests and site tests, as per good
engineering practices. The Owner shall approve all such tests and the supplier shall
conduct all such tests without calling for additional price.
The tests shall cover factory tests, burn-in and elevated temperature tests, simulation
and f unctional tests, insulation tests as applicable, the rating of the contact devices
and co mponents, su rge w ithstand ca pability test, co nformity of i nterconnection
cables, t esting and ch ecking o f o ther co nditions deemed t o be nece ssary with t he
system/equipment items.
14.02.04.05 All instruments and control equipment supplied against this contract shall be f actory
calibrated a t l east at five ( 5) poi nts t hrough out t he r ange and checked f or t heir
Page 153 of 680

functional/performance requirements. The instruments shall also be calibrated at site

prior to commissioning.
14.02.04.06 All panels, instruments enclosures, junction boxes, etc. shall be type tested for
degree of protection and applicable in accordance with IS: 2147. 8.02.04
14.02.04.07 Type, routine and acceptance testing of all equipments, supplied under this contract,
shall be i n acco rdance w ith r elevant N EEA/IS/IEC/ANSI/BS/ISA st andards, i n
addition to the requirements of Owner approved Quality Plans. Six (6) copies of test
reports shall be submitted to the Owner for approval prior to dispatch of respective
equipment
14.02.04.08 The representative of Owner shall be given opportunity to witness the factory tests
which shall be mutually finalized during the progress of the contract.
14.02.04.09 All control systems to be furnished for this project, shall be factory tested f or circuit
continuity and di rection of response. T he Components to be t ested shall include all
controllers, HAND/AUTO station, other system modules, alarm contactors and m ulti-
conductor interconnecting cables. The tests shall be performed with all of the system
components supplied by the B idder co nnected t o form a co mplete sy stem w ith t he
sole ex ception of t ransmitters. T he t ests shall i nclude a m eans of co nfirming t he
mathematical design response of the control system by simulating changes in system
input. The tests shall be a qualitative functional test of each component of control
system, which simulates dynamic inputs and monitors system outputs.
14.02.04.10 Certain control loops shall be factory tested using closed loop mathematical
simulation techniques. Control loops to be tested by closed loop methods are
broadly as under. However, owner has discretion to test and all control loops during
simulation testing.
ii) Firing rate control (fuel and air flow control)

iii) Furnace draft control
iv) Boiler separator level control
(d) Response time for Turbine Control System.
The input simulation equipment shall be designed to produce effects from control system outputs
based on mathematical model of the predicted performance and process dynamics of the main unit
equipment. The control constants of various control loop components shall be adjusted to produce a
stable and optimum control adjusted to produce a stable and optimum control when connected to
the simulation equipment.
14.02.04.11 Simulation data including factory adjustment of control system

constants, and simulation eq uations shall be t abulated and shall be made available
by the Bidder for owner’s use during field check out and the start up of the control
system.
14.02.04.12 Availability of a simulated type test for automatic control loops specified with a
detailed description of testing methods utilized, shall be indicated.
Page 154 of 680

14.02.04.13 The availability of facilities for carrying out the model test for the control systems shall
be indicated by the bidder. Also details of test procedures and copies of test results
conducted for a similar fossil fuel fired unit shall be furnished. The data required from
Boiler and Turbo generator supplies shall also be furnished by the Bidder.
14.02.04.14 Brief description of all tests proposed to be conducted on each control system
components during various stages of manufacture, installation and commissioning
shall be f urnished. C opies of t est dat a acc umulated dur ing t he t ests shall be
submitted to the mutually agreed formats.
14.02.04.15 The owner shall witness the factory tests which shall be performed at a time mutually
agreeable to the Bidder and the owner.
Page 155 of 680

14.02.04.16 Factory Acceptance Tests for DDCMIS, DCS, Simulator & PLC
G 1 FACTORY ACCEPTENCE TEST (FAT): REF NOTE-1 

EN 2 FACTORY ACCEPTENCE TEST (FAT) PROCEDURE: REF.NOTE -2 
ER 3
AL 4
5
TE 6 TEST SHALL BE PERFORMED WITH THE COMPLETELY ASSEMBLED SYSTEM AND ALSO WITH COMPLETE 
ST 7 I&C SOFTWARE AND PERFORMING ALL FUNCTIONS EXPECTED OUT WHILE IN ACTUAL SERVICE AND
RE 8 WITH STSTEM CONFIGURATION AS FINALISED.
Q 9 PROCESS INPUT/OUTPUT CONDITIONS AND OTHER LOAD ON THE SYSTEM TO BE STIMULATED 
UI 10 EITHER BY HARDWARE/SOFTWARE.
R 11 ALL SYSTEM SOFTWARE and APPLICATION SOFTWARE TO BE LOADED AND OPERATIONAL ON THE 
M 12 SYSTEM PRIOR TO FAT
EN 13 FAT TO BE CONDUCTED AT ELEVATED TEMP. OF 45 DEG C FOR MINIMUM 48 HOURES 
TS 14 FAT UNDER FOUR CYLES OF VOLTAGE FLUCATIONS VIZ NOMINAL AT 110 % OF RATED VOLTAGE 
15 PERFORMANCE TEST: 
16 -
17 -
TE 18 TOTAL SYSTEM CONFIGARATION DRAWINGS
ST 19 FAT PROCEDURE CONSITING OF:
D 20 (i) TEST EQUIPMENT
O 21 (ii) TEST ENVIRONMENT
C 22 (iii) TEST CONFIGURATION 
U 23 (iv) TEST PROCEDURE
M 24 (v) TEST SCHEDULE
EN 25 (vi) TEST VENUE
TS 26 (vii) TEST REPORTS- SPECIMEN COPIES
D
27 FUNCTION DESIGN SPECIFICATION FOR EACH EQIPMENT / SYSTEM
RA
28 -
WI
N 29 -
G
S
PR 30 GENERAL APPEARENCE CHECK and BILL OF MATERIALS CHECK 
EL 31 CONSTRUCTION CHECK AS PER OVER ALL GENERAL ARRANGEMENT DRAWINGS 
IMI 32 DIMENSIONAL CHECK 
NA 33 LABELLING, TERMINAL ARRANGEMENT AND EQUIPMENT IDENTIFICATION CHECK 
RY 34 POWER SUPPLY VOLTAGE LEVEL CHECK and POWER 'LEDs -ON CHECK 
C 35 COOLING FAN OPERATION CHECK 
HE 36 GROUNDING NETWORK CHECK 
CK
S
TE 1 POWER SUPPLY UNDER VOLTAGE AND OVER VOLTAGE CHECK (± 10%) 
M 2 PROCESSOR and MAIN DATA BUS NETWORK REDUNDANCY CHECK, IF APPLICABLE 
3 COMMUNICATION COUPLER IF APPLICABLE REDUNDANCY CHECK 
4 COMMUNICATION MODULE OF THE CONTROLLER TO NETWORK REDUNDANCY CHECK, IF APPLICABLE 
5 POWER SUPPLY REDUNDANCY CHECK 
6 HARDWARE ON-LINE MAINTAINABILITY CHECK, 
7 -
8 -
C 9 CLOSED LOOP CONTROL SIMULATION CHECK 
O 10 OPEN LOOP CONTROL SIMULATION CHECK 
NT 11 CONTROL LOOP RESPONSE CHECK 
R 12 BUMPLESS AUTO MANUAL TRANSFER CHECK 
OL 13 OPERATING STATION – GRAPHIC OVERVIEW CHECK 
LE 14 OPERATING STATION- TREND CHECK 
R 15 OPERATING STATION- REAL TIME TREND CHECK 
EN 16 OPERATING STATION- MIMICS CHECK 
GI 17 OPERATING STATION- CHECK FOR OPERATING CONTROL DIRECTLY FROM MIMICS 
NE
18 OPERATING STATION- FUNCTION KEYS CHECK 
ER
19 OPERATING STATION- TOUCH SCREEN FUNCTION CHECK 
IN
G 20 OPERATING STATION- ANALOG CONTROL DISPLAY CHECK 
21 OPERATING STATION- SEQUENCE CONTROL DISPLAY CHECK 
22 OPERATING STATION- OPERATOR GUIDENCE MESSAGE CHECK 
23 OPERATING STATION- ALARM MANAGEMENT FUNCTION CHECK 
Page 156 of 680

24 OPERATING STATION LOGGING FUNCTION CHECK 

25 OPERATING STATION / RESPONSE / UPDATING CHECK 
26 KEYBOARD LOCK FUNCTION CHECK 
27 OPERATING STATION INTERCHANGEBILITY and ASSIGNABILITY CHECK 
28 PRINTER ASSIGNABILITY and BACK-UP FUNCTION CHECK 
29 FLOPPY DISK/ STD / OPTICAL DISK UNIT STORAGE and RETRIEVAL CHECK 
30 OPERATING STATION ASSIGNABILITY CHECK FOR HARD COPIER FUNCTION 
31 PLANT PERFORMANCE CALCULATION CHECK 
32 COMMUNICATION INTERFACE TO OTHER’S SYSTEM SIMULATION CHECK 
33 -
34 DATA BUS DISTANCE BUILDING CHECK (REFER NOTE- 3) 
35 GRAPHIC DISPLAY BUILDING FUNCTION CHECK 
M 36 CLOSED LOOP CONTROL SYSTEM MODIFICATION CHECK 
AI 37 OPEN LOOP CONTROL SYSTEM MODIFICATION CHECK 
NT 38 ALARM DISPLAY PRIORITISATION CHECK 
EN 39 SYSTEM SECURITY CHECK 
AN 40 SYSTEM ALARM CHECK 
CE 41 SYSTEM DIAGNOSTIC FUNCTION CHECK 
42 POINT DETAIL CONFIGURATION CHECK 
43 CONTROL LOOP TUNING CHECK 
44 SYSTEM SELF DOCUMENTATION CHECK 
NO 1. THE INTENT OF THE FAT IS TO DEMONSTRATE AND ENSURE THAT THE I&C SYSTEM MEETS ALL THE
TE FUNCTIONAL REQUIREMENTS AS INTENDED IN THE SPECIFICATION / CONTRACT. A COMPLETED
S INTEGRATED TEST OF THE SYSTEM SHALL BE CARRIED OUT AT VENDOR'S WORKS IN THE PRESENCE
OF OWNER, ON COMPLETION OF INTEGRATION/MANUFACTURING OF THE SYSTEM. THE
SHIPMENT OF I&C EQUIPMENT TO SITE WILL BE EFFECTED ONLY AFTER THE FAT HAS BEEN ACCEPTED
BY THE OWNER.
2. FAT PROCEDURE SHALL BE PREPARED BY VENDOR AND TO BE SUBMITTED FOR OWNER'S/
APPROVAL WELL IN ADVANCE PRIOR TO THE COMMENCEMENT OF FAT
3. FAT SHALL BE CONDUCTED WITH THE DISTANCE BETWEEN THE PROCESSOR AND OTHER SUPPORTING
PERIPHERIALS AS PER THE FINAL LAYOUT IN THE CONTROL ROOM.
4. ALL THE RELEVANT APPROVED DOCUMENTS REQUIRED FOR FAT SHALL BE SUBMITTED BY THE BIDDER IN
ADVANCE PRIOR TO COMMENCEMENT OF FAT.
14.02.04.17 Tests to be performed during FAT of PLC system
Following m inimum tests shall be performed during FAT at manufacturer’s place of

PLC system:
1) Hardware Inspection of PLC Sub System

i) Heat run test
ii) Hardware check / physical software package check
iii) I/O loading specification
iv) PLC start-up and power fail restart
v) PLC processor back-up function
vi) Communication redundancy
2) Application Inspection for Logic Functions

i) Ladder logic functional check and graphic screen check
3) Application Inspection for PLC Panels
i) General arrangement
ii) Appearance and construction
iii) Panel wiring
iv) Panel functional check
v) Power supply redundancy check
Page 157 of 680

4) PLC System Checks
i) PLC Scan time functional test

ii) PLC/IO panel/Engineering station functions
iii) Diagnostic and process alarm test
iv) Controller redundancy test
v. I/O cards redundancy test.
vi) Controller loading test
In addition to above test, Bidder shall also perform other tests as per approved QAP
& FAT procedure. Also bidder shall submit “Type Test” report as per IEC – 61131.2
along with FAT report for PLC.
14.02.04.19 FACTORY ACCEPTANCE TEST FOR SIMULATOR
Factory Acceptance Test (FAT) shall include all required tests to fully demonstrate to
Owner’s satisfaction that each equipment/sub-system/system software modules etc.
furnished as per this specification, as well as Simulator as a whole, fully meets the
functional, par ametric and ot her r equirements of this specification an d O wner’s
approved drawings/documents under all operating regimes.
Bidder t o not e t hat FA T p rocedure given bel ow i n su bsequent cl auses are onl y
indicative in order to help the Bidder in understanding the requirements and help him
in submitting a detailed procedure based on these guidelines meeting all the
specification requirements.
The Bidder shall also carry out the tests included in subsequent clause as
pre FAT and submit its results before inviting Owner for FAT.
The Factory Acceptance Test (FAT) shall include all reasonable exercises, which the
combination of equipment and software can be expected to perform. These tests
shall be divided into, as a minimum, but not limited to the following categories:
i. Pre power on checks

ii. Power on check
iii. Hardware tests
iv. Functional tests
v. Parametric tests
vi. Specific tests on Electronic hardware
14.02.04.19.1The major Functional Tests shall include but not limited to the following:
a) Verification of individual modules in line with approved documents.
b) Verification o f adher ence to par ameters for v arious plant co nfigurations at

different initial conditions.
c) Functional test for C&I Model
Page 158 of 680

Verification o f pr oper r ealization of C ontrol and Log ic functions as per i nput

documents and approved functional design specification (FDS).
d) Functional tests for HMIPIS
i. Verification of all types of displays, logs including their formats, bar

graphs, X -Y pl ots etc. V erification o f al l f unction k eys on k eyboards
and availability of all operator functions.
ii. Verification o f ev ent generation and handl ing c apabilities of H MIPIS

processors by simulating various types of events / data and observing
associated event sequence display and alarm signaling boxes.
iii. Calculations:
All ca lculations shall b e tested t o de monstrate t hat these are i n

accordance with the specification and I/O schedule. The Bidder shall
prepare all tests cases for calculations (3 for each calculation at low,
mid and upper r anges of i nputs) and su bmit t hem for t he ow ner’s
approval. Test cases shall include performance calculations, flow and
level calculations, pressure and temperature compensations, etc.
iv. Checking historical storage and retrieval functions including long-term

storage.
v. Checking heal thiness of pr ocessor, main m emory. T esting o f

initialization and loading of configuration data, etc.
vi. Verification o f al l pr ogrammers’ st ations functions for H MIPIS and

Control System, as well as for documentation facility as specified.
vii. Various display response time / System accuracy etc.
viii. Display update time on OWS
e) Functional test for networking & communication devices
i. Verification of various features as per approved documents.
ii. Verification of throughput after creating high communication traffic.
f) Instructor’s workstation Functions
Verification o f al l features of i nstructor functions like malfunction, i nitial

conditions, sn ap sh ots, t rainee ex ercises etc. i n l ine with sp ecification &
approved documentation.
g) Programming and Documentation functions
Page 159 of 680

i. Verification of all programming function like, modification of application

software, da tabase, a dministrator’s function et c. i n l ine w ith
specification and approved documents.
ii. Verification of all documentation functions in line with specification and

approved documents.
14.02.04.19.2 FAT Procedure
The B idder shall su bmit a de tailed FA T p rocedure for ow ner’s approval dur ing
detailed engineering stage based on the above guidelines. The FAT procedure to be
submitted by the Bidder shall be det ailed and exh austive enough such that owner is
satisfied t hat al l t he S imulator S ystem sp ecification r equirements and f eatures are
being tested and the system meets these requirements.
14.02.04.20 Tests to be performed during FAT of Peripherals & other control system
1. Colour Graphic Video Display Unit (OWS)
i. Functional tests (As per FAT procedure. Note-1)

ii. Test for capabilities of OWS including error detection for the
complete system (Both hardware & software) simulating worst
conditions
iii. Noise test
iv. Surge withstanding capacity as per IEEE or equivalent
v. Quality assurance as governed by BS 5750 or equivalent
vi. Design, construction, components, finishes and testing of electronic
equipment as per EES-1980 (General specification of electronic
equipment) or equivalent
Note-1: Test to be witnessed by Owner.
2. Keyboard
i. Test for satisfactory operation of keyboard controls, push buttons and

all associated functions (As per FAT procedure. Note-1)
ii. Quality assu rance as governed by BS 5750 or e quivalent for
functional test for the complete system simulating worst conditions
iii. Design, construction, components, finishes and testing of electronic
3. Printers
i. Noise level test for the printer

ii. Test of interlock performance and error detection feature.
iii. Quality assurance as governed by BS 5750 or
equivalent
iv. Design, construction, components, finishes and testing of electronic
equipment as per E ES-1980 ( General sp ecification o f el ectronic
Page 160 of 680

4. Floppy / Tape Drive Unit / Bulk Memory Unit / DVD, CD d rive Un it /

DAT Drive
i. Noise test
ii. Surge withstanding capacity as per IEEE or equivalent
iii. Quality assurance as governed by BS 5750 or equivalent
v. Test of Control unit and drive for all features, date checking
features.
5. Vibration Monitoring & Analysis System
i. Simulated functional test (Note-1)

ii. Tests for server, LED monitor, Printer, Keyboard
6. PADO (Performance & Optimization System)

7. ERP System

8. MIS System


9. HMS System

NOTES:
1. The i ntent o f t he FA T i s to dem onstrate and e nsure that t he I &C sy stem

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 t he presence o f Owner or Owner’s representative, on
Page 161 of 680

completion of integration / manufacturing of the system. The shipment of I&C

equipment t o si te w ill b e ef fected onl y af ter t he FA T has been acce pted by
Owner.
2. FAT procedure shall be prepared by vendor and to be su bmitted for Owners

approval well in advance prior to the commencement of FAT.
14.02.04.21 Calibration of Instruments

The B idder sh all ca rry out t he calibration o f i nstruments as indicated bel ow b y
submitting the test procedure and quality assurance plan for the Owner’s approval.
Bidder sh all al so pr epare det ailed ch ecklist/calibration sh eets for e ach o f the
systems/equipment cl early i ndicating t he step-by-step pr ocedures to be ca rried ou t
for calibration pre commissioning, loop checking, powering and commissioning.
The calibration of all instruments shall be ch ecked and ca libration records prepared
for the Owner’s use. If the instruments require recalibration, Bidder shall recalibrate
the instruments and revise the calibration records and submit to the Owner.
i TESTS TO BE PERFORMED FOR FIELD INSTRUMENTS
1. Pressure Gauges
Calibration Hydro test (1.5 times max. pr.)
2. Pressure switches
Calibration test / Hydro test / Contact rating test / Accuracy test / Repeatability
3. Differential Pressure Gauges
Calibration test / Hydro test / Leak test / Over range test / A ccuracy test / Repeatability
test.
4. Differential Pressure Switches
Calibration test / Hydro test / Contact rating test / Leak test / Accuracy test / Repeatability
test.
5. Thermometers
Calibration / Material test / Accuracy test / Bore concentricity : + 5% of wall thickness /
Hydrostatic test for TW (1.5 times max. pr.)
6. Temperature switch
Calibration / Material test / Accuracy test / Bore concentricity : 1 .5% of wall thickness /
Hydrostatic test for TW (1.5 times max. pr.) / Contact rating test.
7. Resistance temperature detector assembly.
Calibration / Material test / Bore concentricity test / Insulation test (< 500 MΩ at 500V DC)
as per ISA, Hydro test for TW. Bore concentricity: + 5% of wall thickness, Accuracy test.
8. Thermocouple assembly
Calibration / Material test, Insulation test (> 500 Ω at 500 V, DC) as per ISA, Hydro static
test (1.5 times max. pr.), Bore concentricity : + 5% of wall thickness.
9. Thermowells
Material test / Bore concentricity : + 5% of wall thickness / Hydrostatic test for TW (1.5
times max. pr.)
Page 162 of 680

10. Level Guages

Hydrostatic test / Material test / Seat leakage test / Ball check test.
11. Level switches (Magnetic)
Material test / Contact rating test / Hydro test / Calibration test.
12. Flow Switch
Material test / Hydro static test (1.5 times max. pr.) / function test.
13. Flow glasses
Material test / Hydrostatic test (1.5 times max. pr.) / function test.
14. Variable area flow meters
Calibration test / Material test / Hydrostatic test (1.5 times max. pr.)
15. Flow element
100% Radiography test / Hydro test / Calibration test, IBR Certificate.
Calibration test for flow element shall be witnessed by Owner.
16. Control valves/Pneumatic block valve/Pressure regulating valve – Refer chapter 11.
17. Position transmitters
Calibration / hysteresis and Accuracy test
18. Electro Pneumatic Convertors
Calibration test / Accuracy test
19. Solenoid valves
Hydrotest / Seat leakage test / CV test / Coil insulation test
20. Air filter regulators
21. Junction Boxes
Test for degree of protection / Material test
22. Tests for terminal blocks
Test for moulding for flame resistant, Non-hygroscopic and Decarbonised / Insulation test
between terminals / Insulation between terminal block and frame.
23. Thermocouple extension cable
Thermo-emf ch aracteristic / C ontinuity t est / M easurement on ca pacitance, i nductance
and loop resistance / Insulation resistance / High voltage test as per latest IS / Tensile
and elongation test / Oxygen index test / Any other test applicable.
24. Mass flow meter
Performance test / Calibration test / Hydrostatic test.
25. Boiler Level Gauge
Hydrostatic test / Material test / Seat leakage test / IBR Certificate
26. pH/Conductivity measurement / Silica / Dissolved oxygen analysers:
Calibration test, Accuracy test
27. Sample cooler :
Page 163 of 680

Hydro test, IBR Certificate

28. Sampling racks :
Hydro test, IBR Certificate for tubes and fittings.
29. S02 / Nox analyser / SPM analyser:
Calibration test, accuracy test
30. Interposing relay
Functional test, temperature rise test, H.V test, Insulation test
31. Transmitter Racks :
Hydro test, air leak test for piping / tubing and fittings. IBR certification as required for
tubing / piping and fittings.
32. Pressure Transmitter
Calibration test / Hydro test / Leak test / Over range test / Accuracy test / Repeatability
test.
33. Differential pressure transmitter
test.
34. Temperature Transmitter
Calibration test / Accuracy test /Ambient temperature error test
35 Pneumatic Block Valves
a) IBR certificate form III C
b) Hydrostatic test : ANSI B 16.34
c) Seat leakage test : As per ANSI B 16-104
d) CV test: As per ISA procedure
e) Magnetic particle test ANSI B 16.34 special class (applicable for pr.>70 bar &
temp< 400 DegC)
f) Liquid penet ration t est: ANSI B 16. 34 sp ecial cl ass (applicable f or pr .>70 bar &
temp< 400 DegC)
g) Radiography test: ANSI B 16.34 special class
h) Calibration and Hysteresis test
i) Actuator leakage test
36. Pressure Regulating Valve
Page 164 of 680


temp< 400 DegC)
temp< 400 DegC)
37. Local Panels :
Visual inspection, wiring & continuity check, H.V. and I.R. tests on panels, checking of bill
of materials, functional tests.
38 Wiring Termination & Accessories
Routine test: Conductor resistance test/High voltage test/Impulse dielectric test/insulation
test/Humidity test/Temperature rise test on power circuits/short time current test on power
circuits.
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
39 Marshalling/System cabinets
Verification of degree of protection/Electrical tests as detailed under wiring Termination&
accessories/Type test and routine test as per relevant Indian standards.
Notes:
1. Test Certificates in addition to inspection at manufacturers works shall be furnished for
all the instruments for Owner's review.
2. Above Test to be witnessed shall be finalized by Owner.
3. In addition to above test, test as per approved QAP shall also be witnessed by owner.
17.02.05 TYPE TESTING
The B IDDER sh all furnish t he Type t est r eports of al l t ype t ests as per r elevant
standards and codes. As well as other specifics test indicated in the specification. A
list of su ch t est ar e gi ven f or v arious equipment i n t able t itled, TY PE T EST
REQUIREMENT FOR C&I SYSTEM and under the item special requirement for solid
state requirements/systems. For the balance equipments/instruments. type test may
be conducted as per manufacturer standards or if required by relevant standards.
A. Out of these test listed , the bidder /subvendor/manufacturer is required
Page 165 of 680

to conduct certain type test specifically for t his contract (and w itnessed by
employer or his authorized representative). Even if the same have been
conducted earlier as clearly indicated subsequently such tests.
B. For t he rest, su bmission o f t ype t est , results, and ce rtificates shall be

acceptable provided following points
i. The same have been ca rried out by the bidder/ subvendor on ex actly
the same model/rating of equipment. (For control valves this shall be
same size, type & design).
ii. There has been no ch ange in the co mponents from the offered
equipments and tested equipments.
iii. The test has been carried out as per the latest standards along with
amendemends as on the date of bid opening.
C. In case the approved equipment is different from the one on which the type
test had been conducted earlier or any of the above g rounds, then the tests
have t o be r epeated and t he co st o f su ch t ests shall be bor ne by the
bidder/sub-vendor within the quoted price and no extra cost will be payable by
the owner on this account.
17.02.05.1 As mentioned against certain items, the test certificates for some of the items shall
be reviewed and approved by the main bidder or his authorized representative and
balanced have to be approved by the employer.
The schedule of conduction of type test/submission of reports shall be submitted and

finalized during pre award discussion.
17.02.05.2 For the type test to be conducted, bidder sh all su bmit detailed test procedure for
approval by o wner. T his shall cl early sp ecify t est se tup, i nstruments to be use d,
procedure, acce ptance nor ms (wherever appl icable). , r ecording of di fferent
parameters, i ntervals of r ecording pr ecaution t o be t aken et c. for t he t est t o b e
carried out.
17.02.05.3 SPECIAL REQUIREMENTS FOR SOLID STATE EQUIPEMNTS /SYSTEMS
The minimum type test report, over and above the requirements of above clause
which ar e t o be su bmitted for each o f t he major C &I sy stems like D DCMIS, D CS,
PLC etc shall be as indicated below:
i. Surge Withstand Capability (SWC) for solid state equipments/equipments
All solid state systems/equipments shall be able to withstand the electrical

noise and t he su rges as encountered i n ac tual se rvice co nditions and
inherent in the power plant . All the solid states systems /equipments shall be
provided with all required protection that needs the surge withstand capability
as defined i n A NSI 37. 90.1/IEEE 472. H ence, al l f ront end ca rds which
receive e xternal si gnals like anal og i nput and out put m odules, B inary i nput
and out put modules etc i ncluding pow er su pply , da ta hi ghway, dat a l inks
shall be pr ovided with protection that meets the surge withstand capability as
Page 166 of 680

defined i n A NSI 37. 90.1/IEEE 472. C omplete det ails of t h features

incorporated i n t he el ectronic system t o m eet this requirement t he relevant
test carried out, the test certificates ,etc shall be submitted along with the
proposal. A s an al ternative t o t he abov e , su itable cl ass of E N 61000 -4-12
which is equivalent to ANSI 37.90.1/IEEE 472 may also be adapted for SWC
test.
ii. The dry heat test as per IEC-68-2-2 or equivalent

iii. Damp heat test as per IEC 68-2-3 or equivalent
iv. Vibration test as per IEC 68-2-6 or equivalent
v. Electrostatic Discharge test as per EN 61000-4-2 or equivalent
vi. Radio frequency immunity test as per EN 61000-4-6 or equivalent
vii. Electromagnetic Field Immunity test as per EN 61000-4-3 or equivalent
Test l isted at I tem no v , v i, vii abo ve ar e appl icable f or el ectronic cards only as
defined under item no. (i) above
17.02.05.4 TYPE TEST REQUIREMENTS FOR C&I SYSTEMS
S.No. Item Test Standard Test t o be Owner’s

requirement specifically Approval
conducted required on
Test
Certificate
1 Electrical As per IS 1248 No Yes
metering standards
instruments
2 Thermocouple Degree of IS - 13947 No No.
Protection
Test
3 Junction Box Degree of IS - 13947 Yes Yes
Protection
Test
4 RTD As per IEC-60751 No No
standards
5 Electronic As per BS 6447/ IEC No Yes
Transmitter standards 60770
6 E/P convertor As per Manufacturing No Yes
standards standard
7 Instrumentation cable (Twisted and shielded) (Refer Vol. V, Chapter 9)
8 Battery As per standard IS 10918 Yes YES
9. Voltage Over load test Approved No YES
stabiliser procedure
Temp. rise test Approved No YES
without r edundant procedure
fans
Input voltage Approved No YES
variation test procedure
10 DDCMIS
CLCS Model Test Approved No No
Page 167 of 680

system procedure
BMS & MFT Safety VDE 0116, No YES
requirement SEC 8.7
11 Conductivity Degree of IS 13947 No No
type level protection test
switch
12 Local gauges Degree of IS 13947 No No
protection test
13 Process Degree of IS 13947 No No
actuated protection test
switches
14 Control CV test ISA 75.02 No YES
valves
15 PLCs As per Standard IEC 1131 No YES
16 LIE/LIR Degree of IS 13947 YES YES
protection test
17 Flue gas O2 Degree of IS 13947 No YES
analyser, protection test
other Fl ue
gas
Analysers
18 Flow nozz les calibration ASME PT C YES YES
&O rifice BS 1042
plates
Note:
Type t est a re to be co nducted onl y for t he i tems, w hich ar e bei ng su pplied as part o f t his
package.
A. For batteries with electric power supply system of main plant C&I, the bidder shall submit
for owner’s approval the reports of all the type tests as per IS-10918 carried out within
last 5 years from the date of bid opening and the test should have been either conducted
at an i ndependent l aboratory or sh ould hav e b een w itnessed by a o wner/client. The
complete type test report shall be for any rating of battery in a particular group, based on
plate dimensions being manufactured by supplier.
For batteries with electric power system of auxiliary plants, type test reports for batteries
shall be as per standard –practice of manufacturer.
14.02.06 Testing at Site [Prior to commercial operation]
a. All equipment shall be checked thoroughly in respect of the following:
i. Visual and mechanical testing
ii. Complete system configuration loading functions; system

diagnostics; system proper operation specified power supply
specifications.
Page 168 of 680

QUALITY PLAN NO.: PE-QP-999-145-I036___

STANDARD QUALITY PLAN VOLUME IIB
FOR SECTION D
PROGRAMMABLE LOGIC CONTROLLER REV. NO. 01 DATE: 24.08.2007
PEM :: C&I SHEET 1 OF 8
Sl. Component / * Type/Method Extent

Reference Acceptance
Format Agency $
Characteristics Checked Cate of of of Remarks
No. operation documents Norms
gory Check Check Records P W V
Materials
1.0
/Components
Physical Inspection for
Dimensions, Painting, Cutouts,
Lifting / Locking Arrangements, Contract As per ref BHEL
Panels & Control
Components, Drawing Pocket, specifications, documents. Quality
1.1 Desks MA Visua l 100% 3/2 2 1
Mounting accessories, Plinth & Approved GA No physical Inspection
AV Pads, Cable Gland Plates, Drawings, BOQ damage. Report.
Hardwares, Hinges, Louvers &
Filters, Fans & Panel Lamps
Power Supply/Packs,
Physical Inspection As per BHEL
Battery & Battery Contract
Physical Damages reference Quality
1.2 charger, Transformer, MA Visua l 100% specifications, 3/2 2 1
Dimensions documents, Inspection
UPS. BOQ.
Mounting Accessories Test Report Report.
Indicating Lamp,
As per ref
Annunciator, Meters,
Physical Verification documents BHEL
Transducers, Signal Contract
Physical Damages No physical Quality
1.3 Converters, MA Visua l 100% specifications, 3/2 2 1
Dimensions damage. Test/ Inspection
Instruments, Single BOQ.
Accessories Calibration Report
Loop Controllers
report.
PLC processors, Physical Inspection Product
I/O modules, Power
• Identification Labels Catalogue, Data BHEL
Supply modules, As per ref
• Physical Damages sheets, Quality
1.4 Communication MA Visua l 100% documents. 3/2 2 1
• Quantity Approved Inspection
modules, Mounting Test Certificates
• Spare Capacity Configuration Report.
Racks, Ethernet
diagram, BOQ
$
LEGEND: * CR - Critical characteristics P - Agency Performing the Test. 1 - BHEL
MA - Major characteristics W - Agency Witnessing the Test. 2 - Vendor
MI - Minor characteristics V - Agency Verifying the Test. 3 - Sub-vendor
Page 169 of 680

FOR SECTION D

Format Agency $
CPU, Monitor,
Physical Inspection Contract
Keyboard, Mouse,
Identification Labels, Tech. specifications,
CD Drives, Printers, As per BHEL
Specification Product
OS, System reference Quality
1.5 Physical Damages MA Visual 100% Catalogue, 3/2 2 1
Software, documents. Inspection
Accessories Approved GA /
Engineering software Report.
Installation arrangements for Configuration
in the form of
Computers & Printers drawing, BOQ.
Licensed CD.
$
Page 170 of 680
FOR SECTION D

Format Agency $
2.0 Ass embly

Functional Test for
Correct
HMI/OWS devices Approved BHEL
Operation of
such as Monitors, Operation Configuration Quality
2.1 MA Functional 100% interconnected 21 1
Keyboards, Mouse, Diagram & BOQ Inspection
Devices of HMI
Printers etc. and FAT Report.
system.
Approved GA
Drawing, Panel
BHEL
Hardware Functional Physical arrangement, Wiring Wiring Diagram,
Visual/ Test Quality
2.2 Verification. check & labeling, Continuity MA 100% IR & HV as per 22 1
Electrical Certification Inspection
Checking, IR & HV test relevant
Report.
International
standard
BHEL
Healthiness of all the All equipment to
Visual Approved power Quality
2.3 Po wering Up modules/equipment, associated MA 100% be healthy on 21 1
/Electrical supply scheme Inspection
with Powering of PLC system power ON
Report.
Healthiness of PLC modules on BHEL

2.4 Burn in test for PLC Continuous Energisation, Visual/ Test certification Quality
MA 100% F AT Procedure 22 1
modules Temperature maintenance Electrical as per FAT Inspection
Report.
$
Page 171 of 680
FOR SECTION D

Format Agency $
Factory
3.0 Acceptance Test
(FAT)
Input Output BHEL
Functional Visual/ Quality
3.1 I/O configuration, I/O operation MA 100% FAT Procedure AS per FAT 21 1
Verification Eletrical Inspection
Report.
BHEL
Processor Processor configuration,
Quality
3.2 Verification Powering up, standby operation MA Visual 100% FAT Procedure AS per FAT 21 1
Inspection
( as applicable) and Loading
Report.
BHEL
Power Supply Module
Quality
3.3 Verification Redundancy Operation MA Electrical 100% FAT Procedure AS per FAT 21 1
Inspection
Report.
Redundancy operation of
Communication BHEL
Communication System,
System Quality
3.4 Measurement of Response MA Electrical 100% FAT Procedure AS per FAT 21 1
Verification Inspection
Time, Communication with third
Report.
party system
Diagnostic BHEL
Verification Self Diagnostic features of PLC Quality
3.5 MA Visual 100% FAT Procedure AS per FAT 21 1
system Inspection
Report.
Operation of PLC driven
BHEL
Control Panel/Desk annunciation system, Mosaic,
Quality
3.6 Verification Push buttons & selector MA Visual 100% FAT Procedure AS per FAT 21 1
Inspection
switches, Indicating lamps
Report.
(i) Control Logics (ii) BHEL
Software
Engineering Features (iii) HMI Quality
3.7 Verification MA Visual 100% FAT Procedure AS per FAT 21 1
Features Inspection
Report.
$
Page 172 of 680
FOR SECTION D
SHEET 5 OF 8
FACTORY ACCEPTANCE TEST (FAT) PROCEDURE
This document covers procedure to conduct/witness PLC system functional tests in

order to demonstrate conformity to purc hase specifications and related engineering
documents. The test shall be conduc ted at the system suppliers works. The system
supplier shall conduct all functional te sts before commencing F AT and tes t results
shall be made available dur ing FAT. Vendor mus t fu rnish following r elevant
drawings, duly approved by BHEL Engineering, for reference during FAT.
a) Technical Specification of PLC.
b) PLC System Configuration
c) General Assembly Drawings.
d) Panel Wiring Diagrams.
e) Bill of Quantity for PLC System.
f) Logic Diagram.
g) HMI Schematics.
h) Input / Output List.
Further the vendor shall furnish applic able produc t specification, datasheets,
catalogues, test-certificates, and internal inspection records to enable F AT. Vendor
shall also submit, to the inspecting agency, his standard test procedure, for clauses
given below; where vendor’s standard practice has been referred.
APPLICABLE TEST PROCEDURE:
1. Input/Output Functional Verification.
Check for correctness of addressing of racks, slots and I/O modules as

per applicable PLC co nfiguration diagram. Appropriate signal generators
shall be used to simulate Input s and out puts to check operation and
SCAN time. Check online replacement of cards, p rocessors, power
supply etc.
2. Processor Verification
PLC Configuration drawing to be referred for ascertaining
i) Redundanc y
Page 173 of 680

FOR SECTION D
SHEET 6 OF 8
ii) Type (Hot or Cold) of redundancy
Both the processors are to be c hecked for healt hiness in case of

redundant configuration as per vendor’s standard practice. In case of hot
redundancy, switchover of control fr om primary processor to standby
processor shall be demonstrated fo r uninterrupted control and dat a
processing as per vendor’s s tandard practice. Switchover shall be
witnessed, by manual power off or resetting the Primary CPU or
simulating failure of primary processor. Checking should be by witnessing
the lighting up of Proc essor’s LEDs as per manufacturer’s product
standard.
Vendor shall demons trate, as pe r Vendor’s standard practice, adequate
Loading (Spare Capacity) of Processors, as mentioned in contract specs.
This shall be done, by simulating wors t load operation of fully integrated
PLC system.
3. Power Supply Module Verification
Check if PSM is in r edundant mode as per specific ation. Check the

healthiness of power supply fr om both the modules ’ lamp
indication/measurement. Simulate fa ilure of one PSM and verify that
standby PSM has taken over without any interruption.
4. Communication System Verification
Communication system has to be in line wit h approved PLC

Configuration Diagram. Verify that both the communication buses are
intact and connected. Communication between PLC processors, I/O rack,
OWS etc. is to be checked through simulation of input data. Simulate the
bus failur e by dis connection of working bus. Check that the
communication continues without interruption or loss of data.
Following response t imes are to be demonstrated as per v endor’s

standard practice for conformance to contract specifications:
1. Screen update time

2. I/O scan time
3. SOE resolution time
4. Data transfer time with third party system using Communication
Protocol as per Contract specif ication and as per quantum of data
as per approved signal exchange list.
5. Diagnostic Verification
Product Catalogue/Literature shall be referred for checking of all

diagnostic features. Hardware failure to be simulated by removing an I/O
Page 174 of 680


Module,PLAN
STANDARD QUALITY Processor, Communication
VOLUME IIB
Module, Power Supply module etc
from
FOR the ru nning system and verify
SECTION D
the co rresponding system diagnostic
messages.
SHEET 7 OF 8
6. Control Panel /Desk Verification
i) PLC driven annunc iation system should be checked by alar m

signal simulation.
ii) Push Button and sele ctor switch operation should be checked by
verification of corresponding change of status of Data Base point.
iii) Indicating lamp / MIMIC should be checked by corresponding Data

Base point simulation.
7. Software Verification
i). Control Logics:– Software switches, lamps and Analog sources shall
be used for simulation of field conditions .Control logics shall be
checked for its correct functionality as per approved logic schemes
ii). Engineering features:-

a) Online changing of parameters, set points.
b) Online modification in Control Logic Diagrams.
c) Online configuration of Graphics, Trends, Logs, HSR.
iii). HMI features:-

Check for configuration & ope ration of Graphics, Trends, Logs,
HSR and Alarms, in the for m of Displays and Printouts, by
simulation of Inputs as per approved documents.
8. Burn in Elevated Temperature test
Electronic equipment s shall be subjected to Burn in elevated temperature

test as per the procedure detailed below:
a) (i) PLC modules are kept at 50 Deg c under continuous energized

condition for 48 hours.
Page 175 of 680

STANDARD QUALITY PLAN QUALITY PLAN NO.: PE-QP-999-145-

I036___
FOR
VOLUME IIB
PROGRAMMABLE LOGIC CONTROLLER
SECTION D
REV. NO. 00 DATE:
23.03.2005
SHEET 8 OF 8
ii) 48 hour s test period shall be divid ed into 4 equal time segment of
12 hours duration eac h. For every 12 hours duration s egment, after
lapse of first 11 hours 110% of nominal voltage sha ll be applied to the
panel under test for a period of 30 minutes followed by application of
90% of nominal voltage for the next 30 minutes.
b) Assembled Panels with complete wiring shall be kept under continuous

energized condition for 120 hours at ambient temperature. Tem perature rise in
panels should be below 10 Deg C above ambient.
Page 176 of 680

STD QUALITY PLAN NO.: PE-QP-999-145-I056

FOR SECTION D
LOCAL CONTROL PANEL REV. NO. 01 DATE: 22-02-2008

Format Agency $
INCOMING
1.0 Sheet Steel (CRCA & 1. Chemical Composition MA Chemical Sample Relevant
IS:1079 Relevant
IS:1079 Test 3 --- 2
HR) analysis IS:513
standard standard
IS:513 Certificate
2. Bend Test CR Mech. test Sample Relevant
IS:1079 IS:1079
Relevant Log Book 2 --- ---
IS:513
standard IS:513
standard
3. Surface finish MA Visual 100% Factory Factory Log Book 2 --- ---
Standard / Standard /
Sample Sample
4. Waviness MA Visual 100% Factory No Waviness Log Book 2 --- ---
Standard
5. Thickness MA Measurement 100% BHEL Spec. BHEL Spec. Log Book 2 --- ---
6. Mill marking MA Visual 100% Factory Factory Log Book 2 --- 1

Standard Standard
2.0 Flats / Angles / 1. Dimensions MA Measurement Sample Relevant
IS:2062 Relevant
IS:2062 Log Book 2 --- ---
Channels standard standard
2. Surface Defects MA Visual 100% Factory Factory Log Book 2 --- ---
Standard / Standard /
Sample Sample
3. Straightness MA Measurement 100% Factory Std. Factory Std. Log Book 2 --- ---
Relevant Relevant
4. Mill marking MA Visual 100% IS:2062 IS:2062 Log Book 2 --- 1
standard standard
3.0 Cables / Wires 1. Visual / Surface defects MA Visual 100% BHEL Spec. BHEL Spec. Log Book 2 --- ---
and
andIS:1554 or
Relevant and
and IS:1554 or
Relevant
IS:694 IS:694
standard standard
2. IR and HV MA Electrical 100% BHEL Spec. BHEL Spec. Log Book 2 --- ---
and IS:1554
Relevantor and
and IS:1554 or
Relevant
IS:694
standard IS:694
standard
$
Page 177 of 680


FOR SECTION D

Format Agency $
3. Conductor
a) Resistance MA Electrical 100% BHEL Spec. BHEL Spec.
b) Size MA Measurement 100% and IS:1554
Relevantor and IS:1554
and Relevantor Log Book 2 --- ---
c) Sheet colour MA Visual 100% IS:694
standard IS:694
standard
4. Type / Routine Test MA Verification 100% BHEL Spec. BHEL Spec. Log Book 3 --- 2
Certificates and
and IS:1554 or
Relevant and Relevant
and IS:1554 or
IS:694
standard IS:694
standard
4.0 Electrical 1. Verification at make and CR Visual Sample BHEL Spec. BHEL Spec. Log Book 2 --- ---
Components like Type and BOM and BOM
Annunciator
Transformers 2. Verification of Test CR Scrutiny of 100% RelevantIS
Relevant Relevant
Relevant IS Log Book 2 --- ---
Lamps Certificates Type / Routine standard standard
T.Cs.
Switches
PBs 3. Operation / Functional CR Electrical Sample+ Relevant
Relevantstandard
Indian Relevant
Relevantstandard
Indian Log Book 2 --- --- + for relay &
Contactors check 100%@ & Catalogue
Std & Catalogue & Catalogue
Std & Catalogue contactors
only
Relays
4. I.R. MA Electrical 100% Relevant
Relevantstandard
Indian Relevant
Relevantstandard
Indian Log Book 2 --- --- @ for all
Timers
&Std
Catalogue
& Catalogue &Std & Catalogue
Catalogue components
Space Heaters
except relays
Thermostat & contactors.
Indicating meters etc. 5. H.V. MA Electrical 100% Relevant
Relevantstandard
Indian Relevant
Relevantstandard
Indian Log Book 2 --- ---
&Std
Catalogue
& Catalogue &
Std & Catalogue
Catalogue
6. Calibration MA Electrical 100% Relevant

Relevantstandard
Indian Relevant
Relevantstandard
Indian Log Book 2 --- 1
&Std
Catalogue
& Catalogue &Std & Catalogue
Catalogue
7. Pick up / Drop off Voltage MA Electrical 100% Relevant

Relevantstandard
Indian Relevant
Relevantstandard
Indian Log Book 2 --- ---
&Std & Catalogue &
Catalogue Std & Catalogue
Catalogue
$
Page 178 of 680


FOR SECTION D

Format Agency $
5.0 Misc. Components 1. Verification of Type / Make MA Visual Sample BHEL Spec. & BHEL Spec. & Log Book 2 --- ---
like Gaskets, Mfrs. Catalogue Mfrs. Catalogue
Terminal Blocks etc.
2. Surface defects MA Visual Sample BHEL Spec. & BHEL Spec. & Log Book 2 --- ---
Mfrs. Catalogue Mfrs. Catalogue
3. IR / HV on Terminal Blocks MA Electrical Sample BHEL Spec. & BHEL Spec. & Log Book 2 --- ---
Mfrs. Catalogue Mfrs. Catalogue
IN PROCESS
6.0 Blanking / Bending / 1. Dimensions MI Measurement 100% Approved Mfr. Approved Mfr. Log Book 2 --- ---
Forming drgs. drgs.
2. Surface defects after MA Visual 100% Factory Factory Log Book 2 --- ---
bending Standard Standard
7.0 Nibbling / Punching 1. Cutout Sizes MI Measurement 100% Approved Mfr. Approved Mfr. Log Book 2 --- ---
drgs. drgs.
2. Deburring MA Visual 100% Approved Mfr. Approved Mfr. Log Book 2 --- ---
drgs. drgs.
ASSEMBLY
8.0 Frame Assembly & 1. Dimensions MA Measurement 100% Approved drg. / Approved drg. / Log Book 2 --- 2
Sheet fixing Mfr. Standards Mfr. Standards
2. Alignment MA Measurement 100% Approved drg. / Approved drg. / Log Book 2 --- 2
Mfr. Standards Mfr. Standards
3. Welding Quality MA Visual 100% Approved drg. / Approved drg. / Log Book 2 --- 2
4. Surface defects MA Visual 100% Approved drg. / Approved drg. / Log Book 2 --- 2
$
Page 179 of 680


FOR SECTION D

Format Agency $
9.0 Pre-treatment and 1. Pretreatment Process MA Visual 100% Factory Factory Log Book 2 --- 1
Painting Standard & Standard &
IS: 6005 standard
Relevant Relevant
IS: 6005 standard
2. Process parameters like MA Measurement Periodic Factory Factory Log Book 2 --- 1
bath temp. concentration Standard & Standard &
etc. IS: 6005standard Relevant
Relevant IS: 6005 standard
3. Dipping / Removal Time MA Measurement 100% Factory Factory Log Book 2 --- 1
Standard & Standard &
IS: 6005standard Relevant
Relevant IS: 6005standard
4. Surface quality after every MA Visual 100% Factory Factory Log Book 2 --- 1
dip Standard & Standard &
IS: 6005 standard Relevant
5. Primer after phosphating MA Visual, 100% Factory Factory Log Book 2 --- 1
Thickness Standard & Standard &
Relevant
IS: 6005 standard
6. Putty Application & MA Visual 100% Factory Factory Log Book 2 --- 1
Rubbing after primer Standard & Standard &
IS: 6005standard Relevant
7. Paint first coat MA Visual, 100% Factory Factory Log Book 2 --- 1
Thickness Standard & Standard &
8. Putty Application and MA Visual 100% Factory Factory Log Book 2 --- 1
Rubbing after first coat of Standard & Standard &
paint IS: 6005 standard Relevant
9. Paint second coat MA Visual, 100% Factory Factory Log Book 2 --- 1
Thickness, Standard & Standard &
Scratch test IS: 6005 standard Relevant
Colour
adhesion
$
Page 180 of 680

FOR SECTION D

Format Agency $
10. Panel Wiring 1. Wiring Layout MA Visual 100% Approved drgs. Approved drgs. Log Book 2 --- ---
& Specs. & Specs.
2. Wiring Termination MA Visual 100% Approved drgs. Approved drgs. Log Book 2 --- ---
(Crimped Lugs) & Specs. & Specs.
3. Ferrule numbers MA Visual 100% Approved drgs. Approved drgs. Log Book 2 --- ---
& Specs. & Specs.
4. Colour of wiring MA Visual 100% Approved drgs. Approved drgs. Log Book 2 --- 1
& Specs. & Specs.
5. Size of Conductor MA Measurement 100% Approved drgs. Approved drgs. Log Book 2 --- 1
& Specs. & Specs.
11. Component Mounting 1. Correct components MA Visual 100% Approved drgs., Approved drgs., Log Book 2 --- ---
Specs. & BOM Specs. & BOM
2. Fixing MA Visual 100% Approved drgs., Approved drgs., Log Book 2 --- ---
Specs. & BOM Specs. & BOM
FINAL
12. Final Inspection 1. Workmanship MA Visual 100% Factory Factory Inspection 2 1 1
Standard Standard Report
2. Component layout MA Visual 100% BHEL approved BHEL approved Inspection 2 1 1 At Random
(neatness, accessibility & drg. / Spec. drg. / Spec. Report by BHEL,
safety) Mounting / Proper based on
fixing of all components 100 %
internal test
reports by
Mfr.
3. Components identification MA Visual 100% BHEL approved BHEL approved Inspection 2 1 1
Marking / Name plates drg. / Spec. drg. / Spec. Report
$
Page 181 of 680


FOR SECTION D

Format Agency $
5. Dimensions MA Measurement 100% BHEL approved BHEL approved Inspection 2 1 1
drg. / Spec., drg. / Spec., Report
BOM BOM
6. Door functioning MA Functional 100% BHEL approved BHEL approved Inspection 2 1 1

drg. / Spec. drg. / Spec. Report
7. Paint Shade CR Visual 100% BHEL approved BHEL approved Inspection 2 1 1

8. Paint Thickness CR Measurement 100% BHEL approved BHEL approved Inspection 2 1 1

9. Workmanship of Gaskets MA Visual 100% Factory Factory Inspection 2 1 1

Standard Standard Report At Random
by BHEL,
based on
10. Wiring Layout MA Visual 100% BHEL approved BHEL approved Inspection 2 1 1 100 %
drg. drg. Report
internal test
reports by
11. Wire Termination MA Pulling Sample ----- Firm termination Inspection 2 1 1 Mfr.
manually Report
12. Continuity MA Electrical 100% ----- Continuity OK Inspection 2 1 1

Report
$
Page 182 of 680

FOR SECTION D

Format Agency $
13. TYPE TEST Degree of Protection CR Mech. Sample BHEL approved BHEL approved Type Test 3 --- 1
Protection spec., drg spec., drg Certificate
relevant
relevant IS- relevant
relevantIS-
13947 Part-1,
IEC-60947, 13947 Part-1,
IEC-60947,
IS-2148.
IEC-60079 IS-2148.
IEC-60079
14 ROUTINE TEST IR before & after HV Test CR Electrical 100% BHEL approved BHEL approved Test Report 2 1 1
spec., drg., BOM spec., drg., BOM
& relevant IS. & relevant IS.
standard standard
15 FUCTIONAL TEST 1. Control Logic Operation CR Electrical 100% BHEL approved BHEL approved Inspection 2 1 1
spec. / drg. spec. / drg. Report
2. Instrument Calibratio CR Electrical 10% BHEL approved BHEL approved Inspection 2 1 1

spec. / drg. spec. / drg. Report
3. Temperature rise CR Electrical 100% BHEL approved BHEL approved Inspection 2 1 1

spec/drg. & spec/drg & Report
relevant
relevant standard
IS. relevant
relevantstandard
IS.
$
Page 183 of 680


SECTION C1 – E
PAINTING SPECIFICATION
Page 184 of 680

CHAPTER - 6
PAINTING
1.0 SCOPE
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/ owner’s representative after the award of contract.
The following surface and material shall require painting:
a. All un-insulated carbon steel and alloy steel equipment like columns,
vessels, storage tanks, pumps, 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, handrails, ladders etc.
The following surfaces and materials shall not require painting :
a. Non-ferrous materials
b. Austentic stainless steel
c. Plastic and / or plastic coated materials
d. Insulated surface of equipment and pipes except color coating wherever
required.
e. Painted equipment like blowers, pumps, valves etc. with finishing coats in
good condition and with matching color code.
2.0 CODES AND STANDARDS
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.
The following Indian Standards may be referred to for 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 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 painting of concrete, masonry

and plaster surfaces (Parts I & II)
Page 185 of 680

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, priming
IS:104 : Ready mixed paint, brushing, Zinc Chrome, priming
IS:2932 : Enamel Synthetic exterior
(a) Undercoating
(b) finishing
IS:4682 : Code of practice for lining of vessels & equipment
SIS 559000 : Swedish standard for blasting
ISO 8504-2 : Preparation of steel substrates before application of paints and
related products. Surface preparation methods Part 2 Abrasive
blast cleaning
ISO 8501-1 : Preparation of steel substrates before application of paints and
related products. Visual assessment of surface cleanliness.
Part 1 : Rust grades and preparation grades of uncoated steel
substrates and of steel substrates after overall removal of
previous coatings.
SIS 05 5800 : Surface preparation by acid pickling
SSPC SP08 : Surface preparation by acid pickling
IS 2629 : Recommended practice for hot dip galvanizing of iron and
steel
ASTM A780 : Standard practice for repair of damaged galvanized coatings
SSPC : Steel structures painting council
NACE : National association of Corrosion Engineers
DIN : Deutsehes Institute for Normung
BS : British Standard
ASTM : American Society for Testing material
AWWA : American Water works association
3.0 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/
Purchaser’s representative.
3.1 BLASTING
The surface of the part/ component shall be blasted before the coating material is
applied.
Compressed air supply for blast cleaning shall be free of water and oil. Air compressors
shall not be allowed to deliver air above 1100C. Blasting activity shall be performed at
temperatures 30C above due point and substrata temperature between 50C & 500C
and relative humidity not exceeding 85% shall be maintained during painting.
Necessary safety precautions for equipment and operator shall be adhered to and shall
comply with applicable laws, regulations, ordinances etc., of the local authority, state or
the nation pertains to the work.
Page 186 of 680

Abrasive used for blast cleaning carbon steel and alloy steel shall be as per ISO 8504-2
and SSPC painting manual. Suggested abrasives are chilled iron grit, shot steel,
malleable iron grit and shots of non metallic abrasive (aluminum oxide, copper slag,
garnet etc.).
The grade of blasting shall be performed in line with the approved painting scheme.
The nature, quality and grain size of abrasives and the parameter of their use are to be
chosen to obtain the required surface profile depth and cleanliness.
Surfaces prepared for coating shall be coated the same day and before any visible
rusting occurs (the time elapsed between blast cleaning and commencement pf painting
shall under no circumstances exceed 4 hours, but in any case must commence before
signs of degradation occur).
The grades of surface finish
ISO 8501-1 SIS 055900 SSPC NACE

White metal Sa3 Sa3 SP5 1
Near White Sa 2½ Sa 2½ SP10 2
metal
Commercial Sa2 Sa2 SP6 3
Blast
Brush off blast Sa1 Sa1 SP7 4
Unless otherwise specified in the documents, the surface shall satisfy the following
requirements after blasting
(a) Blasting according to SIS 055900, Grade Sa 2½
Primer paint shall be Zinc Silicate of approved brand. Dry film thickness of each primer
coat shall be 15-25 µm.
3.2 Manual Rust Removal

Manual rust removal shall be allowed for welded zones and for touching up installed
components.
3.3 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
e) Markings (eg felt up pen) Organic solvents to manufacturer’s
specifications eg Trichloro trifluoro ethane
and solvents containing acetone (renew
solvent and rag frequently)
3.4 Acid Pickling
Prior to galvanizing the surface preparation shall be done by acid pickling as per
SSPC-SP-08.
Page 187 of 680

4.0 PROCESSING
4.1 General
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 30C above dew point.
4.2 Application Procedure
The primer shall be applied by means of brush or by spary. The top coats shall be
applied by means of brush, roller or 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.
4.3 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 specification.
The final top shall be reapplies completely.
4.4 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 upto a distance of 30 mm on each side of the weld edge until erection
and weld examinations, if any, have been completed.
4.5 Bond Strength
The pill off stress determined using the pull off test method for adhesion shall not be
less than 1.5 N/mm2, according to ISO 4624.
5.0 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.
6.0 COATING SYSTEMS
6.1 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 this
Page 188 of 680

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 6.8 )
6.2 Standard Coating System (External Coatings)
(a) Steel Surfaces
(i) All steel structures shall receive two primer coats and two sandwich coat of MIO
Epoxy paint and one finish coat 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 intermediate coats and one finished
coat shall also be applied after erection.
(ii) Steel surface which is to be 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 as explained in clause 3.1 to
Sa 2½ finish as per SIS05-5900. Primer paint shall be Zinc Silicate of approved
brand. Dry film thickness of each primer shall be 60 microns.
(iii) Two intermediate MIO Epoxy paint, and one top polyurethane coating of
approved brand shall be applied. Dry film thickness of each intermediate coat
shall be 90 microns and top polyurethane coating shall be 30 microns. The under
coat and finish coat shall be of different tint to distinguish the same from finish
paint. The total dry film thickness shall be 330 microns. All paints shall be of
approved brand and shade as per owner’s requirement.
(iv) Joints to be site welded shall have weldable primer applied within 100 mm of
welding zone. Similarly where friction grip fasteners are to be used removable
anti corrosive coating shall be provided. On completion of the joint the surfaces
shall receive the paint as specified.
(v) 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 the above number of coats specified before erection. Portion
of steel member embedded/ to be encased in concrete shall not be painted.
(b) Gratings and Step Threads
(i) Surface Preparation
Gratings and step threads shall be cleared by acid pickling as per SSPC-SP-08
(ii) Hot Dip galvanizing

The hot dip galvanizing shall be done as per IS 2629. The average mass of
coating shall be 610 gm/m2.
Page 189 of 680

(iii) Post Treatment
Immediately after galvanizing post treatment such as chromating shall be applied

to retard white rust attack.
(iv) Touch up mechanical damages
The repair of damages coatings shall be done as per the recommended practice
ASTM A780.
6.3 Painting of Indoor components such as valves, pumps, motors, electrical

parts, tanks etc.
At Works
Surface Preparation
Blasting according to SIS 055900 grade Sa 2½. Depending on production flow, a

weldable, inorganic ethyl zinc silicate shop primer of minimum dry film thickness
25 µm may be used.
Prime Coat
Two (2) layers of Zinc phosphate epoxy, total dry fim thickness 75µm.
At Site
Thorough cleaning to remove oil, grease, dirt and any other contaminants.
Derusting of all mechanical damages according to SIS 055900 Grade ST3. Touch
up with dry film thickness 50 µm.
Finish Coat
Application of two (2) finishing coats of chlorinated rubber paint in approved

shades at 30-40 microns DFT each coat in approved shades.
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.
6.4 Painting of Outdoor equipment (external surfaces) such as piping, valves,

pumps, motors, electrical parts, tanks etc.
Weather exposure, weather resistance, temperature upto 1200C as per clause

6.1 & 6.3. However
Surface Preparation
Page 190 of 680

Blasting according to SIS 055900 grade Sa 2½. Depending on production flow, a

weldable, inorganic ethyl zinc silicate shop primer of minimum dry film thickness
15-25 µm may be used.
Prime Coat
Two (2) layers of Zinc phosphate epoxy, total dry fim thickness 75µm.
Intermediate Coat
One (1) layer 2 pack high build epoxy polyamide MIO, DFT 100µm.
Finish Coat
Application of two (2) finishing coats of chlorinated rubber paint in approved

shades at 50 microns DFT each coat in approved shades.
6.5 Special Coating
(a) Parts exposed to temperatures above 1200C, upto 2000C, not insulated
(i) At Works
Surface Preparation
Blasting according to SIS 055900 grade Sa 2½ and ISO 8501-1:1958.

Depending on production flow, a weldable, inorganic ethyl zinc silicate
shop primer of minimum dry film thickness 15-25 µm may be used.
Prime Coat
Inorganic ethyl Zinc silicate, total dry fim thickness 75µm.
(ii) At Site
Pretreatment
Dersuting 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 50µm.
Intermediate Coat
I pack silicon acrylic dry film thickness 35 µm.
Final Coat
1 pack silicon acrylic, dry film thickness as 35µm.

Total system dry film thickness 145µm.
Final coat according to colour code.
Page 191 of 680

(b) Parts exposed to temperatures above 2000C, upto 4000C, not insulated
(i) At Works
Surface Preparation
Blasting according to ISO 8501-1:1958 grade Sa-2½. Depending on

production flow, a weldable, inorganic ethyl zinc silicate shop primer of
minimum dry film thickness 15-25 µm may be used.
Prime Coat
Inorganic ethyl Zinc silicate, total dry film thickness 75µm.
(ii) At Site
Pretreatment
Derusting of all mechanical damages, according to standard Sa 2½ to

ISO 8501-1:1988. Touch up with coating system according to
manufacturer’s recommendations.
(c) Insulated parts continuously exposed to condensing water or parts

exposed to temperatures
For parts that are provided with insulation on site.
(i) Insulated parts exposed to condensing water
At Works
Surface Preparation
Blasting according to Sa 2½ to ISO 8501-1:1988. Depending on

minimum dry film thickness 15-25 µm shall be used.
Prime Coat
Inorganic ethyl Zinc silicate, total dry film thickness 75µm
(ii) Insulated parts exposed to temperatures
Parts exposed to temperatures upto < 4000C
Surface Preparation
Blasting according to Sa 2½ to ISO 8501-1:1988. Depending on

minimum dry film thickness 15-25 µm shall be used.
Page 192 of 680

Parts exposed to temperature above 4000C at works (Steam pipes,

pressure tubes and parts for the HRSG, such as heating surfaces,
heaters and superheaters, reheaters etc)
Temporary Primer
Varnish
(d) Intermittent exposure due to condensing water/ chemicals (Indoors)
(i) At Works
Surface Preparation
Blasting according to Sa 2½ and ISO 8501-1:1988. Depending on

minimum dry film thickness 15-25 µm may be used.
Prime Coat
Two layers of Zinc phosphate primer, total dry fim thickness 75µm.
(ii) At Site
Pretreatment
Dersuting of all mechanical damages, according to standard Sa3 to

ISO 8501-1:1988, touch up with 2 pack high build epoxy with volume
solid content of more than 85%, 75µm.
Intermediate Coat
2 pack high build epoxy, dry film thickness 80 µm.
Finish Coat
2 pack silicon acrylic, dry film thickness of 50µm.
Total system dry film thickness 205µm.
When exposed o weathering, weather resistance finish coat shall be

applied.
(e) Water Exposure
(i) At Site/ Works
Pretreatment
Removal of all welding pearls.
Page 193 of 680

Blasting according to Sa 3 to ISO 8501-1:1988
Coat
4 coats 2 pack coal tar epoxy, dry film thickness 125 µm each.
Total system dry film thickness 500µm

Touch up after erection as required.
6.6 Painting of Pipes
6.6.1 Buried Piping
Internal surfaces
(i) Surface cleaning by sand blasting.
(ii) Two (2) coats of epoxy primer coats. The minimum DFT of each coat shall
be 35 microns.
(iii) Finish coat-Two (2) coats of high build epoxy paint. The minimum DFT of
each coat shall be 35 microns.
The total dry film thickness of 150 microns.
Note : All steel pipes carrying sea water shall be internally coated with
corrocoat/ polyurea coating having thickness 1500 DFT.
Tests to be carried out after application : Bond/ Adhesion test, Holiday test
External surfaces
(i) Surface cleaning by Sand Blasting.
(ii) Coal tar primer compatible with coal tar enamel grade. The number of coats
shall be two with a DFT of 35 microns each.
(iii) Coal tar enamel shall be applied. A single spiral inner wrap of glass fibre
tissues shall be applied overlapping at least 25 mm ensuring impregnation of
glass fibre tissues in the first coat. The second coat of enamel and second
outer wrap of glass fibre felt, Type – I to IS: 7193-1974 will be applied in the
same way confirming to Table – 10 of IS – 10221 – 1982.
The total thickness of the coating will not be less than 4.0 mm
(iv) Alternatively Wrapping with coal tar based anticorrosion tape conforming to
IS 15337: 2003 is also acceptable in lieu of s.no. (iii) above. Wrapping
thickness shall be 4.0 mm.
Page 194 of 680

6.6.2 Overground Piping
Internal surfaces
be 35 microns.
Note : All steel pipes carrying sea water shall be internally coated with
corrocoat/ polyurea coating having thickness 1500 DFT.
External surfaces
be 35 microns.
6.7 Internal Coatings
6.7.1 Tanks (Internal surfaces) as specified in relevant sections of specification
Industrial deionised, demineralised and potable water upto 600C pH range 4.5-9.5
Blasting according to Sa 2½ and ISO 8501-1:1988.
Prime Coat
Two layers of Zinc phosphate epoxy primer, total dry fim thickness >75µm.
Pretreatment
Dersuting of all mechanical damages, according to standard Sa3 to ISO 8501-

1:1988, touch up with 2 pack high build epoxy with volume solid content of more
than 85%, 75µm.
Intermediate Coat
2 pack high build epoxy, dry film thickness 80 µm.
Page 195 of 680

Finish Coat
2 pack silicon acrylic, dry film thickness of 150µm per coat.
In case of service or potable water tanks, the coating material selected shall not
taint the water. The paint system shall confirm to regulations issued by Food &
drug administration/ National Public Health service/ AWWA/ OSHA and comply
with applicable laws, regulations, ordinances etc. of the local authority, state or
the nation pertains to work.
QA/ QC Procedure including pinhole inspection, shall be submitted for approval

by Owner/ Owner’s representative.
6.6.2 Rubber Lining of Pipes, Valves and Tanks for DM Water
Pretreatment
Blasting according to Sa 2½ and ISO 8501-1:1988
Rubber Lining
Hard rubber 5 mm for DM water applications as IS – 4682
6.7 Painting for Electrical items
6.7.1 All the steel work shall be thoroughly cleaned of rust, scale, oil, grease, dirt and
swarf by pickling, emulsion cleaning etc. The sheet steel shall be phosphate/
oven dried and then painted with two coats of zinc rich primer paint. After
application of the primer, two coats of finishing epoxy 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.
6.7.2 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.
6.7.3 Painting of I & C equipment : Epoxy coating required for all I & C equipment.
6.8 SUGGESTED COLOUR CODES FOR PAINTING

SL. ITEM/SERVICE COLOUR IS-5 COLOUR IS-5
NO. (BAND)
1. Structures, platforms, Dark 632 - -
galleries, ladders and Admirality
handrails Grey
2. Boiler casing, ducting Nut Brown 413 - -
Page 196 of 680


NO. (BAND)
3. Crane
3.1 Crane structure Golden 356 Black -
Yellow
3.2 Trolley & hook Crimson 540 - -
4. Fans, pumps, motors, Light Grey 631 - -
compressors
5. Tanks (without insulation
and cladding)
5.1 Outdoor Aluminium - - -
5.2 Indoor Light grey 631 - -
6. Vessels & all other Light grey 631 - -

proprietary equipment
(without insulation &
cladding)
7. Switchgear Light grey - -
(Powder
coated)
8. Control & relay panels Light grey 631/70 - -
(Powder 78 of IS
coated) 1650
9. Turbines Light Grey 631 - -
10. Generators & Exciter Light Grey 631 - -
11. Transformers Aluminum - - -
12. Machinery guards Signal red 537 - -
13. Piping (without insulation
and cladding)
13.1 Water System
a Boiler feed Sea Green 217 - -
Page 197 of 680


NO. (BAND)
b Condenstae Sea Green 217 Light Brown 410
c DM Water Sea Green 217 Light Orange 557
d Soft Water Sea Green 217 French Blue 166
e Bearing Cooling Water Sea Green 217 French Blue 166
f Potable & filtered Water Sea Green 217 French Blue 166
g Service and clarified water Sea Green 217 French Blue 166
h Cooling water Sea Green 217 French Blue 166
I Sea Water Sea Green 217 White -
14. Ash Transmitting Vessels Aluminium - -
and pipe lines
15. Air System
15.1 Station air Sky blue 101 - -
15.2 Control air Sky blue 101 White -
16. Oil system
16.1 Fuel oil Light brown 410 French 166

16.2 Light oil (HSD) Light Brown 410 Brilliant 221
green
16.3 Lubricating oil Light brown 410 Light grey 631
16.4 Transformer oil Light brown 410 Light orange 557
17. Gas System

17.1 Carbon dioxide Canary 309 Light grey 631
yellow
17.2 Hydrogen Canary 309 Signal red 537
yellow
18. Fire services Fire red 536 - -
19. Effluent pipes Black - - -
20. Vacuum pipes Sky blue 101 Black -
Notes :
1. This colour code basically refers to IS:2379 for piping with necessary modifications
Page 198 of 680

2. Where band colour is specified, same shall be provided at 30 meter intervals on long
uninterrupted lines and also adjacent to valves and junctions.
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.
3. Bidder shall provide one final coat additionally of same DFT as specified in SECTION C1
- E (painting specification) of tender specification at site after completion of erection of each
equipment / item. Bidder to adhere the same.
Page 199 of 680


SECTION C1 – F
DATASHEET A
Page 200 of 680

DATASHEET –A
1.0 DESCRIPTION OF TURBO GENERATOR UNIT (TG) FOR WHICH CONDENSATE POLISHING IS TO BE
PROVIDED :
(i) No. of units Two (2)
(ii) Capacity of each unit 660 MW
(iii) Total flow in all the service vessels of each units 1548.8 Tons/hr (VWO, 1% Make Up condition) &1581.5
Tons/hr (for All HP heaters out condition)
2.0 CONDENSATE POLISHER SERVICE VESSELS PER UNIT :
(i) No. of condensate polisher Three (3X50%)
service vessel
(ii) Capacity of each 50% of total condensate flow per unit
condensate polisher
service vessel
(iii) Flow through each 790.75 Tones per hour
condensate polisher
service vessel per unit
(iv) Operating pressure of each 30 kg/cm2 (a)
condensate polisher
service vessel
(v) Design pressure of each 47 kg/cm2 (a)
condensate polisher
service vessel
(vi) Design code of each ASME Sec VIII div 1 Ed-2010/ IS 2825 as applicable
condensate polisher
service vessel
(vii) Working Temp. 55 0 C
(viii) Design temperature of
service vessel, its internals 65 0 C
and accessories
(ix) Type of vessels Vertical (Spherical)
(x) Material of construction
Shell Carbon steel plates to SA 516 Gr. 70
(xi) Inside protection Inside lined with Natural Rubber [4.5 mm thick in (3) layers]
(xii) Resin traps at the outlet of SS with SS 316 Internals

each condensate polisher
service vessel & rinse
outlet
2.2 AIR-BLOWERS FOR RESIN MIXING (SERVICE VESSELS AREA) PER UNIT
(i) Number per unit Two (2x100%)
(ii) Type Rotary, Centrifugal /Twin Lobe, oil free, positive displacement
(iii) Duty Intermittent
(iv) Capacity and head As required
(v) Noise level 80 dB (A) Max. at one meter
(vi) Pressure gauge One per blower
(vii) Location Indoor
(viii) Material of construction Casing – Cast Iron GR FG 260 to IS 210
Lobe – Cast Iron GR FG 260 to IS 210
Shaft – Carbon Steel to EN 8
(ix) Drive motor Energy Efficient-1 as per IS : 12615
3.0 EXTERNAL REGENERATION FACILITIES
3.1 REGENERATION VESSELS
a. RESIN SEPARATION AND CATION RESIN REGENERATION VESSEL
(i) Number One (1) no. vessel common for 2 x 660 MW Units
(ii) Design Temperature 600C
(iii) Minimum Design Pressure 10 Kg/cm2 (g)
(iv) Type Vertical (Cylindrical)
Page 201 of 680


(v) Material of construction
Shell SA 516 Gr. 60 or 70 / SA 282 Gr. C

Dished ends SA 516 Gr. 60 or 70 / SA 282 Gr. C
(vi) Inside protection Inside lined with Natural Rubber [4.5 mm thick in (3) layers]
(vii) Design code ASME Sec VIII div 1 Ed-2010/ IS 2825 as applicable
b. CATION RESIN
REGENERATION VESSEL

c. MIXED RESIN STORAGE
VESSEL

d. Resin traps at the common SS with SS 316 Internals
outlet header of regeneration
vessels
e. Accessories Operating platforms, ladders, supports, lifting lugs (4 nos. minimum),
handhold (1 no. of 150mm dia) & manhole (Minimum-2 nos. of 500mm
dia) etc. For each vessel shall be provided.
The vessels indicated against sr. no. a, b and c above is for reference only. Please note that number and
type of regeneration vessels shall be as per supplier recommendation only.
3.2 BULK ACID AND ALKALI STORAGE TANKS
(i) CHEMICAL TANKS ACID STORAGE TANKS ALKALI STORAGE TANKS
(ii) Number required Two (2) Two (2)
(iii) Design code -------------------As per BS-2594 or equivalent---------------------
(iv) Dimensions (diameter, length -------------------As per BS-2594 or equivalent---------------------
& thickness)
(v) Location ---------------------------------------Outdoor----------------------------------
(vi) Useful capacity (each) 30 m3 20 m3
(vii) Type and Pressure class --Horizontal cylindrical with dished (torishpherical) ends, atmospheric,
above ground--
(viii) Material of construction FRP ----------------Carbon steel (IS 2062
Gr A/B) with rubber lining inside ---
--------
(ix) Protection – Inside ------- 4.5 mm thk rubber lining (in three
layers 1.5 mm each)
(x) Protection – Outside ------- Chlorinated rubber paint DFT 500
microns.
Page 202 of 680


(xi) Concentration 30 -33 % HCl 48 % NaOH
(xii) Accessories Vent, overflow, Drain, fume absorber, CO2 absorber ,seal pot, sample
connection ,spare connection ,Manhole etc.
(xiii) Pipe & flanges M.O.C. CPVC Sch.40
(xiv) Valve M.O.C. CPVC PN 10

(xv) Manhole, staircase, operating Provided Provided
platforms
3.3 ACID AND ALKALI UNLOADING / TRANSFER PUMPS
(i) PUMPS ACID UNLOADING/TRANSFER ALKALI UNLOADING/TRANSFER
PUMPS PUMPS
(ii) Number required Two (2x100%) nos. (1W+1S) Two (2x100%) nos. (1W+1S)
(iii) Type -----------------------Horizontal Centrifugal--------------------------------
(iv) Location ------------------------------------Outdoor-----------------------------------
(v) Service ------------------------------------Intermittent-----------------------------------
(vi) Pressure gauge One per pump with teflon diaphragm seal
(vii) Capacity and head ------------------------------10 m3 / hr and 15 MWC (minimum)-------------------
-------
(viii) Liquid to be handled 30 -33 % HCL 45-48% NaOH
(ix) Material of construction
Casing Polypropylene Polypropylene
Impeller Polypropylene Polypropylene
Shaft BS-970 Hardened Steel EN8 BS-970 Hardened Steel EN8
Shaft Sleeves Ceramic Alloy 20
Types of shaft sealing Mechanical seal Mechanical seal
(x) Pump speed 1450 rpm 1450 rpm
(xi) Drive motor 415V, 3Ф, 50 HZ TEFC.
(xii) Accessories required Coupling guard, drain plug, vent valve ,suction hoses, isolation valves,
y- type strainers etc.
(xiii) Type of coupling between motor Flexible coupling
and pump
(xiv) Reinforced rubber house with One (1) No. of each application size 80NB, minimum 20 meter with
coupling and isolation valve isolation valve, Reinforced Chemical Resistant Rubber.
(xv) MOC for piping, valves & fittings For valve -CPVC PN10,
in acid/alkali handling For piping, flanges & fittings –CPVC Sch. 40
3.4 CHEMICAL HANDLING, PREPARATION & DOSING SYSTEM
a) ALKALI TRANSFER CUM RECIRCULATION PUMPS WITH MOTOR
(i) Nos. required Two (2x100%) (1 W+ 1 S)
(ii) Type Horizontal, centrifugal
(iii) Service Intermittent
(iv) Location Outdoor
(v) Pressure gauge One per pump with teflon diaphragm seal
(vi) Maximum Pump Speed 1500 rpm
(vii) Type of Coupling between pump As per manufacturer’s standard practice
& motor drive
(viii) Type of Sealing Mechanical Seal
(ix) Type of Suction Strainer Y- Type
(x) Concentration of working media. 5-48% Sodium Hydroxide (NaOH)
(xi) Capacity & head of each pump 10 m3/hr & Head as per system requirement
(xii) Suction condition Flooded
(xiii) Materials of construction
a. Casing, impeller Stainless Steel – 316
b. Shaft & shaft sleeve Stainless Steel -410
(xiv) Drive motor 415V, 3Ф, 50 HZ TEFC.

(xv) Accessories required Coupling guard, drain plug, vent valve , isolation valves, etc.
Page 203 of 680

(xvi) Type of coupling between motor Flexible coupling
and pump
(xvii) MOC for piping, valves & fittings For valve -CPVC PN10,
in acid/alkali handling For piping, flanges & fittings –CPVC Sch. 40
b) CHEMICAL TANKS ALKALI MEASURING ALKALI ACID MEASURING
TANK PREPARATION TANK
TANK
(i) Number required One (1) One (1) Two (2)
(ii) Type -Vertical Cylindrical Atmospheric with dished bottom and cover at top -
(iii) Liquid to be handled NaOH NaOH HCL
(iv) Location ------------ To be designed for outdoor duty -----------
(v) Useful capacity (each tank) Adequate to hold 2 m3 Adequate to hold
quantity of alkali quantity of acid
required (48% NaOH) required (30-33%
for single regeneration HCL) for single
of a condensate polisher regeneration of a
mixed bed with 20% condensate polisher
overall margin. mixed bed with 20%
overall margin.
(vi) Material (Shell, Dished end & IS 2062 Gr A/B IS 2062 Gr A/B FRP
top cover)
(vii) Internal protection --------Rubber lined & ---------Rubber lined & Not Applicable
minimum 4.5 mm thick minimum 4.5 mm thick
in three layers ------- in three layers--------
(viii) External painting ---------Chlorinated ---------Chlorinated Not Applicable
Rubber Paint --------- Rubber Paint ------
(ix) Level indicator Provided Provided Provided
(x) Level transmitter per tank One (1) One (1) One (1)
(xi) Stirrer per tank Slow speed stirrer Slow speed stirrer Not Applicable
driven by motor drive driven by motor drive
and reduction gear. and reduction gear.
Speed of stirrer = 200 Speed of stirrer = 200
RPM Max. RPM Max.
(xii) MOC of Agitator SS – 316 SS – 316 Not Applicable
(xiii) Drive motor of stirrer Energy Efficient – 1 as Energy Efficient – 1 as Not Applicable
per IS : 12615 per IS : 12615
(xiv) Dissolving Basket Provide (50-60 mesh Provide (50-60 mesh Not Applicable
B.S.) B.S.)
(xv) MOC of Basket SS – 316 SS – 316 Not Applicable
(xvi) Accessories Fume absorbers, carbon dioxide absorber, vent, overflow, drain
connection, overflow seal pot, sample connection, level transmitter,
operating platform, ladders, lifting lugs (4 Nos. minimum), hand hole etc.
c) DOSING PUMPS ACID DOSING PUMPS ALKALI DOSING PUMPS

(i) Number Two (2x100%) nos. (1 Two (2x100%) nos. (1 W+ 1 S
W+ 1 S)
(ii) Type --Simplex positive displacement hydraulically operated diaphragm type---
(iii) Whether suction strainer --------------- Yes -----------------------
required
(iv) Material of construction
Liquid End (Pump Head, Polypropylene SS-316
Valves, Valve housing, valve
spring etc.)
Diaphragm -------PTFE-----------
Packing -------PTFE-----------
Shaft ----- Hardened steel EN 8 (BS : 970)------
Page 204 of 680


Worm & worm wheel (if --------------Manganese Bronze -------------
applicable)
Connecting rod --------------Manganese Bronze -------------
Cross head guide --------------Bronze -------------
(v) Capacity & head Capable of meeting regeneration one cation /Anion unit (with 20%
margin); head as required (with 20% margin).
(vi) Accessories
Pressure/Pulsation Dampener One per pump One per pump
External safety relief valve (in Two (One per pump) Two (One per pump)
addition to inbuilt safety MOC -Polypropylene MOC- SS-316
valve)
MOC of safety relief valve Poly propylene SS-316
(vii) Pressure gauge ------------- One per pump with Teflon diaphragm seal --------------
(viii) Maximum pump stroke speed --------------------------------------- 100 --------------------------------
per minute
(ix) Accessories required for each Coupling guard, drain plug, vent valve, isolation valves, Y-type
pump strainers, pressure gauges, pulsation dampener etc.
(x) Drive motor of pump The drive motor of each pump will be Energy Efficient-1 as per IS :
12615
d) Density Meter Acid Alkali
Number One (1) at each mixing tee outlet One (1) at each mixing tee outlet
Type Density indicator (Hydrometer Density indicator (Hydrometer
type) type)
Indication Local Local
Location Diluted Acid line Diluted Alkali line
e) Flow Indicator
Number One in each DM water line One in each DM water line

Type Rotameter Rotameter
f) Flow Switch or Flow One in each water line, vane actuated type or DP bellows type /As
Transmitter per P&ID
3.5 ACTIVATED CARBON FILTER FOR ALKALI
(i) Number One (1)
(ii) Type Vertical cylindrical with dished end bottom
(iii) Design Pressure Design pressure shall be the maximum expected pressure to which the
vessel may be subjected plus 5% extra margin. Maximum expected
pressure for vessels placed in the discharge line of pumps shall be
based on the shut-off head of the pumps plus static head at pump
suction or 10 kg/cm2(g) whichever is maximum
(iv) Capacity 10 m3/hr or Not less than the design capacity of alkali transfer cum
recirculation pump
(v) Flow Velocity 12 m/hr (max)
(vi) Bed depth 1200mm activated carbon + 300mm Gravel support
(vii)
Pressure gauge As per P&ID.
(viii)
Number and Location Two No. (One each at inlet and outlet of filter)
(ix)
Seal Teflon diaphragm
(x) Material of construction
Shell Carbon steel plates to IS 2062 / SA 515 Gr. 60 or 70 / SA 516 Gr. 60 or
70.
Dish ends /Head Carbon steel plates to IS 2002 Gr. 2A / SA 515 Gr. 60 or 70 / SA 516 Gr.
Page 205 of 680


60 or 70.
(xi) Inside protection Inside lined with Natural Rubber [4.5 mm thick in (3) layers]
(xii) Design code ASME sec VIII div 1 ed.2010 / IS 2825 as applicable
(xiii)
Influent Distributor Material SS 316
(xiv)
Manhole Two (2) nos. minimum each of Davit type and 500 mm dia.
(xv)
Sight Windows One (1) no. in backwash space
(xvi)
Hand hole One (1) no. of 150 mm dia for removal of activated carbon
(xvii) Accessories Operating platforms, ladders, supports, lifting lugs (4 nos. minimum) etc.
3.6 ALKALI DILLUENT WATER HEATING TANK (HOT WATER TANK)
(i) Number One (1)
(ii) Type/Capacity Vertical Cylindrical with dished end with Electric heater / 120% of water
required for regeneration.
(iii) Electric heater Qty. 2 nos. Electric heater (2X50%)
(iv) Temperature of alkali to be To obtain temp. from 15OC of 50OC at alkali mixing feed out let within 5
heated hours.
(v) Design Pressure Design pressure shall be the maximum expected pressure to which the
vessel may be subjected plus 5% extra margin. Maximum expected pressure
for vessels placed in the discharge line of pumps shall be based on the shut-
off head of the pumps plus static head at pump suction or 10 kg/cm2 (g)
whichever is maximum
(vi) Material of construction
Shell & dished end SS-304 adequately insulated
(vii) Design code ASME sec VIII div 1 ed.2010 / IS 2825 as applicable
(viii) Temperature gauge, To be provided by the bidder (as per P&ID)
Temp. transmitters
(ix) Burn out protection To be provided by the bidder
(x) Accessories Manhole, vent, drain, sample connection, level transmitter, level gauges -
2 nos. (minimum),operating platform, ladders, lifting lugs (4 Nos.
minimum) etc.
3.7 CPU REGENERATION CUM RESIN TRANSFER PUMPS
(i) Number Two (2x100%) nos. (1W+1S)
(ii) Type Horizontal, centrifugal
(iii) Operation Intermittent
(iv) Liquid to be handled DM Water
(v) Capacity & head As required (with 20% margin)
(vi) Suction condition Flooded
(vii) Material of construction
 Casing & impeller SS 316/ ASTM A 351 CF 8M
 Shaft SS 410
 Wearing rings As per manufacturer’s Standard
 Shaft sleeve material SS 410
(viii) Packing seal Mechanical type
(ix) Mechanical Seal To be Provided by bidder
(x) Pump Speed Maximum 1500 rpm
(xi) Pressure gauge One for each pump with Teflon diaphragm seal
(xii) Pressure dampener One number per pump
(xiii) Recirculation line with Provided
motor actuated butterfly
valve
Page 206 of 680


(xiv) Accessories required for Coupling guard, drain plug, vent valve, isolation valves, Y-type strainers,
each pump pressure gauges, pulsation dampener
(xv) Drive motor The drive motor of each Pump will be Energy Efficient -1as per IS
12615.
3.8 AIR-BLOWERS FOR RESIN MIXING (REGENERATION AREA)
(i) Number Two (2x100%)
(ii) Type Centrifugal/Twin lobe type, oil free, positive displacement
(iii) Location Indoor
(iv) Duty Intermittent
(v) Capacity and head As required
(vi) Noise Level 80 dB (A) Max. at one meter
(vii) Pressure gauge One per blower
(viii) Material of construction Casing – Cast Iron GR FG 260 to IS 210
Lobe – Cast Iron GR FG 260 to IS 210
Shaft – Carbon Steel to EN 8
(ix) Drive motor The drive motor of each air blower will be Energy Efficient-1 as per IS
12615.
4.0 NEUTRALISING SYSTEM
4.1 NEUTRALIZATION PIT
(i) Number One (1) no. Pit with two (2) compartments ,common for 2 x 660 MW Units
(ii) Type Necessary air grid arrangement of polypropylene construction shall be
provided in each compartment for effective neutralization of the waste effluent
for air agitation & venturi mixing
(iii) Material of Construction RCC with acid / alkali proof lining bricks
(iv) No. of compartments Two compartments
(v) Capacity of each Adequate to hold 1.5 X quantity of waste effluent generated during single
compartment regeneration of Condensate Polisher Mixed Beds + 1.2 X DM plant waste
generation during RO-DM plant for one regeneration (170 M3)
4.2 NEUTRALIZATION PIT DISPOSAL PUMPS
(i) Number Two nos. (1 working + 1 Standby)
(ii) Type Horizontal, Centrifugal Single stage with priming system
(iii) Capacity & head One section of the neutralization pit in 2 hours (capacity not less than 80
m3/hr) & head as per system requirement.
(iv) Duty Intermittent
(v) Number of priming Two
chamber & tank
(vi) Suction condition Suction from priming chamber / submerged (suction from pit)
(vii) Pump Speed 1450 rpm
(viii) Drive motor Induction motor 415V, 3 phase 50Hz, TEFC
(ix) Suction condition Negative, with priming chamber
(x) Material of Construction
Casing 2.5% Ni Cast Iron IS210 Gr. FG
Impeller Stainless Steel CF 8M
Shaft SS-304/SS-316/SS-410
Shaft coupling SS-316
Shaft sleeve SS-316
4.3 CHEMICAL TANKS FOR ALKALI MEASURING TANK ACID MEASURING TANK
N PIT
(i) Number required One (1) One (1)
(ii) Type ----------------------------Vertical Cylindrical Atmospheric--------------------
Page 207 of 680


(iii) Useful capacity Suitable to meet the requirement for Suitable to meet the requirement for
neutralisation of excess acid/alkali neutralisation of excess acid/alkali
present in the regeneration waste present in the regeneration waste
effluent from CPU & RO- DM plant + effluent from CPU & RO- DM plant +
20% margin 20% margin
(iv) Material (Shell, Dished end IS 2062 Gr A/B FRP
& top cover)
Internal protection --------Rubber lined & minimum 4.5 Not Applicable
mm thick in three layers -------
External painting ---------Chlorinated Rubber Paint ------ Not Applicable
---
(v) Level indicator Provided Provided
(vi) Level transmitter per tank One (1) One (1)
(vii) Stirrer per tank Slow speed stirrer driven by motor Not Applicable
drive and reduction gear. Speed of
stirrer = 200 RPM Max.
(viii) MOC of Agitator SS – 316 Not Applicable
(ix) Drive motor of stirrer Energy Efficient – 1 as per IS : 12615 Not Applicable
(x) Dissolving Basket Provide (50-60 mesh B.S.) Not Applicable
(xi) MOC of Basket SS – 316 Not Applicable
(xii) Accessories Fume absorbers, carbon dioxide absorber, hand hole, vent, drain, sample
connection, level transmitter, operating platform, ladders, lifting lugs (4
Nos. minimum) etc.
5.0 PIPING & VALVES
(i) Resin Transfer piping ASTM A 312 Gr. TP 304 Sch 40 Minimum pipe Size : NB80
(full Port Ball Valves) Velocity : 2-3 m/s
(ii) DM water line ASTM A 312 Gr. TP 304 Sch 40
(iii) Piping-Service vessel Piping-ASTM A 106 Gr C
Inlet Ball Valves – SS-(CF8M )
BFV – ASTM A 216 Gr. WCB- Body
SS-(CF8M) - disc.
(iv) Piping-Service vessel Piping – ASTMA 106 Gr. C
Outlet BFV – SS-(CF8M) - Body & disc both.
Ball Valves – SS-(CF8M)
(v) Service vessel bypass Piping – ASTMA 106 Gr. C
piping (Butterfly Valves ) BFV – ASTM A 216 Gr. WCB – body
CF8M -Disc
(vi) Service vessel rinse CS to ASTM A 106 Gr. C
piping
(vii) Effluent Transfer Piping Piping, & Fittings shall be CPVC Sch. 40 only & valves shall be PN 10
rating.
(viii) Acid & Alkali All piping, Valves & Fittings in regeneration area shall be CPVC Sch. 40
Regeneration piping only & valves shall be PN 10 rating.
(Diaphragm Valves)
(ix) Acid / Alkali Transfer All piping, Valves & Fittings in regeneration area shall be CPVC Sch. 40
piping (Diaphragm only & valves shall be PN 10 rating.
Valves)
(x) Instrument Air piping IS 1239 (Heavy Grade) Galvanized.
(Full Port Ball Valves)
6.0 VALVES
Page 208 of 680


(i) BUTTERFLY VALVES Butterfly valves shall be of double flanged type of low leakage rate
confirming to AWWA-C-504 class 300 (min.) or EN593/ BS:5155 PN
10 (min.)
Condensate polishing plant outlet butterfly valves shall be of stainless
steel construction, SS-316 (for body, disc and shaft).
Condensate polishing plant inlet butterfly valves shall be of Carbon Steel
construction (Body & Disc-CF8M/SS-316 Respectively).
All the butterfly valves shall be provided with Hand wheel or lever as per
the requirements.
For larger sizes i.e. 150 NB and above. Valve provided with motorized or
pneumatic actuator shall be provided with a hand wheel for manual
operation.
All the valves shall be equipped with adjustable mechanical stop-limiting
devices to prevent over travel of the valve disc in the open and closed
positions. The valve operators (Hand wheel or Gear reduction unit or
Motor actuator etc.) shall be designed as per relevant International
Standard.
All the butterfly valves shall be provided with an indicator to show the
position of the disc. Flanges shall conform to ANSI B 16.5 CI.300 (min.)
used for Service vessel area.
Butterfly valves of the bypass line of service vessels shall be double
flanged type.
(ii) ECCENTRIC PLUG These valves shall be used for resin transfer line. These valves shall be
VALVE / BALL flanged type and of SS 316 construction.
VALVE
(iii) DIAPHRAGM VALVE The Diaphragm shall conform to following requirement for DM water
application :
i) Design standard: BS: 5156 or equivalent of required rating / class.
(Minimum rating of valves shall be PN 10).
ii) Type : Flanged and lined body ends, sealed bonnet, weir pattern, tight
shut off type
iii) Material of Construction
a)Body, Bonnet : Cast iron IS 210 Gr. FG 260 or equivalent or Cast steel
ASTM A-216 Gr. WCB
b) Body lining : Soft natural rubber(Neoprene), ebonite, Polypropylene
c) Hand wheel : Cast Iron
d) Compressor : Stainless Steel
e) Stem and Bush : Stainless Steel
For Acid and Alkali services the valve shall be CPVC PN10/Sch 40 only.
7.0 FLANGES
(iv) Feed water / Condensate ASTM 105
(v) DM water ASTM A105 rubber lined (for NB 65 mm to 150 mm)
ASTM A 182 F 304 (for NB 50 mm and below)
(vi) Instrument Air ASTM A 105 galvanized
*******************
Page 209 of 680


SECTION – C2
SPECIFIC TECHNICAL REQUIREMENTS FOR ELECTRICAL
Page 210 of 680

SPECIFICATION NO. PE-TS-412-155A-A001
TECHNICAL SPECIFICATION FOR VOLUME II B
SECTION-C
CONDENSATE POLISHING UNIT REV 01 DATE 29.04.2015
PAGE 1 OF 1
(ELECTRICAL PORTION)
SPECIFIC TECHNICAL REQUIREMENTS: ELECTRICAL
1.0 EQUIPMENT & SERVICES TO BE PROVIDED BY BIDDER/ PURCHASER
1.1 Scope for supply, and erection & commissioning of various equipment forming part of electrical system for this
package shall be as per Annexure–I to Section – C [Scope of Work (Electrical)].
1.2 Make of various equipment/ items in the scope of bidder shall be to approval of owner during detailed
engineering stage without any commercial implications.
1.3 Bidder shall furnish all AC as well as DC loads required for the system at different voltage levels (eg. 415V
AC, 240 V AC, 220 V DC etc.) of all types, such as motor feeders, supply feeders in PEM format along with
the offer.
1.4 All electrical equipment shall be suitable for the power supplies, fault levels and climatic conditions indicated
in project information enclosed with the specification.
1.5 All drawings, data sheets, Quality Plan, calculations, test reports, test certificates, etc. shall be submitted
during detailed engineering stage as per formats enclosed. The same shall be subject to approval without any
commercial implications.
1.6 Technical requirements shall be as per specifications listed in Clause 3.1, 3.2, 3.3, 3.4 & 3.5. In case of any
discrepancy between Customer specification and BHEL standard specification, Customer specification shall
prevail.
2.0 DOCUMENTS TO BE SUBMITTED ALONG WITH BID
2.1 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 AC System’ and sheet “Electrical Scope
between BHEL and Vendor” with bidder’s signature and company stamp.
b) List of Erection and Commissioning spares.
c) List of Erection & Maintenance tools & tackles.
d) Electrical load requirement in the load data format.
2.2 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
3.0 LIST OF ENCLOSURES
3.1 Electrical scope between BHEL & vendor (Annexure-I).

3.2 Technical specification – Customer specification - Motors
3.3 BHEL standard specification for LT motors : PE-SS-999-506-E101
3.4 Datasheets – A and C
3.5 Quality Plan for motors.
3.6 Load data format (Annexure-II).
3.7 Basic Technical Features for Motors (PE-DC-412-565-E003)
Page 211 of 680

THIS IS A PART OF TECHNICAL SPECIFICATION NO. PE-TS-412-155A-A001 REV-0, DATE: 12.06.2015
ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR (FOR EPC PROJECTS)
PACKAGE: CPU
SCOPE OF VENDOR: SUPPLY, ERECTION & COMMISSIONING OF VENDOR’S EQUIPMENT
PROJECT: 2X660 MW ENNORE STPP
S.NO DETAILS SCOPE SCOPE E&C REMARKS
SUPPLY
1 415V MCC BHEL BHEL 240 V AC (supply feeder)/415 V AC (3 PHASE 4 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. Any other
voltage level (AC/DC) required will be derived by the vendor.
2 Local Push Button Station (for motors) BHEL BHEL Located near the motor.
3 Power cables, control cables and screened control cables 1. For 3.b) & c): Sizes of cables required shall be informed by vendor at
for contract stage (based on inputs provided by BHEL) in the form of cable
a) both end equipment in BHEL’s scope BHEL BHEL listing. Finalisation of cable sizes shall be done by BHEL. Vendor shall
b) both end equipment in vendor’s scope BHEL Vendor provide lugs & glands accordingly.
c) one end equipment in vendor’s scope BHEL BHEL 2. Termination at BHEL equipment terminals by BHEL.
3. Termination at Vendor equipment terminals by Vendor.
4 Junction box for control & instrumentation cable Vendor Vendor Number of Junction Boxes shall be sufficient and positioned in the field to
minimize local cabling ( max 10-12 mtrs) and trunk cable.
5 Any special type of cable like compensating, co-axial, Vendor Vendor Refer C&I portion of specification for scope of fibre Optical cables if used
prefab, MICC, optical fibre etc. between PLC/ microprocessor & DCS.
6 Cable trays, accessories & cable trays supporting system BHEL BHEL Local cabling from nearby main route cable tray (BHEL scope) to
equipment terminal (vendor’s scope) shall be through 100/ 50 mm. cable
100/ 50 mm cable trays/ Conduits/ Galvanised steel cable Vendor Vendor trays/ conduits/ Galvanised steel cable troughs, as per approved layout
troughs for local cabling drawing during contract stage.
7 Cable glands ,lugs and bimetallic strip for equipment Vendor Vendor 1. Double compression Ni-Cr plated brass cable glands
supplied by Vendor 2. Solder less crimping type heavy duty tinned copper lugs for power and
control cables.
8 Conduit and conduit accessories for cabling between Vendor Vendor Conduits shall be medium duty, hot dip galvanised cold rolled mild steel
equipment supplied by vendor rigid conduit as per IS: 9537.
9 Lighting BHEL BHEL
10 Equipment grounding (including electronic earthing) & BHEL BHEL Refer note no. 4 for electronic earthing
Page 1 of 3
Page 212 of 680

PACKAGE: CPU
S.NO DETAILS SCOPE SCOPE E&C REMARKS
SUPPLY
lightning protection
11 Below grade grounding BHEL BHEL
12 LT Motors with base plate and foundation hardware Vendor Vendor Makes shall be subject to customer/ BHEL approval at contract stage.
13 Mandatory spares Vendor - Vendor to quote as per specification.
14 Recommended O & M spares Vendor - As specified elsewhere in specification
15 Any other equipment/ material/ service required for Vendor Vendor
completeness of system based on system offered by the
vendor (to ensure trouble free and efficient operation of
the system).
16 a) Input cable schedules (Control & Screened Control Vendor - Cable listing for Control and Instrumentation Cable and electronic earthing
Cables) cable in enclosed excel format shall be submitted by vendor during
b) Cable interconnection details for above Vendor - detailed engineering stage.
c) Cable block diagram Vendor -
17 Electrical Equipment & cable tray layout drawings Vendor - For ensuring cabling requirements are met, vendor shall furnish Electrical
equipment layout & cable tray 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. Cabling arrangement of the same (wherever
overhead cable trays, trenches, cable ducts, conduits etc.) shall be
decided during contract stage. Electrical equipment layout & cable tray
layout drawing shall be subjected to BHEL/ customer approval without any
commercial implications to BHEL.
18 Electrical Equipment GA drawing Vendor - For necessary interface review.
NOTES:
1. Make of all electrical equipment/ 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.
Page 2 of 3
Page 213 of 680

PACKAGE: CPU
3. In case the requirement of Junction Box arises on account of Power Cable size mis-match due to vendor engineering at later stage, vendor shall supply the Junction
Box for suitable termination.
4. Vendor shall indicate location of Electronic Earth pit in their Civil assignment drawing.
Page 3 of 3
Page 214 of 680

REV: 00 DATE:
STANDARD ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR (FOR EPC PROJECTS)
PACKAGE: ELECTRIC HOIST
HOISTFOR
FORWTP
CPU PACKAGES
PLANT
PROJECT ::2X660
4 X 270MW
MW ENNORE STPP
BHADRADRI TPS
SCOPE OF VENDOR: SUPPLY , ERECTION & COMMISSIONING OF VENDOR’S EQUIPMENT
S. NO DETAILS SCOPE SCOPE E&C REMARKS

SUPPLY
1 Isolating Switch Vendor Vendor BHEL will provide one number 415 V(3ph, 4W) supply
feeder only up to isolating switches for cranes. Any other
voltage level (AC/DC) required will be derived by the
vendor. Motor starter shall be part of crane control panel.
2 Power cables, control cables, screened control cables and any Vendor Vendor Cable from supply feeder to isolating switch shall be in
special cables (if required) between equipment supplied by vendor. BHEL scope.
3 Cabling material (cable trays, accessories, cable tray supporting Vendor Vendor
system, conduits etc).
4 Equipment Earthing Vendor Vendor All equipment metallic enclosures / frames, metal
structure etc. shall be grounded at two points each to the
nearest grounding points / risers provided by BHEL.
5 Motors Vendor Vendor
6 Cable glands and lugs for equipment supplied by vendor Vendor Vendor 1. Double compression Ni-Cr plated brass cable
glands
2. Solder less crimping type heavy duty tinned
copper lugs for power & control cables.
7 a) Input cable schedules (C & I) Vendor - Cable listing for Control and Instrumentation Cable in
b) Cable interconnection details for above Vendor - enclosed excel format shall be submitted by vendor
c) Cable block diagram Vendor - during detailed engineering stage.
8 Equipment layout drawings Vendor -
9 Electrical Equipment GA drawing Vendor - For necessary interface review.
Page 215 of 680

CHAPTER – 12
MOTORS
1.00.00 DESIGN CRITERIA
1.00.01 For the purpose of design of equipments /systems, an ambient temperature of 50 °C

and relative humidity of 85% shall be considered. The equipment shall operate in a
highly polluted environment.
1.00.02 Transient voltage dip on starting of the largest motor with DOL shall be limited to 20%
of the nominal system voltage at the voltage terminals.
1.00.03 Rating
The motor rating shall be arrived at considering 15% margin over the duty point
input or 10% over the maximum demand of the driven equipment, whichever is
higher, considering highest system frequency.
All motors shall be continuously rated (S1 duty). However, crane motors shall be
rated for S4 duty, 40% cyclic duration factor.
Whenever the basis for motor ratings are not specified in the corresponding
mechanical specification sub-sections, maximum continuous motor ratings shall be at
least 10% above the maximum load demand of the driven equipment under entire
operating range including voltage and frequency variations.
1.00.04 Starting Voltage requirement for all motors (except mill motors):
1. 85 % of rated voltage for motors up to 1000 kW
2. 80 % of rated voltage for above 1000 kW and up to 4000 kW
3. 75 % of rated voltage for above 4000 kW
For Mill Motors:
1. 85 % of rated voltage for motors above 1000 kW

1.00.05 Canopy shall be provided for outdoor motors.
1.01.00 Contractor shall provide fully compatible electrical system, equipments, accessories
and services.
Page 216 of 680

1.02.00 All the equipment, material and systems shall, in general, conform to the latest edition
of relevant National and international Codes & Standards, especially the Indian
Statutory Regulations.
1.03.00 Voltage and frequency variations:
Frequency: (+) 3% and (-) 5%

Voltage : i. AC
a. ± 6% for 11 kV/3.3 kV
b. ±10% for 415 V
Combined 10 % (absolute sum)
ii. DC- +10% to -15% for 220 V DC
1.04.00 All LV motors above 10 kW with S1 duty shall be compulsorily of Energy efficient
level IE 2 as per IS 12615: 2011.
1.05.00 The responsibility of coordination with electrical agencies and obtaining all necessary
clearances shall be of the contractor.
1.06.00 Type
AC Motors:
(a.) Squirrel cage induction motor suitable for direct-on-line starting.
(b.) Crane duty motors shall be slip ring type induction motor
DC Motors
(a.) Shunt wound.
1.07.00 Temperature Rise
Air cooled motors
70°C by resistance method
Water cooled
80° C over inlet cooling water temperature mentioned elsewhere, by resistance

method.
1.08.00 Degree of Protection
Degree of protection for various enclosures shall be as follows :
i) Indoor motors – IP 54
Page 217 of 680

ii) Outdoor motors – IP 55
iii) CW motors (in case of screen – IP 23

prot. Drip proof)
iv) Cable box – indoor area – IP 54
v) Cable box – outdoor area – IP 55
2.00.00 CODES AND STANDARDS
2.01.00 All motors shall confirm to the latest editions including all applicable amendment of
relevant IS, IEC and CBIP standards/Publications. In case any other standard is
followed that ensures equal or better quality, may be accepted. However the English
version of the Standard adopted shall be submitted.
2.02.00 Major Standards, which shall be followed, are listed below. Any other applicable
Indian standards for any component part even if not covered in the list shall also be
followed
1.) Three phase induction motors : IS:325, IEC:60034

2.) Single phase AC motors : IS:996, IEC:60034
3.) Crane duty motors : IS:3177, IEC:60034
4.) DC motors/generators : IS:4722
5.) Degree of protection by : IS: 4691
enclosures for rotating electrical IS: 4728
machines IS: 6362
IS: 2253
6.) Noise levels for rotating IS: 12065
electrical machines
Mechanical Vibrations for IS: 12075
rotating electrical machines
3.00.00 OPERATIONAL REQUIREMENTS
3.01.00 Starting Time
3.01.01 For motors with starting time up to 20 secs at minimum permissible voltage during
starting, the locked rotor withstand time under hot condition at highest voltage limit
shall be at least 2.5 secs more than starting time .
Page 218 of 680

3.01.02 For motors with starting time more than 20 secs and up to 45 secs at minimum
permissible voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 5 secs more than starting time.
3.01.03 For motors with starting time more than 45 secs at minimum permissible voltage
during starting, the locked rotor withstand time under hot condition at highest voltage
limit shall be more than starting time by at least 10% of the starting time.
3.01.04 Speed switches mounted on the motor shaft shall be provided in cases where above
requirements are not met.
3.01.05 Motors shall be capable of restarting under full load after a momentary loss of voltage
with the possibility of 150 % nominal voltage during fast bus transfer.
3.02.00 Torque Requirements
3.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall be
at least 10% motor full load torque.
3.02.02 Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall
be 275% for crane duty motors.
4.00.00 DESIGN AND CONSTRUCTIONAL FEATURES
4.00.01 Suitable single phase space heaters shall be provided on motors rated 30 kW and
above to maintain windings in dry condition when motor is standstill. Separate
terminal box for space heaters & RTDs shall be provided.
4.00.02 All motors shall be suitable for direct on line starting through any type of breaker.
L All motors shall be either totally enclosed fan cooled (TEFC) or totally enclosed
tube ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors
rated 3000KW or above can be Closed air circuit water cooled (CACW). CW motors
can be screen protected drip proof (SPDP) type. Motors located in hazardous areas
shall have flame proof enclosures conforming to IS: 2148 as detailed below
(a) Fuel oil area : Group - IIB
(b) Hydrogen generation plant Group - IIC

area :
4.00.03 Winding and Insulation
(a) Type : Non-hygroscopic, oil resistant, flame resistant
Page 219 of 680

(b) Starting duty : Two hot starts in succession, with motor initially
at normal running temperature
(c) 11 kV / 3.3 kV : Class F: with winding temperature rise limited to
AC motors class B. They shall withstand 1.2/50 micro sec
switching surges of 4U+5 KV (U=Line voltage in
KV). The coil inter-turn insulation shall be
suitable for 0.3/3 micro sec. surge of 32 KVp
and 12 kVp for 11 kV ad 3.3 kV system
respectively followed by 1 min power frequency
high voltage test of appropriate voltage on inter
turn insulation.
(d) 415V AC & : Class ‘F’ with temperature rise limited to class
220V DC ‘B’
motors
4.00.04 Motors rated above 1000 kW shall have insulated bearings to prevent flow of shaft
currents.
4.00.05 Motors with heat exchangers shall have dial type thermometer with adjustable alarm
contacts to indicate inlet and outlet primary air temperature.
4.00.06 Noise level and vibration shall be limited within the limits prescribed in IS: 12065 & IS:
12075 respectively. Motors shall withstand vibrations produced by driven equipment.
4.00.07 In MV/HV motors, 12 nos. simplex or 6 nos. duplex RTDs (two per phase), each
having D.C. resistance of 100 ohms at 0°C, embedded in the stator winding at
locations where highest temperatures may be expected, shall be provided. The
material of the ETD’s shall be platinum. Each bearing shall be provided with dial type
thermometer with adjustable alarm contact and resistance type temperature detector.
All HV motors shall be provided with shaft grounding rings for bearing protection and
earthing shaft current.
4.00.08 MV/HV motors shall also be capable of satisfactory operation at full load at a
supply voltage of 80% of the rated voltage and shall be capable of either two starts
in quick succession with third start after 5 minutes in cold condition or two starts at
15 minutes intervals in hot condition, both cases with voltage and frequency
variation within specified limits.
4.00.09 Locked rotor current of the MV motors shall be limited to 600% (subject to IS
tolerance) of the full load current of the motors and f o r H V motor shall be
limited to 450% (inclusive of IS tolerance) of full load current of the motor.
Page 220 of 680

Locked rotor current of the LV motor shall not exceed 600% of full load current
inclusive of IS tolerance.
4.00.10 MV Motors shall be provided with differential protection. These motors shall be
provided with star connected stator windings. The 3 nos. current transformers, one
for each phase shall be mounted in a separate compartment in the neutral
side terminal box. The three phases shall be connected to form the star point
after they pass through the CTs. These differential protection CTs shall be supplied
loose by 11/ 3.3 kV switchgear manufacturer.
4.00.11 Motor body shall be grounded at two earthing points on opposite sides with two
separate and distinct grounding pads complete with tapped holes, GI bolts and
washers.
4.00.12 HV motors can be offered with either elastimould termination or dust tight phase
separated double walled (metallic as well as insulated barrier) cable boxes. In case
elastimould terminations are offered, then protective cover and trifurcating sleeves
shall also be provided. Removable gland plates of thickness 3 mm (hot/cold rolled
sheet steel) or 4 mm (non magnetic material for single core cables) shall be provided
in case of cable boxes.
4.00.13 All motors shall be so designed that maximum inrush currents and locked rotor and
pullout torque developed by them at extreme voltage and frequency variations do not
endanger the motor and driven equipment.
4.00.14 The motors shall be suitable for bus transfer schemes provided on the 11 kV, 3.3
kV/415V systems without any injurious effect on its life.
4.00.15 All motors below 15 kW shall be provided with sealed ZZ bearings.
4.00.16 For motors rated 1000 KW & above, neutral current transformers of PS class shall be
provided on each phase in a separate neutral terminal box.
4.00.17 All motors shall be provided with an emergency stop push button near the motor as
per the Indian Statutory regulations.
4.00.18 The motor terminal box shall be suitable for withstanding the maximum system fault
current for a duration of at least 0.25 seconds.
4.00.19 Neutral in case of HV motors shall be kept accessible.
Page 221 of 680

4.00.20 Motors shall be designed to easy access for drilling holes through motor feed of
mounting flange for installation of dowel pins after assembly of the motor and driven
equipment.
4.00.21 Well spacious working platforms shall be provided around the motor area for carrying
out maintenance & testing works. Platform shall be minimum of 300 mm below the
level of motor base plate.
4.00.22 Flow switches shall be provided for monitoring oil flow of forced lubrication bearings,
if used. Alarm switch contact rating shall be minimum 0.5 A at 220 V DC and 10 A at
230 V AC.
4.00.23 For bearing temperature measurement, duplex RTDs shall be provided for each
bearing and shall be wired up to the terminal box..
4.00.24 Lube oil pressure transmitters shall be provided to DCS for remote monitoring. Lube
oil pressure very low trip to HV equipment shall be 2 out of 3 logic.
4.00.25 Capillary type temperature gauge cum switch shall be provided for DE / NDE of HV
Motors
4.00.26 Motors with CACA/CACW heat exchangers shall have dial type thermometer with
adjustable alarm contacts to indicate the following:
-Hot and cold air temperatures of the closed air circuit for CACA motors.
-Hot and cold, air and water temperatures for CACW motors.
The Alarm switch contact rating shall be minimum 0.5 A at 220 V DC and 10 A at 230
V AC.
4.00.27 Lifting Provisions
Motor weighing 25 kg or more shall be provided with eye bolt or other adequate
provision for shifting. Electrical hoists shall be provided for motors above 1000 kgs for
maintenance of the same.
4.00.28 DC MOTORS
DC motors shall be provided where specified/required. DC Motors shall be sized for

operation with fixed resistance starting for reliability. DC motors shall be shunt wound
type. Motors shall be capable of delivering the rated output at 220 V DC with (+) 10%
and (-) 15% variations without exceeding its guaranteed temperature limits. 220 V DC
Page 222 of 680

system shall be unearthed. Starting current of the DC motors shall be limited to 200%
of the full load current of the motor, and is subject to IS tolerance. DC Motors shall be
similar to AC Motors with respect to other features like enclosure type, cooling and
class of insulation
4.00.30 Painting
Motor including fan shall be painted with corrosion proof paints of colour shade
Siemens grey (RAL 7032).
4.00.31 Local Push Button Stations
The LPBS shall be installed near the motors to be controlled. Individual channel
supports shall be used for each LPBS. These shall be installed as per approved
erection detail drawing. LPBS for hazardous areas shall be CMRS certified and CCE
approved.
All LPBS shall have necessary canopies. Wiring of LPBS shall be checked before
giving control supply.
5.00.00 LIST OF TESTS TO BE CONDUCTED FOR HV, MV and LV MOTORS
5.01.00 TYPE TESTS
(a) No load saturation and loss curves up to approximately 115% of rated voltage
(b) Momentary overload test
(c) Temperature rise test at rated conditions. During heat run test, bearing temp.,
winding temp., core temp., coolant flow and its temperature shall also be
measured. In case the temperature rise test is carried at load other than rated
load, specific approval for the test method and procedure is required to be
obtained. Wherever ETD's are provided, the temperature shall be measured by
ETD's also for the record purpose.
(d) Surge withstand test on the sample coil after placing it in stator core at (4U + 5
KV) and with at least five impulse of 1.2/50 micro sec. wave, for HV motors only,
where U is the line to line voltage in kV.
(e) Surge-withstand test with 0.3/3 micro sec. wave on each type of 3.3/11 kV motor
coils with at least five such impulses, followed by one minute power frequency
high voltage test on turn to turn insulation, after cutting the coil and bringing out
Page 223 of 680

the turns suitably. The power frequency test voltage shall be decided during
detailed engineering.
f) Dimensions (for motors covered by IS 1231:1974 and IS 2223:1983 only)

g) Measurement of resistance of windings of stator and wound rotor.
h) Reduced voltage running up test at no load (for squirrel cage motors up to 37kw
only)
i) Full load test to determine efficiency, power factor and slip.
j) Insulation resistance test
k) Test for vibration severity of motor
l) Test for noise levels of motor
m) Test for degree of protection by enclosure
n) Temperature rise test at limiting values of voltage and frequency variations
o) Over speed test
5.02.00 ROUTINE TESTS
The following shall constitute the routine tests.

a) Insulation resistance test
b) Measurement of resistance of windings of stator and wound rotor.
c) No load test
d) Locked rotor readings of voltage, current and power input at a suitable reduced
voltage
e) Reduced voltage running up test ( for squirrel cage motor)
f) Open circuit voltage ratio of stator and rotor windings (for slip ring motors); rotor;
g) High voltage test
6.00.00 INSPECTION AND TESTING AT SITE
6.01.01 Insulation resistance of 415V motors shall be measured between the winding of the
machine and its frame by means of a 500/1000V megger. A minimum value of 1 mega
ohm for 415V motors shall be considered a safe value. In case of lower I.R. Value, the
insulation value shall be brought up by any of the following methods as desired by the
Site Engineer:
(a.) Blowing hot air in case of big motors.

(b.) Putting the motor in electric oven in case of smaller motors.
(c.) Placing heaters or lamps around and inside in case of small motors after making
suitable guarding and covering arrangements so as to conserve the heat.
Page 224 of 680

6.01.02 Site Test
(a.) Measurement of vibration.

(b.) Measurement of insulation resistance and polarization index.
(c.) Measurement of full load current.
(d.) Test running of the motors, checking the temperature rise and identifying the hot
spot etc.
6.01.03 3.3 kV motors shall be tested for insulation by 500/1000V megger and its value should
not be less than the safe minimum insulation of ≥ 20 MΩ resistance at 60 deg. C. In
case the insulation is low, the following method of drying has to be adopted:
a. By locking the motor so that it cannot rotate and then applying such a low
voltage to the stator terminals that full load current flows in the stator, keeping
the stator winding temperature below 90 deg. C. In this a close watch shall be
kept for any possible overheating and I.R. Values vs. temperature shall be
plotted and heating continued till I.R. Value becomes steady.
b. By blasting hot air from external source, Maximum temperature of winding

while drying should be 70 deg. C to 80 deg. C. (Thermometer) or 90 deg. C. to
95 deg. C. by resistance method. Heating should be done slowly till steady
temperature of winding is reached after 4 to 5 hours and for large machines after
10 hours. A record has to be kept for drying process, with half an hour
readings and, after steady temperature is reached, at an interval of 2 hours. In
case it is essential, the drying process can be supplemented by blower.
Page 225 of 680

RATING (KW / A) Nos. CABLE VERIFICATI KKS NO
CONT.(C)/ INTT.(I)
VOLTAGE CODE*
FEEDER CODE**
ON FROM
UNIT (U)/STN (S)
EMER. LOAD (Y)
STARTING TIME
BLOCK CABLE
MOTOR
CONT
MAX. BOARD REMA LOAD DATASHEE
>5 SEC (Y)

STANDBY
LOAD TITLE LOCATION ROL
RUNNING
T (Y/N)
DRG. No.
NAME CONT. NO. SIZE RKS No.
NOs CODE
PLATE DEMAND CODE
(MCR)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
ANNEXURE-II
NOTES: 1. COLUMN 1 TO 12 & 18 SHALL BE FILLED BY THE REQUISITIONER (ORIGINATING AGENCY); REMAINING COLUMNS ARE TO BE FILLED UP BY PEM (ELECTRICAL)/ CUSTOMER
2. ABBREVIATIONS : * 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 (cc): G=220 V, H=110 V, J=48 V, K=+24V, L=-24 V
: ** FEEDER CODE (8):- U=UNIDIRECTIONAL STARTER, B=BI-DIRECTIONAL STARTER, S=SUPPLY FEEDER, D=SUPPLY FEEDER (CONTACTER CONTROLLED)
JOB NO. 412 ORIGINATING AGENCY PEM (ELECTRICAL)
LOAD DATA PROJECT TITLE 2x660 MW ENNORE STPP NAME DATA FILLED UP ON
(ELECTRICAL) SYSTEM CPU SIGN. DATA ENTERED ON
DEPTT. / SECTION MAX SHEET 1 OF 1 REV. 00 DE’S SIGN. & DATE Page 226 of 680
CABLE SCHEDULE FORMAT
CABLE SCOPE TENTATIVE

(BHEL PEM/ CABLE
UNITCABLENO FROM TO PURPOSE VENDOR) REMARKS CABLESIZE PATHCABLENO LENGTH
Page 227 of 680


SECTION – C3
SPECIFIC TECHNICAL REQUIREMENTS FOR CONTROL AND
INSTRUMENTATION
Page 228 of 680

A.GENERAL
&
SPECIFIC
TECHNICAL
REQUIREMENT
FOR
PRE TREATMENT PLANT
Page 229 of 680

FORM NO. PEM-6666-0
SPECIFICATION NO.:
SPECIFICATION FOR VOLUME
CONTROL & INSTRUMENTATION FOR AUX SUB SECTION
PACKAGES
REV. NO. DATE :
SHEET 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 employer’s 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.
Page 230 of 680

2X660 MW ENNORE STPP
SPECIFIC TECHNICAL REQUIREMENTS (C&I)

Specific Technical Requirements (C&I):

The control of CPU shall be through PLC based control system having Redundant Hot
Stand by Processor. The operation and control philosophy of CPU has been
elaborated in separate section in the specification. The control & operation of CPU
service vessel area shall be done from 1 no. OWS (per unit). RPU (with Hot
Redundant Processor) shall be provided near service vessel area of each TG unit. For
control and operation of regeneration system, 2 No. of OWS (1 OWS & 1 OEWS) shall
be provided alongwith 1 No. A4 size B/W Laser jet in regeneration area. In addition
to the above, local control desk with coloured Mimic, Indicators, Ammeters, H.W.
Annunciator, P.B. and indication Lamps shall also be provided. Additional laptop shall
be provided with the CPU package.

1. The communication between PLC and Main plant DCS shall be OPC compliant
(Data Access 2.0) TCP/IP on Fibre Optic link. The communication link between
PLC and Main plant DCS shall be redundant. The necessary
hardware/software including LIU (Light Interface unit) at PLC end shall be in
Bidder’s scope. Repeaters if required for interfacing shall also be provided by
the bidder. For communication between main plant DCS and PLC, the PLC end
shall be considered as server and DCS shall be considered as client. For
details, please refer PLC Configuration Diagram.

2. PLC control system shall be time synchronized with the Master clock system
of the main plant to ensure uniform time indication throughout the Plant.
The required provision (IRIG‐B) shall be made by the bidder at the PLC end to
achieve the same.

3. Bidder to note that all type of hardwares & electronic modules like
controllers, I/O cards, communication modules and interface modules etc.
used in PLC shall be of same family and sourced/supplied from their
Principal’s works.

4. The software and hardware for offered PLC system shall be of latest version
and shall be upgradable. Bidder to ensure the availability of spares and
service support for the offered PLC system for minimum 15 years after
guarantee period.

5. All motorised valves of 200NB or more than 200NB size shall be provided
with integral motorized bypass valves on all process lines.

6. All electrical actuators shall be conventional type of integral starter.
Page 231 of 680



7. Components of instruments, control devices, accessories, piping etc. which
contact with steam, condensate or boiler feed water shall be manufactured
from copper free materials which do not react with media at operating
parameters.

8. Valve end position (Open & Close) shall be monitored for the manual critical
valves, wherever provided.

9. Interface of MCC, HT SWGR, Actuators etc. with PLC based control system
shall be as per Drive Control Philosophy attached in the specification. The
attached philosophy is for DCS based control system. However, the same is
applicable for PLC as well.

10. All the instruments/drives shall be terminated on JBs/Panels in field.
JBs/Panels shall be in Bidder's scope.

11. Scope of Instrumentation cables (Screened Control Cables), Fibre Optic cable
& Control cables shall be as per Electrical Cable scope matrix in Electrical
portion of specification.

12. UPS for PLC & OWS shall be in bidder’s scope with 2X100% configuration. UPS
shall have 2X100%, Ni‐Cd type battery bank with 60 min back up.

13. Bidder shall provide Customer training on the proper application and
maintenance on PLC Hardware & Software at Vendor’s work or at Ennore SEZ
site. Duration of the training, number of persons & the topics to be covered
shall be discussed & mutually agreed during contract finalization stage.

14. Following documents to be furnished by the bidder along with the bid:
 Proposed PLC system configuration drawing with write‐up
 Duly stamped and signed copy of Quality Plan.
 Product catalogues and specifications for PLC as well as HMI application.
 Requirement of electronic earthing, if any, for PLC based control system.

15. Complete Industrial grade furniture required for placing OWS, swivel chairs,
printers, keyboards, computers etc. shall also be furnished by bidder. The
exact details shall be finalized & approved by owner/purchaser during

16. Bidder to comply with codes and standards as mentioned in the specification.
Page 232 of 680



17. Bidder shall provide the necessary hardware & software required for
connecting the PLC system to Bidder's remote service centre, through which
the diagnostics & fault analysis of the PLC system can be carried out. The
method of connection shall be as per Bidder's standard practice. However, it
is preferred to have the connection through a single point in the PLC system.

18. Bidder shall provide an unlimited warranty on all equipment and software for
three years after the start of the warranty period, i.e. after satisfactory
completion of initial operations. This warranty shall include repair,
replacement or correction of identified software or hardware discrepancies
at no cost to OWNER.

19. PLC network shall have Intrusion Detection System (IDS) and Intrusion
Prevention System (IPS) activity and identify suspicious patterns that may
indicate a network or system attack from someone attempting to break into
or compromise a system on the Station LAN Network, the recommended
IDS/IPS should contain the following combined features. Any feature can be
selected depending on whether it is to be configured as IPS or IDS.

20. All local gauges, transmitters and switches shall be mounted on suitable
enclosures, racks subject to owner’s approval. All transmitters shall be HART
compatible.

21. Bidder to delegate /depute their persons/experts as per owner/consultants’
requirement.

22. Bidder must offer general tools and tackles and special calibration
instruments required during start‐up, trial run, operation and maintenance of
the system.

23. The above given scope is indicative & minimum. Any item/ equipment not
indicated above however required for the completeness of the system is to
be supplied by bidder without any technical, commercial and delivery
implication to BHEL.

24. Bidder shall provide Cable Schedule in BHEL excel format provided in
Electrical portion of the specification. Also, Cable Interconnections details for
Complete System shall be in Bidder’s scope.

Page 233 of 680


25. All the instruments/equipment/electrical items shall be provided & designed
with maximum star rating as available in line with energy conservation
policies notified by BEE, GOI at the time of supply.

26. Each communication Network shall be industrial grade and shall be provided
with industrial grade managed type Ethernet switches, external surge
protection system/devices and industrial firewall. Industrial grade managed
type Ethernet switches shall be provided with in built diagnostic features,
20% spare parts & in built redundant power supply.

27. All approval/Inspection are to be carried out by Owner or owner appointed
agency only.

28. Bidder shall offer latest system available at the time of supply / dispatch &
shall also confirm that DDCMIS/PLC system/microprocessor based control
system, MIS, ERP system etc. hardware / software shall be upgraded free of
cost (for hardware up to commissioning of the project and software up to
handing over of the project), whenever at later stage such up gradation takes
place for his system offered by him or by his collaborator.

29. The make/model of various instruments/items/systems shall be subject to
approval of owner/purchaser during detailed engineering stage. No
commercial implication in this regard shall be acceptable. In case of any
conflict and repetition of clauses in the specification, the more stringent
requirements among them are to be complied with.

30. Temperature transmitters shall be provided, wherever Temperature
measurement is required for monitoring purpose.
Page 234 of 680

DESEIN THIS IS A PART OF TECHNICAL SPECIFICATION NO. PE-TS-412-155A-A001
Volume- V: Instrumentation & Control Works

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Page 236 of 680
iii. In addition Hard wired signal interfacing shall also be provided for any signal required for interlock, control & protection. Similarly
cable for hard ware signal transfer between DDCMIS and PLC/relay based control system shall be supplied, laid terminated
by the bidder including preparation of cable schedule. Quantum of hard wired signals for linking each PLC based system and
DDCMIS shall be decided during detailed engineering,.
7. Bidder will provide necessary separate industrial grade parallel redundant UPS power supply with 60 minutes battery backup for each
PLC, Operating station & printer etc. Bidder shall provide necessary separate industrial grade parallel redundant 24 v olts DC charger
with 60 minutes battery backup for each PLC without Operating station . Bidder shall have to provide necessary cabling for redundant
power supply to UPS / charger.
8. Whenever control system is PLC based, annunciation system shall be driven by PLC via Digital output. Mimic LED shall also be driven
from PLC digital output. For other relay based control systems, solid-state annunciation system shall be provided. Mimic acrylic sheet
thickness shall be min 6-7 mm.
9. For each PLC system, without OEWS (Operating Engineering Work Station), Laptop along with software shall be provided for
engineering (Laptop shall be separate for each PLC with out OWES).
10. PLC system without OEWS (Operating & Engineering Work Station) shall have panel mounted push buttons, lamps, H.W. annunciation,
indicators, Ammeters and MIMIC etc for operation & control purpose except specifically requirements of control desk mentioned for any
package listed above.
11. All the PLC control system shall be of same make, model & same family and shall be supplied directly from manufacturer/vendors. PLC
system supplied /engineered by system houses shall not be acceptable. It is preferred to have same family of Plant DDCMIS .
12. All remote I/O cards shall be with IP-65 protection class and should withstand upto 70 deg.C temperature.
13. All ca bles t erminated i n t he t erminal bl ock, pow er di stribution sch eme i nstruments shall be f erruled. Fer ruling sh all be doubl e cr oss
ferruling (i.e.) source and destination addresses shall be marked on both sides of the tube ferruling.
14. Any Package not listed above shall be PLC (redundant hot standby controllers) controlled with one no. OWS, one no. OEWS (Operating
& Engineering Work Station) and one no. A4 B/W LJP.
Page 237 of 680

15. Bidder shall provide local panel for local start/ stop monitoring of auxiliaries and equipment as per requirement .The requirement shall
be decided during detailed engineering. All local panel shall be NEMA 4X with canopy.
16. Bidder sh all pr ovide am meters, v oltmeters, P B i ndicating l amp, m imic, electrical sch eme, i ndicators, chartless recorders and H W
annunciations on the desk/ panels as requirement and shall be decided in detailed engineering.
17. PLC supplier shall prepare graphic for the complete plant with proper tag nos. for drives, binary inputs, analogue inputs, status of drives
etc for the soft link for DDCMIS as per format of DDCMIS.
18. Each P LC/Microprocessor base d sy stem/electrical sy stem sh all be t ime sy nchronized with m aster cl ock system. Redundant T ime
synchronisation signals shall be provided for each control system, wherever redundant controllers/processors are provided.
19. Each subsystem PLC shall be provided with HW interfacing with main system PLC for signals used for command, interlocks, protections
and other importants process parameters.
20. Control, operation & monitoring of electrical distribution system, namely PCC, Bus coupler, Incomer, breakers etc. for respective plant
BOP package shall be controlled & operated from its respective PLC operating station/ backup control desk as well as from respective
switchgear unit. Control system for the same shall be implemented in the respective PLC envisaged in the local control room. Bidder
shall co nsider al l t ransducers for monitoring o f v oltage, cu rrent, K wh, p ower f actor at r espective P LC operating station and back up
control desk. All signals shall be hardwired only.
21. The technical particulars & requirements of PLC, OWS, Printers, LVS and all other related hardwares/softwares shall be as per Vol. V,
Chapter 4.
22. The technical particulars & requirements of UPS & 24 V DC systems shall be as per Vol. V, Chapter 7.
(Refer P LC S ystem C onfiguration D rawings, # 114 -01-0000, 0101, 0105, 0107, 0111, 0113, 011 4 & 0116, I n ca se any ambiguity bet ween
System Configuration Drawings & above Annexure A, Annexure A shall prevail for finalizing the PLC configuration).
Page 238 of 680

DESEIN THIS IS A PART OF TECHNICAL SPECIFICATION
Volume- NO. PE-TS-412-155A-A001
V: Instrumentation & Control Works
f) Remote and Local pressure at discharge header of HSD (LDO) pressuring

pumps
g) Remote and Local temperature of steam & HFO at inlet/outlet of each HFO heater
h) Remote and Local temperature in the connected fuel oil tanks
i) Remote and Local pump suction temperature (for HFO only).
j) Redundant radar type Level Transmitters for each fuel oil tank.
6.00.03 LAY OUT OF CONTROL ROOM
Separate battery room and UPS room shall be provided

The control room shall be Air conditioned
The control room shall be provided with pantry room , Locker room , Toilet etc.,
7.00.00 CONDENSATE POLISHING UNIT
The Condensate polishing unit is designed for fully automatic / manual operation
through the DPU of Plant DDCMIS or redundant PLC system housed in the respective panel.
This PLC shall have interface module for redundant and bi-directional OPC connectivity with
DDCMIS. Taking the equipment into service and regeneration of mixed-bed units shall be
initiated manually from the OWS of control system or local panel and balance operation
shall be carried out sequentially by the control system. Manual override facility is also
provided for all operations.
The PLC shall be preferably from plant DDCMIS family.
The PLC system shall be provided as detailed in chapter 4 of this specification..
Open and Close limit switch feed backs of valves are to be connected to PLC for remote
viewing and for interlocks and protection.
Remote and local indications of various parameters to the process requirement shall be
provided. ( The same can be decided during detailed engineering)
The OLCs and CLCS philosophy shall be as per the chapter 4 of this volume.
The instruments shall be offered as per the process requirement for complete auto
operation.
Necessary instruments pressure gauges, Temperature gauges, DP instruments, Pressure
transmitters, Radar Level transmitters, Differential pressure transmitters, Temperature
Elements Various analysers, Magnetic type level indicators, shall be provided. The
junction boxes and instruments / electronics housing used shall be Non – corrosive material.
Flow transmitters for each stream of CPU are to be provided for monitoring the performance
and accountability
The bidder shall furnish required list and type of instruments during detail
2 x 660 MW ENNORE SEZ Supercritical Thermal Power

Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14
Vol. V :588
Page 239 of 680
engineering subject to the approval of owner.
Annunciations for abnormal conditions shall be available in the Control Panel furnished by
the vendor during detail engineering subject to approval of owner.
Pneumatic actuators with all accessories shall be controlled using solenoid valves, which
shall be energized from OWS / Control Panel. The opening and closing of these valves is
based on system requirement, which is programmed in the Control system. Feed backs to
the control system regarding the valve open / close position are set through the limit
switches.
CPU shall be controller & operated from CCR & SWAS panel room in case of DDCMIS
operation and from LCR & SWAS panel room in case of PLC operation.
Regenerative system shall be controller & operated from SWAS panel room and from local
control panel with 17” LCD/TFT monitor panel mounted.
7.00.01 CONTROL AND OPERATION OF PLANT
i) GENERAL
The regeneration system shall be external. Under normal conditions, it will hold a
complete charge of freshly regenerated and mixed resin, ready for use, in its
storage tank. For regeneration, resin from the exhausted exchanger vessel will be
transferred hydraulically to this facility. The empty exchanger vessel will then be
filled up with the already regenerated resin
which was stored in the regeneration facility. This exchange vessel shall come
into service soon after perquisite condition is satisfied or as and when desired by
the operator. In the meantime, the exhausted resin shall be cleaned, separated,
regenerated, mixed and rinsed before being stored for next use.
ii) CONTROL AND OPERATION OF THE CONDENSATE POLISHING UNIT
a) The condensate polishing unit shall be controlled from the condensate polishing
unit OWS or Local control panel, located near the polishing vessels. This panel
shall be suitably interlocked with the regeneration system control panel.
1. It shall be possible to select each of the CPU vessels for any of

the following operations:
• Service
• Resin transfer from CPU vessel to regeneration plant
• Resin transfer from regeneration plant to CPU vessel
• Isolation from service
• Rinse recycle

Vol. V :589
Page 240 of 680
b) A mimic diagram shall be provided for the CPU scheme on the OWS and as well as
front of the CPU control panel. Status of various valves shall be indicated by LED’s
on the mimic diagram.
iii) CONDENSATE POLISHER CONTROL SYSTEM
Each condensate polishing system shall be provided Same family of plant

DDCMIS or programmable logic control based local panel that will clearly show
the status of each service vessel. From this panel it shall be possible to initiate
any of the following operating modes:
a) RINSE RECYCLE
The rinse recycle shall be a manually initiated in full automatic sequence. This
sequence shall include the rinse down step until the unit effluent quality is
acceptable for boiler feed water. The effluent quality shall be determined by
conductivity monitoring of the rinse water outlet. A panel mounted cation
conductivity indicator shall be interlocked to prevent advancing of the automatic
sequence until the rinse down is complete.
b) SERVICE MODE
Service flow rate for each polishing vessel shall be monitored by panel mounted
flow indicators. During periods of low condensate flow the operator may
select to remove one of the vessels from service by a manually initiated
automatic sequence. A differential pressure switch installed between the
influent and effluent headers shall on a high signal cause an annunciator alarm.
Panel mounted cation conductivity indicators shall be provided to monitor the

polishing system influent and effluent streams as well as the discharge of each
service vessel.
c) The sequence resin transfer from CPU vessel to regeneration plant and from
regeneration plant to CPU vessel shall be initiated from the condensate
polishing unit control panel but shall be controlled by the programmable logic
controller in the regeneration control panel.
iv) REGENERATION CONTROL SYSTEM
a) Manually initiated automatic sequences shall be provided for transferring resin

from a vessel to the remote common facility for physical cleaning and chemical
regeneration and for returning fresh resin to that vessel. Control for chemical
dosing system and alkali preparation facility shall also be provided in it.
b) Regeneration shall include hydraulic reclassification of the resins and the transfer
of the resins to the respective regeneration vessels. The separated resins shall
then be backwashed, cation and anion regenerated with hydrochloric acid and
sodium hydroxide solutions respectively, rinsed and then followed air scrubbing

Vol. V :590
Page 241 of 680
and a good backwash. The resin is then transferred back to the resin
separation vessel and the resins are air mixed. The mixed resins after
regeneration are given a final rinse with the discharge conductivity being
monitored. If the quality is satisfactory, the mixed resin shall be transferred to
the resin storage vessel otherwise regeneration sequence shall be repeated.
c) Demineralized water shall be used throughout the regeneration process for

backwashing, regenerant diluents, rinsing and resin transfer. A conical bottom
hopper having a water ejector will be used for resin make-up.
d) The complete control and operation of the regeneration plant shall be through
Plant DDCMIS or programmable logic controller (PLC).
e) It shall be possible to operate the regeneration plant in auto/semi-auto /manual

mode.
f) Following operations shall be possible from the regeneration control panel:

• Complete regeneration
• Resin transfer from CPU vessel to regeneration plant.
• Resin transfer from regeneration plant to CPU vessel.
g) In 'Auto' mode, once the sequence has been initiated, it shall proceed from step to
step automatically.
h) In 'Semi-auto' mode each step shall be performed only after initiation by the
operator.
i) In ‘Manual’ mode complete operation shall be by the operator by operation of the

control switches on the panel.
j) On Plant DDCMIS or PLC failure, it shall be possible to operate the valves by

means of manual operation of solenoid valves also.
k) It shall be possible to switch mode of operation from one to the other at any
moment and the operation shall proceed on the newly selected mode from that
time.
l) The system shall incorporate the necessary safety features. During automatic
sequential operation, if any pre-requisite criteria is not fulfilled or missing for a pre
determined time interval, the steps should not proceed further, and Alarm shall be
provided. Missing criteria, sequence which is under hold up etc. shall be displayed
on the panel.
m) A mimic diagram of the Regeneration system shall be provided on the front of the
local panel. The status of various drives and valves shall be indicated by LED on
the mimic diagram.
n) Wherever standby equipments are provided, it shall be possible to select each of

Vol. V :591
Page 242 of 680
the drive on ‘standby’ duty.
o) The detailed logic for the sequence and for each of the drive shall be subject
to the Owner’s approval during detail engineering
p) Start, progress and stop of each of the sequence shall be annunciated in all the
control panels.
q) At any time only one of the sequence shall be in progress.
v) INTERLOCKS
All interlocks for safe operation of the plant shall be provided. They shall
specifically include the following as minimum requirement:
a) Service vessels shall be taken back in service, only after they have been
pressurized.
b) Service vessels shall be taken up for resin transfer only after they have been
completely isolated from the condensate system and depressurized.
c) Resin shall be transferred to and from only one service vessel at a time.
d) Resin transfer between the service and the regeneration skids shall be
permitted only when the receiving vessel is initially empty.
e) It shall be possible for the operator to extend the timing of a particular step by
isolating the timer for the duration. The timer will restart once the operator puts
back the system on 'auto' and the other steps will then follow as programmed.
f) The regeneration sequence shall be prevented from advancing further in the event of
tripping of a running motor or other fault condition which do not permit the various
desired parameter of this step to be achieved. A manual override for this shall also
be provided.
g) The immersion heater in the hot water tank can be put on only when there is
adequate water level in the tank.
8.00.00 AIR CONDITIONING SYSTEM &VENTILATION SYSTEM
i) Air conditioning facilities shall be provided for areas of c e n t r a l control room,

control equipment room, shift- in-charge room, Engineer’s room, UPS room,
analyzer room etc. in the main plant building; ESP control room; service building;
all contr ol r oom s and other rooms in the scope of the bidder requiring provision
of air conditioning. The system shall consist of:
a) Central chilled water type air conditioning plant for main plant building and service
building (Including Instrumentation Lab, Electrical lab and Computer server room ,
telephone exchange room, etc., )

Vol. V :592
Page 243 of 680
Page 244 of 680

Page 245 of 680


ANNEXURE I
LIST OF MAKES
Page 246 of 680

TITLE SPECIFICATION NO.
PE‐TS‐412‐155A‐A001
SR.
ITEM SUPPLIERS PLACE REMARKS
NO.
GLOBAL STRUCTURES &

-
COMPOSITE LTD
JASMINO POLYMERTECH TALOJA
SYSCON ENGINEERS AMBERNATH
S.V. FABRICATORS NAVI MUMBAI
SPARK FABRICATORS /
-
STEELCON
ANUP ENGINEERING AHMEDABAD
MURTHAL TANKS & VESSELS SONEPAT
1. PRESSURE VESSELS
TITAN ENGG. DURGAPUR
RISHI INDUSTRIES BAHALGARH
UNIVERSAL HEAT
-
EXCHANGERS
ATS CHEM SALEM/HOSUR
CHEM PROCESS SYSTEM SANAND
PROGEN CHENNAI
CRYSTAL ENGINEERING HOSUR
ISHAN EQUIPMENTS VADODARA
GLOBAL STRUCTURES &
-
COMPOSITE LTD
SYSCON ENGINEERS AMBERNATH
S.V. FABRICATORS NAVI MUMBAI
SPARK FABRICATORS /
-
STEELCON
ANUP ENGINEERING AHMEDABAD
ATMOSPHERIC/ MURTHAL TANKS & VESSELS SONEPAT
2. TITAN ENGG. DURGAPUR
STORAGE TANKS
RISHI INDUSTRIES BAHALGARH
UNIVERSAL HEAT
-
EXCHANGERS
ATS CHEM SALEM/HOSUR
CHEM PROCESS SYSTEM SANAND
PROGEN CHENNAI
CRYSTAL ENGINEERING HOSUR
ISHAN EQUIPMENTS VADODARA
TEMSEC KOLKATA
RISHI INDUSTRIES SONEPAT
RUBBER LINING ( AT
3. CORI ENGINEERS CHENNAI
SHOP)
POLY RUBBER MUMBAI
INDUSTRIAL LINING VADODARA
Page 247 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
ARUL RUBBERS CHENNAI

WESTERN RUBBER NAVI MUMBAI
ELASTOMER LINNING AMBERNATH
EMKAY RUBBER MUMBAI
SWAN PNEUMATIC NOIDA
EVEREST TRANSMISSION NEW DELHI
AIR BLOWERS (TWIN NEW DELHI /
4. KAY INTERNATIONAL
LOBE TYPE) SONEPAT
EVEREST BLOWER BAHADURGARH
KULKARNI POWER TOOLS KOLHAPUR/ PUNE
VK PUMPS NASIK
MILTON ROY INDIA CHENNAI
5. METERING PUMPS SWELLORE AHMEDABAD
POSITIVE METERING PUMPS NASIK
METACHEM MUMBAI
REMI PEOCESS PLANT & M/C MUMBAI
MUMBAI /
FIBRE & FIBRE
6. AGITATOR SILVASA
CEECONS CHENNAI
STANDARD ENGINEERS MUMBAI
BEST AND CROMPTON ENGG CHENNAI
LTD.
BHARAT PUMPS & ALLAHABAD
COMPRESSORS LTD
FLOWMORE LTD. GURGAON
FLOWSERVE INDIA COIMBATORE
HORIZONTAL CONTROLS PVT. LTD.
7. JYOTI LTD. VADODARA
CENTRIFUGAL PUMPS
KIRLOSKAR BROTHERS LTD PUNE
WILO MATHER & PLATT PUNE
PUMPS PVT. LTD.
V-FLO PUMPS & SYSTEMS CO. BEIJING-CHINA
LTD.,
WPIL LIMITED KOLKATA
BHARAT PUMPS & ALLAHABAD
COMPRESSORS LTD
FLOWMORE LTD. GURGAON
FLOWSERVE INDIA COIMBATORE
VERTICAL CONTROLS PVT. LTD.
8.
CENTRIFUGAL PUMPS
JYOTI LTD. VADODARA
WILO MATHER & PLATT PUNE
PUMPS PVT. LTD.
SULZER PUMPS INDIA LTD. THANE
Page 248 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
WPIL LIMITED KOLKATA
HORIZONTAL KISHORE PUMPS PUNE

9. CENTRIFUGAL PUMPS
(RUBBER LINED) SU MOTORS MUMBAI
ENGINEERS COMBINE THANE
NON METALLIC
ANTICORROSIVE VALSAD
10. (PP/FRP) HORIZONTAL
CENTRIFUGAL PUMPS LEAK PROOF PUMPS PVT.
-
LTD. (RAJEDIA)
KBL PUNE
M&P PUNE
MISC. PUMP VERTICAL
11. WPIL GHAZIABAD
TURBINE TYPE
KISHORE PUMPS PUNE
FLOWMORE SAHIBABAD
AMARA RAJA POWER SYSTEMS TRIPUTI
LIMITED
CHHABI ELECTRICALS PVT.LTD. JALGAON
CHLORIDE POWER SYSTEMS & KOLKATA
SOLUTIONS LIMITED
DUBAS ENGG PVT LTD BANGALORE
BATTERY CHARGER
12.
FOR PLC HBL POWER SYSTEMS LTD HYDERABAD
JEMA ENERGY SPAIN FOR STATIC SCR TYPE
FULL WAVE FULLY
CONTROL TYPE
MASS-TECH CONTROLS PVT.LTD. MUMBAI
STATCON POWER CONTROLS NOIDA
LTD
AUSTRALIA/
13. UNDER BED NOZZLE JONSONS SCREEN
IRELAND
IWL LTD. CHENNAI
MP TAR PRODUCT BHILAI
COATING & WRAPPING
14. PORWAL INDUSTRIES RAIPUR
MATERIAL TAPE
RUSTECH KOLKATA
STP JAMSHEDPUR
ESCORTS FARIDABAD
15. HEATER
RACOLDS FARIDABAD
ROHM & HASS FRANCE / USA
16. RESIN LANXESS GERMANY
PUROLITE ROMANIA/CHINA
DeZURICK (Upto 400 NB) USA
HIGH PRESSURE
17. TYCO VALVES (UPTO 450 NB) USA
BUTTERFLY VALVE
BRAY CHINA
18. BALL VALVE (HIGH VELAN CANADA
Page 249 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
PRESSURE) SIZE 100 NB BRAY USA

A.V. VALVES LTD AGRA
ATAM VALVES PVT. LTD. JALANDHAR
FLUIDLINE VALVES COMPANY
GHAZIABAD
PVT.LTD.
CAST IRON
19. G.M. DALUI AND SONS PVT.LTD. HOWRAH
GATE/GLV/NRV/SRV
H.SARKER AND COMPANY HOWRAH
LEADER VALVES LTD. JALANDHAR
VENUS PUMPS AND ENGG.
KOLKATA
WORKS
AKAY INDUSTRIES PVT.LTD. DHARWAD
BELGAUM AQUA VALVES PVT. BELGAUN
LTD.
ASIAN INDUSTRIAL VALVES & CHENNAI
INSTRUMENTS.
ATAM VALVES PVT. LTD. JALANDHAR
DEMBLA VALVES LTD. THANE
M/S GM ENGINEERING RAJKOT
BALL VALVE ( MANUAL HAWA VALVES (INDIA) PVT. LTD. NAVI MUMBAI
20. /PNEUMATIC/ INTERVALVE (INDIA) LTD. PUNE
ELECTRIC) CLASS 150 LEADER VALVES LTD. JALANDHAR
MICROFINISH VALVES PVT LTD. HUBLI
NILON VALVES PRIVATE LIMITED AHMEDABAD
SURYA VALVES AND CHENNAI
INSTRUMENTS MFG CO.
UNIFLOW CHENNAI
VALTECH INDUSTRIES MUMBAI
VAAS AUTOMATION PVT. LTD. NEW DELHI
WEIR BDK VALVES- A UNIT OF NEW DELHI
WEIR INDIA PVT. LTD.
CROMPTON GREAVES AHMEDNAGAR
LAXMI HYDRAULICS PVT. LTD BANGALORE /
HUBLI*
RAJINDRA ELECT INDUSTRIES FARIDABAD* /
BANGALORE
21. ELECTRIC MOTOR GE-POWER
BHARAT BIJLEE MUMBAI
SIEMENS MUMBAI
NGEF BANGALORE
KIRLOSKAR ELECTRIC CO
LTD.
Page 250 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
ASEA BROWN BOVERI

MARATHON KOLKATA
ADVANCE VALVES PVT. LTD. NOIDA
FLUIDLINE VALVES COMPANY
GHAZIABAD
PVT.LTD.
INSTRUMENTATION LTD. PALAKKAD
INTERVALVE (INDIA) LTD. PUNE
R AND D MULTIPLES (METAL
MUMBAI
CAST) PVT LTD
SURYA VALVES AND
CHENNAI
INSTRUMENTS MFG CO.
22. BUTTER-FLY VALVE PENTAIR VALVES AND
CONTROLS INDIA PRIVATE NAVI MUMBAI
LIMITED
UPADHAYA VALVES
MANUFACTURERS PRIVATE KOLKATA
LIMITED,
VENUS PUMPS AND ENGG.
KOLKATA
WORKS
WEIR BDK VALVES- A UNIT OF
NEW DELHI
WEIR BDK HUBLI
DIAPHRAGM VALVE CRANE FLOW PROCESS SATARA
23. (MANUAL / PNEUMATIC) PROCON MUMBAI
CLASS 150 MAJESTIC VALVES ( LABLINE) -
HAWA ENGINEERS AHMEDABAD
ADVANCE VALVES PVT. LTD. NOIDA
FLUIDLINE VALVES COMPANY GHAZIABAD 1. DUAL PLATE CHECK
PVT.LTD. VALVE CI - CLASS 150 &
UP TO 600NB, 2. DUAL
PLATE CHECK VALVE CCS
- CLASS 150 & UP TO
DUAL PLATE CHECK 500NB
24.
VALVES R AND D MULTIPLES (METAL MUMBAI
CAST) PVT LTD
VENUS PUMPS AND ENGG. KOLKATA CI, CCS & STAINLESS
WORKS STEEL SPRING ASSISTED
DUAL PLATE CHECK
VALVES UPTO 700 NB
AND 150 CLASS RATING.
OTOKLIN GLOBAL BUSINESS
Y-TYPE STRAINER / MUMBAI
LIMITED
25. STRAINER (WATER GRAND PRIX NEW DELHI
SERVICE)
JAYPEE NEW DELHI
Page 251 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
GREAVES COTTON MUMBAI

MULTITEX FILTRATION NEW DELHI /
ENGINEERS LIMITED, NOIDA
FILTERATION ENGINEERS (I)
PVT. LTD MUMBAI
FLUIDNYE -
SUNGOV ENGINEERING PVT.
LTD. DELHI
GRAND PRIX FARIDABAD
JAYPEE INDUSTRIES PVT.
DELHI
LTD.
BHATIA ENGINEERING CO. DELHI
ASHVIK VALVES -
FLOW WAY VALVES -
RUBBER FLAP TYPE BDK -
26.
CHECK VALVES MAJESTIC VALVES (LABLINE
-
INST)
ADVANCE VALVES -
DOW
TORAY
27. MEMBRANES KOCH
HYDRONOTICS
NORIT
ROTEX -
28. SOLENOID VALVES
AVCON -
A.N. INSTRUMENTS PVT. LTD. KOLKATA
ASHCROFT INDIA PVT LTD. GUJARAT
BOSE PANDA INSTRUMENTS KOLKATA
PVT.LTD.
FORBES MARSHALL (HYD) LTD. HYDERABAD
PRESSURE GAUGE/
29. DIFFERENTIAL GAUGE BOURDON INDIA PVT. MUMBAI
PRESSURE GAUGE LTD.
H.GURU INDUSTRIES KOLKATA
H.GURU INSTRUMENTS (SOUTH BANGALORE
INDIA) P. LTD
BAUMER TECHNOLOGIES MUMBAI
INDIA PVT. LTD.
ARMSEL MHE PVT. LTD BANGALORE
CENTURY CRANE ENGINEERS
FARIDABAD
PVT. LTD.
30. CHAIN PULLEY BLOCK
HERCULES HOISTS LTD. RAIGAD
LIFTING EQUIPMENTS AND
DELHI
ACCESSORIES
Page 252 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
TUOBRO FURGUSON (INDIA)

KOLKATA UPTO 10 TONNE.
PVT LTD
TRACTEL TIRFOR INDIA PVT.
FARIDABAD
LTD.
TECHNO INDUSTRIES AHMEDABAD
ALPHA SERVICES BHIWADI
CONSOLIDATED HOISTS PVT PUNE UPTO 20 TONNES
LTD
CENTURY CRANE ENGINEERS FARIDABAD
PVT. LTD.
EDDY CRANES PVT. LTD. MUMBAI CAPACITY UPTO 10
TONS. BOIS BHEL
APP.SUB-VENDORS.
GRIP ENGINEERS PVT. LTD., FARIDABAD,
GLOBAL TECHNOLOGIES HYDERABAD
LIFTING EQUIPMENTS AND DELHI
ACCESSORIES
MANGLA HOISTS PVT LTD NEW DELHI
MEEKA MACHINERY PVT. LTD. AHMEDABAD
REVA INDUSTRIES LTD. FARIDABAD UPTO 25.0 T CAPACITY.
ROCKWELL HOISTO CRANES BAHADURGARH
PVT. LTD.
SAFEX ENERGY PVT. LTD. AHMEDABAD
TUOBRO FURGUSON (INDIA) KOLKATA UPTO 15 TONNES.
PVT LTD
ALPHA SERVICES BHIWADI
CONSOLIDATED HOISTS PVT PUNE UPTO 20 TONNES
LTD
CENTURY CRANE ENGINEERS FARIDABAD
PVT. LTD.
EDDY CRANES PVT. LTD. MUMBAI CAPACITY UPTO 10
31. ELECTRIC HOIST TONS. BOIS BHEL
APP.SUB-VENDORS.
GRIP ENGINEERS PVT. LTD., FARIDABAD,
GLOBAL TECHNOLOGIES HYDERABAD
LIFTING EQUIPMENTS AND DELHI
ACCESSORIES
MANGLA HOISTS PVT LTD NEW DELHI
Page 253 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
MEEKA MACHINERY PVT. LTD. AHMEDABAD

REVA INDUSTRIES LTD. FARIDABAD UPTO 25.0 T CAPACITY.
ROCKWELL HOISTO CRANES BAHADURGARH
PVT. LTD.
SAFEX ENERGY PVT. LTD. AHMEDABAD
TUOBRO FURGUSON (INDIA) KOLKATA UPTO 15 TONNES.
PVT LTD
SPX CORPORATION, USA AHMEDABAD
CONTROL COMPONENT INC. CALIFORNIA
DRESSER VALVE INDIA PVT. LTD COIMBATORE
DAUME REGELARMATUREN GERMANY
GMBH,
EMERSON PROCESS CHENNAI
MANAGEMENT CHENNAI
LIMITED
WEIR VALVES & CONTROLS UK U.K
LTD.
HOLTER REGELARMATUREN GERMANY
GMBH & CO.KG
32. CONTROL VALVE INSTRUMENTATION LTD. KERALA
KOSO INDIA PRIVATE LIMITED, NASHIK
LESLIE CONTROLS, INC USA
MIL CONTROLS LTD. KERALA
METSO SINGAPORE PTE. LTD., SINGAPORE
PARCOL S.P.A ITALY
R.K.CONTROL INSTRUMENTS THANE
PVT. LTD.
RINGO VALVULAS S.L, SPAIN
SHENJIANG VALVE CO. LTD. CHINA
VALVITALIA S.P.A. , ITALY
WALDEMAR PRUSS GERMANY
ARMATURENFABRIK GMBH
INDFOSS GHAZIABAD
SOR USA
DRESSOR USA
PRESSURE/DP/VACUUM DELTA CONTROL UK
33.
SWITCH TRAFAG RANIPET
GIC(GAUGES BOURDON) PANVEL
ASHCROFT INDIA PVT LTD. USA/GERMANY
SWITZER CHENNAI
34. TEMPERATURE GAUGE A.N. INSTRUMENTS PVT. LTD. KOLKATA
Page 254 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
ASHCROFT INDIA PVT LTD. GUJARAT

BUDENBERG GUAGE CO.LTD. UK
FORBES MARSHALL (HYD) LTD. HYDERABAD
GOA INSTRUMENTS INDUSTRIES GOA
PVT.LTD.
GOA THERMOSTATIC
INSTRUMENTS PVT.LTD.
GAUGE BOURDON INDIA PVT. MUMBAI
LTD.
H.GURU INDUSTRIES KOLKATA
H.GURU INSTRUMENTS (SOUTH BANGALORE
INDIA) P. LTD
BAUMER TECHNOLOGIES INDIA MUMBAI
PVT. LTD.
SBEM
CHEMTROL
LEVEL GAUGE (F&B, PUNE TECHTROL
35.
TUBULAR, REFLEX) SIGMA
V AUTOMAT
GENERAL INSTRUMENTS
EUREKA INDUSTRIAL PUNE
EQUIPMENTS PVT.LTD.
FLOW STAR ENGINEERING PVT. FARIDABAD
LTD.,
FLOWTECH INSTRUMENTS VADODARA
36. ROTAMETER
SERVICRS
INSTRUMENTATION ENGINEERS TELANGANA
PVT LTD
SCIENTIFIC DEVICES (BOMBAY) NAVI MUMBAI
PVT LTD,
BLISS ANAND PVT. LTD. GURGAON
SERVICRS
HI-TECH SYSTEMS & SERVICES KOLKATA- VENDOR SHALL SOURCE
LTD. IMPORT CONTENTS OF
LEVEL SWITCH
LEVEL SWITCH- (CONDUCTIVITY TYPE)
37.
CONDUCTIVITY TYPE FROM LEVELSTATE
SYSTEMS LTD., UNITED
KINGDOM.
LEVCON INSTRUMENTS PVT. KOLKATA
LTD.
RAMAN INSTRUMENTS PVT.LTD. MUMBAI VENDOR SHALL SOURCE
IMPORT CONTENTS OF
Page 255 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
LEVEL SWITCH
(CONDUCTIVITY TYPE)
FROM MOBREY
MEASUREMENT, AN
OPERATING UNIT OF
MORBEY LTD., SLOUGH,
BERKSHIRE, UNITED
KINGDOM.
SIGMA INSTRUMENTS CO. MUMBAI
SOR INC. USA
SAPCON INSTRUMENT PVT LTD. INDORE
V. AUTOMAT & INTRUMENTS (P)
NEW DELHI
LTD.
LEVCON
CHEMTROLS SAMIL ( INDIA)
PVT LTD.
LEVEL SWITCH ( ALL SWITZER
38.
TYPES) WAAREE (BAUMER
INSTRUMENTS)
V AUTOMAT
PUNE TECHTROL
ABB -
WAAREE (BAUMER
-
INSTRUMENTS)
MAGNETIC FLOW EUREKA -
39. -
METER EMERSON
YOKOGAWA -
HACH (POTENSE) -
KROHNE MARSHALL -
HYDROPNEUMATICS PVT. LTD. GOA
INSTRUMENTATION LTD. PALAKKAD
MICRO PRECISION PRODUCTS FARIDABAD
PVT. LTD.
FLOW ELEMENT -
40.
NOZZLE MINCO (INDIA) FLOW ELEMENTS GOA
PVT. LTD.
STAR-MECH CONTROLS (I) PUNE
PVT.LTD.
SEIKO FLOW CONTROL GMBH AUSTRIA
FLOW STAR ENGINEERING PVT. FARIDABAD
LTD.,
FLOW ELEMENT - HYDROPNEUMATICS PVT. LTD. GOA
41.
ORIFICE INSTRUMENTATION LTD. PALAKKAD
INSTRUMENTATION ENGINEERS HYDERABAD
PVT LTD
Page 256 of 680
PE‐TS‐412‐155A‐A001
SR.
NO.
MICRO PRECISION PRODUCTS FARIDABAD

PVT. LTD.
MINCO (INDIA) PRIVATE GOA
LIMITED
STAR-MECH CONTROLS (I) PUNE
PVT.LTD.
E&H -
KHRONE MARSHALL -
FLOW TRANSMITTERS EMERSON -
42.
(ALL TYPES) ABB -
HONEYWELL -
YOKOGAWA -
EMERSON -
E&H -
ABB -
LEVEL TRANSMITTERS HONEYWELL -
43.
(ALL TYPES) V AUTOMAT -
YOKOGAWA -
SIEMENS -
KROHNE MARSHALL -
EMERSON USA/PAWANE
LAXONS AUTOMATION DAMAN
PRESSURE YIL BANGALORE
44. TRANSMITTERS (ALL SIEMENS THANE
TYPES) FUJI CHINA
YOKOGAWA JAPAN
HONEYWELL USA/PUNE
EMERSON -
E&H -
ABB -
TEMPERATURE HONEYWELL -
45.
TRANSMITTERS V AUTOMAT -
YOKOGAWA -
SIEMENS -
FORBES MARSHALL -
EMERSON -
YOKOGAWA -
HONEYWELL -
46. PH TRANSMITTERS
ABB -
HACH -
FORBES MARSHALL -
47. ANALYSERS (ALL ABB -
Page 257 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
TYPES) EMERSON -
YOKOGAWA -
HONEYWELL -
HACH POLYMETRON -
SIEMENS -
FORBES MARSHALL -
GE INTELLIGENT PLATFORMS
BANGALORE
PRIVATE LIMITED
HONEYWELL AUTOMATION
PUNE
INDIA LIMITED ,
PROGRAMMABLE
48. ROCKWELL AUTOMATION INDIA
LOGIC CONTROLLER SAHIBABAD
LTD
SIEMENS LIMITED MUMBAI
SCHNEIDER ELECTRIC INDIA
NEW DELHI
PVT.LTD.
HITACHI-HIREL GANDHINAGAR
APC BANGALORE
DELTA GURGAON
49. UPS EMERSON MUMBAI
DB POWER PUNE
APLAB MUMBAI
AURA INCORPORATED NEW DELHI

ASTEC VALVES & FITTINGS PVT. MUMBAI
LTD.,
ARYA CRAFTS & ENGINEERING MUMBAI
PVT. LTD.
COMFIT & VALVE PVT. LTD. GUJARAT
FLUIDFIT ENGINEERS PVT. LTD. MUMBAI
FLUID CONTROLS PVT. LTD. MUMBAI
50. INSTRUMENT FITTINGS
HP VALVES & FITTINGS INDIA CHENNAI
PVT. LTD.
PRECISION ENGINEERING MUMBAI
INDUSTRIES
PANAM ENGINEERS, MUMBAI
PERFECT INSTRUMENTATION MUMBAI
CONTROL (INDIA) PVT. LTD.
VIKAS INDUSTRIAL PRODUCTS NOIDA
AJMERA INDUSTRIAL & MUMBAI
ENGINEERING WORKS
51. JUNCTION BOX FLEXPRO ELECTRICALS PVT. METAL TYPE JUNCTION
LTD. BOX ONLY
GUJARAT
Page 258 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
K.S.INSTRUMENTS PVT.LTD. BANGALORE

SUCHITRA INDUSTRIES BANGALORE
SHRENIK & COMPANY, AHMEDABAD
COMET -
52. CABLE GLAND DOWELL -
CHETNA -
ELECTRO BILLETS -
COMET -
53. CABLE LUGS
DOWELL -
CHETNA -
SAIL
ESSAR STEEL
TISCO
RINL
54. MS PLATES JINDAL
LLOYD
ISPAT
INDIAN IRON & STEEL CO.
LTD
INDIAN SEAMLESS METAL
AHMEDABAD UPTO 150 NB
CS PIPE (ASTM A 106 TUBES
55. MAHARASHTRA SEAMLESS RAIGAD UPTO 350 NB
GR. B)
SAIL ROURKELA
GHAZIBAD/HISSA
JINDAL
R
SURYA ROSHNI BAHADUR GARH
TATA TUBE JAMSHEDPUR
CHENNAI/VIZAG/K
PSL
UTCH/DAMAN
LALIT PROFILE THANE
SAMSHI PIPES INDUSTRIES VADODARA
MS PIPES (IS: 1239 & MUKUT PIPES RAJPURA
56.
3589)
INDUS TUBES G B NAGAR
MANN IND INDORE
SURENDRA ENGG RAJPURA
PRATIBHA PIPES &
THANE
STRUCTURE PVT LTD
JCO GAS PIPE CHINDWARA
NUKAT TANKS AND VESSELS TARAPUR
DADU PIPES SIKRANDRABAD
GOOD LUCK TUBES SIKANDRABAD
Page 259 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
ADVANCE STEEL TUBES SAHIBABAD

BIHAR TUBES SIKANDRABAD
HI TECH PIPES SIKANDRABAD
KUTCH/AHMEDAB
RATNAMANI
AD/CHHATRAL
MAHARASHTRA SEAMLESS RAIGAD
WELSPUN ANJAR/BHARUCH
APEX TUBES BEHROR (ALWAR)

RATNAMANI CHATTRAL
57. SS PIPES / TUBES
REMI TARAPUR
PRAKASH STEELAGE -
CORDS CABLE BHIWADI
RADIANT CABLES HYDERABAD
POLYCAB DAMAN
KEI BHIWADI
NICCO KOLKATA
RAVIN CABLES PUNE
INCAB PUNE
HVPL FARIDABAD
POWER/CONTROL/INST
58. TORRENT CABLE NADIAD
RUMENT CABLE
HAVELLS ALWAR
PARAMOUNT KHUSHKHERA
SRI RAM CABLES BHIWADI
THERMOCABLES HYDERABAD
TORRENT CABLE NADIAD
UNIVERSAL CABLES SATNA
GEMSCAB BHIWADI
DELTON FARIDABAD
UNICARE -
59. SAFETY SHOWER MOHAN INDUSTRIES -
SUPER SAFETY SERVICES -
GLOBAL COMPOSITE -
EPP -
DEEPA COMPOSITE -
60. FRP TANKS & FITTINGS COROSEAL INDUSTRIES -
CHEMICAL PROCESS & -
EQUIPMENT PVT LTD
J.R FIBRE INDUSTRIES PVT
-
LTD
Page 260 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
POLYPLAST -
EJECTOR ESSEM TECHNOLOGIES -
61.
RATNA PRASAD -
INDUSTRIAL SWITCHGEAR &
-
CONTROL
POSITRONICS -
LOCAL CONTROL DELTA CONTROL -
62. -
PANEL L&T
GE POWER -
PYROTECH -
C& S -
INDUSTRIAL SERVICE KOLKATA
SUNRISE BARODA
GANDHI & ASSOCIATES AHMEDABAD
63. TANK (FRP)
MODERN EQUIPMENTS CHENNAI
EAGLE PLAST PUNE
OMEGA PLAST MUMBAI
V K PUMPS NASIK
METACHEM MUMBAI
64. STROKE CONTROLLER
SWELORE AHMEDABAD
MILTON ROY INDIA CHENNAI
METACHEM MUMBAI
SAFETY VALVES/RELIEF KEYSTONE BARODA
65.
VALVES V K PUMPS NASIK
MILTON ROY CHENNAI
JAYPEE INDUSTRIES PVT. LTD. NEW DELHI
MULTITEX FILTRATION
ENGINEERS LIMITED, NEW DELHI
66. DUPLEX STRAINER OTOKLIN GLOBAL BUSINESS MUMBAI
LIMITED
SUNGOV ENGINEERING PVT. CHENNAI
LTD.
MICRO PRECISION FARIDABAD
67. ORIFICE PLATE INSTRUMENTAION LTD PALGHAT
CARLO DYNAMICS HYDERABAD
ATAM VALVES PVT. LTD. JALANDHAR (1) CARBON STEEL GATE
68.
STEEL GATE/GLOBE/NR VALVES & NON RETURN
VALVES VALVES: 15 NB TO 50 NB
(#800) & 65 NB TO 300
NB (#150) (2) CARBON
Page 261 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
STEEL GLOBE VALVES:

15 NB TO 50 NB (#800)
& 65 NB TO 200 NB
(#150)
FLUIDLINE VALVES COMPANY KAUSHAMBI
PVT.LTD.
M/S GM ENGINEERING RAJKOT
INTERVALVE (INDIA) LTD. PUNE A) STEEL GATE VALVES:
UPTO 50NB, #800 AND
65NB TO 150NB, #150
B) STEEL GLOBE
VALVES: UPTO 50NB,
#800 AND 65NB TO
100NB, #150
C)SUPPLIER NOT
REGISTERED FOR NR
VALVES
LEADER VALVES LTD. JALANDHAR
NITON VALVE INDUSTRIES PVT MUMBAI
LTD
NSSL LIMITED. NAGPUR
STEEL STRONG VALVES (I) NAVI MUMBAI LIMITED TO RANGES &
PVT.LTD., CLASSES AS AVAILABE
IN VD FILE.
VENUS PUMPS AND ENGG. KOLKATA CC/CSS-GATE-BBT-
WORKS UPTO600NB CL
UPTO300,GATE-PSBT
UPTO250NB CL
1500,GLV-BBT-
UPTO300NB CL
UPTO600,SCNRV-BBT-
UPTO600NB CL
UPTO150,SCNRV-BBT-
UPTO300NB CL
300,SCNRV-PSBT-
UPTO150NB CL UPTO900
VALTECH INDUSTRIES MUMBAI CAST CARBON & ALLOY
STEEL -
VALVE/RATING/SIZE-
GV/150/900,GV/300/400,
GV/600/300 ,
GV/GLV/NRV/900/250 ,
GLV/300/300,GLV/150/35
0/ , SCNRV/150/700,
SCNRV/300/350,
SCNRV/600/250.
Page 262 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
V.K. VALVES PVT. LTD., JALANDHAR

WEIR BDK VALVES- A UNIT OF NEW DELHI
H SARKAR KOLKATA
69. SLUICE GATE JASH ENGINEERING -
YASHWANT INDUSTRIES -
HI TECH AHMEDABAD
ADVANCE VALVES PVT.LTD NOIDA
BDK HUBLI
FOURESS ENGG.INDIA LTD. MUMBAI
FLUIDLINEVALVES COMPANY
MUMBAI
PRIVATE LTD.,
INSTRUMENTATION LTD. PALAKAD
KIRLOSKAR BROTHERS LTD. PUNE
70. 3 WAY VALVE VENUS PUMP & ENGG.
KOLKATA
WORKS
SURYA VALVES AND
INSTRUMENTS
CHENNAI
MANUFACTURING
COMPANY
STAFFORD CONTROLS
PUNE
LIMITED
MICON VALVES (INDIA)
MUMBAI
PVT.LTD
BDK HUBLI
HAWA ENGINEERS / MARCK &
-
CARE
71.
PLUG VALVE(MANUAL) MICON VALVES -
MICON VALVES (INDIA)
MUMBAI
PVT.LTD
M.S. FITTINGS KOLKATA
METAL LLOYDS MUMBAI
TRUE FORGE FARIDABAD
TUBE PRODUCTS BARODA
NL HAZRA KOLKATA
72. FITTINGS (CS/SS)
GUJRAT INFRA PIPES BARODA
EDWARDS USA
PIPEFIT ENGINEERS BARODA
SIDDARTH & GAUTAM FARIDABAD
EBY MUMBAI
PRADEEP METALS LTD MUMBAI
73. FLANGES (SS/CS) TUBE PRODUCT
BARODA
INCOROPORATION
Page 263 of 680
PE‐TS‐412‐155A‐A001
SR.
NO.
MS FITTINGS KOLKATA
HAWA ENGINEERING -
ALIANCE PIPE & PLANGES KOLKATA
JAI AMBE MUMBAI
GEROGE FISHCHER DELHI
PIPE & FILLTING ASTROL PLYTECHINC LTD AHMEDABAD
74.
(PP,HDPE,PVC & CPVC) JAIN IRRIGATION -
ORIPLAST -
GEROGE FISHCHER IPING
VALVES SYSTEMS DELHI
(GATE/GLOBE/NRV/BA PVT LTD
75. ASTROL PLYTECHINC LTD AHMEDABAD
LL)- (PP,HDPE,PVC &
CPVC) JAIN IRRIGATION -
ORIPLAST -
AIR FILTER SHAVO NORGEN -
76.
REGULATOR PLACKA INSTRUMENTS -
GLOBAL ABSORBENT KOLKATA
77. FILTER MEDIA
BHARAT MINERALS
AMCO SAFT INDIA LTD BANGALORE NI-CD BATTERIES ONLY
EXIDE INDUSTRIES LTD NEW DELHI LEAD ACID BATTERIES
ONLY.
DC LEAD ACID / NI-CD
78.
BATTERIES HBL POWER SYSTEMS LTD HYDERABAD NI/CD AND TUBULAR
TYPE FOR LEAD ACID
HOPPECKE BATTERIEN GMBH & GERMANY
CO.KG,
EXIDE INDUSTRIES LTD NEW DELHI
DC LEAD ACID HBL POWER SYSTEMS LTD HYDERABAD TUBULAR TYPE
79.
BATTERIES HOPPECKE BATTERIEN GMBH &
GERMANY
CO.KG,
AMCO SAFT INDIA LTD BANGALORE
HBL POWER SYSTEMS LTD HYDERABAD
80. DC NI CD BATTERIES
HOPPECKE BATTERIEN GMBH &
GERMANY
CO.KG,
B.K.EQUIPMENTS PVT.LTD. CHENNAI
BLISS ANAND PVT. LTD. GURGAON
SIGHT FLOW SERVICRS
81.
INDICATORS INSTRUMENTATION ENGINEERS TELANGANA
PVT LTD
SIGMA INSTRUMENTS CO. MUMBAI
SCIENTIFIC DEVICES (BOMBAY) NAVI MUMBAI
Page 264 of 680

PE‐TS‐412‐155A‐A001
SR.
NO.
PVT LTD,
TELACE EQUIPMENT PVT.LTD. CHENNAI
ASIAN PAINTS (I) LTD.
BERGER PAINTS INDIA LTD
GOODLASS NEROLAC
JENSON & NICHOLSON (I) LTD
CDC CARBOLINE (I) LTD.
82. PAINT SHALIMAR PAINTS LTD.
ADDISON PAINTS LTD
GRAND POLYCOAT
BOMBAY PAINTS
HEMPLE PAINTS (SINGAPORE)
JOTUN PAINTS
PROCON ENGINEERS -
TYCO -
CRANE PROCESS -
83. PNEUMATIC ACTUATOR
BDK -
INTERVALVE -
BRAY CONTROL -
ROTARK -
84. MOTORISED ACTUATOR AUMA -
LIMITORK -
NOTE:
1. The sub vendor list enclosed ANNEXURE-I is indicative only and is subject to approval / acceptance by
customer (TANGEDCO). 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
/TANGEDCO.
2. Any other sub-vendor not listed in above list shall be subject to BHEL / customer approval during
detailed engineering stage without any commercial and delivery implication to BHEL.
3. The inspection category will be intimated after award of contract by BHEL/customer. However the same
will be adhered by the bidder without any commercial and delivery implication to BHEL/ customer.
Page 265 of 680


ANNEXURE II
MANDATORY SPARE LIST
Page 266 of 680


MANDATORY SPARES LIST FOR CONDENSATE POLISHING UNIT
Sr. no. Description of Item Unit Quantity

MECHANICAL
1.0 SERVICE & REGENERATION VESSELS (FOR EACH TYPE & SIZE)
i) Diffuser, Distributors & Nozzle % 10
Perforated Laterals & Under Drain
ii) % 10
Collectors
iii) Gaskets Set 2
iv) Nut & Bolts Set 1
2.0 Valves % 20 % of each type & size
Pumps & Blowers along with Drive
3.0 1 no. each type & size
Motors
4.0 Ejector & Dosing Pump 1 no. each type & size
5.0 Resin Trap 1 no. each type & size
ELECTRICAL
6.0 415 V Motors
i) Nos. 10 Nos. each for small motors upto 30 KW
Terminal plates & 4 Nos. each for more than 30 KW
ii) Heaters Set 2 sets
iii) Greasing arrangements Set 4 sets each type of motor
iv) Motor of each type and rating % 10% of the installed quantity or minimum 1
number whichever be higher.
v) Bearings (DE and NDE) for each Set 4 sets
type and rating of motor
Note: Bidder to please refer the notes of section C1A of this technical specification regarding spares.
Page 267 of 680

MANDATORY SPARES LIST FOR CONDENSATE POLISHING UNIT
CONTROL & INSTRUMENTATION
2x660 MW ENNORE SEZ PROJECTOF TANGEDCO

MANDATORY SPARES
III. CONTROL & INSTRUMENTATION PACKAGES
TANGEDCO Total Ex-Works price *Remarks
Sl no Name of spares Unit Qty in INR

1.0.0 INSTRUMENTATION
(I) Each type of lamps, PBs, ILPBs, fuse, MCB, Nos. 20 % of Installed of PEM-For Fuel Oil Unloading System, included
MCCB used in the equipment/system. each type. under clause Fuel oil system of Mech. List of
mandatory spares
1.00.01 Measuring Instruments 87,87,625 PEM-For CAS included in clause Compressor Air
System of Mech. List of mandatory spares
AND
For Fuel Oil Unloading System, included under

clause Fuel oil system of Mech. List of mandatory
spares
AND
For Air Conditioning system, price included under
clause Air Conditioning system of Mech. List of
mandatory spares
1.00.01.01 Indicators, Recorders, Electrical Metering price included at s.no. 1.00.01 above
and Skid Mounted Instruments
(i) Indicators, recorders and meters offered Nos. 10 % of Installed of price included at s.no. 1.00.01 above
from each model for the project. These each type/Model or a
instruments shall be supplied with three minimum of one
sets of blank scales. number for each model
and type, whichever is
more
(ii) For skid mounted instruments Nos. 10%% of total number of price included at s.no. 1.00.01 above
instruments for each
Type and model or a
minimum of one
number for each model
and type, whichever is
more
1.00.01.02 Temperature Elements and Thermowells 12,60,000 TRY-LOT PRICE FOR THE APPLICABLE ITEMS
UNDER THIS SL NO 1.00.01.02
1. C&I Mandatory spares are indicated in above list. These spares shall be considered as per the applicable items in main
supply of CPU system package.
2.The spares shall be considered as unit wise except for any item/equipment supplied as common for both units. Page 1 of 19
Page 268 of 680


(i) Thermocouple/RTD elements Nos. 10% spare for each type 50,20,675 HYD-Price included forSl no 1.00.01.02 and
and length of element 1.00.01.03
furnished with For items applicable for Pulverisers-refer NOTE-1
thermocouple/RTD below
assemblies, or a minimum
of one number of each Items applicable for Pumps and BFPDT shall be
type & length, whichever is supplied
more.
more
(ii) Thermowells Nos. 10% for each type of 8,960
temperature sensors or a
minimum of one for each
type, whichever is more
1.00.01.03 Temperature,Transmitters and Electronic Nos. 10% of total number of 1,17,63,957 Meters are considered for ROTAMETERS
Transmitters (For Pressure, DP, Temp, Instruments/transducers AND
Flow, Level), Temperature, Pressure, Flow offered for each model
& Level Switch, safety switches, Gauges, and type for the project For CAS included in clause Compressor Air
meters, Transducer or any other or a minimum of one System of Mech. List of mandatory spares
instrument etc. number, whichever is AND
more.
For Mill Reject Sytem, included in clause Mill Reject
System of Mech. List of Mandatory Spares
AND

spares
AND
For Electrochlorination , price included under clause
HORIZONTAL CENTRIFUGAL PUMP FOR EACH
TYPE of Mech. List of mandatory spares
AND
mandatory spares
1.00.01.04 Flue Gas Analyzers & CEMS (Spareparts price included at s.no. 1.00.01 above
shall be furnished in accordance with
manufacturer's recommendations for five
years continuous operation or minimum
quantities indicated as below (whichever is
more)
supply of CPU package. Page 2 of 19
2.The spares shall be considered as unit wise except for any item/equipment supplied as common for both units.
Page 269 of 680

a) Electronic Module/Mother Board Nos. 10% of installed or at price included at s.no. 1.00.01 above
Least one number of
each type of module for
each analyser type.
b) Cooling and purging air blower unit Nos. One No. for each analyser price included at s.no. 1.00.01 above
type
c) Light source and detector unit for smoke Set One set for each analyser price included at s.no. 1.00.01 above
density analyser. type
d) Infrared source and detector unit for CO set One set for each analyser price included at s.no. 1.00.01 above
analyser type
e) Zirconia Cell, ceramic filters, heater & thermo Nos. Two Nos. of each type price included at s.no. 1.00.01 above
couple assembly for flue gas oxygen analyzer.
f) of chopper motor, two nos. protection Nos. Two No. of each type price included at s.no. 1.00.01 above
window, one no. of heater cartridge for CO price included at s.no. 1.00.01 above
analyser
g) Power supply module Nos. 1 no. of each type for price included at s.no. 1.00.01 above
each analyser type.
h) UV Lamp with adopter with SO2 Nos. 2 no. of each type. price included at s.no. 1.00.01 above
analyser
i) Light source and detector unit for SPM, and Nos. 1 no. of each type for price included at s.no. 1.00.01 above
NOX/SOX analyser. each analyser type.
j) Set of filters Nos. 1 No. of each type for price included at s.no. 1.00.01 above
each analyser type.
k) Analysers spares like transmitter lens and Nos. 1 No. of each type for price included at s.no. 1.00.01 above
receiver lens, protection windows for each type of flue gas
transmitter & receiver, intergral pressure and analyser.
temperature sensors, signal processing
unit, electronic modules
1.00.02 DDCMIS/PLC system, Master slave

clock system, Hart Management System, 9,00,03,130 HWR-Spares as applicable to TG C&I shall be
Vibration Monitoring system, CAAQMS, supplied meeting specification. However, if same
ERP/MIS/LAN/Simulator/ WAN, CCTV, spares are specified more than once, the same
Microprocessor based control system, and shall be supplied only once.
other Control System/Sub- TRY-LOT PRICE FOR THE APPLICABLE ITEMS
systems/electronic system listed in NIT. UNDER THIS SL NO 1.00.02
supply of CPU package.
Page 3 of 19
Page 270 of 680


1.00.02.01 I/O cards 4,07,63,100 For CAS included in clause Compressor Air
System of Mech. List of mandatory spares
AND

AND
mandatory spares
a. Analog Input module Nos. 10% of qty Installed of

each category/model or at
least 2 No. of each
type/model (Whichever is
more)
b. Analog output module Nos. 10% of qty Installed of
each category/ model or at
least 2 No. of each
more)
c. RTD/TC cards/modules Nos. 10% of qty Installed of
least 2 No. of each
more)
d Digital input module Nos. 10% of qty Installed of
least 2 No. of each
more)
e. Digital output module Nos. 10% of qty Installed of

least 2 No. of each
more)
1.00.02.02 All types of electronic modules, controllers, Nos. 10% of qty Installed of 28,91,980
function modules, cards, terminal boards, each category/model or at
relay boards, power supply cards etc for least 2 No. of each
above mentioned system and other Control type/model (Whichever is
System/Sub- systems and any other type of more)
PCB not covered above
Page 4 of 19
Page 271 of 680

1.00.02.03 Electronic Cards/modules Nos. 10% of number for each
type or minimum of 2
number for each type
whichever is high.
g
1.00.02.04 Auto/Manual stations, set-point/bias stations Nos. 10% of the number of
etc stations offered for the
project from each type
or a minimum of 2 number
from each model,
whichever is more.
1.00.02.05 Control logic power supply fuses, Nos. 20% spare for each 6,125
MCB,MCCB, at each current rating required type/Model
for the p
project.
proj
oject.
1.00.02.06 Electronic cards of each type used for each Nos. Ten (10) percent or 2
type of Servers supplied with any control no. (Whichever is more)
system
y
1.00.02.07 Electric to pneumatic
p converters off Nos. Ten ((10)) p percent of
each type utilized with automatic control each type or a minimum of
system using pneumatic drives one of each type,
whichever is more.
1.00.02.08 Plug-in type keyboard Nos.
5 10
nos.
yp
nos. of each
of each type/model
type/model.
12,250
1.00.02.09 Control OWS Nos.

OWS/OEWS with 24" LED monitor 1 Two
no. No. of each type
of each type/
with complete accessories
1,71,500
model
& monitors.
1.00.02.10 Utility/Engineering OWS Nos. Two No. of each type yp 1,72,725
with complete accessories
& monitors.
1.00.02.11 DVD/CD Nos. 10 boxes 1,838
1.00.02.12 g
Data highway y cable with adequate
q set. 200 mts. each 67,375
connectors of each type
1.00.02.13 Hard disc drive unit Nos. 2Five
nos. ofeach
nos of each yp type/model
type 17,675
1.00.02.14 Prefab cable connectors Nos. 10% or 5 nos (whichever 12,250
is more) of each type of
Installed
1.00.02.15 Cubicle power supply power supply Nos. Ten (10) percent or 5 32,200
modules nos (whichever is more) of
Installed of each type and
rating
g
1.00.02.16 Interposing/coupling relays. Nos. Ten (10) percent Installed 30,625
of each type and rating
Page 5 of 19
Page 272 of 680


1.00.02.17 Ethernet Switches, Routers & other Nos. 10% of qty Installed of 74,760
communication hardware each type or a
minimum of 2 numbers
from each model,
whichever is more.
1.00.02.18 Sensors with special cables, Power supply Nos. 10% of qty installed or Five 31,72,470
modules, Relay, Interface Module, and no. (Whichever is more)
electronic modules used for vibration of each type)
monitoringg system.
y
1.00.02.19 Printer toners for all printers Nos. 1 no.
Ten (10) percent of qty 52,570
installed or 3 no.
((whichever is more))
1.00.02.20 DMP printer head of the total quantity Nos. 2 nos. of 132 colums of 18,690
Not ypapplicable
each type
1.00.02.21 Drum for A3 sized scanner cum copies, printer Nos. 2for
nos.this package
of each type
1.00.02.22 24“ LED monitor, Nos. 3Not

nos. applicable for 56,070 For Electrochlorination , price included under clause
this package TYPE of Mech. List of mandatory spares
AND
mandatory spares
1.00.02.23 29” LED monitor Nos. 1 no

1.00.02.24 22” LED monitors. Nos. 5 nos
1.00.02.25 RJ 45 connector with box of each type Nos. Twenty (20) percent or 2 2,240 For CAS included in clause Compressor Air
no. (Whichever is more) System of Mech. List of mandatory spares
AND
AND
mandatory spares
1.00.02.26 Hooters, Buzzers, Cooling fans of each Nos. Ten (10) percent or 2 4,690
yp
type. no. ((Whichever is more))
1.00.02.27
1..00.02.27 Interface cables Set 2 sets of each type/model
y
1.00.02.28 Power supply
p modules (AC to DC Nos. 10% or Five no.
convertors) (Whichever is more) of
each type/model
1.00.02.29 DVD/CD drive unit of each type Nos
Nos. 5 nos. 17,675
2 nos.
Page 273 of 680

1.00.02.30 Mouse Nos. 20 nos. of each
5 nos. of
type/model.
each type/model 11,900
1.00.03 Steam and Water Analysis System (SWAS) 50,56,170 Lot price has been given for items under Sl no.
10.00.03
1.00.03.01 High pressure reducing elements for Nos. 10% spare of qty installed.
sample flow.
1.00.03.02 Ion exchange columns with resin as utilized Nos. Four No
with cation conductivity analysers
1.00.03.03 Conductivity cells as utilised with conductivity Nos. Two nos of each type
monitors
1.00.03.04 pH flow-through type cells used with pH Nos. Two nos. of each type
monitors
1.00.03.05 Chemical reagents for all analysers Set 12 months continuous
operation of all analysers
from date of taking over.
1.00.03.06 Chemical reagents for colorimetric silica Set 12 months continuous
analyzers operation of all analysers
from date of taking over.
1.00.03.07 Electronic Modules Nos. One (1) no. for each
type of Analyser.
1.00.03.08 Pressure gauge, solenoid valves, temperature Nos. Two (2) no. of each type
gauge, Back Pressure regulating valves, 3
way grab valves, needle valves, isolation
valves, PRV, flow switch, flow indicator and
temperature switch, erection hardware’s,
valves in SWAS.
1.00.03.09 Primary coolers/secondary coolers. Nos. Three (3) No of each
type
1.00.04 Relay based Control Panels 17,150 PEM-For Air Conditioning system, price included
under clause Air Conditioning system of Mech. List
of mandatory spares
1.00.04.01 LEDs for indicating lights Nos. 10% of qty installed. EDN-Lot Price has been given
1.00.04.02 Control circuit fuses/MCB/MCCB/ Nos. 300% of installed of each

Semiconductor Fuses type, current rating.
1.00.04.03 Relays modules & contactors. Nos. 20% spare of qty Installed
of each type & rating.
Page 7 of 19
Page 274 of 680


1.00.05 Alarm Annunciation System 22,295
PEM-For Electrochlorination , price included under
clause HORIZONTAL CENTRIFUGAL PUMP FOR
EACH TYPE of Mech. List of mandatory spares
AND
mandatory spares
EDN-Lot Price has been given
1.00.05.01 logic modules, group card modules, power Nos. 20% spares of each type
supply modules, Hooters and any other installed
electronic module.
1.00.05.02 un-engraved window boxes complete with Nos. 5% spares of each size
LED etc. installed
1.00.05.03 LEDs for annunciation facia windows and Nos. 20% of qty installed
LEDs box assemblies offered for the proj
project
o ect
1.00.05.04 Annunciator hooter Nos. One (1) No. of each
type
1.00.06 Un-interrupted Power Supply System and 5,36,620
DC Control Power Supply System
1.00.06.01 As per Manufacturer’s

Recommendation for Three Years
Continuous Operation or minimum quantities
indicated as below ((whichever is more)
1.00.06.02 Fuses/Semiconductor Fuses Nos. 300% of installed of each
type, current rating with
each ppanel /board
1.00.06.03 Miscellaneous parts for the power supplies Nos. Minimum of 10% or atleast
such as SCRS, transistors, resistors, diodes, two (which ever is more) of
light bulbs, static switches , blocking diodes each type
etc
1.00.06.04 Battery cells complete with contactor,cover Nos. 10% of qty installed
plates etc
p
1.00.06.05 Electronic Modules like Rectifier Set 1 Set of each type &
control card, inverter control card, Driver card, rating
IGBT Module, DC-DC converter card or any
other card as listed in approved BOM for UPS,
AC supply & 24 V DC supply etc.
2.The spares shall be considered as unit wise except for any item/equipment supplied as common for both units. Page 8 of 19
Page 275 of 680


1.00.06.06
1.00 Miniature Circuit breakers for AC and DC Nos. 20 % of installed or 10 Nos
supply. of each type (which ever is
more) for ACDB and
DCDB.
1.00.06.07 Digital/analog panel meters/indicators Nos. 5% or 2 no. of each type
((whichever is more))
1.00.06.08 CT's, CVT's VT's chokes, AC/DC isolators, Nos. 10% or 2 nos. of each type
contactors, timers, relays. and rating, (whichever is
more))
1.00.06.09 Cooling Fans in UPS & 24 V DC charger Nos. 10% or 2 nos. of each type
panels and rating, (whichever is
more))
1.00.06.10 following accessory equipment for the battery Set Two sets
shall be furnished :
a)) Cell lifting
g facilities
b)) Assemblyy wrenches
c) Vent plug hydrometer d) Vent plug
thermometer
e)) Supply
pp y of corrosion-preventive grease.
f)) 10% spare
p cells.
1.00.06.11 Electronic modules of each type & rating Set One set of with each set
for UPS and DC control power supply system. consisting of at least
one number of each
type of electronic module
for inverters, chargers,
static switch, stabiliser etc.
as per approved BOM.
1.00.06.12 MCCB for UPS & 24 V DC charger panels, Nos. 20 % of installed or 5

ACDB, DCDB. Nos of each type (which
ever is more)
1.00.07 Erection hardware 9,50,250 TRY-LOT PRICE FOR THE APPLICABLE ITEMS
UNDER THIS SL NO 1.00.07
PEM-For Air Conditioning system, price included
under clause Air Conditioning system of Mech. List
of mandatory spares
EDN-Lot price has been given for items Sl no
1.00.07
1.00.07.01 Instrument valves Nos. Ten (10) percent of each
type & Size installed
Page 9 of 19
Page 276 of 680


1.00.07.02 Condensate pots of each type & Size installed Nos. Ten (10) percent of total
number of Installed or
four numbers whichever is
g
higher .
1.00.07.03 Manifold Nos. Ten (10) percent of each
type
yp & Size installed
1.00.07.04 Fittings Nos. Ten (10) percent of each
type & Size installed
1.00.08 LVS 8,58,305 EDN-Lot price has been given for items Sl no
1.00.08
1.00.08.01 LEDs Nos. 20% ( Installed) spares of
each type & size.
1.00.08.02 LVS Filters Nos. 50% spare or min 6 nos.
1.00.08.03 Electronic cards of each type for LVS Nos. 3 nos. or 20% whichever is
more
1.00.08.04 Interfacing cables Set Two Set of each type &
size.
1.00.08.05 Power supply modules of each type for LVS Nos. 3 nos. or 20% whichever is
more
1.00.08.06 Cooling modules of each type for LVS Nos. 3 nos. or 20% whichever is
more
1.00.08.07 LVS Controller of each type for LVS Nos. 2 nos.
1.00.09 Master Slave Clock system 1,45,950 EDN-Lot price has been given for items Sl no
1.00.09
(i) As per Manufacturer’s Recommendation for Set
Three Years Continuous Operation or
minimum quantities indicated as
below (whichever is more)
(ii) Electronic cards Nos. One No. of each type &
model
(iii) Signal Conditioner cards Nos. One No. of each type &
model
(iv) Slave clocks of each type used for Master Nos. Two No. of each type &
slave clock system model
(v) Cubicle power supply power supply Nos. Ten (10) percent or 2
modules nos (whichever is more) of
Installed of each type and
rating
1.00.10 Plant Security and survillance system 5,10,020 EDN-Lot price has been given for items Sl no
1.00.10
Page 10 of 19
Page 277 of 680


1.00.10.01 As per Manufacturer’s
Recommendation for Three Years Continuous
Operation or minimum quantities indicated as
1.00.10.02 Electronic cards Nos. One No. of each type
1.00.10.03 PTZ controller Nos. One No. of each type
1.00.10.04 Electronic modules used for server system Nos. 10% or Two No. of each
type (whichever is more)
1.00.10.05 Special cables & connector Set (5 sets) of each type
1.00.10.06 Cartridges for air filter Nos. Two No. of each type
1.00.10.07 Relay Nos. 5 nos. of each type
1.00.10.08 Power supply modules of each type Nos. 5 nos. of each type
1.00.10.09 Camera of each type used for Plant Security Nos. Two no. of each type
and surveilance system.
1.00.10.10 Automatic door sensors Nos. 10% or 2 nos. min
whichever is more
1.00.10.11 Card reader. Nos. 10% or 2 nos. min
whichever is more
1.00.11 AAQMS 27,12,500 Lot price for applicable items
1.00.11.01 As per Manufacturer’s Recommendation for
Three Years Continuous Operation or
minimum quantities indicated as
1.00.11.02 Electronic cards/Module/Mother Board /Signal Nos. One no. of each type
Processing Unit for each type of Analyzer
1.00.11.03 Power supply module Nos. One no. of each type for
each analyser
1.00.11.04 UV Lamp with adopter with SO2 Nos. One no. of each type
analyser.
1.00.11.05 Light source and detector unit for SPM, and Nos. One no. of each type for
NOX/SOX analyser. each analyser
1.00.11.06 Pump for SPM Analyser Nos. One no. of each type
1.00.11.07 Conference hall mic. Nos. Two no. of each type
1.00.11.08 Conference hall speakers. Nos. Two no. of each type
1.00.12 HMS 90,475
1.00.12.01 As per Manufacturer’s Recommendation for Set

Three Years Continuous Operation
1.00.12.02 Electronic cards Nos. One no. of each type
Page 278 of 680

1.00.13 Mandatory Spares for Control valves, 1,03,31,251 LOT PRICE FOR THE APPLICABLE ITEMS
Power Cylinder, Control Dampers, UNDER THIS SL NO 1.00.13
Actuators and Accessories
(A) Following spares shall be furnished for control 38,32,031 PC-LOT PRICE OFFERED FOR SUBITEMS AS
valves, Power Cylinder, Control Dampers as APPLICABLE TO ALL TYPES OF CONTROL
applicable. VALVES IN PC SCOPE.
HYD-lot price has been given for Sl no 1.00.13 (A)
(Items applicable for BFP control valve shall be
supplied.)
One set of spare control valve stem packing 1,21,34,359 PEM-C&I control valves
for each control valve. AND
Two moulded rubber diaphragms for each spares
control valve. AND
mandatory spares
One sets of each of O-rings and rubber 3,73,310
gaskets for each control valve.
g
d) 100 percent qty. of lubricants for gaskets for 1,86,690 PEM-For Fuel Oil Unloading System, included
each control valve on one year consumption under clause Fuel oil system of Mech. List of
basis. mandatory spares
AND
mandatory spares
Page 12 of 19
Page 279 of 680


2 sets of limit switches and 1 set of valve 21,75,950 HWR-Limit switches are not applicable
positioner for each control valve. PEM-C&I control valves included above under
clause no A1 -1.0013 of C&I list
AND
spares
AND
mandatory spares.
f) 20 percent of position transmitter (4-20mA) for 1,56,520

total qty. of control valve.
g) One (1) set of valve trims (such as plug, stem, 23,28,270

seat ring /cage, guide bushing, stem lock pin,
packing retaining ring, etc) for each control
valve.
h) One completes actuator of each type or min 36,01,710 TRY-VALVES REMARKS: Price already Quoted in
10% for each type and size whichever is more. Mechanical section under the Spares ACTUATOR
FOR MOTOR OPERATED VALVES
i) 20 percent of Solenoid valves or min 2 no. of Not Applicable

each type
yp for total q
qty.
y of control valves.
j) 20% of I to P converters, Pressure regulators.
B) Mandatory spares for each critical 1,17,72,635 PEM-For APRDS
applications special control valves as AND
specified in NIT For Fuel Oil Unloading System, included under
spares
AND
mandatory spares
C)
Page 13 of 19
Page 280 of 680


a. Soft Goods Kit Valve 1 set 65,16,048 PEM-For Fuel Oil Unloading System, included
under clause Fuel oil system of Mech. List of
mandatory spares
AND
mandatory spares
b. Metal seat 1 set HYD-Lot price has been given for items under SL
no.1.00.13 (C) Items applicable for Pumps shall be
supplied.
c. Seat Ring 1 set For C&I control valves included above under clause
no A1 -1.0013 of C&I list
AND
spares
AND
mandatory spares
d. Spindle 1 set
e. Actuator Soft Goods kit 1 set
i. Feed back transmitter unit 2 Nos.
ii. Electronic Position Transmitter 2 Nos.
iii. Solenoid valves 2 Nos.
iv. Air filter regulators 2 Nos.
v. Air Lock Relay 2 Nos.
vi. Complete Actuator for each type and model 1 set
C) Following spares shall be supplied for each of TRY-V: Price already Quoted in Mechanical section
the HP/LP By Pass & Spray control valves under HP BYPASS SYSTEM
i) Stem 1 NO.
ii) Jet Cage 1 NO.
iii) Nozzle Body 1 NO.
iv) Seat 1 NO.
v) Guide bushing 1 NO
vi) Valve Packing 1 Set
vii) Valve Gaskets 1Set
viii) Actuator seal set 1 Set
D) Common spares for HP/LP By Pass & Spray control valves: TRY-V: Price already Quoted in Mechanical section
Page 14 of 19
Page 281 of 680

i) Feedback transmitter 2 NOS. under HP BYPASS SYSTEM
ii) Electronic positioner 2 NOS.
iii) Proportional Valve 2 NOS.
iv) Quick opening device 2 NOS.
v) Seal sets 4 Sets
vi) Solenoid Valves 2 NOS.
vi) Filters for Oil Units 1 set
vii) Supply manifold for oil units 1 No
viii) Hose for each service 1 each
ix) Seal set for oil unit 1 Set
x) Complete actuator for each type and model 1 set
E) 1 NO of Nozzle for each PRDS De Super heater & Spray water desuperheater and orifice plate for CEP flow. 1 No. Nozzle for Spray water Desuperheater is included
in our price. Rest of the flow nozzles not included in our
offer as 'Mandatory spares' are provided for items or
components that require replacement during plant
operation. Flow nozzles and orifice plates do not require
replacement and hence are not provided as mandatory
spares. We have never supplied nozzles and orifice plate
as mandatory spares in any of the existing as well as
previous projects.
1.00.14 Mandatory Spares for Boiler Tube leak Detection System 17,81,920 LOT PRICE FOR THE APPLICABLE ITEMS
UNDER THIS SERIAL NO 1.00.14
Following mandatory spares along with their

individual price required for maintaining boiler
tube leak detection system to supply along with the
package.
1) 2nos. acoustic transducer with rear connector
sealed to IP-65
2) 2 nos. flexible high temperatures lead, 3metre
long for acoustic transducer.
3) 2 nos. acoustic s field amplifier / processor
mounted in a die cast aluminum or polycarbonate
box sealed to IP-65 with mounting brackets,
pairs.
4) 1 no. A/D Convertor cards/field signal interface
module for 32 or more channels.
5) 1 no. Alarm relay output card.
Page 15 of 19
Page 282 of 680


6) Consumables like batteries, fuses etc. for two years
operation of boiler tube leak detection system.
1.00.15 Mandatory spares not covered above 59,50,000 LOT PRICE FOR THE APPLICABLE ITEMS
UNDER THIS SERIAL NO 1.00.15
Bidder to supply 10% or 1 no. (whichever is

more) of each type of sensor/instrument,
instrumentation/mechanical fittings etc for any other
electronic system, feeder control cabinets,
hydrastep (EWLI), Vibration Monitoring System,
CCTV, C&I Lab Instruments, On line Carbon in Ash
analyser system, On line Coal mass flow/speed
measurement system, On line secondary air flow
measurement system Mass Flow meter, Solid flow
meter, 3 D Acoustic type level transmitters,
Nucleonic & non nucleonic density transmitter etc.
1.00.16 OTHER RELATED CONTROL AND

INSTRUMENTATION SYSTEMS/EQUIPMENTS
1.00.16.01 Other SG related sub-systems
1 Flame Monitoring System
(i) Complete Flame Scanner Assembly including 20% or 4 nos. whichever is 39,05,356
scanner head assembly, scanner housing, and fibre more.
optic cables.
(ii) Flame Scanner Lens. 100% 1,08,570
(iii) Electronic cards for scanners 10% or 2 nos. of each type 17,69,852
whichever is more.
(iv) Power Supply Modules 10% or 2 nos. of each type INCLUDED IN SL NO (III) ABOVE
whichever is more.
2 Coal Feeders
(i) Calibration Motor 10% or 2 nos. whichever is NOT APPLICABLE
more.
(ii) Correction Motor 10% or 2 nos. whichever is NOT APPLICABLE
more.
Page 283 of 680

(iii) Motion monitor 10% or 2 nos. whichever is 8,14,275
more.
(iv) Speed pick-up 10% or 2 nos. whichever is 5,69,989
more.
(v) Torque switch 10% or 2 nos. whichever is 15,30,746
more.
(vi) Load Cell 10% or 2 nos. whichever is 62,19,969
more.
(vii) Electronic cards & Power Supply cards 10% or 2 nos. whichever is 12,15,725
more.
(viii) Clutch (if applicable) 10% or 2 nos. whichever is 8,14,275
more.
(ix) Local indication lamps 200% . 4,14,316
(x) Panel meters 10% or 2 nos. whichever is NOT APPLICABLE
more.
(xi) Limit switch assembly for coal-on-belt, no coal flow, 10% or 2 nos. whichever is 3,79,995
shear pin failure, etc. more.
(xii) Coupling (eddy current type etc., if applicable) 10% or 2 nos. whichever is 3,79,995
more.
3 Electromatic Safety Valves
(a) Pressure switches, local PB stations and solenoid 10% or 2 nos. of each type 4,07,498
Valves. whichever is more.
4 Furnace Temperature Probes
(a) Thermocouple 2 Nos. of each type 67,900
5 Acoustic Pyrometers NOT APPLICABLE

(a) Signal Processor and interface modules 10% or 2 nos. of each type NOT APPLICABLE
and model whichever is more
(b) Sensors and Transceivers 20% or 2 nos. of each type NOT APPLICABLE
and model which is more.
6 Furnace and Flame Viewing System 40,25,000 LOT PRICE FOR THE APPLICABLE ITEMS
UNDER THIS SL NO
(a) Flame Cameras 10% or 2 nos. of each type

whichever is more.
(b) Electronic Modules 10% or 2 nos. of each type
whichever is more.
7 Coal Bunker Level Indicating System 1,69,680 EDN -lot price has been given for the itmes under Sl
no 7 to 8
(i) Sensors of each type 20% or 2 nos. of each type

whichever is more.
Page 284 of 680

(ii) Electronic Cards of each types, model 10% or 2 nos. of each type
and model whichever is more.
(iii) Panel indicators/displaysfor Bunker Level 20% or 2 nos. of each type

whichever is more.
8 (i) Solenoids for SG pneumatic drives/valves. 20% or 2 nos. of each type
whichever is more.
(ii) Solenoid valves. 20% or 2 nos. of each type
whichever is more.
(iii) Diaphragms 20% or 2 nos. of each type
whichever is more.
9 Conductivity type level monitoring system NOT APPLICABLE
(i) Electrodes 50% of population of each type NOT APPLICABLE
and model.
(ii) Electronic Cards 20% or 2 nos. of each type NOT APPLICABLE
and model whichever is more.
(iii) Lamps/LEDs of display units 100% NOT APPLICABLE
10 Mill and Air heater Fire detection system. 63,672 Included in Sl No 1.00.01 & 1.00.02 for EDN scope
of supply and lot price indicated here is for Trichy's
scope of supply.
(a) Thermocouple 10% or 2 nos. whichever is -
more
(b) Process actuated switches 10% or 1 no. whichever is NOT APPLICABLE
more
(c) Electronic cards 20% or 2 nos. whichever is NOT APPLICABLE
more
1.00.16.02 Other TG Related Sub-Systems
Turbine Supervisory System/EHTC/TSC/ATT/ATRS/GSPC/TDBFP etc. EDN portion is Included in Sl No 1.00.01 & 1.00.0
(i) Power Supply assemblies of all types 10% or 2 nos. of each type 11,81,034 HYD- Lot price for items under for the Sl no (i) to
whichever is more (viii)
Temperature Sensing elements 10% or 2 nos. of each type Already covered under S.No.1.00.01.02 (i) above,
whichever is more Hence,not offered again.
(iii) CJC assemblies of all types 10% or 2 nos. of each type

whichever is more
(iv) Local gauges/transmitters of all types, range, 5% or 1 no. of each type Already covered under S.No.1.00.01.03 above.
model no. etc. For Temperature, pressure, DP, whichever is more Hence,not offered again.
differential expansion, axial shift etc.
Page 285 of 680

(v) Process Actuated Switch Devices of all types, 5% or 1 no. of each Already covered under S.No.1.00.01.03 above.
range, model no. etc. for pressure, DP, typewhichever is more Hence,not offered again.
temperature, flow, level, proximity/speed etc.
(vi) Electronic Cards/PCB's/interface units/special 10% or 2 nos. of each type

cables etc. of each type of measurement used in whichever is more.
TSI.
(vii) Instrument valves of all types like isolating, 2/3/5 5% or 2 nos. of each type, 1,74,230
way valve manifolds, hi pressure reducing, safety model etc.; whichever is more.
relief, each type of solenoid valves etc.
(viii) Sensors of all types, range, model etc. for vibration, 10% or 2 nos. of each type Sensors for Stop/ control valve position are already
eccentricity, proximity, differential expansion, whichever is more. covered above under C&I spares. Hence,same are
axial shift , EHC position, Stop/Control valve not offered again.
position and any other measurements etc. For rest of measurements, the senors are "Not
applicable"..
(ix) Electro Hydraulic Converter. 1 complete unit of each type. 5,74,276
C& I TOTAL 26,12,61,835
Page 19 of 19
Page 286 of 680


ANNEXURE III
RAW WATER ANALYSIS AND CLARIFIED WATER ANALYSIS
(Not applicable)
Page 287 of 680


ANNEXURE IV
LIST OF TOOLS AND TACKLES
Page 288 of 680

Bidder to consider necessary tools and tackles for mechanical, electrical and control & instrument as per
their system requirement. In addition bidder to adhere relevant clauses of tender specification also. List of
tools and tackles to be furnish by bidder during bid submission.
Page 289 of 680


ANNEXURE -V
DRAWING DOCUMENT / SUBMISSION SCHEDULE
Page 290 of 680


Note:
 Quantity of prints may change during detailed engineering stage based on BHEL / Customer
requirement. However the same will be adhered by the bidder without any delivery/commercial
 All the drawing documents along with the O&M manual (of all the revisions) are necessarily to be
submitted in soft copies in addition to hard copies.
 Bidder to submit soft copies of all the drawing and document along with quality plans for BHEL review
and approval.
 The date of submission of drawing documents shall be considered as the date of submission of hard
and soft copes whichever is later.
 All the drawings shall be prepared on computer auto cad and other documents (like datasheet etc.) on
MS office software. Bidder not complying to the requirement shall not be considered. For the execution
of the contract regular meeting (generally once in 15 days or as per project requirement) is required.
 Bidder has to come for meeting with the concerned dealing persons as per BHEL or customer
requirement in a short notice.
 Bidder to submit instrument schedule, cable schedule and valve schedule in MS- Excel format during
 Bidder to also furnish the auto cad copy / MS-word (as applicable) of the following documents after
award of contract. However any other auto cad copy/MS-Excel/MS-word of any other document as per
the insistence of BHEL / customer will also be submitted by the bidder without any delivery/commercial
 P&IDs.
 Equipment lay out of the service vessel area and regeneration area.
 Equipment Cable tray layout for service vessel area and regeneration area
 Equipment earthing layout service vessel area and regeneration area
 Civil scope drawings.
 Piping lay out drawing for Service vessel area, regenerative area and yard piping layout.
Page 291 of 680

DESEIN Volume-II: General & Schedules
General Technical Requirements
ANNEXURE-I

(sets) ROMs (sets)
1. PLANT DEFINITION MANUAL- - 3 CD-ROMs
2. Drawings "FOR APPROVAL" 10 Soft Copy
3. Drawings "FOR INFORMATION" 10 Soft Copy
4. Drawings "FINAL APPROVED 8 Soft Copy

DRAWING"
5. Drawings "AS BUILT " 8 3 CD-ROMs
6 DATASHEETS,DESIGNCALCULATI
ONS,PURCHASE
SPECIFICATIONS, etc. and Other
type of documents
i) For Approval 10 SOFT COPY
ii) FINAL 8 3 CD-ROMs -
iii) Analysis reports of equipment/
piping/ structures components/
systems employing software
packages as detailed
in the specifications
a) Input 10 SOFT COPY
b) Output 10 SOFT COPY
c) Drawings/ Sketches 10 SOFT COPY
7 Erection manual "FINAL" 8 3CD ROMS

8 Operation & Maintenance manual 10 3CD ROMS
9 Plant Hand Book "DRAFT" 6 SOFT COPY
10 Plant Hand Book "FINAL" 15 3CD ROMS
11 Commissioning and Performance 10 3CD ROMS
Procedure manual
12 Performance and Functional 6 3CD ROMS
Guarantees test report
13 Progress Reports 6 3CD ROMS
14 Project completion report 10 3CD ROMS
15 QA programme including 1
2 x 660 MW Ennore SEZ Supercritical Thermal Power

Spec. No. CE/C/P&E/EE/E/OT.No.03 /2013-14
Vol. II: 58
Page 292 of 680
DESEIN Volume-II: General & Schedules
General Technical Requirements

(sets) ROMs (sets)
Organization for implementation and
QA system manual (with revision-
servicing)
16 Vendor details in respect of proposed 1
vendors including Bidder’s evaluation
report.
17 Manufacturing QPs, Field QPs, Field
welding schedules and their
reference documents like test
procedures, WPS, POR etc.
(i) For review/comment 3
(ii) For final approval 4 1 set CD ROMS
18 Welding Manual, Heat Treatment 4
Manuals,
Storage & preservation manuals
Final 4 2 CD ROMS
19 Monthly Vendor Approval 2 1 CD ROM
and QP approval status
20 QA Documentation Package for 2 2 CD ROMS
items / equipment manufactured and
dispatched to site
21 QA Documentation Package for field 2 2 CD ROMS
activities on equipment/systems at
site
2 x 660 MW Ennore SEZ Supercritical Thermal Power

Spec. No. CE/C/P&E/EE/E/OT.No.03 /2013-14
Vol. II: 59
Page 293 of 680
indigenous supplies. The cost towards this inspection

shall be borne by the Contractor.
b) In the case of imported supplies: - For imported materials

or non- indigenous supplies, the inspection shall be
carried out by a foreign agency of repute to be appointed
by the contractor as approved by the Owner. The cost of
such inspection shall be borne by the Contractor.
18.0 OPERATION AND MAINTENANCE MANUALS:
18.1 For all the equipments supplied by the Contractor, he shall

submit to the Owner ten sets of the O&M manuals. The
manual shall contain the operational features of the
equipment, DOs & DON’Ts, trouble shooting, maintenance
schedules for preventive maintenance, detail dimensional
drawings, cross sectional drawings, method of assembly etc.
to make the Owner’s staff acquainted with the equipment as
well as to enable them to operate and maintain the same in
prescribed manner. Manuals shall contain all information for
ordering of the spares, like part name, part no., Drawing/
material Specifications, address of the supplier with phone
no. & fax no. etc. Contractor shall ensure that these O&M
manuals are made available to the Owner well before
starting of initial trials of equipment.
18.2 ERECTION MANUALS:
18.2.1 In order to enable the engineers of the Owner to

supervise the works properly, Contractor shall furnish five
copies of erection manuals depicting therein the erection
procedure, special precautions to be taken, various
clearance to be maintained, erection checks and tests to be
carried out before the equipment is put to initial trials.
19.0 SUBMISSION AND APPROVAL OF DRAWINGS:
19.1 The contractor shall submit the drawings in sequential order

to match with completion of milestone activity. The contractor
shall submit all the G.A. drawings, mechanical, electrical and
Page 294 of 680

civil drawings, data sheets etc. for approval of the Owner

along with the design calculations and general write up
wherever involved. The drawings for all the systems shall be
properly coordinated. While scrutinizing the drawings, the
Owner shall indicate the corrections to be made in these
drawings and documents, which the contractor shall
incorporate or justify its correctness. The Contractor then
shall submit the revised drawings for approval of the Owner.
On approval of the same, Contractor shall furnish six copies
and soft copy on CD of these approved drawings to the
Owner as per the distribution to be intimated. Any delay in
approval of drawings by Owner, due to submission of
incorrect data, non-submission of data, non-updating the
drawings in line with the corrections indicated shall be to the
Contractor’s account. During the currency of the contract, if
any approved drawings are required to be modified, such
details of the modifications required to be carried out shall be
separately maintained. On completion of all the works, the
Contractor shall incorporate all the changes necessitated in
the drawings and submit 6(six) sets of all the "As built"
drawing for the records of the Owner. As the drawings shall
be approved based on the basic information furnished by the
Contractor, approval by the Owner shall not absolve the
Contractor of his responsibilities towards correctness of
design & performance of the equipment.
20.0 TEST REPORTS:
20.1 On completion of tests of equipment at manufacturer’s

works, the Contractor shall furnish 4 copies of test
certificates to the Owner for approval and subsequent
despatch clearance. The test report shall invariably indicate
identification data, including model no., sl. no. etc. of the
equipment, method of application and duration of test along
with test results. Only on approval of these test results by the
Owner or Owner’s representative, dispatch clearance will be
issued for dispatch of material to site.
Page 295 of 680


ANNEXURE VI
MAIN DRAWING LIST WITH SCHEDULE OF SUBMISSION
Page 296 of 680


DRAWINGS AND DOCUMENTS TO BE FURNISHED AFTER AWARD OF CONTRACT
After award of LOI / PO, following drawing/documents shall be submitted by the bidder in soft as well as
hard form for BHEL/Customer approval / information. However, any additional drawing/documents if found
necessary for completion of the engineering, the same shall be submitted by bidder without any
commercial and delivery implication to BHEL / customer.
S.NO. BHEL DRAWING DRAWING TITLE SCHEDULE OF SIZE

NUMBER SUBMISSION
FROM LOI
PE‐V2‐412‐155‐A001 P& I DIAGRAM OF CONDENSATE POLISHING 4 A1
1 UNIT
PE‐V2‐412‐155‐A002 EQUIPMENT LAYOUT OF CONDENSATE 4 A1
POLISHING UNIT (SERVICE VESSEL AREA )
2
PE‐V2‐412‐155‐A003 EQUIPMENT LAYOUT OF CONDENSATE 4 A1
3 POLISHING UNIT (REGENERATION AREA)
PE‐V2‐412‐155‐A004 PROCESS DESIGN AND SIZING CALCULATIONS , 4 A4
DATA SHEET OF RESIN VESSEL THICKNESS AND
4 PRESSURE DROP CALCULATIONS FOR CPU
PE‐V2‐412‐155‐A005 SUB‐VENDOR LIST AND INSPECTION CRITERIA 4 A4
5
PE‐V2‐412‐155‐A006 OPERATION & CONTROL PHILOSOPHY FOR 6 A4
CPU ALONG WITH CONTROL SYSTEM
6 CONFIGURATION DIAGRAM
PE‐V2‐412‐155‐A007 CIVIL ASSIGNMENT DRAWING OF 8 A1
CONDENSATE POLISHING UNIT (SERVICE
7 VESSEL AREA)
PE‐V2‐412‐155‐A008 CIVIL ASSIGNMENT DRAWING OF 8 A1
8 REGENERATION AREA)
PE‐V2‐412‐155‐A009 PIPING LAYOUT (REGENERATION AREA ) 8 A1
9
PE‐V2‐412‐155‐A010 ELECTRICAL LOAD DATA 8 A4
10
PE‐V2‐412‐155‐A011 PIPING LAYOUT (SERVICE VESSEL AREA) 10 A1
11
PE‐V2‐412‐155‐A012 GA DRAWING OF SERVICE VESSELS FOR CPU 10 A3
12
PE‐V2‐412‐155‐A013 QAP FOR SERVICE VESSEL 10 A4
13
PE‐V2‐412‐155‐A014 GA DRAWING OF PRESSURE VESSELS FOR CPU 10 A3
14
PE‐V2‐412‐155‐A015 QAP FOR PRESSURE VESSELS 10 A4
15
PE‐V2‐412‐155‐A016 GA DRAWING OF ATMOSPHERIC TANKS FOR 10 A3
16 CPU
PE‐V2‐412‐155‐A017 QAP FOR ATMOSPHERIC TANKS 10 A4
17
PE‐V2‐412‐155‐A018 TECHNICAL DATA SHEET OF HORIZONTAL / 10 A4
18 VERTICAL CENTRIFUGALPUMPS
PE‐V2‐412‐155‐A019 TECHNICAL DATA SHEET FOR METERING 10 A4
19 PUMPS
PE‐V2‐412‐155‐A020 TECHNICAL DATA SHEET OF BLOWERS 10 A4
20
PE‐V2‐412‐155‐A021 TECHNICAL DATA SHEET FOR MOTOR 10 A4
21
PE‐V2‐412‐155‐A022 QAP FOR HORIZONTAL / VERTICAL 10 A4
22 CENTRIFUGALPUMPS WITH MOTOR
Page 297 of 680

PE‐V2‐412‐155‐A023 QAP FOR METERING PUMPS WITH MOTOR 10 A4
23
PE‐V2‐412‐155‐A024 QAP FOR BLOWERS WITH MOTOR 10 A4
24
PE‐V2‐412‐155‐A025 TECHNICAL DATA SHEET FOR HIGH PRESSURE 10 A4
VALVES
25
PE‐V2‐412‐155‐A026 TECHNICAL DATA SHEET FOR LOW PRESSURE 10 A4
VALVES
26
PE‐V2‐412‐155‐A027 QAP FOR VALVES 10 A4
27
PE‐V2‐412‐155‐A028 TECHNICAL DATA SHEET FOR INSTRUMENTS 10 A4
28
PE‐V2‐412‐155‐A029 TECHNICAL DATA SHEET FOR ANALYSERS 10 A4
29
PE‐V2‐412‐155‐A030 TECHNICAL DATA SHEET FOR HEATER 10 A4
30
PE‐V2‐412‐155‐A031 VALVE SEQUENCE CHART 10 A4
31
PE‐V2‐412‐155‐A032 INSTRUMENT SCHEDULE 12 A3
32
PE‐V2‐412‐155‐A033 VALVE SHEDULE 12 A3
33
PE‐V2‐412‐155‐A034 PLC DOCUMENTS FOR SERVICE VESSEL AREA & 12 A4
REGENERATION AREA‐‐GA & WIRING DETAILS
OF PLC & RIO PANEL, I/O LIST, BOM, MIMIC
34 DIAGRAM
PE‐V2‐412‐155‐A035 QAP FOR PLC 12 A4
35
PE‐V2‐412‐155‐A036 CABLE TRAY/TRENCH & CONDUIT ROUTING 12 A1
AND EARTHING LAYOUT DIAGRAM FOR
36 (REGENERATION AREA)
PE‐V2‐412‐155‐A037 CABLE TRAY/TRENCH & CONDUIT ROUTING 12 A1
AND EARTHING LAYOUT DIAGRAM FOR
CONDENSATE POLISHING UNIT (SERVICE
37 VESSEL AREA)
PE‐V2‐412‐155‐A038 DATASHET OF RESIN TRAP, CARBON TRAP, 12 A4
38 ACF, AGITATOR
PE‐V2‐412‐155‐A039 GA OF BATTERY BANK AND CHARGER 12 A4
39
PE‐V2‐412‐155‐A040 QAP / ICL FOR CPU (FOR BALANCE OF ITEMS) 12 A4
40
PE‐V2‐412‐155‐A041 ERECTION PROCEDURE 16 A4
41
PE‐V2‐412‐155‐A042 YARD PIPING LAYOUT 16 A1
42
PE‐V2‐412‐155‐A043 CABLE SCHEDULE FOR CONDENSATE 16 A3
43 POLISHING UNIT
PE‐V2‐412‐155‐A044 ERECTION PROCEDURE 16 A4
44
PE‐V2‐412‐155‐A045 PG test procedure for condensate polishing 20 A4
45 unit
PE‐V2‐412‐155‐A047 O&M MANUAL FOR CONDENSATE POLISHING 24 A4
46 UNIT
*High pressure valves are those valves which are subjected to the service vessel pressure. Bidder to refer list of
documents required in section C3 of this specification also.
Page 298 of 680


Notes:
1. The above drawing list is tentative and shall be finalized with the successful bidder after
placement of order. While some of the drawings indicated above may not be applicable, some
additional drawings may also be required based on scope of work.
2. Drawings shall be prepared in Auto-Cad latest edition. Required no. of hard and soft copies
(editable) of the drawings shall be furnished as per requirement specified elsewhere in the
specification.
3. Only manual calculation with authentic supporting literature (e.g. extracts of hand Book/
standard/codes) shall be acceptable. All design calculations and drawings shall be in SI system
only.
4. All the drawings and documents including general arrangement drawing, data sheet, calculation
etc. to be furnished to the customer during detailed engineering stage shall include / indicate the
following details for clarity w.r.t. Inspection, construction, erection and maintenance etc.:-
a) All drawings and documents shall indicate the list of all reference drawings including general
arrangement.
b) All drawings shall include / show plan, elevation, side view, cross - section, skin section, blow -
up view; all major self-manufactured and bought out items shall be labeled and included in BOQ /
BOM in tabular form.
c) Painting schedule shall also be made as a part of general arrangement drawing of each
equipment / items indicating at least 3 trade names.
d) All the drawings required to be furnished to customer during detailed engineering stage shall
include technical parameters, details of paints and lubrication, hardness and BOQ / BOM in
tabular form indicating all major components including bought out items and their quantity,
material of construction indicating its applicable code / standard, weight, make etc.
e) Drawings/ documents to be submitted for purchasers review/ approval shall be under Revision A,
B, C… etc. while drawings /documents to be submitted thereafter for customer’s approval after
purchaser’s approval shall be under R-0, 1, 2, 3 ….etc.
f) Drawings and documents not covered above but required to check safety of machines/ system,
shall be submitted during detailed engineering stage without any commercial implication.
g) All drawings shall include "B.O.M" and indicate quantity, material of construction, make along
with IS/BS No., Technical parameters, dimensions, hardness, machining symbol and tolerance,
requirement of radiography and hydraulic tests, painting details, elevation, side view, plan, skin
section and blow-up view for clarity.
h) All drawings shall be prepared as per BHEL's title block and shall bear BHEL's drawing Number.
i) Schedule of drawings submissions, comment incorporations & approval shall be as stipulated in
the specifications. The successful bidder shall depute his design personnel to BHEL’s/
Customer’s/ Consultant’s office for across the table resolution of issues and to get documents
approved in the stipulated time.
j) Bidder to follow the following the drawing submission schedule:
k) 1st submission of drawings from date of LOI as per the submission schedule.
l) Every revised submission incorporating comments – within 7 days.
m) Bidder to submit revised drawings complete in all respects incorporating all comments. Any
incomplete drawing submitted shall be treated as non-submission with delays attributable to
bidder’s account. For any clarification/ discussion required to complete the drawings, the bidder
shall himself depute his personal to BHEL for across the table discussions/ finalizations/
submissions of drawings.
5. Bidder to note that the successful bidder, during detail engineering, will submit the drg/doc
through web based Document Management System in addition to hard copies to be submitted as
Page 299 of 680

per the Annexure III of this specification. Bidder would be provided access to the
DMS for drg/doc approval and adequate training for the same. Detailed methodology would be
finalized during the kick-off meeting. Bidder to ensure following at their end:
 Internet explorer version – Minimum Internet Explorer 7.

 Internet speed – 2 mbps (Minimum preferred).
 Pop ups from our external DMS IP (124.124.36.198) should not be blocked.
 Vendor’s Internal proxy setting should not block DMS application’s link
(http://124.124.36.198/wrenchwebaccess/login.aspx)”.
 DMS user manuals to be used by BHEL PEM vendors for uploading, viewing, revising,
commenting and tracking documents on PEM’s DMS have been uploaded on PEM internet website
(www.bhelpem.com) under the Vendor session.
 For quick access bidder may refer the link http://bhelpem.com/DMSManuals/DMSManuals.html .
Page 300 of 680


ANNEXURE VII
FORMAT FOR OPERATION AND MAINTENANCE MANUAL
Page 301 of 680


Bidder to submit operation and Maintenance manual with minimum information as listed in below check list
during contract stage.
Check List for Operation & Maintenance Manual
Project name :
Project number :
Package Name :
PO reference :
Document number :
Revision number :
Sl.no. & Description Tick ( √ )if included in Remark

Section Manual s
s
Yes No Not
Applicable
1.
Cover page
1.1 Project Name
1.2 Customer/consultant Name
1.3 Name of Package
1.4 Supplier details with phone, FAX ,email address
, Emergency Contact number
1.5 Name and sign of prepared by , checked by &
approved by
1.6 Revision history with approval Details
2.0
Index
2.1 showing the sections & related page nos

All the pages should be numbered section wise
3.0
Description of Plant/System
3.1 Description /write up of operating principle of
system equipment/ associated sub-systems &
accessories/controls system , operating
conditions, performance parameters under
normal , start up and special cases
3.2 Equipment list and basic parameter with Tag
numbers
3.3 Data sheets approved by Customer/for
information and catalogues provided by original
Page 302 of 680


manufacturer
3.4 Associated other packages and Interface
/terminal points
3.5 P&ID & Process Diagrams
3.6 GA Layout drawings, As-built drawings , Actual
photograph of items/system (Drawings of A2 &
bigger sizes are to be attached in the last)
3.7 Single line/wiring diagrams
3.8 Control philosophy /control write-ups
4.0
Commissioning Activities (if not covered in
separate document i.e. erection manual,
commissioning manual)
4.1 Pre-Commissioning Checks
4.2 handling of items at site
4.3 Storage at site
4.4 Unpacking & Installation procedure
5.0
Operation Guidelines for plant
personal/user/operator
5. 1 Interlock & Protection logic along with the
limiting values of protection settings for the
equipment along with brief philosophy behind
the logic, drawings etc. to be provided.
5. 2 Start up, normal operation and shut down

procedure for equipments along with the
associated systems in step by step mode. Valve
sequence chart, step list, interlocks etc. with
Equipment isolating procedures to be
mentioned.
5. 3 Do’s & Don’t of the equipments.
5. 4 Safety precautions to be taken during normal
operation. Safety symbols, Emergency
instructions on total power failure
condition/lubrication failure/any other condition
5. 5 Parameters to be monitored with normal values
and limiting values
5. 6 Trouble shooting with causes and remedial
measures
5. 7 Routine operational checks, recommended logs
& records
5. 8 Changeover schedule if more than one auxiliary
for the same purpose is given
5. 9 Painting requirement and schedule
5. 10 Inspection, repair , Testing and calibration
procedures
6.0
Maintenance guidelines for plant personal
6.1 List of Special Tools and Tackles required for
Overhaul/Trouble shooting including special
testing equipment required for calibration etc.
6.2 Stepwise dismantling and re-assembly
procedure clearly specifying the tools to be
Page 303 of 680


used, checks to be made, records to be
maintained, clearances etc. to be mentioned.
Tolerances for fitment of various components to
be given.
6.3 Preventive Maintenance & Overhauling
schedules linked with running hours/calendar
period along with checks to be given
6.4 Long term maintenance schedules especially for
structural, foundations etc.
6.5 Consumable list along with the estimated
quantity required during commissioning, normal
running and during maintenance like Preventive
Maintenances and Overhaul. Storage/handling
requirement of consumables/self-life.
6.6 List of lubricants with their Indian equivalent,

Lubrication Schedule, Quantity required for each
equipment for complete replacement is to be
given
6.7 List of vendors & Sub-vendors with their latest
addresses, service centres ,Telephone Nos.,
Fax Nos., Mobile Nos., e-mail IDs etc.
6.8 List of mandatory and recommended spare
parts list
6.9 Tentative Lead time required for ordering of
spares from the equipment supplier
6.10 Guarantee and warranty clauses
7.0 Statutory and other specific requirements
considerations.
8.0 List of reference documents
9.0 Binding as per requirement
Page 304 of 680


ANNEXURE VIII
SITE STORAGE AND PRESERVATION
Page 305 of 680

CONTENT
1 SCOPE OF THE DOCUMENT
2 PURPOSE OF STORAGE & PRESERVATION
3 MEASURES TO BE TAKEN FOR STORAGE AND PRESERVATION
a) GENERAL STORAGE REQUIREMENTS
b) GENERAL PRESERVATION REQUIREMENTS
c) GENERAL INSPECTION REQUIREMENTS
4 TYPE OF STORAGE FOR VARIOUS EQUIPMENT
5. CONCLUSION
6. STACKING ARRANGEMENT FOR PLATES AND STRUCTURAL STEEL
Page 306 of 680

1. SCOPE OF THE DOCUMENT
This guideline is prepared in intent to provide proper site storage and preservation of the
Mechanical, Electrical and C & I items / equipment supplied under various bought out
packages/items. This storage procedure shall be followed at different power plant sites by
concerned agency for storage and preservation from the date of equipment received at
site until the same are erected and handed over to the customer.
2. PURPOSE OF STORAGE & PRESERVATION
Many of the items may be required to be kept in stores for long period. It shall therefore
be essential that proper methods of storage and preservation be applied so that items do
not deteriorate, loose some of their properties and become unusable due to atmospheric
conditions and biological elements.
3. MEASURES TO BE TAKEN FOR STORAGE, HANDLING & PRESERVATION
a) GENERAL STORAGE REQUIREMENTS
1. To the extent feasible, materials should be stored near the point of erection. The
storage areas should have adequate unloading and handling facilities with adequate
passage space for movement of material handling equipment such as cranes, fork lift
trucks, etc. The storage of materials shall be properly planned to minimise time loss
during retrieval of items required for erection.
2. The outdoor storage areas as well as semi-closed stores shall be provided with
adequate drainage facilities to prevent water logging. Adequacy of these facilities shall
be checked prior to monsoon.
3. The storage sheds shall be built in conformity with fire safety requirements. The stores
shall be provided with adequate lights and fire extinguishers. ‘No smoking’ signs shall
be placed at strategic locations. Safety precautions shall be strictly enforced.
4. Adequate lighting facility shall be provided in storage areas and storage sheds and
security personnel positioned to ensure enforcement of security measures to prevent
theft and loss of materials.
5. Adequate number of competent stores personnel and security staff shall be deployed
to efficiently store and maintain the equipment / material.
7. The equipment shall be stored in an orderly manner, preserving their identification

slips, tags and instruction booklets, etc., required during erection. The storage of
materials shall be equipment-wise. Loose parts shall be stored in sheds on racks,
Page 1 of 13
Page 307 of 680
preserving the identification marks and tags in good condition. The group codes shall
be displayed on the racks
6. At no time shall any materials be stored directly on ground. All materials shall be
stored minimum 200 mm above the ground preferably on wooden sleepers
b) GENERAL PRESERVATION REQUIREMENTS
1. All special measures to prevent corrosion shall be taken like keeping material in dry
condition, avoiding the equipment coming in contact with corrosive fluid like water,
acid etc.
2. Materials which carry protective coating shall not be wrapped in paper, cloth, etc., as
these are liable to absorb and retain moisture. The material shall be inspected and in
case of signs of wear or damages to protective coating, that portion shall be cleaned
with approved solution and coated with an approved protective paint. Complete record
of all such observations and protective measures taken shall be maintained.
3. Generally equipment supplied at site are properly greased or rust protective oil is
applied on machined/ fabricated components. However periodic inspection shall be
carried out to ensure that protection offered is intact.
4. While handling the equipment, no dragging on the ground is permitted. Avoid using
wire rope for lifting coated components. Use polyester slings (if possible) otherwise
protective material (e.g. clothes, wood block etc.) should be used while handling the
components with rope / slings
5. For Equipment supplied with finished paint, touch paint shall be done in case any
surface paint gets peeled off during handling. Otherwise such surfaces shall
necessarily be wrapped with polythene to avoid any corrosion. Further for equipment
wherein finish coat is to be applied at site, site to ensure that equipment is received
with primer coat applied.
6. It shall be ensured by periodic inspection that plastic inserts are intact in tapped holes,
wherever applicable.
7. Pipes shall be blown with air periodically and it shall be ensured that there is no
obstruction.
8. Silica gel or approved equivalent moisture absorbing material in small cotton bags
shall be placed and tied at various points on the equipment, wherever necessary.
9. Heavy rotating parts in assembled conditions shall be periodically rotated to prevent

corrosion/jamming due to prolonged storage.
Page 2 of 13
Page 308 of 680
10. All the electrical equipment such as motors, generators, etc. shall be tested for
insulation resistance at least once in three months and a record of such measured
insulation values shall be maintained.
11. Following preservatives/preservation methods can be used depending upon type of

equipment
a. Rust preventive fluid (RPF)
b. Rust protective paints
c. Tarpaulin covers, in case of outdoor storage
d. De-oxy aluminate for weld-ments
c) GENERAL INSPECTION REQUIREMENTS
1. Period inspection of materials with specific reference to –
 Ingress of moisture and corrosion damages.
 Damage to protective coating.
 Open ends in pipes, vessels and equipment -
- In case any open ends are noticed, same shall be capped.
2. Any damages to equipment / materials.
- In case of any damages, these shall be promptly notified and in all cases, the
repairs / rectification shall be carried out.
- Any items found damaged or not suitable as per project requirements shall be
removed from site. If required to store temporarily, they shall be clearly
marked and stored separately to prevent any inadvertent use.
Page 3 of 13
Page 309 of 680
4. TYPE OF STORAGE FOR VARIOUS EQUIPMENT
The types of storage are broadly classified under the following heads:
i Closed storage with dry and dust free atmosphere. (C )
The closed shed can be constructed by using cold-rolled / tubular components for
structure and corrugated asbestos sheets / galvanised iron sheets for roofing. Brick
walls / asbestos sheets can be used to cover all the sides. The floor of the shed can
be finished with plain cement concrete suitably glazed. The shed shall be provided
with proper ventilation and illumination.
ii Semi-closed storage. (S)

The semi closed shed can be constructed by using cold-rolled / tubular components
for structure and corrugated / asbestos sheets for roofing. The floor shall be brick
paved. If required a small portion of sides can be covered to protect components from
rainwater splashing onto the components.
Page 4 of 13
Page 310 of 680
iii Open storage (O )

The open yard shall be levelled, well consolidated to achieve raised ground with the
provision of feeder roads for crane approach along with access roads running all
sides. One part of the open yard shall be stone pitched, levelled and consolidated with
raised ground suitable for storing / stacking heavier and critical components with due
space to handle them by cranes etc . Adequate number of sleepers, concrete block
etc. to be provided to make raised platforms to stack critical materials.
A separate yard to be identified as “scrap yard” slightly away from main open yard to
store wooden/steel scraps, which are to be disposed off. This is required to avoid mix
up with regular components as well as to avoid fire hazard.
Some of the components, which are having both machined & un-machined surfaces
and are bulky, shall be stored in open storage area on a raised ground and suitably
covered with water proof / fire retardant tarpaulin.
Page 5 of 13
Page 311 of 680
The equipment listed below shall be stored and inspected as per requirement mentioned in the
table below.
Type of
Sl. No. Description of the equipment Check for Remarks
Storage
Raw material /mechanical items like pipes, plates, structure sections etc.)
Damage , paint,
Provide end
1. Steel pipes ( lined/unlined) S corrosion, rubber
cap
lining peeling
Damage, paint,
2. MS Plates S
corrosion
3. SS Plates S Damage
Provide end
4. Non-metallic pipes S Damage, cracks
cap
Provide end
5. Stainless steel pipes S Damage ,
cap
Damage, paint,
6. MS sections, beams S
corrosion
Damage, condition of
7. Cable trays S
preservations
8. Insulation sheets S Damage
9. Insulation C Damage, packing
Damage, paint,
10. Hangers Rods S
packing
Damage, paint , Provide end

11. Tubes S
packing cap
12. Hume pipes O Damage
Damage, paint,
13. Castings O
corrosion
Fabricated mechanical items (pressure vessels, tanks etc.)
Damage, paint, Covered

14. Pressure vessels (unlined) O
corrosion, nozzles
Covered
Atmospheric storage tanks Damage, paint, nozzles
15. O
(unlined) corrosion
Page 6 of 13
Page 312 of 680
Type of
Storage
Damage, paint,
16. Pressure vessels (lined) S corrosion, rubber
lining
Damage, paint,
17. Atmospheric storage tanks(lined) S corrosion, rubber
lining
Damage , paint,
18. Support structures O
corrosion
Damage , paint,
19. Flanges C
corrosion
Damage , paint, Provide end

20. Fabricated pipes S
corrosion cap
Damage , paint,
21. Vessels internals C
corrosion ,packing
Damage , paint,
22. Grills S
corrosion
Damage , paint,
23. Angles S
corrosion
Bridge mechanism/clarifier Damage , paint,

24. O
mechanism corrosion
Damage , paint,
25. Cranes, rails S
corrosion
Damage , paint,
26. Stair cases O
corrosion
Damage , paint,
27. Ladders/handrails O
corrosion
Damage , paint,
28. Fabricated ducts S
corrosion
Damage , paint,
29. Isolation Gates O
corrosion
Damage , paint,
30. Fabricated boxes/panels S
corrosion
Mechanical components like valves, fittings, cables glands, spares etc.)
31. Valves S Damage , packing
Page 7 of 13
Page 313 of 680
Type of
Storage
Provide end
32. Fittings S Damage , packing
cap
33. Cable glands C Damage , packing
34. Tools & tackles C Damage , packing
35. Nut , bolts, washers, C Damage , packing
36. Gasket & Packings C Damage , packing
Damage , packing, Provide end

37. Copper tubes C
corrosion cap
Provide end
38. SS tubing C Damage , packing
cap
Rotating assemblies (pumps, blowers, stirrers, fans, compressors etc.)
Damage , packing, Shaft

39. Pumps S
corrosion rotation

40. Blowers/Compressors S
corrosion rotation

41. Agitators/stirrers/radial launders C
corrosion rotation
Rollers for chlorine tonner Damage , packing,

42. C
mounting corrosion
43. Centrifuge S Damage , packing,
Damage , packing,
44. Gear box C
corrosion
Damage , packing,
45. Bearings C
corrosion
Damage , packing,
46. Fans S
corrosion
Damage , packing,
47. Dosing skids S
corrosion
Damage , packing,
48. Pump assemblies S
corrosion
49. Air washers( INTERNALS) S Damage , packing
50. Air conditioners ( split) C Damage , packing
Page 8 of 13
Page 314 of 680
Type of
Storage
Damage , packing,
51. Elevators( CONTAINERIZED) O
corrosion
52. Chillers/VA machines S Damage , packing
53. Air handling Unit/Package unit S Damage , packing
54. Chlorinators & Evaporators C Damage , packing
55. Ejectors C Damage , packing
56. Electrolyser C Damage , packing
Miscellaneous items like chain pulley blocks, hoists etc.
57. Chain pulley blocks S Damage, Packing
58. Electric hoists S Damage, Packing
59. Fire extinguishers C Damage, expiry date
60. Fork Lift Truck S Damage, Packing
61. Hydraulic Mobile Crane O Damage, Packing
62. Mobile Pick Up & Carry Crane O Damage, Packing
63. Motor boats O Damage, Packing
64. Safety showers S Damage, Packing
65. Diffusers/dampers S Damage, Packing
Chemicals and consumables ( acid, alkali, paints, oils, reagents and special chemicals)
Store in
canes/
storage
tank in Date of production/ hazardous
66. Hydro Chloric Acid (HCl)
dyke leakage/fumes chemical
area
Store in
canes/
storage
tank in Date of production/ hazardous
67. Sulphuric acid (H2SO4 )
dyke leakage/fumes chemical
area
Page 9 of 13
Page 315 of 680
Description of the Type of

Sl. No. Check for Remarks
equipment Storage
Store in canes/ hazardous

storage tank in Date of production/ chemical
68. Sodium hydroxide (NaOH) dyke area leakage/ fumes/ ,breather to be
breather checked for air
ingress
hazardous
chemical ,self-life
To be stored Date of production/ normally 15-30
69. Sodium hypo chlorite
under shed leakage/ fumes days after which
strength of
chemical decays
Store in closed
Date of production/ storage tanks,
70. Ammonia S
leakage/ fumes hazardous
chemical
Date of production , Store in closed

71. CW treatment chemicals S
Self-life canes
Date of production , Store in closed

72. RO/UF cleaning chemicals S
Self-life canes
Damage to packing , Prevent moisture,

73. Lime C
seepage rain
Prevent moisture,
74. Alum bricks C Damage to packing
rain
Store in closed
75. Poly electrolyte S
storage tanks
Laboratory chemicals( Damage, Packing self-

76. C
powder) life
Laboratory chemicals( Damage, Packing self-

77. C
liquid) life
78. Lubrication oils C Leakage
79. Paints S Leakage ,air tightness
80. Sand O Damage of packing No hooks
Damage of packing, Prevent moisture,

81. Salt (NaCl) C
water ingress rain
82. Anthracite S Damage of packing
83. Activated carbon S Damage of packing
Page 10 of 13
Page 316 of 680
Description of the Type of

Sl. No. Check for Remarks
equipment Storage
84. Thermal insulation S Damage of packing
Prevent moisture,
85. Cement C Damage of packing
rain
86. Gravels O Damage of packing
Refer
87. ION exchange resins C Damage , packing manufacturer
guidelines
Refer
88. RO membranes C Damage , packing manufacturer
guidelines
Refer
89. UF membranes C Damage , packing manufacturer
guidelines
Refer
90. Cleaning chemicals C Damage , packing manufacturer
guidelines
Refer
Chemicals for
91. C Damage , packing manufacturer
analysers/calibration
guidelines
Electrical and C & I items (motors, cables etc.)
92. Motors C Damage , packing
93. Cable drums O Damage
Control Panel /control desk, UPS

94. S Damage, Packing
,JB
95. Instruments( gauges/analysers) C Damage
As per Manufacturer’s item, like Hydrogen cylinders,

Special items
Ozonator, Analyser, Chlorine dioxide generators etc.
Page 11 of 13
Page 317 of 680
5. CONCLUSION
Concerned storage agency at site should make sure that loss in equipment performance
and wear & tear are minimised through proper storage and preservation. The above are
broad guidelines and cover major equipment / materials. However specific storage
practices shall be followed as per manufacturer recommendation. All the necessary
measures even in addition to the ones mentioned above, if found necessary, should be
taken to achieve the objective.
Page 12 of 13
Page 318 of 680
Figure – 1 – PLATE STACKING ARRANGEMENT
Figure – 2 – STRUCTURAL STEEL STACKING ARRANGEMENT
Page 13 of 13
Page 319 of 680

ANNEXURE IX
INPUT DRAWINGS
Page 320 of 680


SL. DRAWING TITLE DRAWING NO.
NO.
1. P & ID OF CONDENSAT POLISHING UNIT PE-DG-412-155A-A001 ( 2 SHEETS)
2. T.G. EQUIPMENT LAYOUT PLAN AT EL. 0.0M PE-DG-412-100-M003 R2
3. PLOT PLAN PE-DG-412-100-M001-R 1A
Page 321 of 680

Page 322 of 680
Page 323 of 680
Page 324 of 680
Page 325 of 680

SECTION – D
STANDARD TECHNICAL REQUIREMENTS
SECTION – D1: STANDARD TECHNICAL REQUIREMENTS FOR MECHANICAL
SECTION – D2: STANDARD TECHNICAL REQUIREMENTS FOR ELECTRICAL
SECTION – D3: STANDARD TECHNICAL REQUIREMENTS FOR CONTROL AND
INSTRUMENTATION
Page 326 of 680

TITLE SPECIFICATION NO:PE‐TS‐412‐155A‐A001

SECTION – D1
STANDARD TECHNICAL SPECIFICATIONS (MECHANICAL)
Page 327 of 680

STANDARD TECHNICAL SPECIFICATION FOR CONDENSATE POLISHING PLANT
Page 328 of 680

1. INTRODUCTION
For maintaining the feed water purity condensate polishing plant will be provided in the feed water cycle at the
downstream of condensate extraction pumps. The function of the CPU will be to purity the condensate effluent
from the condenser by removing solids and dissolved salts with the intent of reducing corrosion and depositions
in the steam-water cycle. The proposed Condensate Polishing Unit (CPU) shall treat the condensate of the
Turbine-Generator (TG) Units of the power station, using deep Mixed Bed Ion exchange Polisher vessels and an
external regeneration system. One (1) number of Condensate Polishing Plants (CPP), for each TG (Turbine-
Generator) unit, along with one complete common external regeneration system shall be provided alongwith
instrumentations, valves and pipings, controls etc.
2. SYSTEM DESCRIPTION (GENERAL)
2.1 The proposed Condensate Polishing Plant (CPP) shall treat the condensate of the respective Turbine-
Generator (TG) Units of the power station. The system shall be as per tender drawing titled P&ID of
Condensate polishing Plant.
2.2 The proposed schematic arrangement of the condensate polishing plant and its regeneration facilities
shall be as per the enclosed P & ID. Arrangements of vessels, piping, and valves shown in regeneration
area are for reference only. Actual regeneration process shall be supplier specific.
2.3 There shall be three service vessels (3X50%) for each 660 MW unit each polishing 50% of the
condensate flow corresponding to VWO (valve wide open) condition at 1% make up (Flow through each
service vessel indicated in the data sheet) & all HP heaters out of service condition.
2.4 A common external regeneration facility for both the units shall be provided. For regeneration, resin from
the exhausted exchanger vessel will be transferred hydraulically to this facility. The exhausted resin
charge will be cleaned, separated, regenerated, mixed and rinsed before being stored for the next use.
2.5 The common influent and effluent headers of each CPU, will be connected to an automatic bypass
line (s) to be provided by Contractor. On high pressure signal across the service vessel, the
automatic control valve(s) in the bypass line(s) shall open, bypassing the service vessel(s).
2.6 In the event of a tube failure in the condenser, circulating water will enter the condensate system
and will contaminate it. Typical composition for the “START-UP OR CONDENSER LEAK CONDITION”
is given in the technical specification and the condensate polishing plant shall be designed for such
condition as mentioned.
2.7 Polisher mixed bed / service vessels of each 660 MW Unit shall be located in respective TG hall unit.
However the regeneration system shall be common to polisher of both the units and shall be external and
in building (except bulk acid & alkali storage facility & N-pit which is in open area). The CPU regeneration
system will be located near DM plant area (kindly refer plot plan for the same).
2.8 The equipments kept in open area (Pumps, blowers, motors, tanks, instruments, analysers etc.) have
localized shade provisions which is in bidder’s scope. All the instruments associated with condensate
polishing plant shall be provided with proper enclosures by Bidder. All vessels, pumps & blowers and their
drives and other electrical and C&I equipments/accessories of regeneration system shall be suitable for
outdoor duty and enclosures class of all the equipments shall be suitably selected by the bidder.
3. SALIENT DESIGN INPUTS/ CRITERIA
3.1 There shall be three service vessels (3X50%) for each 660 MW unit each polishing 50% of the
condensate flow corresponding to VWO (valve wide open) condition at 1% make up & all HP heaters out
of service condition (Flow through each service vessel indicated in the data sheet)
(a) NORMAL RUN :
The following dissolved solids concentration and conditions shall be used as a basis of design for the condensate
polishing system.
Page 329 of 680

The inlet and outlet quality ionic concentrations for design of CPU exchanger shall be as mentioned below:
CONTAMINANT UNIT INFLUENT EFFLUENT

Ammonia ppb 100 ---
Total dissolved solids ppb 100 < 25
(TDS, ammonia
excluded)
Conductivity (at 25°C) Micro-mhos/cm --- < 0.1 (After Cation Column)
Silica – Dissolved ppb 30 5 (Refer note # 1)
(as SiO2 )
Iron (Dissolved) -as Fe ppb 50 5
Sodium(as Na) ppb 10 2
Chloride (as Cl) ppb 10 2
pH (polisher runs at 25°C 8.5 6.8-7.5
with H/OH mode)
Crud (mostly black oxide ppb 50 5
of iron)
Note-1: For temperature 50°C and above the silica value in the effluent shall be based on the resin supplier’s
recommendations.
Under the Normal Condition, each Condensate Polisher Mixed Bed shall be designed to operate in hydrogen
cycle for not less than 720 hours (30 days) of continuous operation, while maintaining the above treated
condensate quality.
In addition to the dissolved solids, the influent condensate shall also contain some quantities of suspended solids
(crud) derived from the corrosion of water and steam carrying pipelines, turbine condenser, and steam side of
the feed water heater. Normally this concentration will not exceed about 50 ppb and the polisher beds shall
provide sufficient filtering action to restrict the effluent crud content to less than 5 ppb & same shall be
guaranteed.
Under the above operating and design flow through the polisher units, the un-ammoniated resins shall not reach
“ammonia break-point” in less than 30 days (720 hrs.) of continuous operation while maintaining the above
effluent quality. Whenever specific conductivity starts increasing from 0.1 micro mhos/cm in the effluent, it is
deemed that “ammonia break point” is reached. The effluent values indicated above shall be the maximum
values.
(b) START-UP OR CONDENSER LEAK CONDITION :
The inlet and outlet quality ionic concentrations for design of CPU exchanger for startup or condenser tube
leakage conditions shall be as mentioned below:
CONTAMINANT UNIT INFLUENT EFFLUENT

Ammonia ppb 1000 ---
Total dissolved solids ppb 2000 ---
(TDS, inclusive ammonia)
Conductivity (at 25°C) Micro-mhos/cm --- ---
Silica – Dissolved ppb 150 20
(as SiO2 )
Iron (Dissolved) -as Fe ppb 500 ---
Sodium(as Na) ppb 50 20
Chloride (as Cl) ppb 300 --
Crud (mostly black oxide ppb 500 150
of iron)
O
Note-1: For temperature 50 C and above the silica value in the effluent shall be based on the resin supplier’s
recommendations.
Useful service run under this condition shall be 50 hours before regeneration.
Page 330 of 680

3.2 Influent water quality as indicated in the above clauses is minimum only. Bidder to check the
same and higher values, if felt by them, shall be considered in the design so as to meet the specified
effluent quality.
3.3 The bed cross section in the service vessels shall be such that the average velocity of condensate through
it shall not exceed 2 meters/min (120 M3/hr/M2) at the design flow rate. The effective depth of mixed bed
in condensate polisher service vessel shall be not less than 1100 mm.
3.4 At the design flow rate, the pressure drop between inlet and outlet flanges of the polisher Condensate
Polisher Mixed Beds with clean resin bed shall not exceed 2.0 bar (g). This pressure drop shall include
losses due to entrance and exit nozzles, distributors, under drains, resins and the effluent resin traps.
Maximum pressure drop under dirty conditions shall be restricted to about 3.5 bar (g) including the
pressure drop across effluent resin traps.
3.5 Cation resins shall be regenerated by dilution of technical grade hydrochloric acid to IS: 265
(concentration 30-33% by volume) and anion resins by sodium hydroxide, rayon grade to IS: 252 available
as 48% lye. For calculations regeneration temperature should be taken as 25° C.
In no case, the regeneration levels cannot be lower than the valves indicated below:
a) Cation resin: 125 kg of 100% HCl per cubic meter of resin
b) Anion resin: 160 kg of 100% NaOH per cubic meter of resin.
3.6 Rinse water outlet headers from condensate-polisher vessels shall be provided with a pressure reducing
valve and orifice plate, suitably designed to enable the water entry to the condenser hot well under all
operating condition of condenser. The pressure reducing station shall consist of both a pressure reducing
valve from design pressure of service vessel to condenser vacuum or a combination of orifice plates to
reduce pressure from design pressure of service vessel to 2 kg/cm2 and a pressure reducing valve from 2
kg/cm2 to condenser vacuum.
3.7 While calculating pump head, 10% margin (minimum) shall be considered of the value of friction
losses. Pipe friction loss shall be calculated as per William-Hazen formula and “C” value to be
adopted shall be as below:-
1. Carbon Steel pipe : 100

2. CI pipe/ductile Iron : 100
3. Rubber lines steel pipe : 120
4. Stainless steel pipe : 100
Pump recirculation with a regulating valve shall be provided for all the pumping system.
4. GUARANTEES
All the design parameters at clause no 3.0 of this chapter, i.e. the effluent quality, the design flow, design
service length and Pressure drop across the resin bed in clean and dirty condition at rated design flow
shall be guaranteed by the Bidder. In addition to that Bidder to refer detail chapter of guarantees as
specified in Section C1-C of this specification for the same.
5. SYSTEM REQUIREMENT
5.1 The regeneration process offered by the bidder, shall be of proven design and shall essentially be the
same process by virtue of which the bidder is qualified and shall give resin-separation compatible with the
desired effluent quality. Documentary evidence shall be submitted by the bidder to the Customer/BHEL to
establish this requirement during detailed engineering stage if required.
5.2 The bidder shall include inert resin in the system if they feel that it helps in better resin separation.
5.3 In case, after separation of resins, there are undesired contaminant resins, the bidder shall provide a
system either to eliminate this cross contamination of resins or to nullify the detrimental effect of
entrapped resins to the effluent quality.
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5.4 EXCHANGE RESINS
(a) The plant shall include resins for each condensate polisher service vessels along with one (1) spare
charge of resin in the mixed resin storage tank. Two (2) spare charge of resins per unit during
commissioning and one (1) spare charge of resins as mandatory spares. Total resin charges shall be
supplied for the project is twelve (12) nos. One resin charge shall be considered as resin required for one
service vessel i.e. cation resin, anion resin and inert resin ( if any) used for the project.
(b) The resins used for the Condensate Polishing Unit are of the spherical form. Base of the ion-exchange
resins shall be copolymer of styrene and divinyl benzene forming a macro porous or macrorecticular
structure. Other details are as follows:
 Cation Resin : Strong acid, with sulfonic acid as functional group.

 Anion Resin : Strong base, with quaternary ammonium (Type-I) functional group
 Inert Resin (if required) : Non-ionic, compatible with the above resin types
(c) The total wet volume Exchange Capacities shall be based on resin supplier recommendations.
(d) Cation-anion resin ratio shall be 1.5 parts Cation to 1.0 part anion by volume. In case the process require
any non-ionic resin the same shall represent at least 10% of the bed volume, but not less than 15 cm of
the bed depth in the resin separation / cation regeneration tank of the external regeneration facility. The
CPU Grade resin shall be of uniform particle size quality. Cation resins shall be supplied in hydrogen form
and Anion resins shall be supplied in hydroxide form.
(e) Physical Properties:
Particle size: The resins shall be in the form of spherical beads. All resins, when wet screened with U.S.
standard sieves, shall pass through a No.14 sieve no more than 2 percent shall be retained on a no. 16
sieve, and more than 2 percent shall pass through a no. 40 sieve. The particle sizes and densities shall
be carefully controlled to facilitate clear separation between the resins during regeneration process.
Bead Strength: The average force required to fracture individual beads of cation resins in hydrogen
form, anion resins in hydroxide form, and the inert resins, shall exceed 350 grams. Not more than 5
percent of the beads tested in each batch shall get fractured by forces less than 200 grams.
(f) Chemical Properties:
i. Total wet volume ion-exchange capacities in equivalents/liter shall not be less than the following:
Cation in hydrogen form: 1.7

Anion in hydroxide form: 0.8
ii. The resins shall contain a minimum of metallic and organic impurities consistent with good processing.
The processing procedure will include rinsing the resins with demineralized water before packing, so
that further rinsing will not be required before use. Foreign objects in the resins shall constitute a basis
for its rejection.
(g) The resins shall be of reputed manufacturer with adequate past record of successful service for not less
than 3 years in similar application. Some of these possible resin systems shall be as follows:
1.0 Duolite.
2.0 Rohm and Hass
3.0 Dowex
4.0 Purolite.
(h) The resin shall be suitable for the condensate temperature that may be achieved in all operating regimes
of TG cycle. However, the anion resin shall be suitable for a minimum temperature of 60 deg.C.
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6. CONDENSATE POLISHING UNIT:
Condensate polisher vessel shall consist of following:
6.1 Condensate Polisher vessels complete with condensate inlet and outlet connections, connections for resin
transfer to and from the vessels, bed support-cum-under drain system, inlet water distributors air
distribution arrangement for resin mixing, all fittings and appurtenance as specified and as required.
6.2 External resin traps at the condensate & rinse outlet of each of the condensate polisher mixed beds each
designed for in-place manual back flushing facility.
6.3 Condensate inlet and outlet headers with pipe connections to the condensate polisher vessels.
6.4 Resin transfer headers connecting the common external regeneration facilities to the condensate polisher
vessels.
6.5 Rinse water outlet headers from condensate-polisher vessels shall be provided with a pressure reducing
valve and orifice plate, suitably designed to enable the water entry to the condenser hot well under all
operating condition of condenser.
6.6 All necessary valves, and fittings for the installations with actuators necessary for their remote operation
from CP System Control Panel of each 660 MW Unit. These shall include suitable foolproof arrangement
to prevent accidental over pressurization of the resin transfer pipeline and regeneration facilities
connected to it, which are designed for pressure much lower than that of the Condensate Polisher Mixed
Beds.
6.7 A drain header for the condensate polisher service vessels .All necessary drains, vents and sampling
points, with valves as required.
6.8 Emergency bypass between the condensate inlet & outlet headers for each unit.
6.9 Service vessel design pressure shall be equal to shut off pressure of condensate extractions pump
plus 5% margin or as specified in data sheet (A) of this technical specification, whichever is higher.
6.10 Design temperature of the service vessel shall take care of all operating regimes including HP-LP
bypass operation.
6.11 Two (2) nos. (1W + 1S) per unit oil free type air blowers with electric motor drive for supplying air required
for mixing the resins in service vessels.
6.12 The polisher units shall be provided at common inlet and each outlet unit with a minimum of following
analytical online analysers i.e. PH analyzer, Conductivity analyzer, Sodium analyzer, Silica analyzer,
Chloride analyzer and Cation Conductivity analyzer. However the Sodium analyzer, Silica analyzer &
Chloride analyzer provided shall be of multichannel type which shall measure the values of common inlet
and each service vessel outlet.
7. TECHNICAL REQUIREMENT OF EQUIPMENTS OF SERVICE VESSEL & REGENERATION AREA
7.1 All pressure vessels shall be designed and constructed in strictly in accordance with the ASME code
Section VIII Div.-I Ed 2010 /IS-2825 or acceptable equivalent international standard.
7.2 All pressure vessels shall be fabricated from carbon steel plates as per SA-516 Gr. 60/ 70 and lined
internally.
7.3 Lining used shall be natural rubber having a shore durometer reading of 65 ± 5 Shore ‘A’ as per IS 4682
Part I.
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7.4 The lining shall be applied in three layers, resulting in a total thickness of not less than 4.5 mm
anywhere on the internal surfaces of the vessels. The lining shall extend over the full face of all flanged
connections and shall have a minimum thickness of 3 mm in all such external areas.
7.5 Vessel internal shall meet the following requirements:
Inlet water and regenerant distributor- Hub and internals diffuser splash plate or header and perforated
laterals. Material of construction shall be SS-316.
Under Drains-
The under drain system shall be provided with screened laterals with internal perforated pipes and rubber
lined flat bottom. For resin separation/ regeneration/ mixed resin vessels, it may have fully screened
bottom (NEVA – clog type with pora-septanurese screen, fully supported by subway grid or equal)
/Fasteners.
All internal fasteners shall be of SS-316 and heavy duty locknuts shall be used throughout.
7.6 Resin Traps-
Outlet of each condensate polisher vessel, activated carbon filter shall be provided with a resin trap.
Pressure drop at design flow through a clean resin trap shall not exceed 0.35 kg/sq.cm. Resin trap shall
be of steel construction and internals shall be of SS-316 construction. Resin traps of process effluent line
shall have screen opening not exceeding 120 percent of associated process vessel under drain screen
Opening. Other resin traps shall have screen opening of 60 mesh. Manual back flushing shall be provided
for all resin traps.
Carbon Trap (for ACF): Outlet of each Activated Carbon filler on Carbon trap (media trap) shall be
provided.
8. EMERGENCY BYPASS SYSTEM
8.1 Each Condensate polisher service unit shall be provided with an automatic bypass for the condensate
polisher on the condensate inlet and outlet headers of the unit with a Butterfly control valve and Butterfly
isolation valves (resilient material seated, to ensure bubble-tight shut off) on the upstream and
downstream sides of the control valve.
8.2 In the event of excessive pressure differential (0.35 MPa) between the condensate inlet and outlet
headers, this control valve will open automatically to bypass requisite quantity of condensate to prevent
this pressure differential from exceeding a preset limit when two vessel/one vessel/no vessel is in
operation.
8.3 Either 2X50% capacity valves or 1X100% capacity control valve shall be provided to achieve proper
control under all operating conditions.
8.4 The control system shall be so designed that the control valve is able to bypass 50 % of rated flow when
any of the service vessel is out of service & 100% when both the service vessels are out of service.
8.5 The isolation valves shall be provided with geared operators for manual operation. The entire system shall
be designed for an internal pressure of at least the design pressure of service vessels and for a maximum
condensate flow of not less than total design flow of all the working service vessels.
8.6 Complete instrumentation and controls for this system, including the differential pressure transmitters,
panel mounted indicating type controller with provision for remote manual operation, actuator for the
control valve with position indicator shall be furnished by the bidder as part of this package. All tubing,
wiring, air sets, and other fittings, required to complete the system, shall also be installed by bidder.
9. EXTERNAL REGENERATION FACILITY
9.1 One common facility for regeneration of the resins from the condensate polishers for both the units shall
be provided and consisting of following:
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a. Resin Separation & Cation Regeneration Vessel.
b. Anion resin regeneration vessel.
c. Mixed resin storage vessel.
Note: The type of above vessels mentioned under sr. no. a, b, c shall be as per supplier process
requirements.
9.2 One (1) no. Resin Injection Hopper, complete with a water ejector system for resin make-up. The tank
shall be sized to handle up to 150 liters of as received new resins.
9.3 Common waste effluent header with one resin trap designed for in-place manual backwashing.
9.4 Two (2) (1W+1SB) nos. oil free type air blowers, each with electric motor drives for supplying all the
process air required for cleaning of resins and their regeneration processes. Each blower shall be
complete with motor, V-belt drive with belt guard, inlet filter / silencer, v-belts and discharge snubber, all
mounted on a single base, along with Relief valves, Acoustic hood etc. as required.
9.5 Two (2) nos. CPU Regeneration cum Resin Transfer Pumps each with electric drive motor drives, one
normally operating and the other standby, for water supply for chemical preparation / dosing and transfer
of resin from service vessel to regeneration vessels & vice-versa, backwash & rinse activities shall be
provided.
9.6 BULK ACID & ALKALI STORAGE & ACID/LAKALI DOSING SYSTEM:
The Acid and alkali dosing equipment for regeneration of condensate polishing resins shall preferably be
mounted on skid. All the equipment, piping etc. shall be assembled on two structural steel skids one for
acid and one alkali dosing equipment. This shall consist of at least the following:
a. One (1) no. acid measuring tank of adequate capacity to hold 120% acid required for one regeneration.
b. One (1) no. alkali preparation tank complete with electrically driven stirrer, and dissolving basket. The
tank capacity shall be equal to 120% of regeneration requirement of one regeneration.
c. One (1) no. alkali measuring tank complete with electrically driven stirrer, and dissolving basket. The
tank capacity shall be equal to 120% of regeneration requirement of one regeneration.
d. One (1) no. hot water tank for heating of alkali diluent water with (2X50%) electric heating coil,
adequately insulated of stainless steel construction shall be provided. The capacity of tank shall be
minimum 20% higher than the maximum water demand. This tank shall be provided with burn out
protection, pressure relief valve, level switches, temperature indicator etc. The heaters shall be sized for
heating the water from a temperature of 15 to 50 deg. C in 5 hours at the outlet of ejector.
e. One (1) no. Activated Carbon Filter for alkali rated flow of the filter shall not be less than the design
capacity of the alkali unloading pump, and the maximum velocity through the filter for this flow shall not
exceed 12 meters/hour: Depth of the filter materials shall not be less than 1 meter.
f. Two (02) numbers (1W+1S) simplex hydraulically operated diaphragm type acid dosing pumps with
electric motor drive, pulsation dampener & safety relief valve at the outlet header of each pump along
with all other required accessories for acid dosing.
g. Two (02) numbers (1W+1S) simplex hydraulically operated diaphragm type alkali dosing pumps with
electric motor drive, pulsation dampener & safety relief valve at the outlet header of each pump along
with all other required accessories for alkali dosing.
h. One (1) no. hose Station for Transfer of Hydrochloric Acid (30-33% HCl).The hose station shall consist
of one (1) no. of hose pipe. Hose size shall be of 80 mm /NB @ 20 m, provided along with coupling &
diaphragm type isolation valves.
i. One (1) no. hose station for transfer of Alkali (48% NaOH). The hose station shall consist of one (1) no.
of hose pipe. Hose size shall be of 80 mm /NB @ 20 m, provided along with coupling & diaphragm type
isolation valves.
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j. Two nos. (2X100%) Acid unloading pumps each complete with electrical drive motor and all other
k. Two nos. (2X100%) Alkali unloading pumps each complete with electrical drive motor and all other
l. Two nos. (2X100%) Alkali transfer cum recirculation pumps each complete with electrical drive motor
and all other accessories as required.
m. Two (2) nos. Bulk Acid storage tanks complete with integral pipe works, valves, level transmitter, level
gauges, fume absorber cum overflow seal pot and all other accessories required.
n. Two (2) nos. Bulk Alkali storage tanks complete with integral pipe works, valves, level transmitter, level
gauges, CO2 absorber, over flow seal pot and all other accessories required.
o. Carbon trap shall be provided at the outlet line of Activated carbon filter. This carbon trap shall have
screen opening of 60 mesh.
p. One (1) no. Neutralization Pit of RCC construction with two (2) compartments with acid and alkali
resistant lining along with isolation gates shall be provided in the CPU regeneration area. Each section
shall have capacity to hold 150% of waste water generated from CPU in one regeneration + 120% of
waste generated from RO –DM plant in one regeneration. Dosing of acid and alkali shall also be
provided to neutralize effluents of CPU regeneration waste before disposal.
q. One (1) no. Acid Measuring Tank for Neutralization- pit complete with integral pipe works, valves &
instruments all other accessories.
r. One (1) no. Alkali Measuring Tank for neutralization-pit along with slow speed agitator driven by motor
complete with integral pipe works, valves & instruments all other accessories.
s. Two (2 x 100%) capacity Waste Recirculation / Disposal pumps, each complete with electrical drive
motor. These pumps shall be of horizontal centrifugal type with priming arrangement and shall be
supplied for waste recirculation and disposal to CMB of ETP. The pump shall be designed to pump the
total volume of one section of the neutralization pit in 2 hours. Proven agitation system like air agitation,
venture mixing etc. shall be provided in addition to recirculation from pumps.
t. Two (2) nos. Safety Shower with necessary accessories.
u. All interconnecting piping, valves and fittings as required for the CPU regeneration system.
10. VESSEL FREEBOARD REQUIREMENTS
The pressure vessels in the external regeneration facility shall be provided with adequate freeboards over the
top of the settled resins, to minimize resin loss during their use. Minimum permissible freeboards are as
follows:
Mixed resin storage vessel - 50%

Resin separation vessel - 100%
Anion and cation regeneration vessels - 100%
Activated carbon filter - 75%
However if a vessel is used for more than one service, then the vessel design shall be based on the service
which gives maximum free board.
Note: Mill tolerances 0.3 mm shall be considered for determining the thickness of the shells and dished
ends of pressure vessels. A minimum thinning allowance of 2 mm shall be considered for the dished
ends of pressure vessels.
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11. TECHNICAL REQUIREMENT OF REGENERATION EQUIPMENTS
11.1 Activated Carbon Filter (for alkali):
Rated flow of the filter shall not be less than the design capacity of the alkali transfer-cum recirculation
pump, and the maximum velocity through the filter for this flow shall not exceed 12 meters/hour. Depth of
the filter material shall be as specified in DATASHEET –A of this specification.
The filtering medium shall be granulated activated carbon, meeting following minimum requirements. Total
Surface area : Not less than 850 sq.m/gm.
Bulk density : Not less than 400 kg/cu.m.
Iodine number : 850 minimum
Uniformity coefficient : 1.9 or less
Abrasion number : 70 minimum
Ash : 8% maximum
Mean particle diameter shall be about 1.5-1.7 mm with following size distribution:
On 20 mesh : Less than 3%
Through 40 mesh : Less than 10%
Through 50 mesh : Less than 1%
The filter shall be provided with all necessary valves and connections for manual backwashing and rinsing
with demineralized water. Rate set valves shall be provided with adjustable limit stops for setting
backwash and rinse rates.
11.2 DM Water storage tanks (Not in bidder’ scope) for Condensate polishing Plant
DM water required for CPU regeneration as well as resin transfer operations shall be drawn from DM
Water Storage Tanks (not in bidder’s scope) .However provision of suction nozzle & recirculation
nozzle for CPU plant DM water requirement, shall be there is BHEL provided each DM water storage
tanks (2nos.). Bidder to consider the piping from these suction nozzles to CPU regeneration a cum
resin transfer pumps and recirculation line piping from the outlet discharge line of these pumps to
each DM water storage tanks recirculation nozzle with an automatic valve. Further Bidder to
consider interlock (trip) of these pumps from the Level transmitter /level switch provided in both the
DM water storage tanks.
11.3 Resin Injection Hopper
The bidder shall provide a hopper type tank for resin make-up, using water slurry, to the condensate
polishing systems. This make-up system will constitute a portion of the condensate polishing external
regeneration system. The resin hopper shall have a conical bottom and a flat top. The top shall have a
piano type hinged port, having a lifting handle, of sufficient size for easy resin loading. The resin shall
discharge through a bottom connection to a water ejector for transport. Water shall be added to the
hopper to assist in the resin transfer. The ejector discharge shall be to the resin separation-cation
regeneration vessel. Demineralized water shall be used throughout for the resin transfer. Piping of the
resin make-up system shall be the responsibility of the Bidder as a part of the external resin regeneration
system.
a) Capacity
The resin make-up hopper tank shall be sized to handle up to 150 liters of as received new resin per
single injection.
b) Material
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The resin make-up hopper tank shall be fabricated of mild carbon steel having a minimum thickness
of 6 mm and lined.
12. PIPING
12.1 Bidder shall design, supply and erect the piping between the service units and the common external
regeneration facility, for transferring the exhausted and regenerated resins as required.
12.2 All piping shall be laid above ground and generally laid in pipe trestles including crossing of
road/pipe/cable trenches if any. Piping of between chemical tanks area and regeneration area etc. may be
laid on pedestals if layout permits.
12.3 Complete supporting system for the pipeline shall be designed, fabricated and supplied by the
Bidder. Inside the building, the overhead portion of the pipeline may be supported from the building
structures. In outdoors, the pipeline may run on steel posts. Crossing of the roads shall be on a pipe
bridge with a clear height of at least 6.1 meters over the road surface. All the steel structures of the
pipe bridge and the supporting posts along with all necessary hanger, clamps, connecting steel,
fixing bolts, nuts, etc. shall be supplied and erected by the bidder.
12.4 Routing of this pipe line shall be developed by the bidder and shall be finalized in coordination with the
BHEL/Customer, based on the space available and the final layout.
12.5 The resin transfer pipeline arrangement shall avoid any sharp bends which cause segregation of the
mixed resins, and pockets where the resins can get trapped. Suitable observation ports shall be provided
in all critical areas to enable the operator to monitor completeness of the resin transfer operations. All
necessary arrangements for venting and draining of the pipeline shall be provided.
12.6 The resin transfer pipeline shall be sized for a flow velocity of between 2.3 and 3.0 meters/sec.
12.7 The condensate pipeline shall be sized for a flow velocity between 3 and 5 m/sec.
12.8 Remotely operated valves suitably interlocked with the plant operation, shall ensure that the resins get
transferred to and from only the particular service vessel which has been selected by the operator.
12.9 All lined vessel connections and connections in unlined vessels (25 Nb and larger) shall be flanged to
ANSI 150 lb class except the polisher service vessels which shall be ANSI 300 lb class: Flat face flanges
shall be used throughout. All flanged connections shall be supplied complete with matching counter
flanges, nuts, bolts and full face gaskets. All the pipeline in service vessels area where pressure may
attain same as service vessel shall be designed for 300 lb class.
12.10 Bidder to also the refer the detailed specification for low pressure piping for piping inside
regeneration area & power cycle piping for piping inside service vessel area which is enclosed
elsewhere in this specification.
13. PRESSURE VESSELS, ATMOSPHERIC TANKS & MISCELLANEOUS ITEMS
13.1 Design pressure of the condensate Polisher Service Vessels shall be as indicated in the data sheet. For
all other pressure vessels, unless otherwise mentioned design pressure shall be at least 10 kg/cm2(g).
13.2 Design of all vertical cylindrical atmospheric storage tanks containing water, acid, alkali and other
chemicals shall conform to IS: 803.
13.3 Design of all horizontal cylindrical storage tanks containing water, acid, alkali and other chemicals shall
conform to BS 2594/ BS EN12285-2:2005.
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13.4 Unless otherwise mentioned design temperature of all pressure vessels and storage tanks shall be
10 deg.C higher than the maximum temperature that any part of the vessel/tank is likely to attain during
operation.
13.5 In case, tank is subjected to vacuum, the same shall be taken care in designing the tank.
13.6 The design of Demineralized water storage tanks (Vertical type) shall conform to IS: 803. Supporting
frame where required shall be in accordance with IS: 800. The tank shall be ‘‘Non-pressure’’ fixed roof
type with atmospheric vents.
13.7 All vessels/tanks without inside rubber lining shall have a corrosion allowance of minimum 2 mm and mill
allowance (minimum 0.3 mm) for shell and dished ends. Thinning allowance of 2 mm (minimum) shall be
considered for dished end of torishpherical type.
13.8 Spherical vessels for CPU service vessels are acceptable.
13.9 All the atmospheric tanks shall have sufficient free board above the ‘‘Level High /Normal Level’’ as the
case may be. The overflow level shall be kept at least 20 cm or 10% of vessel height above the ‘‘Level
High /Normal Level’’ for all the tank except for the DM tanks for which a minimum height of 300 mm shall
be provided over the ‘‘High Level’’. Further, a minimum 300 mm free board shall be provided above the
top of overflow level to the top of tank.
13.10 Material:
i All pressure vessels shall be designed and constructed in strict accordance with the ASME code
Section VIII or acceptable equivalent international standard. Suitable mill tolerances shall be
considered for determining the thickness of the shells and dished ends. A minimum thinning allowance
of 2 mm shall be considered for the dished ends of torospherical type.
ii Pressure vessel ends shall be of dished design and constructed by forging, pressing or spinning
process. Spherical vessels for CPU service vessels are acceptable. Conical or flat ends shall not be
accepted. All the atmospheric vessels shall be at least 6 mm thickness.
iii All pressure vessels shall be fabricated from carbon steel plates as specified in DATASHEET-A and
lined internally. The lining shall be of rubber having a hardness of 65 plus/minus 5 shore -A meeting
the requirements of IS: 4682, Part-I. The lining shall be applied in three layers, resulting in a total
thickness of not less than 4.5 mm anywhere on the internal surfaces of the vessels. The lining shall
extend over the full face of all flanged connections and shall have a minimum thickness of 3 mm in all
such external areas.
iv Vessel internals shall meet the following requirements:
1) Inlet water and regenerant distributor: - Hub and internals diffuser splash plate or header and
perforated laterals. Material of construction shall be SS-316 except for acid service which will be of
Hastealloy-B.
2) Under drains: Same as above with screened laterals with internal perforated pipes and rubber
lined flat bottom. For resin separation/regeneration/mixed resin vessels, it may have fully screened
bottom (NEVA - clog type with pora septanurese screen, fully supported by subway grid or equal).
3) All internal fasteners shall be of SS-316 and heavy duty locknuts shall be used throughout.
v Resin Traps: Outlet of each condensate polisher vessel, activated carbon filter and waste effluent
header of the common regeneration shall be provided with a resin trap. Pressure drop at design flow
through a clean resin trap shall not exceed 0.35 kg/sq.cm. Resin trap shall be of rubber lined steel
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construction and internals (cord & screen) shall be of JOHNSON SCREENS

IRELAND or equivalent (SS-316) construction. Resin traps of process effluent line shall have screen
opening not exceeding 120 percent of associated process vessel under drain screen opening. Other
resin traps shall have screen opening of 60 mesh. In place manual back flushing shall be provided for
all resin traps.
vi Carbon Trap (for ACF): Outlet of each Activated Carbon filler on Carbon trap (media trap) shall be
provided.
14. OPERATION & CONTROL PHILOSOPHY OF CPU PLANT
The regeneration system shall be external and common to the polisher of both the units. Under normal
conditions, it will hold a complete charge of freshly regenerated and mixed resin, ready for use, in its storage
tank. For regeneration, resin from the exhausted exchanger vessel shall be transferred hydraulically / hydro
pneumatically to this facility.
The empty exchanger vessel will then be filled up with the already regenerated resin which was stored in the
regeneration facility. This exchange vessel shall come into service soon after perquisite condition is satisfied or
as and when desired by the operator. In the meantime, the exhausted resin shall be cleaned, separated,
regenerated, mixed and rinsed before being stored for next use.
The control & operation of regeneration area shall be from OWS as well as OWES located in regeneration area.
Operation of Service vessel shall be from 1 no. OWS located in each unit of service vessel area.
CONTROL & OPERATION OF CONDENSATE POLISHING PLANT
A) GENERAL
(i) It shall be possible to operate the regeneration plant in Auto / Semi auto / Manual mode. In ‘Auto mode, once
the sequence has been initiated, it shall proceed from step to step automatically. In ‘Semi auto’ mode each
step shall be performed only after initiation by the operator. In ‘manual’ mode complete operation shall be by
the operator.
(ii) The control system shall link the various steps such as closing/ opening of different valves, starting / stopping
of various pumps etc. which form a sequence. The logic system shall adhere to the correct sequence of
operation and predetermined time intervals. The system shall have interlocks so that, criteria necessary for
each step are complete prior to proceeding to the next step.
(iii) It shall be possible to switch mode of operation from one to the other at any moment and the operation shall
proceed on the newly selected mode from that time.
(iv) For steps, which require frequent time adjustment and all other steps, it shall be possible to change the time
setting from the OWS/OWES.
(v) For all sequences, the current step number, time of the step, elapsed time of the step and the total elapsed
time of the sequences shall be indicated in the OWS/OWES.
(vi) The system shall incorporate the necessary safety features. During automatic sequential operation, if any
pre-requisite criterion is not fulfilled or missing for a pre-determined time interval, the steps shall not proceed
further, and alarm shall be provided. Missing criteria, sequence, which is under hold up etc. shall be
displayed.
(vii) The safety system for any sequence/step shall check the opening of the required valves and closure of the
remaining valves of the plants to avoid mal operation.
B) CONDENSATE POLISHER CONTROL SYSTEM
(i) Operation of the complete Condensate Polishing System shall be through Programmable Logic Controller
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(PLC).In addition to above, local control desk with colored Mimic, Indicators, Ammeters,
H.W. Annunciator, P.B. and indication Lamps shall also be provided .The control and monitoring of
condensate polishing plant is done at two places:
The condensate-polishing unit shall be controlled from the PLC system, located near the service vessel.
This system shall be suitably interlocked with the regeneration system control panel.
 Service vessel: The control & operation of the CPU service vessels shall be done from the 1 no. OWS for
Each TG unit provided & located in TG hall area near CPU Service vessels. RPU (Remote Processing unit)
shall also be provided near service vessel area of each TG unit.
 Regeneration system: The operation of regeneration system shall be by means of PLC based control
system located in regeneration area. In addition to the PLC based system, Backup Control desk with coloured
Mimic, Indicators, Ammeters, H.W. Annunciator, P.B. and indication Lamps shall also be provided. Also
operation shall be envisaged from 2 No. of OWS (1 OWS & 1 OEWS), in regeneration area.
(ii) Facility to monitor the Condensate Polishing System from the Main control room is not envisaged. However
the status of major parameter shall be sent to the control room for indication purpose only.
(iii) This PLC shall have interface module for redundant and bi-directional OPC connectivity with DDCMIS. Taking
the equipment into service and regeneration of mixed-bed units shall be initiated manually from the OWS of
control system or local panel and balance operation shall be carried out sequentially by the control system.
Manual override facility is also provided for all operations.
(iv) The latest proven PLC system shall be provided. PLC should be sourced from original manufacturers; PLC
from system house shall not be acceptable. PLC system shall be complete with hot standby redundant CPU
of word length of 32bits minimum, Input / Output modules, dual serial link interface module for connecting
Input / Output Modules, dual Communication Processors, dual Memory modules and redundant Power supply
units. Power supply unit shall be redundant for each CPU & I/O rack. PLC system will be interfaced with
DDCMIS through OPC dual redundant communication interfacing (to be provided at PLC & DDCMIS end) for
important process parameters. PLC shall confirm to IEC – 61131.
(v) PLC shall be provided with necessary redundant ports & complete hardwares for Auto time synchronization
from Master clock time.
(vi) Open and Close limit switch feed backs of valves are to be connected to PLC for remote viewing and for
interlocks and protection.
(vii) Remote and local indications of various important parameters to the process requirement shall be provided.
(viii) The instruments shall be offered as per the process requirement for complete auto operation. All the
instruments/equipment/electrical items shall be provided & designed with maximum star rating as available in
line with energy conservation policies notified by BEE, GOI.
(ix) Necessary instruments pressure gauges, Temperature gauges, DP instruments, Pressure transmitters, Radar
Level transmitters, Differential pressure transmitters, Temperature Elements Various analysers, Magnetic
type level indicators, shall be provided. The junction boxes and instruments / electronics housing used shall
be Non – corrosive material.
(x) Flow transmitters at each CPU service vessel inlet shall be provided for monitoring the performance and
accountability.
(xi) Annunciations for abnormal conditions (as per system requirement) shall be provided in the Control Panel.
(xii) Pneumatic actuators with all accessories shall be controlled using solenoid valves, which shall be energized
from OWS / Control Panel. The opening and closing of these valves is based on system requirement, which is
programmed in the Control system. Feed backs to the control system regarding the valve open / close
position are set through the limit switches.
(xiii) Each of the solenoid valves in CPU plant shall be provided with ‘close-Auto-open control switches. In ‘Auto’
position of the control switch the solenoid valve shall receive close/open command from the Automatic
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sequence logic
(xiv) Time synchronization of PLC with master clock system is to be carried out. Necessary hardware/software for
the same shall be provided.
(xv) PLC shall be connected to DCS through OFC with Modbus/OPC protocol for monitoring.
(xvi) 2 x 100% parallel redundant UPS, 1 x 100% Bypass stabilizer & 1 set of battery bank for minimum 60 minute
back up at 100% load shall be provided.
(xvii) Smart positioners shall be provided for pneumatically controlled valves.
(xviii) Each condensate polishing system shall be provided with programmable logic control based local panel
that will clearly show the status of each service vessel. It shall be possible to select each of the CPU vessel
for any of the following operations or mode:
 Service.
 Isolation from service.
 Exhausted Resin Transfer from CPU vessel to Regeneration plant.
 Regenerated Resin Transfer from Regeneration Plant to CPU vessel.
 Rinse recycle mode.
(xix) A mimic diagram shall be provided for the CPU scheme on the OWS and as well as front of the CPU control
panel. Status of various valves shall be indicated by LED’s on the mimic diagram.
Each condensate polishing system shall be provided with a programmable logic control based local panel that
will clearly show the status of each service vessel. From this panel it shall be possible to initiate any of the
following operating modes. This panel shall be located near the respective condensate polishing vessels.
The following requirements of the control system shall be included:
 RINSE RECYCLE MODE
The rinse recycle shall be manually initiated in full automatic sequence. This sequence shall include the rinse
down step using condensate at the desired flow rate until the unit effluent quality is acceptable for boiler feed
water. The effluent quality shall be determined by conductivity monitoring of the rinse water outlet which is
returned to the condenser hotwell for recycle. A panel mounted cation conductivity indicator shall be
interlocked to prevent advancing of the automatic sequence until the rinse down is complete.
 SERVICE MODE
Service flow rate for each polishing vessel shall be monitored by panel mounted flow indicators. During
periods of low condensate flow the operator may select to remove one of the vessels from service by a
manually initiated automatic sequence. A differential pressure switch installed between the influent and
effluent headers will on a high signal cause an annunciator alarm. By observing the individual vessel flow
indicators, or conductivity at vessel outlet the operator can determine which vessel is contributing most to the
pressure drop and is in need of resin cleaning.
Panel mounted cation conductivity indicators shall monitor the polishing system influent and effluent streams
as well as the discharge of each service vessel. A high influent conductivity annunciator alarm will alert the
plant operator that a problem condition such as air or condenser cooling water leakage has occurred. This
conductivity analyzer shall also provide contacts for an alarm at the power station main control room. A high
effluent header or service vessel conductivity annunciator alarm will alert the operator to the need for
regeneration of a polishing vessel.
 ISOLATION FROM SERVICE
Normally ‘‘Service vessel’’ once exhausted shall be isolated from service till the ‘‘Resin Transfer’’ operation is
complete.
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 The sequence ‘Resin Transfer from CPU Vessel to Regeneration plant’ and Resin Transfer from
Regeneration plant to CPU Vessel’ shall be initiated from the condensate polishing unit control panel but shall
be controlled by the programmable logic controller in the Regeneration Control Panel.
C) EXTERNAL REGENERATION CONTROL SYSTEM
(i) One external regeneration system shall be provided to serve the condensate polishing for the unit. This
system shall be designed for physical cleaning and chemical regeneration of the resin system will consist of
required number of resin separation and regeneration vessels, a mixed resin storage vessel, the tank for
introducing the required regeneration solutions and means for adding make-up resin. It will have acid, alkali,
and ammonia (if required) dosing system and alkali preparation facilities.
(ii) Manually initiated automatic sequences shall be provided for transferring resin from a vessel to the remote
common facility for physical cleaning and chemical regeneration and for returning fresh resin to that vessel.
Control for chemical dosing system and alkali preparation facility shall also be provided in it.
(iii) Regeneration shall include hydraulic reclassification of the resins and the transfer of the resins to the
respective regeneration vessels shall be hydraulically/hydro pneumatically. The separated resins shall then
be backwashed, cation and anion regenerated with hydrochloric acid and sodium hydroxide solutions
respectively, rinsed and then followed air scrubbing and a good backwash. The resin is then transferred
back to the resin separation vessel and the resins are air mixed. The mixed resins after regeneration are
given a final rinse with the discharge conductivity being monitored. If the quality is satisfactory, the mixed
resin shall be transferred to the resin storage vessel otherwise regeneration sequence shall be
repeated.
(iv) Regeneration Control System
a) A manually initiated automatic sequence for physical cleaning and chemical regeneration of the resin shall be
provided. Control for chemical dosing system and alkali preparation facility shall also be provided in it.
b) Demineralized water shall be used throughout the regeneration process for backwashing, regenerant
diluents, rinsing and resin transfer.
c) A conical bottom hopper having a water ejector will be used for resin make-up.
d) The complete detail of the regeneration system shall be supplier specific and the extent of automation
offered, operation of the complete system, logic/flow diagrams, type and details of the presentation of
information, the type of mimic, hardware details etc. along with detailed circuit descriptions shall be provided
during detail engineering.
e) The complete control and operation of the regeneration plant shall be through programmable logic controller
(PLC).
(v) Resin Transfer
Manually initiated automatic sequences shall be provided for transferring resin from a Service vessel to the
remote common facility for physical cleaning and chemical regeneration and for returning fresh resin to that
Service vessel.
The sequence resin transfer from CPU vessel to regeneration plant and from regeneration plant to CPU
vessel shall be initiated from the condensate polishing unit control panel but shall be controlled by the
programmable logic controller in the regeneration control panel.
The transfer of resin from the service vessel shall include isolation of the service vessel, hydraulic/hydro-
pneumatic transfer of the resin to the external regeneration system (resin separation vessel) and the
complete drain down of the service vessel to the hot well.
(vi) The complete control and operation of the Regeneration Plant shall be through Programmable Logic
Controller.
(vii) It shall be possible to operate the Regeneration Plant in Auto/Semi-Auto/Manual mode.

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(viii) Following operations shall be possible from the Regeneration Control Panel.
a) Complete Regeneration.
b) Resin Transfer from CPU vessel to Regeneration Plant.
c) Resin Transfer from Regeneration Plant to CPU vessel.
Operation (a) shall be initiated from the Regeneration Control panel whereas operation (b) & (c) shall be
initiated from the CPU service vessel Remote I/O panel.
(ix) In ‘Auto’ mode, once the sequence has been initiated, it shall proceed from step to step automatically.
(x) In 'Semi-auto' mode each step shall be performed only after initiation by the operator.
(xi) In ‘Manual’ mode complete operation shall be by the operator by operation of the Control switches on the
panel.
(xii) ‘Close-Auto-Open’ control switches shall be provided on the panel for the various drives. In ‘Auto’ position,
the drives shall receive stop/start command from the PLC.
(xiii) ‘Start-Auto-Start’ Control switches shall be provided on the panel from the various drives. In ‘Auto’ position,
the valves shall receive close/open command from the PLC.
(xiv) On PLC failure, it shall be possible to operate the valves by means of manual operation of solenoid valves
also.
(xv) It shall be possible to switch mode of operation from one to the other at any moment and the operation shall
proceed on the newly selected mode from that time.
(xvi) For steps which require frequent time adjustment, it shall be possible to change the time setting from the front
of the panel. For all other steps it shall be possible to adjust the time setting from inside the panel.
(xvii) For all sequences, the current step number, set time of the step, elapsed time of the step and the total
elapsed time of the sequence shall be indicated on the front of the panel.
(xviii) A mimic diagram of the Regeneration system shall be provided on the front of the panel. The status of various
drives and valves shall be indicated by LED on the mimic diagram.
(xix) The system shall incorporate the necessary safety features. During automatic sequential operation, if any
pre-requisite criteria is not fulfilled or missing for a pre-determined time interval, the steps should not proceed
further, the Alarm shall be provided. Missing criteria, sequence which is under hold up etc. shall be displayed
on the panel.
(xx) The safety system for any sequence/step shall check the opening of the required valves and closure of the
remaining valves of the plant to avoid mal-operation.
(xxi) Wherever standby equipments are provided, it shall be possible to select each of the drive on ‘standby’ duty.
(xxii) Start, progress and stop of each of the sequence shall be annunciated in all the control panels.
(xxiii) At any time only one of the sequence shall be in progress.
D) SPECIFIC INTERLOCKS RELATED TO SERVICE & REGENERATION SYSTEM
All interlocks for safe operation of the plant shall be provided. The following interlocks as a bare minimum
requirement of the system shall be provided:
(i) Service vessels shall be taken back in service, only after they have been pressurized.
(ii) Service vessels can be taken up for resin transfer only after they have been completely isolated from the
condensate system and depressurized.
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(iii) Resin can be transferred to and from only one service vessel at a time.
(iv) Resin transfer between the service and the regeneration skids shall be permitted only when the receiving vessel
is initially empty.
(v) Regeneration sequence can commence, only when the level in the waste N-Pit is low enough to receive the
entire waste water from the regeneration operation.
(vi) Wherever possible, completion of all timed steps in the regeneration and resin transfer process shall be
physically verified by effluent conductivity etc. as applicable. The automatic sequence shall be prevented from
advancing to next step, till these required physical conditions are achieved, and at the same time this delay shall
be annunciated in the control panel, to draw the attention of the operator. The automatic sequence of operations
shall be interruptive at any time by the operator and he shall be able to take over the control to manual from that
step onwards. Further operator should be able to override sequence, if required.
(vii) It shall be possible for the operator to extend the timing of the particular step by isolating the timer for the
duration. The timer will restart once the operator puts back the system on ‘auto’ and the other steps will then
follow as programmed.
(viii) The regeneration sequence shall be prevented from advancing further in the event of tripping of a running motor
or other fault condition, which do not permit the various desired parameter of this step to be achieved. A manual
over ride for this shall also be provided.
(ix) Annunciation logic shall be carefully designed so that the alarms are activated only under abnormal conditions.
As for example, low flow of diluent water is only relevant when the chemical dosing is in progress. All other times,
when no diluent water flow is required, this annunciation should be blocked. In general, Normal and trouble free
operation of the plant shall not activate any of these alarms.
(x) Adequate diluent water flow shall be established before starting of the ejectors/dosing pumps for acid and alkali.
(xi) The immersion heater in the hot water tank can be put on only when there is adequate water level in the tank.
Note: Bidder to note that for complete control & operation of the CPU plant bidder to also refer the
respective Control & Instrumentation (Section C3, D3) & Electrical (section C2 & D2)
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CHAPTER 32
32.00.00 LAYOUT REQUIREMENT
32.01.00 The general layout criteria to be adopted for this project are indicated below.
1. Minimum clear working space around equipment : 1200mm
2. Clear Head room within Main Plant Building for pipes, ducts : 2.5 m (Minimum)
structures & cable trays etc.
3. No. of Fire Escape staircases in the main : Min-4 Nos. per unit - However the
plant with fire doors at each landing number shall meet the requirement
of insurance companies.
4. Adequate space for handling/removal of pumps, heaters, heat-exchanger, fans, Mills, during
maintenance.
5. Independent floor drains with separate down comers shall be provided where sprinkler
system are provided.
6. Valves in the Bidder’s scope shall be located in accessible positions. All piping shall be
routed at a clear height of 2500 mm (min.) from the nearest access level to clear man
movement.
7. Provision of monorail beams with chain pulley blocks/HOT cranes along with hoists, as
required shall be decided during detailed engineering stage and are in bidder scope.
8. Approach for removal of equipment for maintenance shall be provided.
9. A/C and Ventilation ducts, Bus ducts, and Critical Piping routes to be identified at conceptual
stage.
10. Fuel oil (F.O) piping shall be routed over trestles. The headroom for F.O. Trestle in
Boiler/ESP area shall be 8.0M till the road behind chimney as per the layout requirement.
The headroom for F.O. trestle in outlying area shall be 3.0M except at rail/road crossing
where the headroom shall be 8.0M. F.O. trestle legs or supports shall be located so as to
clear the road spaces, approach to maintenance bays of different equipment buildings
located in the route of F.O. trestle.
11. Routing of cable trays & piping
i) Trestle height in outlying area : 3 Meters(BOS/BOP)
ii) Trestle height from C-row to road : 8 Meters(BOS/BOP)

Behind chimney /in front of XFMR
Yard Boiler/ESP area
iii) Cable/ Pipe trestles height at rail/ road crossings shall be 8M. (BOS/BOP)
iv) Head room below cable / pipe rack in transformer yard area for movement of spare
GT shall be 12.0 Meters.
v) A walkway with hand rails & toe guards of 600mm (minimum) width shall be provided
all along length of the trestle for maintenance of cables & pipes. Ladders for
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approach to these platforms shall be provided near roads, passage ways and turning
points.
vi) At the crossing of pipe/ cable trestles with the dry ash pipe rack/CHP cable rack
trestle, pipe/ cable trestle shall be locally raised to provide a head room of 2.5 M over
the walkways of dry ash pipe rack/CHP cable trestles.
vii) Head room below cable/pipe rack along Mill bay shall be 12.0 Meters.
viii) Head room for man movement shall be 2.5 m at ground floor, over all platforms etc.
ix) Minimum clear hand space required for
a) The application of thermal insulation 100 mm
b) Welding work 150 mm
c) Bolt tightening 150 mm
12. Piping in main plant area (i.e. boiler/ESP/ID fan/chimney/transformer yard) shall be routed
above ground on trestles with a height of minimum 8M. Further, piping in outlying area shall
be routed over trestles with a height of 3M. However, height of trestles at approach roads to
various buildings/ facilities shall be 8M.
13. Fire water piping within the Plant boundary shall be routed above ground on pedestals.
However, fire water pipes in Main Plant Island shall be routed in trenches filled with sand and
covered with pre cast RCC covers. Fire water pipes shall be protected in main plant area as
per TAC requirement. Fire water piping at road crossing shall be encased/culvert. Fire water
pipe at rail crossing shall be on trestle of BOS 8M height from rail top.
14. All other safety requirements as per the factories act, National Electricity code shall be
observed while developing the layout.
15. Insulation of equipment/piping for personnel protection is to be provided if the temperature

exceed 60 deg C.
16. Chequered plate edges should have continuous supports/ stiffeners.
17. Each equipment room shall be provided with alternate exits in case of fire /accidents as per
requirements of factory act and TAC.
18. Each building shall have an identified vacant space for equipment unloading and
maintenance and preferably a separate bay altogether in buildings housing heavy
equipment. Provision for handling equipment by monorail hoist and/or overhead crane shall
be made as specified.
19. Cubicle for operating personnel shall be located for all buildings at safe place near the
equipment.
20. All buildings shall have provision for toilet and associated effluent discharge system together
with facility for drinking water. The criteria for ventilation, fire protection and illumination of
building spaces specified elsewhere in this specification shall be complied with.
21. All gratings shall be of electro forged type with adequate bearing & locking on the supporting
structure.
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22. Approach to all elevated structures like Fans, Pumps, etc shall be through steel stairs with
gratings & hand rail.
23. All cranes shall be provided with approach rung ladders at least at two places. Where ever
cranes can't be maintained in situ on the carriage, facility to draw them to maintenance
platforms as well as provision of suitable platforms shall be considered.
24. All fresh air ventilation louvers shall be 1000 mm from floor level and directed downward at
an angle.
25. The VFD control equipment and transformers for ID fan shall be located along with the ESP
control equipment in the ESP/ VFD control room.
26. Three (3) nos. of staircases per ESP of each unit shall be provided. Two (2) nos. of the
staircase shall be located on the inlet side and one (1) no. on the outlet side of ESP.
27. The grating platform shall be provided in oil equipment room, control fluid room and valve
room.
28. Approach platform shall be provided from ESP outlet to ID fan suction gate.
29. Minimum access opening required 3.5M wide x 4M high or, (with rolling shutter)
transportation wherever entry of truck, for material more depending upon this envisaged
equipment size to be handled.
30. Toilet and drinking water facility required in all buildings and on all floors wherever operating
personnel are to be deployed.
31. Local Pits/trenches in Main Plant building are to be avoided. However pits/sumps which are
unavoidable such as CW (Circulating Water System) pits etc shall be provided with required
dewatering arrangements by means of drainage pumps and piping upto the nearest drainage
network. Bidder shall provide required sump pumps/drainage pumps/submersible pumps &
Piping etc.
32 Pump shall be permanently fixed in the pits/sumps. If the pit depth is shallow, vertical top
mounted sump pumps shall be provided and in deep pits self priming drainage pumps
(horizontal type) at floor level or alternatively submersible type pumps may be provided.
33 Each pit/sump shall be provided with two numbers (2 x 100% Capacity) of respective type
pumps so that the entire pit is evacuated within 15-20 minutes and the operation of the
pumps shall be interlocked through level measurement devices to be installed in the pit/sump
so that the pumps shall start automatically and empty the pit.
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CHAPTER 13
13.0 LP PIPING, VALVES & SPECIALITIES
13.1 Equipment sizing Criteria
13.1.1 All the piping systems and equipment supplied under this package shall be
designed to operate without replacement and with normal maintenance for a plant
service life of 30 years, and shall withstand the operating parameter fluctuations
and cycling which can be normally expected during this period.
13.1.2 For all LP piping system covered under this specification, sizing and system design
shall be to the requirements of relevant codes and standard indicated elsewhere.
In addition to this, requirements of any statutory code as applicable shall also be
taken into consideration.
13.1.3 Inside diameters of piping shall be calculated for the flow requirements of various
systems. The velocities for calculating the inside diameters shall be limited to the
following.
a) Water Application
Water Velocity in m/sec

Pipe Size Below 50-150 200 mm
50 mm mm & above
a) Pump suction ------- 1.2-1.5 1.2-1.8
b) Pump discharge 1.2-1.8 1.8-2.4 2.1-2.5

and recirculation
c) Header ---- 1.5-2.4 2.1-2.4
The pipes in CW, ACW & DMCW system shall be designed to maintain a
maximum velocity of 2 m/s inside the pipelines at pump discharge.
Pipe line under gravity flow shall be restricted to a flow velocity of 1 m/sec
generally Channels under gravity flow shall be sized for a maximum flow
velocity of 0.6 m/sec.
WILLIAM & HAZEN formula shall be used for calculating the friction loss in
piping systems with the following “C” value.
i) Carbon steel pipe 100
ii) CI Pipe/Ductile Iron 100
iii) Rubber lined steel pipe 120
iv) Stainless steel pipe 100
For calculating the required pump head for pump selection, at least 10%
margin shall be taken over the pipe friction losses and static head shall be
calculated from the minimum water level of the tank/sump/reservoir from
which the pumps draw water.
b) Compressed Air Application
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Compressed air – 15.0 m/sec. (under Average Pressure & Temp.

conditions)
13.1.4 The pipes shall be sized for the worst (i.e. maximum flow, temp. and pressure
values) operating conditions.
13.1.5 Based on the inside dia. so established, thickness calculation shall be made as per
ANSI B 31.1 OD and thickness of pipes shall than be selected as per ANSI B
36.10/IS-1239 Heavy grade/IS-3589/ASTM-A-53/API-5L/ANSI B 36.19 as the case
may be.
13.1.6 Corrosion allowance of 1.6 mm will be added to the calculated thickness being
considered.
13.1.7 Bend thinning allowance/manufacturing allowance etc. shall be as per the

requirement of the design code provision.
13.1.8 High points in piping system shall be provided with vents alongwith valves as per
the system requirement. Low points shall be provided with drains alongwith drain
valves as per the system requirement. Drain lines shall be adequately sized so as
to clear condensate in the lines. Material for drain and vent lines shall be
compatible with that of the parent pipe material.
13.1.9 Material of construction for pipes carrying various fluids shall be as specified
elsewhere.
13.1.10 Compressed air pipe work shall be adequately drained to prevent internal moisture
accumulation and moisture traps shall be provided at strategic locations in the
piping systems.
13.1.11 Depending upon the size and system pressure, joints in compressed air pipe work
shall be screwed or flanged. The flange shall be welded with the parent pipe at
shop and shall be hot dip galvanized before dispatch to site. Alternatively, the
flanges on GI pipes may be screwed-on flanges also.
13.1.12 Threaded joints shall be provided with Teflon sealant tapes.
13.1.13 Following types of valves shall be used for the system/service indicated.
System Type of Valves
Butterfly Gate Globe Check Ball Plug

Water x x x x x
Air x x x x
Drains & Vents x x x
Fuel oil x x x x x
In water service, valves above 200 NB size shal be butterfly valves.
13.1.14 Recirculation pipes alongwith valves, breakdown orifices etc. shall be provided for
important pumping systems as indicated in respective process and instrumentation
diagrams (P&IDs). The recirculation pipe shall be sized for minimum 30% design
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flow of single pump operation or the recommended flow of the pump manufacturer
whichever is higher.
13.1.15 All Piping 450 NB & Above shall be designated as Large dia Piping.
13.2.00 TECHNICAL SPECIFICATION
13.1.00 GENERAL
Specific technical requirements of low-pressure piping, fittings, supports, valves,

specialties and tanks etc. have been covered under this Sub-section. It includes
details pertaining to design and material of construction for piping, fittings, valves,
equipment, etc. cleaning/surface preparation application of primer and painting on
over ground piping. It also includes detailed technical requirement of laying
underground/buried piping including water proofing/anti corrosive protection. It
also covers design, engineering, manufacturing, fabrication, technical details of
piping, valves, specialties, piping hangers/supports, tanks etc.
13.2.00 Pipes and fittings
13.2.1 All low pressure piping systems shall be capable of withstanding the maximum
pressure in the corresponding lines at the relevant temperatures. However, the
minimum thickness as adhered to. The bidder shall furnish the pipe sizing /
thickness calculation as per the criteria mentioned above under LP piping
equipment sizing criteria of this Technical Specification.
13.2.2 Piping ad fittings coming under the purview of IBR shall be designed satisfying the
requirements of IBR as a minimum.
13.2.3 Supporting arrangement of piping systems shall be properly designed for systems
where hydraulic shocks and pressure surges may arise in the system during
operation. Bidder should provide necessary protective arrangement like anchor
blocks/anchor bolt etc. for the safeguard of the piping systems under above
mentioned conditions. The requirement will be, however, worked out by the
contractor and he will submit the detailed drawings for thrust/anchor block to the
Employer. External, and internal, attachments to piping shall be designed so as
not to cause flattening of pipes and excessive localized bending stresses.
13.2.4 Bends, loops, off sets, expansion or flexible joints shall be used as required in
order to prevent overstressing the piping system and to provide adequate
flexibility. Flexibility analysis (using software packages such as Caesar-II etc.)
shall be carried out for sufficiently long piping (straight run more than 300M).
13.2.5 Wherever Bidder’s piping coming under this specification, terminates at an

equipments or terminal point not included in this specification, the reaction and the
thermal movement imposed by bidder’s piping on equipment terminal point shall
be within limits to be approved by the Employer.
13.2.6 The hot lines shall be supported with flexible connections to permit axial and
lateral movements. Flexibility analysis shall be carried out for pipelines which
have considerable straight run as indicated above and necessary loops/expansion
joint etc. shall be provided as may be necessary depending on layout.
13.2.7 Piping and fittings shall be manufactured by an approved manufacturer of repute.

They should be truly cylindrical of clear internal diameter, of uniform thickness,
smooth and strong, free from dents, cracks and holes and other defects.
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13.2.8 For rubber lined ERW pipes, beads shall be removed.
13.2.9 Inspection holes shall be provided at suitable locations for pipes 800 NB and
above as required for periodic observations and inspection purposes.
13.2.10 At all intersection joints, it is Contractor’s responsibility to design and provide
suitable reinforcements as per the applicable codes and standards.
13.2.11 For large size pipes/duct, at high point and bends/change of direction of flow, air
release valves shall be provided as dictated by the system requirement and
operation philosophy & tripping conditions of pumping system. Sizing criteria for
air release valves shall be generally on the basis of valve size to pipe diameter
ratio of 1:8. Requirement shall be decided as per relevant code.
Transient analysis / surge analysis wherever specified and required shall be

conducted in order to determine the location, number and size of the Air-Release
valve on certain long distance/high volume piping systems such as CW/ ACW/
Raw Water etc.
13.3.00 Material
13.3.1 Alternate materials offered by Bidder against those specified shall either be equal
to or superior to those specified, the responsibility for establishing equality or
superiority of the alternate materials offered rests entirely with the Bidder and any
standard code required for establishing the same shall be in English language.
13.3.2 No extra credit would be given to offers containing materials superior to those
specified. Likewise no extra credit would be given to offers containing pipe
thickness more than specified.
13.3.4 All materials shall be new and procured directly from the manufacturers. Materials
procured from traders or stockiest are not acceptable.
13.3.5 All materials shall be certified by proper material test certificates. All material test
certificates shall carry proper heat number or other acceptable reference to enable
identification of the certificate that certifies the material.
13.3.6 Material of construction for pipes carrying various fluids shall be as follows:
1. Circulating Water (CW) – CW RCC DUCT WITH INSIDE

Pumphouse to Condenser & PROTECTIVE COATING AS
Condenser to Cooling Tower INDICATED IN VOLUME VI
2. Circulating Water (CW) – Pump IS 3589 FABRICATED FROM IS
Discharge, condenser risers 2062 PLATES –INTERNALLY LINED
including header near condenser WITH CORROCOAT OR POLYUREA
and cooling tower riser. COATING OF 1500 MICRONS DFT
/GRP/ FRP
3. ACW UPTO 150 NB - ASTM A 312 TP 316

L (ERW)/ DUPLEX SS
200 NB & ABVOVE - ERW IS 1978
(OR) API5L (OR) IS 3589
FABRICATED FROM IS 2062-
Internally lined with Corrocoat or
polyureA Coating inside of 1500
microns DFT
4. RO Stage I reject, RO Stage II UPTO 150 NB - ASTM A 312 TP 316
Page 352 of 680

Reject, Guard pond inlet & L (ERW)/ DUPLEX SS

discharge, Piping from Reject 200 NB & ABVOVE - ERW IS 1978
sump,. Ash water piping using sea (OR) API5L (OR) IS 3589
water and all other sea water FABRICATED FROM IS 2062-
applications. Internally lined with Corrocoat or
polyureA Coating inside of 1500
microns DFT/ GRP/ FRP
5. Sea Water Intake Pipe, CT Make GRP
up, Make up upto clarifier & CT
Blowdown Pipe
6. RO Stage I Permeate, Filtered IS-2062 Gr. B/ASTM-A-36/ASTM A-
Water, service water, AHP Seal 53 type ‘E’ Gr. B/IS-3589 Gr.
Water, HVAC Make up, Air Pre- 410/IS-1239 Heavy. 150 NB &
Heater Wash water, Passivated above pipes shall be spiral welded.
DM Water and clarifier sludge.
7. RO Stage II Permeate, Stainless steel to ASTM A-312, Gr.
Dematerialized water, (condenser 304 welded for sizes above 50mm
Make up water, Boiler fill and NB
Deaerator Fill water) & DMCW
overhead tank make-up water Stainless steel to ASTM A312, Gr.
304 sch. 40 Seamless for sizes 50
mm and below
8. Drinking water ASTM A-53 type E Gr. B galvanized
/IS 1239 heavy galvanized/IS 3589
Gr 410 Galvanized to SI-4736 or
equivalent.
9. Instrument air & plant air. ASTM A-53 type E Gr. B galvanized
/IS 1239 heavy galvanized/IS 3589
Gr 410 Galvanized to SI-4736 or
equivalent.
10. Fuel Oil piping API5L
11. HOSES FOR HFO TANKER CARBON STEEL – ELECTRO

HEATING (STEAM/ ZINC PLATED
CONDENSATE)
12. FUEL OIL UNLOADING LINES IS1239 / IS1978 / API5L Gr.B
(ERW) / IS3589
FABRICATED FROM IS 2062
PLATES
13. FUEL OIL PUMP DISCHARGE ASTM A 106 GR B
LINES
14. UF Feed/ Chemical Backwash CPVC ON 10 Sch 40
(Upto 150 NB) (Pipes & Fittings)
15. UF Feed/ Chemical Backwash (> GRP
150 NB)
16. Sodium Hypochlorite (pipes & CPVC Sch 80 ASTM
Fittings)
17. RO High pressuer Discharge Dupless SS
(Pipes & Fittings)
18. Cleaning Solution Line (Pipes & CPVC ON 10 Sch 40
Fittings)
13.3.7 In water lines, pipes upto 150 mm NB shall conform to ANSI B36.10/ASTM-A-53,
Type-E Gr. B/IS:1239 Gr. Heavy and minimum selected thickness shall not be
Page 353 of 680

less than IS: 1239 Grade heavy except for dematerialized water and condensate
spill lines.
13.3.9 Pipes of above 150 mm NB shall be to AWWA-C200/ANSI B 36.10/ASTM A-53/IS

3589 Gr. 410. Pipe to be fabricated by the bidder shall be rolled and butt welded
from plates conforming to ASTM A-53 type ‘E’ Gr. B/IS 2062 Gr. B/ASTM-A-36.
However, larger pipes, i.e. 1000 mm NB and above shall be made from plates
conforming to ASTM A 36/IS 2062 Gr. B and shall meet the requirements of
AWWA-M-11(for deflection & buckling criteria considering water filled pipe as well
as vacuum condition that may prevail during transient/ surge conditions, truck-
load, rail-load and weight density for compacted soil or any other load as the case
may be).
13.3.10 In dematerialized water service, the pipes upto 50 NB shall be of stainless steel
ASTM A 312, Gr. 304 sch. 40 Seamless. The size for these pipes shall be to
ANSI B 36.19. These shall be socket welded. The material for pipe from 65 mm
NB upto and including 400 NB shall be to ASTM A 312, Gr. 304 (welded). In no
case the thickness of fittings shall be less than parent pipe thickness.
13.3.11 Bidder/Contractor shall note that pipes offered as per a particular code shall
conform to that code in all respects i.e. Dimension, tolerances, manufacturing
methods, material, heat treatment, testing requirements, etc. unless otherwise
mentioned elsewhere in the specification.
13.3.12 Instrument air, Plant (service) air lines and Drinking water lines shall be to ASTM
A 53 type E grade B/ANSI B 36. 10/IS 3589, Gr. 410/IS: 1239 Heavy (in case
thickness calculated is more than gr. Heavy, ANSI B 36.10 Schedule numbers
shall be followed) and galvanized to IS 4736 or any equivalent internationally
reputed standard. The material of the pipes shall be to ASTM A 53 type ‘E’ Gr.
B/IS: 3589, Gr. 410/IS: 1239 Gr. Heavy. The fittings shall be of either same as
parent material or malleable iron to IS-1879 (galvanized).
13.3.13 Spiral welded pipes as per API-5L/IS-3589 are also acceptable for pipe of size
above 150 NB. However minimum thickness of the pipes shall be as elaborated
in above clauses.
13.3.14 Condensate lines shall be to ASTM A 106 Gr. B and dimension to ANSI B 36.10
schedule “standard’’ as minimum to be maintained.
13.3.15 If carbon steel plates of thickness more than 12 mm are used for manufacture of
pipes, fittings and other appurtenances, then the same shall be control-cooled or
normalized as the case may be following the guidelines of the governing code.
13.4.0 Piping Wall Thickness
13.4.1 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 Purchaser. In any case a minimum corrosion allowance of 1.0 mm
shall be considered while selecting the thickness.
13.4.2 In case of carbon steel materials, the nominal wall thickness of pipeline shall not be
less than the minimum acceptable values given below:
Page 354 of 680

NB mm 15 30 25 32 40 50 65 80 100 125
(inch) (1/2) (3/4) (1) (1¼) (1.5) (2) (2.5) (3) (4) (5)
Min. 3.2 3.2 3.6 3.6 3.6 3.6 3.6 4.0 4.5 5.4
thickness,
mm
NB mm 150 200 250 300 350 400 450 500 600 (24)
(inch) (6) (8) (10) (12) (14) (16) (18) (20)
Min. 5.4 6.35 6.35 6.35 7.1 7.1 7.1 8.0 8.0
thickness,
mm
> NB 600 mm to NB 900 mm - 8.0 mm

> NB 900 mm to NB 1200 mm - 10.0 mm
> NB 1200 mm to 1400 mm - 12.0 mm
> NB 1400 mm to 1600 mm - 14.0 mm
> NB 1600 mm to NB 2200 mm - 16.0 mm
> NB 2200 mm - 18.0 mm
13.5.00 Piping Layout
13.5.1 Piping shall be grouped together where practicable and routed to present a neat
appearance.
13.5.2 Piping routing shall be such as to provide sufficient clearance for removal and
maintenance of equipment, easy access to valves, instruments and other
accessories. The piping shall not encroach on the withdrawal space of various
equipments.
13.5.3 Over head piping shall have a normal minimum vertical clearance of 2.5 meters
above walkways and working areas and 8 m above roadways/railways. When
several pipelines are laid parallel, flanged joints must be staggered. Welded and
flanged joints should as far as possible be located at one third span from supports.
If the support is situated right under the welded joints this joint must be reinforced
with a strap. Flanged and welded joints must be avoided in the middle of the span.
Valves should be located in such a manner so as to ensure their convenient
operation from the floor or the nearest platform.
13.5.4 Pipelines of NB 50 size and below are regarded as field run piping. It is Bidder’s
responsibility to plan suitable layouts for these system insitu. Bidder shall prepare
drawings indicating the layout of field run pipe work. These drawings shall be
approved by Project Manager to the installation of the field run pipe work. Based
on these approved layouts the Bidder shall prepare the BOQ of field run-pipe and
submit to Employer for approval.
13.5.5 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.
13.5.6 Adequate clearance shall be ensured with respect to the above to accommodate
insulation and pipe movements, if any.
13.5.7 Piping shall generally be routed above ground but where specifically indicated /
approved by the project Manager the pipes may be arranged in trenches or buried.
Pipes at working temperature above the ambient shall however not be buried.
Page 355 of 680

13.5.8 Sufficient up stream and down stream lengths shall be provided for flow measuring
devices, control valves and other specialties.
13.5.9 All local instruments shall be located on pipelines as to render them observable
from the nearest available platforms.
13.5.10 Openings provided in the wall for pipelines must be closed with bricks and mortar
with 10-12 mm clearance between brick work and pipe after taking care of
insulation and thermal movement, if any. The clear space must be filled with felt or
asbestos or approved filling compound.
13.6.00 Slope/Drains and Vents
13.6.1 Suitable slope shall be provided for all pipelines towards drain points. It is Bidder
responsibility to identify the requirements of drains and vents, and supply the
necessary pipe work, valves, fittings, hangers and supports etc. As per the system
requirement low points in the pipelines shall be provided with suitable draining
arrangement and high points shall be provided with vent connections where air or
gas pockets may occur. Vent shall not be less than 15 mm size. Drains shall be
provided at low points and at pockets in piping such that complete drainage of all
systems is possible. Drain shall not be less than 15 mm for line size up to 150 mm,
not less than 20 mm up to 300 mm and not less than 25 mm for 350 mm to 600
mm pipes and not less than 50 mm for 600 mm and above pipes.
13.6.2 Air piping shall be sloped so that any part of the system can be drained through the
shut-off drain valve or drain plugs.
13.7.0 Pipe Joints
In general all water lines 65 mm NB and above, are to be joined generally by butt
welding except the locations where valves/fittings are to be installed with flanged
connections and 50 mm and below by socket welding unless mentioned otherwise
specifically. All air lines shall be of screwed connection and rubber lined pipes of
flanged connections.
13.7.1 Screwed
(a) Threading of pipes shall be carried out after bending, heat treatment etc. If
not possible, threading may be done prior to these operations but proper
care should be taken to protect them from damage. Threads shall be to
ANSI B 2.1 (taper) NPT/IS:554 unless specified otherwise.
(b) Galvanized pipe shall generally be joined by screwing into sockets. The
exposed threaded portion on the outside of the pipes shall be given a zinc
silicate coating. Galvanized pipes shall not be joined by welding. Screwed
ends of GI pipes shall be thoroughly cleaned and painted with a mixture of
red and white lead before jointing. For galvanized pipe sizes above 150
mm NB, screw & socket jointing as per ASTM-A-865 shall be employed for
both pipe-to-pipe and pipe-to-fitting jointing. For pipe to fitting connection
since no direct threading can be done on the fittings (supplied as per
ASTM-A-234 Gr. WPB and ANSI B-16.9) necessary straight pipe lengths
acting as match pieces shall be welded to the fitting at both ends and
subsequently the free ends of the straight lengths shall be threaded as per
ASTM A-865 for jointing with main pipe. Once welding of fittings with
match pieces and threading of free ends of match pieces are over, the
entire fabricated piece shall be galvanized, or in case match pipes an
fittings are already galvanized before the above mentioned fabrication then
Page 356 of 680

suitable application of Zinc-Silicate paste adequately at the welded surface

(both in side & out side) after welding with zinc rich electrode, alongwith
the nascent threaded metal portion at both free ends given the same
application of Zinc Silicate paste. Alternatively flanged jointing may be
employed for pipe sizes 100 NB and above. However, the bidder shall
ensure the galvanized pipe joints do not fail during hydro test.
(c) Teflon tapes shall be used to seal out screwed joints and shall be applied
to the male threads only. Threaded parts shall be wiped clean of oil or
grease with appropriate solvent if necessary and allowing proper time for
drying before applying the sealant. Pipe ends shall be reamed and all
chips shall be removed. Screwed flanges shall be attached by screwing
the pipe through the flange and the pipe and flange shall be refaced
accurately.
(d) For pipe sizes from 350 mm NB to 550 mm NB (including 350 NB & 550
NB) the GI pipes shall be of flanged connection. However, the pipes after
welding of flanges shall be completely galvanized. Any site welding done
on galvanized pipes shall be done with zinc-rich special electrodes and the
welded surfaces whether inside or outside shall be coated with zinc-silicate
pasts. Seal welding of flanges with zinc-rich electrode will be permitted
only when any flange is leak-prone during hydro testing.
(e) For pipe sizes 600 mm NB and above, the GI pipes shall be of welded
connection (with zinc-rich special electrodes) followed by application of
zinc silicate coating at welded surfaces both inside and outside the pipe,
except for the last blank/blind flange, or, equipment connection where
application of zinc-silicate paste after welding cannot be done due to
inaccessibility of the inside welded surface and where galvanic protection
has been impaired due to welding of pipe-to-pipe joint. Thus the last
erection joint shall be flanged joint.
13.7.2 Welded
(a) For making up welded joints (butt weld or socket weld) the welding shall be
performed by manual shielded metal arc process in accordance with the
requirements specified elsewhere in the spec. Any welder employed for
carrying butt welding shall be qualified as per ASME section IX for the type
of joints he is going to weld. Jointing by butt weld, or socket weld shall
depend upon the respective piping material specifications.
13.7.3 Flanged
(a) Flanged connections for pipes are to be kept to the minimum and used
only for connections to vessel, equipments, flanged valves and other
fittings like strainer/traps/orifices etc. for ease of connection and
maintenance etc. Rubber lined pipes shall be flange joined only.
(b) All flanged valves intended for installation on steel piping system, shall
have their flanges drilled to ANSI B 16.5 (or equivalent) and according to
the pressure class stated in their respective piping material specification.
(c) Drilling on flanges of flanged valves must correspond to the drilling of

flanges on the piping system on which the valves are installed.
13.8.00 Bends/elbows/mitre bends/Tees/Reducers & other fittings
Page 357 of 680

13.8.1 Unless otherwise specified elbows shall be of long radius type.
13.8.2 For pipe sizes up to 65 Nb, long radius forged elbows or seamless pipe bends shall
be used. Pipe bends, if used, shall be cold bent to a radius measured to the centre
line of pipe of 3 to 5 times the pipe diameter.
13.8.3 For steel pipes 80 Nb and above, seamless long radius forged elbows shall be
used. For pipe size 250 Nb and above mitre bends may be used for all pipes
except rubber lined pipes. The bend radius shall be 1½ times the nominal pipe
diameter. 90 deg. Bends (mitre) shall be in 4 pieces (3 cuts) and 45 deg. mitre
bends shall be in 3 pieces 22½ deg. Fabrication of mitre bends shall be as
detailed in BS 2633/BS534.
13.8.4 Mitre bends are not acceptable in case of rubber lined mild steel pipes.
13.8.5 For pipe fittings such as reducers an tees, the material shall be to astm-a-234 gr.
WPB up to 300 NB. For pipe reducers and tees above 300 NB, the fittings may be
fabricated conforming to parent pipe material. Provision of compensation pads
shall be kept as per ANSI B 31.1. The fittings shall conform to the dimensional
standard of ANSI B-16.9.
However, for pipes upto 150 NB, pipe fittings may be supplied with material and
dimension conforming to IS 1239 in case parent pipes also conform to IS 1239.
For pipes, above 1200 NB, reducer and tees shall be to dimensional standard of
AWWA-C-208.
13.8.6 Stainless steel fittings shall conform to either ASTM-A-182, Gr. 304 (316 for Sea
water application, if any) or ASTM-A-403, Gr. WP 304 (316 for Sea Water
application, if any) Class-S, for sizes upto and including 50 mm NB, i.e. the fitting
shall be of seamless construction.
However, for stainless steel fittings above 50mm NB, the same shall conform to
ASTM-A-403, Gr. WP 304 (316 for Sea water application, if any), Class W i.e. the
fittings shall be of welded construction strictly in accordance with ASTM-A-403.
13.8.7 In no case, the thickness of fittings shall be less than the thickness of parent pipe,
irrespective of material of construction.
13.9.00 Flanges
13.9.1 Flanges shall be slip on type. Welding of flanges in tension is not permitted.
13.9.2 All flanges and-flanged drilling shall be to ANSI B 16.5/BS EN-1092 of relevant
pressure/temperature class. Flanges shall be fabricated from steel plates
conforming to ASTM A 105/IS 2062 Gr. B. However stainless steel flanges shall
be fabricated from SS plates to ASTM-A-240, Gr. 304 (316 for Sea water
application, if any) or equivalent. For all Sea Water applications including guard
pond, reject sump, CW, ACW, CT make Up, Sea Water Intake, RO Stage I Reject,
RO Stage II Reject, Ash water (Sea water) etc flanges & bolts & nuts shall be SS
316 L construction.
13.10.00 Specific technical requirement of laying buried pipe with anti corrosive
treatment
Page 358 of 680

The pipe in general shall be laid with the top of the pipe minimum 1.0 (one) meter
below finished general ground level.
13.10.1 Trenching
(a) The trench shall be cut true to the line and level and shall follow the
gradient of the pipeline. The width of the trench shall be sufficient to give
free working space on each side of the pipe. Trenches shall conform to IS
5822.
(b) Free access shall be provided for the welding of the circumferential joints
by increasing the width and depth of the trench at these points. There
should be no obstruction to the welder from any side so that good welded
joint is obtained.
(c) The free working space shall conform to IS: 5822. The trench shall be
excavated so as to provide minimum cover of 1000 mm between the top of
the pipe and finished grade.
(d) Prior to lowering and laying pipe in any trench, the bidder shall backfill and
compact the bottom of the trench or excavation in accordance with IS:
5822 to provide an acceptable bed for placing the pipe.
(e) Coating and Wrapping shall be done as under.
13.10.2 Preparation and cleaning of piping
(a) The pipeline shall be thoroughly cleaned of all rust, grease, dirt, weld
scales and weld burrs etc. moisture or other foreign matter by power
cleaning method such as sand blasting, power tool cleaning, etc. Grease
or heavy oil shall be removed by washing with a volatile solvent such as
gasoline. Kerosene will not be permitted for cleaning. This cleaning
operation shall be immediately followed by priming with the mechanical
priming machine.
(b) Certain inaccessible portions of the pipeline (which otherwise not possible
to be cleaned by power cleaning methods) may be scrubbed manually with
a stiff wire brush and scrapped where necessary with specific permission
of the Project Manager.
(c) The cleaning and priming operation shall be carried out at site. The entire
pipe length shall be cleaned but the ends of the pipes shall be left without
coating for a distance of 230 mm for joints, which shall be coating manually
at site after laying, welding and testing the pipe.
13.10.4 Trench bed preparation and back filling
Prior to lowering and laying pipe in any excavated trench, the bottom of the trench
may require to be back filled and compacted (or as the case may be) to provide an
acceptable bed for placing the pipe. Bed preparation in general shall be as per IS:
5822.
13.10.5 Laying of galvanized steel (GI) pipes
All the joints shall be screwed with socket or flanged. Screwed ends of GI pipes
shall be thoroughly cleaned and painted with a mixture of red and white lead before
Page 359 of 680

jointing Threaded portion on either side of the socket joints shall be applied with
Zinc silicate paste.
All the provisions for trenching’ bed preparation’ laying the pipe application of
primer’ coating’ wrapping with tapes and back filling etc. as indicated for “laying of
buried piping” and “anti corrosive protection for buried piping” are applicable for
buried galvanized steel (GI) pipes also.
13.11.00 Cleaning and Flushing
13.11.1 All piping shall be cleaned by the Bidder before and after erection to remove
grease, dirt, dust, scale and welding slag.
13.11.2 Before erection all pipe work, assemblies, sub-assemblies, fittings, and
components, etc. shall be thoroughly cleaned internally and externally by blast
cleaning or by power driven wire brushes and followed by air-blowing. The
brushes shall be of the same or similar material as the metal being cleaned.
Cleaning of Galvanized pipes shall be done in such a manner that the coating on
MS pipe is not affected.
13.11.3 After erection, all water lines shall be 1.2-1.5 times the operating velocities in the
pipelines.
13.11.4 All compressed air pipe work shall be cleaned by blowing compressed air.
.
13.12.00 Painting of Pipes
13.12.1 Buried Piping
Internal surfaces
(ii) Two (2) coats of epoxy primer coats. The minimum DFT of each coat shall be
35 microns.
External surfaces
(ii) Coal tar primer compatible with coal tar enamel grade. The number of coats
shall be two with a DFT of 35 microns each.
(iii) Coal tar enamel shall be applied. A single spiral inner wrap of glass fibre
tissues shall be applied overlapping at least 25 mm ensuring impregnation of
glass fibre tissues in the first coat. The second coat of enamel and second
outer wrap of glass fibre felt, Type – I to IS: 7193-1974 will be applied in the
same way confirming to Table – 10 of IS – 10221 – 1982.
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The total thickness of the coating will not be less than 4.0 mm
(iv) Alternatively Wrapping with coal tar based anticorrosion tape conforming to IS
15337: 2003 is also acceptable in lieu of s.no. (iii) above. Wrapping thickness
shall be 4.0 mm.
13.12.2 Overground Piping
Internal surfaces
35 microns.
External surfaces
35 microns.
13.12.3 Other requirements
(a) Paint manufacturers instructions shall be followed in method of application,

handling, drying time etc.
(b) The color of the finish paint shall be as per approved color-coding.
(c) If finish paint was applied in shop, one coat of finish paint shall be applied
at site.
(d) The dry film thickness of paint shall not be less than 0.15 mm.
13.12.4 Color code for identification
The pipes shall be color painted/banded for identification as per the approved
color-coding scheme and shall be generally as per IS-9404.
13.13.00 Specification for hangers and supports
13.13.1 All supports and parts shall conform to the requirement of power piping code ANSI
B 31.1 or approved equivalent.
13.13.2 While designing supports for rubber lined pipes special consideration should be
given. Any kind of welding on these pipes is not allowed after rubber lining.
Page 361 of 680

13.13.3 Hanger for piping 65 mm Nb and larger and all spring support assemblies
regardless of size shall be completely engineered in conformance with the
provisions of power piping code ANSI B 31.1.
13.13.4 Hangers, saddles, supports etc. shall be fabricated from plates/pipes sections
conforming to ASTM A 53/IS: 2062/IS:226/ or equivalent. They shall be designed
to provide the required supporting effects and allow pipeline movements as
necessary. The structural steel work shall be as per IS: 800/BS:4360. Insulation
protection saddles shall be used at support point of all insulated piping.
13.13.5 The support shall be so interspaced as to minimize sagging of the pipes and to
keep them with in permissible limits where pipes are full with the conveying media.
13.13.6 The maximum spans of the supports of straight length shall not exceed the
recommended values indicated in ANSI B 31.1.
13.13.7 All pipe supports shall be designed to provide an absolute minimum head room of
2.5 m from floor in passages/walkways.
13.13.8 At all sliding surfaces of supports suitable arrangement is to be provided to

minimize sliding friction.
13.13.9 All components of hangers/support shall be provided with two coats of primer (red
oxide paint) at shop before dispatch to site. After erection they shall be given finish
coat of Long Oil Synthetic enamel to IS: 2932 of total DFT 100 to 140 microns.
CLH & VLH will be primed with Epoxy Zinc rich primer of 50 micron followed by
finish painting of Aliphatic Acrylic Polyurethane or equivalent of DFT 65 microns.
13.14.00 Design/Construction/Material Particulars of Gate/Globe/Check Valves/Globe

Stop Valve/Butterfly Valve
13.14.1 GENERAL
(a) All valves shall be suitable for the service conditions i.e. flow, temperature
and pressure, at which they are required to operate.
(b) The valves as well as all accessories shall be designed for easy
disassembly and maintenance.
(c) Valves to be installed outside shall be required to have the stem properly
protected against atmospheric corrosion.
(d) All rising stem valves shall be provided with back seat to permit repacking
(of glands) with valves in operation. All valves shall preferably be of
outside screw and yoke type.
(e) All valves shall be closed by rotating the hand wheel in the clockwise
direction when looking at the face of the hand wheel. In case where the
hand wheel is not directly attached to the valve spindle suitable gearing
shall be introduced.
(f) All valves shall have indicators or direction clearly marked on the hand-
wheel so that the valves opening/closing can be readily determined.
(g) Special attention shall be given to operating mechanism for large size
valves with a view to obtaining quick and easy operation ensuring that a
Page 362 of 680

minimum of maintenance is required. For valves of size 350 mm and

above either bevel or spur gearing shall be provided to facilitate manual
operation.
(h) The valves coming in vacuum lines shall be of extended gland type and /
or water sealed.
(i) The actuator-operated valves shall be designed on the basis of the

following:
(1) The internal parts shall be suitable to support the pressure caused
by the actuators.
(2) The valve-actuator unit shall be suitably stiff so as not to cause

vibrations, misalignments, etc.
(3) All actuator-operated valves shall be provided with hand operated

gearing mechanism also.
(4) All actuators operated valves shall open/close fully within time
required by the process.
(j) Valves coming under the purview of IBR shall meet IBR requirements.
(k) Gate/sluice valves shall be used for isolation of flow. Gate valves shall be
provided with the following accessories in addition to other standard items:
(1) Hand wheel
(2) Position indicator (for above 50 mm NB valve size)
(3) Draining arrangement wherever required.
(l) Globe valves shall be used for regulation purposes. They shall be
provided with hand wheel, position indicator, draining arrangement
(wherever required) and arrow indicating flow direction.
(m) Check valves shall be used for non-return service. They shall be swing
check type or double door (Dual plate) check type with a permanent arrow
inscription on the valve body indicating the fluid flow direction. In long
distance pipes lines with possibility of surge-occurrence, dual plate check
valves are preferable for its spring controlled opening/closing of flaps/doors
against flow reversals. However, dual plate check valves shall not be used
for sizes more than 600 mm NB.
(n) All gate and globe valves shall be provided with back seating arrangement
to enable on line changing of gland packing.
(o) All gate and globe valves shall be rising stem type and shall have limit
switches for full OPEN and full CLOSED indication wherever required.
This will include motor-operated valves also wherever required. In such
cases the limit switches shall form an integral part of the valve. Stop-gap
arrangement in this respect is not acceptable.
(p) All valves shall be provided with embossed name plate giving details such
as tag number, type, size etc.
Page 363 of 680

(q) Wherever required valves shall be provided with chain operator, extension
spindles and floor stands or any other arrangement approved by employer
so that they can be operated with ease from the nearest operating floor.
Wherever necessary for safety purpose locking device shall be provided.
Further, necessary small platforms for facilitating easy valve operation
shall be provided by the contractor wherever necessary in consultation with
project manager within the bid price at no extra cost to employer.
(r) All valves except those with rising stems shall be provided with continuous
mechanical position indicator; rising stem valves shall have only visual
indication through plastic/metallic stem cover for sizes above 50 mm
nominal bore.
(s) For CI gate, globe and check valves wherever thickness of body/bonnet is
not mentioned in the valves standards, thickness mentioned in IS-1538 for
fitting shall be applicable.
13.14.2 VALVE BODY MATERIAL
Valve body material for various services shall be as follows:
Valve body material for water application like DM Cooling Water (Passivated DM
Water) (DMCW), RO Stage I Permeate, AHP Seal Water, APH/ ESP Wash,
Service Water, Potable Water, HVAC Make UP shall be cast iron for sizes 65 NB
and above; gun-metal/ Forged Carbon Steel for sizes 50 Nb and below.
Valve body material for sea water application like Circulating Water. Auxiliary
Coling water, Blowdown, CT make up, sea water Intake, Guard pond inlet &
Discharge, Ash Water using sea water, RO Stage II reject, RO Stgae I reject,
Reject Sump discharge and all other sea water applications shal be SS 316 L for
all sizes.
For compressed air application, valve body material shall be cast carbon steel or
forged carbon steel for sizes 65 mm NB & above and Gun metal for sizes 50 NB
and below.
DM water: SS body and disc alongwith SS internals.
Condensate: Cast Carbon Steel/Forged Carbon Steel.
13.14.2.1 The design, material, construction, manufacture, inspection, testing and

performance of valves shall comply with all currently applicable statutes,
regulations and safety codes n the locality where the valves will be installed. The
valves shall conform to the latest editions of applicable codes and standards as
mentioned elsewhere. Nothing in this specification shall be construed to relieve the
Bidder of his responsibility. Valves in general shall conform to the requirements of
the following standards.
Standards and Codes
AWWA-C-504 Rubber seated butterfly valves
BS-5155/EN-593 Cast iron and steel body butterfly valves

for general purpose.
IS-778 Gun-metal gate, globe and check valves

for general purpose.
Page 364 of 680

BS-5154 Copper alloy globe/globe stop and check

and gate valves for general purpose.
IS-780 Sluice valves for water works purpose (50-

300 mm size)
IS-2906 Sluice valves for water works purpose

(350-1200 mm size)
IS-5150 Cast iron wedge and double disc gate for

general purpose.
BS-5152 Specification for cast iron globe valves
BS-5153 Cast iron check valves for general

purpose.
IS-5312 Swing check type reflux (non-return)

valves
ANSI B 16.34 Standard for valves
API-594 Standard for Dual-check valves
API-600 Steel gate valves
ANSI-B-16.10 Valves face to face and other relevant

dimension
API-598 Valves inspection test
13.14.2.2 End Connections
The end connections, shall comply with the following:
Socket welding (SW) – ANSI B 16.11
Butt Welding (BW) – ANSI B 16.25
Threaded (SC) – ANSI B 2.1
Flanged (FL) – ANSI B 16.5 & AWWA-C-207 (steel flanges), ANSI B 16.1 (Cast
Iron flanges)
13.14.2.3 All cast iron body valves (gate, globe and non-return) shall have flanged end
connections; (screwed ends for Ductile D.2NI body valves are not acceptable).
13.14.2.4 All steel and stainless steel body valves of sizes 65 mm and above shall have
flanged or butt welding ends. Valves of sizes below 65mm shall have flanged or
socket welded ends. Compatibility of welding between valve body material and
connecting pipe material is a pre-requisite in case of butt-welded joints.
13.14.2.5 All gun metal body valves shall have screwed ends.
13.14.2.6 All flanged end valves/specialties shall be furnished alongwith matching counter
flanges, fasteners, gaskets etc. as required to complete the joints
Page 365 of 680

13.15.00 Check Valves
13.15.1 Check valves shall comply with the following characteristics:
(a) For bore greater than 2” the valves must be swing check type or dual plate
check type suitable for installation in all positions (vertical and horizontal);
(b) For bore smaller than or equal to 2” the valves must be of the piston type
to be installed, in horizontal position.
(c) In the case of swing check valves, the body seat shall be inclined at such
an angle from the vertical as will facilitate closing and prevent chatter.
13.15.2 Drilling on flanges of flanged valves must correspond tot eh drilling on flanges of
the piping system on which the valves are to be installed.
13.15.3 All flanged valves intended for installation in steel piping systems shall have their
flanges drilled to ANSI B 16.5 (or equivalent) and according to the pressure class.
13.15.4 Counter flanges to be installed on air pipes shall be screwed-on type irrespective of
size.
13.16.00 Globe Valves
13.16.1 The globe valves shall have the following characteristics;
Straight conveyed flow
Right angle
Preferably, the valves shall be of the vertical stem type.
13.16.2 Globe valves shall preferably have radiused or spherical seating and discs shall be
free to revolve on the spindle.
13.16.3 The pressure shall preferably be under the disc of the valve. However, globe
valves, with pressure over the disc shall also be accepted provided (i) no possibility
exists that flow from above the disc can remove either the disc from stem or
component from disc (ii) manual globe valves can easily be operated by hand. If
the fluid load on the top of the disc is higher than 40-60 KN, bypass valve shall be
provided which permits the downstream system to be pressurized before the globe
valve is opened.
13.16.4 For the regulating valves, valves with regulating plug & parabolic outline disc type
is preferred.
13.16.5 All motorized globe valves with regulating plug for which indication of percentage
(%) opening are required in the control room shall be provided with necessary
position transmitter.
13.17.00 Gate valves
All gate valves shall be of the full-way type, and when in the full open position the
bore of the valve shall not be constricted by any part of the gate.
Page 366 of 680

Gate valves shall be of the solid/elastic or articulated wedge disc and rising stem
type.
13.18.00 Air Release Valve
(a) The air release valves shall be of automatic double air valve with two
orifices and two floats. The float shall not close the valve at higher air
velocities. The orifice contact joint with the float shall be leak tight joint.
(b) The valve shall efficiently discharge the displaced air automatically from
ducts/pipes while filling them and admit air automatically into the
ducts/pipes while they are being emptied. The valve shall also
automatically release trapped air from ducts/pipes during operation at the
normal working pressure.
(c) Body material of automatic air release valves shall comply generally with
BS 1452 Gr. 14/IS:210 Gr. FG 260 and spindle shall conform to high
tensile brass.
(d) Air release valves shall not have any integral isolation devise within them.
Each Air release valve shall be mounted, preceded by a separate isolation
gate/butterfly valve.
13.19.00 Butterfly Valves
13.19.1 Design/Construction
(a) The valves shall be designed for the design pressure/temperature of the
system on which it is installed and in accordance with AWWA-C-504, EN-
593 or any other approved equivalent standard latest edition. Fabricated
steel (IS: 2062 GR. B) butterfly valves instead of cast iron body valves are
also acceptable for size above 300 mm nb diameter. In such a case,
however, the bidder will have to necessarily submit thickness calculations,
in order to establish the integrity of the fabricated valve body under the
system operating pressure condition.
(1) The valves shall be suitable for installation in any position

(horizontal/vertical etc.) and shall be generally of double-flanged
construction. However for sizes 600 NB and below the valves of
Wafer construction are also acceptable.
(2) The seals, both on the body (sleeve) and on the disc shall be of
the material specified. Necessary shaft seal shall be provided and
adequately designed to ensure no leakage across the seal. This
seal shall be designed so that they will allow replacement without
removal of the valve shaft. The sealing ring on the disk shall be
continuous type and easily replaceable.
(3) For all types of valves, the design with shaft eccentric to the disc is
preferred. The shaft shall be solid type and shall pivot on
bushings. Bushings/sleeve type bearings shall be contained in the
hub of valve body. The bearing shall be self-lubricated type with
low coefficient of friction and should not have any harmful effect on
water and on valve components.
(4) The design of the shaft shall be such that it will safely sustain
maximum differential pressure across the closed valve. The shaft
Page 367 of 680

and any key (taper pin etc.) for transmitting the torque between
shaft and disc shall be capable of withstanding the maximum
torque required to operate the valve. However, the shaft diameter
shall not be less than the minimum shaft diameter specified in
relevant code. Necessary Torque Calculation and the torque class
selected on the basis of the same shall be furnished to the
Employer for information.
(5) The disc shall rotate from the full open to the tight shut position.
The disc shall be contoured to ensure the least possible resistance
to flow and shall be suitable for throttling operation. While the disc
is in the throttled position, valve shall not create any noise or
vibration.
(6) The operating mechanism shall be mounted directly on or
supported from the valve body.
(7) All valves shall be complete with:
Position indicator (located in a visible place)
Arrow indicating the flow direction;
Adjustable mechanical stop limiting devices to prevent over
Travel of valve disc in open/close position.
All valves shall be “tight shut off’’
(8) Hand operated valves shall have the following
Local hand controls
The hand controls shall close the valve with clockwise rotation.
The hand controls shall be dimensioned to guarantee an easy

maneuver under most severe conditions.
The hand controls shall be provided with locking systems suitable

to avoid the disc assuming a non-desirable position during the
operation.
Hand wheel shall be made of malleable iron with arms and rims of
adequate strength. The hand wheel of diameters 300 mm or less
shall be provided with handles for ease of operation. The pulling
force required on the hand wheel rim shall not exceed 25 Kgf when
operating the valve under full flow and operating pressure.
Valves-350 Nb and above shall have pressure equalizing bypass

valves, wherever system parameters warrant the same.
Valves-350 Nb and above shall also be provided with gear

operator arrangement suitable for manual operation. Manual
operation of valve shall be through worm and gear arrangement
having totally enclosed gearing with hand wheel diameter and gear
ratio designed to meet the required operating torque It shall be
designed to hold the valve disc in intermediate position between
full open and full closed position without creeping or fluttering.
Page 368 of 680

Adjustable stops shall be provided to prevent over travel in either

direction.
Limit and torque switches (if applicable) shall be enclosed in water

tight enclosures alongwith suitable space heaters for motor
actuated valves, which may be either for On-Off operation or
inching operation with position transmitter.
13.19.2 Material of Construction (Butterfly Valves)
Materials and other design details shall be as indicated below:
(a) Cast Iron Butterfly valves
Body & Disc ASTM A48, Gr. 40 with 2% Ni/
IS: 210. Gr. FG-260, with 2%
Ni and epoxy coated
Shaft BS 970 431 S: 291/EN 57, or
AISI-410 or AWWA-permitted shaft material

equivalent to EN-57/AISI-410 or better.
Seat ring 18-8 Stainless steel
Seal Nitrile Rubber
Companion Flanges IS 2062
External hardware SS 316
Internal hardware SS 316
(b) Duplex Stainless Steel Butterfly valves (All Sea Water applications
including guard pond, reject sump, CW, ACW, CT make Up, Sea Water
Intake, RO Stage I Reject, RO Stage II Reject, Ash water (Sea water) etc. )
Body & Disc SS 316 L
Shaft SS 316 L.
Seat ring SS 316 L
Seal Nitrile Rubber
Companion Flanges SS 316 L
External hardware SS 316 L
Internal hardware SS 316 L
(c) Stainless Steel Butterfly Valves
Body & Disc ASTM A 351, Gr. CF8M/ASTM-A-182-Gr. 304
Page 369 of 680

Shaft ASTM A 182, Gr. 316/ASTM-A-479 Gr.

316/Equivalent
Disc & Seat Rings EPT/BUNA-N/Neoprene
Companion Flanges SS 304
(d) Carbon Steel Butterfly Valves
Body & Disc ASTM A 216, Gr. WCB
Shaft ASTM A 182, Gr. 304/ASTM-A-479 Gr.

304/Equivalent
Disc & Seat Rings EPT/BUNA-N/Neoprene
13.19.3 Proof of Design Test (Type Test) for Butterfly Valves
Proof of Design (POD) test certificates shall be furnished by the bidder for all
applicable size-ranges and classes of Butterfly valves supplied by him, in the
absence of which actual POD test shall be conducted by the bidder in the presence
of Employer’s representative.
All valves that are designed and manufactured as per AWWA-C-504 shall be
governed by the relevant clauses of POD test in AWWA-C-504. For Butterfly
valves designed and manufactured to EN-593 or equivalent, the POD test methods
and procedures shaft generally follow the guidelines of AWWA-C-504 in all respect
except that Body & seat hydro test and disc-strength test shall be conducted at the
pressures specified in EN-593 or the applicable code. Actuators shall also meet
requirements of POD test of AWWA-C-504.
13.20.00 MATERIAL OF CONSTRUCTION (GATE/GLOBE/CHECK VALVE)
(a) The materials shall generally comply with the following:
(1) Cast Steel Valves

Body & bonnet ASTM A 216 Gr. WCB/
ASTM A 105
Disc for non-return ASTM A 216 Gr. WCB/

Valves ASTM A 105
Trim. ASTM A 182 Gr. F6 or Equivalent
Page 370 of 680

(2) Stainless Steel Valves
Body & Bonnet ASTM A 351 Gr. CF 8M/

ASTM A 182 Gr. 304
Disc -do-
Trim. ASTM 182 Gr. F. 316

/ASTM-A-479 Gr. 316 or Integral
with body
Companion Flanges SS 304
(3) Cast Iron Valves
Body & bonnet BS 1452 Gr. 14/IS-210 Gr. FG

260
Seating surfaces and rings 13% chromium steel/13% Chrome

overlay
Disc for non-return valves BS 1452 Gr. 14/IS-210 Gr FG 260
Hinge pin for non-return valves AISI 316
Stem for gate globe valves 13% chromium steel or Equivalent
Back Seat 13% chromium steel / 13%

Chrome overlay
(4) Gun Metal Valves
Body and bonnet IS 318 Gr. 2/Equivalent Standard
Trim -do-
(5) Duplex Stainless Steel (All Sea Water applications including

guard pond, reject sump, CW, ACW, CT make Up, Sea Water
Intake, RO Stage I Reject, RO Stage II Reject, Ash water etc)
Page 371 of 680

Body & bonnet SS 316 L
Disc for non-return SS 316 L
Stem SS 316L
Trim. SS 316 L
Companion Flanges SS 316 L
External hardware SS 316 L
Internal hardware SS 316 L
(b) Cast iron body valves shall have high alloy steel stem and seat.
(c) Material for counter flanges shall be the same as for the piping except for
sea water application.
13.21.00 Float Operated Valves
(a) Valve shall automatically control the rate of filling and will shut off when a
predetermined level is reached and close to prevent over flow on pre-set
maximum water level. Valve shall also open and close in direct proportion
to rise or fall of water level.
(b) DESIGN AND CONSTRUCTION FEATURES
The following design and construction feature of the valve shall be the
minimum acceptable.
(c) Valves shall be right-angled or globe pattern.
(d) Valves shall be balance piston type with float ball.

(e) Leather liner shall not be provided.
(f) The body and cover material shall be cast iron conforming to ASTM-A 126
Grade ‘B’ or Is: 210 Grade 200 or equivalent, and float shall be of copper
with epoxy painting of two (2) coats. For all sea water applications the
complete valve shall be SS 316 L construction.
(g) Valves shall be suitable for flow velocities of 2 to 2.5m/sec.
(h) The valves shall have flanged connections.
13.22.00 PAINTING OF VALVES:
Two (2) coats of primer followed by three (3) coats of epoxy of approved color
code/shade (usually same as that of connected piping) shall be applied to all
exposed surfaces except stainless steel surface, Galvanized steel surface and gun
metal surface at shop as required to prevent corrosion, before dispatch. The use
of grease/oil other than light grade mineral oil, for corrosion protection is prohibited.
The total DFT of paining shall be 150 micron (minimum). If during transport,
unloading/unpacking or erection at site any part of the painted surface gets
Page 372 of 680

damaged, the same shall be made good by the contractor by repainting with
compatible painting primer and enamel to the satisfaction of the project manager.
13.23.00 RUBBER EXPANSION JOINTS
13.23.1 All parts of expansion joints shall be suitably designed for all stresses that may
occur during continuous operation and for any additional stresses that may occur
during installation and also during transient condition.
13.23.2 The expansion joints shall be single bellow rubber expansion joints. The arches of
the expansion joints shall be filled with soft rubber.
13.23.3 The tube (i.e. inner cover) and the cover (outer) shall be made of natural or
synthetic rubber of adequate hardness. The shore hardness shall not be less than
60 deg. A for outer and 50 deg. A for inner cover.
13.23.4 The carcass between the tube and the cover shall be made of high quality cotton
duck, preferably, square woven to provide equal strength in both directions of the
weave. The fabric plies shall be impregnated with age resistant rubber or synthetic
compound and laminated into a unit.
13.23.5 Reinforcement, consisting of solid metal rings embedded in carcass shall be

provided.
13.23.6 Expansion joints shall be complete with stretcher bolt assembly. The expansion
joints shall be suitable to absorb piping movements and accommodate mismatch
between pipelines.
13.23.7 The expansion joints shall be of heavy duty construction made of high grade
abrasion-resistant natural or synthetic rubber compound. The basic fabric for the
‘duck’ shall be either a superior quality braided cotton or synthetic fibre having
maximum flexibility and non-set characteristic.
13.23.8 The expansion joints shall be adequately reinforced, with solid steel rings, to meet
the service conditions under which they are to operate.
13.23.9 All expansion joints shall be provided with stainless steel retaining rings for DM
water application and IS 2062 Gr. B galvanized steel retaining rings for ordinary
water for use on the inner face of the rubber flanges, to prevent any possibility of
damage to the rubber when the bolts are tightened. These rings shall be split and
beveled type for easy installation and replacement and shall be drilled to match the
drilling on the end rubber flanges and shall be in two or more pieces.
13.23.10 The expansion joints shall have integral fabric reinforced full-face rubber flanges.
The bolt on one flange shall have no eccentricity in relation to the corresponding
bolt hole on the flange on the other face. The end rubber flanges shall be drilled to
suit the companion pipe flanges.
13.23.11 All exposed surfaces of the expansion joint shall be given a 3 mm thick coating of
neoprene. This surface shall be reasonably uniform and free from any blisters,
porosity and other surface defects.
13.23.12 Each control unit shall consist of two (2) numbers of triangular stretcher bolt plates,
a stretcher bolt with washers, nuts, and lock nuts. Each plate shall be drilled with
three holes, two for fixing the plate on to the companion steel flange and the third
for fixing the stretcher bolt.
Page 373 of 680

13.23.13 Each joint shall have a permanently attached brass or stainless steel metal tag
indicating the tag numbers and other salient design features.
13.23.14 Bidder to note that any metallic part which comes in contact with DM / Corrosive
water shall be of stainless steel material.
13.23.15 For all Sea Water applications including guard pond, reject sump, CW, ACW, CT
make Up, Sea Water Intake, RO Stage I Reject, RO Stage II Reject, Ash water etc
the bolts & nuts, stretcher plates and companion flanges shall be SS 316 L.
13.24.00 STRAINERS
13.24.1 Simplex type
The strainers shall be basket type and of simplex construction. The strainer shall
be provided with plugged drain/blow off and vent connections. The free area of the
strainer element shall be at least four (4) times the internal area of the connecting
pipe lines. The strainer element shall be 20 mesh. Pressure drop across the
strainers in new condition fitted with a removable plug. The material of
construction of various parts shall be as follows:
(a) Body IS: 318, Gr. 2 up to 50 mm Nb, and IS: 210 Gr.
FG 260 above 50 mm Nb. (For DM water/ -Body:
AISI 316 or equivalent)
SS 316 L (all Sea Water applications including
guard pond, reject sump, CW, ACW, CT make Up,
Sea Water Intake, RO Stage I Reject, RO Stage II
Reject, Ash water etc)
(b) Strainer Element Stainless steel (AISI 316)

(c) End connection Screwed upto 50 mm Nb, and flanged above 50

mm Nb
13.24.2 Duplex type
(a) The strainers shall be basket type and of duplex construction. The strainer
shall be provided with plugged drain/blow off and vent connections. The
free area of the strainer element shall be at least four (4) times the internal
area of the connecting pipe. The mesh of strainer element shall be
commensurate with the actual service required. Pressure drop across the
strainer in new condition shall not exceed 4.0 MWC at full flow.
(b) Wire mesh (if applicable) of the strainers shall be suitably reinforced. The
material of construction of various parts shall be as follows.
Body IS: 318, Gr. 2

Up to 50 mm Nb, and IS:210,
Gr. FG 260 of ASTM-A-515 Gr. 75/IS-2062
Gr. B and internally epoxy-painted above 50 NB.
Page 374 of 680


Strainer element Stainless steel (AISI 316)/ SS 316 L (all Sea

Water applications including guard pond, reject
sump, CW, ACW, CT make Up, Sea Water Intake,
RO Stage I Reject, RO Stage II Reject, Ash water
etc)
End connection Screwed up to 50 mm NB, and Flanged above 50

NB. Gasket shall be of full face type
(c) The strainer will have a permanent stainless steel tag fixed on the strainer
body indicating the strainer tag number and service and other salient data.
(d) The size of the strainer and the flow direction will be indicated on the
strainer body casting.
(e) Thickness of the strainer element should be designed to withstand the

pressure developed within the strainer due to 100% clogged condition
exerting shut-off pressure on the element.
13.24.3 Three shop coats of paint preceded by two coats of primer shall be applied to all
exposed surfaces as required to prevent corrosion. All parts shall be adequately
protected for rust prevention. The use of grease or oil other than light grade
mineral oils for corrosion protection is prohibited.
Page 375 of 680

CHAPTER – 33
POWER CYCLE PIPING, VALVES, FITTNGS & TEHRMAL INSUALTION
33.0 POWER CYCLE PIPING, VALVES, FITTINGS & THERMAL INSULATION
This section covers all the power cycle piping, valves and specialties which connect
the different equipment like the boiler, turbine, condenser, pumps, heaters etc. to
make the power cycle complete and thermal insulation to be provided for the power
plant.
33.1 PERFORMANCE REQUIREMENT
The piping system acts as the pressure boundary for the fluid in circulation,
water and steam in this case, which is subject to high pressure, temperature,
change of phase and various types of transient and steady state operation. All
the piping systems supplied shall be designed to operate without replacement
and with normal maintenance for a plant service life of 30 years and shall
withstand to the maximum sustained load.
33.2 Line Sizing
33.2.1 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
(i) Superheated Steam : 60.0 m/s
(ii) Saturated Steam : 30 m/s
(iii) Wet Steam/ Exhaust Steam : 30 m/s
(iv) Auxiliary Steam : 50 m/s
(v) Main Steam Hot & cold reheat piping : 100 M/s
(Vi) HP Bypas Upstream : 125 m/s
(vii) HP Bypass Downstream : 100 m/s
(viii) LP Bypas Upstream : 100 m/s
(ix) LP Bypass Downstream : 125 m/s
Water
(i) Pump suction : 1.0 m/s
(ii) Pump delivery : 2.5 m/s;
(iv) Feed Water discharge : 4 - 6 m/s
(v) Feed Water Suction : 2 - 3 m/s
(vI) Condensate Discharge : 3 – 5 m/s
(vii) Condensate Suction : 1.5 m/s
Oil
(i) HFO, HSD : 2 m/s
WILLIAM & HAZEN formula shall be used for calculating the friction loss in piping
systems with the following “C” value.
i) Carbon steel pipe 100
Page 376 of 680

ii) CI Pipe/Ductile Iron 100
iii) Rubber lined steel pipe 120
iv) Stainless steel pipe 100
For calculating the required pump head for pump selection, at least 10% margin shall
be taken over the pipe friction losses and static head shall be calculated from the
minimum water level of the tank/sump/reservoir from which the pumps draw water.
33.3 CODES & STANDARDS
The design, manufacture and performance of the LP Piping System

specified hereinafter, shall comply with the requirements of the following
codes and standards and shall include all the latest amendments
ASME-B31.1 : Code for Power Piping
ASME-B16.5 : Pipe Flanges & Flanged Fittings
ASME-B16.9 : Factory-Made Wrought Steel Butt-Welding Fittings ASME-
B16.10 : Face to Face and End to End Dimension of valves. ASME-
B16.11 : Forged Steel Fittings, Socket-Welding and threaded
ANSI B-16.25: Butt Welding Ends.
ASME-B16.34 : Valves – Flanged, Threaded and Welding End
ASME-B36.19 : Stainless Steel Pipe
IBR : Indian Boiler Regulations (Latest Revision)
IS-1239 : Carbon s t e e l tubes, tubular and o t h e r w rought

steel fittings.
IS-3589 : Seamless or Electrically welded steel pipes for

water, gas and sewage.
IS-11428 : Specification for Wrought Carbon S te e l butt welding p i p e
fittings.
IS- 4736 : Hot-dip Zinc coatings on Carbon steel tubes.
IS- 2062 : Steel for general structural Purposes - Specification.
IS- 4682 : Code of practice for lining of vessels and equipments for
chemical processes: Part 1 Rubber lining.
ASTM A312 : Standard Specification for Seamless, Welded, and

Heavily Cold Worked Austenitic Stainless Steel Pipes.
Page 377 of 680

ASTM A403 : Standard Specification for Wrought Austenitic Stainless

Steel Piping Fittings.
API-594 : Check valves: Flanged, Lug, Wafer and Butt-welding.
API-598 : Valve Inspection and Testing
API-600 : Bolted bonnet steel gate valves for Petroleum and

natural gas industries.
API-602 : Compact Steel Gate Valve – Flanged, Threaded,

Welding and Extended Body Valves.
BS- 1873 : Steel Globe and globe stop and check valves ( flanged
and butt-welding ends) for Petroleum, Petrochemical and
allied industries.
BS- 1868 : Steel c hec k valves (flanged and butt -welding ends) f o r
Petroleum, Petrochemical and allied industries.
IS 12709 : GRP pipes, joints and fittings for use for potable water supply
IS 14402 : GRP pipes, joints, and fittings for use for sewerage, industrial
waste and water.
ANSI/AWWA C950-07: AWWA Standard for Fiber Glass pipes.
AWWA M45 : AWWA manual of water Supply & Fiberglass Pipes Design.
Design, fabrication, assembly and testing of pipes, fittings shall generally

conform to the requirements of ANSI B-31.1. But the portions, which come
under the purview of Indian Boiler Regulations (IBR), shall completely comply
the requirements of IBR, as a minimum.
Any other internationally accepted codes and standards are also acceptable.
However, the compliance of ANSI codes and IBR will be considered as
minimum for acceptance of the piping and all appurtenances.
33.4 Scope of Supply
Scope shall include all piping, valves & specialties as indicated in

Annexure-I.of this chapter as a minimum. However all piping as required for
the completeness of the system shall be supplied.
33.4.1 In general, the equipment and materials to be supplied under this

specification shall include, as a minimum:
a. Supply of all power cycle piping including bends, elbows, tees,

branches, laterals, crosses, reducing union, couplings, caps, saddles,
shoes, flanges, blank flanges, Y-pieces etc as required.
Page 378 of 680

b. Matching pipes, matching pieces like reducers/enlargers etc, counter

flanges with bolts, nuts, washers, temporary and permanent gaskets,
threaded union etc.
c. The pipe spools shall be supplied along with necessary test certificates
of the pipes, after necessary machining to the required bore, for
assembly of flow nozzle element. The assembled flow nozzle shall be
installed in the piping system. Additional length of pipes equal to length
of all fully assembled flow nozzle & orifice plates pipe piece shall be
supplied and the same shall also be erected prior to cleaning of the
pipes by flushing or steam blowing or chemical cleaning or both. After
completion of cleaning of piping, the assembled flow nozzles shall be
erected replacing the temporary pipe spools.
d. All motorised valves, manually operated isolating and regulating valves,

non- return valves, steam traps, relief/safety valves, strainers, pressure
reducing orifices, expansion joints and other flexible connections,
complete with the counter flanges and matching connecting pieces as
required within the entire power cycle piping system.
e. Anchors, hangers and supports, vibration dampeners, restraints, shock

absorbers etc as required.
f. Any platform necessary for maintenance and operation of valve and

equipment located 1.5 m above any permanent floor including access
ladders, supporting structures etc.
g. All secondary structural steel members required for pipe supports from
building steel structures and from embedded steel including pipe
supports in trenches.
h. Funnels, tundishes for drips and drains including all miscellaneous drain
piping and drain piping from tundish outlet up to drain points. All drain
and vent lines shall be conveniently terminated either in Blowdown
tank/flash tanks or permanent drain trenches of the Power Station. All
steam and saturated water open drains shall be drained through a water
seal in drain funnels/tundish with a water connection in funnels/tundish
for maintaining water seal level in them. All oily effluent drains shall be
separately routed and connected to separate pit.
i. For the isolation and check valves located on the main steam, hot
reheat, cold reheat, L.P. bypass and extraction lines, suitable line drains
shall be provided just upstream and downstream of each of these
valves. No drain is needed at the downstream of L.P. bypass isolation
valve. Each of these drains shall be independently led to the condenser
with branching off to atmosphere.
Line drains from Main Steam, Hot Reheat, Cold Reheat, L.P. bypass &
high pressure (above 40 kg/cm2) extraction lines shall be provided with
double isolation valves in series for each branch - each located at the
two extreme ties of the line drain route. The valve near the condenser
Page 379 of 680

shall be motorised one. The balance line drains shall be provided with
only one isolation valve for each branch.
j. Bolts, nuts, washers, temporary and permanent gaskets, fasteners as

required for interconnecting piping, valves & fittings.
k. Complete insulation material for piping, valves, specialties & auxiliary

equipment specified in this specification and as called for in the
specification for thermal insulation.
l. Painting of all piping, valves & specialties at site. Coating and wrapping
for buried pipes.
33.4.2 Bidder shall furnish his own technical details of piping, valves, specialties and
accessories along with his offer.
Following general requirements shall however be considered:
(a) Instrument Connections
(b) Pipe stubs and blanking plates required for chemical cleaning and hydro
testing.
(c) Flanges, spool pieces, gaskets, ring joints, jointing materials, aluminium
and stainless steel forged marking plate and temporary piping for steam
blowing.
(d) Drain/drip pockets on steam piping as per stipulation of ASME TDP –

Volume I and general requirement.
(e) Expansion marker for high temperature steam lines.
(f) Fine threaded Radiography holes with stubs and suitable matching
plugs which shall be finally seal welded for piping, more than 25 mm
nominal thickness.
For conducting performance test of Turbo-Generator and Boiler, the

required pressure, temperature, flow measurement points shall be
provided.
(g) Provision for creep measurement on the piping operating in creep

region.
33.4.3 Electrodes and filler wires required for stainless steel and alloy steel welding
during shop fabrication at works and erection/installation at site.
33.4.4 All temporary pipes and accessories, supporting arrangement for cleaning,
flushing and steam blowing of the main steam, cold reheat and hot reheat
piping including HP/LP by pass piping and auxiliary steam piping.
33.5 SCOPE OF SERVICES
Page 380 of 680

a) The Contractor shall design the piping system and perform necessary
stress analysis of all piping and dynamic analysis as necessary for the
piping systems shown in Annexure-I of this chapter as a minimum.
b) For stress analysis purpose, individual piping systems shall be

considered up to the anchor points (location to be decided during detail
engineering). All anchors coming within the piping are to be designed,
supplied and erected by the Contractor.
c) Stress analysis and hanger selection for all piping specified else where,
including piping attachment for hangers/supports, all auxiliary supporting
structures are included in the scope of the Contractor.
d) The Contractor shall submit the design calculations for pipe sizing,
thickness with specified diameters of pipes and stress analysis data to
Owner/Engineer for review/ reference/records. Pressure drop
calculation for main steam, cold reheat and hot reheat piping shall be
submitted by the Contractor to show the adequacy of pipe sizes to meet
steam parameter at turbine inlet.
e) Preparation of detailed fabrication drawings (isometric) of shop

fabricated piping which are of size 50 NB and above should be based
on the "Released for Construction" drawings pertaining to power cycle
piping layout prepared by the Contractor.
"As built" drawings of the power cycle piping layout shall also be
prepared by the Contractor based on any layout modifications made at
site over "Released for Construction Drawings".
f) The Contractor shall design and detail all piping supports including
restraints, guides, stops, snubbers, dampers etc based on the final
stress analysis and hanger load data. The Contractor's design of all
supports shall be submitted to the Owner/Engineer for review.
g) The Contractor shall furnish separate sketches for each support,

restraint, anchor, snubber, dampers, spring hangers etc. These
sketches shall include the location with reference to column
co-ordinates, identification number, bill of material, design loads,
operating load, spring stiffness, amount of spring pre-compression etc
and method of attachment to the pipe and steel structure.
h) In order to ensure that all piping, supporting elements, anchors and

restraints have been installed and adjusted in accordance with the
drawings and other written instructions of the Contractor, the hangers
associated with the main steam, hot reheat, cold reheat, HP & LP
by-pass, feed water, auxiliary steam piping etc. shall be inspected as
follows :
 After hydro test, with the piping in the cold position, with all travel
stops removed, with the pipe completely insulated and in all
respects ready for start-up.
Page 381 of 680

 Piping in the hot position, with the unit operating at maximum load.
 Piping in the hot position after 6 months of operation.
 Piping in the cold position during first complete shutdown after at

least 6 months of operation.
The contractor shall depute his personnel for this purpose to site if the
plant is officially handed over to the owner before such inspection after 6
months of operation.
i) At the time of each inspection, the Contractor shall determine the

necessity for revision, adjustment or replacement of pipe supporting
elements, restraints and anchors. Any changes proposed shall be
incorporated by the Contractor after Owner’s/Engineer's concurrence.
j) All shop tests satisfying the requirements of Indian Boiler Regulations

(IBR), ANSI standards, the standards enumerated herein and/or as
specified.
k) Furnishing drawings, data, design calculations, stress analysis results.
l) Furnishing certified copies of test results for all tests and examinations
specified in the specification and for the mandatory tests and analysis
required by the ASTM material specification, for the materials used for
piping and the pressure parts of the valves.
m) Obtaining approval from Chief Inspector of Boilers as per Indian Boiler

Act, including the following:
• For all pipelines coming under the purview of Indian Boiler

Regulations (IBR), necessary approval of the design and layout
drawings shall be obtained from the Chief Inspector of Boilers and
furnished to the Owner/Engineer. Necessary certificates of design,
manufacture and tests in specified Form of IBR, for each fabricated
pipe with proper identification shall be submitted.
• For fittings and specialties, viz. valves, flanges, traps and other
specialties etc of all pipelines coming under the purview of IBR,
Certificate of design, manufacture and tests in specified Form of IBR
with appropriate identification shall be furnished to the Owner/
Engineer.
• Erection & testing of the pipe lines coming under the purview of IBR
shall meet all the requirements of IBR and certificate of manufacture
& tests in specified Form of IBR, for each of the erected pipe lines
shall be submitted to the Owner/Engineer prior to the application of
insulation and/or flushing the line before commissioning.
n) Steam blowing or chemical cleaning of piping systems, as specified.
Page 382 of 680

o) Omission of specific reference to any item or material or work which is

necessary for completion of the piping systems shall not relieve the
bidder of the responsibility of furnishing all material and services for a
complete installation satisfying the operational and other requirements
stated in the specifications.
Drawing indicating the layout of pipe work shall be prepared in line with the
flow diagrams and shall be provided as part of the Contract. These drawings
shall indicate the position of all supports, guides, restraints and anchors; all
drain and vent connections and the position of all pipes. All piping systems
shall be arranged to allow adequate falls in the direction of flow, except where
otherwise approved by the Engineer. At the points of drainage, drain pockets
of ample size and approved construction shall be fitted as per details
indicated in the enclosed drawings.
33.6 POWER CYCLE PIPING
33.6.1 EQUIPMENT SIZING CRITERIA
(a) All the piping systems and equipment supplied shall be designed to operate
without replacement and with normal maintenance for a plant service life of 30
years and shall withstand the operating parameters fluctuations and cycling
normally expected during this period.
(b) The design engineering erection testing etc. of the complete piping systems shall
be to the requirements of power piping code ASME B 31.1. in addition to this,
requirements as laid down in Indian Boiler Regulations (latest edition) shall also
be met completely.
33.6.1.1 PIPE SIZING
(a) Inside diameters of piping shall first be calculated for the flow requirement of
various systems. The velocity limits for calculating the inside diameters are
indicated in clause 33.2.1.
(b) Inside diameters thus calculated for various piping systems shall be checked for
the allowable pressure drop as per HBD’s.
(c) Pipes shall be sized for the worst (maximum flow temperature & pressure values)
operating conditions for each system considering the maximum occasional
pressure & temperature variations. In case of BFP suction sizing “transient
analysis” shall be carried out for optimum sizing of the system in order to
establish the pipe inside diameter for minimum pressure drop in system to match
with pump NPSH requirement under worst operating conditions. The design
pressure of MS piping system from superheater outlet header upto and including
boiler stop valve shall not be less than the design pressure of superheater outlet
header,
(d) The design pressure for BFP discharge piping upto and including downstream
valve at feed regulating station (FRS) shall be selected such that the minimum
calculated thickness for various pipes at design temperature is sufficient for the
following conditions, considering allowable stresses as per ASME B 31.1.
Page 383 of 680

• Discharge pressure corresponding to turbine driven BFP trip speed at shut off
head flow condition, if TDBFFP characteristics is governing for calculation of
boiler feed discharge piping design pressure.
• Discharge pressure corresponding to motor driven BFP trip speed (frequency
51.5 Hz) at shut off head flow condition, if MDBFFP characteristics is governing
for calculation of boiler feed discharge piping design pressure
However bidder may consider 20% higher stress as per the provision of ASME B 31.1
(for the piping upto downstream valve at feed regulating station only) for which the
requirement of special provision as per stipulation of clause no. 520 of IBR shall be
met as a must by the bidder. The valve rating in such case shall be arrived at based
on design pressure calculated as per above.
(e) The design pressure of boiler feed discharge piping at downstream of FRs shall
be 105% of pressure corresponding to the emergency point of BFP operation.
However pressure relief valve across the HP heaters shall be provided so that
piping & valves beyond feed regulating station are not subjected to shut off head
condition.
33.6.1.2 Inside diameters this calculated for various piping systems shall be checked for the
allowable pressure drop. Pressure drop in the main steam line shall not be moré than
90% of the allowable pressure differential between superheater outlet header and HP
turbine inlet valves at BMCR. Similarly combined pressure drop in cold & reheat
piping will not exceed 90% of the pressure differential between HP turbine exhaust
and IP turbine inlet valves minus pressure drop in reheater. The pressure drop in the
complete reheat line from HPT exhaust to IPT inlet shall not be more than 10% of the
pressure at HPT. Wherever possible 5/6 dia radius bends will be used to minimize the
pressure drop. Pressure drop in CRH NRV shall be considered as furnished by
supplier for calculating the pressure drop in the reheat circuit.
33.6.2 MATERIAL SELECTION
Piping system shall be of carbon steel for design temperature upto 400 Deg C and
alloy steel for design temperature beyond 400 Deg C.
33.6.3 PIPE WALL THICKNESS
Thickness calculation shall be made on the basis of procedure and formula given in
ANSI/ ASME B 31.1. Thickness thus calculated shall be checked based on the
procedure and formula given in IBR. Then, based on the higher value of the two
calculations (after adding manufacturing tolerance), the next heaviercommercual wall
thickness shall be selected from the thickness schedules ( eg Sch 40, sch 80 etc) as
contained in ASME B 36.10 for OD controlled pipes and from manufacturers
schedules for ID controlled pipes.
However, in such cases where the cakculatred thickness for OD controlled pipes falls
beyond the thickness corresponding to the listed schedule nos.as given in ANSI B
36.10 for the pipe size, both ID & OD controlled pipes to manufacturers schedules are
acceptable.
OD controlled pipes shall be to dimensional standards ANSI B 36.10 for carbon steel
& alloy steel pipes and ANSI B 36.19 for stainless steel pipes.
To account for losses due to erosion, corrosion etc dyring the plant service life, an
allowance of 1.6 mm/ 0.75 mm shall be considered in the minimum wall thickness
calculation of pipes as per ASME B 31.1/ IBR respectively.
Page 384 of 680

Further, the design pressure and temperature, downstream of any pressure reducing
valve upto and including the first block valve shall be the same as that at upstream of
pressure reducing valve. The piping at downstream of de superheater shall be
designed for spray failure condition. The length of piping considered for spray failure
condition shall not be less than the length required for proper spary mixing as
recommended by desuperheater supplier.
However in no case, the selected pipe thickness shall be less than Sch 80 for alloy
steel & carbon steel pipes of sizes 50 NB & below. The selected thickness for SS
pipes shall not be less than Sch 40S of ANSI B 36.19.
Further, for the piping systems likely to be subjected to two phase flow, i.e down
stream of control valves on heater drain lines etc. and for length of piping which is
required for the proper mixing of spray water at downstream of de-superheater the
selected thickness shall not be less than :
a. Sch 40 pipe sizes above 50 NB but below 300 NB.

b. Sch STD for pipe sizes 300 NB & above.
33.6.4 LAYOUT
(a) All high points in piping system shall be provided with vents. All low points shall
be provided with drains. Provision of drains on steam piping shall be as per
ASME code TDP-1. Drain lines shall be adequately sized so as to clear
condensate in the line and prevent water hammer and damage to turbine due to
water induction. All piping shall be sloped towards the system low point such that
slope is maintained in both hot and cold condition.
(b) All drain and vent lines in piping system with design pressure 40 Kg/cm2 (g) and
above or with vacuum service shall be double valved.
(c) The piping routing shall be such that clear headroom of not less than 2.5 meters
above the walkaways /working area is available. The contractor shall ensure
correct orientation of and easy access to valves and instruments etc. and
sufficient clearance for removal and maintenance of the same. Thepiping shall
not encroach oc withdrawal space of various equipment and walking space.
(d) Wherever there is possibllity of ingress of rain water through floor /celing opening
at points where any pipe passes through floor /celing suitable weather protection
hood shall be provided.
33.6.5 STRESS ANALYSIS
(a) Flexibility and stress analysis for various iping system shall be carried out by the
contractor as per the requirement of ASMR B31.1 analysis results shall satisfy
the following.
(1.) Calculating stresses in the piping shall be within the allowable limits
stipulated in ASMR B 31.1 as well as in IBR for piping under the purview of
IBR.
(2.) Calculated forces and moments on equipment nozzles/TP are not more than
the allowable loading provided by respective equipment manufacturer(s) /
contractors. Flexibility analysis also calculates the deflections in all directions
(translational and rotational) to enable design and selection of hanger/support
system.
(b) Cold pulling is not permitted. The contractor shall so design the piping system
that there will be no requirement of cold pulls for meeting allowable
reaction/stress values.
Page 385 of 680

33.6.6 HANGERS AND SUPPORTS
All hangers and supports shall be erected such that they are vertical when piping is in
hot condition (rated parameters). However in piping system connected to the rotating
equipment nozzles, it may be required to design and erect the hangers/supports in
the piping near the equipment nozzle as per the requirements/ recommendations, if
any of rotating equipment manufacture(s).
All the hangers/supports shall be of reputed make, approved/tested quality and shall
have proven performance record for similar application. They shall be designed to
provide the required supporting efforts and allow pipeline movement with thermal
changes without causing overstress. The design shall also prevent complete release
of the piping load in the event of spring failure or misalignment and all parts of
supporting equipment shall be fabricated and assembled so that they will not be
disengaged due to movement of the supported piping. Necessary guides, anchors,
braces and structural steel to be attached to building/boiler structure as well as any
braces and/or dampeners required to eliminate piping vibration and seismic loading
shall be provided.
The design of the pipe supports and hangers and their locations shall be
guided by the following general principles:
(a) Criteria of loading.
(b) Design loads for anchors, restraints, hanger supporting structures.
(c) Supports shall be adequate for extra loading due to hydrostatic tests
and when piping system is full of water during chemical cleaning.
(d) Supports for relief valve stacks shall be adequate for both the pipe
weight and the thrust developed when the valve is open.
Besides vibration elimination, hangers shall ensure that the amplitude of

oscillations in the pipe work owing to shock and vibration due to variation of
fluid flow from zero to full capacity remains within approved limits.
33.6.7 THERMAL INSULATION
(a) Thermal insulation shall be provided mainly for the following reasons.
(1) Conservation of heat and maintenance of temperature as per design cycle.
(2) Personal protection/
(b) Design for personal protection

0
For the piping and the equipment with surface operating temperature of 60 C
and above the personal protection insulated shall be applied such that the
0
temperature of protective cladding shall be below 60 C
(c) The contractor shall prepare an insulation thickness schedule covering both the
cases of heat conservation and personnel protection based on the following
design data.
0 0
Design ambient temperature 40 C for inside and 45 C for outside the
main plant building.
Page 386 of 680

0
Maximum cladding temperature 60 C
Wind speed 0.5m/sec. for inside and 0.25m/sec. outside

the main plant building.
Emissivity of cladding 0.2
Pipe/equipment wall temp. maximum operating temperature.
Thickness calculation as per ASTM C-680 or equivalent
33.6.8 FLASH TANKS
(a) The flash tanks shall be adequately sized to take care of the total drains in the
complete power cycle piping system. There shall be sufficient margin to
accommodate the possible carination in drains quantities as well as flash steam.
Flash tanks shall be designed as per the requirement of ASME boiler and
Pressure vessels (B&PV) codes, & ANSI standard. The contractor shall selection
for employer’s review.
(b) However the minimum design pressure and temperature for the flash tanks shall
0
be 3.5 Kg/cm2 (g) and 210 C respectively. Flash tanks shall also be designed for
full vacuum condition.
(c) Corrosion allowance of 3.0 mm shall be added to the design thickness of the shell
and head of the vessels. The minimum thickness of the vessels including
corrosion allowance shall not be less than 8 mm.
(d) The flesh tanks and manifolds shall be designed to take care of the impact forces
due to incoming drains.
(e) In case the spray is in manifold, the material for the flash tank manifold shall
conform to ASTM A335 Gr. P22 or better and its thickness shall not be less than
SCH 100 of ANSI B36.10 irrespective of temperature of the fluid handled
(f) The temperature in the flash tanks shall be maintained by using condensate /feed
water spray, as the case may be and in whichever case applicable. The spray
shall be automatically controlled. However for flesh tanks open to atmosphere
continuous spray through an orifice shall also be acceptable.
33.6.9 SPECIFIC REQ UIREMENTS – PIPES & FITTING
Manufacturing tolerances on pipe diameter (both ID & OD controlled pipes) and

thickness shall be as per ASTM-A530/ A999M, as applicable.
Bend thinning allowance shall be provided for all bends as per the recommendations
of ASME B 31.1. The finished bends wall thickness at any point of the bend shall not
be less than the calculated minimum straight wall pipe thickness.
Steel pipes & fittings shall in general be provided with butt welding ends as per ANSI
B 16.25. Pipe fittings of size 50 NB & below shall be socket welded as per ANSI B
16.11. However in certain cases the preparations of welding end for the pipe may be
required to be done to match equipment terminals, valves etc.
All stubs welded to the pipe including welded thermo wells and instrument source
shall be installed on the pipe prior to stress relieving.
Instrument tubing up to and including the root valves and all drains & vents shall be
generally of the same pipe material as that of the main pipe which they are located
unless & until specified otherwise elsewhere.
Page 387 of 680

Wherever ASTMA 106 Gr B/ Gr C or A – 105 material are used the maximum carbon
content shall be limited to 0.3% (max)
Wherever mitered bends are used the thickness of pipe from which they are
fabricated shall conform to the requirements of regulations 361 (C) of IBR. The angle
between axes of adjoining pipe sections shall not exceed 22.5 Deg C.
Non destructive examinations for butt weld of NPS over 50 mm and for welded
branch connections of branch size over 100 mm NPS shall be specified elsewhere.
For smaller sizes the mandatory minimum requirements shall be as per Table 136.4
of ANSI B 31.1 for non IBR piping as per regulation 360 of IBR or table 136.4 of ANSI
B 31.1, whichever is more stringent, for piping under the purview of IBR.
33.6.10 SPECIFIC REQUIREMENTS – VALVES & SPECIALTIES
For all globe and check valves, the direction of flow shall be clearly stamped on the
body of the valve.
All globe valves shall be capable of being closed against the design pressure.
Where globe valves have been specified for regulation purpose, the disc shall be
tapered plug type and suitable for controlling throughout its lift.
All gate and globe valves shall have bonnet back seating arrangement.
Check valves shall have full floating and accurately guided discs.
All gate, globe & check valves shall be designed for reconditioning seating surfaces
and replacement of stem and disc without removing the valve body from the line.
Hand wheels for all the valves shall close the valve in clockwise direction when
viewing from the top. All hand wheels shall be clearly marked indicating the direction
of opening/ closing.
Manual gear operators shall be provided to open/ close the valve against the
maximum differential pressure across the valve such that the effort required to
operate the valve does not exceed 25 Kgf.
Valves 65 NB & above with rising stem shall be provided with position indicator/
visual indication either through plastic stem covers or through metallic stem covers.
All gate and globe valves of size 50 NB and below in vacuum service shall have extra
deep gland packing without requiring water gland sealing. All gate & globe valves of
size 65 NB & above in vacuum services shall have adequately deep gland packing
and shall be equipped with lantern rings to admit pressurized water for gland sealing.
Where floors and extension spindle arrangement is required for valves, the height of
floor stand shall be about one meter from the floor/ platform. The floor stand shall be
sturdy condition eith column, nut plate and hand wheel made of cast iron conforming
to ASTM-A-126 Grade B. Suitable thrust bearing shall be provided/ between the
hand wheel and floor stand. The connection of the extension spindle to the valve
stem shall be through a flexible coupling and shall be designed to permit valve
thermal movements. Necessary nuts, bolts etc. For mounting the floor stand platform
shall be provided.
33.6.11 INTEGRAL BYPASS VALVES
Page 388 of 680

The requirement of integral bypass valves shown in flow diagrams is the minimum
required. The final requirement shall be worked out as per the process requirement
during detailed engineering.
If integral bypass valve selected is of size 50 NB & below, then the gate or globe type
of forged construction with socket weld end as per ANSI B 16.11 shall be provided.
For integral bypass valves of size 65 mm and above only cast steel gate valves with
butt weld ends as per ANSI B 16.25 shall be provided.
Bypass pipe shall be of seamless constriction and thickness corresponding to

minimum of schedule 80 and shall be of same material class as the main pipe.
Integral bypass shall be motor operated if main valve is motor operated.
33.6.12 SPECIFIC REQUIREMENTS: FABRICATION
33.6.12.1 Piping system fabrication shall be in accordance with the requirement of ANSI B 31.1
however for system under purview of IBR, the requirements of IBR, shall also be
complied with. All dissimilar material piping connection shall be subjected to the
acceptance and approval of the employer. Complete document shall be submitted by
the contractor in addition to the fulfillment of IBR requirement.
33.6.12.2 Where welded pipes and fittings are used the longitudinal weld seams of adjoining
sections shall be staggered by 90 deg.
33.6.12.3 Access holes for radiography at shop for piping requiring 100 % radiography shall be
provided only if the area to be radio graphed is not accessible from pipe ends. Access
holes for field radiography shall be provided.
33.6.12.4 Except where otherwise specified, all piping shall have butt-welded connections with
a minimum of flanged joints, if necessary. All high pressure steam valves and
accessories shall have welded connections. Where flanges are adjacent to welded
fittings, weld neck flanges shall be used.
33.6.12.5 Branches shall, in general, be formed by welding. Standard fittings may be used in
positions and for sizes where approval has been given in detail drawings. Pipe bends
and tees shall be truly cylindrical and of uniform section. All welded branches shall be
reinforced where needed as per the applicable codes/regulations.
33.6.12.6 Unless otherwise specified, for all welded lines with pressure above 7 kg/ cm2(g)
and/or temperature above 2000C, branch connections for branch sizes upto 25% of
welded mains shall be made with special forged steel welded fittings.
Piping shall be fabricated in the shop in the largest transportable sections to

minimise the number of field weld joints. The choice of field weld joints
locations shall be based on the traverse of the pipe through walls, floors,
sleeves or other restrictive areas. Support attachments for major piping shall
be done at shop.
All workmanship shall be carried out using methods and procedures of best
recognised pipe fabrication practice and must be done in a good and
workman like manner in accordance with ANSI standards, ASME Codes, PFI
standards and IBR as applicable.
Page 389 of 680

All high-pressure steam valves and accessories shall have welded

connections.
Mitred bends and elbows will not be accepted unless otherwise specified.
Only forged tees, 900 elbows and 450 elbows are acceptable. In case the
Bidder wants to deviate from this requirement on the ground of
non-availability of such forged items, he may submit his alternative offer for
Owner's consideration with sufficient documents to justify the same. In such a
case, the concerned fittings shall be manufactured with necessary reinforcing
pads, bend thinning allowance etc to satisfy code requirements.
All pipes bends shall be made true to angle with no negative tolerance and
shall have a smooth surface free of flat spots, crease and corrugations.
A cross section through any bend portion of the pipe shall be true in diameter.
All pipe bends shall have a radius of not less than 3 times the nominal pipe
size unless otherwise mentioned. Pipe bends shall be made from straight
pipe pieces of sufficiently higher thickness so that after thinning, the minimum
thickness of bends shall not be less than the minimum thickness required for
the straight pipe. Thinning allowance shall be considered as per ANSI B 31.1.
The ends of pipe and welded fittings shall be bevelled according to details
shown in the relevant piping codes.
For bends in pipes, straight piece of pipes shall be bent to required bend
radius. However, forged bends (Bend radius = 1.5 x pipe diameter) wherever
required shall be provided at no extra cost.
The ends of Pipe and welded fittings shall be bevelled according to details
shown in the relevant piping code. All welding shall be made in such a
manner that complete fusion and penetration are obtained without an
excessive amount of filler metal beyond root area. The reinforcement shall be
applied in such a manner that it shall have a smooth contour merging
gradually with the surface of adjacent pipe and welded fittings. Backing rings
shall not be used on any pipe welds, unless otherwise approved by the
Engineer.
Pipes of size 50 NB and above shall be shop fabricated and of size 40 NB

and below shall be field run.
All welding shall be made in such a manner that complete fusion and
penetration are obtained without any excessive amount of filler metal beyond
root area. The reinforcement shall be applied in such a manner that it shall
have a smooth contour merging gradually with the surface of adjacent pipe
and welded fittings. Backing rings shall not be used on any pipe welds, unless
otherwise approved by the Engineer.
Pipe and attachments shall be properly aligned prior to welding. If tack welds
are used, the tacks shall be either fused into the first layer of weld or else
chipped out.
All welding for steam and feed pipe work shall be electrical welding using the
shielded arc process and electrodes in accordance with the relevant code.
Page 390 of 680

For pipes up to and including 100 NB, provided the pipe does not exceed
12.7 mm in thickness, gas welded butt joints will be accepted without backing
rings.
Welded joints in pipe work shall be pre-heated to a temperature as required

by the agreed standard or code or to the approval of the Engineer. The
temperature shall be maintained during the welding operation and a record of
metal temperature shall be obtained by means of a recording thermometer
throughout the welding operation.
All welds shall be built-up by the application of multiple layers or passes. The
thickness of metal applied for each layer or pass shall not exceed 3 mm.
Each layer shall be cleaned and lightly peeled before the next layer is applied.
Before being assigned to welding work, each operator shall have passed a
qualification test as prescribed in the applicable Code/ Regulations. Each
approved welder shall have an identification number which shall be indicated
on all welds.
Welded joints shall be stress relieved as per ANSI B31.1/IBR. Stress relieving
temperature shall be measured by thermocouple pyrometers or other suitable
equipment. Readings of temperature against time shall be recorded.
33.6.13 BENDS AND ELBOWS
(a) Elbows shall be generally of long radius type.
(b) Bends for piping 65mm NB and above shall be made hot and for piping 50mm NB
and smaller may be made cold.
(c) Bends shall be made in accordance with PFI-ES-24. Bends shall be supplied with
the minimum tangents expect where the piping layout necessitates shorter
lengths in which case the tangents shall be suitably reduced after the bending
operation to suit the requirements of the piping layout.
(d) Heat treatment of bends shall be done as per material specification.
(e) Where examinations of bends indicates that wall thinning has resulted in
thickness less than the minimum specified, repair by weld deposition shall be
allowed only where the length of the affected area is 150mm or less as measured
along the outside arc of the bend. Repairs in excess of this amount shall not be
allowed. All repairs shall be carried out only after approval of the employer.
(f) Circumferential butt weld shall not be used in the area of the bend. Longitudinal
welds, where bends are formed from welded pipe shall be located on the bend’s
neutral axis.
(g) Bend thinning allowance on straight pipe prior to bending shall be applied as per
ANSI B 31.1. For bends of 5D or higher radius, the difference between maximum
and minimum diameters shall not exceed 8 percent of average measured outside
diameter of the pipe before bending.
(h) All bends in 50 NB and larger piping shall be made hot. Bends in 40 NB and
smaller piping may be made cold only when commercially available bending
Page 391 of 680

shoes are used. Finished bends shall be smooth in contour and free from buckles
and distortion.
(i) Pipe bends may be fabricated by the incremental induction heating process.
Circumferential butt welds or longitudinal welds (where seamless piping has been
specified) shall not be used in the arc of the pipe bends, without Engineer's
permission. After bending, such welds, where permitted, shall be re-examined
and re-inspected.
(j) All piping bends are subject to heat treatment as required by the original material
specification unless otherwise approved by the Engineer.
(k) All pipe bends in 50 NB and larger piping shall be examined ultrasonically after
fabrication for wall thickness conformance. Measurements shall be taken in
accordance with PFI Standard ES-20 using the "Pulse Echo" method. Data
reports containing information as recommended in PFI Standard ES-20 shall be
forwarded to the Engineer for record purposes.
(l) Where examination of pipe bends indicates that wall thinning has resulted in less
than code required minimum wall thickness repair by weld deposit shall be
allowed only where the affected area is 150 mm or less as measured along the
outside arc and with Engineer's approval. Repairs in excess of this amount shall
not be permitted.
33.6.14 End Preparation, Cutting etc.
(a) For steel pipes, end preparation for butt-welding shall be done by
machining/flame cutting.
(b) Socket weld end preparation shall be saw/machine cut
(c) For tees, laterals and other irregularities details, cutting template shall
be used for accurate cutting and cutting shall follow the outline of the
template.
Alignment Considerations
• The pipes joined by welding shall be aligned correctly within the existing
tolerances on diameter, wall thickness and out of roundness, which shall
be preserved during welding.
• All flange facings shall be true and perpendicular to the axis of the pipe
with boltholes being off centre.
33.6.14.1 Branch connections shall conform to the requirements of ASME B 31.1. All branch
connection welds shall be full penetration welds, except as permitted by ASME B
31.1/IBR. The branch connections shall generally conform to the following :
• Socket welding and threaded connections on pipelines shall be made by

forged outlet fittings. The holes in pipe headers made for these
connections shall be drilled to the same size as the fitting inside diameter.
All burrs shall be removed and threaded fitting shall be repeated after
welding.
Page 392 of 680

• For branch connection, additional reinforcements shall be provided

wherever necessary by the applicable codes including supply of
necessary material by the contractor at his own cost.
• The design and fabrication details for the instrument stub connection are
included in Tenderer's scope. Materials for instrument connection shall be
the same as that of the pipe to which it is attached. Fittings ratings shall
be in accordance with those specified for the main process pipe.
33.6.14.2 All materials that are bent, forged or informed shall be subjected to heat treatment
after the forming operations as required by the original material specification. For ally
steel materials the preferred heat treatment process is full annealing.
33.6.15 SPECIFIC REQUIREMENTS: WELDING
In addition to the requirements spelt out elsewhere, the followings shall be

taken into consideration:
33.6.15.1 Welding Process
(a) Welding under this specification shall be done by one of the following
processes :
(i) Manual oxy-acetylene welding process
(ii) Manual shielded metal arc process (SMAW)
(iii) Manual inert gas tungsten arc process (TIG)
(b) Automatic or semi-automatic welding shall be done only with the

specific approval of the Owner/Consultant.
(c) Socket weld joint shall be done with low hydrogen type covered
electrodes with manual shielded metal arc process.
(d) Welding at any joint should be completed uninterrupted. If this

procedure cannot be followed for some reason, the weld shall be
insulated for slow and uniform cooling.
(e) As far as possible welding shall be carried out in flat position. If not
possible, welding shall be done in a position as close to flat position as
possible.
(f) As a rule no backing ring shall be used for circumferential butt welds.
33.6.15.2 Alignment and Spacing
(a) Components to be welded shall be aligned and spaced. Root opening

shall be as under :
Page 393 of 680

(i) For wall thickness 2.5 mm or under and for 1.0 mm - 2.0 mm
all thickness in oxy-acetylene welding
(ii) For wall thickness over 2.4 mm 2.0 mm - 3.0 mm
Special care shall be taken for fitting and alignment in case of inert gas
tungsten arc welding. Flame heating for adjustment of ends is not permitted
without the approval of the Owner/Consultant.
(b) A wire spacer of proper diameter may be used for the weld root opening
but must be removed after tack welding and before application in root
pass.
(c) Tack welding for the alignment of pipe joints shall be executed carefully
and shall be free from defects since tack welds form a part of final
welding. Defective welds shall be removed prior to the welding of joints.
Electrode size for tack welding shall be selected depending upon the
root opening.
(d) Tacks should be equally spaced as follows:
(i) For 65 NB pipe and smaller 2 tacks
(ii) For 80 NB to 300 NB pipe 4 tacks
(iii) For 350 NB and larger pipes 6 tacks
33.6.15.3 Welding Technique
(a) Root pass shall be made with respective electrodes/filler wires. The
size of the electrodes shall not be greater than 3.25 mm (10 SWG).
Welding shall be done with direct current values recommended by the
electrode manufacturers.
(b) Upward technique shall be adopted for welding pipes in horizontally

fixed position. For pipes with wall thickness less than 3 mm,
oxy-acetylene welding is recommended.
33.6.17 CLEANING AND PROTECTION
(a) All fabricated piping shall be cleaned as per relevant SSPC cleaning
technique/practice such that both inside and outside surface of the piping are free
of sand, loosely adhering scale, dirt and other foreign matters.
(b) After cleaning outside surface shall be coated with enamel or other protective
paint, the weld end preparation shall be coated with deoxyaluminate paint and
protected adequately. Use of grease or oil. Other than light grade mineral oil is
not allowed.
Page 394 of 680

(c) After desiccating and preservation, the fabricated sections shall be covered,
boxed, capped, or others shielded from further contamination or corrosion.
33.6.18 MARKING
33.6.18.1 All piping shall be marked clearly and legibly at the shop with its identifying pipeline
description and piece no. as per the appropriate component or spool piece fabrication
drawing.
33.6.18.2 Marking shall be by any method which does not produce sharp discontinuities and the
marking does not get erased until the piping is erected. Piping 6 mm and thicker may
be marked by stamping using round nose or dot interrupted die stamps with minimum
nose radius of 0.8mm.
33.6.18.3 Item too small to be marked shall have metal tags securely attached to each bundle
or container of such items such that it does not get erased until the item has been
erected.
33. 6.19 SPECIFIC REQUIREMENTS- ERECTION
33.6.19.1 Where control valves, flow nozzles, orifices and other piping appurtenances are to be
installed, they shall be installed only after steam blowing and chemical cleaning
operation. After the completion of the steam blowing / chemical cleaning the
contractor shall cut spool pieces of required length and install the components.
33.6.19.2 Field run piping shall be erected only after completion of the erection of all other
piping system structures and equipment unless otherwise approved/directed by the
employer.
33.6.19.3 when C clamps are tack welded to the pipe for the purpose for the alignments of a
joint, preheating for the lack welding shall be performed if the main joint adjacent to it
to be preheated as per the requirement of this specification, otherwise preheating for
the tack weld may be omitted after the joint is completed, all tack weld shall be
removes, flushed with the adjacent of pipe by chipping and /or grinding. The areas
where C clamps were attached shall be subjects to stress reliving as required.
33.6.19.4 The hydrostatic testing of the piping system shall be done after proper installation of
all permanent hangers/supports. Springs hangers shall be locked during hydrostatic
test. Prior to steam blowing all hangers which had been locked for the hydrostatic
testing shall be unlocked.
33.6.19.5 The setting and logging of all supports, restraints/limit stop, spring hangers, etc, is the
responsibility of the contractor. The initial setting on all hangers and supports and
clearance on restrains and limit stops shall correspond to the design cold values. The
contractor shall check all readings after completion of erection of piping system and
application of insulation and carry out readjustment as necessary to be in line with the
design cold values. After satisfactory setting of all hangers/restraints. Hangers
reading / clearance shall be logged by the contractor in proper format and a joint
protocol be made.
33.6.19.6 The contractor shall monitor the behavior of all hangers, supports, restrains etc.
during the initial stage of plant operation. When the piping system(s) have attained
their rated temperature the contractor shall log, hanger reading, snubber deflection,
restrains/limits stop clearances as specified elsewhere.
Page 395 of 680

33.6.19.7 All gaskets shall be asbestos free material and suitable for the service
application.
33.6.20 SPECIFICATION FOR POWER CYCLE PIPING & FITTINGS
S. No. Description Alloy Steel Carbon Steel

A PIPES
Material X20 Cr Mo V 121 to DIN ASTM A 106 Gr B/ ASTM 106 Gr C
17175 or ASTM A335 Gr P91 (A 106 Gr C for BFD design
(For all temp above 510 deg parameters, CRH design parameters &
C) above)
ASTM A 672 Gr B 60 CLASS-12/ 22
ASTM A 335 Gr P22

Construction Seamless Seamless
B FITTINGS
Material for 65 NB & X20 Cr Mo V 121 to DIN ASTM A 234 Gr WPB with A 106 gr B
Above 17175 or ASTM A 234 Gr piping
WP91 (for temp above 510
Deg C)
ASTM A 234 Gr WP 22
Material for 50 NB & ASTM A 182 Gr F 91 (For all ASTM A 105
Below temp above 510 deg C)
ASTM A 182 Gr F 22
Construction Seamless Seamless
(forged for 50 NB & below) (forged for 50 NB & below)
Basic Standards ANSI B 16.9 ANSI B 16.9
ANSI B 16.11 ANSI B 16.11
Rating/wall/thickness To match with that of pipe To match with that of pipe
C WELDING
Backing rings Not permitted Not permitted
D MATERIAL
ANALYSIS
MANDATORY All tests, as given in respective material code (other than supplementary
REQUIRMENTS requirements).Shall be carried out as minimum. This includes the tests
wherein it is specified in the respective material code that “the test is to
carried out when specified by the purchaser” or any such indication, in the
code.
E. HYDROSTATIC TEST PRESSURE
(1) Piping system under IBR purview:

At shop All piping including fabricated piping shall be hydro tested at
1.5 times the design pressure subjected to regulation 374 of
IBR. However, non-destructive testing in lieu of hydro test is
also acceptable subject to regulation 343 (3)of IBR
After erection All piping system shall be hydro tested at 1.5 times the design
pressure subjected to regulation 374 of IBR. However for such
systems where it is practically not possible to do hydro tests.
The test as called for in ANSI B 31.1 & IBR in lieu of hydro test
Page 396 of 680

shall also be acceptable.
Hydro test of boiler feed piping: since isolating valve is not provided at
economizer inlet, contractor to make all necessary arrangement of hydro testing
of BFD piping beyond HP heater downstream heating isolating valve upto TP
either by blanking or providing a temporary valve. NDT as per the provision of
IBR & ASME B 31.1 can be carried out for the joint at TP between SG & TG
contractor.
(2) Non- IBR piping system:-
At shop All piping including fabricated piping shall be hydro tested at

1.5 times the design pressure subjected to regulation 374 of
IBR. However, non-destructive testing in lieu of hydro test is
also acceptable subject to regulation 343 (3)of IBR
After erection All piping system shall be hydro tested at 1.5 times the design
pressure subjected to regulation 374 of IBR. However for such
systems where it is practically not possible to do hydro tests.
The test as called for in ANSI B 31.1 & IBR in lieu of hydro test
shall also be acceptable.
Note:
1. EFW pipes as per A 672 are acceptable if the design pressure and design
temperature are such that it calls for ASME 300 class & below piping and
size is 550NB and above. The fitting shall correspond to ASTM A 234 with
grade corresponding to the pipe. Material. Welded construction fitting are
also acceptable with A672 piping. However all requirements as per ASME
B31.1 including the requirements given in mandatory appendix-D, IBR &
respective material code shall be fully complied with, in respect of welded
firings
2. In case the design temperature is above 545 deg C, then P91 material only
shall be applicable for both pipes as well as fittings.
Materials for fittings, specialties and valves shall be corresponding to piping

material.
33.6.21 SPECIFICATION FOR POWER CYCLE VALVES
33.6.21.1 General Requirements
33.6.21.1.1 All the control station configuration shall be as follows.
(a) For Continuous Service requirement:
(i) One (1) pneumatically/hydraulically operated control valve.
(ii) One (1) motor operated isolation valve at the upstream side of
control valve.
(iii) One (1) manual operated isolation valve at the downstream side
of the control valve.
Page 397 of 680

(iv) One (1) pneumatically/hydraulically operated bypass control

valve.
(v) One (1) motor operated isolation valve at the upstream side of
the bypass control valve.
(vi) One (1) manual operated isolation valve at the downstream side
of the bypass control valve.
(vii) Non return valve in the common downstream line, for spray
piping.
(viii) Drain valves at upstream and downstream of the control valves.
(b) For Intermittent Service requirement:
(i) One (1) pneumatically/hydraulically operated control valve.
(ii) One (1) motor operated isolation valve at the upstream side of
control valve.
(iii) One (1) manual operated isolation valve at the downstream side
of the control valve.
(iv) One (1) motor operated inching type regulating bypass valve.
(v) One (1) motor operated isolation valve at the upstream side of
the bypass valve.
(vi) One (1) manual operated isolation valve at the downstream side
of the bypass valve.
(vii) Non return valve in the common downstream line, for spray
piping.
(viii) Drain valves at upstream and downstream of the control valves.
All valves shall have cast/forged steel bodies with covers and glands of
approved construction. The valves shall be provided with electric motors/
solenoids and actuators as required.
Locating the valves on vertical runs shall be avoided as far as possible
All valves shall, unless otherwise approved, have ends prepared for
butt-welding and the internal diameter shall be the same as the internal
diameter of the pipes to be joined.
Page 398 of 680

All valves shall receive tests at Manufacturer's or Contractor's works in

accordance with the specific requirements of the approved Codes of Practice so
that the same is acceptable to IBR where applicable. Valves shall be rising stem
or otherwise as approved by the Owner.
All valves shall function smoothly without sticking, rubbing or vibration on

opening or closing.
Material, design, manufacture, testing etc. for all valves and specialties along
with the accessories shall conform to the codes as specified or approved
equivalent and acceptable to IBR.
By-pass valves shall be provided for high pressure and larger size valves
(including control valves) as per standards followed and as felt necessary for
smooth and easy operation, even though not specifically mentioned in the
specification.
Valves subjected to vacuum shall have sufficient long deep-seated packing.

Valves in general shall preferably be of such design as to permit repacking
while in service by providing back seating arrangement duly tested during
manufacture.
All valves shall have outside screwed spindles and screwed thread of spindle
shall not pass through or into the stuffing box. Where valves are exposed to the
weather, protective covers shall be provided for the spindles, which shall be
subject to approval.
Valves requiring sealing water shall be adequately deep and shall be equipped
with lantern ring to admit pressurised water for gland-sealing. Gland sealing
water shall be tapped from one tapping point on the condensate extraction
pumps discharge header and shall be reduced in pressure as per the
requirement.
The stops which limit the travel of any valve in the "Open" or "Shut" position
shall be arranged exterior to the valve body.
All regulating valves shall be designed to prevent erosion of the valve plugs and
seats when the valves are operated partially opened. The valves shall have
contoured plug.
Approved access arrangements shall be provided for all valves and particular
attention shall be given to those valves fitted with gearing, which require
lubrication of the valve itself.
Valves which cannot be operated from the floor or walkways shall be provided
with suitable extension rods and linkages. If such a valve is provided with
integral bypass then similar arrangement shall be done for the bypass valve
also. The extension shall be such that the hand wheel is at a height of
approximately one metre above the level of the floor or platform from which the
valve is to be operated. Where required, valves shall be provided with
head-stocks and pedestals of rigid construction and where gears or level
wheels are used, these shall be of cast steel or suitable quality cast iron with
Page 399 of 680

machine cut teeth. Where extension spindles are fitted, all thrust when
opening or closing the valves shall be taken directly on the valve body. The
extension linkage shall be so designed to take care of the thermal
movements of the valve body with the pipe on which the valve is installed.
The connection of the extension spindle to the valve stem shall be through a
flexible coupling.
The extension spindle shall be of the same material as that of the valve stem.
The floor stands shall have column, not less than Group-B of ASTM-126.
Necessary nuts and bolts for mounting the floor stands on foundation shall have
to be provided. Adequate means of easy lubrication shall have to be provided
for valves and operating extension components.
Stems shall preferably be arranged vertically with gland at the top, however, in
no circumstances must the stem be inclined downward from horizontal or gland
be at the bottom. Globe valves shall be installed with the pressure under the
disc. Valves shall not be fitted in inverted position.
Where necessary, for accessibility, grease nipples shall be fitted at the end of
extension piping and where possible these shall be grouped together and
mounted on a common panel situated at a convenient position. A separate
nipple shall be provided to lubricate each point. The Contractor shall supply the
first fill of oil or grease for these parts. The Contractor shall supply a suitable
manually operated grease gun for the standard type of nipple provided.
The spindles for all valves for use outside the building shall have weatherproof
protection covers of approved construction.
All valves shall be fitted with indicators so that it may be readily seen whether
the valves are open or shut. In the case of those valves fitted with extended
spindles, indicators shall be fitted both to the extended spindles and to the
valve spindles.
Plastic or bakelite valve hand wheels are not permitted.
All valves shall be closed by rotating the hand wheel in a clockwise direction
when looking at the faces of the hand wheel. The face of each hand wheel shall
be clearly marked with the words `Open' and `Shut' with arrows adjacent to
indicate the direction of rotation to which each refers.
Each valve hand wheel shall be fitted with a circular nameplate of approved
material indicating the valve tag number, duty or service intended and the
function of the valve. The nameplates shall incorporate the colour code
corresponding to the service of the piping.
Wherever practicable, heavy valves of total weight including actuator, drive

motor, integral by-pass etc equal to or greater than 500 kg shall be provided
with suitable lugs to permit direct suspension by hanger rods or direct resting
on bottom support, as applicable.
Page 400 of 680

Special attention shall be given to the operating mechanism for large size
valves in order that quick and easy operation is obtained and maintenance is
kept to a minimum.
Eyebolts shall be provided where necessary to facilitate handling heavy valves

or parts of valves.
The Bidder shall supply during the course of the Contract, comprehensive
drawings showing the design of valves, test pressure and working pressure
/temperatures. They should include a parts list referring to the various materials
used in the valve construction.
Gate valves below 100 NB shall be solid wedge/Flexible wedge type. Valves of
150/300 and size 100 NB and above shall be flexible wedge type. However, for
sizes 100 NB and above for temperature 300oC above, parallel slide gate
valves shall be used.
All sampling and root valves shall be of integral body bonnet type.
For butterfly valves, Contractor shall guarantee that in the closed position and
with a disc differential pressure as specified, the valves shall be water tight.
Contractor shall guarantee that the operating mechanism shall open and close
the valve under the specified maximum differential pressure within the time
specified.
Page 401 of 680

A. CAST STEEL VALVES (GATE/ GLOBE/ CHECK 65 NB & Above)

S. No. Description Alloy Steel Carbon Steel Stainless
Steel
600 lbs & 600 lbs 600 lbs & 600 lbs & 400 lbs & below
below & above below above
1.0 Basic Standard ANSI B 16.34
2.0 Construction
a Bonnet/ cover Bolted Type Pressure Bolted Pressure Bolted Type
Type Type Type
b Disc
Globe Valves Throttling Type Plug
Check Valves Twilting/ swing type
Gate Valves Solid/ flexible wedge below 100 NB
Flexible Wedge for 100 NB & above
c Seat Integral Type
3.0 Material
a Body, Bonnet & ASTM 216 ASTM ASTM A 217 WC9 ASTM A 351
Cover Gr WCB 216 Gr ASTM A 217 Gr C 12A CF 8
WCC
b Stem 13% Chrome Steel ASTM A 182 Gr F6A ASTM 182
F316/ F 304
c Hinge Pin (for 13% Chrome Steel ASTM A 182 Gr F6A ASTM 182
check valves) F316/ F 304
d Disc & Seat ring ASTM A 216 ASTM A ASTM A 217 Gr WC9 ASTM 182
(heat treated & Gr WCB 216 Gr ASTM A 217 Gr C12A F316/ F 304
hardened minimum WCC
Hardness Seating surface hard faced with satellite 350 BHN
250 BHN
e Back seat/ stem ASTM A 182 gr F6a ASTM 182
guide bushing 13% Cr SS with stellite hard facing F316/ F 304
Page 402 of 680

B. FORGED STEEL VALVES (GATE/ GLOBE/ CHECK 50 NB & Below)
S. No. Description Carbon Steel Alloy Steel Stainless

Steel
1.0 Basic Standard ANSI B 16.34
2.0 Construction
a Bonnet/ cover Bolted Type for 600/ 800 lbs Seal Welded/
Seal welded for 900 lbs & above Bolted Type gor
600/ 800 lbs
Seal welded for
above 800 lbs
b Disc
Gate Valves Solid Wedge Type
Globe Valves As per mfg std
Check Valves Piston Lift
c Seat Integral Type
3.0 Material
a Body, Bonnet & ASTM A 105 ASTM A 182 Gr F22 ASTM 182
Cover ASTM A 182 Gr F91 F316/ 304
b Stem 13% Chrome Steel ASTM A 182 Gr F6A ASTM 182
F316/ F 304
c Hinge Pin (for 13% Chrome Steel ASTM A 182 Gr F6A ASTM 182
check valves) F316/ F 304
d Disc & Seat ASTM A 105 with stellite ASTM A 182 Gr F22/ F ASTM 182
ring minimum Hardness 350 91 hard faced with F316/ F 304
BHN satellite minimum hard faced with
hardness 350 BHN satellite
minimum
hardness 350
BHN
C.ANGLE GLOBE VALVE
S. No Description Alloy Steel Carbon Steel

1.0 Design Standard ASME B 16.34
2.0 Material
a Body & Bonnet A 182 Gr F22/ F 91 or better A 105 or better
b Spindle/ disc Stellited
c Body Seat & Stellited
Back Seat
d. Gland Packing Graphite
3.0 Construction
a Valve Type Outside Screw & yoke Type
b Body & Bonnet Forged body with integral/ welded bonnet connection
c Disc type Taper plug or parabolic type to suit system requirement
d End connection Socket weld (ANSI B 16.11) for sizes 50 Nb & below
Butt weld (ANSI B 16.25) for sizes 65 NB & above
e Pressure rating To suit the service condition. However minimum pressure rating shall be
corresponding to ANSI Class 1500
Page 403 of 680

D OTHER VALVES (65 Nb & Above)
S. No Description Safety Valve Relief Valve BF Valve

Alloy Steel Carbon Steel
1.0 Design Standard ASME B 16.34 AWWA C 504
2.0 Pressure Class 400 lbs & below 75 B & above
3.0 Accumulation 10% (max)
4.0 Blowdown 5% (max) 10% to 15%
5.0 Construction
a General Spring loaded with weld end inlet, Spring loaded Long body butt
pop up type with flanged inlet welded
& outlet
b Bonnet Bolted trype
c Seat bushing Renewable type screwed on and held in position type
d Shaft seat O ring type
6.0 Material
a Body & Bonnet ASTM A 217 ASTM A 216 Gr WCB/ WCC ASTM A 216 Gr
cover WC 9/ C 12A WCB
b Spindle/ Shaft Stainless Steel ASTM A 182 Gr
304
c Disc, nozzle, ASTM A 182 F 316 ASTM A 216 Gr
seat ring WCB
Seal & O Ring :

EOT/ BUNA – N/
Neoprene for
water service
EOPT/ EPDM for
steam service
d Spindle Guide 17% Chrome steel or monel, heat treated and hardened to minimum hardness
250 BHN
e Spring Stainless Steel Carbon Steel
or Tungsten
Steel
f Retainer Rings SS 304
and Internal
Bolts
g Bearing Sleeve type self
lubricated
Note the material of body, bonnet/ cover & disc shall be corresponding to that of pipe material on which
valve is installed.
33.6.22 SPECIFIC REQUIREMENTS
1. Valve of size 65 NB and above shall have butt welded ends as per ANSI B16.25
and valves 50 NB and below shall have socket weld ends as per ANSI B16.11
2. Locking arrangement, wherever specified shall be of non-detachable type.
3. Valve shall be tested in accordance to ANSI B 16.34, however, for butterfly

valves; the requirements of AWWA C-504 shall also be met.
Page 404 of 680

4. All gates and globe valves shall be without side screw and yoke with rising stem.
5. Gate valve below 100 NB shall be solid wedge/flexible wedge type, valve of size
100 NB and above shall be of flexible wedge type. However, for sized 100mm NB
0
and above for temperature above 300 C, parallel slide valves are also
acceptable.
6. Specification for valve shall be as indicated in C&I subsection.
7. Stem for all valves shall be heat treated and hardened- minimum, hardness
200HB and surface finish of 16 RMS or better in area of stem packing.
8. Gland packing for gate and globe valves shall be alloy steel/SS wire rainforced
graphite with stem corrosion inhibitor.
9. All bolts and nuts shall be ASTM A-193 Gr. B 7 and ASTM A-194 Gr. 2H
respectively.
10. Hand wheel for valves shall be of malleable iron / carbon steel.
11. Minimum differential hardness between seat and other disc material shall be 50
HB in case of 13 % chrome hardened with heat treatment of steel.
12. Valves closure test shall be as per supplied complete with discharge elbow and
drip pan along with drain.
13. For valve of size 65 NB and above in vacuum service, water gland-sealing
arrangement shall be provided. For valve of size 50 NB and below, deep gland
packing shall be provided. Butterfly valves, subjected to vacuum, shall be tested
for vacuum as per relevant code.
33.6.23 SPECIFICATION FOR HANGERS/SUPPORTS
Design and manufacture of hangers/supports shall conform to ANSI B 31.1 MSS-SP-

58,MSS-SP-89
.
Where hangers rod angularity exceed 4 degree from cold to hot position (at rated
parameters), the hanger and structural attachments shall be offset in the cold position
in such a manner that the hanger rod is vertical in hot position unless otherwise
specified.
The contractor shall furnish, detailed arrangement sketches for each support,
restrains, anchor, etc. the sketches shall include the key plan identification no. bill of
quantities, design load , operating load, spring stiffness, amount of precompression,
centre line elevation of pipe, spring box position/orientation, etc.
Hangers support tag no. shall be marked on all pipe hangers/support, restraints and
anchor assemblies, the design loads, hot and /or cold loads shall be stamped on
respective constant and variable springs.
33.6.24 TECHNICAL REQUIRMENTS
(a) Each threaded connection and adjustable rod shall be provided with lock nuts.
(b) Each rod of a double rod hanger support shall be designed for the full hydro test
load coming on the double rod hanger assembly.
Page 405 of 680

(c) Hanger support rods of less than 10mm diameter for supporting pipes of 50 NB
and smaller and less than 12mm diameter for supporting pipes of 65 mm NB
and larger, shall not be used.
(d) Parts of the hanger or support which move relative to the pipes during operation
shall be connected to the pipe attachments in such a manner that they lie
entirely outside the pipe thermal insulation.
(e) Attachment to piping shall be as far as possible by clamps.
(f) Where axial movement is to be restricted or riser clamps are used, suitable lug
stops to prevent pipe movement shall be designed for welding on to pipe.
(g) Bolted pipe clamps shall have a minimum thickness of 5mm for weather
protected locations and 6 mm for locations exposed to weather.
(h) Beam clamps shall be forged steel equipment with a rod to fix a nut.
(i) All sliding surface of supports and restrains shall have Teflon lining on one
surface coming in contact with stainless steel lining on the other surface.
(j) All piping hangers and supports shall be designed to carry the weight of the
piping fitting, thermal insulation, self weight of the hanger assembly and medium
transported or test medium whichever is heavier. In addition all rigid rod hangers
and variable spring shall be designed to carry the operation load in hot condition.
(k) All design and fabrication including loading and allowable stresses shall be in
accordance with ANSI B31.1. Note shall be taken of the requirements against
earthquake at site. Hangers and supports for systems shall be completely
engineered and prefabricated for all piping 50 NB and above. Sufficient random
materials shall be furnished for field support of all lines of smaller diameter.
(l) For pipes of design temperature 1000C and more, bottom supports shall be
avoided as far as possible and hanger type supports shall only be used.
However, where bottom support cannot be avoided, the same shall be provided
with suitable shoes along with balls/rollers/rockers (if movement is more than 50
mm) and SS/Graphite is to be used (if the movement is more than 20 mm) to
minimise frictional resistance against thermal movements. The material of shoe
as well as the ball/rockers/rollers shall be suitable for the design temperature of
the supported pipe and shall be of sufficient hardness so as to permit a
reasonably long life keeping its roundness and maintaining a low friction factor.
Where a constant load type support is required, the bottom support shall also be
of constant load type.
(m) Provision shall be made for support of piping which may be disconnected during
maintenance work.
(n) Support steel shall be of structural quality. Perforated strap, wire or chain shall
not be used. Support components shall be connected to support steel by
welding, by bolting or by beam clamps. Bolt holes shall be drilled, not burned.
Support components may be bolted to concrete using approved concrete
anchors.
(o) Double nuts or lock-nuts shall be used on hanger rods and bolts in all cases.
(p) Variable springs shall be furnished with travel stops. The travel stops shall be
factory installed at the "cold" position.
Page 406 of 680

(q) Spring hangers should not be loaded more than 80% of the spring travel range.
(r) Both constant load and variable spring support/hanger shall be provided with
outside indicators for deflection and load. Provision for the site adjustment of
_ 10% shall be incorporated. Also spring locking arrangement and
load at least +
turnbuckles of load/position adjustment shall be provided for all hangers.
(s) Constant load type spring support/hangers shall be so selected as to permit, for
the specific load, an over-travel of at least 25 mm or 20% (whichever is greater)
of the specified range of vertical travel. The initial setting of the hangers/supports
shall be such that half of the "over-travel" is allowed in either direction. Constant
support hangers shall have a support variation of not more than 6% throughout
the total travel range.
(t) Rigid hangers & restraints shall be judiciously selected, without exceeding the
stipulated limits of terminal forces & moments & stress level. Struts shall be
considered where compressive load is expected.
(u) Where the piping system is subject to shock loads, such as thrust imposed by
the actuation of safety valves (SV), hanger design shall include provision for
shock absorbing devices of approved design.
(v) Vertical restraints near safety valves shall be preferred for taking SV discharge
thrust, provided equipment terminal reactions remains within allowable limit.
(w) Attempts shall be made to avoid use of shock absorbers, dampers etc as far as
possible to take care of occasional loading like seismic effect etc by proper
engineering of the piping design and effective use of restraints. However, shock
absorbers, VISCO- dampers, wherever felt necessary are to be supplied and
erected by the bidder.
(x) Layout of piping shall be properly designed to avoid excessive vibration by

effective use of restraints. However, wherever felt necessary, shock absorbers,
VISCO- dampers may be employed.
(y) Hanger rods (except rigid hangers where both tension and compression may
occur) shall be subjected to tensile loading only. At hanger locations where
lateral movement is anticipated, suitable linkage and rocking washers shall be
provided to permit swing.
(z) For all hangers, the length of suspension shall be so selected that the hanger
rod may never make an angle of more than 40 with vertical due to horizontal
pipe movements. If this cannot be avoided by erecting the hanger vertically for
cold condition, it shall be suitably off set so that the above requirement is fulfilled
in cold as well as hot conditions. Hangers shall be designed so that they cannot
become disengaged by movements of the supported pipe.
(aa) Hanger support rods of less than 10 mm diameter for supporting pipes 40 NB
and smaller and less than 13 mm diameter for supporting pipes of 50 NB and
larger, shall not be used.
(bb) Supports, guides and anchors shall be so designed that excess heat will not be
transmitted to the building steel.
(cc) Tie rods/struts shall preferably be used for restraints to achieve low friction
restraining.
Page 407 of 680

(dd) The Tie-rods/struts shall have proper arrangement and adequate length, so that,
thermal movements in other directions, which are intended to be free are not
constrained and there is no appreciable shift in centreline of pipe or the elevation
of the supporting point on pipe due to sway. The design shall have provisions for
adjusting the length to take up any slack and securely locking in position
permanently once adjustment is done.
(ee) Snubbers & dampers shall be designed to take seismic/dynamic loads, thrust
due to safety valve discharge. Effort shall be made to limit its use by judicious
placement of rigid hangers.
(ff) Bottom support spring hangers to be avoided as far as possible.
33.6.25 SPRING HANGERS
Constant load hangers shall generally be used when vertical displacement exceeds
40 mm or where the supporting effort variation of available variable spring exceeds
25%.
Constant load hanger shall be of moment coil spring counter balanced design or cam
& spring type. Variable spring hangers shall be of helical spring design. Spring
hanger/ assembly shall be constructed such that complete release of piping load is
impossible in case of spring miss alignment or failure.
Constant load hangers shall have a minimum field adjustment range of 15% of the
load. The total travel for constant speed load hangers shall be design travel plus 20%
but in no case shall be difference between total travel and design travel be less than
15 mm. The supporting effort variation throughout the travel range of constant load
hangers shall not exceed 6%.
Variable spring hangers shall have supporting effort variation of not more than 25%
throughout the total travel range.
All springs shall remain under compression throughout their operating regime and
never under tension.
Spring hangers shall have provision of rlocking the hangers in any position of the
travel.
Spring hangers shall be adjusted to the cold position before shipment and locked in
that position. The cold and hot position shall be clearly marked on the travel indicator
scales.
All spring hangers shall be locked before performing the hydro test. The locking shall
be removed before the line is placed under operation.
33.6.26 SNUBBERS
Snubbers shall be designed to allow normal movement of pipe due to thermal

expansion and shall require minimum maintenance.
Snubbers shall be of hydraulic type of Lisega/ ITT Girnell, Germany or owner

approved eqvt.
Axes of anubbers/ restraints shall be parallel to the direction of the expected reaction
force in operating condition.
Page 408 of 680

33.6.27 RESTRAINTS & ANCHORS
All anchors shall be designed for direct rigid fastening to the structural steel member.
Anchors, guides and restraints shall be capable of withstanding the forces and
moments due to thermal expansion and dynamic effects.
33.6.28 STEAM STRAPS & STRAINERS
Steam traps shall be of inverted bucket/ thermostatic type with integral or separate Y
type strainers.
Traps shall have stainless steel internals.
All Y type strainers shal have stainless steel screen of not more than 20 mesh size.
Screen open area shall be at least four (4) times the pipe cross sectional area.
Strsiner shall have screwed blow off connection with removable plug.
Y type strainers shall be provided along with each steam trap in case the strainer
does not form an integral part of the trap.
33.6.29 SPECIFICATION FOR THERMAL INSULATION
Insulation materials, cladding and accessories

(a) The insulating material and cladding material shall be as per the tables of
material given in the subsequent clauses.
(b) All insulating materials, accessories and protective covering shall be non-
sulphurous, incombustible, low chloride content, chemically rot proof, non-
hygroscopic and shall be guaranteed to withstand continuouslay and without
deterioration the maximum temperature to which they will be subjected under the
specification conditions.
(c) The use of insulation of finishing materials containing asbestos in any form is not
permitted.
(d) Insulation mattress/section shall be supplied in thickness of 25,40,50 and 75 mm.

insulation of higher thickness shall be made up in multiple layer using
mattress/slabs of thickness specified above. However; if the required thickness is
not achieved, the mattress/slabs in increment of 5mm shall be acceptable. The
min. & the innermost layer shall be thicknest.
33.6.30 INSULATION MATERIALS
(a) Rock/glass insulation mattress shall be of long fibered rock or glass processed
into fibrous form bonded with a binder. No kind of slag wool inclusion is
acceptable.
(b) Calcium silicate pipe insulation shall be composed principally of hydrous calcium
silicate reinforced with mineral fibre. It should be asbestos free.
Page 409 of 680

(c) All insulation shall conform to the quality requirements laid down below and test
certificates on samples from the lot to be supplied shall be furnished to employer
for approval.
33.6.31 OTHER ACCESSORIES
The contractor shall also provide other accessories such as ceramic boards. Sealants
and washers as required.
33.6.32 INSTALLATION
(a) All surface to be installed shall be cleaned of all foreign materials such as dirt,
grease, rust etc, and shall be dry before the application of insulation.
(b) Before applying the insulation the contractor shall check that all instrument
tappings, clamps, lugs and other connections on the surface to be insulated have
been properly installed as per the relevant erection drawing.
(c) All flanged joints shall be insulated only after the final tightening and testing.
(d) The insulation shall be applied to all surfaces when they are eat ambient temp.
ample provision shall be made for the maximum possible thermal movement and
the insulation shall be applied so as to avoid breaking/ telescoping due to
alternate periods of expansion and contraction
(e) All cracks voids and depressions ahall be filled with finishing cement suitable for
the equipment operating temp. so as to form a smooth base for the application of
cladding.
33.6.33 INSULATION MATERIALS
Type#1 Type#2 Type#3 Type#4 Type#5 Type#6
Type Lightly resin Lightly resin Bonded glass Resin bonded Resin bonded Calcium
bonded bonded wool mineral (rock) glass mineral silicate
mineral (rock) mineral (rock) wool wool performed
wool wool performed performed block type
pipe section pipe section
3 3 3 3 3
Apparent 120-150 100 Kg/m 64Kg/m 140-150Kg/m 60-80 Kg/m 20-25 Kg/m
3
density Kg/m
Mtl. IS: 8183 IS: 8183 IS: 8183 IS: 9842 IS: 9842 IS: 8154
standards
Applicable Piping system Piping system Piping Piping system Piping system Piping
service & equipment & equipment system & of 350 NB and of 350 NB and system &
with operating with operating equipment below with below with equipment
temp. above temp. in range with operating operating with
0 0
400 C of 60- 400 C operating temp. in range temp. in range operating
0 0
temp. in of 60- 650 C of 60- 400 C temp. in
range of 60- range of
0 0
400 C 400- 600 C
Page 410 of 680

Testing As per 8183 8183 8183 IS:9842 IS:8154

requirement IS:8183
33.6.34 CLADDING MATERIAL & ACCESSORIES SHALL BE AS SPECIFIED HERE

UNDER:
Sl. No. Item Basic specification Description

1. cladding Aluminium ASTM B-209-1060 Thickness of sheathing
temper H14 or IS:737 Gr.19000/H2 (a) 18SWG (1.219) for diameter for
insulated surface 450mm and
above and for flat surfaces.
(b) 20 SWG (0.91mm) for diameter
of insulated surface 150mm and
above upto 450mm.
(c) 22 SWG (0.71mm) for diameter
of insulated surface 150mm and
below.
2. Binding & lacing Galvanized steel wire to IS: 280 for 20 SAWG for all insulation interface
0
wire temp. below 400 C and stainless temperature.
0
to IS:6528 for temp above 400 C
3. Straps & brands (i) Aluminium where interface Band shall be 20 mm wide & 0.6 mm for
temperature are below securing aluminium sheathing anodized
0
400 C aluminium bends shall be used.
(ii) Stainless steel where
temperature are above
0
400 C
4. screws Stainless steel Self tapping, chese headed
5. Hexagonal wire (i) Galvanized wire to IS :280 Wire mesh netting shall be 10 to 13mm
mesh mesh for interface aperture at least 0.56 mm diameter wire
temperature upto
0
400 C
(ii) Stainless steel wire for
temperature above
0
400 C
33.6.35 INSTALLATION ON PIPING
(a) All vertical pipes shall be provided with the suitable insulation supports to prevent
collapsing/ crushing of insulation due to its self weight. Support rings shall be
provided on all vertical piping with a difference in elevation of 4 meter or above,
and there shall not be more than 3 meter straight length between support ring.
(b) Longitudinal joints of insulation mattresses section of horizontal piping shall be on

the bottom or at the sides of the pipe.
(c) When more than one layer of insulation mattress/section is required on piping the
circumferential joints on adjacent layer shall be staggered by atleast 150mm and
longitudinal joints shall be fitted on pipe using binding wires.
Page 411 of 680

(d) The mattress type insulation shall be formed to fit the pipe and applied with the
mattress edges drawn together at the longitudinal joints and secured by lacing
wire pipe section insulation shall be fitted on pipe using binding wires.
(e) The mattress type insulation is applied in two or more layers each layer of
mattress shall be backed with hexagonal wire mesh. For the first layer of
insulation and in case of single layer insulation, hexagonal wire mesh shall be
provided on both the surface of the mattress. For pipe sections, the sections shall
be held in place by binding wires without any wire mesh.
(f) The ends of all wire loops shall be firmly twisted together with pliers, bent over
and carefully pressed into the surface of insulation. Any gap in the insulation shall
be filled with loose mineral wool or finishing cement.
(g) Insulation mattress/section ends shall be terminated at a sufficient distance from

the flanges to facilitate removal of bolts.
(h) The insulation shall be held in place by fastening over with binding wire for
insulation surface with diameter upto and including 550mm and with metal bends
for insulation surfaces with diameter over 550mm. the fastening shall be done at
intervals of 250mm except where specified otherwise. The ends of the binding
wire shall be hooked and embedded in the insulation the straps shall be
mechanically starched and fastened with metallic clamping seals of the same
materials as the strap.
(i) Insulation for the application on bends and elbows shall be cut Into mitred
segments, sufficiently short to form a reasonably smooth internal surface. after
the application of insulation material in place, insulating cement shall be applied
as required to obtain a smooth surface.
(j) Weather hoods shall be provided for insulated piping passing though floors/walls.
(k) All pipe attachments coming on horizontal pipes, included pipes and bends shall
be insulated along with pipe such that there will be no insulation applied to
hanger rod and the component connecting hanger rod to pipe attachment. All
pipe attachments exposed to weather shall be provided with weather proof.
(l) Upstream of all drain lines and the lines connected to steam traps, shall be
insulated upto and including first isolating valve for heat conservation. Rest of
such lines such as downstream of the drain valves, traps etc. and other lines
such as safety valve discharges, vents, etc. shall be insulated for personal
protection.
33.6.36 INSTALLATION ON VALVES AND FITTINGS
(a) All valves fittings and specialties shall be insulated with the same type and
thickness of insulation as specified for the connected piping with the special
provision and or exceptions as given below.
(b) All valves and flanges shall be provided with removable box type of insulation
covered with box fabricated from aluminum sheets of thickness same as the
connected pipe cladding. Adjoining pipe insulation shall be believed back to
permit removal bolts and nuts or bends. The portion of the valve which can not be
covered by box type insulation shall be filled by loose insulating material of
packing density at least equal to that of the insulating material of adjoining pipe.
The insulation for valve/flanges shall be applied after the finishing has been
applied over the connected piping. The cladding shall be applied in such a
Page 412 of 680

manner that the bonnet flange can be exposed easily without disturbing the
complete insulation and cladding.
(c) Expansion joints, metallic or rubber shall not be insulated unless otherwise
specifically indicated.
33.6.37 INSULATION ON EQUIPMENT
a The insulation applied to the equipment shall be reinforced with hexagonal wire
mesh. One layer of wire mesh shall be provided on the equipment surface prior to
application of insulation.
b Installation on horizontal cylindrical vessel/tanks (including heaters, deaerator, heat

exchanger etc.)
c All the surface of insulation layer, applied on horizontal cylindrical al vessel shall be
securely fastened by brands upto vessel/tanks outer diameter of 150mm and below.
Where vessel/tank outer diameter exceeds 1500mm, binding wire passing through
insulation clip provided both longitudinally and circumferentially at 500 centers shall
be used. Gaps in the insulation shall be filled with insulation mineral wool and
finished with finishing cement so as to obtain a smooth surface for the supplication of
cladding. The contractor shall provide a support ribs/lugs on the surface of the
vessel/tank as necessary. The the contractor shall obtain the approval of the
employer and the equipment supplier’s field engineering representative before
performing any wlding on equipment. Any heat treatment equipment as per
recommendation of equipment supplier shall be performed by the contractor.
d Installation on vertical cylindrical vessel/tanks (including flash tanks etc.)
e All vertical vessels/tanks shall be provided with support rings/ribs with other
necessary frame work to take up the weight of the insulation prior to HT. the
contractor shall obtain the approval of the employer and the equipment supplier’s
field engineering representative before performing any welding on equipment. Any
heat treatment of vessel/equipment that is required after welding of rings/ribs on the
vessel/equipment shall be as per recommendation of equipment supplier and shall
be as per recommendation of equipment supplier and shall be performed by the
contractor.
f The mattresses shall be held in position by means of 9 SWG steel wire nails, the
nails being 25 mm longer than the thickness of insulation to be applied. After the
mattresses have been placed over the nails, the nails shall be bent and embedded in
the insulation. Alternative, wire loops may be tack welded at 250mm centers to hold
the insulation in place.
33.6.38 INSTALLATION OF CLADDING
(a) All insulation shall be protected by means of an outer covering of aluminium

sheathing. All insulation/cladding joints shall be sealed and made effectively
weather and waterproof. All flat surfaces shall be given suitable slope to prevent
collection of pools of water on the cladding surface. All sheathing shall be
protected internally by the application of two coats of bitumenastic paint.
(b) All longitudinal joints shall have a minimum overlap of 50mm and shall be located
0
at 45 C or more below the horizontal for horizontal equipment joints shall be
made with cheese headed self tapping galvanized steel screws at 150mm
centers.
Page 413 of 680

(c) All circumferential joints shall have a minimum overlap of 100mm and shall be
held in position by stainless steel or anodized aluminium bands, stretched and
clamped.
(d) Removable box type cladding for valves and flanges shall be fitted on the
connected pipe cladding, with bands.
(e) Aluminium cladding shall not come directly into contact with either the equipment
surface or with the supporting arrangement on the equipment surface. to this end,
adequate layers of 3 mm thick ceramic board shall be provided between the
cladding and any supporting arrangement equipment surface, and fitted with self
tapping screws/metal bands, as applicable.
(f) For bends, fittings etc. the cladding shall be provided in segments as to ensure a
smooth finish of the cladding.
(g) For cladding on vertical pipes/equipment, provision for load take up shall be
made at every 2 to 4 meters along pipe/equipment axis.
(h) All joints shall be sealded with acrylic emulsion weather barrier.
(i) Galvanic corrosion shall be prevented by carefully avoiding permanent contact of

aluminium cladding with copper, copper alloys, tin, lead, nickel or nickel alloys
including monal metal.
33.6.39 TESTING AND GUARANTEE
(a) All tests, as per the applicable material standards and as specified shall be
carried out in accordance with the methods prescribed. Employer shall have the
right to witness any or all of the tests conducted by the contractor at the shop or
laboratory.
(b) The contractor shall guarantee that if on actual measurement the specified
maximum insulation surface temperatures are exceeded, the contractor shall
either replace the insulation with a superior material or provide additional
insulation thickness at no extra cost.
33.6.40 SPECIFICATION FOR HYDROSTATIC TEST OF PIPING SYSTEM
33.6.40.1 on completion of insulation/erection of the piping systems a hydraulic test in

accordance with the requirements of the Indian boiler regulations, shall be performed
by the contractor, the procedure adopted for hydraulic test shall have the prior
approval of the employer, the detailed schemes and procedure for carrying out
hydraulic testing shall be prepared and furnished by the contractor and it shall be
discusses and finalized during detailed engineering stage.
33.6.40.2 Cutting /welding/edge preparation and re-welding required for blanking, temporary
piping connection and /or for replacements by spool pieces including reinstallation of
components after hydraulic testing shall be the responsibility of contractor.
33.6.40.3 The water for the hydraulic test shall be made alkaline by addition of suitable
chemicals. After the test, the steam generator and high pressure external piping shall
be suitably drained and preserved.
33.6.40.4 all the valves, high pressure piping and interconnected pipes connecting the pressure
parts, shall be subjected to hydraulic test along with the pressure parts, all blank
flanges, removable plugs, temporary valves, piping and fittings, spools other
Page 414 of 680

accessories and services required for carrying out hydraulic testing of piping shall be
furnished by the contractor, the the pressurization equipment including water piping
from the supply, needed for the above test shall also be furnished b the contractor,
any defect noticed during the testing shall be rectified and the unit shall be retested
by the contractor.
33.6.40.5 The hydraulic test shall be considered successful only on certification to that effect by
the concerned inspecting authority as per the provision of the IBR and the project
manager.
33.6.41 SPECIFICATION FOR CHEMICAL CLEANING OF PIPING SYSTEM AND

EQUIPMENTS
33.6.41.1 It is indented to chemically clean the following piping system
(a) boiler feed piping
(b) heater drains piping
(c) main condensate piping
(d) extraction steam piping
(e) The following equipment which form a part of the above system shall also be
included in the cleaning operation.
i. H.P. heater
ii. L.P. heater
iii. Deaerator
iv. Gland steam cooler
v. Drain cooler
33.6.41.2 Before including chemicals, all the piping system and equipment listed above shall be
water flushed, water flushing will be followed by alkaline cleaning acid cleaning and
passivation.
33.6.41.3 How ever the bidder shall submit along with the offer his usual procedure and
practices for chemical cleaning of the piping and equipment specified. The bidder
shall submit all schematics, write-up, details of chemical to be used etc. and detailed
procedures he intends to follow, these schematics and procedures shall be subjected
to the approval of the employer.
33.6.42 PRE-CLEANING PROCEDURE
Prior to starting any phase of cleaning operation the following procedure shall be
ensured.
(a) Installation of all temporary piping valves, pumps and equipments as required for
the flushing and chemical cleaning operations.
(b) Temporary piping shall be routed at floor level as far as possible and secured in
place to prevent movement /vibration beyond applicable limits.
(c) Installation of the instruments as required to ensure satisfactory monitoring and

control of the cleaning process. The contractor shall also determine and arrange
location for sampling of the cleaning solution during cleaning.
Page 415 of 680

(d) Bypassing all regulation/control valves coming in the cleaning circuit or

installation of temporary spool pieces.
(e) Installation of special end covers and temporary suction strainers, for boiler feed
pumps and condensate pumps. Pump internals shall not be installed.
(f) Installation of the plastic seal in the condenser neck to protect the turbine from
alkaline fumes.
(g) Blocking and securing of all spring hangers in the steam lines which may be
flooded during the cleaning operation.
(h) Hand cleaning of the interiors of all vessels which are included in the cleaning
operation.
33.6.43 GENERAL CLEANING PROCEDURE
(a) Seal water lines to pump shall be broken and flushed.
(b) Where pipe lines terminate in spray headers, these headers shall be
inspected after each phase of the cleaning operation and cleaned if
necessary.
(c) All strainers shall be observed closely during the cleaning operation by
reading differential pressure gauges, and shall be cleaned when the
differential pressure exceeds a predetermined value.
(d) All high points, vents shall be opened periodically to ensure full system flow.
(e) Upon completion of each stage of cleaning, the waste products shall be
drained and transferred to the waste treatment basins, the contractor shall
then supply and add the necessary chemicals to the basin to neutralize all
waste solutions and rinses generated by the cleaning process, and arrange
for its disposal to an area to be indicated by the employer/engineer.
(f) Strictest safety precautions shall be exercised at all times during the chemical
cleaning and during storage and handling of the chemicals, the contractor
shall ensure provision of all protective clothing, apparatus and equipment
along with necessary first aid kits as required for handling the chemical and
for carrying out the cleaning operation.
33.6.44 SPECIFICATION FOR FLASH TANKS
33.6.44.1 The flash tanks and accessories shall be designed, manufactured and tested in
accordance with ASME boiler and pressure vessels (B&PV) codes (latest) and other
applicable ANSI standards referenced in the above codes.
33.6.44.2 NUMBER AND SIZING
Flash tank shall be provided into which all recoverable drains from turbine casing
extraction lines, valves, strainers, main steam, CRH and HRH line drains, cascaded
drains from heaters etc. shall be led. Number of flash tanks shall be as per tender
drg. Requirement/details of various flash tanks are given below.
Page 416 of 680

(a) High pressure HP flash tank for accommodating high pressure (above and
including hot reheat design pressure) steam drain and HP heater emergency
drains, as included in the tender drawing.
(b) Low pressure LP flash tank for accommodating low pressure (below hot reheat
design pressure) steam drain and LP heater emergency drains, as included in the
tender drawing.
(c) Atmospheric flash tank to accommodate alternate drains of steam lines, feed
water safety valve discharge and aux. steam line drains, as indicated in the
tender drawing.
33.6.44.3 CONSTRUCTIONAL FEATURES
(a) Flash tanks shall be vertical cylindrical design and of welded construction with
torispherical or hemi spherical heads.
(b) Drains/hot water inlet nozzles shall be tangential to the vessel periphery. Suitable
vortex breaker arrangement shall be made at the liquid outlet to the vessel. In the
contractor finds better alternative arrangement, the same can be submitted for
the employer acceptance & approval.
(c) The drain & the vent of the flash tanks shall be adequately sized and lead to the
condenser. There shall not be any valve on the drain and vent lines. Loop seal
shall be provided on the drain if required.
(d) A man hole shall be provided on the flash tanks for inspection purpose, it shall be
diameter of 500mm minimum. The man hole shall be of davit type and shall be
provided with grip.
(e) The flash tanks shall be located on the ground/mezzanine floor of the power
house. Necessary structural supports including anchor bolts shall be provided.
Three (3) support lags at 120 degree spacing shall be provided on each flash
tank. Necessary lugs for handling by the TG hall EOT crane shall be provided.
(f) The flash tanks shall be provided with a full length level including gauge glass
complete with protective rods. Isolation valves and drains. Temperature indicator
and temperature switches shall be provided on the flash tanks.
(g) The flash tanks shall be provided with access ladders. If required for the access
to the instruments, valves, main holes etc.
33.6.45 SCHEDULE OF MATERIAL
Shell and head ASTM A 285 Gr.C

Wear plate/baffle ASTM A 285 Gr.C
Nozzle neck ASTM A 106 Gr.B
Manhole nozzle flange and cover ASTM A 285 Gr.C
Couplings ASTM A 105
Bolts and studs ASTM A 193 Gr.B7
Nuts ASTM A 194 Gr.2 H
Gaskets spiral wound SS 316 with graphite
However the material as per ASTM A 516 Gr. B shall be acceptable subject to the
relevant codes / standards permitting so for the design parameters of various flash
tanks.
Page 417 of 680

33.6.46 SPECIFICATION FOR METALLIC EXPANSION JOINTS
33.6.46.1 The expansion joint shall be metallic multi-bellows construction shall be used to
reduce the reactions (force and moments) at the connected equipment terminals due
to thermal expansion / contraction and/or vibration of connected equipment and
piping.
33.6.46.2 the design material, construction, manufacture, inspection testing and performance of
the expansion joints shall comply with the currently applicable requirement of EJMA,
boiler and pressure vessel code section III, ANSI B-31.1 and all statutes, regulations
and safety codes.
33.6.47 CONSTRUCTION DETAILS
(a) Bellows
i. The bellow shall be hydraulically or roll formed from perfect
cylinders of single ply, 304 grade stainless steel.
ii. The number of longitudinal weld seams shall be minimum and

there shall be no circumferential weld seam.
iii. Cold formed stainless steel bellows shall not be heat treated.
iv. All bellow elements shall be pickled after forming.
v. Equalizing rings, where required, shall be either from high quality

casting of from fabrication metal.
vi. Flanged expansion joints shall be provided with adequate pipe

stubs.
vii. Butt welded expansion joints shall have adequate length of pipe
so that site welding dose not impair or reduce the joints
efficiency.
(b) sleeves
i. Expansion joints will be furnishes with internal sleevs of the same
material as the belloes and installed with sufficient clearance to
allow full rated deflection. The sleeves shall be welded on the
flow inlet end of the joint only.
ii. Bellow shall have external sleeves with an arrow including the
direction of flow on the outside. The external steel covers
provided to protect bellows from physical damages, shall be
suitable for supporting insulation where necessary and shall be
detachable.
(c) Tie bars
i. Joints shall be shipped at neutral length. They shall be provided

with suitable erection and knock-off type temporary tie bars to
prevent damage and misalignment during transit and also with
permanent tie bars along with necessary nuts, bolts, etc.
ii. The rod on pressure balanced type expansion joints shall be
adequately sized to prevent buckling in vacuum services or
services either other external loads.
Page 418 of 680

33.6.48 TYPE TEST OF METALLIC EXPANSION JOINT
Following tests (type tests) shall be carried out for metallic expansion joints as per the
procedures given in EJMA.
(a) Life cycle test
(b) Meridonal yields-rupture testing
(c) Squirm testing
33.6.49 for the purpose of carrying out type tests: metallic bellows shall be grouped based on
the parameters as give below. The bellows conforming to the same combination of
these parameters shall constitute one group. Type test shall be carried out on one or
specific above.
i. Material of bellow: based on material of bellow, bellow shall be categorized in

to three category namely carbon steel, stainless steel (Eg. SS304,316,321
etc.) & high alloy steel (Eg. inconal).
ii. Profile of convolutions: each profile shall be considered as separate category
(e.g. U profile, V profile & Lyra profile etc.)
iii. Dimension of bellows: based on the size, the categories shall be as under:
• Nominal diameter of metallic expansion joint up to and including
800mm NB.
• Nominal diameter of metallic expansion joint greater than 800mm NB

up to and including 1600mm NB.
• Each size above 1600mm NB shall be a separate category.
iv. Design pressure: based on the design pressure, bellows shall be categorized
as under:
• Deign pressure from full vacuum up to 5Kg/sq.cm(g).
• Design pressure above 5Kg/sq.cm(g) and up to 10Kg/sq.cm(g) with

or without vacuum.
33.6.50 NUMBER OF CYCLES
For the life cycle test, the number of test cycles shall be minimum 10,000 cycles.
Other tests for the metallic expansion joint shall be carried out as per the approval
QP/QA section. Further, other terms and conditions for type test shall be as specified
elsewhere in the specification.
33.6.51 SPECIFICATION FOR SURFACE PREPARATION & PAINTING
33.6.51.1 Surface preparation methods and paint/ primer materials shall be of the type specified
herein. If the contractor desires to use any paint/primer materials other than that
specified specific approval shall be obtained by the contractor in writing from the
employer for using substitute material.
33.6.52.2 All paints shall be delivered to job site in manufactures sealed containers, each
container shall be labeled by the manufacture with the manufacture’s name type of
paint , batch no. and color.
Page 419 of 680

33.6.52.3 unless specified otherwise paint shall not be applied to surface of insulation, surface
of stainless /nickel/copper/brass/monal/aluminum/hastelloy/lead/galvanized steel
items, valve stem, pump rod, shaft gauges, bearing and contact surface, lined or clad
surfaces.
33.6.52.4 All pipelines shall be colour coded for identification as per the colour-coding scheme
indicated in Volume II and which will be furnished to the contractor during detailed
engineering.
33.6.53 SURFACE PREPARTION
33.6.53.1 All surfaces to be paints shall be thoroughly cleaned of oil, grease and other foreign
matter, surfaces shall be free of moisture and contamination from chemicals and
solvents.
33.6.53.2 the following surfaces scheme are envisaged here, depending upon requirement any
one or a combination of these may be used for surface preparation before application
of primer.
SP1 solvent cleaning

SP2 application of rust converter (Ruskil or equivalent grade)
SP3 power tool cleaning
SP4 shot blasting (shot blasting shall be used as surface
preparation method for hot worked pipes prior to application of
primer)
SP4* shot blast cloning /abrasive blast cleaning to SA 21/2 (near
white metal) 35-50 microns
SP5 phosphating
SP6 Emery sheet cleaning/ manual wire brush cleaning.
33.6.54 APPICATION OF PRIMER /PAINT
33.6.54.1 The paint /primer manufacturer’s instructions covering thinning, mixing, method of
application, handling and drying time shall be strictly followed and considered as part
of this specification. The dry film thickness (DFT) of primer / paint shall be as
specification herein.
33.6.54.2 Surface prepared as per the surface preparation scheme indicated herein shall be
applied with primer paint within 6 hours after preparation of surface
33.6.54.3 Where primer coat has been applied in the shop, the primer coat shall be carefully
delaminated, cleaned and spot primed with one coat of the primer before applying
intermediate and finish coats. When the primer coat has not been applied in the shop,
primer coat shall be applied by brushing, rolling or spraying on the same day as the
surface is prepared, primer coat shall be applied prior to intermediate and finish
coats.
.
33.6.54.4 Steel surface that will be concealed by building walls shall be primed and finish
painted before the floor is erected. Tops of structural steel members that will be
covered by grating shall be premed and finish painted before the grating is
permanently secured.
Page 420 of 680

33.6.54.5 Following are the primer/painting schemes envisaged herein:
PS3 - zinc chrome primer (Alkyd base) by brush/Spray to IS104.
PS3* - zinc chrome primer (Alkyd base) by dip coat.
PS4 - synthetic Enamel (long oil alkyd) to IS2932.
PS5 - red oxide zinc phosphate to IS-12744.
PS9 - aluminum paint to IS 2339.
PS9* - heat resistant aluminium paint to IS-13183 Gr.-I (for

0 0
temperature 400 C – 600 C) , IS -13183 Gr.-II (for
0 0
temperature 200 C -400 C) and IS-13183 Gr.-III (for
0
temperature up to 200 C)
PS13 - rust preventive fluid by spray, dip or brush.
PS14 - wieldable primer-Deoxaluminate or equivalent.
PS16 - high build Epoxy CDC mastic `15’.
PS17 - aliphatic acrylic polyurethane CDE134, %V=40.0 (min.)
PS18 - Epoxy based TiO2 pigmented coat.
PS19 - Epoxy based zinc phosphate primer (92% zinc in dry film
(min.)%VS=35.0 (min.)
PS20 - Epoxy based finish paint.
33.6.54.6 All weld edge preparation for site welding shall be applied with one coat of wieldable.
33.6.54.7 For internal protection of pipes/tubes, VCI pellets shall be used at both ends after
sponge testing and ends capped. VCI pellets shall not be used for SS components
and composite assemblies.
Page 421 of 680

33.6.55 Primer/painting schedule
Sl. Description Surface Primer coat Intermediate coat Finish coat Total Colour
No preparatio Syste Coat Min. min. shade
n m DFT/coat (microns
(microns) )
1 All insulated piping’s. Fittings/ SP3/SP4 PS 9* 1 20 - - - PS9* 1 20 40
componantes, pipe clamps,
vessels/tanks, equipments etc.
2 All insulated Design SP3/SP4 PS 5 2 25 - - - PS4 3$ 35$ 155$
piping’s. temperature
0
Fittings/ <60 C
componantes, Design SP3/SP4 PS 9* 1 20 - - - PS9* 1 20 40
pipe clamps, temperature as per
vessels/tanks, 600C-2000C NTPC
equipments Design SP3/SP4 PS 9* 1 20 - - - PS9* 1 20 40 colour
etc. temperature shade/
>200 C
0 coding
3 Constant load SP4* PS 19 1 - - - PS17 1 30 70 scheme
hanger (CLH).
Variable load 40
hanger (VLH)
and other
supports
4 Valves
Cast/forged Design SP1/SP2/S PS 9 1 20 - - - PS9 1 20 40
temperature P3
0
<95 C
Design SP1/SP2/S PS 9* 1 20 - - - PS9* 1 20 40
temperature P3
0 0
95 C-200 C
Design SP1/SP2/S PS 9* 1 20 - - - PS9* 1 20 40
temperature P3
0
>200 C
Page 422 of 680

Sl. Description Surface Primer Coat Intermediate coat Finish coat Total Colour
No preparatio min. shade
n (microns
)
Syste Coat
m
5 All structural outside TG SP4* Inorga 1 75 PS18 1 75 a)) 2 25

steel building and in nic epoxy
componants SG envelope Ethyle coat 250
Zinc b)) final 1 30
Silicate coat of
paint
PS1
Within TG SP4* ---do--- 1 35 PS18 1 35 a)) 2 25 150

building epoxy
coat
b)) final 1 30
coat of
paint
PS1
6 Weld edges SP6(hand PS13 1 25 - - - - - - -
cleaning by (wielda
wire ble
brushing) primer)
rd
$ The first 2 finished coats (total min. DFT of 70 microns) shall be done at shop and the 3 finish coat (min. DFT 35 microns) shall be applied at site.
Page 423 of 680

33.6.56 Testing requirements:
The detailed testing requirements for power cycle piping and its components are given in the subsection for quality Assurance
(QA). The requirements pertaining to testing given in this subsection if in variance with that given in QA subsection, then the
more stringent of the two shall be followed.
Page 424 of 680

ANNEXURE – 1
LIST OF POWER CYCLE PIPING
The following list of power cycle piping is an indicative one and is provided for the guidance
of the Bidder only. Items not mentioned but deemed necessary for making the system
complete shall also be included.
SR. NO. NAME DESCRIPTION
1.0 Main Steam lines : From SH outlet to inlet of turbine
2.0 Main Steam Equalising : Between RHS and LHS Main Steam
line lines
3.0 HP By-pass line : Between Main Steam line and CRH line
4.0 Cold Reheat line : Between HP turbine outlet and Reheater
5.0 Extraction line from CRH : Between CRH and Deaerator
6.0 Extraction line from CRH : Between CRH and H.P. heater
7.0 Extraction line from MS : From MS equalising line to auxiliary

equalising line steam header
8.0 Steam supply to BFP : From the main and alternative source
Turbine point to BFP Turbine Inlet
9.0 Extraction from BFP : 1. Between BFP discharge and H.P.

discharge By-pass 2. Between BFP discharge and
PRDS
10.0 Warm up line for HP : Between MS line and H.P. By-pass line
By-pass
11.0 Hot Reheat lines : Between Reheater and I.P. turbine
12.0 HRH equalising line : Between LHS and RHS Hot Reheat lines
13.0 LP By-pass line : Between HR line and condenser
14.0 Warm up line for LP : Between LP By-pass line and HR line

By-pass
15.0 CEP Suction line : Between condenser hot well and CEP.
16.0 Main condensate line : Between CEP outlet and Deaerator

through
GSC, CPU, Drain Cooler, L.P. heaters.
Page 425 of 680

17.0 CEP Minimum : Between main condensate line after CEP

Recirculation line to condenser.
18.0 GSC Minimum : Between main condensate line after GSC

Recirculation line to condenser.
19.0 Deaerator filling line : Between Condensate Transfer pump

discharge and deaerator
20.0 Boiler filling line : Between Condensate Transfer pump

discharge and Boiler bottom ring header
/economiser inlet.
21.0 Fill up and Emergency : From Condensate Transfer pump

discharge to make-up to condenser.
22.0 DMCW make-up tank : From Cycle make-up pump discharge to

DMCW make-up tank.
23.0 Gravity Make-up to : From condensate storage tank to

condenser condenser.
24.0 Condensate Dump Line : Between M.C. line after GSC and
condensate storage tank.
25.0 Cycle make-up Pump : Between Cycle make-up pump discharge

Recirculation header and Condensate Storage Tank.
26.0 Cycle make-up Pump : From condensate storage tanks to Cycle

Suction Line make-up pump suction header.
27.0 By-pass line : For all control valves
28.0 By-pass lines for heaters : GSC, LP Heaters and HP Heaters.

(group bypass/individual
bypass)
29.0 CEP sealing line : Bidder’s choice.
30.0 All extractions from main : For

condensate line
(a) Exhaust Hood spray
(b) Turbine Flash Tank spray
(c) L.P. By-pass spray
Page 426 of 680

(d) Water sealing of valves
(e) Vacuum breaker line sealing
(f) CEP sealing
(g) Analytical measurements
(h) Alkali flushing
(i) Spray water to GSC

desuperheater
(j) Sampling
(k) Instrument seal pot
(l) Water sealing of valves & water

washing of BFP Turbine
(m) Spares
31.0 Turbine flash tank drain : From turbine Flash Tank drains to
and vent line condenser hot well
From flash vessels vent to condenser

steam
space
32.0 BFP Suction lines : Between Deaerator and individual BFP

suction
33.0 Main Feed Water Line : From BFP discharge through HP heaters,
control station up to economiser inlet
header
34.0 Steam turbine drive for : Associated piping

BFP
35.0 Inlet line to attemperation : From main feed water line to
water header attemperation water header
36.0 Extraction from BFP : From BFP suction to sample cooler

suction, BFP warm-up & Balance Leak-
off line.
37.0 All extraction from Main : (a) To Auxiliary Steam pressure

Feed Water line reducing de-superheating station
Page 427 of 680

(b) Stub for alkali flushing
(c) HP By-pass spray
(d) Blind Stub
(e) Minimum re-circulation lines
38.0 Extraction lines : From various stage of turbine/CRH to

L.P. Heaters, H.P. heaters, Deaerator
and BFP Turbines.
39.0 All vents of H.P and L.P. : (a) L.P. Heater vents to Condenser
heaters
(b) H.P. Heater vents to Condenser
40.0 All cascade drain (a) From each HP Heater to next

connection between lower pressure HP Heater
heaters
(b) From the lowest pressure H.P.

heater to Dearator
(c) From each L.P. Heater to next

lower pressure L.P. heater
(d) From lowest pressure L.P. heater

to flash vessel through drain
cooler.
41.0 All Drip connections to : (a) From H.P. Heaters

Flash Tanks
(b) From L.P. Heaters (except the
lowest pressure L.P. heater)
(c) From Gland Steam condenser
42.0 Air Steam mixture line : (a) To GSC

from Turbine Glands
(b) To Atmosphere
43.0 Vapour extraction line for : From GSC through vapour extractors to
GSC atmosphere
44.0 By pass Line to GSC : Through desuperheater to atmosphere
Page 428 of 680

45.0 Air steam mixture line : To vacuum pumps

from condenser
46.0 Drip connections to : From H.P. Heaters

Deaerator
47.0 Connections for air outlet : From vacuum pumps to atmosphere
from vacuum pump
48.0 Steam connection to : From final superheater outlet

Auxiliary steam header
49.0 High Temperature : One with interconnection

Auxiliary Steam Header
50.0 Auxiliary Steam from High : (a) To Gland Sealing unit

Temperature Header
(b) For mill inerting (if required)
(c) For soot blowing
51.0 Low Temperature : One with interconnection

Auxiliary Steam Header
52.0 Auxiliary Steam from Low : (a) For Deaerator pegging

Temperature Header
(b) For atomizing
(c) For F.O. Heating
53.0 Extraction line from CRH : From CRH line to auxiliary steam header
line
Page 429 of 680

CHAPTER 10
10.0 MISCELLANEOUS PUMPSETS
10.1 GENERAL INFORMATION
10.1.1 Sump pumps specified hereinafter shall be used to dewater various sump pits in various
plant areas like BTG area, Plant Water System, Ash Handling plant etc. where gravity
draining is not be envisaged and to ensure general housekeeping
10.1.2 Pumps under this specification have been divided into following three (3) groups
according to different duty envisaged and location of sumps/pits.
10.1.2.1 Group - A
The Group - A pumps shall be electric motor driven permanently installed

vertical wet pit bottom suction volute type and shall handle drainage water,
containing solid particles with sludges, polluted liquid, oils etc. from the area where they
are installed. These pumps shall run intermittently by the use of high and low level
switches in the sump. Particle size in the water shall not normally exceed 15 mm.
Group-A pumps shall also be provided to all indoor sumps of the plant and outdoor
sumps of capacity 5 cu.m and above and underground cable vaults (if any) under the
scope of this specification.
10.1.2.2 Group - B
These pumps shall be horizontal centrifugal electric motor/diesel engine driven

portable type. Each pump set along with control panel etc. shall be mounted on a
trolley for ease of transportation. These pumps shall be suitable for dewatering
of pipelines of large diameter, if required and alike jobs and handling of liquids
containing hard solid particles, sludge, polluted liquid, significant amount of fuel
oil/HSD etc. and particle size shall not normally exceed 20 mm. These types of
pumps shall be used in different plant areas.
10.1.2.3 Group - C
The Group - C pumps shall be vertical submersible portable type pump motor sets with
suitable arrangement for carrying to any place and for lowering to and raising from
various water reservoirs and pits. The pump motor set shall be suitable for handling
water containing mud/sludge, solid particles, cotton waste, silica, ash particles, coal
particles, polluted liquid etc. The particle size in water shall not exceed 20 mm. These
pumps shall be utilised to dewater various deep sumps/pits (e.g. C.W pump house) in
case of any eventuality.
10.2.1 The design, manufacture and performance of the sump pumps and drives
specified, hereinafter, shall comply with the requirements of all applicable codes,
the latest applicable Indian/British/American/DIN Standards, in particular the
following:
10.2.2 IS-1710 : Vertical Turbine Pumps for clear cold and fresh water.
Page 430 of 680

10.2.3 IS-5120 : Technical Requirements – Roto-dynamic special

purpose pumps.
10.2.4 IS-5600 : Sewage and drainage pumps.
10.2.5 Hydraulic Institute Standards of USA.
10.2.6 The materials of the various components shall conform to the applicable
IS/BS/ASTM/DIN Standards.
10.3 GENERAL PERFORMANCE REQUIREMENT
10.3.1 The pumps shall be designed to have best efficiency at the specified duty
point. The pump set shall be suitable for continuous operation at any point
within the "Range of Operation" as stipulated by the manufacturer.
10.3.2 Pumps shall have a continuously rising head capacity characteristics from the
specified duty point towards shut off point, the maximum head being at shut off.
10.3.3 Permanently installed vertical pumps shall be suitable for parallel operation. The head
vs capacity, the bhp. vs capacity characteristics etc. shall match to ensure equal load
sharing and trouble free operation throughout the range. Drive Motor shall not be
overloaded when pump discharge is more than rated condition.
10.3.5 The static head requirement of portable submersible type sump pump may have a
considerably wide range of variation depending upon the depth of pit being dewatered.
While the pump shall have adequate capacity at the maximum head, the motor
shall be sufficiently rated to cater for any overloading during the pump
operation at its minimum possible head, i.e., maximum discharge.
10.3.6 Pump motor set shall run smooth without undue noise and vibration.
Acceptable peak to peak vibration limits shall generally be guided by
Hydraulic Institute Standards (latest edition).
10.4 SCOPE OF WORK
10.4.1 Pumps under groups A, B and C as listed in the Annexure- I along with drive units,
couplings and other accessories mentioned below, as also those needed to
make the pump-motor sets complete in all respect, for proper operation and
maintenance. All motors in outdoor duty shall be provided with
IP-55 enclosure and canopy. In addition to the accessories listed in
Annexure-I, each pump set shall also include the following:
10.4.2 For the vertical Group - A sump pump motor sets
Two (2) nos. redundant unltrasonic type level transmitter (2 Nos.) with limiter
technique shall be provided for alarming, auto start & auto stop. along with necessary
junction box, local control panel, control cables etc. to achieve automatic
starting/stopping of the sump pumps, and also ON/OFF indication for sump pump shall
be monitored at DDC system. The entire assembly being mounted on the same
base frame as mentioned above (item "b"). The control panel shall also be
equipped with start/stop push button for starting/stopping individual sump pumps
manually. Local control panel and cable shall be as per requirements described else
where in the specification.
Page 431 of 680

10.4.3 For each of the trolley mounted horizontal Group-B sump pump motor sets/pump-
Diesel Engine sets
a) One (1) no. 7.5 meters long hose for the pump suction and one (1) no.30 meters
long hose for the pump discharge, either ends of each hose being provided with
female hose coupling.
b) One (1) no. 500 mm long straight pipe piece, with both ends flanged, one end
matching with the pump suction nozzle.
c) Two (2) nos. male type hose couplings, one of which is suitable for
coupling with the above mentioned 500 mm pipe piece on one side and
the 7.5 meters long suction hose on the other side, whereas the other is suitable
for coupling with the pump discharge nozzle on one side and the 30 metres
long hose on the other side. The pump suctions pipe-piece and discharge
nozzle shall be of flanged type. As such each coupling end that is to match
with the pipe/pump nozzle shall also be flanged and shall be equipped with
necessary bolts, nuts
& gaskets.
d) A foot valve (of Bidder's recommended size) with suction strainer,

necessary coupling and matching piece/reducer (if necessary) to couple
with the 7.5 meter long suction hose end.
e) A starter panel complete with incoming switch/contactor, fuse,

overload relays, start-stop push button, O/L reset push button, cable
gland, wiring terminals, red and green indication lamps (LED type),
necessary control cables etc., and also 50 metres length of flexible
power cable with power plug at one end and arrangement to connect the other
end with the starter panel.
f) The pump motor set with a baseframe along with the starter panel,
power cable, suction & discharge hoses etc., as mentioned above, shall
be mounted on a suitable trolley with swivelling front wheel and having
adequate fixing arrangement for all equipment, for operation without any
undue vibration and with facility for being handled by a single operator.
10.4.5 For each of the portable submersible Group-C sump pump motor sets.
a) Two (2) nos. 30 metres long discharge hose, having female hose coupling at
both ends.
b) One (1) no. 500 mm long pipe piece with both ends flanged, one end
connected by necessary bolts, nuts & gaskets with the flanged discharge
nozzle of the sump pump.
c) One (1) no. male type hose coupling, one end of which is suitable to couple
with the discharge hose and the other end is flanged, matching with the
above mentioned 500 mm long pipe end and connected therewith by
necessary bolts, nuts & gaskets.
d) Suitable attachment for temporary seat of the pump motor set on the floor at
sump bottom.
Page 432 of 680

e) One (1) no. 25 metres long submersible type power cable having a power
plug at one end and a hermetically sealed (waterproof) cable gland for
connection with the pump drive- motor at the other end.
f) Suitable lugs and other attachments on the pump motor assembly frame, for
hoisting and lowering of the pump motor set from and to the sump.
g) One starter panel, having a plug socket as receptacle of the above

mentioned power plug (item "e"), a 25 metre long incoming power cable
with switch/contactor and fuse, start- stop push buttons, red and green LED
type indication lamps, over load relays, O/L reset push button, cable
gland etc., and also a suitable arrangement for temporarily mounting
the starter panel, near the sump, where the portable sump pump-motor
set is to work. The incoming 25 metre long power cable shall also be provided
with a suitable power plug at one end.
10.4.6 Lubrication of one (1) initial fill and one additional fill after commissioning.
10.4.7 Rust inhibiter paint at Manufacturer's works.
10.5 DESIGN AND CONSTRUCTION
10.5.1 The design, construction testing and other details of the sump pumps and
related accessories shall be in line with the stipulations and data in this
chapter.
10.5.2 Each sump pump shall be equipped and coupled with a drive motor, with rating
so selected as to have at least 15% margin over the maximum power required by
the pump, throughout its range of operation. All other requirements of the
drive motors shall be as stipulated in the Electrical Specification Vol IV.
The discharge rate of sump pump is uncontrolled. As such pump should be capable to
operate even under a condition of as low as 25% of specified total head. Motors of
group-B pumps should be designed to cater such eventuality.
10.5.3 All electrical items shall conform to the stipulations of Electrical Specification Vol IV as
applicable.
10.5.4 All piping shall be as per IS-1239 of medium or heavy grade (as suited for the
maximum operating pressure) and shall be either galvanised or painted with approved
rust inhibiting paint. Pipe size shall be as per Appendix-II. Any matching
piece/reducer required to match the pipe with pump nozzle, hose, etc. shall be
provided.
10.5.5 All valves shall be steel body type as per applicable IS/BS/ANSI standard,
with pressure class compatible with the maximum working pressure.
10.5.6 All hoses shall be of steel wire reinforced type. Pump suction hose shall be suitable for
working under vacuum. Pump discharge hose shall be suitable to withstand the
maximum pressure that it may be subjected to in all working conditions,
including hydrostatic testing of the sump pump discharge line.
10.5.7 Pump suctions strainer shall have openings large enough just to permit the entry of solids
having maximum size as stipulated under clause no. 1.02.00.
Page 433 of 680

10.6 Pumps
10.6.1 Pumps under Group-A shall be wet pit type, vertical shaft, centrifugal, vertical
submerged suction, non-clog volute type complete with enclosed shaft, discharge
pipe, head assembly thrust bearing and drive assembly, cover plates etc.
10.6.2 Pumps under Group-B shall be of horizontal shaft, single stage, end suction, radially
split casing, centrifugal, non-clog design complete with common base plate, drive
assembly etc. These pumps shall be trolley mounted portable type.
10.6.3 Pumps under Group-C shall be submersible pump-motor type, single stage and
non-clog design and shall be portable type.
10.7 Casing
a) Casing shall be so designed to allow free passage of specified maximum

size of solid.
b) Casing shall be designed to withstand the maximum shut-off pressure developed

by the pump.
c) The casings shall be cast, free from blowholes, sand holes, other
detrimental defects. The casing shall be complete with suction and discharge
connections.
d) For pumps under Group-A adequate seal arrangement shall be made

to keep leakage of liquid from casing to column assembly to minimum and
adequate drain shall be provided in column assembly to permit escape
of the leakage flow. The casing shall also include the bearing housing of the
bottom pump shaft bearing.
e) Casing of pumps under Group-B shall be provided with vent

connections and drain connections with valves. These pumps shall be
manually primed.
10.8 Impeller
a) The impeller shall be open/semi-open non clog type, cast in one piece and
specially designed to pass large solids or unscreened liquids. The clearance
between stationary and moving parts should be such as to allow sustained
performance without exclusive maintenance.
b) Impellers of pumps under Group-A shall have provision for adjustment from
an accessible location and for pumps under Group-C shall be capable of
passing fibrous material like cotton waste, jutes, etc.
10.9 Pump Shaft
a) Shaft size selected shall be such that critical speed is at least 20% away
from the operating speed and the runway speed.
b) The shaft shall be ground and polished to final dimension and of ample
size to withstand all stresses resulting from rotor weight, hydraulic loads
and across the line starting. Shaft shall be provided with renewable
sleeves particularly under stuffing boxes and other locations as
recommended by pump manufacturers.
Page 434 of 680

c) The coupling between shafts shall be so designed that they become tight during
pump operation.
10.10 Column Pipe (for pumps under Group-A)
The discharge pipe shaft assembly shall be flanged or screwed as per

manufacturer's standard and standard length of each piece of column pipe shall
be in conformity to the shaft piece lengths from consideration of easy handling.
10.11 Bearings
a) Adequate nos. of properly designed bearings shall be furnished. Bearings for

pumps shall be antifriction type and lubricated by grease. Line shaft bearings
of vertical pumps shall also be grease lubricated. All necessary grease gun,
grease cup and tubing shall be included.
b) Thurst bearing of adequate design shall be furnished for taking the

entire pump thurst arising from all probable conditions of continuous
operation through out its "range of operation" and also the shut-off
condition. The life of thurst bearing shall be 20,000 working hour
minimum for the load corresponding to the duty point. The bearings shall
be lubricated by grease from a location conveniently accessible. Design shall
be such that the lubricant cannot contaminate the handling liquid.
10.12 Wearing Ring/Liner Plate
Renewable wearing rings/liner plates shall be provided either on impeller or on the

casing or on both impeller and casing.
10.13 Stuffing Box
Stuffing Box of pumps under Group-A shall be of mechanical packing type. For
pumps under Group-B and Group-C mechanical seal of reliable design shall be
provided.
10.14 Coupling
Pump and motor shall be connected with a suitable flexible coupling.

Coupling shall be provided with coupling guard.
10.15 Mounting Plate for Group-A Pumps and Base Plate for pumps under
Group-B.
Each pump under Group-A shall be provided with a suitable mounting plate. The
mounting plate shall be adequately sized to accommodate the level switches,
discharge pipe, grease cups etc. if any. Pumps and motor under Group-B shall
be mounted in one base plate. Base plate shall be of rigid construction properly
ribbed as needed. Suitable drain with valve and drain funnel shall be furnished by the
Bidder.
The necessary supporting plate, mounting frame, base plate etc. as required shall be
supplied under this specification, along with anchor bolts, foundation bolts, pipe,
sleeves etc. Lifting lug, eyebolts, etc. as required for the proper handling of each pump
set shall be furnished.
Page 435 of 680

10.16 Suction Bell
The pumps under Group-A, C shall be complete with adequately dimensioned suction
bell to guide and streamline intake fluid.
10.17 Material of Construction
For material of construction of various parts of data specification sheet shall be

referred to.
10.18 INSPECTION AND TESTING
10.18.1 All pumps shall be tested at the shop for capacity, head, efficiency and brake horse
power. These tests are to be done according to the requirements of
"Hydraulic Institute Standard".
10.18.2 The pump integral accessories like thrust bearing, pump motor coupling etc. shall be
subject to tests as per manufacturer's standard.
10.18.3 Test on motors, control panels, starter panels, cables shall be conducted as per the
requirement of Vol.IV of this specification and as per Quality Assurance Plan to
be approved by Owner during detail engineering.
10.18.4 After delivery/erection at site, pumps shall be operated to prove satisfactory and trouble
free performance.
10.19 DRAWINGS, DATA, INFORMATION REQUIRED
10.19.1 Location and dimension of all sumps which requires assisted evacuation, present in
the areas covered under the scope of this specification.
10.19.2 List of location of Group-A .
10.19.3 Characteristic curves of pumps showing effective head, pump input power,
efficiency, submergence and NPSH, against capacity ranging from shut-off
condition to 125% or rated capacity for Group A, B pumps and to 150% of
rated capacity for Group C pumps.
10.19.4 Speed vs. torque curve of the pump corresponding to recommended mode of pump
starting, super-imposed on speed vs. torque of the motor,
corresponding to 80% and 100% rated voltage.
10.19.5 Diagram showing the type of lubrication system etc.
Page 436 of 680

DATA SPECIFICATION SHEET
S. No. Description Group A Group B Group C

1 Pumps
1.1 Rated Capacity Capacity of each Twenty (20) Fifty (50)
pump should be
so selected to
empty sump pit
in 10 to 15
minutes
1.2 Total Dynamic Head at To be calculated 15 20
rated Capacity (MLC) with 10% margin
on frictional drop
1.3 Minimum suction lift - 6 -
1.4 Nos. required These pumps Four (4) (2 Four (4)
shall be provided electric motor
in all indoor driven and 2
sumps and diesel engine)
outdoor sumps of
5 cum & above
and underground
cable vaults and
CW pumphouse.
Pumps shall be
of 2 x 100%
capacity for each
sump.
1.5 Duty Intermittent
1.6 Pump design standard IS 5120/ IS 1710/
HIS
1.7 Parallel operation Yes No Yes
1.8 Material of Construction
a) Base Plate/ Cover Plate MS – IS 2062 MS – IS 2062 MS – IS 2062
b) Column Pipe MS – IS 2062 MS – IS 2062 MS – IS 2062
c) Casing 2% NiCi 2% NiCi 2% NiCi
d) Impeller 2% NiCi 2% NiCi 2% NiCi
e) Pump/ Impeller Shaft SS 410 SS 410 SS 410
f) Shaft Sleeve SS 410 SS 410 SS 410
g) Shaft Coupling SS 410 SS 410 SS 410
h) Shaft Bearing BUSH GM as per BUSH GM as per BUSH GM as per
IS 306 IS 306 IS 306
i) Gland CI IS 210 FG CI IS 210 FG CI IS 210 FG
260 260 260
j Fasteners SS 304 SS 304 SS 304
Note : In all areas where Group A pumps are installed and will handle Sea Water like CWPH Pit the
material of construction of all components of the pumps shall be Duplex Stainless steel.
Page 437 of 680

TITLE: SPECIFICATION NO. PE-TS-412-155A-A001
2X 660 MW ENNORE SEZ STPP VOLUME - II B
SECTION - D1
REV.NO. 0 DATE :
TECHNICAL SPECIFICATION FOR
HORIZONTAL CENTRIFUGAL PUMPS
Page 438 of 680

SECTION - D1
REV.NO. 0 DATE :
1.00.0 SCOPE
1.01.0 This specification covers the design, material, construction features, manufacture, inspection,
testing the performance at the Vendor’s/Sub-Vendor’s Works and delivery to site of Horizontal
Centrifugal Pumps.
2.01.0 The design, material, construction, manufacture inspection and performance testing of Horizontal
Centrifugal Pumps shall comply with all currently applicable statutes, regulations and safety codes
in the locality where the Equipment will be installed. Nothing in these specifications shall be
construed to relieve the Vendor of this responsibility. The Equipment supplied shall comply with the
latest applicable Indian Standards listed below. Other National Standards are acceptable, if they
are established to be equal or superior to the Indian Standards.
2.02.0 List of Applicable Standards.
1 IS : 1520 Horizontal Centrifugal Pumps for clear cold fresh water.
2 IS : 5120 Technical requirements of roto dynamic special purpose

pumps.
3 API : 610 Centrifugal pumps for general refinery service.
4 IS : 5639 Pumps Handling Chemicals & corrosion liquids.
5 IS : 5659 Pumps for process water.
6 HIS Hydraulic Institute Standards, USA
7 ASTM-1-165-65 Standards Methods for Liquid Penetration Inspection.
2.03.03 In case of any contradiction with aforesaid standards and the stipulations as per the technical
specifications as specified hereinafter the stipulations of the technical specifications shall prevail.
3.00.00 DESIGN REQUIREMENTS
3.01.00 The Pump shall be capable of developing the required total head at rated capacity for continuous
operation. Also the pumps shall be capable of being operated to give satisfactory performance at
any point on the HQ characteristics curve over the operating range of 40% to 120% of the duty
point. The maximum efficiency of pump shall be preferably be within +/- 10% of the rated design
flow as indicated in the data sheets.
3.02.00 The total head capacity curve shall be continuously rising from the operating point towards shut-off
without any zone of instability and with a minimum shut-off head of 15% more than the design
head.
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SECTION - D1
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3.03.00 Pumps of a particular category shall be identical and shall be suitable for parallel operation with
equal load division. The head Vs capacity and BHP Vs capacity characteristics should match to
ensure even load sharing and trouble free operation throughout the range. Components of
identical pumps shall be interchangeable.
3.04.00 Pumps shall run smoothly without undue noise and vibration. Peak to peak vibration limits shall be
restricted to the following values during operation:
Antifriction Bearing Sleeve Bearing

SPEED
1500 rpm and below 75.0 micron 75.0 micron
3.05.00 The noise level shall not exceed 85 dBA. Overall sound pressure level reference 0.0002 microbar
(the standard pressure reference for air sound measurement) at a distance of 1 M from the
equipment.
3.06.00 The pumps shall be capable of starting with discharge valve fully open and close condition. Motors
shall be selected to suit to the above requirements. Continuous Motor rating (at 50 deg.C ambient)
shall be atleast ten percent (10%) above the maximum load demand of the pump in the entire
operating range to take care of the system frequency variation and no case less than the maximum
power requirement at any condition of the entire characteristic curve of the pump.
3.07.00 The kW rating of the drive unit shall be based on continuously driving the connected equipment for
the conditions specified. However, in cases where parallel operation of the pumps are specified,
the actual motor rating is to be selected by the Bidder considering overloading of the pumps in the
event of tripping of operating pump(s).
3.08.00 Pumps shall be so designed that pump impellers and other accessories of the pumps are not
damaged due to flow reversal.
3.09.00 The Contractor under this specification shall assume full responsibility in the operation of pump and
motor as a unit.
4.00.0 DESIGN CONSTRUCTION
4.01.00 Design and construction of various components of the pumps shall conform to the following
general specifications. for material of construction of the components, data sheets shall be
referred to.
4.02.0 Pump Casing
4.02.01 Pump casing shall have axially or radially split type construction. The casing shall be designed to
withstand the maximum shut-off pressure developed by the pump at the pumping temperature.
4.02.02 Pump casing shall be provided with a vent connection and piping with fittings & valves. Casing
drain as required shall be provided complete with drain valves, piping and plugs. It shall be
provided with a connection for suction and discharge pressure gauge as standard feature. It shall
be structurally sound to provide housing for the pump assembly and shall be designed hydraulically
to minimum radial load at part load operation.
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SECTION - D1
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4.03.00 Impeller
4.03.01 Impeller shall be closed, semi-closed or open type, and it shall be designed in conformance with
the detailed analysis of the liquid being handled.
4.03.01 The impeller shall be secured to the shaft, and shall be retained against circumferential movement
by keying, pinning or lock rings. On pumps with overhung shaft, impellers shall be secured to the
shaft by a lockout or cap screw which tightness in the direction of normal rotation.
4.04.00 Impeller/Casing Wearing Rings
4.04.01 Replaceable type wearing rings shall be provided at suitable locations of pumps. Suitable method
of locking the wearing ring shall be used. Wearing rings shall be provided in pump casing and/or
impeller as per manufacturer’s standard practice.
4.05.00 Shaft
4.05.01 The critical speed shall be well away from the operating speed and in no case less than 130% of
the rated speed.
4.05.02 The shaft shall be ground and polished to final dimensions and shall be adequately sized to
withstand all stresses from rotor weight, hydraulic loads, vibration and torques coming in during
operation.
4.06.00 Shaft Sleeves
4.06.01 Renewable type fine finished shaft sleeves shall be provided at the stuffing boxes/mechanical
seals. Length of the shaft sleeves must extend beyond the outer faces of gland packing of seal
end plates so as to distinguish between the leakage between shaft and shaft sleeve and that past
the seals/gland.
4.06.02 Shaft sleeve shall be fastened to the shaft to prevent any leakage or loosening. Shaft and shaft
sleeve assembly should ensure concentric rotation.
4.07.00 Bearings
4.07.01 Heavy duty bearings, adequately designed for the type of service specified in the enclosed pump
data sheet and for long, trouble free operation shall be furnished
4.07.02 The bearings offered shall be capable of taking both the radial and axial thrust coming into play
during operation. In case, sleeve bearings are offered additional thrust bearings shall be provided.
Antifriction bearings of standard type, if provided, shall be selected for a minimum life 16,000 hrs.
of continuous operation at maximum axial and radial loads and rated speed.
4.07.03 Proper lubricating arrangement for the bearings shall be provided. The design shall be such that
the bearing lubricating element does not contaminate the liquid pumped. Where there is a
possibility of liquid entering the bearings suitable arrangement in the form of deflectors or any other
suitable arrangement must be provided ahead of bearings assembly.
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SECTION - D1
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4.07.04 Bearings shall be easily accessible without disturbing the pump assembly. A drain plug shall be
provided at the bottom of each bearings housing.
4.08.00 Stuffing Boxes
4.08.01 Stuffing box design should permit replacement of packing without removing any part other than the
gland.
4.08.02 Stuffing boxes of packed ring construction type shall be provided wherever specified. Packed ring
stuffing boxes shall be properly lubricated and sealed as per service requirements and
manufacturer’s standards. If external gland sealing is required, it shall be done from the pump
discharge. The Bidder shall provide the necessary piping valves, fittings etc. for the gland sealing
connection.
4.09.00 Mechanical Seals
4.09.01 Wherever specified in pump data sheet, mechanical seals shall be provided. Unless otherwise
recommended by the tenderer, mechanical seals shall be of single type with either sliding gasket or
bellows between the axially moving face and shaft sleeves or any other suitable type. The sealing
faces should be highly lapped surfaces of materials known for their low frictional coefficient and
resistance to corrosion against the liquid being pumped.
4.09.02 The pump supplier shall coordinate with the seal maker in establishing the seal chamber of
circulation rate for maintaining a stable film at the seal face. The seal piping system shall form an
integral part of the pump assembly. For the seals under vacuum service, the seal design must
ensure sealing against atmospheric pressure even when the pumps are not operating. Necessary
provision for seal water supply along with complete piping fittings and valves as required shall form
integral part of pump supply.
4.10.00 Pump Shaft Motor Shaft Coupling
4.10.01 The pump and motor shafts shall be connected with an adequately sized flexible coupling of
proven design with a spacer to facilitate dismantling of the pump without disturbing the motor.
Necessary coupling guards shall also be provided.
4.11.00 Base Plate
4.11.01 A common base plate mounting both for the pump and motor shall be provided. The base plate
shall be fabricated steel and of rigid construction, suitably ribbed and reinforced. Base plate and
pump supports shall be so constructed and the piping unit so mounted as to minimize
misalignment caused by mechanical forces such as normal piping strain, internal differential
thermal expansion and hydraulic piping thrust. Suitable drain troughs and drip lip shall be
provided.
4.12.00 Assembly and Dismantling
4.12.01 Assembly and dismantling of each pump with drive motor shall be possible without disturbing the
grouting base plate or alignment.
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SECTION - D1
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4.13.00 Drive Motor (Prime Mover)
4.13.01 The kW rating of the drive shall be based on continuously driving the connected equipment for the
conditions specified. In case, where parallel operation of the pumps are specified, the actual motor
rating is to be selected by the tenderer considering overloading of the pumps in the event of
tripping of operating pumps.
5.00.00 TESTING FOR HORIZONTAL CENTRIFUGAL PUMPS
The manufacturer shall conduct all tests required to ensure that the equipment furnished shall
conform to the requirements of this specification and in compliance with the requirement of
applicable Codes and Standards. The particulars of the proposed tests shall be submitted to the
Owner for approval before conducting the tests.
5.01.00 Hydrostatic Tests
All pressure parts shall be hydraulically tested at 200% of pump rated head or at 150% shut off
head whichever is higher. The test pressure shall be maintained for 1/2 hr. and no leakage shall
be permitted. While arriving at the above pressure, the maximum suction head specified in Data
Sheet shall be taken into account.
5.02.00 Performance Tests
5.02.01 All the pumps shall be tested in the Manufacture’s Works at rated speed for capacity, efficiency
and brake horse power. Pumps shall be given running test over the entire operating range
covering from the shut off head to the maximum flow. The duration of test shall be minimum one
(1) hour. A minimum of seven readings approximately equidistant shall be taken for plotting the
curves with one point at design flow. Testing of pumps shall be in accordance with stipulations of
Hydraulic Institute Standards or as applicable equivalent
5.02.02 The test shall be preferably conducted with the actual motor being furnished.
5.02.03 Only those pumps shall be subjected to strip down examination visually to check for mechanical
damages after testing at shop in case abnormal noise level and excessive vibration is observed
during the performance test. Otherwise strip down examination is limited to bearing inspection only.
5.02.04 The pump accessories e.g. the thrust bearing, couplings etc. shall be subjected to tests as per
manufacturer’s standards.
5.03.00 Mechanical Balancing
All rotating components of the pumps shall be statically balanced. In addition to static balancing,
rotating components of the pumps shall be balanced dynamically at or near the operating speed.
Tenderer shall furnish acceptance norm for this test.
5.04.00 Visual Inspection
Pumps shall be offered for visual inspection by the bidder before shipment. The components of the
pumps shall not be painted before inspection.
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SECTION - D1
REV.NO. 0 DATE :
5.05.00 NPSH Test
NPSH test shall be conducted with water as medium if required. NPSH shall not be mandatory in
case type test certificates are furnished for the similar rating of pumps.
5.06.00 Noise and Vibration Measurement
Noise and vibration shall be measured during the performance testing at shop as well as during the
site test.
5.06.01 The noise level shall not exceed 85 dBA. Noise level measurement will be made as per applicable
internationally acceptable standard. The measurement shall be carried out with calibrated
integrating sound level meter meeting the requirement of IEC:651 or BS:5969 or IS:9779. Sound
pressure level will be measured all round the pump and motor set at a distance of one meter from
the nearest surface of the machine and at a height of 1.5 m from the floor level. A minimum of six
(6) points should be covered for measurement. The measurement shall be done with a slow
response on the A-weighted scale. The average of the A-Weighted sound pressure
measurements expressed in decibels to a reference 0.0002 microbars shall not exceed the
specified value.
The tests shall be carried out on the machine operating at rated speed and as near as possible to
the rated power. Corrections for background noise and correction on account of test environment
will be considered in line with applicable standard. For this purpose all the additional data required
should necessarily be collected during the test.
5.06.2 Vibration check will also be done as per HIS. Vibration would be checked at thrust bearing
locations on horizontal, radial and vertical direction. The acceptance limits would be as per HIS.
The instrument used would be IRD 308 or equivalent with velocity pick-up. Vibration limits to be
specified as per the speed of the pump.
5.07.00 Material Test Certificate
5.07.01 Material of the various pump components shall be tested in accordance with the relevant
standards. Test certificates for these shall be furnished for the Owner’s approval.
5.07.02 Where stage inspection is desired by BHEL/customer all material test certificates shall be
correlated and verified with the actual material used for construction before starting fabrication by
BHEL/customer’s inspector who will stamp the material. In case mill test certificate for the material
are not available, the supplier shall carry out physical and chemical tests at his own cost from a
testing agency, approved by BHEL/Customer, as per the requirement of specified material
standard. The sample for physical and chemical testing shall be drawn up in presence of
BHEL/Customer’s inspector who shall also witness the testing.
5.08.00 Non Destructive Testing
(a) UT shall be carried out on shafts of diameter more than 50 mm.
(b) DP tests shall be carried out on shaft and impeller.
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SECTION - D1
REV.NO. 0 DATE :
(c) No weld repair shall be allowed on cast iron.
5.09.00 Field Testing
5.09.01 After installation, the pumps offered shall be operated to prove satisfactory performance as
individual equipment as well as a system run. If the performance at site is found not to the
requirements then the equipment shall be rectified or replaced by the Vendor, at no extra cost to
the Owner. The procedure of the above testing will be mutually agreed between the Owner and
the contractor. Noice and vibration tests shall also be repeated at site.
5.09.02 Based on observation of the trial operation, if modifications and repairs are necessary, the same
shall be carried out by the contractor to the full satisfaction of the engineer and then the
performance and guarantee tests to be repeated at site as per relevant clauses of the specification.

Page 445 of 680

SECTION - D1
REV.NO. 0 DATE :


METERING PUMPS
Page 446 of 680

SECTION - D1
REV.NO. 0 DATE :

1.00.0 GENERAL
1.01.01 Specification cover the design, material, construction features, manufacture, inspection, testing the
performance at the vendor's/sub-vendor's works, delivery to site, erection, commissioning and
testing of metering pumps.
2.00.0 GENERAL DESIGN FEATURES
2.00.01 Pumps shall be simplex positive displacement hydraulically operated diaphragm design, driven by
squirrel cage induction motor through suitable speed reduction unit. Maximum pump stroke speed
shall not exceed 100 per minute.
2.00.02 The stroke shall be continuously adjustable to give a capacity variation 0-100% range while the
pump is running or stopped. Adjustment of capacity shall be done by manual control facility
(micrometric adjusting type) to be provided locally for each of the pump.
2.00.03 The stroke shall be continuously adjustable to give a capacity variation 0-100% range while the
pump is running or stopped. Adjustment of capacity shall be done by manual control facility
(micrometric adjusting type) to be provided locally for each of the pump.
2.00.04 Capacity variation may be effected by changing eccentricity of the driving crank or by suitable
hydraulic circuit. Pump accuracy shall be industry standard ± 1% of capacity setting.
2.00.05 Pumps shall be provided with an integral relief valve, spring operated to release pressure when
delivery line blockage occurs.
2.00.06 Crankcase shall be constructed of high quality cast iron, which will also house the gearbox and
guides of cross head.
2.00.07 Guided, controlled travel, double-ball check valves or equivalent, shall be provided both on the
suction and discharge side.
2.00.08 Material of construction of the various parts shall be as per the details furnished elsewhere in the
specification. However all parts coming in contact with acid shall be of Haste alloy 'B' and for alkali
it should be of SS-316 only.
2.00.09 Suitable gland seal shall be provided to prevent leakage.
2.00.10 Electric drive motor particulars should follow enclosed electrical chapters.
3.00.00 TESTING
3.01.00 Testing and Inspection at Manufacturer's Works
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SECTION - D1
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3.01.01 The manufacturer shall conduct all tests required to ensure that the equipment furnished conforms
to the requirements of this Specification and is in compliance with requirements of the applicable
codes. The particulars of the proposed tests and the procedures for the tests shall be submitted to
Owner for approval before conducting the tests.
3.01.02 The Owner's representatives shall be given full access to all tests for which the Manufacturer shall
inform the Owner allowing adequate time so that if the Owner so desires, his representatives can
witness the test.
3.01.03 All materials and castings used for the equipment shall be of tested quality. The test certificates
shall be made available to Owner.
3.01.04 The pump casing shall be hydraulically tested at 200% pump operating pressure or 150% of design
pressure whichever is higher. The test pressure shall be maintained at least for ½ an hour.
3.01.05 The rotating parts of pump drive shall be subjected to static balancing.
3.01.06 All pumps shall be tested at the shop for capacity, volumetric accuracy, repetitive accuracy, power
and volumetric efficiency. The tests are to be done according to the requirements of the "Hydraulic
Institute" of U.S.A. and Indian Standards as applicable.
3.01.07 The pump accessories e.g. gear box, speed reduction unit etc. will be subjected to tests as per
manufacturer's standards. The test results shall be furnished to the Owner.
3.01.08 The combined variation of the pump and motor should be restricted within limits specified by
Hydraulic Institute Standard, USA when the pump operated singly or in parallel.
3.01.09 All pumps shall be subject to strip down examination visually to check for mechanical damages
after performance testing at shop.
3.01.10 Diaphragm of the metering pump shall be type tested as per applicable code/standard.
3.01.11 Performance test shall be carried out for the setting of pressure relief valve.
3.01.12 Test reports and certificates of all the above-mentioned tests to ensure satisfactory operation of the
system shall be submitted to the Owner for approval before dispatch.
3.02.00 Test at Site
After erection at site pumps as detailed under different groups shall be operated to prove
satisfactory performance as individual equipment as well as a system. If the performance at site is
found to be not to the requirements, then the equipment shall be rectified or replaced by the
Vendor at no extra cost to the Owner.
Page 448 of 680

SECTION - D1
REV.NO. 0 DATE :

PRESSURE & STORAGE VESSEL
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SECTION - D1
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1.00.00 GENERAL
The following principal pressure and atmospheric vessels for the system has been covered
in this part of specification.
1. Condensate Polisher Service vessels.
2. Condensate Polisher Resin Separation and Cation Regeneration vessel.
3. Condensate Polisher anion regeneration vessel.
4. Condensate Polisher mixed resin storage Vessel.
5. Alkali diluent Heating cum Storage Vessel.( hot water tank)
6. Activated carbon filter
7. Alkali Preparation Tank
8. Alkali Day Tank
9. Resin Injection Hopper
10. Acid Measuring Tank.
11. Acid Storage Tank
12. DM storage tank.
13. Alkali storage tank
1.01.00 Of these, the items specified from Sr. no. 1 to 6 shall be designed as pressure vessels and
the rest shall be atmospheric vessels.
1.01.01 All other vessels, not specifically listed here, but required for the Bidder’s system shall also
meet the general requirements of this specification.
1.01.02 Process requirements of these vessels shall be governed by the requirements of the
Condensate Polishing System, which will determine their design conditions. Following
sections only indicate some of the minimum requirements which must be met, and the
actual design of these vessels shall be better than these, if that is required from process
considerations.
2.00.00 GENERAL DESIGN FEATURES
2.01.00 Design
2.01.01 Design of all pressure vessels shall conform to ASME Section VIII or acceptable equivalent
international standard. Design pressure shall be the maximum expected pressure to which
the vessels may be subjected to plus 10% additional margin. Maximum expected pressure
for vessels placed in the discharge line of pumps shall be based on the shut-off head of the
pumps plus static head at pumps suction if any. Design pressure of condensate service
vessels is indicated elsewhere in this specification. For all other pressure vessels, design
pressure shall be at least 10 Kg/cm² (g).
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SECTION - D1
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2.01.02 Design of all vertical cylindrical atmospheric storage tanks containing water, acid, alkali and
other chemicals shall conform to IS: 803.
2.01.03 Design of all horizontal cylindrical atmospheric storage tank containing water, acid, alkali
and other chemicals shall conform to BS: 2594.
2.01.04 Design temperature of all pressure vessels and storage tanks shall be 10 deg. C higher
than the maximum temperature that any part of the vessel/tank is likely to attain during
operation.
2.01.05 In case, tank is subjected to vacuum; the same shall be taken care in designing the tank.
2.01.06 The design of Demineralised water storage tanks (Vertical type) shall conform to IS: 803.
Supporting frame where required shall be in accordance with IS: 800. The tank shall be
"Non-pressure" fixed roof type with atmospheric vents.
2.02.00 All vessels / tanks without inside rubber lining shall have a corrosion allowance of minimum
2 mm and mill allowance (minimum 0.3 mm) for shell and dished ends. Thinning allowance
of 2 mm (minimum) shall be considered for dished end. Vessel / tanks ends shall be of
dished design and constructed by forging, pressing or spinning process. Conical or flat
ends shall not be accepted. All dished ends shall be stress relieved.
2.03.00 All the atmospheric tanks shall have sufficient free board above the “Level High”/”Normal
Level” as the case may be. The overflow level shall be kept at least 20 cm or 10% of
vessel height above the “Level High”/”Normal Level” for all the tanks except for the DM
tanks for which a minimum height of 300 mm shall be provided over the “High Level”.
Further, a minimum 300 mm free board shall be provided above the top of overflow level to
the top of the tank. Wall thickness of atmospheric tanks shall not be less than 6 mm.
2.04.00 Vessels coming under preview of IBR shall be designed accordingly.
2.05.00 Interior surfaces of all tanks shall be clear of stiffeners and other structural supports.
Tanks shall be reinforced and stiffened externally as required.
2.06.00 All welds on inner tank surface shall be free of voids, gaps craters, pits, high spots, sharp
edges, abrupt ridges and valleys or undercut edges. High spots, irregularities and sharp
edges shall be removed by grinding. Inside weld seams shall be ground flush and smooth
applicable for corrosion resistant coating or lining.
2.07.00 All internal baffles, wear plates, pipes etc. shall be continuously welded on both sides at all
contact points with full fillet welds which shall be free of voids, gaps, craters, high spots,
sharp edges, and undercutting. Sharp edges shall be ground to a 3 mm minimum radius.
2.08.00 Weld splatter shall be removed.
2.09.00 All welding shall be performed by ASME qualified welders under Section-IX of ASME Boiler
and Pressure Vessel code and welding electrodes shall be as per relevant
Codes/Standards viz. AISC Section 1.17 etc.
2.10.00 The plates for cylindrical tanks shall be accurately formed in bending rolls to the diameters
called for, and the completed shells be concentric and plump. Plates shall be cold-rolled by
plate bending machine in a number of passes to true curvature and joined by welding.
2.11.00 Vessels seam shall be so positioned that they do not pass through vessel connections.
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3.00.00 MATERIAL OF CONSTRUCTION
3.01.00 All pressure vessels shall be fabricated from carbon steel plates as specified in datasheet
A of this specification and lined internally. All atmospheric tanks shall be fabricated of
material as specified in datasheet A and lined internally.
4.00.00 APPURTENANCES
4.01.00 Manholes
4.01.01 All the pressure vessels and horizontal type storage tanks shall be provided with manhole
of 500 mm diameter minimum size, preferably at the top head, complete with cover plate,
lifting handle, davit cap, nuts, bolts, gaskets etc. to ensure leak tightness at the test
pressure.
4.01.02 The vertical type storage tanks shall be provided with a manhole of 500 mm dia on the top
cover, if the diameter of the tank is 1200 mm or more. For the DM water storage tanks,
manholes shall be provided as per IS:803.
4.01.03 All the vessels and tanks shall be normally provided with a six inch gasketed handhole
located near the bottom of the straight side.
4.01.04 The required lining/coating for the inside surface of the manhole/handhole, nozzle and
cover plate of the manhole/handhole shall be same as that of the respective vessel/tank.
4.01.05 Sight Glasses
All the vessels mentioned shall be provided with pad type sight glasses on their vertical
sides. Locations of these sight glasses shall be as follows:
4.01.06 One with the centre line at the normal level of the bed top, and one near the bottom of the
straight side, for each of these vessels.
4.01.07 In addition, item no. 1.00.00 shall be provided with sight glasses, with their center lines at
each of the normal separated resin interfaces.
4.02.00 Lifting Lungs
All vessels of diameter 1200mm or greater shall be provided with a minimum of 4 lifting
lugs. Smaller vessels shall be provided with at least 2 lifting lugs.
4.03.00 Vessels Supports
Adequate supporting arrangements like straps, saddles, skirt rings, or legs of steel shall be
provided to transfer all loads to the respective skid structures.
4.04.00 Vessel Internals
The internals for pressure Vessels shall be designed for a low pressure drop to promote
uniform distribution and flow through the vessels and to withstand the full design pressure
of the vessel in both directions.
Specification requirements for vessel internals are as follows:
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4.05.00 Inlet water and Regenerant Distributors
Hub and laterals with diffuser splash plates or header and perforated laterals. Material of
construction shall be type 316 stainless steel, except for acid service which shall be of
Hastelloy B.
4.06.00 Underdrains
Same as above with screened laterals with internal perforated pipes, and rubber-lined false
bottom. For resin separation/regeneration/mixed resin vessels, it may have fully screened
bottom (NEVA – clog type with para Septanurse screen, fully supported by subway grid, or
equal).
4.07.00 For lined vessels, they shall also be lined in the same manner as the internal surfaces of
these vessels. For the caustic diluent heating/storage tank, they shall be of type 304
stainless steel construction.
4.08.00 Internal Fasteners
All internal fasteners shall be of type 316 stainless steel and heavy duty locknuts shall be
used throughout.
4.09.00 Piping Connections
All lined vessel connections and connections in unlined vessels 25 NB and larger shall be
to ANSI 300 lb class. Flat face flanges shall be used throughout. Nozzle material shall be
ASTMA-106. Grade B. schedule 80 pipe. All flanged connections shall be supplied
complete with matching counter flanges, nuts, bolts and full-face gaskets.
4.10.00 All vessel connections in unlined tanks smaller than 25 NB shall be screwed to ANSI 2.1
for schedule 80 pipe.
4.11.00 Resin Traps
Outlets of each of the condensate polisher service vessel and the waste effluent header of
the common external regeneration facility, shall be provided with a resin trap. These resin
traps shall be a minimum, conform to the following:
4.11.01 The resin trap shells shall be of steel construction and lined internally with saran or
Polypropylene. The internals for all traps shall be johnson well screen type, of 316 stainless
steel in both directions, resin traps located in processes effluent lines shall have a screen
opening that does not exceed 120 percent of the associated process vessel under drain
screen opening. Resin traps located in waste effluent headers shall have a screen opening
of approximately 60 mesh.
4.11.02 Each resin trap shall be fully piped and valved for inplace manual back flushing.
5.00.00 SPECIFIC DETAILS
5.01.00 Alkali Diluent Heating – Storage Tank (Hot water tank)
One (1) no. hot water tank for heating of alkali diluent water with (2X50%) electric heating
coil, adequately insulated of stainless steel construction shall be provided. The capacity of
tank shall be minimum 20% higher than the maximum water demand. This tank shall be
provided with burn out protection, pressure relief valve, level switches, temperature
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indicator etc. The heaters shall be sized for heating the water from a temperature of 15 to
50 deg. C in 5 hours at the outlet of ejector.
All tank internals, including the inlet water tail pipe, shall be fabricated of type 304 stainless
steel.
5.02.00 Atmospheric Tanks
Wall thickness of these tanks shall not be less than 6mm.

5.03.00 Resin Injection Hopper
The supplier shall provide a hopper type tank for resin make-up, using water slurry, to the
condensate polishing systems. This make-up system will constitute a portion of the
condensate polishing external regeneration system. The resin hopper shall have a conical
bottom and a flat top. The top shall have a piano type hinged port, having a lifting handle,
of sufficient size for easy resin loading. The resin shall discharge through a bottom
connection to a water ejector for transport. Water shall be added to the hopper to assist in
the resin transfer. The ejector discharge shall be to the resin separation-cation
regeneration vessel. Demineralized water shall be used throughout for the resin transfer.
Piping of the resin make-up system shall be the responsibility of the Bidder as a part of the
external resin regeneration system.
a) Capacity
The resin make-up hopper tank shall be sized to handle up to 150 liters of as received new
resin per single injection.
b) Material
The resin make-up hopper tank shall be fabricated of mild carbon steel having a minimum
thickness of 6mm and lined.
5.04.00 Chemical preparation and day tanks
These shall be vertical cylindrical tanks. They shall be of carbon steel fabrication, lined and
provided with full height level gauges right up to the overflow levels.
The alkali preparation tank shall be provided with a dissolving basket of type 316 stainless
steel constructions, and a motorized slow speed stirrer mounted eccentrically to the tank by
a bracket fixed to the side wall. The stirrer shall have impellers of type 316 stainless steel.
The alkali day tank shall be provided with an airtight cover complete with a breather
arrangement, to prevent absorption of carbon dioxide from the atmosphere by the alkali
solution contained in it. The overflow connection shall also be provided with a suitable seal
for this purpose.
The tanks for ammonia solution (if applicable) shall also be provided with similar
arrangements to prevent escape of ammonia vapour to outside.
5.05.00 LINING
All internal lining of vessels provided under this specification shall be of natural rubber,
meeting the following minimum requirements.
5.05.01 Hardness
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Lining used may be soft rubber having a shore durometer reading or 65 on the A scale, or
semi-hard rubber having a durometer reading of 65 on the A scale. Variations in hardness
of the rubber lining between the different areas of a specific tank shall be within +/-5
durometer reading.
5.05.02 Chemical Resistance
The lining material shall be suitable for prolonged service in the chemical environment
described below:
a) Hydrochloric acid, 2 to 8% concentration, at temperature from 10 deg C to

50 deg C.
b) Sodium hydroxide, 1 to 4% concentration, at temperature from 30 deg C to 50 deg
C.
c) 100 to 500 mg /l of sulphuric and hydrochloric acid combined. Ratio of

concentration of these two acid 1 : 5 to 5 : 1 and temperatures from 10 deg C to 40
deg C.
d) 1 to 10mg/l of sodium hydroxide at temperature from 10 deg C to 40 deg C.
The linings will be subjected to the condition (a) or (b) for intermittent periods of
approximately one hour out of eight hours, and to conditions (c) or (d) remainder of the
time.
5.05.03 Thickness
The lining shall be applied in three layers, resulting in a total thickness of not less than 4.5
mm anywhere on the internal surfaces of the vessels. The lining shall extend over the full
face of all flanged connections and shall have a minimum thickness of 3 mm in all such
external areas.
5.05.04 Surface Preparation
Prior to rubber lining all surfaces must be prepared in he following manner.
a) Degrease surface prior to blasting.
b) The surface is to be blasted with steel grit or sharp silica sand to a white and
bright metal surface.
c) All traces if grit and dust should be removed with a vacuum cleaner or by brushing.
Care must be taken to avoid contaminating the surface.
d) Immediately after blasting and removal of grit, the first coat of primer or cement
shall be applied and allowed to dry.
5.05.05 Protection
After the lining is completed the vessels shall not be subjected to any prolonged exposure
to direct sunlight in course of it’s transportation erection, etc. They shall not also be stored
in direct sunlight. No further welding or burning shall be carried out on the vessel, after
application of the lining.
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All lining projecting outside of the vessel, shall be protected adequately from mechanical
damages during shipment, handling, storage etc.
Suitable warning, indicating the special care that must be taken with respect to these lined
vessels, shall be stenciled on their outside surfaces with the letter at least 12mm high.
Example:
“Warning – Tank is lined”
“Do not weld or Burn”
“Do not Store in Direct Sunlight” etc.
The design, manufacture, shop testing, site fabrication and erection, testing and
commissioning of the pressure and storage vessels shall conform to the latest revisions of
the following standards, in addition to other standards mentioned elsewhere in the tender
document subject to any modification and requirement, as specified here in after.
a) IS: 803 - Code of practice for design, fabrication and erection of

Vertical Mild Steel cylindrical welded oil storage tanks.
b) IS: 816 - Code of practice for use of metal arc welding for general
construction in mild steel.
c) IS: 817 - Code of practice for training and testing of metal arc
welders.
d) IS: 822 - Code of procedure for inspection of welds.
e) IS:1363 - Black hexagonal bolts, nuts and locknuts (dia 6 to 39 mm)

and black hexagon screws (dia to 24 mm).
f) IS:1367 - Technical supply conditions for threaded fasteners.
g) IS:2062 - Specification for weld able structural steel.
h) IS:2002 - Steel plates for pressure vessels for intermediate and High
temperature service including boilers.
i) IS:2825 - Code of unfired pressure vessels.
j) IS:3133 - Manhole and inspection opening for chemical equipment.
k) IS:4049 - Specification for formed ends for tanks and pressure

vessels.
l) IS:4682 - Code of practice for lining of vessels and equipment for

chemical processes Rubber Lining.
m) BS:2594 - Specification for carbon steel welded horizontal cylindrical

storage tanks.
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n) ASME - Boiler and pressure vessel Section VIII code.
o) ASTM - American Society for Testing and Materials.
7.00.00 FABRICATION
7.01.00 The vessel ends for storage tanks of vertical type shall have flat bottom. However, the
ends of horizontal storage tanks, and all the pressure vessels shall be dished design of
Tori-spherical type designed.
7.02.00 The plates to be used for fabrication shall preferably have a minimum width of 1500 mm.
7.03.00 All the joints (circumferential / longitudinal) shall be continuous butt welded, inside and
outside. Connection shall be flush with inner surface of tanks and welded continuously on
both sides of shell. Sharp inside edges shall be rounded to a minimum 3 mm radius.
7.04.00 Welding sequence shall be adopted in such a way so as to minimize the distortion due to
welding shrinkage. Contractor shall indicate in his drawing the sequence of welding
proposed by him which should meet prior approval of the engineers. Welding shall not be
carried out when the surface of the parts to be welded are wet from any cause and during
periods of rain and high winds unless the welder and work are properly shielded.
7.05.00 All pressure vessels and storage tanks except Demineralised water (D.M.) shall be
fabricated complete and tested at manufacturer’s works to ensure better workmanship.
7.06.00 Tank Connections
7.06.01 Bidder shall furnish all pipe material required for tank connection for the process
requirement. In addition to these, additional connections, if required by the Owner for the
inter-connection of their piping, instrumentation etc. shall also be provided. Such additional
requirement will be intimated to the successful Bidder later and Contractor shall provide
these fittings to match with the Owner’s items. Adequate pipe support attachments in the
external surface of the tank/vessel shall be provided for Owners pipes for all the
vessels/tanks. All lined vessels connections shall be conforms to ANSI 300 lb class. Nozzle
material shall be ASTM-106 Grade B, Schedule 80.
7.06.02 All flanged connections should be supplied complete with matching counter flanges, nuts
bolts and gasket materials. The flange design, (thickness and drilling etc.) shall match with
the interconnected piping flanges.
7.06.03 Bolts and nuts to be used externally to the vessels shall be of hexagonal head conforming
to IS:1367. However, internal fasteners if any, shall be of IS:316 /SS-304 or Hastalloy-B as
per the duty conditions.
7.06.04 Gaskets shall be of full face type.
7.06.05 Sight glasses shall be provided for the tanks/vessels as specified in the standard
specification. The material for sight glass shall be high quality transparent PLEXIGLASS of
sufficient thickness to withstand the test pressure. The sight glass shall be provided with
suitable gaskets and bolts to ensure leak tightness at the test pressure.
7.07.00 Vessels Supporting Lifting Lugs
7.07.01 Adequate supporting arrangements like straps, saddles, skirt boards, pillars etc. shall be
provided to transfer all loads to civil foundation. All foundation bolts, inserts etc. shall also
be provided.
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7.07.02 All vessels of internal, diameter of 1200 mm or greater shall be provided with minimum four
(4) lifting lugs for safe and effective handling during erection. Smaller vessels shall be
provided with at least two (2) lifting lugs.
7.07.03 Material of construction for these vessel supports, saddles, lugs shall conform to IS:2062 of
tested quality.
7.08.00 Special Accessories Storage Tanks
7.08.01 Vessel internals wherever required shall be provided as detailed out elsewhere in the
specification.
7.08.02 All the pressure vessels and tanks shall be provided with drain connections along with
drain valves of suitable size. Further all the atmospheric storage tanks shall be provided
with over flow connection designed for the filling rate of the respective tank.
7.08.03 All the pressure and tanks shall be provided with the vent connections. The design shall
be as to offer adequate area for venting. Venting area shall be such that over
pressure/vacuum is not created in the tank during maximum filling/drain-off rate. The
maximum draw off rate for the DM storage tanks shall be intimated later to the successful
bidder.
7.08.04 Various instrumentation and the fittings required for the same shall be supplied as
elaborated in data sheets.
7.08.05 Water seal shall be provided for the overflow line of DM and degassed water storage tanks.
The vent and overflow lines of alkali preparation /measuring / day tanks and vent line of DM
storage tanks shall be provided with Carbon dioxide absorber of proven design to prevent
contamination from atmospheric air. Carbon dioxide absorber shall preferably be located
at ground level. The vent and overflow lines of Acid measuring tanks shall be provided with
fume absorber using suitable packing material, such as pall rings/raschig rings.
7.08.06 Conservation vent valves shall be provided in the vent line of DM storage tanks so that, at
a vacuum to the extent of 65 mm water column, the valve shall open to relieve the vacuum.
Body and trim of the valve shall be Die Cast Aluminum.
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SECTION - D1
REV.NO. 0 DATE :
TECHNICAL SPECIFICATION
FOR
VERTICAL CENTRIFUGAL PUMPS
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SECTION - D1
REV.NO. 0 DATE :
1.00.00 GENERAL INFORMATION
1.01.00 The general guidelines as illustrated in the subsequent clauses of this section shall be
applicable for vertical pumps to be procured under the scope of this package.
2.01.00 In addition to the requirements spelt out elsewhere in the specification, the equipment to
be provided under this section shall specifically conform to the following codes,
standards, specifications and regulations, as applicable, including all the latest
amendments subsequent to the year of publication as mentioned below.
2.01.01 IS 1710/1989: Vertical Turbine Pumps for Clear, Cold and Fresh
Water.
2.01.02 IS 5120/1977: Technical requirements - Rotodynamic special

purpose pumps.
2.01.03 IS 5639/1970: Pumps for handling chemical and corrosive liquids.
2.01.04 IS 5659/1970: Pumps for process water.
2.01.05 IS 6536/1972: Pumps handling volatile liquids.
2.01.06 IS 9137/1978: Code for acceptance for centrifugal, mixed flow and
axial
Flow pumps - Class ‘C’
2.01.07 BS 5316 Acceptance tests for Cetrifugal, mixed flow Part-I/1976

And axial flow pumps - Class ‘C’ Tests (ISO
2548/1973)
2.01.08 BS 5316: Acceptance tests for Centrifugal, mixed flow Part-

II/1977
And axial flow pumps - Class ‘B’ Tests (ISO
3555/1977)
2.01.09 ANSI B 73.2M Vertical inline centrifugal pumps for chemical process
1984
2.01.10 API 610/1989: Centrifugal pumps general refinery services.
2.01.11 Hydraulic Institute Standards of USA (1983).
2.01.12 PTC 8.2/1965: Power Test Codes - Centrifugal pumps.
3.00.00 Accessories:
All the pumps under this specification shall be complete with following standard/special
accessories.
3.01.00 Standard accessories:
a) Pump motor coupling along with coupling guard

b) Common base plates for pump and motor.
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c) Lubrication system along with all internal piping, valves, fittings, specialties etc. as
required.
d) Counter flanges for suction/ discharge nozzles along with fixing nuts, bolts and gaskets.
e) Anchor bolts, nuts, seating steel works, etc. as necessary for mounting the pump-motor
unit on Civil foundations.
f) Suitable vent (with valves)/ lifting/ handling attachments for the pump/ motor/
Accessories.
g) Suitable drain connections with isolating valves as applicable.
h) Set of “Special” Tools & Tackles for Pumps and motors, if any.
i) Erection and commissioning spares, “on as required” basis.
j) Bidder shall provide various drawings, data, calculations, test reports/ certificates,
Operation and maintenance manuals, As-built drawings, etc. as specified and as
necessary.
3.02.00 Services included in Bidder’s Scope:
3.02.01 The pumps shall be guaranteed to meet the performance requirements as specified vide
datasheet – A and also for trouble free operation after commissioning.
4.00.00 TECHNICAL REQUIREMENTS:
4.01.00 The pumps shall be Electric motor driven.
4.02.00 The Pumps shall conform to HIS
4.03.00 Vertical type pumps with 1500rpm.
4.04.00 Minimum efficiency of vertical pump will be 40%.
4.05.00 No negative tolerance shall be permitted in rated capacity & TDH.
4.06.00 No negative tolerance shall be permitted in efficiency at rated capacity.
4.07.00 The shut off head of pumps shall be at least 115% of pump rated TDH.
4.08.00 The pumps shall be capable of developing the required total head at rated capacity for
Continuous operation. The pumps shall operate satisfactorily at any point on the Q-H
Characteristic curve over a range of 0% to 130% capacity and shall be suitable for
Continuous operation between 30% to 130% capacity.
4.09.00 Selection of the pumps shall be such that the design point shall be met even with
negative manufacturing tolerance.
4.10.00 The total head capacity curve shall be continuously rising towards the shut off, the pumps
shall preferably be non-overloading type and stable.
4.11.00 The pumps shall be capable of running over the entire range of NPSH conditions
required without any noise, vibration or cavitations.
4.12.00 The pumps shall be of stiff shaft design. The minimum internal clearances should be
sufficiently more than the max. Static deflection of the shaft. Shaft size selected must
take into consideration the critical speed as specified in API-610.
4.13.00 Pumps and motors shall run smooth without undue noise and vibration. The vibration
shall be within 75 microns for pump - motor set. The noise level shall be limited to 85 dB
at distance of 1.0M.
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4.14.00 High reliability of the pumps is an essential requirement and therefore it gets weight age
over its efficiency. It is therefore essential that the bidder choose a standard proven
model from the range of pumps manufactured.
4.15.00 If water handled by pump is dirty/ not suitable for lubrication/ cooling, the bidder shall
provide requisite strainer/ filters, tanks, motorized valves, etc. after the tap off for the
required service, the arrangement provided shall be subject to Purchaser's approval.
5.00.00 OTHER REQUIREMENTS:
5.01.00 The materials of construction for various components specified are the minimum
Requirements indicated in datasheet – A section C and materials of construction for
other components not specified shall be similarly selected by the bidder for the intended
duty.
6.00.00 PAINTING FOR PUMPS:
a) The surface of SS, Gun metal, brass, bronze and non metallic component shall not be
applied with any painting.
b) The Steel surface to be applied with painting shall be thoroughly cleaned before applying
painting by brushing, shop blasting etc. as per the agreed procedure.
For all the steel surfaces inside the (indoor installation) building, a coat of red oxide
primes of min. thickness of 50 microns followed up with under coat of Synthetic Enamel
paint of min. thickness of 50 microns shall be applied. the top coat shall consist of two
coats each of min. thickness of 50 microns of synthetic enamel paint and thus total
thickness shall be min. 200 microns.
7.00.00 PERFORMANCE REQUIREMENTS
7.01.00 Pump (s) shall preferably be designed to have the best efficiency at the specified duty
point. Further, the pumps (s) shall be suitable for continuous operation at any point within
its ‘range of operation’.
7.02.00 Under all circumstances, the ‘range of operation’ of the pump (s) shall exclude any
Unstable operating zone of the head-capacity curve.
8.00.00 DESIGN AND CONSTRUCTION
Pumps shall be of vertical shaft, complete with bowl, column pipe, discharge head and
base plate with all accessories. General design and constructional features of the pumps
shall be as follows:
8.01.00 BOWL ASSEMBLY
8.01.01 This will be either a single, mixed flow or axial flow type with discharge co-axial with
shaft. Type of impeller shall be chosen on the basis of the pump specific speed and the
characteristics of handling fluid.
8.02.00 IMPELLER SHAFT, LINE SHAFT AND HEAD SHAFT
8.02.01 Shaft size shall be selected on the basis of maximum torque to be applied on the pump
shaft. Critical speed of the shaft shall be sufficiently away from the pump operating speed
and in no case shall lie between 90% and 110% of the rated speed.
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8.02.02 Impeller shaft shall be guided by bearings provided in each bowl or above and below the
impeller shaft assembly. The butting faces of the shaft shall be machined square to the
assembly and the shaft shall chamfer at the edges.
8.02.03 Line shaft may be single or multiple pieces as required. In case of multiple pieces, line
shaft shall be coupled as per the standard practice of the manufacture. For screwed
coupling, directions shall permit tightening of the joint during pump operation.
8.02.04 Replaceable shaft sleeves shall be furnished at applicable location, particularly under
stuffing box and at other locations, as considered necessary.
8.03.00 BEARINGS
8.03.01 SHAFT BEARINGS
Adequate number of properly designed bearings shall be provided for smooth and
trouble free operation of the pump. Number of bearings shall consider the number of
shaft pieces used and the critical speed of the shaft. Bearings shall be either lubricated
by external clear water/oil/grease or self-lubricated. In case of external water/oil
lubrication, complete lubrication arrangement shall be furnished with the pump.
8.03.02 THRUST BEARING
Thrust bearing of adequate size and capacity shall be provided to take the vertical thrust
of the impeller arising out of the pump operation and dead weight of the rotating
Components. Life of the thrust bearing shall be guided by the design standard of the
pump. Thrust bearing shall be capable of running continuously at maximum load. Thrust
bearing shall be either grease or oil lubricated. Lubrication arrangement shall be such
that the lubricant does not contaminate the handing fluid. The arrangement shall also be
adequate to protect the bearing, while the pump coast down to stop in case of power
failure of the station. Pre-lubrication of the thrust bearing, if recommended by the pump
manufacturer, shall be taken care of in designing the lubrication system. Cooling of the
thrust bearing, if necessary, shall be done by the handing fluid/external Water, depending
on the fluid handled. Location of the thrust bearing may be at the pump body or at the
driver, or at both depending on the requirement.
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SECTION – D2

ELECTRICAL
Page 464 of 680

TITLE : SPECIFICATION NO.
GENERAL TECHNICAL REQUIREMENTs PE-SS-999-506-E101
VOLUME NO. : II-B
FOR
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
SHEET : 1 OF 1
GENERAL TECHNICAL REQUIREMENTS
FOR
LV MOTORS
SPECIFICATION NO.: PE-SS-999-506-E101 Rev 00
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VOLUME NO. : II-B
FOR SECTION : D
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
SHEET : 1 OF 4
1.0 INTENT OF SPECIFIATION
The specification covers the design, materials, constructional features, manufacture, inspection and
testing at manufacturer’s 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.
Motors shall fully comply with latest edition, including all amendments and revision, of following
codes and standards:
IS:325 Three phase Induction motors

IS : 900 Code of practice for installation and maintenance of induction motors
IS: 996 Single phase small AC and universal motors
IS: 4722 Rotating Electrical machines
IS: 4691 Degree of Protection provided by enclosures for rotating electrical machines
IS: 4728 Terminal marking and direction of rotation rotating electrical machines
IS: 1231 Dimensions of three phase foot mounted induction motors
IS: 8789 Values of performance characteristics for three phase induction motors
IS: 13555 Guide for selection and application of 3-phase A.C. induction motors for
different types of driven equipment
IS: 2148 Flame proof enclosures for electrical appliance
IS: 5571 Guide for selection of electrical equipment for hazardous areas
IS: 12824 Type of duty and classes of rating assigned
IS: 12802 Temperature rise measurement for rotating electrical machnines
IS: 12065 Permissible limits of noise level for rotating electrical machines
IS: 12075 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.
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REV NO. : 00 DATE : 29/08/2005
LV MOTORS
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.
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VOLUME NO. : II-B
FOR SECTION : D
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
SHEET : 3 OF 4
4.4. Motors shall not be provided with any electric or pneumatic operated external fan for cooling the
motors.
4.5 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 10°C.
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 Page 468 of 680

VOLUME NO. : II-B
FOR SECTION : D
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
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-Q-
007/2 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) OGA drawing showing the position of terminal boxes, earthing connections etc.
b) Arrangement drawing of terminal boxes.
c) Characteristic curves:
(To be given for motor above 55 kW unless otherwise specified in Data Sheet).
i) Current vs. time at rated voltage and minimum starting voltage.

ii) Speed vs. time at rated voltage and minimum starting voltage.
iii) 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.
iv) Thermal withstand curve under hot and cold conditions at rated
voltage and max. permissible voltage.
Page 469 of 680

Page 470 of 680

Doc. No. PE-DC-412-565-E003

2 x 660 MW ENNORE SEZ STPP
Rev. No. 01
BASIC TECHNICAL FEATURES
FOR HT / LT MOTORS Dated 13-03-2015
`
(FOR BHEL-PEM SCOPE PACKAGES)
Page 2 of 7
1.0 This document covers the basic technical features of high tension (HT) and low tension (LT) squirrel
cage induction AC motors employed for driving auxiliaries of BHEL-PEM scope packages in 2 x 660
MW ENNORE SEZ STPP.
The motors shall generally conform to IS 325/IEC-60034. LT motors above 10 kW with

continuous duty (S1) shall be energy efficient IE2 conforming to IS-12615: 2011.
3.0 DESIGN REQUIREMENTS
3.1 General Requirements
The design ambient temperature shall be 50 deg C.
3.2 Supply system and rated voltage of motors

KW rating Supply system Rated voltage of motor
Above 1500 kW 11 KV 11 KV
Above 160 kW up to & 3.3 KV 3.3 KV
including 1500 kW
From 200W up to & including 415 V 415 V
160 kW
Below 200W 240V 240V
3.2.1 Supply voltage & variations shall be as follows:-
Voltage variation (AC Supply) (+/-) 10%

Frequency variation (+) 3% to (-) 5%
Combined V & F variation 10% (sum of absolute values)
3.2.2 Motors shall be capable of running continuously at rated output for each of the conditions specified.
3.3 Motor Rating
Motor ratings shall be adequate to meet the requirements of the drive equipment. Motors shall be
continuously rated at the design ambient temperature of 50 degree C and relative humidity of 85%.
Maximum continuous motor ratings shall have at least a 10% margin above the maximum load demand
of the driven equipment under entire operating range including voltage & frequency variation.
3.4 Starting Requirements
3.4.1 Motor shall start smoothly and rapidly. 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% of the motor’s
full load torque.
Page 471 of 680

Doc. No. PE-DC-412-565-E003

Rev. No. 01
`
Page 3 of 7
3.4.2 Motors shall be capable of starting and accelerating the load with direct on line starting without
exceeding acceptable winding temperature.
Minimum Starting Voltage requirement for all motors (except mill motors):
2. 80 % of rated voltage for above 1000 kW and up to 4000 kW
3. 75 % of rated voltage for above 4000 kW
3.4.3 The locked rotor current of the HV (11 kV) motors (except MDBFP motors) shall not exceed 650% of
full load current inclusive of tolerance as per IS: 325 and for MV (3.3 kV) motors locked rotor current
shall not exceed 700% of full load current inclusive of tolerance as per IS: 325. For LT motors (except
energy efficient motors) locked rotor current shall not exceed 700% of full load current inclusive of
tolerance as per IS: 325. For LT energy efficient motors above 10kW with S1 duty, locked rotor current
shall be as per IS: 12615-2011.
3.4.4 The following frequency of starts shall apply to HV (11 kV), MV (3.3 kV) & LT motors
i) Two nos. consecutive cold starts in quick succession with third start after 5 minutes in cold
condition.
ii) Two nos. consecutive hot starts in the interval of 15 minutes in hot condition.
3.4.5 Locked motor withstand time of motors under hot condition at highest voltage limit shall be as follows:
a) For motors with starting time up to 20 sec.
- at least 2.5 sec. more than starting time.
b) For motor with starting time above 20 secs but not exceeding 45 secs.
- at least 5.0 sec. more than starting time.
c) For motors with starting time above 45 secs.
- at least 10% more than starting time.
The starting time of the motor referred above is at minimum permissible voltage. For motors and in
cases where the above requirements are not complied with, speed switches of approved make & type
shall be provided to bypass the locked rotor protection for a pre-selected time during starting of motors.
The speed switches shall have one NO & one NC contacts having maximum interrupting capacity of 5
Amps at 240V AC and 0.25 amps at 220 V DC.
3.5 Running Requirements
3.5.1 Motors shall run satisfactorily at a supply voltage of 80% of rated voltage for 5 minutes with full load
without injurious heating to the motor.
3.5.2 Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall be 275% for
crane duty motors.
Page 472 of 680

Doc. No. PE-DC-412-565-E003

Rev. No. 01
`
Page 4 of 7
3.6 Stress during bus Transfer
3.6.1 Motors shall withstand the voltage 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.
3.6.2 Motor windings shall be adequately braced to satisfactorily withstand the mech. Stresses during above
condition.
3.6.3 Motors shall be capable of withstanding heavy in-rush transient current caused by bus transfer without
damage.
3.6.4 Motor and driven eqpt. Shafts shall be adequately sized to satisfactorily withstand transient torque
under above condition.
3.7 Noise level
The maximum noise level for motors shall be in line with IS 12065.
3.8 Vibration
The maximum vibration for motors shall be in line with IS: 12075.
4.0 CONSTRUCTIONAL FEATURES
4.1 Degree of Protection
4.1.1 Indoor motors shall conform to degree of protection IP: 54 as per IS: 4691. Outdoor motors shall
conform to degree of protection IP: 55 as per IS: 4691 and shall be of weather-proof construction.
Canopy shall be provided for outdoor motors. CW motors (in case of screen prot. Drip proof) shall
conform to degree of protection IP: 23 as per IS: 4691. The degree of protection for terminal boxes
shall be IP 55 for outdoor area & IP 54 for indoor area as per IS 4691.
4.1.2 The stator laminations shall made from suitable silicon steel/magnetic steel sheet varnished on both
sides and pressed to form a rigid core.
4.1.3 The rotor shall be of rigid cage construction with die cast aluminium / copper alloy / copper bars firmly
wedged in bar slots and brazed to the end rings. The rotor cage shall be designed to operate
satisfactorily under respective starting and load duty cycle.
4.2 Enclosure and Cooling
4.2.1 Motors shall generally have totally enclosed fan cooled (TEFC) or totally enclosed tube ventilated
(TETV) enclosures or Closed Air circuit Air (CACA), the method of cooling conforming to IC-0141 or
IC-0151 or IC-0161 of IS: 6362 up to 3000 kW motor. CW Motors may be screen protected drip proof
(SPDP).
Page 473 of 680

Doc. No. PE-DC-412-565-E003

Rev. No. 01
`
Page 5 of 7
4.2.2 Motors shall not be provided with any electric or pneumatic operated external fan for cooling the
motors.
4.2.3 Frames shall be designed to avoid collection of moisture and all enclosures shall be provided with
facility for drainage at the lowest point.
4.3 Class of Insulation
HV/MV/LT motors shall have class F insulation. The temperature rise of all motors shall be limited to
the limits applicable to Class ‘B’ insulation. In case of continuous operation at extreme voltage limits,
10deg C rise above the temperature limits specified in IS: 325 shall be permissible.
4.4 Bearings
4.4.1 Horizontally mounted motors shall have grease lubricated ball/roller or sleeve bearings. For HV/MV
motors, the bearings shall be regreasable type and for LV motors, these bearings can be either sealed
life lubricated type or regreasable type as per manufacturer’s standard.
4.4.2 The vertical motors shall have a combined thrust and guide bearing on top and guide bearing at bottom.
If the ball or roller bearings can take vertical thrust, thrust and guide bearing need not be provided.
4.4.3 After taking all motor driven equipment loads and thrust (if any) into account, the bearings shall be
suitable for min. 20,000 working hours. Re-greasable bearings shall be provided with grease nipples
and relief holes for on-line re-greasing and shall be suitable for 8000 working hours without changing
of the grease.
4.4.4 The bearings of solidly coupled motors shall be of the same type as those of the driven equipment.
4.4.5 For motors below 15 kW shall be provided with sealed ZZ bearing.
4.4.6 Motors rated above 1000kW shall be provided with insulated end shield on non-driving end to prevent
flow of shaft current.
4.5 Terminals and Terminal Boxes
4.5.1 Motors of rating 90 kW and up to 160kW will be controlled by air circuit breaker with numerical
protection. For all motors of rating up to 90kW shall be provided with MCCBs. The terminal box of
motors for HV (11 kV), MV (3.3 kV) & LT motors shall be designed for the maximum fault current for
a duration of at least 0.25 secs.
4.5.2 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.
4.5.3 For HV/MV motors, the main terminal box shall be of phase-segregated type with clamping
arrangement for the terminals.
4.5.4 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 V, W & U respectively.
Page 474 of 680
Doc. No. PE-DC-412-565-E003

Rev. No. 01
`
Page 6 of 7
4.5.5 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.
4.5.6 Motor terminals and terminal leads shall be fully insulated with no bar live parts.
4.5.7 Separate terminal boxes shall be provided for space heaters and temp. Indicators. If this is not possible
in case of LT motors, the space heater terminals shall be adequately segregated from the main terminals
in the main terminal box. Detachable gland plates of thickness 3 mm (hot/cold rolled sheet steel) or 4
mm (non-magnetic material for single core cables) with double compression tinned brass glands shall
be provided in terminal boxes.
4.5.8 Phase terminal boxes shall be suitable for 360 degree of rotation in steps of 180 and 90 degree for HT
and LT motors respectively.
4.5.9 Cable glands and cable lugs as per selected cable sizes shall be provided in line with cable erection
philosophy. For single core cable termination, gland plates shall be of non-magnetic material.
4.6 Grounding
Two separate earthing terminals suitable for connecting G.I. strip grounding conductor shall be
provided on opposite sides of motor frame. Each terminal box shall have a grounding terminal.
4.7 General
4.7.1 Motors provided for similar drives shall be interchangeable.
4.7.2 An arrow block shall be screwed on the body of the motors on the non-driving end to indicate the
direction of rotation of the motors.
4.7.3 Motors for Fuel oil unloading and drain oil pumps located in hazardous areas shall be with flame-proof
enclosures in accordance with IS 2148 / IEC 60079.
a) Fuel oil area: Group - IIB.
b) Hydrogen generation plant area: Group - IIC
5.0 ACCESSORIES
5.1 SPACE HEATERS
All motors rated 30KW and above shall be provided with space heaters to maintain the motor internal
air temperature above the dew point. Space heaters shall be suitable for a supply of 240V AC, single
phase, 50 Hz.
The leads from space heaters of each motor shall be brought out to a separate terminal Box. Space
heaters shall be mounted inside the motor in accessible places so that their removal and replacement is
simple.
Page 475 of 680

Doc. No. PE-DC-412-565-E003

Rev. No. 01
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Page 7 of 7
5.2 RESISTANCE TEMPERATURE DETECTORS (RTDs)
5.2.1 HV/MV motors stator windings shall be provided with 12 nos. Simplex 3 wire Platinum RTDs with
100 ohms resistance at 0 deg C for remote monitoring of winding temperature. The leads from RTDs of
each motor shall be brought out to a separate terminal Box.
5.2.2 For HV/MV motors, each bearing shall be provided with 1 no. Duplex 3 wire Platinum RTDs with 100
ohms resistance at 0 deg C for remote monitoring of bearing temperature. The leads from these RTDs
shall be brought out to a separate terminal Box or the terminal box same as for winding RTDs.
5.3 DIAL TYPE TEMP. INDICATORS
5.3.1 For HV/MV motors, each bearing shall be provided with dial type thermometer with adjustable alarm
contact and resistance type temperature detector. The indicators shall have 2 nos. NO contacts rated for
5A, 240 V AC and 0.5 A, 220 V DC for alarm/trip purpose.
5.4 Vibration monitoring pads
5.4.1 Provision shall be made in all HV/MV motors for mounting vibration detectors.
6.0 NAME PLATE
Motors shall have stainless steel name plate with all particulars as per IS: 325. In addition bearing
identification number and type of lubricant is to be indicated.
7.0 PAINTING
Motor including fan shall be painted with corrosion proof paints of colour shade Siemens grey (RAL
7032).
8.0 TESTING
8.1 Type Tests
For HT & LT Motors, type test reports for type tests as per IS: 325/ IS: 12615 conducted on equipment
similar to those proposed to be supplied and carried out within last five years shall be submitted.
However, if such reports are not available, one motor of each type shall be subjected to type tests for
free of cost.
8.2 Routine Tests
All motors shall be subjected to routine tests as per IS: 325/ IS: 12615 in the presence of customer or
customer representative.
Page 476 of 680

SPECIFIC ELECTRICAL REQUIREMENT
SL.NO. PARAMETERS UNIT ENNORE

MOTOR
1 DESIGN AMBIENT TEMP DEG. C 50
2 VOLTAGE SUPPLY AND VARIATION VOLT 415V, + 10%
3 FREQUENCY WITH VARIATION Hz 50 (+) 3% to (‐) 5%
COMBINED VOLTAGE & FREQUENCY
4 10%
VARIATION
MAX ACCEPTABLE RATING OF
5 KW 160 kW
MOTOR AT 415 V
SYSTEM FAULT LEVEL AND ITS
6 KA 50 KA, 1 Sec
DUARTION
SUTABILITY OF TERMINAL BOX FOR
7 50 KA, 0.25 sec
FAULT LEVEL AND DURATION
CLASS OF INSULATION & TEMP RISE
8 Class-F and temp rise limited to Class-B
LIMITED TO
9 MIN. STARTING VOLTAGE 85%
MOTOR RATING FOR SINGLE PHASE
10 Upto 200W
SUPPLY
For LT motors (except energy efficient motors)
locked rotor current shall not exceed 700% of full
MAXIMUM LOCKED ROTOR % OF load current inclusive of tolerance as per IS: 325.
11
CURRENT FLC For LT energy efficient motors above 10kW with
S1 duty, locked rotor current shall be as per IS:
12615-2011.
12 ACCEPTABLE NOISE LEVEL DB 85dB at 1.0m in line with IS 12065
TYPE OF STARTER PROVIDED IN
13 N.A.
MCC
Indoor motors shall conform to degree of
protection IP: 54 as per IS: 4691. Outdoor motors
shall
conform to degree of protection IP: 55 as per IS:
14 DOP OF ENCLOSURE 4691 and shall be of weather-proof construction.
The degree of protection for terminal boxes shall
be IP 55 for outdoor area & IP 54 for indoor area
as
per IS 4691.
15 SPACE HEATER REQUIREMENT 30KW & ABOVE
16 PAINT SHADE Shall be confirmed during detailed engineering.
For HT & LT Motors, type test reports for type
tests as per IS: 325/ IS: 12615 conducted on
equipment similar to those proposed to be
supplied and carried out within last five years shall
be submitted. However, if such reports are not
available, one motor of each type shall be
17 SPECIAL REQUIREMENT subjected to type tests for free of cost.
All motors shall be subjected to routine tests as

per IS: 325 / IS: 12615.
The motors shall generally conform to IS: 325 /

IEC-60034.
Page 477 of 680

MOTOR VOLUME II B
SECTION D
DATA SHEET - C REV NO. 00 DATE 19/06/2015
SHEET 1 OF 2
S. Description Data to be filled by successful

No. bidder
A. General
1 Manufacturer & country of origin
2 Motor type
3 Type of starting
4 Name of the equipment driven by motor & Quantity
5 Maximum Power requirement of driven equipment
6 Rated speed of Driven Equipment
7 Design ambient temperature
B. Design and Performance Data
1 Frame size & type designation
2 Type of duty
3 Rated Voltage
4 Permissible variation for
5 a Voltage
6 b Frequency
7 c) Combined voltage & frequency
8 Rated output at design ambient temp (by resistance method)
9 Synchronous speed & Rated slip
10 Minimum permissible starting voltage
11 Starting time in sec with mechanism coupled
12 a) At rated voltage
13 b) At min starting voltage
14 Locked rotor current as percentage of FLC (including IS tolerance)
15 Torque
a) Starting
b) Maximum
16 Permissible temp rise at rated output over ambient temp & method
17 Noise level at 1.0 m (dB
18 Amplitude of vibration
19 Efficiency & P.F. at rated voltage & frequency
a) At 100% load
c) At 75% load
NAME OF VENDOR
REV.
NAME SIGNATURE DATE SEAL
Page 478 of 680

MOTOR VOLUME II B
SECTION D
DATA SHEET - C REV NO. 00 DATE 19/06/2015
SHEET 2 OF 2
S. Description Data to be filled by successful

No. bidder
c) At starting
C. Constructional Features
1 Method of connection of motor driven equipment
2 Applicable Standard
3 DOP of Enclosure
4 Method of cooling
5 Class of insulation
6 Main terminal box
a) Type
b) Power Cable details (Conductor, size, armour/unarmour)
c) Cable Gland & lugs details (Size, type & material)
d) Permissible Fault level ( kArms & duration in sec)
7 Space heater details (Voltage & watts)
8 Flame proof motor details (if applicable)
a) Enclosure
b) suitability for hazardous area
i Zone O / I / II
ii Group IIA / IIB / IIC
9 No. of Stator winding
10 Winding connection
11 Kind of rotor winding
12 Kind of bearings
13 Direction of rotation when viewed from NDE
14 Paint Shade & type
15 Net weight of motor
16 Outline mounting drawing No (To be enclosed as annexure)
D. Characteristic curves/ drawings
(To be enclosed for motors of rating  55KW)
a) Torque speed characteristic
b) Thermal withstand characteristic
c) Current vs time
d) Speed vs time
NAME OF VENDOR
REV.
NAME SIGNATURE DATE SEAL
Page 479 of 680

Explanatory notes for filling up cable list for routing through Win Path, the cable routing
program (developed by Corporate R&D) being used in PEM.
1. For the purpose of clarity, it may please be noted that the information given in regard to the cables
to be routed through WinPath as per the system elaborated below is called “Cable List”, while the
term “Cable Schedule” applies to the cable list with routing information added after routing has
been carried out.
2. The cable list shall be entered as an MS Excel file in the format as per enclosed template
EXT_CAB_SCH_FORMAT.XLS. No blank lines, special characters, header, footer, lines, etc. shall
be introduced in the file. No changes shall be made in the title line (first line) of the template.
3. The field properties shall be as under:
a. UNITCABLENO: A/N, up to sixteen (16) characters; each cable shall have its own unique,
unduplicated cable number. In case this rule is violated, the cable cannot be taken up for
routing.
b. FROM: A/N, up to sixty (60) characters; the “From” end equipment/ device description and
location to be specified here. Information in excess of 60 characters will be truncated after
60 characters.
c. TO: A/N, up to sixty (60) characters; the “To” end equipment/ device description and
location to be specified here. Information in excess of 60 characters will be truncated after
60 characters.
d. PURPOSE: A/N, up to sixty (60) characters; the purpose (i.e. power cable/ indication/
measurement, etc.) to be specified here. Information in excess of 60 characters will be
truncated after 60 characters.
e. REMARKS: A/N, up to forty (40) characters; Any information pertinent to routing to be
specified here (e.g., cable number of the cable redundant to the cable number being
entered). Information in excess of 40 characters will be truncated after 40 characters.
f. CABLESIZE: A/N, 7 characters exactly as per the codes indicated below shall be specified
here. The program cannot route cables described in any other way/ format.
g. PATHCABLENO: Field reserved for utilization by the program. User shall not enter any
information here.
4. One list shall be prepared for each system/ equipment (i.e., separate and unique cable lists shall
be prepared for each system).
5. The cables shall be described as per the scheme listed below:
A NN A NNN
| | | |
Cable No. of cores Cable code Cable size
Voltage (e.g. 01,03,3H, 07) (See C below) (e.g. 035,185,2.5, 0.5)
Code (see B
below)
(A) SYSTEM VOLTAGE CODES:

(ac) A = 11KV, B = 6.6KV, C = 3.3KV, D = 415V, E = 240V, F = 110V
(dc) G = 220V, H = 110V, J = 48V, K = +24V, L = -24V
(B) CABLE VOLTAGE CODES:

A = 11KV (Power cables)
B = 6.6KV (Power cables)
C = 3.3KV (Power cables)
D = 1.1KV (LV & DC system power & control cables)
E = 0.6KV (0.5 sq. mm. Control cables)
Page 480 of 680


(C) CABLE CODES
PVC Copper
A = Armoured FRLS B = Armoured Non-FRLS
C = unarmoured FRLS D = Unarmoured Non-FRLS
PVC Aluminium
E = Armoured FRLS F = Armoured Non-FRLS
G = unarmoured FRLS H = Unarmoured Non-FRLS
XLPE Copper
J = Armoured FRLS K = Armoured Non-FRLS
L = unarmoured FRLS M = Unarmoured Non-FRLS
XLPE Aluminium
N = Armoured FRLS P = Armoured Non-FRLS
Q = unarmoured FRLS R = Unarmoured Non-FRLS
S = FIRE SURVIVAL CABLES

T = TOUGH RUBBER SHEATH
U = OVERALL SCREENED
V = PAIRED OVERALL SCREENED
W = PAIRED INDIVIDUAL SCREENED
Y = COMPENSATING CABLES
I = PRE-FABRICATED CABLES
Z = JELLY FILLED CABLES
Page 481 of 680


SECTION – D3
CONTROL AND INSTRUMENTATION
Page 482 of 680

C&I SPECIFICATION
FOR
FOR
2X660 MW ENNORE SEZ STPP
DESIGN KT
CHECKED SK
APPROVED SCS
REV- 00 DATE 15.06.15
JOB NO. 412
Page 483 of 680

TABLE OF CONTENTS
B. List of vendor deliverables for C&I for CPU Plant

C. Specification for motorized valve actuator
D. Specification for field instruments
E. Specification for PLC
F. Specification for UPS
G. Specification for Control panels
H. Drive control philosophy
I. Applicable codes and standards
J. Specification for Quality assurance & Testing
L. Drawings
M. Erection Hardware
Page 484 of 680

B. C&I DELIVERABLES
Page 485 of 680

LIST OF DELIVERABLES OF PEM ‐ C&I DEPARTMENT FOR CONDENSATE POLISHING UNIT

2X660MW ENNORE SEZ TPP
Sl.No. DRAWING NO. DRAWING/DOCUMENT TITLE CATEGORY CUSTOMER FROM USER REMARKS
INSTRUMENTATION
1 PE‐V9‐412‐155‐I901 INSTRUMENT DATA SHEETS A ‐ VENDOR C&I
2 PE‐V9‐412‐155‐I902 INSTRUMENT SCHEDULE I ‐ VENDOR C&I
3 PE‐V9‐412‐155‐I903 INSTRUMENT INSTALLATION/ HOOK UP DIAGRAMS A ‐ VENDOR C&I
4 PE‐V9‐412‐155‐I904 FIELD JB TERMINATIONS /GROUPING DOCUMENT I ‐ VENDOR C&I
5 PE‐V9‐412‐155‐I905 QUALITY PLANS (CV,FE, Tx and Analyser) A ‐ VENDOR C&I
PLC PANEL
1 PE‐V9‐412‐155‐I906 PLC CONFIGURATION DRAWING A A VENDOR C&I
2 PE‐V9‐412‐155‐I907 PLC PANEL GA (INTERNAL & EXTERNAL) DRAWING A ‐ VENDOR C&I
3 PE‐V9‐412‐155‐I908 CONTROL SCHEMES (BLOCK LOGIC) A ‐ VENDOR C&I
4 PE‐V9‐412‐155‐I909 PLC INPUT / OUTPUT SIGNAL LIST I ‐ VENDOR C&I
5 PE‐V9‐412‐155‐I910 UPS BATTERY CHARGER/ BATTERY DATASHEET & SLD I $$ VENDOR C&I
6 PE‐V9‐412‐155‐I911 UPS SIZING CALCULATIONS I ‐ VENDOR C&I
7 PE‐V9‐412‐155‐I912 BATTERY SIZING CALCULATIONS I ‐ VENDOR C&I
8 PE‐V9‐412‐155‐I913 CONTROL DESK LAYOUT / GA DRAWING A ‐ VENDOR C&I
9 PE‐V9‐412‐155‐I914 PLC‐OWS/PRINTER FURNITURE BOM A ‐ VENDOR C&I
10 PE‐V9‐412‐155‐I915 PLC CONTROL ROOM LAYOUT DRAWING A ‐ VENDOR C&I
11 PE‐V9‐412‐155‐I916 PLC CATALOGUE I ‐ VENDOR C&I
12 PE‐V9‐412‐155‐I917 PLC QUALITY PLAN & FAT PROCEDURE A ‐ VENDOR C&I
LIST OF SIGNAL EXCHANGE WITH DDCMIS (BOTH HARDWIRED & SERIAL
13 PE‐V9‐412‐155‐I918 A ` VENDOR C&I
INTERFACE IN BHEL FORMAT)
14 PE‐V9‐412‐155‐I919 PROCESS GRAPHIC MANUSCRIPTS PLC I ‐ VENDOR C&I
15 PE‐V9‐412‐155‐I920 PROCESS GRAPHIC MANUSCRIPTS FOR DDCMIS I ‐ VENDOR C&I
CABLE SCHEDULE (IN BHEL EXCEL FORMAT) & CABLE INTERCONNECTION
16 PE‐V9‐412‐155‐I921 I ‐ VENDOR C&I
DETAILS
17 PE‐V9‐412‐155‐I923 PANEL & ELECTRONIC EARTHING REQUIREMENT I ‐ VENDOR C&I
18 PE‐V9‐412‐155‐I924 PANEL HEAT DISSIPATION DATA I ‐ VENDOR C&I
19 PE‐V9‐412‐155‐I925 MANDATORY SPARES BILL OF MATERIAL A A VENDOR C&I
20 PE‐V9‐412‐155‐I926 PLC O & M MANUAL I ‐ VENDOR C&I
21 PE‐V9‐412‐155‐I927 PLC EARTHING SCHEME I ‐ VENDOR C&I
Notes: 412 ‐ Project No.
155 ‐SI No of MAX Package (CPU)
$$ ‐Approval by BHEL if Vendor BBU Item Approval by Customer if Customer BBU Item
Documents of C&I System shall be submitted to end user/owner for approval during detail engineering. Changes, if any, shall
Page 486 of 680
be accommodated by the bidder without any price/time implication.
C.SPECIFICATION
FOR
MOTORISED
VALVE ACTUATOR
Page 487 of 680

SPECIFICATION NO.: PE-ID-412-145-I902
FORM NO. PEM-6666-0 Data Sheet VOLUME II B
FOR
SECTION D
MOTORISED VALVE ACTUATOR
REV. NO. 00 DATE: 18.05.15
SHEET 1 OF 3
Data Sheet A & B

DATA SHEET-A DATA SHEET-B
(TO BE FILLED BY PURCHASER) (TO BE FILLED-UP BY BIDDER)
* PROJECT 2x 660 MW ENNORE STP

OFFER REFERENCE
* TAG NO. SERVICE
* DUTY  ON / OFF  INCHING
* LINE SIZE (inlet/outlet): MATERIAL
 GLOBE  GATE  REG. GLOBE
* VALVE TYPE
 BUTTERFLY
GENERAL* * OPENING / CLOSING TIME
* WORKING PRESSURE
SHALL BE SUITABLE FOR CONTINUOUS
AMBIENT CONDITION OPERATION UNDER AN AMBIENT TEMP. OF 0-55
DEG C AND RELATIVE HUMIDITY OF 0-95%
VALVE SEAT TEST PRESS BIDDER TO SPECIFY
REQUIRED VALVE TORQUE BIDDER TO SPECIFY
ACTUATOR RATED TORQUE BIDDER TO SPECIFY
CONSTRUCTION TOTALLY ENCLOSED, WEATHER PROOF, IP:68
MECHANICAL POSITION INDICATOR TO BE PROVIDED FOR 0-100% TRAVEL
DOUBLE SHIELDED, GREASE LUBRICATED ANTI-
BEARINGS
FRICTION.
METAL (NOT FIBRE GEARS). SELF-LOCKING TO
GEAR TRAIN FOR
PREVENT DRIFT UNDER TORQUE SWITCH
LIMIT SWITCH/TORQUE SWITCH
CONSTRUCTION SPRING PRESSURE WHEN MOTOR IS DE-
OPERATION
AND SIZING ENERGIZED.
OPEN/CLOSE AT RATED SPEED AGAINST
DESIGNED DIFFERENTIAL PRESSURE AT 85% OF
RATED VOLTAGE. FOR ISOLATING SERVICE
THREE SUCCESSIVE OPEN-CLOSE OPERATIONS
SIZING
OR 15 MINS. WHICHEVER IS HIGHER. FOR
INCHING SERVICE - 150 STARTS/HR MINIMUM &
FOR REGULATING SERVICE - 600 STARTS/HR
MINIMUM.
* REQUIRED  YES  NO
HANDWHEEL * ORIENTATION  TOP MOUNTED  SIDE MOUNTED
*TO DISENGAGE AUTOMATICALLY DURING MOTOR OPERATION.

ACTUATOR MAKE/MODEL BIDDER TO SPECIFY
MOTOR MAKE / MODEL / TYPE / RATING
BIDDER TO SPECIFY
(KW)
SQUIRREL CAGE INDUCTION MOTOR, STARTING
@ MOTOR TYPE CURRENT LIMITED TO SIX TIMES THE RATED
CURRENT-INCLUSIVE OF I.S. TOLERANCE
 ENCLOSED (BIDDER TO CONFIRM)
A:  DRG. NO. 3-V-MISC-24227 R00
B:  DRG. NO. 3-V-MISC-24550 R00
ACTUATOR APPLICABLE WIRING
C:  DRG. NO. 3-V-MISC-24283 R00
DIAGRAM
ELECTRIC D:  DRG. NO. 4-V-MISC-90271 R11
ACTUATOR E:  For Thyristor based Integral starter,
Bidder/Vendor to furnish wiring diagram
COLOUR SHADE  BLUE (RAL 5012)  DURING DETAIL ENGG.
PAINT TYPE (## Refer Notes)  ENAMEL   EPOXY  …….
SHAFT RPM BIDDER TO SPECIFY
OLR SET VALUE BIDDER TO SPECIFY
@ STARTING / FULL LOAD CURRENT BIDDER TO SPECIFY
NO. OF REV FOR FULL TRAVEL BIDDER TO SPECIFY
@ PWR SUPP TO MTR / STARTER 415V, 3PH, AC
TO BE DERIVED FROM THE POWER SUPPLY TO
@ CONTROL VOLTAGE REQUIREMENT
THE STARTER  230 V  110 V
Page 488 of 680

FOR
SECTION D
REV. NO. 00 DATE: 18.05.15
SHEET 2 OF 3
Data Sheet A & B

@ ENCLOSURE CLASS OF MOTOR  IP 68  FLAME PROOF
@ INSULATION CLASS CLASS-F TEMP. RISE LIMITED TO CLASS-B

 THERMOSTAT (3 Nos.,1 IN EACH PHASE)
@ WINDING TEMP PROTECTION
 ---------------------------------------------------------
SINGLE PHASE / WRONG PHASE
REQUIRED
SEQUENCE PROTECTION
INTEGRAL STARTER  REQUIRED  NOT REQUIRED
TYPE OF SWITCHING DEVICE  CONTACTORS  THYRISTORS
TYPE  CONVENTIONAL  SMART (NON-INTRUSIVE)
STEP DOWN CONT. TRANSFORMER  REQUIRED
OPEN / CLOSE PB  REQUIRED  NOT REQUIRED
STOP PB  REQUIRED  NOT REQUIRED
INTEGRAL
STARTER INDICATING LAMPS  REQUIRED  NOT REQUIRED
LOCAL REMOTE S/S REQUIRED  NOT REQUIRED
STATUS CONTACTS FOR MONITORING  REQUIRED  NOT REQUIRED

REQUIRED (MOTOR THERMOSTAT TRIP, O/L
RELAY OPERATED, CONT./POWER SUPPLY
INTEGRAL STARTER DISTURBED
FAILED, PHASE LOSS, S/S IN LOCAL/OFF MODE,
SIGNAL
STOP PB OPTD,TORQUE OPEN/CLOSE CUTOFF)
 INTERPOSING RELAY  OPTO COUPLER

TYPE OF ISOLATING DEVICE
 EITHER
QUANTITY 2 NOs.  3 NOs.
DRIVING VOLTAGE  20.5 – 24V DC  _____________V DC
INTERPOSING DRIVING CURRENT  125mA MAX  _____________mA MAX
RELAY/OPTO  > 192 ohms - <25 k ohms
COUPLER LOAD RESISTANCE
 > _______ohms - < __________ohms
(Applicable for
NO. OF IPR CONTACT(in case of IPR) 2 SETS SILVER PLATED CHANGEOVER CONTACT
integral Starter)
IPR CONTACT VALUE (in case of IPR) 0.5A/220V DC or 8A/ 240V AC
a) FREE WHEELING DIODE AND SELF
RESET TYPE STATUS INDICATOR
IPR FEATURE (in case of IPR)
b) MA NUAL FORCING/ OVERIDING
FACILITY
TORQUE MFR & MODEL NO. BIDDER TO SPECIFY
SWITCH OPEN / CLOSE 1 No. 2Nos. / 1 No. 2Nos
(Not Applicable
CONTACT TYPE 2 NO + 2 NC
for Smart
Actuator) RATING 5A 240V AC AND 0.5A 220V DC
($$ Refer CALIBRATED KNOBS(OPEN&CLOSE TS) REQUIRED FOR SETTING DESIRED TORQUE
Notes) ACCURACY +3% OF SET VALUE
LIMIT SWITCH MFR & MODEL NO. BIDDER TO SPECIFY

(Not Applicable 1 No 1 No.
OPEN : INT : CLOSE 2 Nos. (ADJ.)
2 Nos. 2Nos.
for Smart
Actuator) ($$ CONTACT TYPE 2 NO + 2 NC
Refer Notes) RATING (AC / DC) 5A 240V AC AND 0.5A 220V DC
Page 489 of 680

FOR
SECTION D
REV. NO. 00 DATE: 18.05.15
SHEET 3 OF 3
Data Sheet A & B

POSITION TRANSMITTER (For inching

 REQUIRED  NOT REQUIRED
duty & other specific applications)
MFR & MODEL NO. BIDDER TO SPECIFY
 ELECTRONIC (2 WIRE) R/I CONVERTER

POSITION TYPE
 ELECTRONIC (2 WIRE) CONTACTLESS
TRANSMITTER
SUPPLY  24V DC  ………
OUTPUT  4-20mA
ACCURACY + 1% FS
@SPACE HEATER REQUIRED
SPACE @ POWER SUPPLY (NON INTEGRAL) 230V AC,1 PH.,50 Hz

HEATER @ POWER SUPPLY (INTEGRAL) BIDDER TO SPECIFY
@ RATING
ACTUATOR/MOTOR TERMINAL BOX REQUIRED
ENCL CLASS ACTUATOR/MOTOR T.B. @ IP 68 @………

TERMINAL
BOX @ EARTHING TERMINAL REQUIRED
PLUG & SOCKET(9 PIN) REQUIRED  NOT REQUIRED
(FOR COMMD, LS/TS FEED BACK, PoT)  2 NOS.  ----------------
@ POWER CABLE GLAND SIZE:-----------------------
CABLE GLANDS @ SPACE HEATER CABLE GLAND SIZE:-----------------------

QUANTITY & SIZE :Cable gland suitable for 8Px0.5
OTHER CONTROL CABLE GLANDS
sq mm & 2P x 0.5 sq mm Cable.
TOTAL WEIGHT (ACTUATOR +
WEIGHT BIDDER TO SPECIFY _________________ Kg.
ACCESSORIES)
NOTES:
1. SCOPE: DESIGN, MANUFACTURE, INSPECTION, TESTING AND DELIVERY TO SITE OF ELECTRIC ACTUATOR FOR INCHING OR OPEN / CLOSE DUTY.
2. CODES & STANDARDS: DESIGN AND MATERIALS USED SHALL COMPLY WITH THE RELEVANT LATEST NATIONAL AND INTERNATION STANDARD. AS A MINIMUM,
THE FOLLOWING STANDARDS SHALL BE COMPLIED WITH:
IS-9334, IS-2147, IS-2148, IS-325, IS-2959, IS-4691 AND IS-4722
3. ACTUATOR SHALL HAVE HARDWIRED CONTACTS FOR FOLLOWING SIGNALS (a) ACTUATOR IN LOCAL MODE (b) ACTUATOR IN REMOTE MODE.
4. ACTUATOR SHALL INCLUDE A DIGITAL POSITION INDICATOR WITH A DISPLAY FROM FULLY OPEN TO FULLY CLOSE IN 1% INCREMENTS.
5. BIDDER TO ENSURE AVAILABILITY OF SPARE 1NO + 1NC LIMIT SWITCH & TORQUE SWITCH.
6. SS TAG NAME PLATE SHALL BE PROVIDED.
7. TEMPERATURE RISE SHALL BE RESTRICTED TO 70 DEG. C FOR AMBIENT TEMPERATURE OF 50 DEG C.
8. CABLE GLANDS OF DOUBLE COMPRESSION TYPE, Ni PLATED BRASS MATERIAL SHALL BE PROVIDED.
9. THE TORQUE SWITCHES SHALL BE PROVIDED WITH MECHANICAL LATCHING DEVICE TO PREVENT OPERATION WHEN UNSEATING FROM THE END POSITIONS.
THE LATCHING DEVICE SHALL UNLATCH AS SOON AS THE VALVE LEAVES THE END POSITION. IF SUCH PROVISION IS NOT POSSIBLE, THE TORQUE SWITCHES
SHALL BE BYPASSED BY END-POSITION LIMIT SWITCHES WHICH OPENS ON VALVE LEAVING END POSITION.THESE LIMIT SWITCHES ARE ADDITIONAL TO THE
NUMBER OF LIMIT SWITCHES SPECIFIED ELSEWHERE.
10. THE MOTOR SHALL OPERATE SATISFACTORILY UNDER THE +/- 10% SUPPLY VOLTAGE VARIATION AT RATED FREQUENCY, -5% TO +3% VARIATION IN
FREQUENCY AT RATED SUPPLY VOLTAGE, SIMULTANEOUS VARIATION IN VOLTAGE & FREQUENCY THE SUM OF ABSOLUTE PERCENTAGE NOT EXCEEDING 10%.
11. THE MOTOR SHALL BE SUITABLE FOR DIRECT ON LINE STARTING.
$$ TORQUE SWITCH & LIMIT SWITCH SHALL ACT INDEPENDENT OF EACH OTHER. TANDEM OPERATION IS NOT ACCEPTABLE.
## EPOXY PAINT IS RECOMMENDED FOR COASTAL AREAS.
NOTES* = TO BE FILLED BY MPL (LEAD AGENCY). @= TO BE FILLED BY ES
Page 490 of 680

D.SPECIFICATION
FOR
MEASURING INSTRUMENTS
Page 491 of 680

CHAPTER-3
FIELD AND MEASURING INSTRUMENTS
3.00.00 FIELD & MEASURING INSTRUMENTS (PRIMARY & SECONDARY INSTRUMENTS)
3.01.00 GENERAL REQUIREMENTS
3.01.01 Instruments, co ntrol de vices and ot her eq uipment ac cessories covered under this
specification shall be furnished in accordance with I&C specification sheets and drawings
enclosed herewith and the requirements of all applicable clauses of this specification.
3.01.02 The i nstrumentation an d co ntrol e quipment sh all co nform t o al l appl icable co des and
standards including those referred in Cl. no. 1.08.00 in this Volume. All equipment and
systems shall also fully comply with the design criteria stated in chapter-2 of this part.
3.01.03 The instrumentation/control equipment and acce ssories shall be f rom the latest proven
design for which the performance and high availability have been dem onstrated by
a considerable record of successful operation in power station service for similar
applications. The bidder shall furnish sufficient evidence to fully satisfy the Owner in
this regard.
3.01.04 For pl ug i n type i nstruments, The pl ug & so ckets shall be pol arized t o pr event w rong
connections and hav e f acility f or se cure co upling i n pl ug-in posi tion t o pr event l oose
connections.
Signal/Electrical connection shall be screwed connection with double compression type
Nickel-plated br ass ca ble glands for E xplosion proof ar ea, Fl ame pr oof ar ea and hi gh
vibration prone area.
3.01.05 Every instrument requiring pow er su pply sh all be pr ovided with a pai r of easi ly
replaceable g lass cartridge fuse o f suitable r ating. E very i nstrument shall be pr ovided
with a grounding terminal and shall be suitably connected to the panel grounding bus.
3.01.06 All field instruments shall be weatherproof, drip tight, dust tight and splash proof suitable
for use under outdoor ambient conditions prevalent in the subject plant. All field-mounted
instruments shall be mounted in suitable locations where maximum accessibility for
maintenance is achieved. The enclosures of all electronic instruments shall conform to
IP-65 unless otherwise specified (Explosion proof for NEC article 500, class 1, Division 1
area & f lame proof) and an anti corrosive paint shall be appl ied to the field mounted
enclosures / i nstruments. A ll t he f ield i nstruments shall al so be pr ovided w ith S S t ag
nameplate and doubl e compression t ype N ickel-plated br ass cable gland. Ga skets,
Fasteners, Counter and mating flange shall also be i ncluded wherever required with the
field instruments.
3.02.00 Following m inimum requirement o f field i nstruments sh all be fulfilled by B idder ( In

addition, R edundancy criteria for field instruments shall be as specified el se w here in
specification): -
i. Level switches / pressure switches / flow switches/any other process switches

etc. for OLCS / Alarms / Interlocks / Protection. Pressure switches at inlet, outlet
Page 492 of 680

of individual pumps and discharge header of pumps for protection and auto start /
stop & alarms.
ii. Level switches for sump/tank level high/normal/ low/very low interlocks.
iii. Level T ransmitters (Type as per O wner appr oval) f or open su mp/
tank/bunker/vessel/heaters.
iv. Stand pipes on both side of tank for all level instruments (LT, LS & LG).
v. Flow el ements with f low t ransmitter & Fl ow meter for flow m easurement of
process medium like Steam, Water, Air, Flue Gas, Fuel oil, open ch annel liquid,
solid fuel, ash flow, DM water, Raw water, Instrument and Service air etc. as
decided by owner.
vi. Pressure gauges and t emp. G auges at i nlet and out let o f each hea t ex changer
and cooler.
vii. DPG, DPT & DPS across the filters/strainers.
viii. Tapping points/test points shall be provided.
ix. All primary I nstruments, har dwares & JBs etc used f or m easurement f or HFO,
LDO & Turbine Lube Oil system shall be flame proof (IEC-79.1, Part I). All primary
Instruments, hardwares & JBs etc used for measurement for Hydrogen shall be
intrinsically safe and explosion proof as per NEC article 500, class 1, Division 1
area I.
x. All Thermocouples & RTDs shall be Duplex.
xi. All Field Instruments used in acid or alkaline atmosphere shall be with standard
Anti corrosion coating i.e. the combination of Polyurethane and epoxy resin baked
coating (ANSI/ISA-71.04).
xii. All primary instruments installed at “Minus level or Floor” shall be w ith protection
class of IP 68.
xiii. Transmitters (all type) for monitoring & controls purpose.
xiv Pull co rd, bel t sw ay, z ero sp eed sw itches, e mergency st op P B for co nveyers,
other l imit sw itches, cable g land et c. o f C HP w hich pr oduce sp ark shall be
provided with dust and flame proof enclosure conforming to IS-2148.
xv Lockable Deinterlock switches shall be provided for CHP as per requirement.
xvi Bidder shall provide electronics weighing in motion system as per IS-11547,
hermitically sealed load cell of precision strain gauge type,100% over load
protection of cell and 250% overload protection for the construction; one calibrator
attachment with two weighers.
Page 493 of 680

xvii All field mounted push button, selector switch etc. shall be as per IEC or NEMA 4X
protection.
xviii All limit switch shall be conform to IEC-60947-5-1.
xix At APH, temperature measuring device of different lengths forming grid shall
be provided to have average temperature for variable flow of flue gas, secondary
air and primary air. These temperatures may be connected to nearest remote I/O
panel.
xx. On both left and r ight sides of furnace, separate lines shall be laid and provided
with furnace pr essure t ransmitters hav ing wide r ange than the f urnace
pressure transmitter.
xxi. Temp. Transmitters are envi saged w ith R TD & T hermocouples for monitoring
services/application onl y. H owever any RTD & T hermocouples are use d f or
control, interlock & protection application, same shall be directly wired to
DDCMIS/DCS/PLC using instrumentation & Extension cables respectively.
xxii. As for t he w ater flow/ st eam flow m easurements, necessary f low el ements/
transmitters ar e chose n i n t he pr ocess l ine and suppl ied such t hat t heir
algebric sum mation s hall be m ass bal anced f or cal culating the system
efficiency.
xxiii. Contacts less, electronic 2-wire position transmitters shall be provided for all inching
type motorised valve and dampers.
xxiv. For CW sump level, Raw water reservoir level, Turbine oil tank, coal bunkers, Ash
Silo, LDO/HFO tank, DM water tanks, CS tank, Acid and al kali applications, only
non contact type level transmitters like Acoustic, Ultrasonic, Radar based shall be
provided by bidders as specified in NIT and as approved by owner.
xxv. Considering the type of application, wireless technology to bring signals to

DDCMIS m ay be adopt ed by i nterfacing w ith O PC g ateway t o av oid ca bling for
smart l evel t ransmitters specified abov e at sr . no. xx iv. H owever Wireless
technology as adopted by Bidder shall be reliable and field proven in power plants
and same shall be approved by Owner.
xxvi. For Turbine oil, HFO/LDO applications & H2 Gas application, zener protection on
power supplies shall be included.
xxvii. Where t he pr ocess fluids are co rrosive, v iscous, so lid bear ing or sl urry t ype,
diaphragm se als sh all be pr ovided. P arts below t he di aphragm shall be
removable for cl eaning. The ent ire v olume a bove t he di aphragm s hall be
completely f illed w ith an i nert l iquid su itable for the appl ication. For H FO, LF O
Applications, SS capillary with thin wafer element with ANSI RF flanged ends are
to be provided. For hazardous area, explosions proof enclosure as described in
NEC article 500 shall be provided.
FIELD INSTRUMENTS SHALL BE SUPPLIED & OFFERED AS PER DATA SHEETS SPECIFIED BELOW:
Page 494 of 680

3.03.00 TRANSMITTERS, SWITCHES, GAUGES AND PANEL MOUNTED INSTRUMENTS
3.03.01 Pressure, Differential Pressure, DP type Level and F low Transmitters (PT, DPT, LT
& FT)
Smart Transmitters of the electronic type shall be furnished.
All Transmitter shall be i nstalled in closed LIE in the boiler area. Similarly transmitter for
TG shall also be in LIE except the transmitters located in covered area on T G floor and
these shall be mounted in LIR.
Transmitters shall be equipped with m ounting br ackets suitable f or a m ounting in

transmitter enclosures.
In general, Transmitters are envisaged to be grouped at several places as to be decided

during detailed engg . stage. For this pur pose, su itable enclosures complete with all
tubing, fittings, purge meters, loop cable trays etc. shall be provided.
Type/Construction : Sealed ca pacitance/ I nductance/ S ilicon

resonance type
Material
- Body : Die cast Aluminum with epoxy coating for air
& flue gas
SS316 for other services
- Diaphragm : 316 SS
- Measurement element : Teflon seal
- Valves : Carbon steel for non-corrosive

Applications
SS316 for corrosive applications.
Output signal : 4 to 20 m Amp. DC (Two wires)

HART Compatible
Local Indicator : LCD indicator (5 digit) with scale
of Engg. unit
Overall Accuracy : + 0.04% or better of Span for
BTG package
+ 0.065% o r bet ter of Span for BO P
packages
+ 0.2% or better of span for remote seal type
transmitter.
Turn down ratio : 100:1 in general

Stability : + 0.15% of URL for 5 years.
Response time : 150 msec.
Power supply : 24V DC nominal
Drive capability : 600 Ohms nominal
Enclosure Class : IP-65 (Explosion proof for NEC
Class-1, Division 1 area)
Span and Zero : Locally adjustable, non-interacting
Page 495 of 680

Zero suppression /
elevation : At least 100% of Span
Connection
- Process : 1. Half (1/2) inch NPT (F)

Quarter (1/4) inch NPT
with/without oval flanges
- Electrical : Suitable for Plug in type connection (Both
side of transmitter), unused entry with blind
plug.
Accessories :
- For Absolute Pressure Transmitters: Two (2) valve SS316 manifold

- For Gauge & Vacuum : Three (3) valve SS316 manifold
pressure transmitter
- For DP, level & flow : Five (5) valve SS316 manifold
transmitter
- For oil and corrosive : Separator diaphragm seals
liquids
- For all transmitters : Mounting bracket
Manifold sh ould not be mounted o n t he t ransmitter, Manifold shall be n on i ntegral and

standalone type. Snubbers/Pulsation dampners shall be used where the process media
is unstable for measurement such as the discharge of a pump. Over range protection
shall be used where necessary. The co il sy phons & condensate pots shall be use d
for steam services. Transmitters shall be provided with suitable drain & vent points.
3.03.01.01 Transmitters & ot her H ART based i nstruments sh all be su pplied a long with 3 N os. o f
universal type hand held/portable pressure calibrators. Temperature transmitters shall be
supplied along with 3 Nos. of hand held/portable mV source generators.
3.03.02 PRESSURE SWITCHES (PS) & DIFFERENTIAL PRESSURE SWITCHES (DPS)
Applicable Standards : IS3624 - 1966/ISA-RP-8.1 except as

modified in spec.
Type/Construction : Bourdon/Sealed Diaphragm Piston

Actuated preferable. Indicators with
contacts are not acceptable.
Materials
- Bellows : 316 SS
- Bourdon tube : 316 SS
- Movement : 316 SS
- Enclouser : Die-cast aluminum with stoved
enamel black finish. Epoxy coating
shall be provided for corrosive
atmosphere.
- Protective Diaphragm : Teflon
Page 496 of 680

Accuracy : + One (1) percent or better

Repeatability : + 0.5(half) percent or better
Setting & Differential : Adjustable
Contact
- Number : DPDT /2 SPDT
- Type : Auto reset with internal Adjustable

snap action micro switch
- Rating : 5 Amp, 240V AC / 0.2 Amp, 220V DC
Connection - instrument : Half (1/2) inch NPT Male Process
Electrical : Suitable for Plug in type connection. All the

switches are i nternally co nnected and
brought to the su rface w ith A mphenol
male/female co nnection. C abling need no t
terminated inside the switch. Cable ends are
to be so ldiered i n co nnector and to be
inserted for easy maintenance.
- Over range protection : One Fifty (150) percent of full scale

Enclosure Class : IP-65 or better (Explosion/Flame proof for
NEC Class-1, Division 1 area)
Accessories
- 3 / 5 valve manifold : As applicable for all switches
- Self cleaning type : Pump and compressor
pulsation dampners/Snubber discharge lines
(Material SS316)
- Syphon : For all steam lines
- Protective separating : For fuel oil & corrosive liquid lines.
diaphragm
Mounting : Local (in LIE/LIR for BTG package).
3.03.03 PRESSURE & DIFFERENTIAL PRESSURE GAUGES (PG & DPG)
Applicable standard : IS:3602-1966, IS/3624, ASME B 40.1

Type/Construction
-760 mm to 1.0Kg/cm2 : Bellows/Diaphragm

-Above1.0Kg/cm2 : Bourdon Tube
- Suction side of pumps : Compound gauge
Materials
- Bourdon tube : 316 SS
- Bellows : 316 SS
- Movement : 316 SS
- Case : SS 316/ Die-cast aluminum with stoved
enamel black finish. Epoxy coating
Page 497 of 680

shall be provided for corrosive

atmosphere.
- Protective Diaphragm : Teflon
Dial size : 150mm with shatter proof glass
Scale Details : Graduations in black lines on

white dial, on white dial, 270 Deg.
pointer deflection scale provided with
glass cover. Smallest scale division
shall be one (1) percent of full scale
value or smaller. Pointer stop for all
gauges.
Accuracy : + One (1) percent or better

Connection - Instrument Process : 1/2 inch NPT Male Bottom
Mounting : Local
: 1/2 inch NPT Male (Back entry)
mounted on local gauge board.
Enclosure Class : IP-65 or better (Explosion/Flame proof for
NEC Class-1, Division 1 area)
Accessories
- 3 way needle valve/manifolds : For all gauges

- Self cleaning type : Pump and compressor discharge
Pulsation dampener/snubber (S316) lines
- Syphon : For all steam lines
- Protective separating : For fuel oil and corrosive liquid lines
Other particulars
- External Zero adjustment : For all gauges

- Safety device
Ranges 5 to 20 Kg/cm2 : Rubber blow out disc with open front

construction.
Ranges above 20 Kg/cm2 : Neoprene safety diaphragm at the
back with solid front construction.
- Over range protection : One Fifty (150) percent of full scale
Other Requirments : Movement mechanism shall be

glycerin filled for oil services &
vibration prone area.
: For Fuel oil & corrosive liquid lines

diaphragm type sensors required.
Armored capillary of 10 M for Fuel oil
& Corrosive liquid service.
Page 498 of 680

: Contact type pressure gauges are

not acceptable for interlock &
protection.
: For condensate storage tank the pressure

gauge in terms of0-10000 mm wc or suitable
range having dial size of 300mm or bigger
size shall be provided.
3.03.04 TEMERATURE TRANSMITTERS
Type : SMART type configurable from control

room through HART protocol (HMS
System).
Display type : Indicating type (5 digit LCD Display),
Accuracy : +0.10%,
Ambient temperature error : 0.1% per 10°C change
Output : 4-20 mA DC (2 wire system) HART
compatible signals for analogue
monitoring inputs to the distributed
control system (DDCMIS), DCS & PLC.
Protection class : NEMA 4/IP66 or equivalent degree of
protection for enclosure)/
(Explosion/Flame proof for NEC Class-1, Division 1
area)/ flame proof
(IEC-79.1, Part I). As applicable).
Material of accessories : SS316.
Stability : + 0.1 % or + 0.1 deg C of reading
(whichever is great) for 2 years in
case of RTD inputs and for 1 year in
case of Thermocouples inputs.
Operating Voltage : 16 – 48 V DC
Calibration : as per NIST monograph 125 for T/C &
European Curve Alpha = 0.00385 for
RTD .
Ref. Junction compensation : Provided
Span/zero adjustment : Locally adjustable, Non interacting
Auto calibration : Provided
Burn out protection upscale : Provided
Input - output isolation : Provided
Circuit ungrounded : Provided
Any R TD & T hermocouples shall be di rectly wired t o D DCMIS/DCS/PLC f or m etal

temperature application, bearing & winding temp application only.
The T emperature t ransmitter sh all accept Universal dual i nputs of al l t ypes of

thermocouples & RTD, 0-5V input signals etc.
Page 499 of 680

Temp., Fuel oil temp. measurement

as per IBR rules and regulations
3.03.10 TEST THERMOWELLS (TW)
Applicable Standard : ASME PTC 19.3 TW - 2010

Type/Construction : Machined from Bar Stock
Material : 316 SS/F11/F22/F91
Connection
- Pipe : M33 x 2
- Test Instrument : To suit test instruments

Accessories : Plug with chain
IBR Certification : For high pressure service,
Steam Temp., Fuel oil temp.
measurement as per IBR rules and
regulations
Bidder shall provide calculation
for thermowell as per ASME – PTC-
19.3 TW - 2010.
Test wells shall be pr ovided on m ain steam, reheat steam, extraction steam, feed water,
condensate, spray water lines and other piping as required to meet ASME test require-
ments.
3.03.11 DIRECT MOUNTED LEVEL TRANSMITTERS (LT)
Displacer type level transmitter shall not be used in the process anywhere in the plant.
3.03.12 Ultrasonic Level Transmitter (for Water sump/Tank level, Raw water reservoir level,
Cooling water fore bay level measurements)
Principle of Operation : Detection of reflected ultrasonic pulse

Measuring Ranges : Up to 30 meters (typical)
Signal Processing : Microprocessor Controlled Signal Processing
Operating Freq. : 10 KHz to 50 KHz (typical)
Display : Head mounted alpha-numeric back lit
LCD/LED
Calibration & Configuration : Accessible from front of panel & HART calibrator.
Diagnosis : On-line
Status : For power, Hi / Lo / V. Hi / V. Lo-
level indication, fault etc.
Construction : Plug-on board
Power supply : 240 V AC 50 Hz / 24V DC
Signal Output : 4-20 mA DC with HART (isolated) - 600 Ohm load.
Hysteresis : Fully adjustable preferred
Output contacts : 2SPDT Potential free changeover
contacts @ 8A 230V AC.
Accuracy & Repeatability : + 0.25% of span or better
Resolution : + 0.1% of span
Temperature Compensation: To be provided with Transducer.
Page 500 of 680

Operating temp. : Transmitter-50 deg C and Sensor – 80 deg C

MOC Sensor : Body- PVDF and Face – Polyurethene
Humidity : 1% to 95% non condensing.
Enclosure : IP-67 Epoxy painted die cast
Aluminum or SS316L housing.
Cable Connection : 3/4" ET
Mounting : 2” – 4” NPT or flanged
Accessories : Cable gland, prefab cable,
mounting accessories like EPDM seal, SS316
flanged etc.
Additional separate local display unit with large
Alphanumeric back light LCD/LED & to be provided
for the applications which will be decided during
3.03.13 CAPACITANCE TYPE LEVEL TRANSMITTER
The total system shall consist of capacitance probe, pre-amplifier and transmitter
Type : Capacitance type

Probe : a) Rod or suspended electrode.
b) Rope type probes may be used only where
required probe length is greater than 3 meters
Probe Mounting : Stainless steel 1-1/2 ANSI RF Flange / ¾“ NPT (M)
Material of construction : 316 SS

Insulation : PTFE Part/Full as per service.
Transmitter : The transmitter shall receive output of the preamplifier
and convert it into 4-20 mA DC output signal.
Accuracy : + 1% of Full scale
Repeatability : + 0.5 % of Full scale
Load : Min 600 Ohms

Enclosure : Powder/Epoxy coated Die cast aluminum. with
neoprene gasket conforming to IP-65. (Explosion
proof for NEC Class-1, Division 1 area).
Ambient temperature : 0-60 ºC.
Mounting : Wall / Surface
Supply voltage : 240V AC, 50Hz / 24V DC
Response time : 100 m sec or better
Cable connection : ¾” ET
Accessories : Counter flange, Cable gland, prefab cable if any
Preferable features : Alarm output contacts with adjustable set point facility
3.03.14 GUIDED WAVE RADAR/RADAR LEVEL TRANSMITTER (FOR ACID SERVICES)
Type : Guided wave Radar (Contact

type)/Radar (Non contact type) as finalized by owner.
Application : For Turbine Lube oil tank, HFO & LDO tank level,
Page 501 of 680

Output Signal : Pulse

Material of Construction : AISI 316
Sensor Seal : PTFE / higher based on temperature
Flow range : As required.
Linearity : 0.25% or better.
Repeatability : 0.02% or better.
Ambient temperature : 50 deg C
Mounting : On-Line mounting with flanges of stainless
steel.
Enclosure : IP 65
Accessories : Nuts, bolts, gaskets etc.
Transmitter
Electronics : Solid State
Power Supply : 240V AC, 50Hz. UPS
Input : Input from Sensor
Display : 4 1/2 digit LCD
Output : Isolated 4-20mA DC HART
Measuring Accuracy : 0.5% of full scale range
Totalized Value : Required
Housing : IP-65 (Explosion proof for NEC Class-1,
Division 1 area)
Nameplate : Tag number, service engraved in stainless
steel tag plate
Accessories : Clamping strip, bracket, prefab cable etc.
Special tool kit for calibration/ configuration .
3.03.23 Flow Transmitter (Ultrasonic)
Type : ULTRA SONIC, 2-wired

Sensing element : Non-contact
Output : 4-20mA with HART Protocol
Accuracy : + 0.1% FS
Supply : 24 V DC
Enclosure class : IP-65
Transmitter
Mounting : On Nozzle
Mounting position : Top mounted
Housing : Plastic
Display : Head mounted LCD Display and remote LCD
display
Process connection : NPT/Flanged
Electrical connection : NPT
Turn Down ratio : 1:100
Measuring range : Adjustable (as per process requirement)
Totaliser : Required
Accessories : As per process requirement
Additional separate local display unit with large
Alphanumeric back light LCD/LED & to be provided
for the applications which will be decided during
Page 502 of 680

3.03.24 Positive Displacement Flow Transmitter
Positive di splacement flow t ransmitters shall be o ffered. A n el ectronic totalizer sh all be

provided for each flowmeter and t he location of the totalizers shall be ac ceptable to the
Owner. Air eliminators shall also be provided to ensure maximum accuracy.
Type : Hall Effect Sensor
Body Material : AISI 316L/Die Cast Aluminium.
Wetted part Material : AISI 316L/Die Cast Aluminium.

(Like Piston, Bearing, gear
etc)
O ring material : PTFE / higher based on temperature
Flow range : As required.
Accuracy : + 0.5% or better of reading
Repeatability : + 0.03% or better.
Ambient temperature : 50 deg C
Mounting : On-Line mounting with flanges of

stainless steel.
Electronics : Solid State
Power Supply : 230V AC, 50Hz. UPS
Display : 4 1/2 digit LCD for Flow rate &

totalized value.
Output : Isolated 4-20mA DC
Turn Down ratio : 1:30
Totalized Value : Required
Housing : IP-65/ (Explosion proof for NEC

Class-1, Division 1 area)/ flame proof
(IEC-79.1, Part I). As applicable).
Nameplate : Tag number, service engraved in
stainless steel tag plate
Accessories : a) Clamping strip, bracket, prefab

cable, battery etc.
Page 503 of 680

Accessories : a) Isolating valves (for Bypass

type only)
b) Bolts, Nuts and Gaskets as
required
Tests : Shall be tested at two hundred
(200) percent of the maximum
process pressure
3.03.27 SIGHT FLOW GLASS INDICATORS
Type/Construction : Flapper type.
Materials :
Body : Carbon steel/SS316 as per process requirement
Glass : Toughened Borosilicate
Gaskets : Neoprene
Bolts & nuts : SS
Flappers / Rotating Wheel : 316 SS
Flappers / Rotating Wheel : 304 SS
holder
Process Connection : SW (Socket Welded)
Accessories : Scale, Bolts, Nuts, Cover plates and Gaskets as
required
Tests : Tested at two hundred (200) percent of the maximum
process pressure.
3.03.28 SOLID FLOWMETER
Type : Online Impact type Microprocessor Based
Measuring Principle : The system measurement is basically pertains to

the m easurement o f horizontal def lection usi ng
LVDT, c reated by t he i mpact o f so lid flow up on
online sensing plate. The horizontal deflection being
proportional to the impact forces, LVDT convert this
horizontal movement into electrical signal. The
inbuilt integrator convert this signal into time based
flow rate indication & provide totalized flow also.
Sensing plate : 316 SS
Sensing head : Sensing mechanism shall be mounted
outside the process flow line.
Enclosure : 316 SS
Enclosure protection : IP 67 class

Accuracy : +/-1%
Repeatability : +/- 0.2%
Drift : Both zero & span + 2% / month
Output : 4-20mA DC isolated, load 600 ohm (min)
Digital communication : yes, (HART) facility
Power supply : 240 V AC, 50Hz. UPS
Ambient condition : Temperature -600 C, RH-95%
Environment – Highly Dusty
Page 504 of 680

Accessories : Shall be complete with all the

accessories including digital display for flow rate,
integral vents, baffles for air separation, et c. which
ever required for satisfactory operation.
Note:-
1. The above on line flow meter shall not create any obstruction on flow.
2. User’s list shall be submitted to support on proven satisfactory performance for

similar process application.
3.03.29 Instrument Air System
The i nstrument A ir S upply S ystem for v arious pneumatic Control & Instrumentation
devices like pneumatic actuators, power cylinders, I/P converters, pneumatically
operated valves etc. shall be complete in all respect with necessary Air Filter Regulators,
valves, piping/tubing etc.. Each pneumatic instrument shall have an individual air shut off
valve. T he pr essure-regulating v alve sh all be e quipped w ith an internal f ilter, a 50 m m
pressure gauge and a built in filter-housing blow down valve.
Filter shall be of minimum 5-micron size & sintered bronze material.
On collection of water in the drains of instrument air lines, mechanical automatic drains
and periodically solenoid operated drains (with electronic timer - 15m, 30m, 60m and 2
Hours & Timing adjustable) are to be provided.
For mechanical type & Electrical type, the locations to be provided in the instrument air
lines of boi ler ar ea, C himney ar ea, t urbine ar ea et c., sh all be deci ded dur ing de tailed
Engineering.
Bulk header nearby the crowded applications shall be provided and from this bulk
header individual air lines with necessary isolation values are laid to the application.
These bulk header are to be provided with mechanical / electronic based automatic
Drains.
Individual moisture separator for O 2 analyzer or vital application shall be provided nearby
the i nstrument so as to enhance t he ce ll l ife o r t he pe rformance o f v ital f inal co ntrol
elements.
3.03.30 Air Filter Regulator (AFR)
Constant bleed type AFR with an accuracy of + 1.0 % inlet pressure range of 5-8 kg/ cm2
and suitable spring ranges (AFR) for use with positioners in control valves, control
damper, E /P convertors and sh ut o ff v alves for phosp hor br onze filter element;
Filtering particles above five microns. Weather and water proof enclosure. Material of
accessories will be SS316.
Air filter regulators shall be provided in the :
(a) Air supply line to valve positioners / power cylinders

(b) Air supply line to electric to pneumatic converters.
Page 505 of 680

(c) Air supply line to pneumatic interlocked block valves.

(d) For each instrument rack, field instruments enclosure for purging.
3.03.31 Electro-Pneumatic Convertors (E/P)
Two wire type E/P convertors with an accuracy of +0.25% accepting 4-20 mA dc signals
from co ntrol sy stem an d co nverting to 0 .2 t o 1 kg /cm2 ai r p ressure t o oper ate v alve
positioner of all final control elements; Housed in cast aluminum casing (with
polyurethane paint); NEMA 4 or equivalent degree of protection for enclosure. Material
of acce ssories will be S S. E /P co nvertors shall hav e f ail freeze ( stay put ) feature al so.
Process connection shall be 1/4” NPT (F) and Electrical connection shall be ½” NPT (F).
Zero/span ad justment facility sh all be pr ovided. T he E t o P co nverters shall retain t he
pneumatic si gnal (last v alue) ev en i n f ailure of cont rol s ignal and sh all have self
volume boosters. Necessary air lock devices and pressure switches for air pressure low
alarming shall be provided.
3.03.32 Solenoid Valves
Solenoid valves shall be provided with control valves / pneumatic control valves hooked
up with process interlock requirements and where direct tripping is involved. The number
of ways for solenoid valve shall be provided as indicated below:
(a) Two (2) way solenoid valves shall be provided, where process line of less than 50
mm with low pressure and temperature application.
(b) Three (3) way solenoid valve shall be pr ovided commonly, where the pressure is
admitted o r ex hausted from a di aphragm v alve or si ngle ac ting cylinder, e .g,
Pneumatic operated spray water block valve.
(c) Four ( 4) w ay so lenoid v alve sh all be pr ovided for ope rating doubl e act ing
cylinders, e.g, Pneumatically operated on-off type dampers.
(d) For operation of the fuel oil corner nozzle valves, fuel oil trip valves etc., double
coil solenoid valve ( latch coil & relatch coil) shall be adopted.
Single coil usage requires always power and loss of power leads to closure
of above valves resulting the unit trip or loss of generation.
(e) Solenoid V alve co ils shall be C lass-H h igh-temperature or C lass-F co nstruction
as applicable and sh all be desi gned for continuous duty. Three-way so lenoid
valves shall be desi gned for uni versal oper ation so that t he su pply ai r m ay be
connected to any port. Solenoid enclosures shall be NEMA-4)/ (Explosion proof
for NEC Class-1, Division 1 area)/ flame proof (IEC-79.1, Part I) As applicable).
Body material of solenoid valve shall be Die Cast Aluminum or SS316.
.
(f) All solenoid shall be with varister, LED indication, surge suppress diode and circuits.
3.03.33 Power Cylinders (Pneumatic)
Mounting Type : a) Fixed position mounting (End

mounting).
: b) Trunnion mounting
Control Signal : 0.2 to 1 Kg/Sq. cm. from I/P converter for
modulating purposes. 24V/48VDC operated
solenoid valve operating on pneumatic line.
Page 506 of 680

The Pilot solenoid will have separate coils for

open closing purpose.
Supply Air : 0-7 Kg / Cm2.
Selection : Based upon thrust / torque, stroke length,
angular movement, full-scale travel time,
repeatability, space factor etc. Provision for
air-to-open and air-to-close operation.
Casing : IP-65.
Accessories (as required) : a) Air lock relay
b) Hand wheel.
c) Air filter regulator with gauge.
d) Volume Booster.
e) Limit Switches.
f) Positioner with Input, Output and
supply pressure gauges.
g) Pilot Solenoid Valve (Double Coil
type)
h) Position Transmitter (4-20 mA DC
linear output, LVDT or non contact
type).
Fail-safe operation : Stay put, open or close position on pneumatic
/ electrical power supply failure as per process
safety criteria.
Repeatability : Better than 0.5% of full travel.
Hysterisis : Less than 1% of full travel.
3.03.34 Nucleonic Type Density Meter (For Ash Handling Plant):-
Type : Nuclear type radiation

Application : Abrasive Slurries & Corrosive Chemicals
Accuracy : < 1% of Span
Orientation : As per requirement.
System Type : Radiation Source & Scintillation Detector
Meter Material : SS 316L/ Aluminium with PVC coating
Connection material : SS 316L
Compensation : Temp. Compensation required
Type (Transmitter) : SMART, 2 Wire HART based
Operating Principle : As the density increase, the
lower the radiation field at detector and vice
versa.
Output : With photomultiplier, 4-20 mA, DC
Electrical Connection : ½” NPT
Enclosure Class : IP 66
Local Display : Provided
Accessories : Radiation Survey Meter and all
erection/installation hardware
3.03.35 Non - Nucleonic (Vibration) Type Density Meter (For DM & AHP Plant):-
Application : Liquid Density measurement

Detector
Page 507 of 680

• Failure Diagnostics
• Long Term Stability
• Fast Response
• IP 66 / NEMA4X Protection
• Supplied with Calibration Certificate Traceable
to National & International Humidity Standards
• Sensor protection with sintered filter
• Local LCD Display for Dew Point
3.03.42 Junction Boxes
v. Type : Flame proof/weather proof

vi. Enclosure : IP-65/Explosion/Flame Proof as per area
classification.
vii. Material : FRP with protective Coating
viii. Cable entry : Bottom or Side
ix. Cable glands : Double compression type – Nickel plated
brass with PVC hoods.
x. Mounting : Indoor/Outdoor
xi. No. of terminals : As required with standardization with 20%
spare of each size & type.
xii. Terminals : Phoenix/Wago (screw less cage clamp type spring
loaded)
xiii. Grounding : Two terminals for body and shield ground
xiv. Door : Hinged, lockable type.
xi. Suitable mounting clamps and other accessories shall be in scope of bidder.
xii The b rackets, bol ts, nu ts, sc rews, g lands, l ugs required for er ection sh all be of
brass, i ncluded i n bi dder sco pe o f su pply. H igh v oltage & i nsulation r esistance
test shall also be conducted.
Xiii M6 Ni plated Brass earthing stud shall be provided (external 2 nos. internal 1 no.)
xiv Gasket (Normal)- Neoprene thickness 6.0 mm
3.03.43 Interposing Relays (IPR)
Electro m agnetic t ype I PRs with m odular desi gn, pl ug-in t ype co nnections,
suitable for channel/DIN rail mounting in cabinets; coil rating 24V D.C; 2 set of silver
plated change over contacts rated for 0.5A 220 V DC/8 A 240 V AC. Free wheeling diode
across relay copper coil and self reset type status LED indicator flag (electronic) shall be
provided. Manual f orcing/override facility is required. The test voltage for relay shall not
be less than 4 K V with operating temperature from –20 deg. C to 60 deg. C. The relay
shall hav e t he nece ssary appr ovals like V 0 i nflammability cl ass in acco rdance w ith
UL94”, IEC60664/IEC60664A/DIN VDE 0110. Facility to stimulate IPR manually shall be
provided.The V A bu rden o f relays shall be su itable t o match the ca pacity of out put
modules. Interposing relay & sockets for mounting the interposing relay shall be of same
make only.
3.03.44 RECORDERS (CHARTLESS)
Type : Micro-processor based, Digital

TFT display type
- No. of Channels : Forty Eight (48) point).
Page 508 of 680

6 N os. of r ecorders shall be su pplied with

BTG packages and the parameters shall be
decided dur ing det ailed E ngineering.
Quantities of recorders for BOP packages
shall be deci ded dur ing det ailed
Engineering.
(Simultaneous parameter display preferred)
Input Signal : Fully configurable multi range
(Programmable) universal (input)
Recording method : Continuous with different colour,
for each channel
Display colour : Selectable from 30 Colours
Bar graph facility : To be provided
Digital indication : To be provided
Accuracy : +/- 0.1 % for reading for DC V
Input And 0.1 Deg for TC/RTD input
Programmability : Front key board
Data Storage : hard disk/ Flash Memory
Data Retrieval : Compact 4 GB flash Memory card
and USB port with 8 GB USB drive.
Scan rate : < 20 m second for individual channel.
Selection of s can t ime f or i ndividual
channel is required.
Power Supply : 240 VAC 1 Phase UPS
Ambient Temperature : 0-50 Degrees
Mounting : Front panel mounted weather &
Dust proof IP 65
Application software : Yes, To be provided
Internal Memory : 400 MB or more
Screen : > 10.5” colour LCD TFT
Resolution : > 640 X 480 Pixels
Type of Display : i) Trends
ii) Bar Graph
iii)Digital display/ values
Event Sampling : 1/2/5/10/30/60/120 sec.
Zoom & Scroll Facility : Required
OWS and printer connectivity port : Required
: Necessary software shall be
supplied for uploading the data.
Communication : Additional MODBUS/PROFIBUS ports
connectivity between recorder and third
party systems.
3.03.45 DIGITAL INDICATOR
Type : Programmable electronic digital indicator

with floating point decimal.
Input : 4-20 mA DC/1-5V DC/RTD/T/C.
Number of inputs : One
Range : As per requirement/adjustable by end user
Page 509 of 680

through key pad available on the indicator.

Number of digits : Four plus sign
Digit height : 20 mm or larger
Display : Fluorescent red
Input over range/open : All digits to flash
sensor (T/C)
Input hold time : 0.7 seconds max.
Accuracy : +0.25% of span
Power supply : 240V AC, 50Hz
Mounting : Flush panel, compatible for
mounting on mosaic grid panel
Size : 96x48 mm
Other Particular : Indicator receiving thermocouple
signal sh all ha ve aut omatic cold j unction
compensation.
: Retransmission O utput 4 -20 m A i solated
required.
: 24 V DC inbuilt power supply
: Alarm co ntact w ith 2 N O/NC co ntact (rating
5A/230 V AC)
3.03.46 RECEIVER INDICATORS (SINGLE/DUAL CHANNEL)
Type : Analogue indicator

Input Signal : Universal input (T/C, RTD,
4-20 mA, Voltage)
Scale : Range fully configurable and
programmable
Measurement Accuracy : + 0.2% of span + 1 count
Resolution : 0.5% Span
Dead band : + 0.2% of span
Repeatability : 0.2% of span
Full scale response time : Less than two(2)seconds
Power Supply : 240V AC, 50 Hz
Connection : Plug in type
Accessories : Mounting Bracket for Bins
Other Particulars : Indicator receiving thermocouple
Signal sh all ha ve aut omatic cold j unction
compensation.
: Retransmission O utput 4 -20 m A i solated
required.
3.03.47 Temperature Scanner
Type : Microprocessor based Electronic Digital Scanner.

No. of channels : 16/24 (as per the application)
Input : RTD /Thermocouple/4-20mA
Accuracy : + 0.1 of FS + 1 count
Number of digits : 4 digit (7 segment display with Engg. Units)
Digit height : 12 mm or larger
Display color : Fluorescent red/green
Display mode for
Page 510 of 680

Input over range/open : All digits to flash

sensor
Mounting : Panel mounting
Zero and Span : Adjustable by digital calibration
Serial communication : Isolated RS232/485 for modbus-RTU
communication
Memory Capacity : 5MB Flash
Alarm output : Required
Contact rating : 2A at 220 V AC
Power supply : 240 V AC/24 V DC
Properties : i. Any channel shall be configured for
Data Logging
ii. Channel to Channel online Isolation
shall be provided
iii. Real Time RTC Interface for Printer
shall be provided
Operation Modes : Auto/manual mode, Run mode, Verify mode,
Calibration Mode, Program mode.
3.03.48 AMMETERS (AMM)
Input : 4-20 mA DC
Mounting : Flush panel, compatible for
Face Dimensions : 96 x 96 mm
Scale/Type : Moving coil, circular, FSD 240
deg. With six times suppression scale
Zero adjustment : Screw on meter face
Accuracy : + 1 percent (class 1)
Indication : Pointer with scale
Magnetic Shield : Shielded Case
Quantities : For all HT Motors & LT motor
with rating > 30 KW and other critical
application motors/drives.
3.03.49 VOLTMETER:
Input : 4 - 20 mA DC
Mounting : Flush Panel, compatible for
Face Dimension : 96x96 mm
Range : As per requirement
Accuracy : + < 0.5 %
Indication : Digital type 4 1/2 digit
Quantities : For 230 V AC input power supply, UPS
power supply, 24 V DC interrogation voltage
& 220 V DC.
3.03.50 FREQUENCY METER/MW METER (DIGITAL)
Page 511 of 680

Type : Electronic digital 7- segment with

fluorescent display
Input : 4 - 20 mA DC
Mounting : Flush Panel compatible for
mounting On mosaic grid panel
Number of digits : 41/2 digit
Face Dimension : 192X192 mm
Digit size : Approximately 40 mm
Range : As per requirements
Accuracy : + 0.2 Hz
Display : Red LED display.
3.03.51 AC CURRENT TRANSDUCERS
Input : 0 - 1 A CT current
Output : Dual 4-20 mA with 500 impedance
Mounting : Back rail
Accuracy : + 0.25%
3.03.52 DC CURRENT TRANSDUCERS
Input : 0 - 75 mV
Output : Dual 4-20 mA with 500 impedance
Accuracy : + 0.25%
3.03.53 AC VOLTAGE TRANSDUCERS
Input : 0 - 110 V PT, Volts

Output : 4-20 mA with 500 impedance
Accuracy : + 0.25%
3.03.54 DC VOLT TRANSDUCERS
Input : System Voltage

Accuracy : + 0.25%
3.03.55 TRANSDUCERS FOR POWER
Input : CT and PT (1A) (110V)

Accuracy : + 0.25%
3.03.56 TRANSDUCERS FOR FREQUENCY
Page 512 of 680

Input : 110 V PT Volts

Accuracy : + 0.25%
3.03.57 TRANSDUCERS FOR POWER FACTOR
Input : PT (110V)
Accuracy : + 0.25%
3.03.58 TRANSDUCERS FOR MVAR
Input : CT & PT (110V/1A)

Accuracy : + 0.25%
3.03.59 DIFFERENTIAL FREQUENCY TRANSDUCERS (FOR SYNCHRONIZATION)
Input : 110 V PT
Accuracy : + 0.25%
3.03.60 DIFFERENTIAL VOLT TRANSDUCERS (FOR SYNCHRONIZATION)
Input : System voltage

Accuracy : + 0.25%
3.03.61 PUSH BUTTONS (PB)/ ILPBs FOR ON/OFF, OPEN/CLOSE, START/STOP
Type : Momentary/Miniaturised
Suitable for mosaic grid 24x48
Mm with 2 PB and 3 coloured LED.
Contact Configuration : 2 NO + 2 NC
Contact Material : Hard Silver Alloy
Contact Rating : 500V / 10 A
Insulation Voltage : 2 KV for 1 minute between
terminals and earth
Lamp Rating :-
a) Voltage : 240 V AC
b) Watt : 2 Watt (approx.)
Colour
Page 513 of 680

Power supply to all instruments and control systems shall be separately fused with MCB
and it should be possible to disconnect any instrument without interrupting power supply
to any other equipment/device.
UPS shall provide power supply to the complete SWAS system.
5.09.00 LIGHTING AND RECEPTACLES
Sample t able and anal yzer se ction sh all be pr ovided with r apid st art, l ow noi se,
fluorescent strip fixtures installed in a continuous row along the top of each section. The
panel sh all hav e a ce iling mounted LED lamps for illumination. Li ght sw itches shall be
provided within the panel sections at suitable locations.
Universal type Three receptacles shall be provided on the front of the sample table below
the work surface. These will be equally spaced. Two more receptacles shall be provided
inside the sample table and one receptacle shall be installed inside the panel.
Wiring for lighting and receptacles shall be run in flexible metallic conduits.
5.10.00 GROUNDING
One ear thing t erminal w ith acce ssories shall be pr ovided at each e nd of st rip for
connecting G.I. earthing strip of 50 x 6 mm size.
5.11.00 Technical Specifications of Conductivity Analyser
a) Applicable standard ASME PTC 19.11-1970 except as

modified in this specification.
b) Type:
i) Cell Flow through type/ removable type (withdraw able
with sealing valve)
ii) Monitors Electronic (Microprocessor base d) i ndicating t ype
with multi range facility
c) Material :
i) Cell Epoxy resin/SS316
ii) Electrode Platinised/SS316
iii) Monitors body Carbon steel/Aluminum/Polycarbonate
d) Monitor output i) 4-20 mA D.C. with HART protocol spare

out put
ii) 4-20mA DC with HART protocol for
DDCMIS
Output load : 500Ω
e) Power supply 240V, AC, 50 Hz from UPS

f) Accuracy + 1% of full scale span
g) Stability + 1% of full scale per month
non-cumulative
h) Repeatability + 0.3% of span
Page 514 of 680

i) Annunciation contacts from monitors
i) Number 2SPDT
ii) Type Snap action micro switch
iii) Rating 5 amp, 240 V, 0.2 Amp, 220V DC
j) Connection:
i) Cell On line/pipe mounted

(ON LINE in sample table)
1/4 (Quarter) inch NPT (F) SCRD for
on-line t ype and Three quarter ( 3/4) i nch N PT (M)
SCRD for pipe mounted.
ii) Monitors flush panel mounting
k) Electrical Half (1/2) inch NPT (F) SCRD
l) Accessories i) Automatic temperature

compensation in the range 0-100°C
ii)Ammonia (NH3) removal equipment.
iii) Sample coolers
iv) Flow and pressure regulators
v) SS316 impulse tubing and fittings
vi) Isolation & drain valves as required
vii)Other accessories as required
viii)Adequate length of cables for
connecting coils to monitors
ix) Sample rate set valves
x) Alarm settings and Alarm
indications on monitor.
m) Other particulars Cell shall be suitable for maximum pressure of 7

kg/cm2 and maximum temp. of 100°C
n) Response time < 3 seconds
5.11.01 CONDUCTIVITY COMPARATOR
Applicable Standard : ASME PTC 19-11-1970 except as

modified this specification
Type of cells : Flow through type / removable type with draw able
with sealing valve)
Transmitter : Electronic (Micro processor based) indicating type

with multi range facility pipe mounted.
Material of Cell body : SS316
Material of cell Electrode : Platinised/SS316
Output : 4 to 20mA DC isolated with HART output
Page 515 of 680

Power Supply : 240V AC, 50 Hz. From UPS
Accuracy : +/-1% of full scale span.
Stability : +1% of full scale per month non-cumulative
Repeatability : +/-1% of span
Protection class : IP - 65
Process connection : ¼ inch NPT (F) / SCRD for on line type.

¾ inch NPT (M) SCRD for pipe mounted
Electrical connection : ½ inch NPT (F) SCRD
Accessories : Automatic temp. Compensation in the range of 0-100 Deg.C
5.12.00 Technical Specification of pH Cell and Transmitters
a) Applicable Standard pH electrodes shall conform to IS:

6804-1972 except as modified in this specification
b) Type:
i) Cell Measuring and Reference Electrode

Combination w ith Fl ow t hrough t ype
(SS316/Polypropylene flow chambers) for power
plant’s steam & water application. Sensor shall not
be af fected by f low variation. S ensor sh all be
designed for power plant applications.
ii) Monitors Electronic (microprocessor based)
indicating type with adjustable range facility.
c) Material:
i) Measuring & reference Toughened sensitive

ii) Electrode pH glass
iii) Monitor body Carbon steel/Aluminum/Polycarbonate
d) Monitor output i) 4-20 mAmp D.C. with HART protocol spare

out put
ii) 4-20mA DC with HART protocol for
DDCMIS
Output load : 500Ω
e) Power supply 240V AC, 50 Hz from UPS

f) Accuracy/repeatability + 0.03 pH/+0.02PH
g) Resolution + 0.01 pH or 1 mV. 1C
h) Stability 0.02 pH per week
i) Annunciation contacts from monitors:
Page 516 of 680

i) Number 2 SPDT 'Hi' and 'Lo'

iii) Rating 5 amp, 240V AC, 0.2 Amp, 220V DC
j) Connection:
i) Process One-quarter (1/4)inch NPT(F) SCRD

ON-LINE
ii) Electrical Half (1/2) inch NPT(F) SCRD
k) Mounting:
i) Cell Pipe Mounted

ii) Monitors Flush panel mounting
l) Accessories i) Automatic temperature

compensation with fast response integral
temperature sensors in the range 0-100°C
ii) Co-axial cable as required
iii) Sample coolers
iv) low and pressure regulators
v) Standard pH solutions
vi) SS316 impulse tubing and fittings
vii) Isolation & drain valves as required
viii) Electrode holders
ix) Other accessories as required
x) Sample rate set valves
xi) Alarm settings and indications on monitor.
xii) RFI/EMI shielded, weather and corrosion
proof casing
5.13.00 Technical Specification of Dissolved Oxygen Analyser
a) Applicable Standards ASTM PTC 19.11-1970 except as

modified in this specification
b) Type Microprocessor based Electro-chemical
c) Material Die-cast aluminum/SS/Polycarbonate
d) Output i) 4-20 mAmp DC spare output

ii) 4-20 m Amp, DC Isolated output for
DCS.
e) Supply 240V AC, 50 Hz from UPS

f) Accuracy + 5 % of reading
g) Response:
i) Sensitivity + Two (2) per cent overall

ii) Time (sensor) Less than 30 seconds for 90% step change.
h) Connection:
Page 517 of 680

i) Process One quarter (1/4) inch NPT(F)

SCRD
ii) Electrical Half (1/2) inch NPT (F) SCRD
i) Accessories i) Sample cooler assembly with

shut o ff v alve at co oling w ater i nlet, w ith
thermometer and reducing valve at sample
outlet.
ii) Flow stabilizer
iii) Automatic temperature
compensation
iv) Other accessories as required
v) Calibration device.
j) Ranges As per sample stream detail table

k) Mounting Flush
l) Annunciation contacts:
i) Number 2 SPDT
ii) Type Snap action microswitch
iii) Rating 5 Amp 240V AC, 0.2 amp 220V DC
5.14.00 Technical Specification of Silica Analyzer (SI OX)
a) Applicable standard ASME PTC 19.11-197 except as

modified in this specification
b) Type Multi Channel ( max of each Three channel)

Colorimetric Analyzer ( with aut o reagent sh ut o ff
feature in case of sample loss or power loss) built in
phosphate i nhibition f eature. M icro pr ocessor
based.
c) Material:
i) Case Die cast aluminum

d) Cycle/Response Time Twelve (12) minutes Maximum
e) Analyser output i) 4 to 20 m Amp DC for spare output

ii) 4 to 20 m Amp DC Isolated
output for DCS/PLC
f) Power supply 240V AC, 50 Hz from UPS

g) Accuracy + 1% of span
h) Repeatability + 2% of full scale
i) Sensitivity 0.2 micrograms/liter
j) Connection:
i) Process Quarter (1/4) inch NPT(F) SCRD

ii) Electrical Half (1/2) inch NPT (F) SCRD
k) Ranges As per sample stream detail table
Page 518 of 680

l) Mounting Flush
m) Annunciation contacts:
i) Number 2 SPDT
iii) Rating 5 amp 240V AC 0.2 Amp 220V DC
n) Accessories i) Automatic temperature compensation

between 5 to 50 deg C
ii) Automatic zeroing provision
iii) SS316 tubing & vessels
iv) All ch emical r eagents f or 12 months
operation of the analyzer
v) Sample rate set values
vi) Comprehensive diagnostic and alarm
features.
vii) Auto sampling facility with necessary
valves & solenoids in the sample lines
shall be provided.
5.15.00 Technical Specification of Hydrazine Analyzer
i) Type Microprocessor based Electrochemical

ii) Case material Die-cast aluminum/SS/Polycarbonate
iii) Analyzer output i) 4-20 mA DC for spare output

ii) 4-20 mA DC isolated output
for DDCMIS
iv) Power supply 240V AC, 50 Hz from UPS

v) Accuracy +2% of full scale
vi) Response Time <4 minutes.
vii) Sensitivity 1.0 microgram/liter
viii) Annunciation contacts:
- Number 2 SPDT
- Type Snap action micro switch
- Rating 5A 240V AC, 0.2 A, 220V DC
- Mounting Flush mounting
ix) Accessories i) Flow regulator

ii) Flow gauges
iii) Other accessories as required
iv) Sample rate set valves
v) Chemical reagents as applicable for 12
months consumption
5.16.00 Technical Specification of Sodium Ion Analyzer
i) Type Microprocessor based Continuous flow

through sample type with sodium responsive
Page 519 of 680

electrode and reference electrode having pH

adjustment facility (Max 3 streams)

iii) Analyzer power supply 240V AC, 50 Hz from UPS
iv) Analyzer output i) 4-20 mA DC for spare output
ii) 4-20 mA DC isolated output for DDCMIS
v) Accuracy Better than + 5% of full scale
vi) Response Time 6 minutes. max
vii) Sensitivity 0.1 ppb
viii) Annunciation contacts:
- Number 2 SPDT
- Type Snap action microswitch
- Rating 5A 240V AC, 0.2A, 220V DC
- Mounting Flush
ix) Terminal points All components piped & wired to

terminal points
x) Accessories i) Flow regulator

ii) Flow gauges
iii) Sample rate set valves
iv) Other accessories as required t o m ake t he
system complete
months consumption
5.17.00 Technical Specification of Phosphate Analyzer

through sample type
with colorimetric detection system (Max 3 streams)

iii) Analyzer power supply 240V AC, 50 Hz from UPS
iv) Analyzer output i) 4-20 mA DC for spare output
ii) 4-20 mA DC isolated output for DDCMIS
v) Accuracy Better than +4% of full scale

vi) Sensitivity Better than 1 ppm
vii) Annunciation contacts:
- Number 2 SPDT
- Rating 5A 240V AC, 0.2A, 220V DC
- Mounting Flush
viii) Terminal points All components piped & wired to terminal points
Page 520 of 680

ii) Flow gauges

system complete
months consumption
5.18.00 Technical Specification of Chloride Analyzer

through sample type.
ii) Analyzer power supply 240V AC, 50 Hz, Single Phase from UPS
iii) Analyzer output i) 4-20 mA, DC spare output

ii) 4-20 mA, DC isolated output for DDCMIS
iv) Accuracy Better than +10 % of full scale

v) Sensitivity Better than 1 ppm
vi) Range As per Requirements.
- Number As per schedule, 2 SPDT

- Rating 5A, 240V AC, 0.2A, 220V DC
- Mounting Flush

ii) Flow gauges
system complete
5.19.00 Technical Specification of Chlorine Analyzer

through sample type with automatic temperature
compensation.
ii) Analyzer power supply 240V AC, 50 Hz, Single Phase from UPS
iii) Analyzer output i) 4-20 mA, DC spare output
ii) 4-20 mA, DC isolated output for DDCMIS
iv) Accuracy 0.005 mg/ltr. or 1% of range.

v) Sensitivity 0.001 mg/ltr. (1 ppb)
vi) Range As per schedule.
- Number As per schedule, 2 SPDT
Page 521 of 680


- Rating 5A, 240V AC, 0.2A, 220V DC
- Mounting Flush

ii) Flow gauges
system complete
5.20.00 Technical Specification of Residual Chlorine Analyser
SENSOR
Method : Amperometric
Electrodes : Gold Cathode/Silver Anode
Cell Material : PVC
Electrolyte : Potassium Bromide
TRANSMITTER
Type : Microprocessor Based

with self diagnostic features
Transmitter Output : 4 – 20 mA
Enclosure Protection : IP65
Enclosure Material : Polyester coated Al.
Electrical Connection : ½” NPT (F)
Mounting : FIELD
Display Type : LCD
Display Details : 4 digit backlit LCD matrix
Diagnostics : Required
Meter Range : 0-1 mg/l
Resolution : 0.01 ppm
Area Classification : SAFE
Electromagnetic Compatibility : BUILT – IN
Temp. Compensator : AUTO – BUILT – IN
Temp. Compensating element : PT100
5.21.00 Technical Specification of Turbidity Analyser
SENSOR
Reference type : On Line

Operating principle : Alternating Light Source
Cleaning : Self Cleaning
Electrode holder – type : Flow Through
Body Material : CPVC
Process Connection : ½” NPT (F)
Page 522 of 680

E.SPECIFICATION
FOR
PLC
Page 523 of 680

Bidder’s equipment which are vulnerable to electrical noise shall be hardened to

eliminate possible problems.
The Bidder shall be fully responsible for detailed recommendations on the type, size,
shielding, input balancing, ripple amplitude and frequency, isolation and grounding for
field i nputs and for e quipment furnished by t he B idder t o ach ieve an i nstallation w ith
minimum noise from all sources.
The B idder sh all ca refully r eview t he E lectrical Fi eld C onstruction and ca bling
specifications given in Section-9 of t his volume. I f the performance of the equipment
furnished by the Bidder is likely to be adversely affected in any m anner beca use
of t hese ca bling and electrical f ield co nstruction pr actices, t he B idder shall bring
this to the attention of the Owner along with his proposal.
Any additional equipment, services required for effectively eliminating the noise
problems shall be i dentified by t he B idder a nd sh all be included i n hi s lump su m
proposal.
The B idder sh all be fully r esponsible for satisfactory el imination o f any noi se
problems that evidence themselves following the installation of the equipment. All
expenses incurred in the elimination of noise problems shall be borne by the Bidder.
2.14.00 SURGE-PROTECTION DESIGN CRITERIA FOR SOLID STATE/MICRO PROCESSOR

BASED EQUIPMENTS/DCS/DDCMIS/PLC/UPS etc.
i. All solid-state equipment shall be able to withstand the noise and surges inherent in
a powerhouse. The equipment shall be designed to successfully withstand without
damage t o c omponents and/ or wiring, appl ication of s urge w ithstand ca pability
(SWC) w ave whose s hape and c haracteristics are def ined i n A NSI pu blication
C37.90a - 1974 entitled "Guide for surge withstand capability (SWC) Tests".
ii. All so lid st ate e quipments, pow er su pply t o el ectronic cards, pow er s upply t o
controllers, P LC panel s, D DCMIS panel s, S MPS po wer su pply, U PS, bat tery
chargers etc shall have external surge protection device with Plug ability and life
indication as per IEC 61643-1:1998-02 and E DIN VDE 0675 par t 6:1996-03/A2:
1996-10, to w ithstand max. 40 kA, 8 /20 u S ec of S urge. The connection o f the
devices should be made as per TT configuration wherever applicable.
iii. Signal lines shall have surge protection devices with pluggability and testability as
per IEC 61643-21:2000-09 and E VDE 0845 par t 3-1:1999-07, to withstand max.
20 kA, 8/20 u Sec of surges.
iv. For data lines, communication lines, Ethernet/Can networks/LAN, Coaxial l ines
modular surge protection device should be used as per IEC 61643- 21:2000-09 to
withstand a min of 2.5 kA, 8/20 u Sec of surges. The surge protection device
should be use d with the corresponding connector as being used for the lines i.e.
RJ45, D-Sub, BNC, N-Type etc.
"The Bus systems (like Profibus/ Modbus etc) or the Serial Port Systems (like RS-
232/ R S-485 et c) sh all be pr otected w ith su itable su rge pr otection devices,
confirming to the latest IEC-61643-21 guidelines. The surge handling capacity of
Page 524 of 680

device sh all at l east be 10 K A, 8/ 20 µ Sec between co re-core and 20 K A, 8/ 20

µSec between core-ground. The device shall be pluggable & on-site testable".
v. All e lectronic c ards/modules s hall also be protected from failure against

accidental/inadvertent ap plication of hi gh v oltage upto 500V D C ( common mode)
even t hough t hese m odules m ay be desi gned t o oper ate at l ower voltage l evels
such as 24V/48V.
vi. In the case of DC powered system/subsystem/instrument, the design shall ensure

protection against reverse polarity.
iv. The Bidder shall provide details of production tests being carried out to fully satisfy
the O wner t hat t he pr oposed eq uipment m eets t he abo ve r equirements and t o
assure that the products furnished shall be of the desired grade.
2.15.00 General Tools and Tackles, Special Calibration Instruments:
Bidder must offer general tools & tackles and special calibration instruments required
during start-up, trial run, operation and maintenance of the plant.
2.16.00 PG TEST POINTS
2.16.01 Pressure, temperature and flow test points shall be provided in line with latest
performance test code requirements.
2.16.02 In addition, pr essure and temperature t est 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
2.16.03 Pressure test points shall be complete with root valves and shall terminate with a
nipple.
2.16.04 Temperature test points shall be provided with thermowell with a cap and chain.
Page 525 of 680

required to monitor important plant parameters and control & operation shall be
provided as a back up as elaborated elsewhere.
4.01.01 Functions of Main Plant DDCMIS/DCS
The principal functions of the DDCMIS/DCS are as follows:-
a) Provide the control of the steam Generator (SG) & Turbine generator (TG).
b) Provide control of the main steam cycle, steam bypass and water cycle.
c) Provide control of pulverizers, combustion air, burner ignition, and flame man-
agement.
d) In ca se S CADA f or S witchyard C ircuit B reakers control i s not from the sa me
family of DDCMIS, then a redundant gateway shall be pr ovided to monitor switch
yard operation.
e) Receive input signals that represent the status of process variables and equip-
ment s tatus; co ndition t he si gnals; and u tilize t hem for control, pr otection,
monitoring, status display, annunciation and SER.
f) Provide the output signals to modulate and control the final devices, such as
control valves, control drives, dampers and pumps.
h) Provide alarm logging and sequence-of-events recording (SER) capability with 1
ms resolution.
i) Provide plant and equipment performance calculation, capability and plant
optimizing functions.
j) Provide Auto Plant start-up, loading, auto synchronization and shutdown.
k) Perform i nformation pr ocessing functions including l ogging and pr intout of
historical data, trend displays, elapsed time monitoring, and totalisation of fuel
and energy usage and generation.
l) Provide a m eans to coordinate the load control of the prime movers in response
to remote dispatch load change requests.
m) Status of all drives, pumps, tanks, etc should also be available in central control
room.
4.02.00 Control System Basic Features/Design Requirements
4.02.01 Design Requirements
1. The instrumentation and controls shall be designed for maximum availability,

reliability, operability and maintainability.
All components shall function in a sa tisfactory manner within their rated capacity
under the specified conditions during the continuous service life of the plant.
2. All like instrumentation, control hardware, control and protective system should be
of sa me make and m odel no. i n or der to ach ieve t he goal o f co nsistent co ntrol
philosophy and to minimize the diversity of I&C equipment & spares.
3. Control system shall comply with following general failure criteria :
a. No single fault can cause the complete failure of the control system.
b. No single fault can cause the boiler or turbine/generator protection system
to malfunction or become inoperative.
Page 526 of 680

c. The grouping o f co ntrol functions into sy stem blocks sh all be ar ranged

such that failure of any one block will only partly degrade the control of the
overall system. Such degradation shall always be manageable by operator
intervention.
d. The control system shall be structured to reflect the redundancy provisions
of the plant so that no single fault within the control system can cause the
failure of the duty equipment or make the standby equipment unavailable.
Start command or stop command/trip command towards safety of process
or process equipment shall be hardwired parallel from the two different
DO cards.
e. As a result of a control system fault, a pl ant item or control function shall
always respond t o i ts c ontrols at the ac tuator l evel ( i.e., remote manual
control). That item or control function shall be r equired to be isolated from
automatic control system.
f. No single random fault in the entire automation and control system will
cause a load loss, forced outage or unit trip.
g No two simultaneous faults shall lead to or potentially cause damage to
plant
h Safety related instrumentation and control shall be designed with a fail-
safe mode.
i No single fault shall jeopardise the functioning of the entire system.
j The control and automation system and the field instruments and
actuators as well a s it’s support systems, power supplies and data
networks shall be immune to the electromagnetic interference and shall
conform to the internationally accepted standards.
k To meet the operational and safety requirements, the control system

hardware and software shall conform to a modular, hierarchical
architecture.
l When more than one device utilizes the same measurement or control
signal, the transmitter and other components shall be fully equipped to
provide al l si gnal r equirements w ithout ov erloading and w ith pr oper
isolation. Tr ansmitters required t o se rve m ultiple r eceivers shall be
arranged so that disconnecting, shorting or grounding of one receiver
device shall not have any perceptible influence on any ot her consumer
point of the same signal nor shall change the transmitter calibration.
4. Distributed co ntrol eq uipment sh all em ploy m odern di stributed m icroprocessor

based t echnology, as required t o co mply with t he pr oject sp ecification and t he
DDCMIS system should not be more than 5 year old. A truly integrated DCS is
envisaged with all the self sustaining subsystems communicating with each other
over the bus network and thus ensuring that the system has a truly global data
base.
5. The active control system including the plant protection system is the heart of the
DCS sy stem and t herefore m ost s tringent s afety, av ailability and r eliability
Page 527 of 680

requirements have t o be f ulfilled by t his subsystem. The bi dder must b ring ou t

very clearly in his proposal how he intends to satisfy these requirements.
6. The control system shall be functionally distributed, (For Boiler, TG and BOP and
similarly the control for 2 similar equipments like ID Fan A , B and C should be i n
different co ntrollers & I/ O cards) hi ghly m odular and a rranged t o r eflect the
functional grouping plant equipment and systems to be controlled. This functional
group control strategy shall also form the basis for the partitioning of the controller
to enhance t he sy stem reliability and flexibility. I n case o f redundant A nalogue
and B inary S ignals, t hese w ill be co nnected t o di fferent i nput m odules and
different C PU. Similarly whenever inputs are more than one and needs
temperature and pr essure co rrection, the sa me shall be ca rried out i n di fferent
CPU.
In ca se o f r edundant/multi P umps/Drives for sa me se rvice, al l r elated Inputs &

outputs of main pump/drive shall be in separate I/O cards and similarly all related
Inputs & outputs of respective standby pump/drive shall be in separate I/O cards.
Inputs/outputs of any two same services pumps/drives shall not be mixed in one
common I/O card.
7. To meet the above failure c riteria a t s r. no. 3, t he I &C sy stem sh all i ncorporate
self-checking facilities so t hat i nternal faults can be det ected w ithin t he sy stem
itself prior to any resulting disturbance to the process. In addition, the protection
and sa fety sy stems shall i ncorporate ch annel r edundancy or di versity o f
measurement as well a s self-checking and ad equate t est facilities. F or so me
important sy stems, “on l ine” t est sh all be em ployed with no ef fect t o the pr oper
functioning of the protection system.
8. In order to m ake su re that t he D DCMIS i s an extremely use r friendly sy stem a

centralized engineering subsystem is envisaged. An integrated subsystem has to
be pr ovided w hich t akes over t he co mplete task of pl anning, I/O al location,
generation of function schemes and wiring documentation (in design stage) and
finally t he aut omatic linking and l oading o f the pl anned f unctions in t he t arget
hardware.
The complete en gineering o f al l the au tomation and da ta ac quisition functions

should be possible from this central tool. This shall included all modulating and
sequence control functions as far as the automation is concerned, generation of
plant graphics, logs and other MMI functions. I n addition the central engineering
system must support all service, maintenance and commissioning assistance
functions.
9. For pr otection appl ications, multi-channel m easurements shall be provided

incorporating 2 out o f 3 t rip act ion. Faci lities for t he on -line t esting of each
independent ch annel shall be pr ovided w ithout l oss of pr otection. E ach
measurement channel shall include discrete transmitters and instrument loops,
i.e. multi channel measurement of the same process variable shall not be derived
from common instrument. As per NFPA, Triple supply viz.240VAC UPS, 24 V DC
and 220 V DC shall be ensured for critical Boiler and Turbine protection.
Both redundancy and diversity of trip criteria shall be considered to achieve
sufficient guarantee a gainst non oper ability or unnece ssary oper ation of the
Page 528 of 680

protection system. The principle of de ene rgized t o trip (Fail safe logic) shall be
adopted.
10. Individual co ntrol el ements shall be eq uipped w ith per missive t o pr event t he i n-
appropriate operation of the item and “active interlocks” to trip the item in case of
dangerous operation conditions.
11. Each o f t he multifunction co ntroller together w ith i ts I/O and d rive l evel co ntrol
modules is to be under stood as a se lf su staining aut omation i sland, w hich
executes the f unction al located t o i t i ndependently and is not af fected by a
disturbance i n the ad jacent i sland. For t he p urpose o f l ateral co mmunication
between t he aut omation i slands, a hi gh sp eed r edundant bus (the so-called
control bus ) sh ould be pr ovided which sh ould be so lely r esponsible for the
automation (control) signal exchanges.
12. Alarms shall be pr ovided for all abnormal conditions over which the operator has
control in the control room, plus those abnormal conditions which are of interest to
the operator because they may affect plant operation or security.
13. The following colors shall be selected for equipment status indicating lights:
- Red----energized, running, valve open
- Green----de-energized, stopped, valve closed
- Light yellow ----abnormal, discrepancy
- White----control power available
14. The functions of DDCMIS System are achieved through bus communication units,
bus interfaces, pr ocess co ntrollers, I/O modules and co mputers. The sy stem
shall be versatile and provide the user, the flexibility to freely choose configuration
and redundancy. The system shall ensure very high reliability and safety through
complete distribution and decentralization which goes right down to the individual
I/O level.
15. Interposing r elays with su itable co ntact r ating sh all be pr ovided between
DCS/PLC and MCC/Swgr in Interposing relay panels for giving command signals
ON/OFF or OPEN/CLOSE. Interposing relays shall have minimum 2 NO and 2
NC contacts.
16. All parameters on which protection is achieved through pressure/ temperature/

flow switches; the measurement shall also be made available through
transmitters. “ Provision of t ransmitter/remote sensor will be appl icable f or
70% of total protection signals for such i mportant services which w ill be
decided during detailed engineering”
17. Also the system shall have the flexibility to easily reconfigure any controller at any
time, without requiring additional hardware or system wiring changes and without
disabling the devices from their normal operating mode.
18. The system shall ex ecute al l co ntrol functions w ith t he hel p o f a set of pr e-
programmed functions resident in controllers.
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The offered system shall have provision for open system architecture to establish
communication to any other system using open system standards such as UNIX,
WINDOWS NT, WINDOW XP/7, TCP/IP, OSF, MOTIF, SQL Access etc.
19. The system shall be provided with extensive diagnostic features so that a system
failure can be di agnosed down to the module level giving location and nature of
fault. Ease of maintenance and trouble-shooting shall be a primary consideration
in equipment selection.
20. The system shall provide inherent safe operation under all plant disturbances and
component failures so that under no circumstance safety of the plant personnel or
equipment is jeopardized.
21. The desi gn of the control sy stem and r elated equipment sh all adher e t o t he
principle of “ fail sa fe” o peration at al l sy stem l evels and pr ovide r eliable and
efficient operation of the plant under dynamic conditions and attainment of
maximum station availability.
22. The D DCMIS sh all be fully ca pable t o oper ate pl ant i n a ll r egimes of pl ant
operating co nditions, i ncluding e mergency ope ration/trip conditions, bl ack out
conditions etc. without resorting to manual control. The DDCMIS shall be capable
of bringing the plant to safety state automatically without operator interventions.
23. All process input/output cards shall have built in galvanic/optical/electronic

isolation for each input and output channel.
24. The failure of controller module and each I/O module shall be indicated on control
cubicles and all operator stations.
25. For all the trip signals (very high/very low) employed for the boiler/Turbine Control
System, the a larms (High/Low) shal l appear f or cor recting t he pr ocess b y
the operators.
26. For measurement of boiler metal temperature flue gas temperature, air pre-heater
grid temperature etc., The bidder shall provide permanent/removable duplex type
mineral insulated thermo-couples terminated in junction boxes at boiler platforms.
Remote I/O unit has been envisaged for these inputs. The remote I/O panel shall
be pr ovided w ith I /O cards, r edundant pow er su pply uni t and r edundant
communication m odules et c. These par ameters are br ought t o D DCMIS via
DDCMIS I/O bus or via redundant soft link (either TCP/IP on OPC or MODBUS
with RS485) to have real time data. This remote I/O panel shall be powered from
UPS or 24V DC source of respective unit. The unit enclosure shall be of weather
proof, dust tight and water proof. Bidder shall provide necessary air conditioning
unit, if require for the system. This panel shall also be accommodate able for 4-20
mA and RTD signals of monitoring parameter and not for control parameters. The
quantities of remote I/O panels shall be decided during detailed Engineering.
27. For m easurement o f turbine m etal t emperature t urbine ca sing temperatures,

stator w inding t emperature, Generator se al oi l sy stem, Turbine bear ing
temperature, Turbine oil temperature, Turbine bearing drain oil temperature, BFP
turbine measurement p arameters, M DBFP m easurement parameters etc., T he
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bidder sh all pr ovide p ermanent/ r emovable dupl ex t ype m ineral i nsulated

thermocouple/ RTD terminated in junction boxes at respective turbine side floors.
Remote I/O unit has been envisaged for these inputs. The remote I/O panel shall
be pr ovided w ith I /O cards, r edundant pow er su pply uni t and r edundant
communication m odules et c. These par ameters are br ought t o D DCMIS via
DDCMIS I/O bus or via redundant soft link (either TCP/IP on OPC or MODBUS
with RS485) to have real time data. This remote I/O panel shall be powered from
UPS or 24V DC source of respective unit. The unit enclosure shall be of weather
proof, dust tight and water proof. Bidder shall provide necessary air conditioning
unit, if require for the system. This panel shall also be accommodate able for 4-20
mA and RTD signals of monitoring parameter and not for control parameters. The
quantities of remote I/O panels shall be decided during detailed Engineering.
28. 8 Nos. temperature elements/sensors in each units control room shall be

provided for monitoring the room temperature.
29. On unit tripping, about hundred Engineers shall be informed through SMS
automatically from DDCMIS. Incase of tripping of major fans/pumps/HT drive the
concerned Engineer configured in such a way shall get the SMS information.
To ach ieve t he au tomatic SMS f acility, G SM ( global sy stem for m obile

Communication) with redundant Ethernet connectivity shall be provided by bidder
for SMS f acility. Same shall be co nnected with DDCMIS/OPC server/MIS server
as decided during detailed engineering.
30. For A uto g eneration o f t rip m essage o f uni t & m ajor fans/pumps/HT dr ive t hru
Email, Email facility in DDCMIS/OPC server shall be provided by bidder.
31. All the 4 nos. 40” LED TV monitors per unit and 2 nos. 40” LED TV monitors for
common system at CCR shall be erected at the false roof top of central control
room.
4.02.02 CONTROL SYSTEM PHILOSOPHY
4.02.02.1 In order to minimise the bur den on the unit oper ator, all control functions within
the operational load range shall be fully automated. The control system shall be
structured in acco rdance w ith a well-defined control hi erarchy t o permit operator
intervention at appropriate levels during abnormal modes of operation.
4.02.02.2 The automation shall meet the following objectives as minimum:
(a) Consistent start-up, shut down and running of the plant under all operational
condition
(b) Achieve minimum run-up and loading time
(c) Maximize fuel economy during start-up, shut down and normal on load
operation cycle
(d) Maximize plant life expectancy
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(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.
4.02.03 Different Level of Controls
4.02.03.1 Drive Level
4.02.03.1.1 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.
4.02.03.1.2 Control at this level shall either be initiated directly from the remote manual
control interface or automatically by the next hierarchical level.
4.02.03.2 Subgroup Level
4.02.03.2.1 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.
4.02.03.2.2 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.
iii. Auto Standby-Start initiation in the event of duty item failure.
4.02.03.2.3 A functional group consists of different units, which individually represent and control a
part o f t he co mplete pl ant and ca n be divided i nto t wo or m ore g roups. E very
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 g roup control brings the sub group from one state into another operating condition
by issuing command si gnals in a p rogrammed se quence. It brings the su b group
from a shut down st ate into a working condition and vice-versa. The f unctional
group i nstrumentation and co ntrol sy stem co -ordinates t he ent ire su b g roup
controls belonging to one functional group.
4.02.03.2.4 Group Level
4.02.03.2.4.1 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.
4.02.03.2.4.2 The group co-ordinate the sub group of a functional group. Its main function is to
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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”..
4.02.03.2.4.3 The aforesaid concept of functional group control is independent of the control
techniques-freely programmable.
4.02.03.2.5 Unit Co-Ordination Level
4.02.03.2.5.1 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.
4.02.03.2.5.2 The typical sequence control functions to be implemented at this level would include:
i. The sequential initiation of the subordinate functional group sequences for

automatic start up and shutdown.
ii. The sequential initiation of the subordinate functional group sequences for
automatic start up and shutdown of a part/full.
iii. The sequential transition to the various combination of subordinate functional

Groups.
4.02.03.2.5.3 The m odulating co ntrol f unctions to be i mplemented at t his level would include
the following:
i. Unit load control with frequency regulation incorporating load balancing

(remote set point adjustment from the CCR /LCR shall be provided).
ii. Station load demand and demand rate limiting
4.02.03.2.5.4 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 CCR.
4.02.03.2.5.5 Communication links shall be provided between the various control systems to allow
for access to the system from any of the operator’s interface stations.
4.02.04 CONTROL SYSTEM - LEVEL OF AUTOMATION
4.02.04.1 The unit co ntrol and monitoring shall be pe rformed from control room by m eans
of OWS/KB oper ation i nterface m ounted o n uni t control des k, t hrough a
microprocessor based distributed Digital control monitoring and information system.
4.02.04.2 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 o ther equipment that have to
be operated during start up, operation and shut down, belonging to the Main
Systems, sh all be r emotely co ntrollable f rom uni t co ntrol r oom by t he op erator t hrough
Distributed digital control monitoring and Information system.
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4.02.04.3 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.
4.02.05 CLOSED LOOP CONTROL SYSTEM (CLCS)
4.02.05.1 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.
4.02.05.2 The CLCS shall have the following features:
(a) Provision of predictive and/or adaptive controls in addition to PID controls

as required by t he sy stem. Availability o f advance cont rol
techniques/Algorithms ensuring process optimization.
(b) Set poi nt adj ustments and i ndication f rom oper ating w ork stations/ KBs for
process variables which need to be changed during load changes, start-up,
shutdown, normal or under any other emergency conditions.
(c) Fixed se t poi nt at the so ftware l evel/hardware level (only changeable by

the maintenance engineer) and i ndication 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 co ntrol el ement ( control v alve, co ntrol dam per, speed dr ive et c.)
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 pr ovided in OWS. Auto tuning facility shall
be an inherent f eature o f t he DDCMIS. Availability o f control l oop o f process
parameters i n aut o for different l oads. I f required, t he sy stem sh all h ave t he
feasibility o f auto changi ng of P ID const ants ( K const ants) in m icro-
processor/controller for different loads so as to avoid hunting of control valve.
(f) Characterization 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 characterization 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
Page 534 of 680

Signal.
(l) Redundancy criteria of sensors for CLCS shall be dictated as per NIT, Vol. V, Cl.
No. 2.05.05.
(m) Redundancy cr iteria of I /O ca rds and Wiring for r edundant or non r edundant
signals from field to control system (I/O cards & controllers) shall be di ctated as
per NIT, Vol. V, Cl. No. 4.02.08.02 and 4.02.08.02.1 respectively.
4.02.06 OPEN LOOP CONTROL SYSTEM (OLCS)
4.02.06.1 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 r esult i n the failure and l ess u tility o f t he e quipment an d pr otect the
operating personnel. C ontrols shall be pr ovided t o st art/shutdown v arious systems
and/or any equipment with asso ciated aux iliaries and to ope rate the U nit on l ine
with optimum number of operations and higher safety.
4.02.06.2 The OLCS shall have the following features as a minimum:
Features-General Requirements
(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
4.02.06.3 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 l ubrication oi l p ressure no rmal, sw itchgear i n se rvice, sw itchgear not i n
test, no protection trip command persisting (as applicable) etc.
(b) The permissive conditions from a process system related equipment are
Page 535 of 680

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.
4.02.06.4 Features-Sequence Control Requirements
Sequence control shall be provided to start and stop the equipment and the
associated auxiliaries. The sequence control shall have the following features:
(a) Once t he start-up o r shutdown of an e quipment i s initiated ei ther manually

or automatically f rom the system, the control of asso ciated 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 ac tual co ndition i s fulfilled. This activity sh all 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.
4.02.06.5 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.
4.02.06.6 Redundancy cr iteria o f sensors for OLCS sh all be di ctated as per N IT, Vol. V , Cl. No .
2.05.05.
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4.02.06.7 Redundancy criteria of I/O cards and Wiring for redundant or non redundant signals from
field to control system (I/O cards & controllers) shall be dictated as per NIT, Vol. V, Cl.
No. 4.02.08.02 and 4.02.08.02.1 respectively.
4.02.07 System Architecture for Main Plant Control System (unit wise)
Following Operating work stations & Engineering work stations per unit except wherever
specifically asked for both unit, are envisaged for control & operation of main power plant
from Unified D istributed D igital Control, Monitoring and Information System ( DDCMIS)
(Refer System Configuration Drawing, # 114-01-0100).
4.02.07.01 Option 1 – For Unified DDCMIS
4.02.07.01.01 Operating Work stations:-
i. 6 nos of Operating Stations (one no. of boiler control system like MFT, two nos.,
for BMS (FSSS), Boiler auxiliaries, two nos. for Turbine auxiliaries and one no. for
electrical sy stem & B OP) sh all be co nnected d irectly on P roprietary/ pr eferably
Industrial Data Highway/higher level network of DDCMIS with 2 LJP A 4 B/W and
1 LJP A4 Color.
ii. 2 nos. of Operating Stations for Turbine Control System (governing system), like
DEHGC, ATRS, ATT, ETS from the respective system shall be connected directly
on P roprietary/ pr eferably I ndustrial Da ta Hig hway/higher l evel net work of
DDCMIS with 1 LJP A4 B/W & 1 LJP A4 Color.
iii. 1 no. of Operating Station for TSE for Unit incharge (shift supervisor) with 1 LJP
A4 Color (if this is not integral of DDCMIS, TSE shall be connected with DDC MIS
through redundant OPC connection).
iv. 1 no. of Operating Station for Unit incharge (shift supervisor) - Printer not required
v. 1 no. o f Operating Station for Station incharge (in the cadre of Executive
Engineer) with 1 LJP A4 B/W.
vi. 1 no of O perating S tation f or per formance ca lculations & opt imization for U nit
incharge (shift supervisor) shall be provided with 1 LJP A4 B/W.
vii 1 no. o f Operating S tation f or per formance ca lculations & opt imization at t he
Office of Executive Engineer/Efficiency shall be provided with 1 LJP A3 B/W.
viii. 1 no. o f Operating S tation for w ater ch emistry par ameters connected w ith
performance ca lculations & opt imization at t he SWAS / C hemical E xpress lab
shall be provided with 1 LJP A4 B/W.
ix. 1 no. co mmon Operating S tations at Fact ory m anager, and 1 no. co mmon
Operating Stations at Electrical System incharge room shall be pr ovided for both
units, oper ation/ co mmand sh all not be ex ecuted from t hese three consoles to
start/stop the equipments. Software and har dware security lock shall be p rovided
not to use these controls for any operations. 1 LJP A4 Color with each Operating
station shall be provided.
Page 537 of 680

x. 2 nos. of common Operating Stations for both units at common DDCMIS network
in CCR with A3 sized color LJP.
4.02.07.01.02 Engineering Work stations & Servers:-
i. 2 nos. of Engineering Stations for system maintenance Engineer for unit D DC

MIS system with 2 LJP A4 Color, 1 No. A3 sized Scanner, copier cum printer, 1
LJP Heavy Duty Industrial grade A3 Color.
ii. 1 no. E ngineering S tation for sy stem m aintenance E ngineer for Turbine C ontrol
System with 1 LJP Heavy Duty Industrial grade A3 Color.
iii. 1 no Engineering Station for Turbine Stress Evaluation with 1 LJP A4 Color (if this
is not in tegral o f DDCM IS, T SE sh all be co nnected w ith D DC MIS through
redundant OPC connection).
iv. 1 no. of Engineering Station for Sequential Event Recording with 1 no. A3 sized
DMP
v. Redundant H istorian se rver ( Historical D ata S torage & R etrieval sy stem) with
Work station and 2 no. A3 sized DMP.
vi. 1 no. redundant server system for performance calculation & optimization (PADO)
with Engineering work Station and Heavy Duty Industrial grade A3 Color printer.
vii. Redundant OPC se rver for OPC co nnections with D DCMIS f rom o ther s ystems
with Work station & 1 LJP A4 B/W.
viii. Redundant MIS server with one no. MIS work station, and 1 no. LJP A4 B/W.
ix. Common Redundant OPC server for OPC connections with both units DDCMIS
from other common systems with Work station & 1 LJP A4 B/W.
4.02.07.01.03 “The local operating stations 6 nos. per unit namely at locations like ESP, Zero M Elev.
Turbine building, Boiler - A Elevation, HT Switchgear room, SWAS / Chemical Express
lab room & CWPH (with 1 no. A4 sized B/W LJP) and 1 nos. namely at common
locations like FOPH shall be pr ovided with 24” LE D co lor sc reen/OWS, w ith m inimum
configuration connected to DDCMIS on redundant connection to show the status/
conditions of various process parameters/equipments in process mimics, trends, logs etc
with real time data.
Operation/command sh all not be e xecuted f rom t hese l ocal oper ators’ co nsoles to
start/stop the equipments. Software and Hardware security lock shall be provided for not
using these consoles for any control/operations. Specification of these local stations shall
be same as specified at cl. no. 4.03.03.04 respectively.
All t he l ocations/rooms availing t he oper ating s tations namely FO PH, C WPH, B oiler A
elevation, Turbine 0 m eter, ESP, Ash handling Control room, HT Switchgear room, 400
KV switchyard control room and SWAS / Chemical Express lab, DM Plant are to be ai r
conditioned.
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4.02.07.01.04 All operating stations connected on redundant data highway shall be interchangeable
and operation of the plant shall be possi ble from Engg. station after security check. A ll
operator st ations shall hav e f ull acce ss to t he ent ire pl ant da ta base and sh all hav e
identical f unctionalities. T he sy stem sh all hav e f ull dat a base r edundancy. T he dat a
base shall be independent and shall reside separate from the operator stations.
4.02.07.02 Option – 2
i. Separate DCS based control system is provided for Turbine integral control and
DEHGC, ATT, same shall be provided with complete configuration (OWS & EWS
with printers) as specified above at cl. No. 4.02.07.01.01 (ii) & 4.02.07.01.02 (ii)
and T SE’s work stations & TSE’s Engineering s tations with pr inters & TSI w ork
station with printers as specified else where in the specification.
ii. Separate DCS base d c ontrol sy stem i s provided for Turbine p rotection ( ETS –
Emergency t rip sy stem), sa me shall be pr ovided w ith one no. oper ating station
and one no. operating cum engineering station and one no. A4 sized B/W LJP.
iii. Separate DCS base d c ontrol sy stem i s provided f or M FT & B oiler pr otection
controls, same shall be provided with one no. operating station, one no. operating
cum eng ineering st ation and one no. A 4 si zed B/W L JP and one no. A 4 si zed
color LJP.
iv. For opt ion 2 , Qunatities o f OWS & E WS sh all r emain sa me w ith D DCMIS as
specified above at cl. No. 4.02.07.01.01 (i & iv to viii), 4.02.07.01.02 (i & iv to vii)
& 4.02.07.01.03 irrespective of separate control systems (DCS) for Boiler integral
controls and Turbine integral control respectively.
v. In ca se bi dder p rovide se parate Turbine co ntrol system & B oiler co ntrol system
from D DCMIS. T hen co nfiguration o f LV S sh all be 4 no. L VS with Disp lay
controller as part of DDCMIS package, 1 no. LVS with display controller as part of
Turbine control system and 1 no. LVS with display controller as part of Boiler MFT
control system.
4.02.07.03 Option – 3
i. Separate DCS based control system is provided for DEHGC, TSC, ATT & Turbine
protection (ETS – Emergency trip system), same shall be provided with complete
configuration ( OWS & E WS w ith pr inters) as specified abov e at cl . N o.
4.02.07.01.01 (ii) & 4.02.07.01.02 (ii), one no. OWS for ETS/Turbine protection,
and T SE’s work stations & T SE’s Engineering s tations with pr inters & TSI w ork
station with printers as specified else where in the specification.
ii. MFT & Boiler protection controls shall be part of DDCMIS.
iii. For opt ion 3 , Qunatities o f OWS & E WS sh all r emain sa me w ith D DCMIS as
specified above at cl. No. 4.02.07.01.01 (i & iv to viii), 4.02.07.01.02 (i & iv to vii)
& 4. 02.07.01.03, i rrespective of se parate co ntrol sy stems ( DCS) for Turbine
integral control system.
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iv. In ca se bidder pr ovide separate Turbine co ntrol system from D DCMIS. Then
configuration of LVS shall be 5 no. LVS with Display controller as part of DDCMIS
package and 1 no. LVS with display controller as part of Turbine control system.
4.02.07.04 Total 6 No. 80/ 84” diagonal sized LVS per unit shall also be provided for monitoring,
operation and co ntrol o f pow er pl ant as per det ails specified el sewhere i n t he
specification.
2 no. common 80/84” diagonal sized LVS with their own display controller connected to
both unit DDCMIS on common redundant OPC network to show the status/ conditions of
various process parameters/equipments in process mimics, trends, logs etc of co mmon
BOP/Offsite pac kages with r eal t ime dat a sh all be pr ovided by bi dder. These two nos,
LVS ar e co mmon t o bot h 2 X 660 MW u nits and sh all be l ocated i n C CR.
Operation/command shall not be e xecuted from these LVS to start/stop the equipments.
Software and H ardware security lock shall be pr ovided for not using these local LVS for
any control/operations.
4.02.07.05 Modulating Controls (CLCS) and D iscrete Open Loop Control (OLCS) shall be desi gned
to el iminate t he nece ssity o f ope rator ac tion ex cept manual / au to se lection, se t point
changes, bi asing and si milar ac tions during no rmal oper ation. B umpless and bal ance
less transfers between automatic and manual operation modes and vice-versa shall be
provided automatically without need of operator act ion. Complete backup shall also be
provided for safe shutdown operation of plant.
The system shall have built in redundancies for all system functions both at the processor
and device level. No failure of any single device or processor shall lead to any system
function being lost. It shall have redundant data highway on a "master less" principle.
Redundant equipment wherever provided shall be powered from redundant power supply
units in order to improve system availability and reliability.
The sy stem sh all hav e t he ca pability and f acility f or ex pansion t hrough addi tion o f
station/drops, controllers, processors, process I/O cards etc., while the existing system is
fully oper ational. T he sy stem sh all hav e t he ca pability to add any ne w control l oop i n
CLCS and ne w group, sub group, drive functions in OLCS while existing system is fully
operational. Intelligent I/O cards will be preferred.
All the basic systems shall be connected through redundant data high way/bus system.
The local bus system with associated bus couplers shall be provided for communication
between di fferent I /O m odules and pr ocessors. T he co mmunication sy stem sh all be
designed keeping in view the integrity & security aspects for the control system. In case
the sy stem e mploys master co mmunication controllers, facility f or 100 % hot bac k up
controllers with automatic switch over shall be provided and it shall be ensured that no
loss of data takes place during failure of communication controller.
The DDCMIS shall be fully capable to operate plant in all regimes of plant operating
conditions, i ncluding e mergency oper ation/trip co nditions, bl ack out co nditions etc.
without resorting to manual control. T he DDCMIS shall be ca pable of bringing the plant
to safety state automatically without operator interventions.
Page 540 of 680

The application programmes for the functional controllers shall reside in EPROMS or in
non v olatile R AMS. T he appl ication pr ogramme sh all be al terable b y a ccess through
programmer's console. Parts replacement o r par ts removal sh all not be r equired for
accomplishing ch anges in appl ication pr ogrammes including co ntrol l oop t uning. E ach
controller shall be equipped with the amount of functional capacity required to perform its
specified functions and still have an overall spare capacity of 40%.
4.02.08 Redundancy & Availability Requirements
The CPU / Controllers, communication modules, data highway, power supply modules, etc
for a ll DDCMIS/DCS/PLC shall be 100% hot standby redundant. I/O cards redundancy
shall be as per cl. No. 4.02.08.02.
4.02.08.01 Controller Redundancy
All f unctional co ntrollers for se quence co ntrol, f unctional co ntrollers for cl osed l oop
control and functional controller for D AS & monitoring shall be provided with hundr ed
percent hot standby controllers. However controller redundancy is not mandatory, where
controller is purely executing data acquisition & monitoring functions. DAS function can
also be integrated within CLCS/OLCS controller. All processors for modulating controls
shall have self-tuning facility.
All the 100% hot back up controllers shall be i dentical in hardware and software to their
corresponding main controllers. Further, each of the 100% hot back up controller shall be
able to perform all the tasks of their corresponding main controller. The 100% hot back
up controller shall continuously track/update its data corresponding to its main controller.
There shall be an automatic and bumpless switchover from the main controller to its
corresponding ba ck-up controller i n ca se o f main co ntroller failure and vice v ersa. T he
changeover shall take place within 50 msec. Engineered solution for redundancy in CPU
are not acceptable. Dual redundant controllers shall be placed separately and shall not
share the same motherboard or shall not have any other common sharing point.
Any s witchover f rom m ain co ntroller t o 100 % hot bac k up co ntroller and v ice versa,
whether aut omatic or manual sh all not r esult i n any pr ocess upset or any ch ange i n
control status. The transfer from main controller to the back-up & vice-versa shall be
indicated as alarm on all operator station OSs.
In ca se o f switchover f rom m ain co ntroller t o b ack up co ntroller, t he b ack-up co ntroller

shall be designated as the main controller.
All t he i nput v ariables shall be a vailable t o t he m ain co ntroller as well as its 100% ho t
back up controller so that any failure within the main controller shall not degrade the input
data being used by the 100% hot back-up controller and vice-versa.
Each controller shall have 40% spare functional capacity to implement additional function
blocks, ov er and abov e i mplemented l ogic/ l oops under w orst l oad co nditions. E ach
controller shall have battery backup or EEPROM/NVRAM for program memory.
Parts replacement or parts removal shall not be required for accomplishing changes in
application programmes including control loop tuning.
Page 541 of 680

Each of the corresponding communication controllers shall also have same spare
capacity as that of controller.
For controller, the worst loading condition shall include the following tasks:
(a) All pr ocess inputs scanning and pr ocessing i s in pr ogress and al l t he dat a i s
transmitted over the main data bus every one (1) second.
(b) All closed loop controls in operation
(c) All open loop controls in operation
(d) All output devices are in operation with rated performance/speed.
(e) Control/information request is initiated on all control Operating stations.
(f) In burst mode operation (in case of major equipment trip), 100 di gital alarms are
generated per second for a period of 10 seconds.
4.02.08.02 Redundancy in Input/output Modules
Hot standby 100% redundancy shall be provided for all input/output cards where
inputs/outputs are used for CLCS and O LCS. All input/output of SCADA from/ to breaker
& i solators s hall b e r edundant. No redundancy at I/O ca rd l evel is required which are
executing purely data acquisition/monitoring functions. I/O card shall have 16 channels
per AI/RTD/TC/AO card and 32 channels for DI/DO card. No. of channels per I/O card
indicated are maximum, which may also further reduced to meet the I/O cards features
specified elsewhere in specification.
Wherever redundant I/O modules/cards are used as per specification requirement, both
(1:1 redundant) input or output modules shall execute the designated functions parallely.
The offered system shall have facility to enable final output from any of redundant
input/output module, in case both modules are healthy. In case one of redundant
card/module is unhealthy, the system shall detect the same and the output to and from
system shall be given from the healthier card. I/O card redundancy shall not be achieved
through relays, diodes or any other additional hardware or software, Engineered solution
for redundancy in I/O cards are not acceptable.
Wherever r edundant se nsors are em ployed each se nsor sh all be w ired t o bot h i nput
modules of redundant modules so that even if one input module fails, the both signals will
be available from the other input module. This arrangement is necessary to avoid loss of
both i nput si gnals due t o failure o f one i nput m odule w here bot h t he si gnals are
connected.
In addi tion t o ab ove, 20 % f ully wired i nput/output s pare c hannel s hould be pr ovided f or
each I/O modules.
Bidder to note that all type of hardwares & electronic modules like controllers, I/O cards,
communication modules and i nterface modules etc used in DDCMIS/DCS/PLC shall be
sourced/supplied from their Principal’s works.
4.02.08.02.1 Wiring Scheme for inputs/outputs to/from control system shall be as follows:
Page 542 of 680

i. Each of t he t riple redundant bi nary & anal og i nputs shall be w ired t o s eparate
input m odules. I n addi tion, for functions employing 2V 3 co ntrollers (eg. Turbine
protection, MFT, B oiler pr otection, D EHGC et c.), each o f the triple redundant
binary & analog signals shall be wired to separate input modules associated with
each controller, so that even if one i nput module fails, the signal will be av ailable
from the other input module.
In case of dual redundant binary & analog inputs, each of the signal shall be wired
to bot h i nput modules of r edundant modules, so t hat ev en i f one i nput m odule
fails, t he bot h si gnals will be av ailable f rom the ot her i nput m odule. T hese
redundant modules shall be placed in different racks, which will ha ve se parately
fused pow er su pply di stribution. Implementation o f multiple m easurement
schemes of these i nputs will be per formed i n the r edundant har dware. Loss of
one input module shall not affect the signal to other modules. Other channels of
these modules can be used by other inputs of the same functional group.
ii. The si ngle ( i.e. non -redundant) bi nary & ana log si gnal r equired for co ntrol
purposes shall be wired as follows:
All si ngle anal og & bi nary i nputs (used for O LCS & C LCS) i ncluding the l imit
switches of valves/dampers MCC/SWGR check-backs of all drives, SOE &
information related signals shall be wired to redundant input modules.
The bi nary and anal og out puts from one su bsystem o f the C ontrol S ystem t o
other which are required in these systems for control & protection purposes, shall
be made available from triple/dual redundant binary and anal og output modules.
Other binary & analog outputs used for DAS shall be non-redundant only. Failure
of any single module shall not affect operation of more than one single drive.
4.02.09 DDCMIS/DCS Controller Grouping/Partitioning
All controllers shall be dual r edundant except Tr iple m odular redundant c ontrollers f or
Turbine DEHC, Turbine protection & Boiler MFT/protection. Following tentative segregation
for controls (OLCS, CLCS) & DAS is proposed, however final segregation shall be subject
to Owner’s approval during detailed engineering:-
a) Coordinated master controls, FTP, Oil System, Misc. Drives, Burner Tilt
b) IDF A, FDF A, Air flow and excess air correction, PA fan –A/AH – A/SCAPH-
A/PA header Pr. Control.
c) IDF B, FDF B, Furnace draft, PA fan –B/AH – B/SCAPH-B
d) Mill related controls such as air flow/feeder rate/outlet temperature, Mill L ube o il
controls; Two mills per redundant processor
i. AB
ii. CD
iii. EF
iv. GH
v. JK
vi. MN
e) Feed water/BFP Scoop control/CBD
Page 543 of 680

f) TDBFP - A integral controls per redundant processor

i. ATRS 1 SGC & Turbine Protection
ii. ATRS 2 SGC, TSI & CLCS
iii. DEHC (Digital Electro Hydraulic Governing System)
g) TDBFP - B integral controls per redundant processor

i. ATRS 1 SGC & Turbine Protection
ii. ATRS 2 SGC, TSI & CLCS
iii. DEHC (Digital Electro Hydraulic Governing System)
h) MDBFP – C & Aux and Boiler fill up Pumps

i) Deaerator (three element controls), CEP, hot well, & Hot well makeup Pumps.
j) HP heaters 5, 6, 7 & 8.
k) LP Heaters 1, 2, & 3.
l) SH steam temperature control (multi variable control) & RH
steam temperature control (multi variable control), Metal Temp.
m) DMCW Pumps & DMCW system for SG & TG and CPU* (* CPU incase DDCMIS
controlled) .
n) COLTCS, HP & LP Dosing System and Cooling Tower & Aux.
o) Electrical system 1
p) Electrical system 2
q) Electrical system 3
r) Remote I /O panel with r edundant pr ocessor f rom D DCMIS f amily is to be
implemented with following grouping for CW & ACW system
i. CW Pump – A, CW P ump – C, ACW Pump A & CW lines to/from unit # 1

Condenser/Hotwell.
ii. CW Pump – B, ACW Pump B, CW makeup system & CW lines to/from unit #
2 Condenser/Hotwell.
s) Turbine integral controls per redundant processor
i. ATRS SGC Oil Supply, Turbine & Drains

ii. ATRS SGC Condensate & Evacuation System
iii. GSPC (Gland Steam Pressure Control), LP Bypass
iv. GAMP (Generator Aux. Monitoring)
v. TSC (Turbine Stress Evaluation Control System) & TSI
vi. ATT (Automatic Turbine Tester)
t) SG integral controls per redundant processor
i. Oil A B & Oil CD

ii. Oil E F & Oil G H
iii. Oil J K & Oil M N
iv. Coal A B
v. Coal C D
vi. Coal E F
vii. Coal GH
viii. Coal JK
ix. Coal MN
Page 544 of 680

x. SADC & APRDS

xi. SBC controls, SBC PR & Drain Temp. controls.
xii. HPBP
u) Steam Turbine controls like DEHGC (TMR – Triple modular Redundant philosophy)
and Turbine Protection (TMR – Triple modular redundant philosophy) with fail safe
design cards can be Integral or separate stand-alone.
v) Triple M odular R edundant (TMR) pr ocessors for MFT & Boiler protection w ith f ail
safe design cards can be Integral or separate stand-alone.
All controllers at “sr. no. a to t shall be dual redundant (92 Nos. total)” and at “sr. no. u to v
shall be triple redundant (9 Nos)” for each unit. Hence, altogether minimum 101 processors
are envisaged for each unit. During detailed engineering, processor task allocation will be
done a mongst t hese pr ocessors (and s hall be subject to ow ner’s app roval) t aking i nto
consideration the turbine c ontrol, boi ler c ontrol a nd t he s tation C &I po rtion al together. In
addition, loading of signal interfacing from other BOP packages, Aux. & control/monitoring
system shall be considered for finalization of quantity of controllers.
For c ommon s ystem between t wo uni ts, following r edundant controller grouping s hall be
provided with unit 1 DDCMIS, which shall also be interfaced with unit - 2 DDCMIS for control
& operation. Remote I/O panel with processor from DDCMIS family is to be implemented
because of the long distance. Controllers shall be 1 no. dual redundant (2 Nos. total).
i) BTG (FOPH) Fuel Oil System
Above quantity o f c ontrollers i s minimum, i ndicative an d tentative onl y. H owever final

quantities of processors in addition to above quantities shall be finalized depending upon I/O
handling capacity of the processor and design parameters like response time,
communication bus s peeds e tc. Overcrowding of c ontrol l oops i n c ontrollers s hall be
avoided.
Each group has sufficient spare capacity of at least 25% to meet modification/extension of
the s ystem. Multi-function processors c an incorporate t he corresponding i nterlocks ( open
loop control tasks of the system). Interlock and modulating controls are to be so assigned to
the processors in such a way that failure of any processor does not lead to shut down of the
entire uni t. I n n o c ase C PU l oading s hould ex ceed 60% o f i ts c apacity. B idder t o s ubmit
calculation of CPU loading along with his bid.
4.02.10 Response Times
The system shall have adequate speed of response through all regimes of system
loadings. The minimum criteria to be ensured are as follows:-
a) Key boar d co mmand to field eq uipment sh all be ex ecuted and i ts confirmation

shall be displayed on the screen within1 second.
b) The response for operator requested display (time between pressing of last key
and appearance of last character on screen) shall be o f the order of one to two
seconds under all loading conditions.
c) Dynamic parameters in the OS displays shall be updated in one second interval.
Page 545 of 680

d) The cycle time for open loop and closed loop controls shall be as follows:-
i) For critical closed loops like Steam Separator level control, main steam temp.
control, feed water flow control, HRH steam temp. control, HP/LP bypass control,
furnace draft control & combustion control, the loop cycle time shall be m ax. 100
milli seconds preferably 50 milli seconds.
ii) For non -critical cl osed l oops it sh all be m ax. 2 50 m illi se conds (preferably 150
milli seconds).
iii) For al l open l oops, se quential i nterlocks & pr otection i t sh all be m ax. 100 m illi
seconds.
(The loop cycle time is defined as the time taken from change at input module to
change in output module for command).
e) All analog i nputs to CLCS sh all be acq uired a nd dat a base updated within an
interval of 50 m illi seconds. D ata for critical loops shall be acq uired & data base
updated at a faster rate to suit the requirements of (d) above.
f) The digital inputs for SOE shall be monitored at 1 milli second resolution.
g) The system shall acquire & check all inputs at the input scan rate. If the input is in
alarm state (i.e. the input is in an o ff normal condition) the alarm status shall be
annunciated, printed out and displayed within 1 second after the input is scanned.
4.02.11 Established Reliability
i) All co mponents and systems offered by the B idder sh all be of est ablished
reliability. T he minimum target reliability of each component shall be est ablished
by t he B idder, co nsidering i ts failure r ate/meantime between failures (MTBF) &
meantime t o repair (MTTR), su ch t hat t he av ailability of t he complete s ystem i s
assured for 8700 hours / year (99.7%) or better.
ii) In or der to en sure t he t arget reliability t he bi dder sh all per form ne cessary
availability t ests and burn i n t ests for major systems. S urge pr otection for
electronic control systems, annunci ation system and ot her so lid s tate sy stems
conforming to SWC test per ANSI C 37.90a (IEEE standard 472) and selection of
proper materials, m anufacturing processes, q uality co ntrolled co mponents and
parts, adequate derating of electronic components and parts shall be ens ured by
the Bidder to meet the reliability and life expectancy goals.
iii) Continuous self checking features shall be incorporated in system design with
automatic transfer t o he althy/redundant circuits to enhance t he r eliability of t he
complete system.
iv) In general, failure of equipment used for alarm purpose will cause switching to the
alarm state.
Page 546 of 680

The Historical storage unit (HSU) shall augment the global memory in the system and will
archive data and parameters for logs and historical storage unit shall be a stand-alone
unit on the data highway performing as file server.
Historical storage unit shall be redundant. Redundant facility has been envisaged for both
the hi storical s torage un its by dual di sc imaging and ot her su ch t echnique so t hat any
single failure will not lead to any loss of historical data.
The m emory ca pacity of t he H SU sh all be determined base d on t he m onitoring

requirements for plant data indicated in the logs. The average minimum and maximum
values are t o be i ndicated. P arameter ca n be archived/ co nfigured at Historian w ith
selectable sa mple t ime. Module sh all al so ha ve t he ca pacity of s trong both sn apshots
and average value.
Facility for a rchiving t he hi storical dat a i n D VD & BLUE R AY disc shall be pr ovided.
Historian node sh all ha ve D VD & BLUE RAY d isc read w rite – (for CD, V CD, DV D &
BLUE RAY disc - with read & write).
The historical data storage and retrieval system shall collect and store process system
data from t he da ta bus. T he sy stem sh all be furnished w ith f acilities for an aut omatic
storage of data on a D AT drive for long term storage and its retrieval by the operator for
subsequent processing and printing. T he operator sh all be abl e to display and print the
retrieved data on colour OS and printer.
4.03.03.04 Specifications for Operator Station, Engineering Work Stations
Each op erating station & E ngineering w ork stations and any ot her w ork stations/PC
envisaged in plant shall meet following minimum requirements & as per latest trends at the
time of supply:
- On board Intel – Xeon quad core, 3.46 GHz processor with 1066 MHz bus with
Hyper threading or higher.
- 4GB DDR3 RAM (min.)
- 1 x 1000 GB IDE Hard Disc Drive of 7200 RPM or higher
- 1024 MB Graphic Accelerator
- System chipset: Intel Express
- 2 x RS – 232 ports
- 1 x parallel port
- 4 nos. USB ports. (2 nos. on front side)
- 1 x 52X DVD/CD Read Drive
- 16 X DVD R/W Drive
- 2 x Ethernet (10 / 100 / 1000MB) cards (Industrial Grade)
- UXGA graphics and monitor 1920 X 1080 , 256 co lours with M RPII co mpliant,
viewing angle 178° vertical & Horizontal and fastest response time.
- 1 x w indows XP/7 Professional or l atest & p roven v ersion of Windows OS
professional with Multimedia
- Ethernet adapter
- Third party operating system, graphical users interface
and software, if required.
- 2 nos. graphic output crads minimum
Page 547 of 680

- Optical mouse
- Sound card
- Internal speakers
- Wireless internet & Blue tooth Interface
- Redundant power supply (In built)
- General MS Windows latest, MS-Office Professional, Adobe
Acrobat, anti-virus McAfee or equivalent, AutoCAD etc.
- Application engineering & HMI software - to suit project Specific requirement
- All OWS shall be interchangeable
Preferred makes of OWS/EWS/PC’s are DELL, HPCOMPAQ, NEC & IBM.
4.03.03.04.01 Peripherals for Operator Station, Engineering Work Stations & Server System
4.03.03.04.02 Full flat Monitors with LED back lighting
The bidder shall furnish OWS/EWS/Servers/PC with coloured Full flat Monitors w ith
LED back l ighting. O WS/EWS/Servers/PC w ith Monitors shall have a f ast cu rsor
control dev ice l ike a t rack bal l/optical m ouse. A ll Monitors shall be of hi gh r esolution
colour graphics type and w ith not less than 32 c olours. The picture frequency shall not
exceed 85 H z. T he resolution required is 1920 X 1080 pixel or better. The picture shall
be stable and co mpletely free of any flickering. The screen illumination shall be enough
to give good readability. The screen dimensions shall not be less than 24" screen
diagonal.
Antiglare hard coating shall be provided. High reliability and long life 24” (Industrial type)
or better size monitors shall be supplied by the bidder. Monitors shall be eq uipped with
all adj usting el ements accessible on t he front p late. Monitors with 3D capabilities for
graphics shall be provided by bidder.
Monitors along with keyboard & optical mouse shall be m ounted on su pervisory control
console specified elsewhere in the specification.
4.03.03.04.03 Key Board:
Functional k ey boar ds for pl ant oper ator st ation sh all be of sp ecial t ype adopt ed t o
operation t asks and m onitor functions. I t sh all co ntain al l k eys necessary f or pl ant
operation ar ranged i n a n er gonomically m anner. M ulti f unction keys shall be pr ovided
with automatic display for modified functions. Freely programmable keys (Minimum 101)
shall be available for special user application.
Key Board shall be integrated into supervisors control consoles horizontal part.
Provision of functional keyboard shall be in addition to facility for operator control through
mouse/track ball.
Membrane t ype k eyboard sh all be pr ovided f or oper ator i nterface with pr ocess for
plant control and di splay functions to access plant data in conjunction with control
OPERATING S TATIONs. M embrane k eypad sh all be ass ignable with LE D al arms,
dedicated display selection keys with spare provision, har dware locking f acility to se t
OPERATING STATION in engineer, supervisor or operator mode. The keyboard
Page 548 of 680

shall have a m inimum of 101 configurable keys for assigning most frequently used
displays. A minimum of forty of those keys shall have two independently lit LED's used
for event-specific alarm annunciation.
Keyboard shall be pr ovided t o enabl e t he sh ift supervisor t o dev elop g raphic displays,
control system software and system configuration for the DDCMIS. It shall be possi ble
to per form oper ating i nterface functions from eng ineering OPERATING S TATION.
Assignable function keys shall be pr ovided f or ex ecution of co mmand, pr ogram et c.
Hardware f acility shall be pr ovided t o se t OPERATING S TATION in eng ineer o r
operator m ode. Q WERTY t ype k eyboard shall be provided f or engineer’s functions.
QWETRY type Key Board may be offered alternatively for OWS.
4.03.03.04.04 PRINTERS
Line Impact Heavy Duty Dot Matrix Printers
All pr inters shall be l ow noi se ( less than 60dB ) t ype w ith a m inimum o f 136 co lumns.
Printing sp eed s hall be a m inimum o f 300 ch aracters per se cond. S ince t he co ntrol
room printers are high-speed printers, the system shall output to these printers at the rate
of 1000 l ines of printout per minute as a minimum. This rate shall be i ndependent of the
number o f p rinters in s imultaneous operation. S tyle of pr inting av ailable sh all be
indicated by the Bidder. The printers shall have graphic capability and any OPERATING
STATION display may be printed on the printer. The printing shall be bi-directional and in
two colours black and red for sequence of event recording. Paper input capacity shall be
with continuous paper feed.
Printers sh all acce pt and pr int al l A SCII ch aracters via an E .I.A. R S-232 C or
twenty milliamp current loop interface. Parity checking shall be utilized.
All printers mounted shall be provided with a separate printer enclosure each. The
enclosures shall be designed to permit full enclosure of the printers at a convenient
level. P lexiglas windows shall be used to pr ovide visual inspection of the printers and
ease of reading.
Printer enclosures shall be designed to protect the printers from accidental external
contact and each should be removable from hinges at the back and shall be pr ovided
with a lock at the front.
If one of the printers fails to operate, it's functions shall automatically be transferred
to t he ot her p rinter. Failure o f t he p rinter s hall be i ndicated on al l O PERATING
STATION's. Printer shall be offered and supplied from reputed manufacturer with latest
proven t echnology. 5 Rims of pape rs shall b e pr ovided by bi dder f or each pr inter
provided with subject plant.
Coloured Laser Jet printer
Printing Speed 20 ppm (min.)

Resolution 1200 X 600 dpi
Memory 128 MB (min.)
External Port 1 no. USB 2.0 port, and TCP/IP 10/100
Ethernet, Blue tooth interface
Page 549 of 680

Duty Cycle 40,000 pages per month

Pages size A3, A4, and Transparency etc. with automatic
duplex printing facility.
Laser Jet printer (B & W)

Memory 128 MB (min.)
Pages size A4, A3, and Transparency etc. with automatic
duplex printing facility. Paper tray - 2
Ink Jet Printers (Coloured)

Memory 64 MB (min.)
Pages size A4, Transparency etc.
Duplex printing Automatic
Five sets of print cartridges and Five rims of papers shall be pr ovided with each printer
provided anywhere in the plant by bidder with each DDCMIS, DCS & PLC system and
any other system specified elsewhere in specification.
Preferred makes of printers are HP, Canon, Fuji Xerox, & Epson.
4.03.03.04.05 External DAT Drive
The DAT drive is a serial back-up device. The DAT drive shall have read/write capability
and shall be provided with all required hardware interface including error detection and
correction facilities in each co ntrol r oom. The t ape ( total 10 nos. ) o f S ony m ake sh all
have the capacity of 12/24 GB min. The tape drive shall be specified as follows:-
- DC drive
- Tape format - QIC-80
- Data Transfer Rate – 5MB/minute.
- Seek time – 22 milli second
4.03.03.04.06 Hard Copy Facilities
The system shall be capable of copying hard copy of OPERATING STATION graphics
through a video colour copier switch able to any OPERATING STATION.
The printer/copier offered shall be capable of copying OPERATING STATION image in

20 seconds.
Page 550 of 680

4.03.03.04.07 USB Port Pen Drive
Twenty Five (25) no. USB Port pen drive per unit having 32 GB memory with read/write
facility shall be provided.
Preferred makes of USB pen Drive are HP, Sandisk, Kingston, Strontium.
4.03.03.04.08 Scanner, Copier cum Printer (A3 size)
Resolution : 1200 x600 dpi (optical) (min) for Printer

600 x600 dpi (optical) (min) for Scanner
Colour Depth : 48 bit
Scaling : 10 to 2000% in 1% increments
USB interface : required.
Memory : 1 GB
Printing Speed : 30 ppm (min.) for A4 size
20 ppm (min) for A3 size
Duplex printing Automatic
4.03.03.04.09 DVD Writer
The D VD w riter sh ould be ca pable t o r ead and w rite any D VDs as well as CDs. and
shall be provided with all required hardware interface including error detection and
correction. The DVD writer shall meet following minimum requirements:
- DVD write speed - 16x

- CD write speed - 52x
- Cache / Buffer size - 2MB
- Buffer under protection technology
Five nos of D VD ( Re-writeable) sh all be pr ovided with each O WS/server pr ovided

anywhere in the plant by bidder with each DDCMIS, DCS & PLC system and any other
system specified elsewhere in specification.
4.03.03.04.10 Digital B/W Copier cum Printer (A3 size)

01. Type : Laser, tabletop / latest
02. Printer Memory : 512 MB (min.)
03. Speed : Monochrome 30 ppm - A4
20 ppm – A3
04. Resolution : 600 x 600 DPI
05. No. of color (Basic) : Monochrome
06. Duty cycle : Monochrome more than 75000 pages / month
07. Power supply : 240 V, 50 Hz, 1 phase UPS
08. Ambient temperature : 0-50° C
09. Humidity : 95% non-condensing.
10. Size of paper : Paper weight of 45 to 165 g/M2
Page 551 of 680

11. Networking Capability : USB / Ethernet

12. Coping : Max Original Size – A3, Continuous Coping ( 1-999)
13. Accessories : i) Adapters
ii) Connector Cable
iii) Duplex Unit. Automatic
iv) Optional Paper feeder- 2 Nos
4.03.03.05 Lap Top
The LapTop shall meet following minimum requirements:
a) Intel CentrinoTM Mobile Technology.

b) Intel Core – i7 Processor with 3.46 GHz, 4 MB L2 cache, 1066MHz
FSB.
c) 14” WXGA LED Screen with wide angle viewing.
d) 500 GB 7200 rpm HDD with shock absorber.
e) 4 GB 800 MHz DDR3 SDRAM (slot for 1no. additional RAM slot should be provided)
f) 1 x windows XP Professional or latest & proven version o f Windows O S with
Multimedia
g) Slim type DVD-RW/DVD ROM combo drive.
h) Internal 10/100/1000Mbps Ethernet card
i) IEEE 802.11B connectivity port
j) IR port
- Optical mouse
k) 2Nos. USB ports & Wireless INTERNET & blue tooth interface
l) External mouse connectivity and optical mouse
m) Minimum 8 hrs battery backup.
n) Recovery software tools.
o) Sound cards
p) Internal speakers
- General MS Windows latest, MS-Office Professional, Microsoft
Visual Studio, Adobe Acrobat, anti-virus McAfee or equivalent,
etc.
q) Application engineering & HMI software - to suit project
specific requirement
Preferred makes of Laptop are DELL, HPCOMPAQ, VAIO (Sony), Lenovo.
4.03.03.06 General Specification of the server:
Enclosure : 6U Rack Mountable server / Tower type

Sever
Processor : Intel Xeon Quad (4) Core 64 bit

Processor capable 3.6 GHz with
16MB L3 cache memory per processor,
Dual independent 1333 MHz
system bus (2 way SMF) or better.
Memory : 64GB ECC DDR – 3, 800 SDRAM
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Video : Integrated with 64MB SDRAM
Resolution : 1920 x 1080
Drives : HDD – RAID 5 (1000 GB)

Ultra 320 SCSI adaptors with internal storage
capacity 3.6 TB
DVD/CDROM – 24X CD – RW/DVD IDE combo
USB – 4 ports
DAT – 36 / 72 GB
Peripherals : PS/2 keyboard

Optical Mouse
Operating system : Windows 2008 server version standard / latest

Enterprise Edition or latest & proven version of
Windows Operating system
Backup & Disaster Recovery : VERITAS \ CA \ Tivoli \ any other
Environmental : Operating Temp range - 10°C to 35°C

Humidity range - 8 to 80%
(Non-Condensing)
Vibration 0.25 G at 3 to 300 Hz for 15
Minutes.
Software - General MS Windows latest, MS-

Office Professional, Adobe Acrobat, anti-
virus McAfee or equivalent, etc.
Application eng ineering & H MI so ftware - to su it
project Specific requirement
Miscellaneous : i. 1 Parallel port

ii. 1 Serial port
iii. 4 – 10/100/1000 MB/1GB network ports
iv. Two non-boards and two added
v. External SCSI port
vi. Dual hot plug power supplies
vii. Dual Hot plug fans
viii. 2 PCI Express slots (1x4 lane and 1x8
lane)
ix. 2 PCI X slots (64bit/100MHz)
x. 2 PCI slots (one 32bit/33MHz, 5V & one
64bit/66Mz)
xi Redundant Server shall be provided,
wherever required.
xii. LED based 24” sized Monitors.
Preferred makes of OWS & Servers are DELL, HPCOMPAQ, Lenovo.
Page 553 of 680

4.03.03.07 Industrial grade managed type Ethernet switches
Industrial grade managed type Ethernet switches shall be provided with in built diagnostic
features, 20% spare ports & inbuilt redundant 24 V DC power supply features and
Integrated Security features (IPS, ACL, Firewall). Industrial grade managed type Ethernet
switch sh all be r ack m ounted and co mply with the I EC 61850 ( 3) a nd I EEE 1613
requirements. Switches shall have 10 GB module support for future upgradeability
4.03.03.08 The Firewall shall meet following minimum requirements:
Industrial grade Firewall appliance should facilitate multi-vendor, m ulti-application

environment and should support third-party products on open al liance. It should support
Active-Active configuration.
i. The firewall should contain following features:
(a) Stateful inspection of packets.
(b) NAT functionality, including dynamic and static NAT translations
(c) Latest version of SNMP

ii. The firewall must send log information to a se parate log server via an encr ypted
connection. Firewall logging must not impact firewall performance.
iii. Remote ne twork acce ss to t he firewall sh ould onl y be possible through t he
administration interface.
iv. The firewall administration station m ust be capable of pushing firewall se curity
policies and co nfigurations to i ndividual or m ultiple firewalls through a secure,
encrypted connection to the firewall administration interfaces.
v. Graphical User Interface (GUI) and a Command Line Interface (CLI) for making
changes to the firewall rules set should be provided. (Access to the firewalls via
the GUI or the CLI must be through an secure encrypted channel).
vi. Any changes or commands issued by an aut henticated user should be l ogged to
a dat abase co nfigured on any of t he machines i n t he LA N. The adm inistration
station must allow for a hierarchical architecture for rules set administration and
viewing of firewall configurations Management.
vii. The firewall must not support any unencrypted means of access to the firewall.
viii. It should Monitors ALL network traffic-traffic at Firewalls (Internet and external
networks), in the DMZ and detect known threat through deep packet inspection.
ix. Detects unknown threats via anomaly scanning.
x. Detect unknown threats via behavior pattern to protect from zero day attacks.
xi. Keeps up-to-date on new threats and vulnerabilities.
4.03.03.09 Software License:
The B idder sh all pr ovide so ftware l icense for al l so ftware being use d i n
DDCMIS/PLC/simulator/any other electronic/microprocessor based system. The software
licenses shall be pr ovided for the project (e.g. organisation or site license) and sh all not
be hardware/machine-specific. That is, if any hardware/machine is upgraded or changed,
the same license shall hold good and it shall not be nece ssary for Owner to seek a new
license/renew license due to upgradation/change of hardware/machine in
Page 554 of 680

DDCMIS/PLC/simulator/any other electronic/microprocessor based system at site. All

licenses shall be valid for the continuous service life of the plant.
In case the s/w license is dependent on no of points, then quantity to be considered is

30% above the finally implemented points.
Software Upgrades
As a customer/owner support, the Bidder shall periodically inform the designated officer
of the Owner about the software upgrades/new releases that would be t aking place after
the each system i s commissioned and handi ng over to ow ner, so that sa me ca n be
procured & implemented by bidder at site.
The future updated version of any type of software shall be su pplied free of cost as and
when such software is upgraded, on request by owner until 5 years from the date of
commissioning of the unit.
4.03.03.10 Separate Laptops shall also be provided with all master software loaded and engineering
of DDCMIS, DCS, simulator & any other control system individually. Similarly additional
Laptops shall be provided with all master software loaded and engineering of PLC
system individually.
As explained abov e, O ne N o. Lap t op w ith nece ssary m aster so ftware l oaded and
engineering of each control System shall be supplied individually.
4.03.03.11 SOFTWARE DOCUMENTATION AND SOFTWARE LISTINGS
All t echnical m anuals, r eference manuals, use r’s guide et c., i n E nglish r equired for
modification/editing/addition/deletion of features in the software of the DDCMIS, DCS &
PLC / any ot her m icroprocessor base d co ntrol s ystem/simulator e tc shall be f urnished.
The B idder sh all furnish a co mprehensive l ist o f al l sy stem/application so ftware
documentation after system finalisation for Owner’s review and approval.
The software l istings shall be su bmitted by t he B idder for so urce co de o f appl ication
software and all special-to-project data files.
4.03.04 Programming, Diagnostic and Engineering Work Station
There shall be Two ( 2) no. w ork st ation with 24” si zed (Industrial type) LED monitor,
associated hard disk 3½”, Two color laser jet printer and associated peripherals, as like
52X CD drive, DVD Drive, DVD/CD writer, 1 No. A3 sized Scanner copier cum laserjet
printer, and A3 heavy duty industrial grade Coloured LJP with DDCMIS.
For PLC based control system, same shall be provided as listed in Annexure A.
The Engineering stations provided wth DDCMIS, DCS & PLC shall have all the function
of pr ogramming/ co nfiguration/modification/ r econfiguration and docu mentation. T he
features and facilities to be included are as under:-
a) Configuration or re-configuration of a system.

b) Possibility to introduce or modify parameters.
c) Documentation of system configuration.
Page 555 of 680

4.05.00 Design Criteria for BOP packages’ Control System
4.05.01 Design Criteria for Programmable Logic Controller (PLC) System
The PLC for BOP packages shall have following features:
i. The PLC system shall fulfill and demands emanating from the domains
- Automation
- Monitoring
- Process control
- Management
- Engineering
ii. Uniform operator machine interface
iii. Reliable user guidance
iv. Comprehensive redundancy concept
v. Modern object oriented software structure
vi. Shall be able to communicate with external system and intelligent field equipment
vii. Simple central project planning and configuration aids
viii. Integrated documentation system
ix. Integrated diagnosis and service
x. Commissioning support
The Control System shall have on-line simulation & testing facility.
xii. The sy stem sh all hav e the flexibility to easi ly r econfigure any co ntroller at any
time without requiring additional hardware or system wiring changes and without
disabling other devices from their normal operation mode. Modifications shall not
require switching off power to any part of the system.
xiii. Fault Diagnostics
Complete so ftware for microprocessor based sy stem i ncluding the
communication so ftware bet ween sy stems, M IS sy stem et c., sh all be su pplied
and implemented. The software shall be also included for equipment performance
test, life evaluation, equipment capability curve and alarm analysis, Management
information system, etc.
xiv General I/O requirements of PLC based system shall be as per cl. No. 4.02.08.02,
4.03.11 and Annexure B.
xv Bidder t o not e t hat al l P LC sy stem sh all be f rom sa me manufacturer o nly. P LC
system supplied & engineered through system house shall not be acceptable. It
should be su pplied & engineered di rectly f rom P LC manufacturer o nly. It i s
preferred to hav e each PLC sy stem w ith har dwares from sa me family of P lant
DDCMIS.
xvi. Design & Functional Requirements a s p er t he c l. N o. 4. 02.00 d etailed f or
DDCMIS/DCS system shall be applicable for each PLC based control systems.
xvii. PLC shall be provided with necessary redundant ports & complete hardwares
for Auto time synchronization from Master clock time by bidder.
4.05.02 Technical specification for PLC
4.05.02.1 The l atest pr oven P LC system sh all be p rovided. P LC sh ould be so urced from o riginal
manufacturers; P LC from sy stem house sh all n ot be ac ceptable. P LC system sh all be
complete with hot standby redundant CPU of word length of 32bits minimum, Input /
Page 556 of 680

Output modules, dual serial link interface module for connecting Input / Output Modules,
dual Communication Processors, dual Memory modules and redundant Power supply
units. Power supply unit shall be redundant for each CPU & I/O rack. PLC system will be
interfaced with DDCMIS through OPC dual redundant communication interfacing (to be
provided at PLC & DDCMIS end) for important process parameters. PLC shall confirm to
IEC – 61131.
4.05.02.2 Redundant C PUs in h ot s tandby m ode sh all oper ate on fault tolerant mode w ith
continuous self and cross monitoring facility. Redundant CPU/controllers shall be pl aced
separately and shall not share the same motherboard.
Failure of the active CPU shall not adversely affect the operation of the plant in any
perceptible w ay. Fai lure o f t he ac tive C PU will l ead t o t ransfer o f t he t asks being
performed to the other healthy CPU within fastest possible transfer time (i.e. < 50 m sec.)
without causing any output to drop during the Transfer period. In the Event of the both
the C PU failure, the sy stem sh all r evert t o t he F ail-safe mode. The C PUs shall not be
loaded over 60% of the Individual capacity even under worst data loading conditions. It
shall be possi ble t o sw itch from the ac tive t o t he bac k-up C PU and v ice v ersa from
Operating s tation as well f rom the C PU f ront panel . ( The w orst dat a c ondition of P LC
means all modules in active mode, printer in operation, OLCS&CLCS logics active and
process in r unning co ndition). Data bus loading sh all not be more than 50% . This
configuration shall be applicable for each type of PLC based control system. Engineered
solutions for redundancy in CPU & I/O cards are not acceptable.
4.05.02.3 The sy stem sh all be o f m odular co nstruction and ex pandable b y addi ng har dware
modules and incorporating them in the address register. Bidder shall provide at least
20% ov erall w ith m inimum t wo no. sp are c hannels as hot-on-rail sp ares in ea ch
configured cards / Modules. In addition to this 10% or minimum one no. extra assigned
complete spare cards mounted on rails in sub-racks for each type of I/O modules shall
also to be pr ovided. The spare channel and ca rds shall be fully wired up to termination
cabinets. Spare Philosophy a s detailed i n c l . N o . 4 . 0 3 . 1 1 for D D C M I S / DCS
system shall be applicable for each PLC based control systems.
4.05.02.4 The memory uni t o f the C PU sh all be f ield ex pandable. T he memory c apacity sh all be
sufficient ( min. 8 M B pe r C PU) f or sy stem oper ation and sh all ha ve t he ca pability for
future expansion at least to the tune of 40%. The application program / sequence logic
etc. shall be stored in non-volatile memory (EPROM). However all the dynamic memories
shall be pr ovided with battery back up with at least for 96 hours. Lithium or Ni-cd battery
shall be use d. T he quantities of H ot s tandby r edundant C PU/controllers f or each P LC
system sh all be f inalized dur ing det ailed eng ineering by o wner d epending upon
CPU/controller’s worst dat a l oading co nditions and C PU/controller’s functional
distribution.
4.05.02.5 The max number of Input / Output points per card shall be 32 for digital and 16 for Analog
/ Thermocouple / RTD. No. of channels may also reduced to meet the I/O cards feature
specified in N IT. Individual input channels shall have galvanic isolation. Output points
shall al so ha ve opt ical / g alvanic isolation. M erely f using o f i ndividual or a gr oup of
channels is not acceptable. The I/O cards shall be rack mounted. Failure of Analogue I/O
cards, binary cards / modules shall also be displayed on the Engineering cum diagnostic
station.
Page 557 of 680

4.05.02.6 The data communication system of the PLC including that of its redundant system bus
with hot bac k up and ot her al lied buse s such u s I/O bus, l ocal bus etc., sh all fulfill t he
following m inimum features. The bi dder sh all furnish al l t he ca lculation details of C PU
utilization and Bus loading. Bidder shall also furnish communication protocol used for the
offered PLC.
i. Communication links (I/O bus) between CPU a nd individual Input & Output (I/O)
modules rack shall be dual redundant with 10 M bps speed and 16 bi t CRC data
protection feature. In no case failure of a link shall affect the control of the plant.
ii. The co mmunication sy stem desi gn sh all ensu re that any si ngle poi nt failure on
the sy stem bus / media sh all not di srupt not m ore t han si ngle m essage an d
disrupted message shall be automatically retransmitted after the standby
communication link takes over control.
iii. Failure of physical removal of any station / modules connected on the system bus
shall not lead to any loss of communication.
iv. Diagnostics display both at operating workstation and module front end shall be
provided for easy fault detection.
v. Bus change over from active bus to stand by bus, during failure of active bus shall
be performed automatically and bumpless. Such event shall be suitably logged or
alarmed.
vi. The system co mmunication bet ween P LC controllers and t he oper ators stations
shall be co nducted at high speed minimum 100 Mbps with Ethernet based open
protocol with no collision feature to avoid data jamming / overloading of the
system. The co mmunication bus, se rial l ink e tc. shall hav e adeq uate pr otection
against electrical noise and mechanical damage.
vii. System should have open bus structure and should allow further extension facility
and connection with any third party system.
h. PLC Network sh all al so be pr ovided w ith ex ternal su rge p rotection sy stem and
industrial firewall.
4.05.02.7 Man Machine I nterface (MMI) sh all be i ndustrially r uggedised Operator’s station base d
on latest window based market available software along with its peripherals like LED
monitor, pr inter, m ouse. E ngineering functions sh all nor mally be ca rried out f rom
dedicated workstation or operating st ation as per annexure-A “control system for BOP”.
In case a dedicated engineering station is provided, EWS shall also be worked as
operating station through password / Hardware lock. The monitor refresh time i.e. latency
time should be < 2 second.
4.05.02.8 The Operator’s station shall perform the following minimum requirements.
a. Selection of Auto / Manual, Open / Close operation, sequence auto, start / stop
operation etc.
b. Dynamic Mimic display detecting t he entire pr ocess for control m onitoring
purpose.
Page 558 of 680

c. Alarm m onitoring, r eport generation, l ogs, calculations and pr inting of l ogs,

reports, trends etc.
d. Online / historical trending, historical storage and retrieval of data.
4.05.02.9 Software pr ovided sh all be l atest, modular, up gradable and i ndustrially proven. I t shall
have capability for multi tasking, multi programming, multi user operation in real time
environment and su pport for t hird par ty sy stem. B idder sh all pr ovide t he following
minimum requirements:
1. Required software for fulfilling the complete implementation of the control logics,
operation di splays, l ogs, dat a st orage, r etrieval, di agnostic and ot her functional
requirements as indicated in this specification.
2. Detail documentation on al l programming software’s and this shall be pa rt of the
O & M manual.
3. Supply of Licensed version of all software both in edit and r un mode with multi –
user license. All the third party softwares should be latest and market available.
4.05.02.10 a. Bidder shall provide and connect suitable communication hardware / software/
cables and other accessories required for connecting all numerical relays as per
IEC – 61850 of auxiliary in PLC / SCADA where PLC with OWS.
b. Bidder sh all pr ovide f irewall ( hardware) i n v arious layers to p rotect P LC from

other ne twork as per I SA – SP – 99. Communication t o any t hird par ty sy stem
shall be via industrial grade anti spam, anti virus Firewall only.
c. Bidder shall provide redundant software/hardware link with “online” in Motion

Bridge computer and other belt weight system with CHP PLC system to calculate
coal flow to indicate following status:
i. Daily and cumulative coal unloaded by track hopper.

ii. Daily and cumulative coal sent to stockpile.
iii. Daily and cumulative coal sent to boiler bunker.
iv. Amount of coal available in stockpile.
d. Remote indication in centralized control room (DDCMIS) for total coal unloaded in
24 hours from ECHS shall be provided.
e. A pneumatic control valve s hall be pr ovided at the i nterconnection line between

service air header and instrument air header before air dryer unit. When instrument
air header pressure falls below set value, the control valve will start opening and
maintain the instrument header pressure at specified level in line with plant
requirement. A gain w hen i nstrument ai r header pr essure g oes abov e s pecified
level in line with plant requirement the control valve will fully close automatically.
Complete system shall be in bidder scope.
4.05.02.11 PLC shall specifically meet the following requirements:

(a) PLC shall have extensive self-diagnostic capability. Self diagnostics shall include
both module level diagnostics as well as channel level diagnostics
(b) PLC shall have h o t s t an db y redundant processors/controllers. This shal l
mean t h e fulfillment of the following requirements:
Page 559 of 680

(i) Automatic synchronisation of primary processor/controller of PLC with

secondary processor/controller
(ii) Bumpless switchover to secondary processor/controller of PLC when

the primary fails.
(c) Automatic program and data equalisation in the event of any on-line program /
edit executed in the primary processor/controller of PLC.
(d) Automatic “Forcing Bit” update in the secondary processor/ controller of PLC
when any “ Forcing is applied in the primary processor/controller of PLC.
4.05.03 SYSTEM REQUIREMENT & SPECIFICATION
4.05.03.1 The system shall have high MTBF and sh all be hot maintainable. The system hardware
shall be designed to be fault av oidant by selecting high grade components of proven
quality and properly thermally de-rated design. The system shall have extensive fault
monitoring, se lf su rveillance & on -line se lf di agnostic capability so t hat failure up t o
module / ca rd l evel i s immediately det ected. E ach o f the m odules shall hav e i ts self –
diagnostic system. The operator station located at the area control room shall be used for
fault data presentation and monitoring purpose.
4.05.03.2 The system shall have capability to automatically check & correct gain & drift for ADCs
on-line.
4.05.03.3 All data exchanged in a bus shall be fully monitored & checked for validity.
4.05.03.4 Loop Cycle time in PLC shall be equal to or less than.
a. OLCS : 100 ms or less

b. CLCS : 250ms or less
4.05.03.5 Following operations will be performed on I/Os, as required:
1. Square root extraction

2. Pressure & Temperature compensation
3. Responsibility check of all inputs (analog specially), validate and quality tagging
like good, bad, suspects etc
4. Channel wise engineering unit conversion.
5. Contact bounce filtering with adjustable time constant.
4.05.03.6 All controllers shall be freely configurable with respect to requisite control algorithms. An
extensive l ibrary of m acros shall be i ncluded f or t he pur pose adeq uate so ftware
capability shall be provided to implement closed loop control functions as follows:
i) P, PI, PD and PID control and their variations.

ii) Open loop (On- Off, sequence control)
iii) Cascade control
iv) Ratio control
4.05.03.7 For open Loop Controls, the system shall have, as a minimum, the following features:
Page 560 of 680

a) Logic functions like A ND/OR/NOT g ates, ti mers (on-delay, o ff-delay), sh ift

registers, counters, latches, flip-flops, mono – shots, tantalizers etc.
b) The automatic sequence control to ensure sequential start up and shut down of
auxiliaries / eq uipment. Sequence co ntrol sh all be per formed i n g roups initiated
by co mmand from oper ator’s console. A se quence sh all be m ade of st eps
executed in predetermined order according to logic criteria. For each step there
shall be a pr ovision for ‘waiting time’ and ‘ monitoring time’, and it shall output an
action on t he pr ocess. System sh all hav e t he ca pability t o b y pass one st ep i f
desired by the operating personnel by forcing an input or output from the
operator’s station. S uch act ion how ever w ill be r egistered as an ex ception or
alarm.
c) Increase the r eliability a nd av ailability of t he pl ant as a w hole, f or ex ample, by
timely and correct switchover to standby drives etc.
d) Basic interlock and protection logic related to safety of individual drive a nd plant
equipment. All inputs required for protection system shall be on high priority basis.
In the event of either loss of control power or control signal input to the drive, the
drive sh all r emain i n i ts last posi tion unl ess specifically r equired ot herwise. The
system sh all be desi gned su ch t hat no upse t o ccurs either t o p rocess or t o the
drive when the power is restored.
4.05.03.8 Interface of the PLC system with AC Solenoids & DC Solenoids shall be in the form of
potential free contacts via interposing relay modules mounted in the interposing r elay
cabinet. 20% addi tional interposing r elay m odules shall be pr ovided as installed sp are.
For A C so lenoids and co ntactors directly dr iven f rom out put ca rds, ar c suppressors &
MCB shall be provide across the coil.
4.05.03.9 Displays
4.05.03.9.1 The oper ator’s station s hall be r esponsible f or handling al l co mmands as well as in
generating desi red di splays, l ogs, r eports, al arms and pr intouts. S ecurity i n di fferent
levels shall be provided to prevent unauthorized access to the system.
4.05.03.9.2 Programming shall also be permissible by drawing Ladder or Boolean diagram or through
any easily understandable language. Single programming instruction / command shall be
sufficient to delete a program rung from memory. Similarly, any rung can be inserted into
the existing program. The active and the st andby CPU programs shall equalize
automatically, once the new program is permitted to ‘RUN’.
4.05.03.9.3 Updating time and reaction time (system’s response to an operator’s command) shall be
provided for operator station as follows:
a. Calling up a mimic : 1 sec or better

b. Updating status signal in mimic : 1 sec or better
c. Updating variables in a mimic : 1 sec or better.
d. Issuance of command to output : 2 sec. or better
(without considering travel time and process lag)
4.05.03.9.4 Programmable C ontroller sh all be r esponsible f or r eal t ime pr ocess Parameter

monitoring, storage and display. Basic requirements are (i) Operator Interface, (ii) Basic
Page 561 of 680

Calculation, ( iii) A larm Monitoring & R eporting, ( iv) D isplay g eneration, ( v) Lo gs, (vi)
Trend Recording & (vii) Historical Storage & Retrieval.
4.05.03.9.5 The di splays at the op erator co nsole sh all be cl assified i nto ov erview D isplay, g roup
display, point display, alarm display and trend display.
a) Overview display – This display is to enable the operator to set an overview of the
entire plant section.
b) Group di splay – The gr oup di splay page sh all di splay se veral su b-sections &
present status information.
c) Point di splay – Along w ith t he s pecified pa rameter v alue, t his page sh ould
indicate historical trend of the parameter.
d) Trend di splay – This display include r eal t ime/historical trend di splay facility
including Dynamic Graphic Display & Bar Graph Display.
e) Alarm Message Display – It shall be possible to display process as well as system

and di agnostic alarms for oper ator’s attention a nd act ion. A larm shall appear
immediately on t he operator station as and when they occur on pr iority basis. I n
addition to alarms appearing on displays, the system shall also be able to display
alarm summary and alarm history listing the date and time of occurrence, tag
number, poi nt descr iption, t ype of al arm ( absolute v alue or de viation), se rial
number of alarm in the sequence of occurrence etc. A larm shall disappear from
display on ly when they are acknowledged and cl eared. Any abnormal condition
in any sub-system or any ot her function devices shall be displayed as system
alarm message on the operator console irrespective of display selected.
4.05.03.9.6 The system shall print the following logs as minimum as defined in the Following clauses.
The printing of these logs shall be initiated automatically at prescribed time intervals, or
initiated on demand by the occurrence of predefined events.
Shift/Daily Log
A S hift/daily l og shall be pr ovided t o furnish dat a for routine a nalysis of pl ant
performance. This log shall be aut omatically printed at specified time each day and on
demand at any time.
4.05.04 Salient hardware / software features of the PLC system
The salient hardware / software features of the PLC system for I/O handling shall be as
follows.
1. Input filters to attenuate noise.

2. SWC of 500v DC common mode and 500V AC peak to peak
3. Comm. Mode Noise rejection for analog inputs of 120dB at 50 HZ
4. Normal mode noise rejection for analog inputs of 60 dB at 50 HZ
5. LED indicators on each card to show status of input
6. All the outputs shall be with individual fuse.
7. K type thermocouple mV input where applicable.
8. Pt-100 three wire resistance thermometer input where applicable.
Page 562 of 680

9. 24 V DC power supply to field mounted two wires transmitters.
4.05.04.1 The salient hardware / software features of the CPUs as follows:
a) Watch dog timer : Periodical reset, Alarm and interruption, if

not reset within stipulated time.
b) Max. Scan time for I/Ps : 1 sec. max. for measurments
c) Maximum Scan Rate : 2.5 ms (per k word)
d) Memory Capacity : 40% spare capacity after full utilization
Expandable in multiples of 16K.
e) Comm. Processor : Integral / Separate
f) Power Supply : Dual redundant at each CPU rack
g) Control Processor : 32 bit processor , RISC based.
h) Battery back up for RAM : Ni-Cd / lithium type, at least for 96 hrs
continuous Operations during power failure.
i) Diagnostic feature : Periodic, automatic, self-diagnostic. Result
available at the Operator’s Station.
4.05.04.2 Input / Output Modules:
Bidder t o note t hat A ll I/O ca rds shall be so urced from their or iginal
manufacturers/Principal. Indigenous cards shall not be accepted. No. of channels per I/O
card may reduced to meet the I/O cards features specified in NIT. The salient features of
the Input / Output modules are as follows:
a) All I/O Cards
1. Ambient temp. : 0-50 degree C

2. Surge withstand capability : IEC-255.4
3. Power Supply : Dual redundant at each I/O rack
b) Digital General
1. No. of channels / card : 32 max

2. Interrogation voltage : 24/48 VDC
3. Status Indicator : LED Type./channel
4. Isolation : Optical (channel to channel)
5. Electrical Isolation : between system and field
c) Digital Input Module
1. Contact bounces filtering : Adjustable time constant of 15m.sec.

2. Self Diagnostic : Wire break, Short Circuit
d) Digital Output Module
1. Output protection : Short ckt protected and individual fuse
e) Analog General
Page 563 of 680

1. No. of channels/card : Input /output – 16 channel

2. Isolation : Galvanic/Optical (channel to channel)
3. Status Indicator : LED Type./channel
4. Fuse protection for failure : Individual for each signal
f) Hi-Level Analog Input Module
1. Type of input : 4-20mA DC & 1-5VDC

2. A/D Converter : 14 bits + Sign (or better)
3. Accuracy : 0.1% or better
4. Diagnostic : A to D / Channel fault, Short
circuit, wire break
5. Power of transmitter : 24 V DC 2W type
g) Low Level Analog input Module
1. Type of output : PT-100; T/C (As required)

2. C-J-C : On Module
3. Accuracy : 0.1% or better
4. A/D converter : 14 bits + sign (or better)
5. Diagnostic : A to D / Channel fault, short
circuit, wire break
h) Analog Output Module
1. Type of output : 4-20mA DC

2. Accuracy : ±0.1% or better
3. Load : 600 OHM
4. Diagnostic : Channel fault
i) The maximum number of channels with LEDs indications that can be p rovided in
a single module shall be:
(i) Digital input module/ Digital output module - 32

(ii) 4-20mA input/output modules - 16
(iii) Thermocouple / RTD input module - 16
j. Input/Output modules shall have the following features:
The functions performed on digital inputs shall include:
(i) Signal isolation (optical)

(ii) Fuse protection & monitoring
(iii) Short circuit protection
(iii) Contact bounce protection
(iv) Contact monitoring for trip and causes of trip inputs
(v) Contact interrogation at 24/48 V DC
(vi) Configurable as status input, latched input or pulse input
(vii) Direct or reverse sense
(viii) Alarming of abnormal state
Page 564 of 680

k. Digital outputs shall have the following characteristics:
i) Individually fused
ii) Individual contact suppression
iii) Configurable as momentary, latched or pulse- width modulated
Outputs
iv) Individually definable default state
v) Output read back verification
vi) Short circuit protection
l. Analog inputs can be 4-20 mA DC, RTD, thermocouple. A/D converter shall have
a m inimum r esolution of 1 4 bits. Funct ions performed on anal og i nputs shall
include
i) Signal isolation (Galvanic/opto coupling)

ii) Fuse protection and fuse failure detection
iii) Transmitter power supply at 24 V DC
iv) Input filtering for noise level
v) Cold junction compensation for thermocouples
vi) Transmitter monitoring for parity, wire break, live zero and end
limit values
vii) Monitoring of A/D conversion
viii) Test for substituted value
ix) Conversion to engineering units
x) Test for normal or extended range
xi) Detection of open circuit for thermocouples
xii) Alarm limit testing for high, low, high high and low low
substituted values
xiii) Rate of change - positive and negative dead band
xiv) All analog signals fed to the control system shall be acquired and
validated.
m. Analog outputs shall be 4-20 mA DC with the following characteristics:
i) Direct or reverse operation

ii) D/A per output and power regulator per output
iii) Loop check back of output
iv) Default options upon failure
v) 5-segment output characterization
vi) Go to zero current
4.05.05 PLC Configuration:
The PLC configuration will have a hierarchy of industrial grade open system architecture
for management information system (MIS) and closed system architecture for plant
operation and control system.
The specification of Peripherals for Operator S tation, E ngg S tation & pr inters for
PLC/microprocessor based system shall be as same as specified at cl. no. 4.03.03.04.
Page 565 of 680

The complete MIS system including hardware, software, cables etc, as

required shall be provided. This shall acquire dynamic pre configured points and mimics
as required by Owner.
The closed system architecture for plant operation and control system is secure and
deterministic system for real time operations of the plant.
Industrial grade managed type Ethernet switches shall be provided with features as same
as specified at cl. no. 4.03.03.07.
PLC Network shall also be provided with external surge protection system and firewall.
"The Bus systems (like Profibus/ Modbus etc) or the Serial Port Systems (like RS-232/
RS-485 etc) shall be pr otected with suitable surge protection devices, confirming to the
latest IEC-61643-21 guidelines. T he surge handling capacity of device shall at least be
10 KA, 8/20 µSec between core-core and 20 K A, 8/20 µSec between core-ground. The
device shall be pluggable & on-site testable".
All the operator stations will be ’work st ations grade’ as same as specified at cl. n o.
4.03.03.04 and are required to reside on the main redundant bus running on IEEE 802.4
or IEEE 802.5 to facilitate determinism.
4.05.06 Redundancy Criteria (For details also refer chapter no. 2)
i. Redundancy of components and systems shall be dictated by availability criteria to

ensure t he sy stem a vailability t arget as well as safety c onsiderations in c ritical
applications.
ii. Dual/Triple redundancy f or s ensors and t ransmitters w ill b e us ed f or c ritical and
semi critical applications i.e for interlocks/trip/protection conditions (as decided by
Owner).
iii. The Wiring S cheme for i nputs/outputs to/from PLC co ntrol sy stem sh all be as
same specified at Vol. V, cl. No. 4.02.08.02.1.
iv. Sensor redundancy (1 out of 2 or 2 out of 3 ) requirement shall be indicated in the
respective control system.
v. The C PU / C ontrollers, c ommunication m odules, dat a hi ghway, po wer s upply
modules, etc for all PLCs shall be 100% hot standby redundant.
vi. All drive input/output modules redundancy shall be as per Annexure – B.
vii. All input/output of SCADA from/ to breaker & isolators shall be redundant.
viii. Redundant Cooling fans with fire retarded filter for panels/cabinets
4.05.07 CONTROL PANEL AND OPERATOR INTERFACE (For details also refer chapter no.
6)
i. Operating console desks for OPERATING STATION's and KB shall be provided

by bidder along with their printers in AC control room.
ii. OPERATING STATION/KBD shall generally be used for control and monitoring.
iii. Complete industrial grade Furniture for mounting Operating stations, Swivel
Chairs, Printers, Keyboards, Computer etc. shall be furnished by bidder.
Page 566 of 680

iv. In the Back up C ontrol desk and relay based system following operator interface
devices shall be provided as per Annexure A.
a) Control station (illuminated P.B. stations, Desk P.B., control switches etc).
b) Hardwired Annunciator with push buttons.
c) Coloured Mimic with LEDs for Drive status (ON, OFF, & trip) and level
(Low & High) of tanks.
d) Process recorders, indicators & A mmeters as deci ded dur ing det ailed
engineering.
v. Control panels housing the control cards/equipment marshalling cabinets shall be

located in a co ntrol room; and shall have IP-32 min. degree of protection as per
IS-13947 offering dust and vermin protections, 2 mm thick steel sheets (CRCA)
shall be adopt ed for fabrication, co nsistent with w eight o f dev ices, co ntrol
equipment t o be m ounted. U PS panel s shall b e w ith 2 m m t hick st eel sh eet
(CRCA). Cable gland plate thickness size shall be 3mm. Mimic shall be made of
Acrylic sheet with thickness of minimum 6/7 mm.
vi. Panels shall be furnished co mplete w ith requisite acce ssories such as
transformers, regulators, switch fuse units, MCB, MCCB and ot her power supply
equipment to adopt the sources of power supply to requirements of panel
mounted instruments and devices.
vii. All panels, cabinets and enclosures shall be furnished, fully, wired with necessary
provisions for convenience outlets, internal lighting, grounding, ventilation, space
heating, and v ibration i solation pads, doubl e co mpression ca ble glands, i ntegral
piping and other accessories as per IS: 5039- 1969.
viii. The sealing o f panel s/cabinets/enclosures bottom w ith bot tom plate. Double
compression cable glands and suitable sealing material to prevent entry of dust
shall be in t he B idder's scope. S uitable ar rangement for pr eventing fire
propagation through cable entry points like fire seals etc. shall also be provided at
cable entry points.
xi. Fire/Smoke D etector, N eoprene/silicon G asket, E xhaust Fans with l ouvers &
filters shall be provided in all consoles and panels.
x. All the panels shall be equipped with Anti vibration pad of 15 mm size.
xi. PLC with OWS –
a. All winding/Bearing Thermocouple/ RTD shall be connected to PLC.

b. All anal og i nputs i.e. Temperature, P ressure, flow, l evel, v ibration et c.
shall be connected to PLC.
c. Only important parameters shall be display on desk / Panel.
d. Bidder shall provide Ammeter on panel for all HT Motor current & > 15 KW
LT Motor and very important LT drives as decided during detail
engineering.
xii. PLC without OWS or Relay based control System –
a. All winding/ bea ring Temperature, T/C, R TD s hall be co nnected to 1 6
Page 567 of 680

Checklist for Serial Communication between maxDNA Systems and Foreign Device :BHEL
A Device Specific :
SN Parameters Options available Remarks if any
1 Modle No.& Make of Device
2 Communications Link Options Multidrop Peer to Peer N/w topology attached
3 Protocol Mode (Device is a) Master Slave Master/Slave
4 Protocol RTU ASCII Other -------------------
5 Master System maxDNA Other -------------------
6 Dist.bet.maxDNA System & Device* -------------- Feet --------------- Meters
B Electrical Spcific :
1 Interface Type RS232 RS422 RS485
2 Wiring at Device end 2 W ire 4 W ire
3 Transmission Channel Half Duplex Full Duplex
4 Baud Rates (bps) 1200 2400 4800 9600 19200
5 Databits 8 7
6 Stopbits 1 2
7 Parity None Odd Even
8 H/w & Software Handshake Yes No
9 Response Timeout time (Sec) -------------- Configurable timeout
10 Data Formats Supported Boolean Real Char Sn.Int UnSn.Int
11 Transmission mode Asynchronous Synchronous
C Application Specific : *
1 Primary Function* Data Acquisition Data Acquisition & Control
Download parameter s ets
2 Analog Points to read --------Nos. Details attached Details not attached
3 Analog Points to write --------Nos. Details attached Details not attached
4 Digital Points to read --------Nos. Details attached Details not attached
5 Digital Points to write --------Nos. Details attached Details not attached
6 Memory / Flag Points to read --------Nos. Details attached Details not attached
7 Memory / Flag Points to write --------Nos. Details attached Details not attached
D Hardware Specific :
1 Cable type Boolean cable Twisted pair cable
2 Cable Details Enclosed Yes No
3 Any specific Converter required Yes No Details enclosed
E Device Documents :
1 Manufacturer's Documents* Tech., Spec. Operating Manual
*Notes:
A6 To identify converter requirement and cable length.
C The sr.no.1 to 7 are reqd.to be furnished for interface impl. :such as Tagname,Description,point type,
modbus(Register) address,EU,range & device (dlave) address
C1 What is the primary purpose of the communications link?
E1 Reqd. Contents : This document must provide an overview of the device including its intended
use(a general technical,communication & electrical details)
Page 568 of 680

Format for vendor to furnish signal
Exchange list between DCS-PLC
Tag Name Tag Description Modbus address Point type Range Alarm Setpoint Alarm priority History reqd Function code
Page 569 of 680

FOR SECTION D

Format Agency $
Materials
1.0
/Components
Physical Inspection for
Dimensions, Painting, Cutouts,
Lifting / Locking Arrangements, Contract As per ref BHEL
Panels & Control
Components, Drawing Pocket, specifications, documents. Quality
1.1 Desks MA Visua l 100% 3/2 2 1
Mounting accessories, Plinth & Approved GA No physical Inspection
AV Pads, Cable Gland Plates, Drawings, BOQ damage. Report.
Hardwares, Hinges, Louvers &
Filters, Fans & Panel Lamps
Power Supply/Packs,
Physical Inspection As per BHEL
Battery & Battery Contract
Physical Damages reference Quality
1.2 charger, Transformer, MA Visua l 100% specifications, 3/2 2 1
Dimensions documents, Inspection
UPS. BOQ.
Mounting Accessories Test Report Report.
Indicating Lamp,
As per ref
Annunciator, Meters,
Physical Verification documents BHEL
Transducers, Signal Contract
Physical Damages No physical Quality
1.3 Converters, MA Visua l 100% specifications, 3/2 2 1
Dimensions damage. Test/ Inspection
Instruments, Single BOQ.
Accessories Calibration Report
Loop Controllers
report.
PLC processors, Physical Inspection Product
I/O modules, Power
• Identification Labels Catalogue, Data BHEL
Supply modules, As per ref
• Physical Damages sheets, Quality
1.4 Communication MA Visua l 100% documents. 3/2 2 1
• Quantity Approved Inspection
modules, Mounting Test Certificates
• Spare Capacity Configuration Report.
Racks, Ethernet
diagram, BOQ
$
Page 570 of 680
FOR SECTION D

Format Agency $
CPU, Monitor,
Physical Inspection Contract
Keyboard, Mouse,
Identification Labels, Tech. specifications,
CD Drives, Printers, As per BHEL
Specification Product
OS, System reference Quality
1.5 Physical Damages MA Visual 100% Catalogue, 3/2 2 1
Software, documents. Inspection
Accessories Approved GA /
Engineering software Report.
Installation arrangements for Configuration
in the form of
Computers & Printers drawing, BOQ.
Licensed CD.
$
Page 571 of 680
FOR SECTION D

Format Agency $
2.0 Ass embly

Functional Test for
Correct
HMI/OWS devices Approved BHEL
Operation of
such as Monitors, Operation Configuration Quality
2.1 MA Functional 100% interconnected 21 1
Keyboards, Mouse, Diagram & BOQ Inspection
Devices of HMI
Printers etc. and FAT Report.
system.
Approved GA
Drawing, Panel
BHEL
Hardware Functional Physical arrangement, Wiring Wiring Diagram,
Visual/ Test Quality
2.2 Verification. check & labeling, Continuity MA 100% IR & HV as per 22 1
Electrical Certification Inspection
Checking, IR & HV test relevant
Report.
International
standard
BHEL
Healthiness of all the All equipment to
Visual Approved power Quality
2.3 Po wering Up modules/equipment, associated MA 100% be healthy on 21 1
/Electrical supply scheme Inspection
with Powering of PLC system power ON
Report.
Healthiness of PLC modules on BHEL

2.4 Burn in test for PLC Continuous Energisation, Visual/ Test certification Quality
MA 100% F AT Procedure 22 1
modules Temperature maintenance Electrical as per FAT Inspection
Report.
$
Page 572 of 680
FOR SECTION D

Format Agency $
Factory
3.0 Acceptance Test
(FAT)
Input Output BHEL
Functional Visual/ Quality
3.1 I/O configuration, I/O operation MA 100% FAT Procedure AS per FAT 21 1
Verification Eletrical Inspection
Report.
BHEL
Processor Processor configuration,
Quality
3.2 Verification Powering up, standby operation MA Visual 100% FAT Procedure AS per FAT 21 1
Inspection
( as applicable) and Loading
Report.
BHEL
Power Supply Module
Quality
3.3 Verification Redundancy Operation MA Electrical 100% FAT Procedure AS per FAT 21 1
Inspection
Report.
Redundancy operation of
Communication BHEL
Communication System,
System Quality
3.4 Measurement of Response MA Electrical 100% FAT Procedure AS per FAT 21 1
Verification Inspection
Time, Communication with third
Report.
party system
Diagnostic BHEL
Verification Self Diagnostic features of PLC Quality
3.5 MA Visual 100% FAT Procedure AS per FAT 21 1
system Inspection
Report.
Operation of PLC driven
BHEL
Control Panel/Desk annunciation system, Mosaic,
Quality
3.6 Verification Push buttons & selector MA Visual 100% FAT Procedure AS per FAT 21 1
Inspection
switches, Indicating lamps
Report.
(i) Control Logics (ii) BHEL
Software
Engineering Features (iii) HMI Quality
3.7 Verification MA Visual 100% FAT Procedure AS per FAT 21 1
Features Inspection
Report.
$
Page 573 of 680
FOR SECTION D
SHEET 5 OF 8
FACTORY ACCEPTANCE TEST (FAT) PROCEDURE
This document covers procedure to conduct/witness PLC system functional tests in

order to demonstrate conformity to purc hase specifications and related engineering
documents. The test shall be conduc ted at the system suppliers works. The system
supplier shall conduct all functional te sts before commencing F AT and tes t results
shall be made available dur ing FAT. Vendor mus t fu rnish following r elevant
drawings, duly approved by BHEL Engineering, for reference during FAT.
a) Technical Specification of PLC.
b) PLC System Configuration
c) General Assembly Drawings.
d) Panel Wiring Diagrams.
e) Bill of Quantity for PLC System.
f) Logic Diagram.
g) HMI Schematics.
h) Input / Output List.
Further the vendor shall furnish applic able produc t specification, datasheets,
catalogues, test-certificates, and internal inspection records to enable F AT. Vendor
shall also submit, to the inspecting agency, his standard test procedure, for clauses
given below; where vendor’s standard practice has been referred.
APPLICABLE TEST PROCEDURE:
1. Input/Output Functional Verification.
Check for correctness of addressing of racks, slots and I/O modules as

per applicable PLC co nfiguration diagram. Appropriate signal generators
shall be used to simulate Input s and out puts to check operation and
SCAN time. Check online replacement of cards, p rocessors, power
supply etc.
2. Processor Verification
PLC Configuration drawing to be referred for ascertaining
i) Redundanc y
Page 574 of 680


FOR SECTION D
SHEET 6 OF 8
ii) Type (Hot or Cold) of redundancy
Both the processors are to be c hecked for healt hiness in case of

redundant configuration as per vendor’s standard practice. In case of hot
redundancy, switchover of control fr om primary processor to standby
processor shall be demonstrated fo r uninterrupted control and dat a
processing as per vendor’s s tandard practice. Switchover shall be
witnessed, by manual power off or resetting the Primary CPU or
simulating failure of primary processor. Checking should be by witnessing
the lighting up of Proc essor’s LEDs as per manufacturer’s product
standard.
Vendor shall demons trate, as pe r Vendor’s standard practice, adequate
Loading (Spare Capacity) of Processors, as mentioned in contract specs.
This shall be done, by simulating wors t load operation of fully integrated
PLC system.
3. Power Supply Module Verification
Check if PSM is in r edundant mode as per specific ation. Check the

healthiness of power supply fr om both the modules ’ lamp
indication/measurement. Simulate fa ilure of one PSM and verify that
standby PSM has taken over without any interruption.
4. Communication System Verification
Communication system has to be in line wit h approved PLC

Configuration Diagram. Verify that both the communication buses are
intact and connected. Communication between PLC processors, I/O rack,
OWS etc. is to be checked through simulation of input data. Simulate the
bus failur e by dis connection of working bus. Check that the
communication continues without interruption or loss of data.
Following response t imes are to be demonstrated as per v endor’s

standard practice for conformance to contract specifications:
1. Screen update time

2. I/O scan time
3. SOE resolution time
4. Data transfer time with third party system using Communication
Protocol as per Contract specif ication and as per quantum of data
as per approved signal exchange list.
5. Diagnostic Verification
Product Catalogue/Literature shall be referred for checking of all

diagnostic features. Hardware failure to be simulated by removing an I/O
Page 575 of 680


Module,PLAN
STANDARD QUALITY Processor, Communication
VOLUME IIB
Module, Power Supply module etc
from
FOR the ru nning system and verify
SECTION D
the co rresponding system diagnostic
messages.
SHEET 7 OF 8
6. Control Panel /Desk Verification
i) PLC driven annunc iation system should be checked by alar m

signal simulation.
ii) Push Button and sele ctor switch operation should be checked by
verification of corresponding change of status of Data Base point.
iii) Indicating lamp / MIMIC should be checked by corresponding Data

Base point simulation.
7. Software Verification
i). Control Logics:– Software switches, lamps and Analog sources shall
be used for simulation of field conditions .Control logics shall be
checked for its correct functionality as per approved logic schemes
ii). Engineering features:-

a) Online changing of parameters, set points.
b) Online modification in Control Logic Diagrams.
c) Online configuration of Graphics, Trends, Logs, HSR.
iii). HMI features:-

Check for configuration & ope ration of Graphics, Trends, Logs,
HSR and Alarms, in the for m of Displays and Printouts, by
simulation of Inputs as per approved documents.
8. Burn in Elevated Temperature test
Electronic equipment s shall be subjected to Burn in elevated temperature

test as per the procedure detailed below:
a) (i) PLC modules are kept at 50 Deg c under continuous energized

condition for 48 hours.
Page 576 of 680

STANDARD QUALITY PLAN QUALITY PLAN NO.: PE-QP-999-145-

I036___
FOR
VOLUME IIB
PROGRAMMABLE LOGIC CONTROLLER
SECTION D
REV. NO. 00 DATE:
23.03.2005
SHEET 8 OF 8
ii) 48 hour s test period shall be divid ed into 4 equal time segment of
12 hours duration eac h. For every 12 hours duration s egment, after
lapse of first 11 hours 110% of nominal voltage sha ll be applied to the
panel under test for a period of 30 minutes followed by application of
90% of nominal voltage for the next 30 minutes.
b) Assembled Panels with complete wiring shall be kept under continuous

energized condition for 120 hours at ambient temperature. Tem perature rise in
panels should be below 10 Deg C above ambient.
Page 577 of 680

Page 578 of 680

Page 579 of 680

F. SPECIFICATION
FOR
UN-INTERRUPTED
POWER
SUPPLY
Page 580 of 680

CHAPTER-7
UNINTERRUPTIBLE POWER SUPPLY SYSTEM & 24 V DC SYSTEMS
7.01.01 This subsection covers design, construction an d performance requirements of par allel
redundant i ndustrial grade U ninterruptible P ower S upply ( UPS) S ystem & par allel
redundant 24 V DC System to be furnished by the Bidder for BTG, Station C & I Package
& BO P/offsite packages & an y ot her co ntrol sy stem/sub sy stem sp ecified el sewhere i n
the sp ecification. The B idder sh all f urnish se parate par allel r edundant i ndustrial gr ade
UPS S ystem for each unit D DCMIS/DCS Package and se parate par allel r edundant
industrial gr ade U PS S ystem for each B OP p ackage i ncluding st atic inverters, s tatic
switches, manual bypass switch, chargers, A.C. Power distribution panels and Batteries
with all required isolating and protecting devices and all other equipment and accessories
required for co mpleteness of this system. B idder t o no te t hat there w ill be no co mmon
component l ike i n phas e t ransformer (IPT), co mmon pow er su pply t o any r edundant
component and common point of failure in the UPS & 24 V DC system.
7.01.02 The requirements of UPS system & 24 V DC system are specified herein on system
basis. The B idder shall be r esponsible for en gineering and furnishing a co mplete an d
operational system fully meeting the intent and requirements of this specification and
Owner approved drawings.
7.01.03 The equipment furnished under this subsection sh all meet t he requirements o f all
applicable codes and standards including ANSI, NEMA, TEEE, NEC and IS.
7.01.04 The U PS S ystem & 24 V D C s ystem har dware sh all be f rom t he l atest est ablished
product range of a qualified manufacturer. The Bidder shall furnish documents to satisfy
the ow ner t hat t he des ign, pe rformance and high av ailability of t he proposed U PS
System, 24 V DC system and all system components have been established by a
considerable record of successful operation in utility power station for similar application.
All UPS system & 24 V DC system cabinets, enclosures and distribution boards shall be
manufactured, assembled, wired and fully tested as a complete assembly as per the
requirements of this specification in the manufacturing works of a qualified manufacturer
prior t o sh ipment t o t he pr oject si te. C lass of i nsulation o f w ound co mponents (All
transformers, chokes/inductances etc.) shall be class H with temp rating up to class B.
7.01.05 The U PS, 24 V D C s ystem e quipment and t he co mplete sy stem sh all ha ve su rge
withstanding capability (SWC) to meet the requirements of A NSI C 3 7.90a – IEEE
Standard 472 –1974. UPS & 24 V DC charger system should be pr ovided with Class C
type surge protection device. The Class C type surge arrester should be single MOV type
, pl uggable, sh ould have f ault i ndication and sh ould be tested as per I EC 61643 -1 t o
withstand 40KA 8/20 µs pulse. The arresters should have potential free contact to ensure
maintainability.
7.01.06 All non-interrupting components of UPS system & 24 V DC systems shall be ca pable of
withstanding al l av ailable sh ort ci rcuit cu rrent without dam age. A dditionally, al l ci rcuit
interrupting components shall be capable of withstanding and interrupting all encountered
short circuit currents without damage.
Page 581 of 680

7.01.07 All co ntrol and i nstrument ci rcuits shall be f used. Fuse s shall be m ounted i nside t he
enclosures and shall have easy accessibility. Fuses shall be Buss man low-peak type or
Owner appr oved eq uivalent. A ll l oad f uses sh all be t o O wner’s approval eq ual. T he
Bidder shall co -ordinate all load and line fuses applications to ensure that load fuses
operate properly.
7.01.08 The bidder shall be responsible for ensuring that UPS System, 24 V DC system and the
downstream power distribution system f or equipment to be serviced by are coordinated
such that UPS loads continue to operate without interruption and i n accordance with the
power supply tolerance requirements (both voltage and frequency) for these UPS loads
as long as at least one source is within the limits of voltage and frequency as specified
herein. T he Bidder shall furnish single line diagrams with his proposal t o demonstrate
how this requirement is met for all equipment and system covered under Bidders scope.
7.01.09 The UPS system & 24 V DC System shall be installed in AC room.
7.01.10 Acoustic noise at rated linear load shall be < 75 dBA at 1 meter distance from UPS as
per ISO 3746.
7.02.00 FUNCTIONAL REQUIREMENTS OF UPS
7.02.01 CAPACITY O F U PS SYSTEM F OR main pl ant P ACKAGE, r emote I /O pane ls and

BOP/OFF-SITE PACKAGES
Parallel redundant UPS shall be sized by the bidder to cater to power for the bidder
furnished l oads such as plant co ntrol, monitoring sy stem. M in. ca pacity sh all be
considered as 150 KVA ( or as per sy stem r equirement i n ca se ca pacity i s higher t han
150 KVA) at 50 deg. C ambient. All microprocessor based system, I/o cards, digital
equipments, oper ating stations, pr inters, per ipherals, r eceiver i nstruments, S WAS,
CEMS, L VS, HMS, TSI, VM S, PAD O, C &I L ab, O perator t raining Simulator system and
other devices mounted in supervisory control desk, control panels and other
microprocessor based system for BTG shall be operated on UPS power.
Each I ndividual par allel r edundant U PS sh all be desi gned co nsidering 20 % desi gn
margin over and above any capacity mentioned in specification; UPS sizing calculation
shall be submitted for approval. While computing the base capacity of the UPS, inrush
requirements of connected loads shall be duly considered. The inrush shall be taken as
300% o f s teady st ate l oad l asting for 100 milli se conds. The ba se ca pacity sh all b e
computed by bidder on above basis and to provide for at least 10% variation to cater to
changed load requirements during detailed engineering stage. B idder shall detail in the
technical bi d, t he s teady st ate as well as inrush r equirements of eac h o f t he l oads
furnished by him and justify the selection of UPS capacity duly satisfying the requirement
of 20% design margin.
This base capacity shall be guaranteed at 240 V AC, 50 Hz single phase output at 50
deg. C & 95 % RH – non condensing at ambient conditions. Ratings other than standard
ratings of t he manufacture sh all not be acce ptable. N umber o f di stribution feeders in
completely r edundant configuration sh all be o ffered to su it t he l oad distribution as
decided during engineering. Spare feeders of at least 20% of the total number of feeders
with 2 nos. minimum spare feeder of each rating shall be built in.
Page 582 of 680

Separate industrial grade parallel redudnat UPS system for each set of Remote I/Os cum processor
panel of DDCMIS and each BOP/Offsite package & any other control system/sub system specified
elsewhere in the specification, shall be provided of suitable capacity with similar features as of main
plant UPS by the bidder. UPS system for remote I/Os panels and BOP/Offsite package & any other
control system/sub system specified elsewhere in the specification shall be kept in the respective
package UPS rooms.
UPS sizing calculation shall also be submitted for approval for each system/package. Diversity factor
shall be considered as 1 for calculating the UPS capacity.
7.02.02 The pa rallel r edundant Uninterruptible P ower S upply ( UPS) sy stem o f continuous duty
shall su pply, r egulated, filtered and uni nterrupted 240 V , 50 H z, si ngle phase pow er,
within specified tolerances, to system AC loads, UCB mounted monitoring system, and
other c ritical l oads. E ach o f these c ritical l oads shall r eceive one feeder from t he A C
Distribution B oard o f Inverter-“A” and ano ther feeder from t he A C D istribution B oard of
Inverter-“B”. However, each inverter shall supply only 50% loads under normal conditions
as indicated below. SLD of UPS as per NIT drawing # 114-17-0100 shall also be referred
by bidder.
7.02.03 All nece ssary equipment r equired for pr otecting U PS eq uipment and co nnected i nputs
and outputs shall be furnished by the Bidder as an integral part of this system. Complete
UPS system shall be automatic without any manual interference at any time of operation.
7.02.04 True, 100 % pa rallel r edundant co nfiguration a lso m eans availability of “ Criss-Cross
Redundancy”. H ence T he U PS s ystem desi gn sh all ensu re t hat i n ca se of one o f the
charger failure, the other healthy charger, shall feed to one of or both the invertors as the
case may be and continue to charge the common/individual DC battery banks at all load
conditions. U PS sy stem sh all w ork in “Criss-Cross R edundancy” configuration t o
safeguard the battery bank from unnecessary drainage. The bidder should note that this
situation should not in any way lead to the discharge of the DC battery and m aintain the
UPS power supply to all loads.
7.02.05 The i ndustrial g rade U PS sy stem f or B TG & for each i ndividual B OP pack age sh all
include the following equipment:
Sr. Descriptions Quantities for UPS of Quantities for UPS for

No. main plant Package each r emote I/O panel
& BOP package
1. 100% c apacity of I GBT 2 nos. 2 nos.
based P WM I nverter with
output Voltage, current,
frequency, K VA & K W
digital display/meter.
2. 100% ca pacity st atic (As required) 2 no. ( (As required) 2 no .(
switches with in put Min) Min)
Voltage, current, frequency
digital di splay/meter at
bypass line.
3. Manual by-pass switch 1 no. 1no.
4. 100% ca pacity o f 1 2 2 nos. -
Page 583 of 680

pulse controlled f loats-

cum-boast Chargers
5. 100% capacity of 6 pulse - 2 nos.
controlled floats-cum-
boast Chargers
6. 100% Battery Set each 2 set (each For 2 hour 1 se t (For 1 hour bac k-
back-up) up) in case of UPS
rating less than 15 KVA.
2 sets (For 1 hour back-
up) in case of UPS
rating more than 15
KVA.
7. Step-down transformer 1 no. 1 no.
(415 V, three phase , to
240V, single phase) of
required capacity)
8. Static Votage S tabilizer 1 set 1set
with i nput & out put O N
Red i ndication and i nput
& output Voltage, current,
frequency di gital
display/meter.
9. Input isolation 1 no. each 1 no. each
transformer with input &
output ON red indication
and input Voltage, current,
frequency di gital
display/meter.
Out put isolation
transformer
10. A.C. P ower D istribution 2 s ets (Quantities of 2 s ets (Quantities of
Panels (including 20 % feeders shall be as on feeders sh all be as on
spare feeders on eac h required basis). required basis).
panel with 2 no s.
minimum spare f eeder of
each rating) and digital
type A mmeter, V oltmeter,
Frequency m eter, P F
meter, Watt meter & VA
meter
11. Interconnecting A rmored As required As required
FRLS ST2 (inner & outer
sheath), PVC type C
insulated stranded
Copper co nductor power
Cable between
UPS equipment & battery,
UPS & ACDB, AC DB &
loads.
For em ergency t rip pu sh
Page 584 of 680

buttons, Fi re al arm
system, sa fety cr itical
circuit, t rip pr otection
circuit and for o ther
services specified
elsewhere in the
specification shall be fire
survival po wer ca ble
conforming to IEC 60331,
BS6387 ( CWZ), B S6207
standard and t his
specification.
12. MCCB ( At i nput, out put, 1 no. each 1 no. each
battery side, Bypass side,
ACDB si de et c) and t ie
breaker with ON, OF F &
Trip indication.
13. Online B attery H ealth 1 set 1 set
Monitoring System
14. Battery Junction Boxes 1 set each 1 set each
with M CCB, V oltmeter &
Current meter.
Any ot her eq uipment necessary f or co mpletion o f t he sy stem sh all be pr ovided b y
bidder.
All equipment, enclosures and accessories for UPS system shall be desi gned, arranged
assembled and connected in accordance with the requirements of this specification.
7.02.06 NORMAL OPERATION
Two inverters each of 100% capacity, two battery packs of 100% capacity and two 100%
battery chargers are used for main plant UPS. Two inverters each of 100% capacity, one
battery packs of 100% capacity and two 100% battery chargers are used for BOP
packages UPS.
1. During no rmal ope ration, U PS l oads shall be s upplied by bot h 100% capacity
inverters each working at 50% load. The inverters shall receive power from DC
source (Charger / B attery), their s tatic switches shall be i n the respective
“Inverter” position and t he manual by-pass switch shall be i n “Position-2”. In this
mode the two inverters shall act as standby for each other.
Necessary paralleling networks shall be included to ensure equal load sharing by

both i nverters. Load sh aring net work det ails shall be det ailed t o est ablish al l
functionalities including fuse clearance. C apabilities of the UPS System as well
as each 100% r ated i nverters are fully sa tisfied. I n addi tion t o U PS out put
paralleling, Rectifier DC outputs shall also be properly paralleled.
2. One inverter will act as “Master”, working on its internal oscillator and the other
inverter w ill f ollow b y u sing t he sy nchronizing si gnal from master i nverter for
automatic control of its output frequency.
Page 585 of 680

7.02.07 EMERGENCY OPERATION
The static transfer switches and the manual by-pass switch sh all pr ovide s witching
means during emergency operation as follows:
1. In case of failure of any inverter the static switch shall automatically transfer the
UPS Loads of faulty inverter (say Inverter – “A”) to the healthy Inverter-“B” which
will start working at 100% capacity. Thus the feeding of UPS power is continued
automatically t o al l l oad co nnected to bo th i nverters despite pow er su pply t o al l
UPS l oads co nnected t o bot h i nverters shall be maintained w ithout i nterruption.
Isolation of faulty inverter shall be automatic and achieved in less than 4 milli
seconds.
2. Based on inverter failure alarm, the operator will transfer manual by-pass switch
to “Position-1” bringing in the plant AC source as the standby source to healthy
Inverter –“B” now working at 100% capacity. In this mode the healthy Inverter-
“B” shall get the synchronizing signal from the stand by-AC source and automatic
synchronization, oper ation on i nternal osci llator and t ransfer / retransfer to
standby source shall be as follows:
i) The output frequency of the concerned inverter shall be automatically

synchronized with the plant stand-by source by using synchronizing signal
from t he st andby so urce. The frequency l imits for t his synchronism ar e
specified i n cl ause 7. 03.05. I f the frequency o f t he st andby so urce i s
beyond these limits, the Inverter frequency control shall be automatically
disconnected f rom stand-by sy nchronizing si gnal and t he i nverter sh all
maintain t he out put frequency at 50 H z within + 0.1 per cent under a ll
conditions of load and input voltage by working on their own internal
oscillators.
ii) During operation on its own internal oscillator, the inverters shall
continuously monitor the frequency of standby source. U pon restoration
of proper frequency conditions of stand-by source, the inverter shall
automatically start using stand-by source frequency as the synchronizing
signal for inverter output frequency control.
iii) During t he oper ation of any i nverter on i ts internal osci llator due to
synchronising frequency being beyond the specified limits, the transfer of
static switch from “Inverter” to “Standby” shall be inhibited.
3. During any fault in the branch circuit feeders or inverter output bus, the inverter
shall be capable of clearing a fast acting fuse of largest rating in 4 milliseconds
and simultaneously provide UPS power to all connected loads (i.e. 50% capacity).
In view of the above fault clearing capability of each inverter and due to
availability of plant AC source as standby source for inverters the static switches
shall not transfer the loads to the other inverter for fault clearing purposes.
4. Retransfer of static switch shall be manual in all cases and shall be accomplished
only after synchronism of the inverter output with the stand-by source has been
automatically accomplished.
Page 586 of 680

5. The manual by pass switch sh all hav e t he pr ovision ( position –4) f or f ully by-
passing the UPS system and connecting all UPS loads to the standby AC source.
This provision may be used during start up to limit the inrush current and at other
occasions at the option of the operator.
7.03.00 STATIC INVERTERS AND AUXILIARY EQUIPMENT
7.03.01 The static inverters shall be solid state type using proven IGBT based pulse width
modulation ( PWM) to convert direct current power to essentially si nusoidal alternating
current pow er as per t his specification. T he inverter eq uipment sh all i nclude al l
necessary ci rcuitry and dev ices to co nform t o r equirements like v oltage regulation,
current limiting, wave shaping, transient recovery, surge suppression network, automatic
synchronization etc. as specified herein.
7.03.02 INVERTER CAPACITY
Each st atic inverter sh all hav e t he following m inimum capabilities without ca using any
damage to the components and with current limit not operation :-
1) Continuous full load rating
2) Over load capacity: 125% of full load rating as above for 10 minutes, 150% for 1
minute, 200% for 10 se conds minimum & 300% for 4 m sec for all specified input
voltages.
3) Fuse clearing capacity : Upon a f ault in any branch circuit lateral feeder, the
inverter shall have the capacity to carry a load equal to one half of its full load
rating plus it shall clear the largest rated fast acting fuse in 4 milliseconds or less.
All f uses used i n i nverter pow er and co ntrol ci rcuit sh all be fast act ing type
operating i n l ess than 5 m illisecond and each o f these fuses shall be pr ovided
with k ick fuse and al arm co ntact. I ndication and al arm sh all be pr ovided t o
enable fault location.
4) Step load pick up: Upon transfer of full load, the inverter output voltage shall not
drop bel ow 85% o f nom inal v oltage du ring the first hal f cy cle a fter t ransfer an d
90% of nominal voltage in the next half cycle. The recovery to within + 1% of
voltage shall be in less than 50 milliseconds.
5) The inverter shall have sufficient I2t capacity to clear a slow acting HRC fuse
having a co ntinuous cu rrent rating e qual t o at l ease 20% o f the continuous full
load current rating of the inveter, while feeding 100% rated loads of the inverter.
7.03.03 INPUT VOLTAGE
The inverters shall be fed from a D C Battery and ch argers which do not feed any other
loads. I nput voltage shall be nom inal DC output voltage of battery and c harger of range
from final voltage after discharge of battery to maximum DC bus voltage during equalize
charging of battery. The inverter shall also be capable of working satisfactorily meeting
the specification requirements with only the chargers connected to its input without
battery in circuit. DC input window of each inverter shall be either 315-434 or 320-450 V
Page 587 of 680

DC. Filtering on t he input of the inverters shall be f urnished is required to operate within
the out put r ipple o f t he ch argers furnished by t he B idder. E ach i nverter sh all i nclude
equipment nece ssary t o pr otect i tself from dam age r esulting from ex cursios, l oss, or
restoration o f D C i nput voltage and sy nchrnising v oltage. The i nverter output v oltage
shall be 230 V AC , 50 Hz, Single phase.
7.03.04 OVER LOADS, SHORT CIRCUITS AND LOAD LOSS PROECTION
1. The inverters shall be pr ovided with suitable fuses at the input and output w hich
will permit proper co-ordination with other protective devices and at the same time
protect t he i nverter a gainst dam age due t o i nternal faults. A ll nece ssary
equipment sh all be pr ovided t o pr otect t he i nverters against ov er l oads, sh ort
circuits and 100% l oss of l oad. T he i nverter shall be se lf pr otecting ag ainst
damage if energized with full load connected.
2. The inverter shall be provided with current limiting circuitry which will limit the
output current to a value which will not damage the inverter or blow its fuses.
3. The i nverter sh all hav e sufficient I 2 t ca pability t o pr event dam age t o i tself unt il
short circuit conditions on the output are cleared.
4. Each inverter shall be capable of operation with nonlinear loads. For bidders
loads bidder shall detail the nature of non linearity. For loads provided by owner,
bidder m ay assu re a n on l inear w ave f orm w ith a cu rrent cr est factor o f 3 .0
occuring coincident with voltage peak. With nonlinearity consisting of third, fifth
and seventh order harmonics. Output waveform of the inverter(s) shall remain
within sp ecified l imits when oper ating w ith nonl inear l oads at 100 per cent r ated
load.
5. The i nverters shall be s elf pr otecting a gainst al l A C and D C t ransients, v oltage

surges and steady st ate abnormal voltages and current likely to be encountered
in utility power station.
7.03.05 Automatic Synchronisation
Inverter equipment shall include st able solid st ate oscillator devices designed to
automatically m aintain t he i nverter out put i n p hase and i n sy nchronization w ith t he
standby A C so urce. The frequency r egulation sh all be aut omatic within + 0.1 H z o f a ll
conditions of i nputs, l oads and temperature occu rring si multaneously or i n any
combination.
Facility shall be provided for automatic transfer to internal oscillator operation when the
standby source frequency is not within the synchronization limits.
Provision sh all be m ade f or st ep l ess adjustment o f sy nch di sconnect frequency r ange

from 50 Hz +/- 0.5 Hz to 50 Hz +/- 2 Hz.
Automatic adjustment o f phase r elationship be tween i nverter ou tput an d st andby A C

source sh all be g radual, at a co ntrolled sl ew r ate, w hich sh all not e xceed 0. 1 H z per
second.
Page 588 of 680

The inverter shall normally work on t he internal oscillator with either of the two inverters
as master synchronizer and the other following it. Suitable selector facility shall be
provided to select the master. When any one inverter fails the healthy inverter gets the
synchronizing signal from the standby AC source.
The D C i nputcurrent sh all ne ver ex ceed t he f ull l oad cu rrent ex cept for a sh ort ci rcuit
within the inverter. The limitation applies to transient as well as steady state currents and
includes in r ush cu rrents upto i nitial ener gisation o f t he U PS, l oad en ergisation, short
circuits external to the inverter etc. For any value of the load and load power factor drawn
by t he eq uipment se rved, t he i nverter sh all not i mpose on D C so urce any v oltage
oscillations in excess of 5 volts (RMS total, all frequencies) or any current oscillations in
excess of 3 %(RMS total, all frequencies ) of the DC current at full load.
7.03.06 The i nverter sh all m eet t he f ollowing sp ecifications in add ition t o ot her r equirements
stated herein :-
1. Voltage input : As per system

(Battery output ) requirement
2. Nominal voltage output: 240V, 50Hz, single phase
3. Inverter capacity : As per clause 7.03.02
(output KVA)
4. Voltage regulation :
a) Steady state : +1%

(0-100% load
at all input
voltages & all power factors)
b) Transient voltage : + 5%
regulation
(on application or
removal of 100% load)
c) Time to recover : <50 milli

from transient second
to normal voltage
with + 1% of steady
state ( on application
or removal of 100% load)
5. Wave Form
a) Nominal : 50 Hz
Frequency
b) Frequency regulation : + 0.1Hz
for all conditions of
input supplies, loads
and temperature occurring
simultaneously or in any
combination
(automatically controlled)
Page 589 of 680

c) Synchronization : 48 Hz to
limits ( for maintenance 52 Hz
& synchronism between the ( factory
inverter and standby AC test)
source).
d) Field adjustment : 50 + 0.5 Hz
range for (c ) to 50 + 2 Hz
above
e) Total harmonic : <4% max.
content
f) Harmonic content : <2.5%
max.for any single harmonic
6. Rated output current at rated output voltage with current limit not
operating :
a) Current : 200%
b) Duration : 10 seconds
7. Overload capacity at 100%

voltage :
a) For 4 ms (fuse clearing): App. 300%

b) For 10 seconds : 200%
c) For 10 minutes : 125%
d) The proposed inverter has : ---
the capacity to clear
largest acting fuse in
5 milli second &
without entering into
current limiting mode
8. Efficiency (watt output/watt input )
a) at 100% load 1.0 P.F. / 0.8 P.F: >91%/ 91%

b) at 75% load 1.0. P.F. / 0.8 P.F. : >90% / 90%
c) at 50% load 1.0 P.F. / 0.8 P.F. : >89% /89 %
9. Duty : Continuous
10. Cooling : Natural convection
or forced cooling
using redundant fans.
Equipment to be
designed for operation with
full load even without cooling
availability.
11. Ambient temperature : 50 deg C, maximum
12. SCR derating from : 50%
Page 590 of 680

peak voltage and peak ratings.
7.03.06 STATIC INVERTER AUXILIARY EQUIPMENT
In addi tion t o t he i nverter e quipment sp ecified abov e, au xiliary equipment sh all be

furnished with each static inverter as follows:
1) Equipment and material furnished, mounted and wired on the front panel of the
inverter enclosures :
ITEM QUANTITY
Output ammeter, AC, indicating, Scale-0 to 1

150 percent of rated continuous full load inverter
output current, 1 percent accuracy.
Output voltmeter, AC, indicating 0-300 volt scale, 1

1 percent accuracy.
Output KVA, AC indicating scale 0-150 percent of 1
Rated capacity, 1 percent accuracy.
Input voltmeter DC, indicating 0-300 volts scale, 1
1 percent accuracy.
Frequency meter, 45-55 hertz, 1 percent accuracy. 1
Power factor meter, (0-1. 0-0), 1 percent accuracy
Inverter ON-OFF switch 1
Alarm Reset Push Button 1
2) Indicating l ights listed bel ow with pr oper act uating dev ices, ci rcuitry and l egend
shall be furnished on front of the Ups panels. For these abnormal conditions
which co uld be o f a momentary nat ure, t he i ndicating l ights sh all r emain
energized and t he co ntract r emain cl osed unt il cleared by a r eset push but ton
furnished on the panel. The indicating lights shall be of make subject to Owner’s
approval.
The following indications shall be provided as a minimum :
a) DC voltage to the Inverter - Low

b) DC voltage to the Inverter - High
c) Loss of DC input to the inverter
d) Inverter output voltage - High
e) Inverter output voltage – Low ( after a t ime
delay to avoid unnecessary alarm due to low voltage on load in rush etc.)
f) Inverter A failure / Inverter B failure
g) Standby AC source failure
h) Inverter A / Inverter B not synchronized with AC source
i) Automatic transfer to AC source. Blown Fuse or Tripped Breaker.
j) Inverter A/ Inverter B feeding 100% UPS Load
k) Standby source feeding 100% UPS loads
l) Redundant fan failure and temperature high ( if provided)
7.04.00 STATIC TRANSFER SWITCHES AND AUXILIARY EQUIPMENT
Page 591 of 680

7.04.01 The static transfer switches shall be provided to perform the following functions
1) To transfer the load automatically without any break between the inverter to the
standby i nverter as required t o m aintain t he co ntinuity of pow er su pply to U PS
connection loads. The load shall be automatically transferred from “Inverter” to
the inverter source upon any malfunction of one inverter.
2) To t ransfer U PS l oad under m anual co ntrol from st andby A C so urce t o i nverter

when placing the UPS System in service and f rom inverter to standby AC source
when taking the UPS out of service.
7.04.02 The static transfer switches shall ha ve t wo modes of operation namely automatic and
manual.
7.04.03 The static transfer switches shall use silicon controlled rectifiers and other static devices
required for automatic transfer of load from “Inverter” to Standby” source and vice versa.
The s tatic switches shall co nform to the r equirements sp ecified her ein i ncluding t he
following:
1. Capacity (continuous) : Equal to the continuous full load capacity of the inverter.
2. Capacity (overload) : 200% for 10 seconds, 150% of continuous for 60 seconds
and 125% of continuous rating for 10 minutes and 300% of continuous rating for
4 msec.
3. Capacity (Peak) : 1000 % of continuous rating for 5 cycles.
4. Transfer Time : < 4 msec. The transition shall be “ make before break”, voltage
failure shall be sensed at the output of the static switch.
5. Voltage Rating ( Nominal) : 240 Volts, 50 Hz. Single phase.
6. Transient Voltage Tolerance : 340 Volts peak above the normal line voltage.
7. Ambient temperature : 50 deg C max.
8. Cooling : Natural or forced circulation , using redundant fans.
9. Duty : Continuous
7.04.05 TRANSFER INITIATION
1) The transfer of static switch from normal “Inverter” position to “Stand-by” position
shall be initiated by one of the following causes :
a) Inverter failure and UPS System trouble

b) Inverter output voltage failure
c) Over current
d) Manual push button operation
e) Static Output voltage failure.
2) The UPS bus shall be monitored by two voltage detectors. One fast acting circuit
shall be use d for detecting a co mplete and i nstantaneous, voltage loss while the
other slower acting averaging circuit with adjustable trip level shall be employed
to detect voltage deviation beyond selected limits. B oth voltage detector circuits
shall automatically initiate operation of static transfer switch.
Page 592 of 680

3) The static switch shall automatically transfer the load from inverter to stand-by AC
source w hen t he m aximum I2t ca pability of t he i nverter is reached w hen t he
inverter output voltage drops below 90%.
4) UPS bus current sh all be co ntinuously m onitored by a cu rrent m onitoring

detector. T his detector sh all oper ate t he st atic transfer sw itch when t he l oad
current exceeds the overload rating of any inverter. The detector shall rest when
the load current falls below the rated current of the inverter resulting in retransfer
of static switch with inverter position.
5) Over current transfer limit shall be continuously adjustable from inverter

continuous rating to inverter current limit rating.
7.04.06 TRANSFER INHIBIT
The transfer of static switch shall be inhibited under the following conditions:
1) Automatic or manual transfer of load from inverter to stand-by AC source or vice

versa, sh all be i nhibited w hen t he i nverter frequency i s not sy nchronized t o the
alternative source.
2) Transfer resulting from overload shall be inhibited when the standby AC source is
not available. In this case the load fed by the inverter shall be automatically
disconnected
7.04.07 RETRANSFER TO NORMAL
1) The retransfer to normal shall be manual in all cases.
2) Manual transfers shall be initiated by push button actuation.
7.04.08 Static transfer sw itches shall be pr ovided with nece ssary pr otective dev ices (circuit
breakers / current limiting fuses) both in “Normal” as well as “Stand-by” position.
7.04.09 The s tatic transfer sw itches shall be pr ovided dul y m ounted and w ired i n encl osures
furnished by the bidder.
7.04.10 The s tatic switches shall be f urnished w ith co ntacts to al arm failure o f t he al ternate
source or opening of any fuse protecting the static switches.
7.05.00 MANUAL BY-PASS SWITCH
7.05.01 The m anual by -pass switch w ill be use d t o i solate any st atic switch f rom i ts load and
stand-by pow er su pply and t o take the st atic sw itch out o f se rvice w ithout pow er
interruption to the load. In doing so the manual by-pass switch shall connect both load
buses to a si ngle inverter. T he manual by-pass switch shall also provide the facility for
bypassing the entire UPS system during start up at the option of the operator.
7.05.02 The manual bypass switch shall have make before break contacts to ensure continuous
supply to UPS loads during the operation of this by-pass switch.
Page 593 of 680

7.05.03 The manual by-pass switch shall be rated for 600 Volts, 50 Hz, single phase operation. It
shall hav e co ntinuous load ca rrying ca pacity eq ual t o full l oad i nverter cu rrent and
necessary short term load carrying and interrupting capacity to meet the requirements of
the UPS system.
7.05.04 All other by-pass and disconnect devices shall be pr ovided by the Bidder as required for
orderly st art up and s hut dow n and m aintenance o f U PS sy stem and sy stem
components.
7.05.05 The Bidder shall provide potential free contacts, one closed in each position, for use in
DDCMIS & PLC system.
7.05.06 The m anual by-pass switch and r equired di sconnect dev ices shall be furnished dul y
mounted and wired in enclosure, furnished by the Bidder.
7.06.00 FLOAT-CUM-BOOST CHARGERS AND AUXILIARY EQUIPMENT
Two no. 100 % ca pacity S CR base d fully co ntrolled 12 pul se float cu m boost ch argers
shall be f urnished for m ain B TG U PS sy stem a nd T wo no. 100% ca pacity S CR base d
fully co ntrolled 6 pul se f loat cu m boos t ch argers sh all be f urnished for BOP pac kages
UPS system. Each charger shall confirm to the following requirements.
7.06.01 CHARGER CAPACITY
Each charger furnished for UPS system shall be adequately rated to ensure that any one
shall m eet full D C l oad of U P sy stem oper ating at 100% r ating pl us recharge the f ully
discharged UPS battery within 8 hours.
The Bidder shall furnish the charger rating calculations to the Owner to satisfy that this
requirement is met. The charger shall be furnished as per rating approved by the Owner
during engineering stage.
7.06.02 The ch argers shall be s upplied f rom a 415 v olt, 50 H z. 3 phase sy stem. The ch argers
shall maintain the output voltage within plus and minus 0.5 percent from no load to full
load with an input power supply deviation in voltage level of plus or minus 10 percent and
input pow er su pply deviation i n f requency o f pl us or m inus 5 per cent and with bot h
deviations present in any combination.
7.06.03 In addition to supplying DC power for inverters, the chargers shall be designed to charge
a fully discharged battery without over loading or causing over voltage or without causing
interrupting operation of AC or DC circuit breakers for the entire range of intended
operating r egimes. S uitable so lid st ate el ectronic circuits shall be pr ovided t o ensu re
that the ch arging current i s voltage regulated an d cu rrent l imited. A fter t he bat tery i s
recharged the charger shall maintain the battery at full charge until the next emergency
operation when the UPS battery is again required to provide DC power.
7.06.04 Float and equalizing controls shall have an adjustment range of + 5% continuous
(without steps).
Page 594 of 680

7.06.05 The chargers shall be self-regulating, solid state, silicon controlled, full-wave rectifier type
designed for single and parallel operation with the battery specified under clause 7.07.00.
The chargers shall be designed for automatic load sharing during parallel operation.
7.06.06 The charger sh all be current limited at 125% of full load to r educe out put voltage for
charger circuit protection and for protection of battery from overcharge. The current limit
shall be continuously adjustable from 80% to 125%.
7.06.07 All necessary equipment and devices shall be pr ovided to protect the charger from short
circuits, t ransient v oltage su rges, l oad and su pply fluctuation i ncluding su dden l oss of
input or load.
7.06.08 The charger shall have a slow walk-in circuit which shall prevent application of full load
DC current in less than 10 seconds after AC power is energized.
7.06.09 The m inimum f ull load efficiency at nominal input and float output shall be 96 %.The
output regulation, ripple co ntent and pow er factor sh all m eet t he requirements o f U PS
system as well as the inverters furnished by the Bidder as per clause 7.03.00.
7.06.10 Chargers and auxiliary equipment shall be mounted in free standing cabinets furnished
by the Bidder. C harger cabinets shall be folded steel construction with top, front, back
and sides fabricated from not less than 3 m m thick sheet steel. T he cabinet front, back,
end sides shall extend to the floor to present a finished appearance. C abinet door shall
be pr ovided t o pe rmit e asy acce ss to al l co mponents for m aintenance o r r eplacement.
Doors shall have concealed hinges and three-point latches. Louvers shall be provided
for ventilation as required for operation at the specified ambient but the cabinet top shall
be solid. All louver openings shall be covered with corrosion resistant fine screen
coverings.
7.06.11 GROUND DETECTOR SYSTEM
a) Each ch arger sh all be furnished w ith a g round det ector sy stem co nsisting o f a
relay and a center tapped resistor. The resistor shall be connected between the
positive bus and the negative bus.
The r elay co il sh all be connected bet ween t he ce ntre t ap o f t he r esistor and

ground. The r elay sh all be f urnished w ith one n ormally open and one n ormally
closed contact wired to terminal blocks for connection to external circuits.
7.06.12 UPS Signal interfacing with DDCMIS/DCS & PLC
a) The bidder shall provide alarms and status indications, current, voltage
,frequency, P F et c through se rial l ink w ith MODBUS or anot her co mpatible
protocol .
b) The Bidder shall furnish 4-20 mA signals to DDCMIS/PLC for the following:
i) Inverter A & B output voltages

ii) Inverter A & B output currents
iii) Inverter A&B output frequency
Page 595 of 680

c) List of alarms (min.) to DDCMIS through potential free contacts shall be as

follows:-
i. Rectifier – 1 Trip.
ii. Inverter – 1 Trip.
iii. UPS battery low.
iv. Rectifier – 2 Trip.
v. Inverter – 2 Trip.
vi. Load on static Bypass.
vii. Static Bypass failure
viii. ACDB – 1 Incomer Tripped.
ix. ACDB – 2 Incomer Tripped.
x. UPS – 1 Fan Tripped.
xi. UPS – 2 Fan Tripped.
7.07.00 UPS/24 V DC System BATTERY AND ACCESSORIES
The UPS/24 V DC system batteries shall be heavy duty Ni-Cd type as specified below:
i. Expected se rvice l ife i s greater t han 20 y ears when oper ated on float o r t rickle
charge.
ii. Low maintenance – minimal topping up frequency and self - discharge.
iii. Capable of rapid recharging.
iv. Transparent containers for ease of inspection and maintenance.
v. Battery racks provided for battery shall be 2 t ier made from heavy teak wood to
bear 150% over load, anti acid paint etc.
vi. One no. 2 sided Folding Aluminium ladder (height 180 cm) for maintenance &
removal of battery cells and mounting bracket for ladder shall be provided by
bidder with each battery set.
The bat teries shall be heavy dut y N ickel-cadmium Fiber pl ated type and sh all be
sized f or an hou r o f full l oad oper ation dur ing n on-availability of A C su pply / ch argers.
The Ni-Cd batteries shall conform to IS:10918. For sizing calculation, design margin of
120%, an aging factor of 0.8 and a t emperature correction factor (Based on temperature
characteristics curve to be submitted by the Bidder and at a temperature of 4 deg. C).
Capacity f actor sh all be t aken i nto co nsideration, and am bient t emperature sh all be
considered as the electrolytic temperature. The sizing of the battery shall be as approved
by Owner during detailed engineering. However, Bidder shall consider a suitable voltage
drop from ba ttery r oom to U PS and U PS t o l oad, w hile si zing t he bat tery. The sy stem
shall also be su itably designed to overcome any over voltage that may arise during low-
load operation of the charger. The bidder shall clearly bring out in his offer how the same
is being implemented.
The battery size shall be calculated taking UPS/24 V DC system capacities as base load.
Bidder shall also consider voltage drop from battery room to UPS/24 V DC systems,
while si zing t he bat tery. For P lant U PS & p lant 24 V D C sy stem, bat tery back up t ime
shall be 2 hour s and for BOP packages UPS & BOP 24 V DC system, the back up time
shall be for 1 hour.
For Fire alarm panels, batteries shall be provided with min. 10 hours backup.
Page 596 of 680

7.07.01 In order to monitor the batteries, online battery health monitoring system shall be
employed. I t i s a bat tery m anagement sy stem base d on m onitoring t he v oltage o f
individual battery cell, which provide the information/details about battery health status to
end use r/owner. C omplete ha rdware l ike de tector uni ts, B attery cl ips, cables, monitor
(power control unit) and other accessories etc as required to complete the system shall
be pr ovided by bidder. LED i ndication sh all be pr ovided on det ector uni ts for pow er,
alarm and R UN indication etc. Data from Online Battery Health Monitoring System shall
be co mmunicate/transferred to D DCMIS f or M onitoring and anal ysis using di fferent
protocol like RS485 Modbus/OPC etc.
7.07.02 One complete set of all accessories and devices required for maintenance and testing of
batteries shall be supplied for each set of the batteries of each unit/plant auxiliary system.
Each set include at least the following:
a) Hydrometer 5 Nos
b) Set of hydrometer syringes suitable for
the vent holes in different cells 5 Nos
c) Thermometer for measuring electrolyte temperature 5 Nos
d) Specific gravity correction chart 5 Nos
e) Wall mounting type holder made of teak woodfor
hydrometer & thermometer 5 Nos
f) cell testing voltmeter(3-0-3 V) 5 Nos
g) Alkali mixing jar 5 Nos
h) Rubber aprons 5 Nos
i) Pair of rubber gloves 5 Nos
j) Set of spanners 5 Nos
k) No smoking notice for each battery room 2 Nos
l) Goggles (industrial) 5 Nos
m) Instruction card 10 Nos
n) Minimum and maximum temperature indicator
for battery room 1 No.
o) Cell lifting facility 1 Set
p) Vent Caps 2 set
q) Terminal Bolts & Washers 1 Set
r) Plastic Filling Bottles 10 Nos.
s) Alkali resistant funnel & Mugs 10 Nos.
7.07.03 Cell booster charger shall be provided with main plant UPS & 24 V DC batteries set to
charge the new & sick cell for revival of cell. The cell booster shall be built in separate
portable panel. Resistive load discharge bank shall also be provided with main plant UPS
& 24 V DC batteries set to discharge the batteries in case of over charged batteries.
7.08.00 VOLTAGE STATIC STABILISER
7.08.01 One 415 Volt, 3 phase to 240 Volt, single phase transformer along with associated static
voltage stabilizer shall be furnished with each UPS set.
This transformer and stabilizer combination shall convert 415 V olt + 10% plant auxiliary
AC supply to 240V + 1% single phase standby AC Power which will serve as UPS
system back up supply source.
Page 597 of 680

7.08.02 The transformer and stabilizer shall be sized for 100 percent UPS load and shall
coordinate w ith the l argest br anch ci rcuit pr otection device for feeder short ci rcuit
current without sacrificing voltage regulation. The voltage stabilizer shall employ silicon
solid state circuitry and shall maintain the specified output voltage for 0-100% load with
input voltage variations as indicated above. Class of insulation of wound components
like transformers etc shall be class H with temp rating up to class B.
7.08.03 The stabilizer shall meet the following characteristics as a minimum

- Fast rate of correction - within 5 cycles
- Output distortion - less than 5% under worst conditions
- Efficiency - better than 95%
- Overload Capacity – 300% for 200 mSec.
The make and rating shall be subjected to Owners approval.
7.09.00 24 V DC CONTROL POWER SUPPLY SYSTEM FOR MAIN PLANT
7.09.01 The bi dder sh all o ffer a completely se parate par allel r edundant sy stem with 50 % l oad
sharing on each charger to cater to 24 V DC requirements for control, protection interlock
& se quencing sy stems for B TG ( Turbine pr otection, M FT & so lenoid v alves etc.). 24V
DC system shall consist of
1. 100% ca pacity 12 P ulse float c um 2 nos. ch arger i n par allel

booster charger redundant configuration
2. Battery Bank for 100 % load 2 Bank (100% capacity) each
for 120 minutes back up
3. DCDB (including 20 % spare feeders 2 set, ( Quantities of feeders
on each panel with 2 nos. m inimum shall be as on required basis).
spare feeder of each rating)
4. Armored FR LS S T2 (inner & out er Complete power cables for 24
sheath), P VC t ype C i nsulated V D C sy stem with b attery,
stranded copper conductor Cables. DCDB and loads.
For em ergency t rip p ush but tons,
Fire alarm system, safety critical
circuit, t rip pr otection ci rcuit and for
other services specified elsewhere in
the specification shall be fire survival
power cable conforming t o I EC
60331, B S6387 (CWZ), B S6207
standard and this specification.
5. MCCB (At input, output, battery side, 1 no. each
& DCDB si de e tc) with O N, O FF &
Trip indication.
Input for 24 V DC systems shall be from 3 phas e MCC system. 24VDC power supply to
load will be through MCCB, MCB, and r edundant feeders DCDB - 1 and DCDB – 2.
Grounding cubicle for 24 V DC system shall be included in scope of supply.
SLD of 24 V DC charger system as per NIT drawing # 114-17-0200 shall also be referred
by bidder.
Page 598 of 680

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599 of 680
Page

7.11.00 CONSTRUCTIONAL FEATURES FOR CABINETS/ENCLOSURES
The C onstruction det ails for U PS & 24 V D C c harger sy stem ca binets/enclosure sh all
conform to the requirements indicated in chapter 6.
7.11.01 Grounding
Normal, AC power supply will be g rounded at the source. For grounding other than this,
I/P and O/P isolation transformers shall be furnished with the UPS.
7.11.02 All the transformers used any where in UPS & 24 V DC charger circuitry shall be copper
wire winded with class H insulation.
7.12.00 DC DISTRIBUTION BOARD PANEL
7.12.01 Distribution board shall be furnished with components, devices and materials meeting the
requirements specified herein.
7.12.02 Each DC distribution board shall be constructed for 2 wire DC distribution .All bus bars
shall be of solid copper. Each panel shall have four double pole 800 amps MCCB and
properly sized fuses for three incoming feeders (two from chargers and one from battery)
and two double pole 800 amps Moulded case circuit breakers with thermal over current
relays and electromagnetic over current relays for two out going feeders to inverters.
Isolators and circuit breakers shall open and close with snap action. Fuses of appropriate
capacity sh all be pr ovided f or i ncoming feeder from bat tery. A ll s witches, fuses, ci rcuit
breakers and buses shall be rated for D C system fault level, which shall be indicated by
the bidder in his proposal. Circuit identification cards mounted in card holders shall be
provided on t he hi nged panel boar d front. The num ber o f feeders (WITH 20% sp are
feeders) and rating of each feeder shall be t o suit the individual load keeping in view the
fuse cl earance ca pability of U PS system al ready st ipulated and sh all be as finalised
during engineering. No price implication is admissible for the number ratings of feeders
as decided dur ing en gineering and ow ners decision i n t his shall be f inal. E ach feeder
shall have fast acting semi conductor fuse, MCB & LED indication for ON status.
7.13.00 AC DISTRIBUTION BOARDS PANEL
7.13.01 Panel boar ds for di stribution o f co ntinuous AC power t o esse ntial l oads shall be dead -
front type panel boards rated for 600/1100 V, AC service. The hinged panel board front
shall cover the fuses and wiring gutter but not the switch handles. The hi nged front and
switch handles shall be covered by the enclosure door.
7.13.02 Each panel board shall be constructed for 2 wire, single- phase distribution with a so lid
neutral bar. Phase and neutral bars shall be of copper. Rating of the main lugs shall be
equal to the rated continuous full load current of each inverter.
7.13.03 Each panel board shall have one fused disconnect switch & MCCB of adequate rating
for incoming feeder for A C Bus and requisite double pole, suitably rated ampere
fused, di sconnect sw itch br anch ci rcuit de vices (MCB). Fuse d sw itches shall be
equipped w ith ar c quenchers, v isible bl ades, and quick-make quick-break
operating mechanisms. Maximum size fuse which branch circuit fuse holders will accept
shall be r ated at 60 am peres. A s each U PS f ed l oad w ill be pr ovided w ith t wo hot
Page 600 of 680

redundant 100% rated feeders. Main feeders to ACDB shall be provided with digital type
Ammeter, Voltmeter, Frequency meter, PF meter, Watt meter & VA meter. One from
ACDB-A and other from ACDB-B, boards with feeders shall be co nstructed in line. T he
number of feeders (WITH 20% spare feeders) and rating of each feeder shall be t o suit
the individual load keeping in view the fuse clearance capability of UPS system already
stipulated and shall be as finalised during engineering. No price implication is admissible
for the number ratings of feeders as decided during engineering and ow ners decision in
this shall be final. Each feeder shall have f ast acting semi conductor fuse, MCB & LE D
indication for ON status.
7.14.00 FACTORY TESTS
7.14.01 The UPS system & 24 V DC system shall be factory tested under various stages of
manufacture and upon full co mpletion as per O wner appr oved q uality Assurance pl an,
the tests shall include, but shall not be limited to the following:
7.14.02 Type and Routine Tests
Type and routine tests for various components and sub assemblies in accordance with IS
and/or NEMA, TEE Test Standards.
7.14.03 Functional Tests
Functional tests to demonstrate compliance with all specified requirements and published
specifications, su ch as frequency r egulation, v oltage r egulation, cu rrent l imiting, fuse
clearing capability of inverters, demonstration of phase and frequency control of inverters
for synchronisation with range of adjustments; transfer and retransfer of static switches
under influence of under voltage and ov er current, tests on charges, batteries and other
system components to confirm compliance with specification.
7.14.03.1 UPS (Factory Acceptance Test)
i) Power Efficiency (IEC 146-2, IEC 146) at 100% load, 50% load.
ii) Load test (Approved Procedure)- load regulation test
iii) Audible noise test (IEC 146-2 )
iv) Fuse clearing capability (Approved Procedure)
v) Relative harmonic content (IEC 146-2)
vi) Synchronous transfer & synchronization test (IEC 146-4)
vii) Temperature rise test without redundant fans (IEC 146-2)
viii) Input voltage variation test (Approved Procedure)
ix) Overload test on inverter & charger (Approved Procedure)
x) Insulation test (IEC 146)
xi) Restart test (IEC 146-2)
xii) Short circuit current capability (IEC 146-2 clause 5.10)
xiii) Output voltage & frequency tolerance (IEC 146-2)
xiv) Voltage current division (IEC 146-2)
xv) Relative harmonic content (IEC 146-2)
xvi) Parallel redundancy ( * Simulation of Parallel redundant fault (IEC 146-4 )
xvii) Overload test (final acceptance test)
xviii) Any other required as per national international standard or QAP
Page 601 of 680

G. SPECIFICATION
FOR
CONTROL PANELS
Page 602 of 680

CHAPTER-6
SUPERVISORY CONTROL PANELS, SUPERVISORY CONTROL DESKS,

EQUIPMENT PANELS
6.00.00 PANEL AND DESKS

All DD CMIS/PLC/any ot her control sy stem’s el ectronic modules, power su pply
components, other control devices (except field mounted sensors/transmitters) and
required for co mpleteness of the sy stem sh all be house d i n ca binets furnished by t he
Bidder. A ll eq uipment a nd dedi cated ca binets required for termination, marshalling and
proper i nterface w ithin Bidder’s system and al so w ith ot her sy stems sh all a lso be
provided by the Bidder.
The cabinet mounted equipments shall be fully assembled, installed in mounting racks,
wired and fully tested as per specification requirements and Owner approved drawings in
the manufacturing works of a qualified manufacturer prior to shipment to the project site.
The Bidder shall ensure that the cabinets are complete and ready for installation before
dispatch from manufacturing works. The installation work at project site for these
cabinets should only involve connections through multi pair cables from marshalling
cabinets (wherever pr ovided) t o s ystem c abinets and i nter-cabinet/cabinet t o
UCD/UCP/BUP.
The Control cabinets shall house all types of modules / hardware to achieve all functions
of C ontrol S ystem i ncluding si gnal co nditioning m odules, co ntroller m odules, I /O
modules, co mmunication co ntroller modules, a nd al l ot her requisite h ardware for a
complete system.
6.02.00 SUPERVISORY CONTROL PANELS AND DESKS
6.02.01 Control Desks & Other Furnitures
Supervisory control desks for DDCMIS and other systems shall be supplied for mounting
the r equired ope rating station as sp ecified el se where i n t he sp ecification. Also co ntrol
desk will be provided for balance work stations – located in computer room, supervisor
room etc. All furniture including chairs and tables for printers etc. shall also be pr ovided
by the bidder.
Also control desk & co mplete furniture will be provided for work stations & printers –
located in respective control room for BOP packages.
Industry standard Cushioned revolving, wheel, independently, adjustable seat and back
chairs with provision for adjustment of height shall be pr ovided for the operator & unit in
charge & other personnel in central control room area & BOP’s control rooms, simulator
rooms, C onference room, m eeting r oom, docu mentation r oom, st aff r oom, C AAQMS
shelters, CAAQMS room etc. These shall be designed for sitting for long duration such
that these are comfortable for the back. The exact details shall be finalised & approved
by Owner during detailed engg.
The ac tual nos. , pl acement and p rofile o f the m ain pl ant co ntrol r oom des k sh all be
decided during the detailed Engineering.
Page 603 of 680

The tentative layout of central control desk, LVS & consoles are shown in the Drg. No.
114-05-0108, 0105 & 0111.
Control D esk for pr ogrammer’s, M aintenance E ngineer’s, E WS, Serves, P C &

diagnostic OWSs: -
Required numbers of control desks for accommodating programmer’s/main-tenance

engineer’s/diagnostic etc shall be su pplied. T hese sh all pr eferably hav e t he sa me
dimension as that of supervisory control desks. Also required nos. of control desk will be
provided f or w ork s tations & pr inters – located i n r espective co ntrol room for B OP
packages.
Desks for accommodating printer:
Adequate number of table/desks/stands for accommodating printers in bidder’s scope

shall be supplied. Each printer shall be on a separate table / stand.
Care shall be t aken to ensure ergonomically aspects so as to create ergonomically ideal

work pl ace co nsidering phy sical asp ects such as an av erage I ndian per son’s size and
reach, physiological aspects such as line of sight and field of vision and cognitive factors
such as concentration and perceptivity. Extreme care shall be taken to design the desks
with correct angles and dimensions.
Glass top t eak wood o ffie table w ith l ockable dr awers shall be pr ovided f or C hief
Enginner room and all other executive rooms.
6.02.02 Supervisory Panel Unit Control Panel
In addi tion to the LV S a nd O WS, a l imited oper ation from bac kup uni t control panel i s
envisaged for emergency operation and to provide safe shut down of plant. The U nit
control panel shall housed Conventional Push-button (ILPB) stations, Console inserts (for
SG, TG & Generator like FSSS, HPBP, SADC, APRDS, ATRS, ATT, DEHC, LPBP etc),
Trip Push Buttons, EWLI, Ammeters, chartless recorders, & min. 15 nos. programmable
digital display un its for Boiler, T urbine & Generator’s parameters. The mosaic grid shall
be heat resistant, flame retardant, self extinguishing, and shrinkage free, non reflecting
type. Finish of mosaic grid shall be m at type with out flaring. Hard wired emergency trip
pushbuttons shall be arranged on operator station desk & in parallel on UCP.
Unit control Panel (UCP), shall be located suitably in the CCR.
In addition to above, 21 nos. Programmable digital display units common for both units
showing total MW shall be pr ovided by bidder at different locations of plant. The data to
this DDU will be fed from DDCMIS through MOD BUS/PROFI BUS /RS 485 protocol and
not hard wired. The digit size of the display unit will be 300 mm for 6 Nos. and 200 mm
for 15 Nos. The placements/locations shall be decided during detailed Engineering.
Control panel cum desk with HW annunciation windows, ILPBs, Ammeters, Annunciation
& desk PBs, mimic, lamps, Indicators, recorders, etc. shall be pr ovided as per Annexure
A – Control System Philosophy for BOP packages.
Page 604 of 680

(Exact service & quantities will be worked out & approved during detailed engineering by
owner).
6.02.03 Two ( 2) nos. v ertical S teel A lmirahs shall be pr ovided f or keeping docu ments in eac h
BOP package’s control room. Glass doors for each rack shall be pr ovided such that the
documents are visible from outside. Size of the rack shall be sufficient to easily fit
technical manuals. The exact details shall be approved by Owner during detailed engg.
Suitable lockers (min. 24 nos. per unit) shall be provided in the room adjacent to the each
central uni t co ntrol r oom for st oring o f per sonal ar ticles of co ntrol r oom per sonnel.
Similarly suitable l ockers (min. 8 nos in each co ntrol r oom) sh all be pr ovided in B OP
package co ntrol rooms for st oring o f per sonal ar ticles of co ntrol r oom pe rsonnel. A lso,
vertical steel almirahs (min. 4 nos. per unit) shall be pr ovided in Documentation Room
for storing of documents.
Vertical S teel A lmirahs shall al so be pr ovided f or the following r ooms, w herein f inal
quantity may be decided by owner during detailed engineering
a. Maintenance room – 6 nos. min. (per Unit)

b. ERP room – 2 nos. min (Common for both unit).
c. PADO Room – One (1) no. min.(per unit)
d. Station In charge room – One (1) no. min (common for both unit).
e. Simulator room – 4 nos. min. (per Unit)
Thickness of steel almirah sheet shall be 18 gauges.
In addition to above, All industry grade furniture including chairs, control tables, tables for
printers etc. & Almirahs for storage of consumables/catalogues/manuals shall also be
provided by the bidder as on required basis and finalized by owner any where in power
plant. Details shall be finalised and approved by Owner during detailed engineering.
6.02.04 Control panels for service system like C.W. Pumps etc. will be l ocated in the respective
control r oom. In addi tion , some l ocal panel s will be pr ovided n ear r espective
system/equipment su ch as Boiler Feed P ump, Hydrogen se al oi l sy stem, E lectrostatic
precipitator etc.
6.03.00 TERMINATION/Marshalling CABINETS & Interposing Relay Panel
Marshalling/Termination cabinets for the control system shall be su pplied for terminating
all ca bles originating from t he field, M CC/SWGR or any ot her so urce o f si gnal and for
distributing the signals to different functional panels, MCC/SWGR and control cubicles.
Incoming cables from the field, MCC/SWGR or any other source of signal shall be
terminated in suitable terminal blocks in logical sequence.
Prefabricated cables with plug in connectors at both ends shall be used for extending the
signals to the functional panel s. M atching pl ug sockets shall be p rovided i n t he
termination cabinets for terminating the plugs.
Page 605 of 680

Interposing relay panels for the system shall be s upplied for mounting interposing relays
& t erminating al l ca bles originating from t he D O ca rds in ca se o f so lenoid valves, and
other required services etc. IPR panels shall be placed in CER and LCR.
Interposing relay shall be mounted in respective SWGR/MCC/integral starter required

for commands signals of HT/LT unidirectional drives and bidirectional drives,
breakers, isolators & bus couplers etc from DDCMIS/DCS/PLC or any control system.
Terminal blocks shall be located inside the cabinets on support wings fabricated of metal
plates.
The plug socket shall be mounted on hinged plates to provide an access to the rear pins
of the plugs.
General features of t ermination ca binets and a ccessories shall co nform t o the g eneral
design and co nstruction sp ecification o f panel s. T erminal bl ocks shall be R ail m ounted
Terminal blocks (Screw less cage clamp type) with markers.
6.04.00 CONSTRUCTIONAL F EATURES OF P ANELS, C ONSOLES, CONTROL DE SK,

CUBICLES & ENCLOSURES
All pane ls, cu bicles, co nsoles, S OV panel s and encl osures furnished as per t his
specification shall be of free standing type and shall be constructed of specified gauge of
steel pl ates. The panel sh eet thickness shall b e not l ess than 2 mm u nless otherwise
specified herein.
The panels, consoles/desks shall be r einforced as required to ensure true surfaces and
adequate su pport for i nstruments mounted t hereon. A ll i nstrument cu touts, m ounting
studs, and support brackets shall be accurately located. All welds on the exposed panel
surfaces shall be ground smooth. Finished panel surfaces shall be f ree f rom waves,
bellies, or other imperfections. Unless specified, otherwise, panel doors shall be 4 points
hinged and shall have turned back edges and additional bracing where required to
ensure rigidity. Door hinges shall be of the concealed type. Door latches shall be of the
three-point type t o ensu re t ight cl osing. D oor l ocks shall be furnished which w ill al low
actuation o f al l l ocks by a si ngle m aster key. All panel s shall hav e r emovable l ifting
eyebolts for safe lifting from top during storage and installation handling.
Cabinet doors shall be h inged and shall have turned back edges and ad ditional braking
where required ensuring rigidity. Hinges shall be of concealed type. Door latches shall be
of three/four-point type to assure tight closing. Detachable lifting eyes or angles shall be
furnished at the top of each separately shipped section and all necessary provisions shall
be m ade t o facilitate handl ing w ithout dam age. Front and r ear door s shall be pr ovided
with locking arrangements with a master key for all cabinets. If width of a cabinet is equal
or more than 800 mm, double doors shall be provided.
All panel s sh all be m ounted on v ibration dam pers, w hich ar e se cured t o ch annels
mounted on the floor. The ch annels shall be field welded t o st eel pl ates set i nto t he
concrete flooring. The steel plates shall be located such as to approximate the outline of
panel bases. The exact mounting details shall be as approved by the owner during
detailed engineering stage. All panels shall be provided with adequate ventilation and
packaging density of components shall be restricted so as to limit the temperature rise
Page 606 of 680

above am bient t o 10° C under t he w orst conditions. A ll panel s shall hav e aut o on/ off
switch f or in ternal lig hting. All t he pow er su pply ci rcuit for control pa nels shall be
provided with auto changeover circuitry.
In each panel /cabinet, a 24 VDC Voltmeter digital type shall be provided to check the
Field Interrogation voltage.
Exhaust Fans with louvers & filters shall be provided on door’s (front & Rear) upper side to
remove hot air in all consoles, control desk and panels.
Fire/Smoke detectors shall be pr ovided inside the Control room mounted system/control
cabinets.
UPS, 24 V DC & non UPS’s Feeder failure/ healthy indication shall be p rovided in each
cabinet & remote indication shall be hooked up to DDCMIS/ PLC/annunciation & suitably
grouped.
All the pan els shall be e quipped with Anti vibration pad of min. 15 mm size. Cable gland
plate thickness shall be 3 mm.
Doors shall be provided with neoprene/polyurethene gasket only.
All the cable entries shall be at the bottom of electronic cubicles/control panels.
Protection class of panels shall be as specified at Vol. V, chapter 2.
6.04.01 Operator Control Desk
6.04.01.1 In CCR, Operator work station consoles/desk shall be of granite top of curved nature with
powder coated frame. OWS consoles shall be provided with the facility for locating the
CPU, document etc with all required utilities.
Unit In charge desk/consoles shall be of granite top of curved nature with powder coated
frame. OWS consoles shall be pr ovided with the facility for locating the CPU, document
etc with all required utilities.
Station In charge desk/consoles shall be of granite top of curved nature with po wder
coated frame. OWS consoles shall be provided with the facility for locating the CPU,
document etc with all required utilities.
6.04.01.2 Engineer w ork s tation and al l ot her co nsoles/desk sh all be er gonomically desi gned
industrial grade type with swivel chairs for use at the various Programming stations and
all ot her pl ant l ocations. A ll t he e quipment l ike P rogrammers stations, P C's, v arious
peripherals & similar devices shall be complete with desks and they shall be of industrial
grade stands and other mounting accessories and the same shall be completely erected
& commissioned by the bidder. Details for other operating and en ginering stations shall
be as below:
i. Operator Control desk shall be free standing table top type with doors at the back
and sh all be co nstructed o f 3 mm t hick CRCA st eel pl ates. I t sh all hav e
concealed cable & wire way management system. The t op su rface of control
Page 607 of 680

desk sh all be 30m m thick w ith t he t op 12m m o f acr ylic solid su rface and t he
remaining 18mm of laminated medium density fibre board. Control desk shall
consist o f v ertical, hor izontal and base su pports with t heir co verings for w ork
surface, keyboard trays, Mouse pads, Monitor shelf and concealed cable and wire
way m anagement, per forated t rays with co vers in bot h hor izontal & v ertical
directions.
ii. To achieve durable & water resistant finish, a sheet of “plastic PVC membrane"
on t he su rface o f co ntrol desk s shall be pr ovided. Fi nal pai nt f inish w ith pr oper
smoothening is to be ensured. Final finish of CD should be in line with relevant
International standards. For more durability, the membrane sheet of the Control
desk should extend 200 mm more into the underside of the desk. The cabling /
wiring bet ween O WS & C PU’s, pow er su pply c ables etc. sh all be aes thetically
routed and concealed from view.
iii. All the control desk shall be eq uipped with Anti vibration pad of min. 15 m m size.
Cable gland plate thickness shall be 3 mm.
iv. Doors shall be provided with neoprene/polyurethene gasket only.
6.05.00 SURFACE PREPARATION AND PAINTING
All panel exterior steel surfaces shall be ground smooth, and painted as specified below:
Suitable filler shall be appl ied to all pits, blemishes and voids in the surfaces. The filler
shall be sand blasted so that surfaces are level and flat, corners are smooth and even.
Exposed raw metal edges shall be ground burr free. The entire panel surface shall be
sand blasted to remove rust and scale and all other residue due to the fabrication
operation. Oil grease and salts etc. shall be removed from the panels by one or more
solvent cleaning methods. Alternatively 7 tank process shall be followed.
Two spray coats of inhibitive epoxy primer – surface shall be appl ied to all exterior and
interior surfaces, each coat of primer surfacer shall be of dry film thickness of 1.5 mil. A
minimum of two spray coats of final finish colour (Catalysed epoxy finish) shall be applied
to al l su rfaces of d ry f ilm t hickness 2.0 mil. The finish co lours for ex terior and i nterior
surfaces shall conform to the following shades:
a) Exterior - RAL 7032/RAL 7035.
b) Interior - Glossy white two coats/RAL 7035 with fire resistant paint
One uniform colour shade as finalized shall be applicable for complete plant.
Paint f ilms, w hich sh ow sa gs, ch ecks, bl isters teardrops, fat edg es or ot her pai nting
imperfections, sh all not be acce ptable and i f a ny su ch def ects appear, t hey sh all be
repaired by and at the expenses of the Bidder.
6.06.00 PANEL WIRING
Interconnecting w iring s hall be pr ovided bet ween al l el ectrical dev ices mounted i n the
panels, and bet ween the devices and terminal blocks if the devices are to be co nnected
Page 608 of 680

to equipment outside the panels by cabling and through pre-fabricated plug in cables. All
alarm contacts located within a panel shall be wired to terminal blocks. Thermocouple
and other special circuits shall be f ield wires direct to instrument terminal blocks without
the use of panel wiring.
All control and instrument wiring used within the panels shall confirm to NEC and NEMA
standards and shall be factory installed and tested at the works of a qualified
manufacturer. A ll i nterior w iring sh all be i nstalled neat ly and ca refully, and sh all be
terminated a t su itable terminal bl ocks. S ufficient cl earance sh all be provided f or al l
control and i nstrumentation l eads, and al l i ncoming and ou tgoing l eads shall be
connected to terminal blocks suitably located for connecting external circuits.
All panel wiring shall have appropriate ferruling for clear identification. Interior wiring
shall be so arranged that the external connections can be made with only one wire per
terminal point. Any common connections shall be made internal side of the terminal
blocks. Common connections shall be limited to two wires per terminal. Instrumentation
cable shield wires shall be connected to separate terminal at the terminal block. Signal
circuit shields shall be grounded separately.
All internal wiring (except low level instrument wiring) shall be National Electric Code
Type S IS, P olymetric/Elastomeric insulated, t inned co pper s tranded co nductor,
switchboard wire, or owner approved equal.
Panel wiring sh all ha ve a f lame r esistant i nsulation with adeq uately s ized 650/ 1100 V
grade tinned copper stranded conductor based on current carrying capacities as etc forth
by the National Electric Code.
Wire sizes shall be as specified herein and suitable for intended applications.
Wiring t o door mounted devi ces shall be pr ovided with ( 49 st rand m inimum) adeq uate
loop lengths of hinge wire so that multiple door openings will not cause fatigue braking of
the conductor.
Wiring shall be arranged to enable instruments or devices to be removed and/or serviced

without unduly disturbing the wiring. No wire shall be routed cross the face or rear of any
device in a manner, which will impede the opening of covers or obstruct access to leads,
terminals or devices.
Panel wires shall be identified with wire number and each termination by means of Action
craft products split sleeve or Borden Chemical Co. indelible tubing markers or owner
approved equal. C orrections and modifications of all panel wiring shall be B idder’s sole
responsibility. Any corrections/modifications required at site for successful commissioning
shall be done by the Bidder without any additional costs. Terminal lugs furnished must
be of the compression, insulated sleeve, half ring tongue type. Open-ended terminal lugs
will not be accepted. Wires shall not be looped around the terminal screws or studs.
Wires shall not be tapped or spliced between terminal points.
Panels, cabinets, consoles/desks will be pr ovided with removable, gasketed cable gland
plates and cable glands, for all floor slots used for cable entrance. S plit type grommets
shall be used for prefab cables.
Page 609 of 680

Internal wiring in factory prewired electronic systems cabinets may be installed according
to the Bidder’s standard as to wire size, insulation, and method of termination on internal
equipment except that insulation for all wiring power supply wiring, and interconnecting
cables between devices shall pass the following tests.
a) Flammability test IEEE 383/1974

b) When t ested unde r U ITPP t est method or A STM 2893/ 77 l ight t ransmittance of
80%
c) When t ested un der IEC 754 -1 maximum aci d gas generation sh all be 2% by
weight
d) Oxygen index not less than 30 as per ASTM D 2863.
All t erminations for i ntra panel w iring i nter pan el ca bling and connecting the B idders
panels, PB stations, control stations etc. shall be with cage clamp Screwed less
connections. S oldered connections are no t acc eptable. A ll f ield si de o r ex ternal i nput
connections shall also preferably of Cage clamp/Spring Clamp/ Screwed less connection.
Conductor Clamping shall also confirm to Standard IEC – 60947-1 & IEC-60947-7-1.
Identification of conductors may be done by insulation colour coding identified on

drawings or by printed wiring lists. Terminal blocks for connection of external circuits in
to factory pr ewired el ectronic system ca binets sh all m eet al l t he r equirements as
described elsewhere in the specification. For all multicore cables, the outer sheath shall
satisfy t he pr operties identified abov e. H owever, for panel w iring, t he wiring i nsulation
shall al so sa tisfy t he p roperties identified abov e. The i nternal w iring s hall be done i n
coloured wiring.
6.06.01 Following Wire size shall be utilized for internal wiring:
a. Current (4-20 mA) : 0.75 sq.mm

Low voltage signals :
(AI/AO & DI signals)
b. DO signals, Ammeter/ : 1.5 sq.mm

voltmeter circuit,control
switches, indicator,recorder
c. Internal Illumination : 2.5 sq.mm
d. Size of Power supply cables shall be as below:-
i. 1 to 16 Amp. - 2.5 sq. mm

ii. 17 to 20 Amp. – 4 sq. mm
iii. 21 to 32 Amp. - 6 sq. mm
iv. 33 to 40 Amp. - 10 sq. mm.
v. 41 to 60 Amp. - 16 sq. mm
vi. Power earth - 4 sq. mm
6.07.00 INSTRUMENTS MOUNTING
Page 610 of 680

6.07.01 Instruments and relays mounted on the panels shall be easi ly accessible f or repair and
replacement without disturbing other equipment their connected wiring. No special tools
shall be needed for the purpose.
6.08.00 PANEL ILLUMINATION
Panels shall be pr ovided with LED based illuminating lamps with door switch and si x (6)
point 6/ 16A, 240V A C uni versal t ype po wer so ckets with sw itch f or m aintenance
purposes. These switches shall be with quick make and break mechanism. 100 % spare
LED l amps shall be p rovided with each panel , t hese a re i n addi tional t o mandatory
spares.
6.09.00 FUSE BLOCKS
Where fuse blocks rated 30 amp. 250 Volts are required by the specifications or the
manufacturer’s design, t hey sh all be m odular t ype w ith bak elite frame and r einforced
retaining clips. B locks shall be cl ass H.2 pol e, scr ew t erminal fuse bl ocks. B locks for
other current and voltage ratings shall be similar in construction.
6.10.00 FUSES & MCB
All fuses shall be fast acting semiconductor types for AC supply and compatible to the
UPS f uses. For al l D C P owered dev ices, si milarly t he f uses shall be f ast ac ting
compatible to DCDB fuse provisions. All the AC power supplies shall be provided with the
protection of Fast acting semi conductor fuses & 2 P thermomegnetic type MCB. Make of
Fuses shall be G E or Siemens. For all the DC power supply circuits, electronic type DC
MCB sh all be use d onl y. M ake o f D C M CB sh all be S iemens, P hoenix contacts, M urr,
Weidmuller, or Lutze.
50 % spare fuses shall be provided with each panel, these are in additional to mandatory
spares.
6.11.00 MOULDED CASE CIRCUIT BREAKERS
Moulded ca se ci rcuit br eakers used i n e quipment co vered under t hese sp ecifications

shall have not less than 5000 amp. Interrupting capacity at 220 Volts DC 10,000 Amp.
Symmetrical interrupting capacity at 240 Volts AC. MCCB shall be provided at each main
feeder line like ACDB & DCDB main feeders, PLC main feeder, control panels, UPS
circuits etc.
6.12.00 GROUNDING
All panels and cabinets shall be provided with a continuous bare copper ground bus of
minimum 6 mm x 25/50 mm cross section. The ground bus shall be bol ted to the panel
structure and effectively ground the entire structure. Each Ground bus shall have
provision at each end for co nnection o f ground l eaks ( 6 m m x 50 mm GI Fl ats) by
suitable bolting. All system cabinets shall be brought to a common system ground by the
bidder. Electronic earthing resistance shall be < 0.5 ohms.
Each circuit requiring grounding shall be i ndividually and di rectly connected to the panel
ground bus by r ing t ongue t ype co mpression l ugs. For el ectronic system ca binets the
system ground bus shall be insulated from the cabinet enclosure and shall be separately
Page 611 of 680

connected t o the system ground. All sy stem cabinets shall be brought to a common
system ground by the bidder.
The Bidder shall furnish his recommendations regarding grounding requirements for all
equipment/systems and shall sp ecifically i ndicate t he dev iations if any f rom the abov e
requirements as a part of his proposal.
6.13.00 TERMINAL BLOCKS
For all inputs to the system emanating from the field or other systems, the bidder shall
furnish terminals suitable for correct size of field cables.
6.13.01 All outputs going to MCC/SWGR terminal blocks, shall be rated 600 volts minimum and
shall hav e st rap scr ew l ess terminals suitable for co nnection o f w ires with r ing tongue
type lugs. Standard terminal blocks shall be screw less cage clamps type. Terminal
blocks shall be appr oximately si zed f or l arger w ire si ze of hi gher v oltage i nsulated
incoming conductors as necessary. All the TBs used shall be 6. 6 polymide to withstand
corrosion and the metallic portion shall be coated against rust /corrosion. All metal parts
should be non –ferrous in nature.
6.13.02 Terminal blocks shall be provided with white marking strips and re permitted by the safety
codes and standards shall be without covers.
6.13.03 Fuses shall not be mounted on t erminal bl ocks. N either step t ype t erminal bl ocks nor
angle mounting of terminal blocks will be acceptable.
6.13.04 At least 20 per cent spare unused fully wired terminals shall be provided on each terminal
block for ci rcuit modifications and for t ermination o f al l co nductors in a multi-conductor
control cable with each panel, enclosure, cubicle, SOV Boxes etc.
6.14.00 NAME PLATES AND LABELS
Name plates of adequate size shall be provided for each panel on front and rear of the
panel. Instruments/other accessories mounted inside the panels shall have identification
marking clearly visible from inside.
Devices to be mounted on t he panels shall also be labeled on the panels shall also b e
labeled on the outside of the panel. Name plates shall be of polyamide sheets with black
letters on w hite background. N ame plates shall be at tached to the boards by means of
stainless steel panhead screws. Fuses provided for protection of various boxes shall be
accessible for replacement. Fuse boxes shall be provided with circuit label and fuse
rated current and voltage.
Markings/Labels
All m arkers/labels shall be m ade o f hal ogen & si licon f ree pol yamide m aterial w ith
inflammability class V2 as per UL 94, ensuring scratch proof printing with the use of
environment friendly solvent free ink & latest BLUEMARK UV technology so as to comply
the WIPE RESISITANCE according to DIN EN 61010-1/VDE 0411-1.
Page 612 of 680

H.DRIVE
CONTROL
PHILOSOPHY
FOR
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&
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DRIVES
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Page

ASME, I EEE, NEC, NEMA, ISA, DIN, VDE, NFPA, IEC, EIA, TIA and Indian Standards
and their equivalents. Bidder to note that in no case, OEM/manufacturers own standards
shall be accepted.
1.08.02.01 Temperature Measurement
1. Performance Test Code for temperature measurement ASME PTC 19.3 (1974 –
R 1998)
2. Temperature measurement - Thermocouples ANSI-MC 96.1 – 1982, IEC 584
3. Temperature measurement by electrical resistance thermometers - IS-2806.
4. Thermometer-element-platinum resistance-IS-2848, IEC 751/DIN 43760
5. RTD Design Code – DIN EN 60751:1996, BS EN 60751 : 2008
6. Thermowell Design Code – ASME PTC 19.3 TW – 2010
1.08.02.02 Pressure Measurement
1. Performance Test Code for pressure measurement - ASME PTC 19.2 (2010)
2. Bourdon tube pressure and vacuum gauges - IS 3624, IS 3602, ASME B 40.1
1.08.02.03 Electronic measuring Instruments & Control hardware

1. Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev.
1973), IS 9319
2. Safety requirements for electrical and electronic measuring and controlling
instrumentation - ANSI C 39.5 - 1974.
3. Compatibility of analog signals for electronic industrial process instruments -
ISA-S 50.1:ANSI MC 12.1 - 1975.
4. Dynamic response testing of process control instrumentation - ANSI MC 4.1
(1975): ISA-S26 (1968).
5. Surge w ithstand ca pability ( SWC) t ests - ANSI C 37.90A (1974) I EEE S td. 472
(1974). IEC – 255.4.
6. Printed circuit boards - IPC TM-650, IEC 326 C
7. General requirements and tests for printed wiring boards - IS 7405 (Part-I) - 1973
8. Edge socket connectors - IEC 130-11.
9. Requirements and m ethods of testing of wire wrap terminations DIN 41611
Part-2.
10. Dimensions of attachment plugs & receptacles ANSI C73-1973.
11. Direct acting Electrical Indicating Instruments: IS-1248-1968.
1.08.02.04 Instrument Switches and Contacts
1. Contact rating - AC services NEMA ICS Part-2 125, A600

2. Contact rating - DC services NEMA ICS Part-2-125, N600.
1.08.02.05 DDCMIS & other Control System
1. Application of Safety Instrumented System – ANSI/ISA 84.01 1996

2. Functional Safety - Safety Instrumented System for Process Sector – IEC –
61151
Page 621 of 680

3. IEEE Application Guide for Distributed Digital Control Monitoring for Power Plant
– IEEE 1046
4. Fossil Fuel Power Plant Steam Turbine Bypass System – ANSI/ISA – 77.13.01
5. Human System Interface Design Review Guide lines – NUREG – 700
6. Annunciation Sequence and Specification – ANSI/ISA 18.1
7. “IEEE 1050, IEEE guide for Instrumentation & control system grounding in
generating station”,
8. ANSI/ISA-77.44.01-2007 - Fossil Fuel Power Plant - Steam Temperature Controls
9. ANSI/ISA-RP77.60.05-2001 ( R2007) - Fossil Fuel P ower P lant H uman-Machine
Interface: Task Analysis
10. ANSI/ISA-77.42.01-1999 (R2006) - Fossil Fuel Power Plant Feedwater Control
System – Drum-Type
11. ANSI/ISA-77.20-1993 (R2005) - Fossil Fuel Power Plant Simulators - Functional
Requirements
12. ANSI/ISA-77.41.01-2005 - Fossil Fuel Power Plant Boiler Combustion Controls
13. ANSI/ISA-RP77.60.02-2000 ( R2005) - Fossil Fuel P ower P lant H uman-Machine
Interface: Alarms
14. ANSI/ISA-77.70-1994 ( R2005) - Fossil Fuel Power P lant I nstrument P iping
Installation
15. ANSI/ISA-TR77.60.04-1996 ( R2004) - Fossil Fuel P ower P lant H uman-Machine
Interface-Electronic Screen Displays
16. ANSI/ISA-77.43.01-1994 ( R2002) - Fossil Fuel Power P lant U nit/Plant Demand
Development-Drum Type
17 ANSI/ISA-77.13.01-1999 - Fossil Fuel Power Plant Steam Turbine Bypass
System
1.08.02.06 Electronic Cards, Subassemblies and Componets
a) Unpackaged
i) Vibration : IEC-68.2.6
ii) Shock : IEC-68.2.27
iii) Drop & Topple : IEC-68.2.31
b) Packaged
Vibration, Drop & Static Compression - NSTA
C) Electromgnetic Compatibility
i) Electrical Fast Transient : IEC-801.4

ii) Surge Withstand : IEC-255.4
iii) Radiated Electromagnetic Field : IEC-801.3
iv) Electrostatic Discharge : IEC-801.2
v) Electromagnetic Emission : VDE 0871, Class B
1.08.02.07 UPS System/DC control power supply system:
1. Practices and r equirements for se mi-conductor pow er r ectifiers - ANSI

C34.2-1973.
Page 622 of 680

2. Relays and relay systems associated with electrical power apparatus - IEEE Std.
3.13, ANSI C 3790-1983.
3. Surge withstand capability tests - ANSI C37.90a-1974. IEEE Std. 472 - 1974
4. Recommended pr actice for si zing l arge lead storage bat teries for generating
stations & substations - IEEE-485.
5. Performance testing of UPS - IEC 146.
6. IEC 62040 – General & Safety requirement of UPS.
7. IEC 62040-2 - UPS – EMC Requirement.
8. IEC 62040-3 - UPS – Method of specifying the
performance and test requirement.
9. IEC 60269-2 – Main Supply Fuse.
10. IEC 60947 – MCCB.
11. IEC/EN 60623 – BATTERIES.
IEEE485/IEEE1115
IS : 10918, IS : 1069
12. IEC 60146 - For DC system.
1.08.02.08 Control Valves
1. Control Valve sizing - Incompressible fluids - ISA S39.2 - 1972.

2. Control valve sizing - Compressible fluids - ISA S39.3 - 1973, ISA S39.4 -
1974.
3. Face to face dimensions of control valves - ANSI B16.10
1) ISA Hand book of control valves - ISBN B1047-087664-234-2.
2) Valves - flanged, threaded and welding end : ANSI B 16.34(2009)
3) Casting : ASTM A 216 / A 351 (2008)
4) Welded end connection : As per ASME boiler and pressure vessel
code / ANSI.B 16.34(2009), B16.25 (2009), B 16.11(2009).
5) Defect removal: ANSI B 16.34 2009.
6) Cleaning : ASTM A 380 2006.
7) CV test : As per ISA procedure S 75.02 (2008).
8) Control Valve seat leakage : ANSI/FCI 70.2
1.08.02.09 Enclosures
1. Types of enclosures - NEMA Std. ICS-6-110.15 through 110.22 (Type 4 to 13).

2. Racks, panels, and associated equipment - EIA: RS-310-B (ANSI C83.9 - 1972)
3. Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-13947-
1962.
1.08.02.10 Apparatus, enclosures and installation practices in hazardous areas
1. Classification of hazardous area - NFPA Art. 500, Vol.70-1984.

2. Electrical Instruments in hazardous dust locations - ISA-RP 12.11
3. Intrinsically safe apparatus - NFPA Art.493 Vol.4.1978
4. Purged and pressurized enclosure for electrical equipment in hazardous location
- NFPA Art. 496 1982.
1.08.02.11 Sampling System
Page 623 of 680

1. Stainless steel material of tubing and v alves for sampling system - ASTM A269-
82 Gr TP316.
2. Submerged helical coil heat exchangers for sample coolers ASTM D 11-98.
3. Water and Steam in power cycle - ASME PTC 19.11(2008).
4. Standard methods of sampling system - ASTM D 1066-69.
1.08.02.12 Annunciators
1. Specifications and guides for the use of general purpose annunciators - ISA RP
18.1-1979.
2. Surge withstand capability tests - ANSI C.37.90a - 1974 and IEEE std. 472-1974
1.08.02.13 Interlocks, Protections
1. Relays and relay system associated with electric power apparatus - IEEE
std.3.13.
2. Surge w ithstand ca pability t ests - ANSI C .37.90a - 1974 and IEEE St d. 4 72 -
1974.
3. General r equirements & t ests for sw itching dev ices for co ntrol and aux iliary
circuits including contactor relays - IS-6875 (Part-I) 1973.
4. Turbine water damage prevention - ASME - TDP-1980.
5. Boiler safety interlocks - NFPA Section 85B, 85D, 85E, 85F,85G.
1.08.02.14 Process Connection and Piping:
1. Codes for pressure piping power piping ANSI B31.1

2. Seamless carbon steel pipe ASTM A-106.
3. Forged and R olled A lloy st eel pi pe f langes, forged fittings, v alves and par ts -
ASTM A-182.
4. Material for socket welded fittings - ASTM A-105.
5. Seamless ferrite alloy steel pipe - ASTM A-335.
6. Pipe fittings of wrought carbon steel and alloy steel - ASTM A-234.
7. Composition bronze or metal castings - ASTM B-62.
8. Seamless copper tube, bright annealed ASTM B-168.
9. Seamless copper tube - ASTM B-75.
10. Dimensions of fittings - ANSI B-16.11
11. Valves flanged and butt welding ends - ANSI B16.34.
12. Nomenclature for Instrument tube fittings ISA-RP-42.1 - 1982.
1.08.02.15 Instrument Tubing
1. Seamless carbon steel pipe - ASTM - A106.

2. Material for socket weld fittings - ASTM - A105.
3. Dimensions of fittings - ANSI B16.11
4. Code for pressure piping, welding, hydrostatic testing - ANSI B31.1.
1.08.02.16 Cables
1. Thermocouple extension wires/cables - ANSI C 96.1 - 1982.

2. Colour coding of single or multi-pair cables – VDE 0815
Page 624 of 680

3. Guide for design and i nstallation of cable systems in power g enerating stations
(insulation, jacket materials) - IEEE Std. 422 - 1977.
4. Requirements of vertical tray flame test - IEEE 383 - 1974.
5. Standard specification for tinned so ft or annea led co pper w ire for e lectrical
purpose - ASTM B-33 - 81.
6. Oxygen index and temperature index test - ASTM D-2863.
7. Smoke generation test - ASTMD-2843 and ASTME-662.
8. Acid gas generation test - IEC-754-1.
9. Swedish chimney test - SEN - 4241475 (F3)
10. Instrumentation ca bles and i nternal w iring I S-1554 ( Part-I, 1976 ) and I S-
5831(1984).
11. Standard f or Control, Thermocouple E xtension and
Instrumentation ca ble - NEMA W C57-2004
ICEA S-73-532, Rev. 2, 2004)
12. PVC insulated (heavy duty) Electric cables for working voltages upto and
including 1100V - IS:1554 (Part-I)
13 Conductors for insulated electric cables and flexible cords. - IS:8130
14 PVC insulation and sheath of electric cables - IS:5831
15. Mild steel wires, strips and tapes top armoring cables - IS:3975
16. Water Immersion Test - VDE 0815
17 Drums for electric cables - IS : 1048
1.08.02.17 Cable Trays, Conduits
1. Guide for the design and installation of cable systems in power generating
station (cable trays, support systems, co nduits) - IEEE Std. 422, NEMA VE-1,
NFPA-70-1984.
2. Guide for the design and installation of cable systems in power generating
station (Cable trays, support systems, conduits) Test Standards, NEMA VE-1 -
1979.
3. Galvanising of Carbon steel cable trays - ASTM A-386-78.
1.08.02.18 Flow measurement
1. ASME Performance Test Code PTC-19.5 (2004), ISA RP3.2

2. BS 1042
3. ISO 5167
1.08.02.19 Surge Protection System
1. Surge withstand capability tests - ANSI C37.90a-1974. IEEE Std.

472 – 1974
2. IEC 61643-1:1998-02 and E DIN VDE 0675 part 6:1996-03/A2: 1996-10
3. IEC 61643-21:2000-09 and E VDE 0845 part 3-1:1999-07
1.08.02.20 Digital Video Recording & Management System (DVRMS)
1. ISO 9001 (2000)

2. ISO/IEC15504 Level3 or higher (SPICE 2.0 Software Process Improvement and
Capability Determination)
Page 625 of 680

3. SEICMM Le vel3 or hi gher ( American S oftware E ngineering Institute - Capability

Maturity Model)
Where:
i) IEEE - Institute of Electrical and Electronics Engineers.

ii) ISA - Instrument, Systems and Automation Society
iii) NEMA - National Electrical Manufacturers Association
iv) ANSI - American National Standards Institute
v) NFPA - National Fire Protection Association
vi) ASME - American Society of Mechanical Engineers
vii) IS - Indian Standards
viii) IEC - International Electro-technical Commission
ix) ASTM - American Society for Testing Materials
x) EIA - Electronic Industries Association
xi) DIN - Deutsche Institute Normale
xii) TIA – Telecommunication Industries Association
Page 626 of 680

I.SPECIFICATION
FOR
QUALITY ASSURANCE
&
TESTING
Page 627 of 680

CHAPTER-14
QUALITY ASSURANCE AND TESTING AND GUARANTEES
14.01.00 GENERAL REQUIREMENT
14.01.01 All equipment furnished under this specification shall be subject to test by authorized
quality assu rance per sonnel of the B idder, representatives of the O wner during
manufacture, e rection a nd on co mpletion. B idder'’ quality assu rance pe rsonnel for
these shop and site tests shall be identified in advance and shall be acceptable to the
Owner. The app roval of t he O wner or passi ng of su ch i nspection o f t ests will not,
however, prejudice the right of the owner to reject the equipment if it does not comply
with the specifications when erected or fails to give complete satisfaction in service.
14.01.02 The Bidder shall furnish details of shop and si te tests proposed to be co nducted by
him at v arious stages to m eet the sp ecification r equirements for ea ch t ype of
instrument/system al ong w ith hi s proposal. B idder sh all al so f urnish d etails of hi s
proposed shop and site quality assurance organization for this contract
14.01.03 Bidder shall prepare a detailed shop and site ‘Quality Assurance Programme’ to meet
the requirements of these specifications for Owner’s approval. T his document shall
also contain the formats for reports and maintenance of test records specification of
test equipment to be used for site tests.
14.01.04 All eq uipment and sy stems furnished under t his sp ecification sh all be s ubjected t o
shop & site tests in accordance with the Quality Assurance Program approved by the
Owner and shall be adequate to ensure full compliance with these specification, all
applicable co des & st andards and det ailed en gineering dr awings and docu ments
approved by the Owner.
14.01.05 The Bidder shall provide all required test equipment and simulation devices for
performing al l shop and si te t ests. A ll t ests equipment sh all be of r eputed m ake,
required accuracy class and shall be recently calibrated. The record of calibration of
test equipment shall be made available to the Owner on demand.
14.01.06 The cost of all tests as per the requirements of this specification and approved quality
assurance programme shall be i ncluded in Bidder’s lump sum price for this package
and no ex tra price shall be pay able by the Owner for conducting any test as per the
intent and requirements of this specification.
14.01.07 All approval/Inspection are to be carried out by the Owner only.
14.02.00 SHOP TESTS
14.02.01 General Requirement
14.02.01.00 Shop tests shall include all tests to be carried out at Bidder’s works at of this sub-bidder and at works
where raw materials used for manufacture of equipment is produced.
Page 628 of 680

14.02.01.01 Individual co mponents, instruments and dev ices furnished i n acco rdance w ith
specification sheets, and I&C device list enclosed with these specifications shall be
shop t ested by m anufacturer pr ior t o sh ipment. T he m anufacturer sh all co nduct
these tests for certifying compliance with published specifications for the equipment
and pr ovide t est r esults t o t he O wner i n writing. T hese t ests and t est certificates
shall be in acco rdance w ith t he ag reed ' QA’ pr ogramme for m ajor
systems/equipments. However, manufacturer’s standard methods shall be followed if
details of tests for a ny eq uipment ar e no t co vered under t his agreed ‘ QA
Programme’.
14.02.01.02 Whenever t ested quality m aterial i s specified an d w herever ca lled upon by I ndian
Boilers Regulations or b y t he desi gn co de, the test pi eces ar e t o be p repared and
tested to Owner's satisfaction.
been ca rried ou t by t he su ppliers of material, t he O wner may, at hi s discretion,
14.02.02 Material Tests
14.02.02.01 Whenever tested quality material specified and whenever called upon by Indian
Boilers Regulations or by design code, the test pieces, are to be prepared and tested
to Owner’s satisfaction.
been carried out by the suppliers of material, the Owner may, at his discretion,
14.02.03 Test at Manufacturer’s Works
14.02.03.01 Works tests are to include electrical, mechanical performance and hydraulic tests in
accordance with relevant IS, IBR or any other approved standard or any other tests
called f or by t he O wner under t hese sp ecifications to ensu re t hat t he equipment
being supplied fulfills the requirements of these specifications. For equipments not
covered by any IS or other approved standards, the tests to be carried out shall be in
accordance with Bidders’ quality assurance programme approved by the Owner.
14.02.03.02 Control sy stems, monitoring sy stems ,control panel s instrument encl osures ,and
power su pply sy stems shall be sh op t ested a ccording t o uni que requirements
specified in the applicable section of these specifications for each item and quality
assurance program approved by the owner.
14.02.03.03 All shop tests shall be performed prior to shipment and the Owner shall be given the
opportunity t o w itness these t ests. The B idder sh all not ify t he O wner r egarding
readiness for shop test at least 10 day s before the scheduled date if the tests to be
conducted within Indian and at least 60 days before the schedule date if the test is to
be conducted abroad.
14.02.04 Factory Tests
Page 629 of 680

14.02.04.01 Automatic Control and Monitoring system (DDCMIS, PLC & any other
microprocessor based control system) including alarm annunciation system furnished
as per t his specification sh all be su bject to shop and si te t ests as per t he
requirements of t his specification, appl icable c odes and O wner appr oved Q uantity
Assurance Program so as to demonstrate to the Owner that the equipment furnished
by t he B idder m eets the i ntent and requirement o f this specification. T hese t ests
shall include but shall not be limited to the tests indicated in the subsequent clauses.
14.02.04.02 Surge Protection Test for Solid State Equipment
All solid state equipment shall be able to withstand the noise and surge inherent in a Power House,
and shall strictly comply with SWC tests ANSI C 37.90A, 1974 for IEEE-472 (1974). C omplete
details of the features incorporated in electronic system to meet this requirement, the relevant test
carried out, and the test certificates shall be submitted along with the proposal.
14.02.04.03 Burn-in and Elevated Temperature Test
All solid state electronic equipment shall be t ested as a complete system/equipment

with all devices connected for a minimum of 168 hours continuously under energized
conditions prior to shipment from manufacturer’s works, as per the following cycle :-
During the first 48 hours of testing the ambient temperature shall be maintained at 50
deg.C and r elative humidity at 95%. T he equipment shall be i nterconnected with all
devices, which will ca use i t t o r epeatedly per form al l oper ations; i t i s supposed t o
perform in actual service, with load on various components being equal to those,
which will be experienced in actual service.
The 48 hours tests period shall be continuous but shall be divided into four 12 hours
segments. The input voltage during each 12-hour segment shall be nom inal voltage
for 11 hour s, followed by 110% o f no rmal v oltage for 30 minutes followed b y 90
percent of nominal voltage for 30 minutes.
The 48 hou rs elevated t emp t est sh all be followed by 120 hour s of bur n i n t est a s
specified in the above paragraphs except that the temperature is reduced to ambient
temperature prevalent at that time. Alternatively copy of type test certificate for burn-
in test shall be submitted.
14.02.04.04 The Bidder shall furnish full details regarding shop tests and site tests, as per good
engineering practices. The Owner shall approve all such tests and the supplier shall
conduct all such tests without calling for additional price.
The tests shall cover factory tests, burn-in and elevated temperature tests, simulation
and f unctional tests, insulation tests as applicable, the rating of the contact devices
and co mponents, su rge w ithstand ca pability test, co nformity of i nterconnection
cables, t esting and ch ecking o f o ther co nditions deemed t o be nece ssary with t he
system/equipment items.
14.02.04.05 All instruments and control equipment supplied against this contract shall be f actory
calibrated a t l east at five ( 5) poi nts t hrough out t he r ange and checked f or t heir
Page 630 of 680

functional/performance requirements. The instruments shall also be calibrated at site

prior to commissioning.
14.02.04.06 All panels, instruments enclosures, junction boxes, etc. shall be type tested for
degree of protection and applicable in accordance with IS: 2147. 8.02.04
14.02.04.07 Type, routine and acceptance testing of all equipments, supplied under this contract,
shall be i n acco rdance w ith r elevant N EEA/IS/IEC/ANSI/BS/ISA st andards, i n
addition to the requirements of Owner approved Quality Plans. Six (6) copies of test
reports shall be submitted to the Owner for approval prior to dispatch of respective
equipment
14.02.04.08 The representative of Owner shall be given opportunity to witness the factory tests
which shall be mutually finalized during the progress of the contract.
14.02.04.09 All control systems to be furnished for this project, shall be factory tested f or circuit
continuity and di rection of response. T he Components to be t ested shall include all
controllers, HAND/AUTO station, other system modules, alarm contactors and m ulti-
conductor interconnecting cables. The tests shall be performed with all of the system
components supplied by the B idder co nnected t o form a co mplete sy stem w ith t he
sole ex ception of t ransmitters. T he t ests shall i nclude a m eans of co nfirming t he
mathematical design response of the control system by simulating changes in system
input. The tests shall be a qualitative functional test of each component of control
system, which simulates dynamic inputs and monitors system outputs.
14.02.04.10 Certain control loops shall be factory tested using closed loop mathematical
simulation techniques. Control loops to be tested by closed loop methods are
broadly as under. However, owner has discretion to test and all control loops during
simulation testing.
ii) Firing rate control (fuel and air flow control)

iii) Furnace draft control
iv) Boiler separator level control
(d) Response time for Turbine Control System.
The input simulation equipment shall be designed to produce effects from control system outputs
based on mathematical model of the predicted performance and process dynamics of the main unit
equipment. The control constants of various control loop components shall be adjusted to produce a
stable and optimum control adjusted to produce a stable and optimum control when connected to
the simulation equipment.
14.02.04.11 Simulation data including factory adjustment of control system

constants, and simulation eq uations shall be t abulated and shall be made available
by the Bidder for owner’s use during field check out and the start up of the control
system.
14.02.04.12 Availability of a simulated type test for automatic control loops specified with a
detailed description of testing methods utilized, shall be indicated.
Page 631 of 680

14.02.04.13 The availability of facilities for carrying out the model test for the control systems shall
be indicated by the bidder. Also details of test procedures and copies of test results
conducted for a similar fossil fuel fired unit shall be furnished. The data required from
Boiler and Turbo generator supplies shall also be furnished by the Bidder.
14.02.04.14 Brief description of all tests proposed to be conducted on each control system
components during various stages of manufacture, installation and commissioning
shall be f urnished. C opies of t est dat a acc umulated dur ing t he t ests shall be
submitted to the mutually agreed formats.
14.02.04.15 The owner shall witness the factory tests which shall be performed at a time mutually
agreeable to the Bidder and the owner.
Page 632 of 680

14.02.04.16 Factory Acceptance Tests for DDCMIS, DCS, Simulator & PLC
G 1 FACTORY ACCEPTENCE TEST (FAT): REF NOTE-1 

EN 2 FACTORY ACCEPTENCE TEST (FAT) PROCEDURE: REF.NOTE -2 
ER 3
AL 4
5
TE 6 TEST SHALL BE PERFORMED WITH THE COMPLETELY ASSEMBLED SYSTEM AND ALSO WITH COMPLETE 
ST 7 I&C SOFTWARE AND PERFORMING ALL FUNCTIONS EXPECTED OUT WHILE IN ACTUAL SERVICE AND
RE 8 WITH STSTEM CONFIGURATION AS FINALISED.
Q 9 PROCESS INPUT/OUTPUT CONDITIONS AND OTHER LOAD ON THE SYSTEM TO BE STIMULATED 
UI 10 EITHER BY HARDWARE/SOFTWARE.
R 11 ALL SYSTEM SOFTWARE and APPLICATION SOFTWARE TO BE LOADED AND OPERATIONAL ON THE 
M 12 SYSTEM PRIOR TO FAT
EN 13 FAT TO BE CONDUCTED AT ELEVATED TEMP. OF 45 DEG C FOR MINIMUM 48 HOURES 
TS 14 FAT UNDER FOUR CYLES OF VOLTAGE FLUCATIONS VIZ NOMINAL AT 110 % OF RATED VOLTAGE 
15 PERFORMANCE TEST: 
16 -
17 -
TE 18 TOTAL SYSTEM CONFIGARATION DRAWINGS
ST 19 FAT PROCEDURE CONSITING OF:
D 20 (i) TEST EQUIPMENT
O 21 (ii) TEST ENVIRONMENT
C 22 (iii) TEST CONFIGURATION 
U 23 (iv) TEST PROCEDURE
M 24 (v) TEST SCHEDULE
EN 25 (vi) TEST VENUE
TS 26 (vii) TEST REPORTS- SPECIMEN COPIES
D
27 FUNCTION DESIGN SPECIFICATION FOR EACH EQIPMENT / SYSTEM
RA
28 -
WI
N 29 -
G
S
PR 30 GENERAL APPEARENCE CHECK and BILL OF MATERIALS CHECK 
EL 31 CONSTRUCTION CHECK AS PER OVER ALL GENERAL ARRANGEMENT DRAWINGS 
IMI 32 DIMENSIONAL CHECK 
NA 33 LABELLING, TERMINAL ARRANGEMENT AND EQUIPMENT IDENTIFICATION CHECK 
RY 34 POWER SUPPLY VOLTAGE LEVEL CHECK and POWER 'LEDs -ON CHECK 
C 35 COOLING FAN OPERATION CHECK 
HE 36 GROUNDING NETWORK CHECK 
CK
S
TE 1 POWER SUPPLY UNDER VOLTAGE AND OVER VOLTAGE CHECK (± 10%) 
M 2 PROCESSOR and MAIN DATA BUS NETWORK REDUNDANCY CHECK, IF APPLICABLE 
3 COMMUNICATION COUPLER IF APPLICABLE REDUNDANCY CHECK 
4 COMMUNICATION MODULE OF THE CONTROLLER TO NETWORK REDUNDANCY CHECK, IF APPLICABLE 
5 POWER SUPPLY REDUNDANCY CHECK 
6 HARDWARE ON-LINE MAINTAINABILITY CHECK, 
7 -
8 -
C 9 CLOSED LOOP CONTROL SIMULATION CHECK 
O 10 OPEN LOOP CONTROL SIMULATION CHECK 
NT 11 CONTROL LOOP RESPONSE CHECK 
R 12 BUMPLESS AUTO MANUAL TRANSFER CHECK 
OL 13 OPERATING STATION – GRAPHIC OVERVIEW CHECK 
LE 14 OPERATING STATION- TREND CHECK 
R 15 OPERATING STATION- REAL TIME TREND CHECK 
EN 16 OPERATING STATION- MIMICS CHECK 
GI 17 OPERATING STATION- CHECK FOR OPERATING CONTROL DIRECTLY FROM MIMICS 
NE
18 OPERATING STATION- FUNCTION KEYS CHECK 
ER
19 OPERATING STATION- TOUCH SCREEN FUNCTION CHECK 
IN
G 20 OPERATING STATION- ANALOG CONTROL DISPLAY CHECK 
21 OPERATING STATION- SEQUENCE CONTROL DISPLAY CHECK 
22 OPERATING STATION- OPERATOR GUIDENCE MESSAGE CHECK 
23 OPERATING STATION- ALARM MANAGEMENT FUNCTION CHECK 
Page 633 of 680

24 OPERATING STATION LOGGING FUNCTION CHECK 

25 OPERATING STATION / RESPONSE / UPDATING CHECK 
26 KEYBOARD LOCK FUNCTION CHECK 
27 OPERATING STATION INTERCHANGEBILITY and ASSIGNABILITY CHECK 
28 PRINTER ASSIGNABILITY and BACK-UP FUNCTION CHECK 
29 FLOPPY DISK/ STD / OPTICAL DISK UNIT STORAGE and RETRIEVAL CHECK 
30 OPERATING STATION ASSIGNABILITY CHECK FOR HARD COPIER FUNCTION 
31 PLANT PERFORMANCE CALCULATION CHECK 
32 COMMUNICATION INTERFACE TO OTHER’S SYSTEM SIMULATION CHECK 
33 -
34 DATA BUS DISTANCE BUILDING CHECK (REFER NOTE- 3) 
35 GRAPHIC DISPLAY BUILDING FUNCTION CHECK 
M 36 CLOSED LOOP CONTROL SYSTEM MODIFICATION CHECK 
AI 37 OPEN LOOP CONTROL SYSTEM MODIFICATION CHECK 
NT 38 ALARM DISPLAY PRIORITISATION CHECK 
EN 39 SYSTEM SECURITY CHECK 
AN 40 SYSTEM ALARM CHECK 
CE 41 SYSTEM DIAGNOSTIC FUNCTION CHECK 
42 POINT DETAIL CONFIGURATION CHECK 
43 CONTROL LOOP TUNING CHECK 
44 SYSTEM SELF DOCUMENTATION CHECK 
NO 1. THE INTENT OF THE FAT IS TO DEMONSTRATE AND ENSURE THAT THE I&C SYSTEM MEETS ALL THE
TE FUNCTIONAL REQUIREMENTS AS INTENDED IN THE SPECIFICATION / CONTRACT. A COMPLETED
S INTEGRATED TEST OF THE SYSTEM SHALL BE CARRIED OUT AT VENDOR'S WORKS IN THE PRESENCE
OF OWNER, ON COMPLETION OF INTEGRATION/MANUFACTURING OF THE SYSTEM. THE
SHIPMENT OF I&C EQUIPMENT TO SITE WILL BE EFFECTED ONLY AFTER THE FAT HAS BEEN ACCEPTED
BY THE OWNER.
2. FAT PROCEDURE SHALL BE PREPARED BY VENDOR AND TO BE SUBMITTED FOR OWNER'S/
APPROVAL WELL IN ADVANCE PRIOR TO THE COMMENCEMENT OF FAT
3. FAT SHALL BE CONDUCTED WITH THE DISTANCE BETWEEN THE PROCESSOR AND OTHER SUPPORTING
PERIPHERIALS AS PER THE FINAL LAYOUT IN THE CONTROL ROOM.
4. ALL THE RELEVANT APPROVED DOCUMENTS REQUIRED FOR FAT SHALL BE SUBMITTED BY THE BIDDER IN
ADVANCE PRIOR TO COMMENCEMENT OF FAT.
14.02.04.17 Tests to be performed during FAT of PLC system
Following m inimum tests shall be performed during FAT at manufacturer’s place of

PLC system:
1) Hardware Inspection of PLC Sub System

i) Heat run test
ii) Hardware check / physical software package check
iii) I/O loading specification
iv) PLC start-up and power fail restart
v) PLC processor back-up function
vi) Communication redundancy
2) Application Inspection for Logic Functions

i) Ladder logic functional check and graphic screen check
3) Application Inspection for PLC Panels
i) General arrangement
ii) Appearance and construction
iii) Panel wiring
iv) Panel functional check
v) Power supply redundancy check
Page 634 of 680

4) PLC System Checks
i) PLC Scan time functional test

ii) PLC/IO panel/Engineering station functions
iii) Diagnostic and process alarm test
iv) Controller redundancy test
v. I/O cards redundancy test.
vi) Controller loading test
In addition to above test, Bidder shall also perform other tests as per approved QAP
& FAT procedure. Also bidder shall submit “Type Test” report as per IEC – 61131.2
along with FAT report for PLC.
14.02.04.19 FACTORY ACCEPTANCE TEST FOR SIMULATOR
Factory Acceptance Test (FAT) shall include all required tests to fully demonstrate to
Owner’s satisfaction that each equipment/sub-system/system software modules etc.
furnished as per this specification, as well as Simulator as a whole, fully meets the
functional, par ametric and ot her r equirements of this specification an d O wner’s
approved drawings/documents under all operating regimes.
Bidder t o not e t hat FA T p rocedure given bel ow i n su bsequent cl auses are onl y
indicative in order to help the Bidder in understanding the requirements and help him
in submitting a detailed procedure based on these guidelines meeting all the
specification requirements.
The Bidder shall also carry out the tests included in subsequent clause as
pre FAT and submit its results before inviting Owner for FAT.
The Factory Acceptance Test (FAT) shall include all reasonable exercises, which the
combination of equipment and software can be expected to perform. These tests
shall be divided into, as a minimum, but not limited to the following categories:
i. Pre power on checks

ii. Power on check
iii. Hardware tests
iv. Functional tests
v. Parametric tests
vi. Specific tests on Electronic hardware
14.02.04.19.1The major Functional Tests shall include but not limited to the following:
a) Verification of individual modules in line with approved documents.
b) Verification o f adher ence to par ameters for v arious plant co nfigurations at

different initial conditions.
c) Functional test for C&I Model
Page 635 of 680

Verification o f pr oper r ealization of C ontrol and Log ic functions as per i nput

documents and approved functional design specification (FDS).
d) Functional tests for HMIPIS
i. Verification of all types of displays, logs including their formats, bar

graphs, X -Y pl ots etc. V erification o f al l f unction k eys on k eyboards
and availability of all operator functions.
ii. Verification o f ev ent generation and handl ing c apabilities of H MIPIS

processors by simulating various types of events / data and observing
associated event sequence display and alarm signaling boxes.
iii. Calculations:
All ca lculations shall b e tested t o de monstrate t hat these are i n

accordance with the specification and I/O schedule. The Bidder shall
prepare all tests cases for calculations (3 for each calculation at low,
mid and upper r anges of i nputs) and su bmit t hem for t he ow ner’s
approval. Test cases shall include performance calculations, flow and
level calculations, pressure and temperature compensations, etc.
iv. Checking historical storage and retrieval functions including long-term

storage.
v. Checking heal thiness of pr ocessor, main m emory. T esting o f

initialization and loading of configuration data, etc.
vi. Verification o f al l pr ogrammers’ st ations functions for H MIPIS and

Control System, as well as for documentation facility as specified.
vii. Various display response time / System accuracy etc.
viii. Display update time on OWS
e) Functional test for networking & communication devices
i. Verification of various features as per approved documents.
ii. Verification of throughput after creating high communication traffic.
f) Instructor’s workstation Functions
Verification o f al l features of i nstructor functions like malfunction, i nitial

conditions, sn ap sh ots, t rainee ex ercises etc. i n l ine with sp ecification &
approved documentation.
g) Programming and Documentation functions
Page 636 of 680

i. Verification of all programming function like, modification of application

software, da tabase, a dministrator’s function et c. i n l ine w ith
specification and approved documents.
ii. Verification of all documentation functions in line with specification and

approved documents.
14.02.04.19.2 FAT Procedure
The B idder shall su bmit a de tailed FA T p rocedure for ow ner’s approval dur ing
detailed engineering stage based on the above guidelines. The FAT procedure to be
submitted by the Bidder shall be det ailed and exh austive enough such that owner is
satisfied t hat al l t he S imulator S ystem sp ecification r equirements and f eatures are
being tested and the system meets these requirements.
14.02.04.20 Tests to be performed during FAT of Peripherals & other control system
1. Colour Graphic Video Display Unit (OWS)
i. Functional tests (As per FAT procedure. Note-1)

ii. Test for capabilities of OWS including error detection for the
complete system (Both hardware & software) simulating worst
conditions
iii. Noise test
iv. Surge withstanding capacity as per IEEE or equivalent
v. Quality assurance as governed by BS 5750 or equivalent
vi. Design, construction, components, finishes and testing of electronic
2. Keyboard
i. Test for satisfactory operation of keyboard controls, push buttons and

all associated functions (As per FAT procedure. Note-1)
ii. Quality assu rance as governed by BS 5750 or e quivalent for
functional test for the complete system simulating worst conditions
iii. Design, construction, components, finishes and testing of electronic
3. Printers
i. Noise level test for the printer

ii. Test of interlock performance and error detection feature.
iii. Quality assurance as governed by BS 5750 or
equivalent
Page 637 of 680

4. Floppy / Tape Drive Unit / Bulk Memory Unit / DVD, CD d rive Un it /

DAT Drive
i. Noise test
ii. Surge withstanding capacity as per IEEE or equivalent
iii. Quality assurance as governed by BS 5750 or equivalent
v. Test of Control unit and drive for all features, date checking
features.
5. Vibration Monitoring & Analysis System

6. PADO (Performance & Optimization System)

7. ERP System

8. MIS System


9. HMS System

NOTES:
1. The i ntent o f t he FA T i s to dem onstrate and e nsure that t he I &C sy stem

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 t he presence o f Owner or Owner’s representative, on
Page 638 of 680

completion of integration / manufacturing of the system. The shipment of I&C

equipment t o si te w ill b e ef fected onl y af ter t he FA T has been acce pted by
Owner.
2. FAT procedure shall be prepared by vendor and to be su bmitted for Owners

approval well in advance prior to the commencement of FAT.
14.02.04.21 Calibration of Instruments

The B idder sh all ca rry out t he calibration o f i nstruments as indicated bel ow b y
submitting the test procedure and quality assurance plan for the Owner’s approval.
Bidder sh all al so pr epare det ailed ch ecklist/calibration sh eets for e ach o f the
systems/equipment cl early i ndicating t he step-by-step pr ocedures to be ca rried ou t
for calibration pre commissioning, loop checking, powering and commissioning.
The calibration of all instruments shall be ch ecked and ca libration records prepared
for the Owner’s use. If the instruments require recalibration, Bidder shall recalibrate
the instruments and revise the calibration records and submit to the Owner.
i TESTS TO BE PERFORMED FOR FIELD INSTRUMENTS
1. Pressure Gauges
Calibration Hydro test (1.5 times max. pr.)
2. Pressure switches
Calibration test / Hydro test / Contact rating test / Accuracy test / Repeatability
3. Differential Pressure Gauges
Calibration test / Hydro test / Leak test / Over range test / A ccuracy test / Repeatability
test.
4. Differential Pressure Switches
Calibration test / Hydro test / Contact rating test / Leak test / Accuracy test / Repeatability
test.
5. Thermometers
Calibration / Material test / Accuracy test / Bore concentricity : + 5% of wall thickness /
Hydrostatic test for TW (1.5 times max. pr.)
6. Temperature switch
Calibration / Material test / Accuracy test / Bore concentricity : 1 .5% of wall thickness /
Hydrostatic test for TW (1.5 times max. pr.) / Contact rating test.
7. Resistance temperature detector assembly.
Calibration / Material test / Bore concentricity test / Insulation test (< 500 MΩ at 500V DC)
as per ISA, Hydro test for TW. Bore concentricity: + 5% of wall thickness, Accuracy test.
8. Thermocouple assembly
Calibration / Material test, Insulation test (> 500 Ω at 500 V, DC) as per ISA, Hydro static
test (1.5 times max. pr.), Bore concentricity : + 5% of wall thickness.
9. Thermowells
Material test / Bore concentricity : + 5% of wall thickness / Hydrostatic test for TW (1.5
times max. pr.)
Page 639 of 680

10. Level Guages

Hydrostatic test / Material test / Seat leakage test / Ball check test.
11. Level switches (Magnetic)
Material test / Contact rating test / Hydro test / Calibration test.
12. Flow Switch
Material test / Hydro static test (1.5 times max. pr.) / function test.
13. Flow glasses
Material test / Hydrostatic test (1.5 times max. pr.) / function test.
14. Variable area flow meters
Calibration test / Material test / Hydrostatic test (1.5 times max. pr.)
15. Flow element
100% Radiography test / Hydro test / Calibration test, IBR Certificate.
Calibration test for flow element shall be witnessed by Owner.
16. Control valves/Pneumatic block valve/Pressure regulating valve – Refer chapter 11.
17. Position transmitters
Calibration / hysteresis and Accuracy test
18. Electro Pneumatic Convertors
19. Solenoid valves
Hydrotest / Seat leakage test / CV test / Coil insulation test
20. Air filter regulators
21. Junction Boxes
Test for degree of protection / Material test
22. Tests for terminal blocks
Test for moulding for flame resistant, Non-hygroscopic and Decarbonised / Insulation test
between terminals / Insulation between terminal block and frame.
23. Thermocouple extension cable
Thermo-emf ch aracteristic / C ontinuity t est / M easurement on ca pacitance, i nductance
and loop resistance / Insulation resistance / High voltage test as per latest IS / Tensile
and elongation test / Oxygen index test / Any other test applicable.
24. Mass flow meter
Performance test / Calibration test / Hydrostatic test.
25. Boiler Level Gauge
Hydrostatic test / Material test / Seat leakage test / IBR Certificate
26. pH/Conductivity measurement / Silica / Dissolved oxygen analysers:
Calibration test, Accuracy test
27. Sample cooler :
Page 640 of 680

Hydro test, IBR Certificate

28. Sampling racks :
Hydro test, IBR Certificate for tubes and fittings.
29. S02 / Nox analyser / SPM analyser:
Calibration test, accuracy test
30. Interposing relay
Functional test, temperature rise test, H.V test, Insulation test
31. Transmitter Racks :
Hydro test, air leak test for piping / tubing and fittings. IBR certification as required for
tubing / piping and fittings.
32. Pressure Transmitter
test.
33. Differential pressure transmitter
test.
34. Temperature Transmitter
Calibration test / Accuracy test /Ambient temperature error test
35 Pneumatic Block Valves
temp< 400 DegC)
temp< 400 DegC)
36. Pressure Regulating Valve
Page 641 of 680


temp< 400 DegC)
temp< 400 DegC)
37. Local Panels :
Visual inspection, wiring & continuity check, H.V. and I.R. tests on panels, checking of bill
of materials, functional tests.
38 Wiring Termination & Accessories
Routine test: Conductor resistance test/High voltage test/Impulse dielectric test/insulation
test/Humidity test/Temperature rise test on power circuits/short time current test on power
circuits.
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
39 Marshalling/System cabinets
Verification of degree of protection/Electrical tests as detailed under wiring Termination&
accessories/Type test and routine test as per relevant Indian standards.
Notes:
1. Test Certificates in addition to inspection at manufacturers works shall be furnished for
all the instruments for Owner's review.
2. Above Test to be witnessed shall be finalized by Owner.
3. In addition to above test, test as per approved QAP shall also be witnessed by owner.
17.02.05 TYPE TESTING
The B IDDER sh all furnish t he Type t est r eports of al l t ype t ests as per r elevant
standards and codes. As well as other specifics test indicated in the specification. A
list of su ch t est ar e gi ven f or v arious equipment i n t able t itled, TY PE T EST
REQUIREMENT FOR C&I SYSTEM and under the item special requirement for solid
state requirements/systems. For the balance equipments/instruments. type test may
be conducted as per manufacturer standards or if required by relevant standards.
A. Out of these test listed , the bidder /subvendor/manufacturer is required
Page 642 of 680

to conduct certain type test specifically for t his contract (and w itnessed by
employer or his authorized representative). Even if the same have been
conducted earlier as clearly indicated subsequently such tests.
B. For t he rest, su bmission o f t ype t est , results, and ce rtificates shall be

acceptable provided following points
i. The same have been ca rried out by the bidder/ subvendor on ex actly
the same model/rating of equipment. (For control valves this shall be
same size, type & design).
ii. There has been no ch ange in the co mponents from the offered
equipments and tested equipments.
iii. The test has been carried out as per the latest standards along with
amendemends as on the date of bid opening.
C. In case the approved equipment is different from the one on which the type
test had been conducted earlier or any of the above g rounds, then the tests
have t o be r epeated and t he co st o f su ch t ests shall be bor ne by the
bidder/sub-vendor within the quoted price and no extra cost will be payable by
the owner on this account.
17.02.05.1 As mentioned against certain items, the test certificates for some of the items shall
be reviewed and approved by the main bidder or his authorized representative and
balanced have to be approved by the employer.
The schedule of conduction of type test/submission of reports shall be submitted and

finalized during pre award discussion.
17.02.05.2 For the type test to be conducted, bidder sh all su bmit detailed test procedure for
approval by o wner. T his shall cl early sp ecify t est se tup, i nstruments to be use d,
procedure, acce ptance nor ms (wherever appl icable). , r ecording of di fferent
parameters, i ntervals of r ecording pr ecaution t o be t aken et c. for t he t est t o b e
carried out.
17.02.05.3 SPECIAL REQUIREMENTS FOR SOLID STATE EQUIPEMNTS /SYSTEMS
The minimum type test report, over and above the requirements of above clause
which ar e t o be su bmitted for each o f t he major C &I sy stems like D DCMIS, D CS,
PLC etc shall be as indicated below:
i. Surge Withstand Capability (SWC) for solid state equipments/equipments
All solid state systems/equipments shall be able to withstand the electrical

noise and t he su rges as encountered i n ac tual se rvice co nditions and
inherent in the power plant . All the solid states systems /equipments shall be
provided with all required protection that needs the surge withstand capability
as defined i n A NSI 37. 90.1/IEEE 472. H ence, al l f ront end ca rds which
receive e xternal si gnals like anal og i nput and out put m odules, B inary i nput
and out put modules etc i ncluding pow er su pply , da ta hi ghway, dat a l inks
shall be pr ovided with protection that meets the surge withstand capability as
Page 643 of 680

defined i n A NSI 37. 90.1/IEEE 472. C omplete det ails of t h features

incorporated i n t he el ectronic system t o m eet this requirement t he relevant
test carried out, the test certificates ,etc shall be submitted along with the
proposal. A s an al ternative t o t he abov e , su itable cl ass of E N 61000 -4-12
which is equivalent to ANSI 37.90.1/IEEE 472 may also be adapted for SWC
test.
ii. The dry heat test as per IEC-68-2-2 or equivalent

iii. Damp heat test as per IEC 68-2-3 or equivalent
iv. Vibration test as per IEC 68-2-6 or equivalent
v. Electrostatic Discharge test as per EN 61000-4-2 or equivalent
vi. Radio frequency immunity test as per EN 61000-4-6 or equivalent
vii. Electromagnetic Field Immunity test as per EN 61000-4-3 or equivalent
Test l isted at I tem no v , v i, vii abo ve ar e appl icable f or el ectronic cards only as
defined under item no. (i) above
17.02.05.4 TYPE TEST REQUIREMENTS FOR C&I SYSTEMS
S.No. Item Test Standard Test t o be Owner’s

requirement specifically Approval
conducted required on
Test
Certificate
1 Electrical As per IS 1248 No Yes
metering standards
instruments
2 Thermocouple Degree of IS - 13947 No No.
Protection
Test
3 Junction Box Degree of IS - 13947 Yes Yes
Protection
Test
4 RTD As per IEC-60751 No No
standards
5 Electronic As per BS 6447/ IEC No Yes
Transmitter standards 60770
6 E/P convertor As per Manufacturing No Yes
standards standard
7 Instrumentation cable (Twisted and shielded) (Refer Vol. V, Chapter 9)
8 Battery As per standard IS 10918 Yes YES
9. Voltage Over load test Approved No YES
stabiliser procedure
Temp. rise test Approved No YES
without r edundant procedure
fans
Input voltage Approved No YES
variation test procedure
10 DDCMIS
CLCS Model Test Approved No No
Page 644 of 680

system procedure
BMS & MFT Safety VDE 0116, No YES
requirement SEC 8.7
11 Conductivity Degree of IS 13947 No No
type level protection test
switch
12 Local gauges Degree of IS 13947 No No
protection test
13 Process Degree of IS 13947 No No
actuated protection test
switches
14 Control CV test ISA 75.02 No YES
valves
15 PLCs As per Standard IEC 1131 No YES
16 LIE/LIR Degree of IS 13947 YES YES
protection test
17 Flue gas O2 Degree of IS 13947 No YES
analyser, protection test
other Fl ue
gas
Analysers
18 Flow nozz les calibration ASME PT C YES YES
&O rifice BS 1042
plates
Note:
Type t est a re to be co nducted onl y for t he i tems, w hich ar e bei ng su pplied as part o f t his
package.
A. For batteries with electric power supply system of main plant C&I, the bidder shall submit
for owner’s approval the reports of all the type tests as per IS-10918 carried out within
last 5 years from the date of bid opening and the test should have been either conducted
at an i ndependent l aboratory or sh ould hav e b een w itnessed by a o wner/client. The
complete type test report shall be for any rating of battery in a particular group, based on
plate dimensions being manufactured by supplier.
For batteries with electric power system of auxiliary plants, type test reports for batteries
shall be as per standard –practice of manufacturer.
14.02.06 Testing at Site [Prior to commercial operation]
a. All equipment shall be checked thoroughly in respect of the following:
i. Visual and mechanical testing
ii. Complete system configuration loading functions; system

diagnostics; system proper operation specified power supply
specifications.
Page 645 of 680

L.DRAWINGS
Page 646 of 680

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842
4
439
800
3
2300
40
0
550
340
2
96
100
210
635
ANTI VIBERATION PAD
NOTE:-
15
1 : Panel for Mounting annunciation P.B.,
Desk release PB, Emergency Trip P.B.
100
2 : Panel for Mounting ILPB for OLCS / Sequential Operation.
3 : Sheet metal panel for mounting MIMIC , Ammeters,Indicator,
Totalizer, recorder etc.
1500
4. Inclined Sheet metal panel for mounting Annunciation Facia windows.
Page 653 of 680

Page 654 of 680

Page 655 of 680

M.ERECTION HARDWARE
Page 656 of 680

CHAPTER-9
ERECTION HARDWARE
9.00.00 PROCESS CONNECTION AND PIPING
9.00.01 General Requirements
This section co vers the m aterial r equirement for i nstrument co nnection t o pr ocess,
instrument process, piping, tubing, supports, Instrumentation cables, control cables and
power cables for connecting UPS, 24/48 V DC, unregulated power supply for cubicle
illumination, co mpensating ca bles/Extension ca bles, t ransmitter r acks and m ain
accessories to be furnished under this specification and t he requirements of installation
and r outing. I mpulse lines, fittings and other acce ssories required for the erection of
complete I nstrumentation and C ontrol S ystem su pplied under various packages of t his
specification shall be su pplied on “ as required’ basis. B idder sh all o ffer al l nece ssary
items for this section based on his experience on similar plants, plant layout diagrams,
installation dr awings and ot her appl icable se ctions of this specification. B ased on t he
good engineering practices Bidder shall furnish installation drawings during the
engineering o f the sy stem for O wner’s review and appr oval . The i nstallation o f the
drawings shall be suitable for his installation of his range of instrumentation.
The Bidder shall furnish and test all required erection hardware, which is necessary for
proper installation and interconnection of the equipment/systems furnished by the Bidder
and t heir i ntegration w ith m ain e quipment/systems as per the encl osed i nstallation
drawings and ot her ap plicable cl ause. The Bidder shall furnish all har dware and
accessories to ensure that the equipment/systems furnished form a co mplete and
operational system meeting the intent and requirement of this specification.
All materials, furnished shall conform to the latest editions of America National Standard
Code for Pressure piping, Power piping, ANSI B311.1, ANSI B16.11, ASME Boiler and
Pressure V essel C odes, I BR and ot her appl icable A SME, A NSI and I ndian S tandards.
Schedule nu mbers, s izes a nd di mensions o f al l c arbon s teel, s tainless steel and al loy
seamless steel pipe shall confirm to ANSI B.36.10 and of stainless steel pipe shall confirm
to ANSI B 36.19 unless otherwise specified.
All m aterials supplied u nder t his section sh all b e su itable for i ntended s ervice; pr ocess
operating co nditions an d t ype o f i nstruments used and sh all fully co nform to the
requirements of this specification.
The Bidder is responsible for the performance of the equipment furnished on system
basis any sh ortfall i n erection material obs erved dur ing e rection stage sh all be
compensated by the Bidder at no ex tra cost. (Installation drawings # 114-04-0000, 0100
to 0113 shall also be referred by bidder).
9.01.00 GUIDLINE FOR INSTALLATION AND ROUTING OF INSTRUMENT PIPING
9.01.01 General Requirements
The following g eneral er ection g uidelines have been enum erated her e t o enabl e t he
Bidder to estimate the requirement of instrument piping in plant:-
Page 657 of 680

i) All instrument piping shall be in accordance with good engineering practice. It

shall be f inalized dur ing eng ineering s tage. I nstrument pi ping sh all be c omplete
with fittings, valves and other required accessories.
ii) Instrument piping shall not be routed:-
a) Across equipment removal areas

b) Below mono-rails and cranes
c) Above or below removable gratings
d) Above or below cable trays.
iii) Primary Impulse Piping System:
a) The primary impulse piping system shall include the instrument piping and
all required accessories from process tap off point (root valves onwards)
up t o the r espective i nstruments. Fr om t he s ame so urce, Tee o ff for
instruments are not allowed. Separate tapping shall be provided for each
instrument. The B idder sh all pr ovide t he nece ssary fittings and
accessories along with impulse pipes for completeness and arrangements
as per the finalized Instrument Installation Diagrams. Special accessories
such as reservoirs and other dev ices shall be i nstalled as required for
flow primary element connection as required by the design of instruments,
in accordance with the instructions of the instrument manufacturer.
b) The Bidder shall prepare impulse pipe routing drawings.
c) Impulse piping shall include a blow-down line and shut-off valve adequate
for the duty requirements and for withstanding continuous design pressure
and t emperature o f pr ocess medium. For pr ocess pressure abov e 4 0
Kg/Cm²g, double valves shall be used before connecting to the blow-down
header (This arrangement shall be provided for installation for the new
transmitter if the existing transmitter has the same arrangement.)
d) To assure a constant static head the connections from low pressure steam
and l ow pr essure l iquid f illed l ines should pr eferably sl ope do wnward
continuously towards the instrument as the instrument is mounted below
the source poi nt. I f do wnward sl ope i s not f easible or t he i nstrument i s
mounted above the source point, the line should slope upward
continuously and a “ pigtail” i nstalled at t he i nstrument to assu re a w ater
seal for t emperature pr otection. U pward sl oping l iquid l ines should b e
used only if the process pressure is sufficient to assure a head o f liquid at
the instrument. Horizontal runs should have a slope of not less than 40
mm per meter and must be adeq uately supported to maintain a constant
slope. V acuum connections to the co ndenser sh ould al ways slope
upward to the instrument.
e) Primary pr ocess piping for s team flow, l iquid flow and m anometric level
measurement sy stems sh ould pr eferably sl ope dow nward f rom the
primary element connections to the instrument. Primary piping for flue gas
and ai r flow m easurement sy stems should p referably sl ope upw ard f rom
Page 658 of 680

the primary element connections to the instrument. If these requirements

cannot be met, sp ecial v enting or dr ain p rovisions will be r equired.
Horizontal r uns must h ave a sl ope of not l ess t han 40 millimeters pe r
meter and must be adequately supported to maintain a constant slope.
f) Primary pr ocess piping from t he field w hich ent ers the i nstrument
enclosure from t he bot tom sh all ex tend i nto t he enclosure appr oximately
150 m illimeters and be equipped w ith a so cket weld t o flare l ess tubing
coupling of stainless steel. This coupling shall be used to connect the field
primary pr ocess line to t he encl osure pr ocess l ine. The field p rimary
process line shall be anchored to the enclosure angle with U-bolts. Holes
for supporting U-bolts shall be field or drilled.
g) All i mpulse pi ping sh all be su pported r igidly at an i nterval not ex ceeding

1.5 meters so as to prevent excessive sag in piping. Process piping shall
not be used for supporting impulse piping.
h) Impulse lines subject to severe sonic pulsations such as boiler feed pump
discharge, shall be o f sufficient l ength and o f su itable co nfiguration to
scatter harmful sonic wave energy before it reaches the instrument.
i) Impulse pi ping sh all be i nstalled t o per mit t hermal ex pansion without

placing excessive stress on the piping and without affecting the gradient of
slope. Long continuous straight runs of piping shall always be avoided. If
required, ex pansion l oops shall be pr ovided at l east ev ery 2. 5 m eters to
break the continuity.
j) All welded and screwed fittings shall conform to ANSI B16.11. Threads of
piping components shall be taper pipe thread in accordance with ANSI
B2.1. A ll t hreads shall be c lean m achine cu t with al l bur rs and ch ips
removed. Lub ricants shall be of d ry filc type. Any one of the following
compounds may be use d as a pipe thread sealer. Bidder shall supply
adequate amount of his preferred sealer for erection purpose.
a) Permatex
b) Molycote
c) Neolube
(Teflon tape shall not be used as a pipe thread sealer).
9.01.02 Impulse Piping System
Impulse pi ping sy stem consists of p rimary i mpulse pi pes/tubes, v alves, fittings, v alve
manifolds and ot her acc essories between t he so urce co nnection poi nt ( source sh ut-off
valve on wards) and al l i nstruments/devices. I mpulse pi pe sp an for supporting cl amp
shall be 1.5 mtr. This will also include all piping and valves etc. required for instrument
drain and v ent co nnections. The B idder sh all furnish and t est al l i tems required for
completeness of this specification.
9.01.03 AIR SUPPLY PIPING
Page 659 of 680

The piping for air supply shall be as specified below (However the Bidder shall supply the
materials as required basis to complete the system in all respect)
i) Individual Supply Lines and Control Signal Lines:-
Air lines shall be ¼ inch size, connected by brass/SS316 flare less tubing fittings.
Copper/SS316 tubing s hall be l ight dr awn t ampered tubing co nforming t o A TM
B75 except copper tubing in tubing cables shall be annealed soft temper tubing
conforming t o A STM B 68 or B 75. Fi ttings on the br anch l ine t o f acilitate
connections to the individual supply line shall be cast brass screwed type.
ii) Flexible Hoses:-
Flexible hoses shall be ¼ inch SS flexible hose pipe and with Buna-N liner steel
wire braid reinforcement complete with ¼ inch brass/SS316 fittings and shall have
swivel male pipe threads. Each hose shall be done meter in length.
iii) Pipe Material Specification:-
The piping m aterial sh all be ca rbon st eel hot-dipped g alvanized i nside and
outside as per I S-1239 or t he e quivalent o f t hese st andard heav y q uality w ith
screwed ends. The piping threads shall be as per ASA B.2.1.
iv) Isolating Valves:-
Gate valves as per ASTM B62 inside screw rising stem screwed female ends as
per ASA B.2.1 valve bonnet shall be uni on type and t rim shall be st ainless steel
body rating 150 pounds ASA. Valves sizes shall be ½ inch to 2 inch.
v) Fittings:-
Forged cast steel A234 Gr. WPM galvanized inside and outside; screwed as per
ASA B2.1 dimensions as per ASA B16.11, rating 2000 pounds, elbows and soft
seats. The size of the fittings shall be ½ inch through 2 inch.
vi) Air Filter Regulator Set:-
An instrument Air Filter Regulator Set with mounting assembles shall be provided
for each pneumatic device requiring air supply.
vii) Instrument Air Piping System:-
a) Instrument Air shall be made available by the bidder at 3.5 to 7.0 Kg/cm²
pressure. The instrument air may be arranged as under:-
11. For t he control v alves and pow er c ylinders in o wner’s scope but
controlled by bi dder’s co ntrol sy stem, the i nstrument ai r
requirement f or E/P co nverter shall be t apped f rom the near by
instrument ai r header l aid by b idder / al ready l aid exi sting pi ping
with a ccessories available near the co ntrol v alves or dam per.
Page 660 of 680

Complete ha rdware r equired for i nterfacing w ith O wner sy stem

shall be in bidder scope.
b) Air supply piping shall be installed at site always with a slope of over 1/100
to prevent accumulation of condensed water within the pipe.
c) All joints in the instrument air sub-header shall be of screwed type.
d) Instrument ai r l ine sh all be se parate for eac h i ndividual instrument,

equipment & drive with own isolation valve and other required hardware.
Tee off of instrument line for two or more same/similar services
instrument, equipment & drive are not acceptable.
e) Instrument air flushing/purging l ines shall be provided for Bowl Mill DP,
secondary air flow measurement instrument and other all flue gas services
instruments etc.
viii) Signal / Control Air Tubing System:-
Necessary tubes with fittings and accessories for output signal from pneumatic
instruments mounted in the field and control signals to final control elements shall
be covered under this tubing system.
9.02.00 SPECIFICATION FOR ERECTION HARDWARE
The erection hardware shall meet the following specifications:-
Item Specification
9.02.01 Impulse Piping
i) High pressure and high Seamless Alloy Steel

temperature services piping to ASTM A335
(Medium: Steam & Water GR.P91/22 (schedule XXS/160
and furnace region) for high pressure &
high temperature)
ii) Low pressure and low Seamless carbon steel

temperature services piping to STM A106, Gr.C
(Medium: Steam & Water)
iii) Low pressure and low ERW carbon steel

temperature services piping to IS 1239:1973
(Air, Flue gas) Heavy class System)
iv) Steam and water Seamless stainless

analysis system steel piping to ASTM
A312 GR. TP-321
v) Seamless copper tubing ASTM B-75
Page 661 of 680

9.02.02 Fittings Double compression type
i) Material for socket weld fittings ASTM A105

ASTM A182,
Gr. F22
6000/3000 lbs
ii) Dimensions of fittings ANSI B16.11
iii) Fittings for steam and Gr. F-321

water analysis.
9.02.03 Valves
i) 3 – way valves SS body/forged CS

body stellited internals and SW ends
as per requirement for 2500 lb/800 lb
ASA ratings.
ii) 5- valve manifolds FAS body/FCS body

316SS stellited internals with NPT(F)
SCRD ends for 30 00/2500 l b/1500
lb/800 lb ASA ratings. Construction –
Single block (Bar stock)
iii) 3-valve manifolds FAS body/FCS body

316SS stellited internals with NPT(F)
SCRD ends for 3000/ 2500 l b/1500
lb/800 lb ASA ratings. Construction –
Single block (Bar stock)
iv) 2-valve manifolds FCS body, 316SS

stellited in ternals, NP T(F) S CRD
ends. C onstruction – Single bl ock
(Bar stock)
v) Isolation and drain valves Globe valves with

FAS body/FCS body, 316SS stellited
internals SW ends for 3000/2500
lb/1500 lb/800 ASA ratings.
9.02.04 Condensation vessels FAS/FCS body with NPT (F) SCRD

connection and v ent plugs for 3000/2500/1500/800
lb ASA ratings.
9.02.05 Racks and Associated ANSI C83.9-1972

Equipment
9.02.06 Code for pressure piping, ANSI B-31.1

welding and Hydrostatic
testing
Page 662 of 680

9.02.07 Flexible conduits with fittings Lead coated, paper insulated, heat
resistant flexible m etallic conduits with nece ssary
fittings.
9.02.08 3 V alve m anifold sh all be use d, w herever D iff Pressure t ransmitter/switch hav e been
used for pressure measurement.
9.02.09 5 Valve manifold shall be used for Diff. Pressure & Flow measurement
Transmitters/Switches.
9.02.10 In addition to above, table # 9.1 shall also be followed for selection of specific erection
hard ware as per process requirements.
9.03.00 TRANSMITTER & SWITCHES ENCLOSURES
In general, B TG pr ocess transmitters & sw itches installed at out door location and i n
areas where they are subjected to splashing oil, water, st eam etc., shall be m ounted in
closed type transmitter rack. For other areas (indoor), open t ype racks may be use d for
installation of t ransmitters and pr ocess switches. H owever t he act ual r equirement sh all
be finalized during detailed Engineering considering following:-
i) Transmitter/Switches enclosures s hall be f ree s tanding, enc losed t ype of fering

protection ag ainst dus t, moisture and v ermin. E nclosures s hall be s uitable f or
outdoor installations, in thermal power plants.
ii) The enclosures shall comprise of Galvanized Sheet mounting plate internally. Also
external-mounting brackets in Polyamide or Stainless Steel shall be available.
Alternatively transmitter enclosures can be glass Fiber Reinforced Polyester (GRP)
compression moulded and shall be weather proof.
iii) Instrument piping inside the enclosure shall conform to the specification and in line
with typical installation drawings enclosed with the specification.
iv) Blow down header shall be provided inside the enclosure as called for.
v) Bulk head connection shall be provided to receive and terminate the impulse pipes
from root valves.
vi) Instrument tubing, fittings and isolation, drain valves shall be to ANSI code for
pressure pi ping. P iping/tubing shall be subject to hydrostatic tests at 1.5 times
maximum system pressure.
vii) Support angles shall be provided for valve manifolds, wiring trays etc. Enclosures
shall be c omplete with nec essary bu lk head fittings, j unction box es, dr ain header
and other accessories as needed on the basis of approved hook up drawings.
viii) Sufficient s pacing am ong adj acent t ransmitters s hall be m aintained t o of fer eas y
accessibility and oper ational c onvenience. T he enclosure s hall be des igned w ith
sizes to suit the grouping and to completely include all the hardware for hooking up
Page 663 of 680

the transmitters to the process on the basis of approved installation diagrams. A

maximum of five (5) transmitters are envisaged to be grouped in one enclosure.
x) A m inimum o f twenty ( 20) per cent s pare t erminals s hall be provided. O nly one
wire per terminal shall be used on the outgoing side of these blocks (for cable
panel). A ny common connections required shall be provided on t he panel side of
the block. A ll incoming power terminals are to be clearly identified in a manner
distinctly different from all other terminals and grouped in a logical pattern.
xi) Chapter no. 6 of t his v olume shall a lso be r eferred for des igning of
Transmitter/Switches enclosures.
9.04.00 LOCAL INSTRUMENTS, LOCAL BOARDS AND TAPPING POINTS
i) All local gauges as well as sensors, Transmitters and switches any other
instruments for parameters like pressure, temperature, level, f low etc for safe and
efficient operation of equipment under the scope of specification, shall be p rovided
by bi dder a s approved by O wner. S uch eq uipment s hall be l isted b y t he B idder
detailing t he i tems w ith t he r espective f unctions i n s ervice. A ll f ield m ounted
instruments shall be mounted in such a way as not to be affected by vibration &
environmental conditions. Racks to mount these instruments shall be f urnished by
bidder complete with requisite erection hardware, tubings and j unction boxes with
all terminals of the instruments duly wired complete with cable glands. Groupings of
instruments, actual number of racks for instruments and its construction shall be to
Owners approval.
ii) Transmitters & S witches pr ovided s hall b e m ounted i n t ransmitter/Switches

enclosures to owner’s approval. The junction box for electrical connections shall be
outside the transmitter enclosures.
iii) All erection har dware r equired for complete installation/ implementation of entire
instrumentation s pecified i s i ncluded in bi dders s cope. A ny ch ange i n s ize, t ype,
rating or in quantity deemed necessary during engineering shall be s upplied within
package price with no additional financial implication to owner.
iv) Bidders scope includes providing counter flanges on pipe lines/ vessels to suit
owner arranged f langed devices. Counter f langes shall be complete with gaskets,
nuts, bolts and other requisite accessories for proper installation.
v) Separate and independent tapping on equipment/associated piping s hall be

provided to suit the philosophy of redundant primary sensors. Separate sensors for
control and m onitoring etc are as decided by Owner. This shall include application
such as first stage pressure. Wherever the process value being measured needs
to be compensated for temp, pressure variations, the tapping points for such
compensating el ements s hall be pr ovided i n r equisite number al ong w ith t he
tapping for the process value.
vi) Whereever transmitters & switches are provided, in addition Local gauges shall
also be provided by bidder for local field monitoring.
Page 664 of 680

vii) Local instruments and r emote s ensors & t ransmitters t o be f urnished with t he
equipment s hall g enerally be as i ndicated her ein and as per r edundancy c riteria
indicated elsewhere but not be limited to the following: -
1. Pressure Measurement
i. Pressure Gauge for:
a) Shell pressures of all Deaerator, HP and LP heaters and other vessels.

b) Mercury m anometers s hall be pr ovided dur ing ai r out let flows
measurement.
c) Bleed steam pressure at extraction point for all turbine extractions and for
pressure on drain lines.
d) Pressure gauges at inlets and outlets of condensate extraction pumps,
main oi l pum p, eac h aux iliary oi l pum p, A C s tandby o il p ump, D C
Emergency oi l pum p, j acking oil pum ps, D M makeup pum ps, D MCW
pumps, BFP, or any other pumps etc.
Pressure Gauge at outlet of each type of Fan.
e) Lube oil pressure before and after oil coolers, HPT & IPT front seal
chamber leak off pressure.
f) MS pressure do wnstream of ESV, after HPT control valves and after HPT
first s tage, HRH s teams pr essure af ter I V, Gland s team header pr essure,
HPT exhaust etc.
g) Condensate pressure in condensate pump discharge header, and feed
water pressure at inlet and outlet of each LP & HP heaters.
h) LP turbine exhaust pressure and condenser pressure
i) Relay/Lube/Control oil pressure, Drain oil lines pressure.
j) Pressure gauges for vacuum pumps and each pump discharge.
k) Pressure gauge at Instrument and service air header in compressor room
and in the field at t he m ain l ocation o f i nstrument/service ai r he ader, t he
pressure gauges shall be provided.
l) Pressure gauges at inlet and outlet of each heat exchanger and cooler.
m) Frame mounted P ressure G auges (FMG) sh all be pr ovided f or M ain
steam P ressure, Feed w ater pr essure t o e conomizer, C RH S team
Pressure, HRH Steam Pressure etc.
n) For condensate storage tank the pressure gauge in terms of 0-10000 mm
wc or suitable range having dial size of 300 mm or bigger size shall be
provided.
o) U tube manometer with Hg filled for direct measurement of
condenser vacuum shall be pr ovided in the fixed with isolation valve for
local indications.
p) Above ar e t he m inimum r equirements, ac tual q uantities shall be as
decided during detailed engineering by owner.
q) Pressure g auge for al l B oP pac kages as decided dur ing det ailed
engineering by owner.
ii. Pressure Switches
a) Pressure switches at condensate Extraction Pump Discharge header, Boiler

feed pump, seal water line or any other pumps for alarm (high & low) an d
interlock purpose.
Page 665 of 680

b) Pressure switches for steam supply to LP/HP heaters.

c) Pressure switches for initiation of turning gear.
d) Pressure switches for control oil, jacking oil and lube oil pressure
for all required alarms and interlocks.
e) Steam pressure downstream of ESV, steam pressure after first stage of
HPT, gland steam header pressure and s uction line from turbine glands to
Gland cooler.
f) Pressure swi tches f or c ondenser vacuum l ow, v ery low a larms &
interlocks.
g) Condenser water box pressure for alarm interlocks.
h) Pressure s witches ( low & hi gh) f or i ndividual pum ps/blowers
suction/discharge and discharge header – alarms, interlocks and protection
i) At t he m ain l ocation o f i nstrument ai r heade r t he pr essure l ow s witches
shall be provided for alarms in DDCMIS
j) Pressure switches/any other process switch etc. for OLCS / Alarms /
Interlocks / P rotection. Pressure sw itches at i nlet, out let o f i ndividual
pumps and discharge header of pumps for protection and auto start / stop
& alarms.
k) Above ar e t he m inimum r equirements, ac tual q uantities shall be as
decided during detailed engineering as per redundancy criteria by owner.
l) Pressure sw itches for all B oP pack ages as decided dur ing de tailed
engineering. by owner.
iii. Differential Pressure Transmitters, Diff Pressure Switches & Diff. Pressure
Gauges
a) Pressure across strainers and filters.

b) Diff. P ressure T ransmitters/switches/Gauges f or al l B oP packages as
decided during detailed engineering by owner.
c) Diff. Pressure Transmitter ac ross c ondenser on CW l ines, A ir pr e heat ers
on ai r & f lue g as l ines, on P A lines, CEP s uction s trainers, Feed c ontrol
station etc.
d) Above ar e t he m inimum r equirements, ac tual q uantities shall be as
decided during detailed engineering as per redundancy criteria by owner.
iv. Pressure Transmitters
a) For all services as mentioned for Pressure gauges & Pressure Switches.
b) Pressure Transmitters at condensate Extraction Pump individual Discharge
and discharge header, Boiler feed pump individual Discharge and discharge
header, seal water line or any other pumps/fans/HT/LT unidirectional drive
for alarm (high & low) and interlock purpose.
c) Pressure transmitter for wind box (Left/Right) & pulverizer seal air fans
discharge pressure.
d) Pressure T ransmitters a s on r equired bas is for m onitoring, i nterlocks &
controls as per redundancy criteria and approved by owner.
e) Above ar e t he m inimum r equirements, ac tual q uantities shall be as
decided during det ailed eng ineering as per r edundancy c riteria and
approved by owner.
f) Pressure Transmitters for all BoP packages as decided during detailed
engineering by owner.
Page 666 of 680

2. Temperature Measurments:-
The B idder s hall f urnish all t emperature s ensing el ements t o be installed in t heir
piping. The scope of supply shall include, but not limited to the following: -
i) Duplex RTDs for all bearing, drain oil from bearings, LPT exhaust steam, 3 no’s of
duplex RTDs each on left and right CW outlet of condenser etc.
ii) 6 no. duplex or 12 no. simplex Embedded temperature detectors for various motor
stator windings and duplex RTDs for Motor/Pump bearing temp.
iii) Chromel-alumel surface/other thermocouples for turbine casings, ESV, IV bodies,
superheated steam, hot reheat steam piping, steam of first stage HPT, inlet bowl of
IPT, steam exhaust of HPT, down stream of ESV and I V, steam in ESVs and IVs,
steam adm ission pi pes metal t emperatures, H PC, I PC f lange m etal t emperature
etc.
iv) For al l H P heat ers remote m onitoring w ith r edundant i ndependent se nsors of
inlet/outlet temperatures of feed water and extraction st eam shall be pr ovided in
addition to local gauges.
v) For al l LP heat ers remote monitoring w ith r edundant i ndependent se nsors of
inlet/outlet temperatures of feed water and ex traction steam shall be provided in
addition to local gauges.
iv) Temperature sensors for HP-LP b ypass system for measurement as well as f or
control.
v) Adequate number of temperature Elements shall be f urnished to provide initiating
contacts for temperature interlocking and t rip circuits. The temperature elements
shall be provided, but not limited to the following: -
Steam temperature of HPT exhaust, steam temperature after ESV (L&R), IV (L&R),
LPT ex haust h ood s team, dr ain oi l t emperature of al l j ournal bear ings and t hrust
bearing & l ube oil hea der t emperatures, thrust bear ing o f eac h c ondensate
extraction pump and vacuum pump protection, interlocks.
vi) Metal Temp measurement and steam temp measurement at each super heater &
Reheater location.
vii) Temp. Element & Temp gauges at Feed water line to economizer inlet, economizer
to steam separator, spray water lines to desuperheaters, Soot blower steam, Soot
blower steam drain lines, steam drain lines, Flue gas & air lines etc
viii) Temp. M easurements ( Local & r emote) for al l B oP pac kages as dec ided dur ing
ix) Thermocouples for Temp. above 200 deg C shall be provided by bidder.
x) For pl ate heat ex changers, sp are t hermowell pr ovision sh all be m ade a t i nlet &
outlet of ACW & DMCW lines in addition to local & remote temperature monitoring
points.
xi) Each ESP Hopper shall be provided with RTDs to control the temperature of ash
through Hopper heater.
xii) Temperature gauges.
a) For bear ing t emperatures A C and D C l ube oil p umps, LP T ex haust hoo d
etc.
b) For condensate and f eed w ater at inlet and out let of HP heaters, Vacuum
pumps, LP heaters etc.
Page 667 of 680

c) Steam & water inlet/outlet of LP and HP heaters, steam and air mixture inlet
to vacuum pumps, and drain lines etc.
d) Journal/thrust bearing drain oil, lube oil at inlet/outlet of oil coolers,
cooling water at inlet and outlet of oil coolers etc.
e) Thrust bearing of each condensate extraction pump.
f) Temp. Gauges at inlet and outlet of each heat exchanger and cooler.
g) Frame m ounted Temperature G auges (FMG) sh all be pr ovided f or M ain
steam Temperature, Feed water Temperature to economizer, CRH Steam
Temperature, HRH Steam Temperature etc
xiii) Above ar e t he m in. r equirements, ac tual q uantities s hall be as dec ided dur ing
detailed engineering by owner.
3. Level Measurement
i) Level g auges - level gauges for boi ler s eparator, H P heat ers, LP heaters,
deaerator, dr ain c ooler, gland s team c ooler, v acuum t anks, c ondenser h ot w ell
CBD t ank, st ator w ater t ank, S tator w ater ex pansion t ank and ot her pr essure
vessels, main oil tank and all oil tanks in BTG & BOP package. The level gauges
shall be mica shielded steel armoured transparent glass type. Level gauges for
condenser hot well shall be provided on both sides.
ii) Level switches for HP/LP heaters, drain cooler, gland steam cooler, condenser hot
well, deaerator, main o il tank and other pressure vessels, tanks, sumps etc. The
separate swi tches for hi gh, v ery hi gh and l ow levels s hall be pr ovided as per
interlocks and protection requirements.
External cage mounted magnetic level switches/ displacer type shall be em ployed
for low pressure & low temp. services.
However conductivity type level switches shall be provided for high pressure & high
temp services like HP heaters, CRH/HRH drain Pot, Turbine Drains etc.
iii) Level T ransmitters (Type as per O wner appr oval) f or open

sump/tank/bunker/vessel/heaters.
iv) Level measurement for all BoP packages as decided during detailed engineering.
v) Level s witches for OLCS / A larms / I nterlocks / P rotection. Lev el sw itches for
sump/tank level high/normal/ low/very low interlocks.
vi) Each ESP hopper must be provided with 3 nos. level switch (switches 2 nos. for
high level and One no. for low level.)
vii) Above ar e t he m in. r equirements, ac tual q uantities s hall be as dec ided dur ing
detailed engineering by owner.
4. Flow Measurements:-
a) Primary Elements: Flow nozzles shall be used for feed water flow and other critical
measurements where weld-in construction is required. Flow nozzles shall be made
of stainless steel, with three sets of pressure taps installed in the pipe wall where
required. One no. spare set of pressure tap shall also be pr ovided on f low nozzle,
Page 668 of 680

wherever required. Installation of flow nozzles and pressure taps shall be made in
the pipe fabricator's shop and s hall be witnessed by a r epresentative from the flow
nozzle manufacturer.
b) Paddle type orifice plates shall be used for other flow measurements where flanged
construction and h igher pressure loss are acceptable. Orifice plates shall be made
of s tainless s teel. O rifice f langes s hall be of t he r aised f ace w eld n eck type with
dual sets of taps.
c) Construction and installation of flow nozzles and orifices shall conform to the
requirements o f A SME P erformance T est C ode P TC-19.5, and di scharge
coefficients s hall be pr edicted i n ac cordance w ith dat a pub lished in A SME
Research Report on Fluid Meters.
d) Airfoil or venturi flow sections, shall be used for measuring boiler combustion
airflow.
e) A special high accuracy flow nozzle pipe shall be provided to determine feed water
flow to the economizer. This nozzle shall be hydraulically calibrated and utilized for
feed water flow control and for turbine testing as described in ASME PTC 6 (latest
revision).
f) Orifice plates shall be supplied with carrier rings as per process requirement.
g) Doppler effect type flow meters shall be used for sludge applications.
h) For Raw water, water treatment plant and effluent treatment plant, ultrasonic type
flow meters to be used.
i) Secondary Elements: Secondary elements for differential type flow sensors shall be
strain g auge or c apacitance t ype di fferential pr essure t ransmitters. S quare r oot
extraction required f or the DP transmitters shall b e performed electronically in the
transmitter itself.
j) HFO/LDO f low m eters s hall be b ased o n c oriolis mass f low t echnology. Fuel O il
meters shall be pr ovided for fuel oil unloading system and near boiler after day oil
tank (at main supply & return lie).
k) Flow nozzles shall be provided for following services in main plant:-
i) Steam flow measurement for BFP Turbines.

ii) Feed water flow measurement
iii) Auxiliary steam flow measurements
iv) HP bypass flow measurements
v) BFP suction flow.
vi) Deaerator water flow measurement
vii) HP heaters drain Flow measurements.
Orifices shall be provided for following services:-
i) Spray water flow measurement
Page 669 of 680

ii) Condensate flow measurements

iii) DM/hotwell makeup to condenser.
iv.) Condensate dump flow to CST
v) Gland Steam Condensate flow measurements
l) For DM water flow & Ash Slurry flows measurements online

electromagnetic flow meter shall be used.
m) At CW & ACW pump discharge headers flow transmitters shall be pr ovided (Non
Contact ultrasonic Type are preferable). In addition flow measurement shall also
be provided for CW water used any where except condenser service.
n) Instrument and Service Air - Vortex/Swirl type Flow meter
o) Flow t ransmitters for g eneral appl ications sh all be of t he d ifferential

pressure type
.
p) Flow switches for OLCS / Alarms / Interlocks / Protection.
q) Lubricating oi l Flow transmitter/meter with switch shall be pr ovided for Bearing

systems of APH, FD, PA, etc.,
r) Sight glasses flapper i ndication type shall be pr ovided on lube oil cooling water
piping as required to ensure indication of fluid flow.
s) On l ine Fuel f low & velocity m easurement facility i n each P ulverized F uel ( PF)
pipe f or each co al pulveriser sh all be pr ovided by bi dder f or ac curate, a bsolute
and simultaneous measurement of coal velocity, coal density, coal mass flow rate
and ai r-to-fuel r atio. The eq uipments sh all co mpromise o f se nsors w orking o n
micro wave technology.
t) In addi tion t o t he conventional triple DP measurement techniques involving

venturi/Airfoil f or se condary ai r f low m easurement, One num ber Flow
measurement system each on Le ft si de and Right si de sh all be p rovided as
redundant/checking measurement for secondary air flow which co uld be
used in the optimization package.
On line secondary air flow & velocity measurement facility in each on l eft side &
right side shall be provided by bidder f or accurate, absolute and simultaneous
measurement of air velocity & flow rate. The equipments shall compromise of
sensors working on tribo-electric (Correlation technique) technology.
u) Any ot her f low el ement/meter r equired for sy stem sh all be f inalised as per
system requirement and as per approved drawings/documents by owner.
9.05.00 Process Connections
The type of instrument source connection shall depend upon the process parameters and
the t apping si ze. T he so urce co nnection dr awings shall be f inalised dur ing the
engineering stage.
Page 670 of 680

Size of tapping point stub, number and size of root valves for different types of
measurements are as follows:
Sl. Quantity of Size of stub and Service Condition

No. root valves root valve
Pressure and Differential Pressure Measurement
(i) 2 25NB > 40 bar(g) OR 4250C
(ii) 1 15NB < 40 bar(g) AND 4250C.
Level Measurement
(a) Level Gauge & Switch
(i) 2 25NB > 40 bar(g) OR 4250C
(ii) 1 25NB < 40 bar(g) AND 4250C
(b) Level transmitter (displacement type)
(i) 2 40NB >40 bar(g) OR 4250C
(ii) 1 40NB <40 bar(g) AND 4250C
(c) Stand pipe for level measuring instrument
(i) 2 80 NB >40 bar(g) OR 4250C
(ii) 1 80 NB < 40 bar(g) AND 4250C
Flow Measurement
(i) 2 25NB > 40bar(g) OR 4250C
(ii) 1 25NB < 40 bar(g) AND 4250C
Sampling system measurement (Steam and Water Service)
(i) 2 25 NB >40 bar(g) OR 4250C
(ii) 1 25 NB < 40 bar(g) AND 4250C
Page 671 of 680


VOLUME III
Page 672 of 680


LIST OF DOCUMENTS TO BE SUBMITTED ALONG WITH BID
 Technical pre-bid clarification if any strictly in the enclosed Schedule of pre bid clarification s only
with mention of specification clause for which clarification is being asked. (Stamped & Signed).
 Technical Deviation if any strictly in the enclosed Schedule of deviation with cost of withdrawal only
with mention of specification clause for which deviation is being asked. (Stamped & Signed).
 Compliance cum confirmation certificate (Stamped & Signed).
 Un Price Schedule duly filled in (Stamped & Signed).
 Electrical Load List in BHEL format (Stamped & Signed).
 List of Start-up & commissioning spares if any (Stamped & signed).
 List of tools & tackles (Stamped & signed).
 List of recommended spares for 3 years of normal operation of the Condensate polishing plant.
 Following guaranteed chemical consumption required per regeneration per vessel (in kg) to be
furnished.
i) Acid (30% HCL) consumption per vessel per regeneration
ii) Alkali (48 % NaOH) consumption per vessel per regeneration.
NOTE: Any other documents submitted by bidder except as asked above shall not be evaluated &
considered as null & void.
Page 673 of 680


COMPLIANCE CUM CONFIRMATION CERTIFICATE
The bidder shall confirm compliance with following by signing / stamping this compliance certificate (every
sheet) and furnish same with the offer.
1. The scope of supply, technical details, construction features, design parameters etc. shall be as
per technical specification & there are no exclusions, other than those mentioned under “exclusion
and those resolved as per ‘Schedule of Deviations’, with regard to same.
2. There are no other deviations w.r.t. specifications other than those furnished in the ‘Schedule of
Deviations’. Any other deviation, stated or implied, taken elsewhere in the offer stands withdrawn
unless specifically brought out in the ‘Schedule of Deviations’.
3. Bidder shall submit QP in the event of order based on the guidelines given in the specification &
QP enclosed therein. QP will be subject to BHEL / CUSTOMER approval & customer hold points
for inspection / testing shall be marked in the QP at the contract stage. Inspection / testing shall be
witnessed as per same apart from review of various test certificates/ Inspection records etc. The
charges for 3rd party inspection (Lloyds, TUV or equivalent) for imported components shall be
included in the base price of the equipment by the bidder. This is within the contracted price
without any extra implications to BHEL after award of the contract.
4. All drawings/data – sheets etc. to be submitted during contract shall be subject to BHEL/Customer
review/ approval. GA drawings, as submitted with offer at tender stage are for reference purpose
only and shall be subject to approval during contract stage.
5. The offered materials shall be either equivalent or superior to those specified in the specification &
shall meet the specified / intended duty requirements. In case the material specified in the
specifications is not compatible for intended duty requirements then same shall be resolved by the
bidder with BHEL during the pre-bid discussions, otherwise BHEL / Customer’s decision shall be
binding on the bidder whenever the deficiency is pointed out. The offered materials shall be either
equivalent or superior to those specified. Also for components where material is not specified it
shall be suitable for intended duty, materials shall be subject to approval in the event of order.
6. The commissioning spares (if any) are supplied on ‘As Required Basis’ & prices for same included
in the base price (If bidders reply to this is “No commissioning spares are required” and if some
spares are actually required during commissioning same shall be supplied by bidder without any
cost to BHEL).
7. All sub vendors shall be subject to BHEL/CUSTOMER approval in the event of order.
8. Guarantee for plant/equipment shall be as per relevant clause of GCC / SCC / Other Commercial
Terms & Conditions
9. In the event of order, all the material required for completing the job at site shall be supplied by the
bidder within the ordered price even if the same are additional to approved billing break up,
approved drawing or approved Bill of quantities within the scope of work as tender specification.
This clause will apply in case during site commissioning, additional requirements emerges due to
customer and / or consultant’s comments. No extra claims shall be put on this account.
10. Schedule of drawings submissions, comment incorporations & approval shall be as stipulated in
the specifications. The successful bidder shall depute his design personnel to BHEL’s / Customer’s
/ Consultant’s office for across the table resolution of issues and to get documents approved in the
stipulated time.
11. As built drawings shall be submitted as and when required during the project execution.
Page 674 of 680

12. The bidder has not tempered with this compliance cum confirmation certificate and if at any stage
any tempering in the signed copy of this document is noticed then same shall be treated as breach
of contract and suitable actions shall be taken against the bidder.
13. Successful bidder shall furnish detailed erection manual for each of the equipment supplied under
this contract at least 3 months before the scheduled erection of the concerned equipment /
component or along with supply of concerned equipment / component whichever is earlier.
14. Document approval by customer under Approval category or information category shall not
absolve the vendor of their contractual obligations of completing the work as per specification
requirement. Any deviation from specified requirement shall be reported by the vendor in writing
and require written approval. Unless any change in specified requirement has been brought out by
the vendor during detail engineering in writing while submitting the document to customer for
approval, approved document (with implicit deviation) will not be cited as a reason for not following
the specification requirement.
15. In case vendor submits revised drawing after approval of the corresponding drawing, any delay in
approval of revised drawing shall be to vendor’s account and shall not be used as a reason for
extension in contract completion.
16. Any special tools & tackles, if required, shall be in bidder’s scope.
17. Performance guarantee test parameters shall stand valid till the satisfactory completion of
Performance guarantee test and its acceptance by BHEL/Customer.
PARTICULARS OF BIDDER / AUTHORISED REPRESENTATIVE
NAME DESIGNATION SIGNATURE DATE COMPANY SEAL
Page 675 of 680

PRE BID CLARIFICATION SCHEDULE
All clarification from the Technical Specification shall be filled in by the BIDDER clause by clause in this
format only.
VOLUME SECTION CLAUSE PAGE SPECIFICATIO CLARIFICATIO REASONS FOR

NO. NO. N N CLARIFICATIO
REQUIREMENT N
PARTICULARS OF BIDDER / AUTHORISED REPRESENTATIVE
NAME DESIGNATION SIGNATURE DATE COMPANY SEAL
Page 676 of 680

THIS IS A PART OF TENDER TECHNICAL SPECIFICATION PE-TS-412-155A-A001
SCHEDULE OF DEVIATIONS WITH COST OF WITHDRAWAL
PROJECT:- 2X 660 MW ENNORE SEZ STPP
TENDER ENQUIRY REFERENCE:-
NAME OF VENDOR:-
REFERENCE OF
NATURE OF
PRICE
TECHNICAL COST OF
COST OF SCHEDULE ON
SL VOULME/ PAGE CLAUSE SPECIFICATION/ COMPLETE DESCRIPTION OF withdrawal OF REASON FOR QUOTING
withdrawal OF WHICH COST OF
NO SECTION NO. NO. TENDER DEVIATION DEVIATION DEVIATION
DEVIATION withdrawal OF
DOCUMENT (POSITIVE/
DEVIATION IS
NEGATIVE)
APPLICABLE
TECHNICAL DEVIATIONS
COMMERCIAL DEVIATIONS
PARTICULARS OF BIDDERS/ AUTHORISED REPRESENTATIVE
NAME DESIGNATIONS SIGN & DATE
NOTES:
1. For self manufactured items of bidder, cost of withdrawal of deviation will be applicable on the basic price (i.e. excluding taxes, duties & freight) only.
2. For directly dispatchable items, cost of withdrawal of deviation will be applicable on the basic price including taxes, duties & freight.
3. All the bidders have to list out all their Technical & Commercial Deviations (if any) in detail in the above format.
4. Any deviation not mentioned above and shown separately or found hidden in offer, will not be taken cognizance of.
5. Bidder shall submit duly filled unpriced copy of above format indicating "quoted" in "cost of withdrawal of deviation" column of the schedule above along with their Techno-
commercial offer, wherever applicable.
6. Bidder shall furnish price copy of above format along with price bid.
7. The final decision of acceptance/ rejection of the deviations quoted by the bidder shall be at discretion of the Purchaser.
8. Bidders to note that any deviation (technical/commercial) not listed in above and asked after Part-I opening shall not be considered.
9. For deviations w.r.t. Payment terms, Liquidated damages, Firm prices and submission of E1/ E2 forms before claiming 10% payment, if a bidder chooses not to give any cost of
withdrawal of deviation loading as per Annexure-VIII of GCC, Rev-06 will apply. For any other deviation mentioned in un-priced copy of this format submitted with Part-I bid but not
mentioned in priced copy of this format submitted with Priced bid, the cost of withdrawal of deviation shall be taken as NIL.
10. Any deviation mentioned in priced copy of this format, but not mentioned in the un-priced copy, shall not be accepted.
11. All techno-commercial terms and conditions of NIT shall be deemed to have been accepted by the bidder, other than those listed in unpriced copy of this format.
12. Cost of withdrawal is to be given seperately for each deviation. In no event bidder should club cost of withdrawal of more than one deviation else cost of withdrawal of such
deviations which have been clubbed together shall be considered as NIL.
13. In case nature of cost of withdrawal (positive/negative) is not specified it shall be assumed as positive.
14. In case of descrepancy in the nature of impact (positive/ negative), positive will be considered for evaluation and negative for ordering.
Page 677 of 680
Page 1 of 1
PROJECT: 2X 660 MW ENNORE SEZ STPP
SUGGESTIVE PRICE SCHEDULE
THE PRICES SHOULD BE SUBMITTED IN THE

ENCLOSED PRICE SCHEDULE FORMAT ONLY.
FOLLOWING PRICE / GUARANTEED AUXILIARY
POWER SCHEDULE FORMATS ARE ENCLOSED
ANNEXURE ‘A’ : LUMP SUM PRICES AND MAJOR

BREAK-UP OF PRICES
ANNEXURE-'B' : LIST OF CIF CONTENTS FOR
Bidder shall furnish this price schedule in his price offer only
particulars of bidder / authorised representative
name designation signature date company seal
Page 678 of 680

PROJECT:2 X 660 MW ENNORE SEZ STPP
SUGGESTIVE PRICE SCHEDULE
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
ANNEXURE-'B' : LIST OF CIF CONTENTS FOR CONDENSATE POLISHING UNIT
Bidder shall furnish this price schedule in his offer only
Particulars of bidder / authorised representative
Name Designation Signature Date Company seal
ANNEXURE -A
1 Total lump sum firm price on FOR site basis for design, engineering, manufacture, fabrication, assembly, inspection &
testing at manufacturer’s works, painting, forwarding, supply and delivery at site including start up and commissioning
spares, mandatory spares, properly packed for transportation, loading/unloading / handling and storage at site, in site
transportation, assembly, erection and commissioning, trial run ,preparation and submission of “As Built” drawings, site
testing, carrying out performance guarantee tests at site etc. inclusive of all prevailing taxes, duties and other levies and
handover of 'CONDENSATE POLISHING UNIT' to customer complete with all accessories as per details elaborated in
different sections / volumes of technical specification (PE-TS-412-155A-A001) for 2 X 660 MW ENNORE SEZ STPP.
a) 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.
b) In case, price indicated above does not match with item wise break-up 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.
2 MAJOR BREAK-UP OF PRICES GIVEN IN 1 ABOVE
2.1 Total lumpsum firm price for EQUIPMENT (SUPPLY, DESIGN & ENGINEERING) i.e. manufacture, fabrication,
assembly, inspection and testing at vendor's & sub-vendor’s works, painting, startup and commissioning as required,
forwarding, proper packing, shipment and delivery at site, inclusive of all taxes & duties for the complete scope of supply
of CONDENSATE POLISHING UNIT as per details elaborated in different sections / volumes of technical specification
(PE-TS-412-155A-A001) for 2X 660 MW ENNORE SEZ STPP.
2.2 Total lump sum firm price all services including loading/unloading / handling and storage at site, in site transportation,
assembly, erection and commissioning, trail run, preparation and submission of “As Built” drawings, site testing etc.
required for completion of CONDENSATE POLISHING UNIT as per details elaborated in different sections / volumes of
technical specification (PE-TS-412-155A-A001) for 2X 660 MW ENNORE SEZ STPP.
2.3 Price for Performance Guarantee test and handing over the plant to the customer.
2.4 Price for Mandatory spares (as per list indicated in Section C1 of tender technical specification).
3.0 Break-up (%) of prices given at Sl No-2.1 above (To be used during contract execution for payment).
3.1 Lumpsum firm price for supply of Atmospheric tanks inclusive of all taxes, duties and other levies as 6 % of sl no 2.1
applicable. above.
3.2 Lumpsum firm price for supply of Pressure Vessels inclusive of all taxes, duties and other levies as 18% of sl no 2.1
applicable. above.
3.3 Lumpsum firm price for supply of Valves inclusive of all taxes, duties and other levies as applicable. 12% of sl no 2.1
above.
3.4 Lumpsum firm price for supply of Instruments & analysers inclusive of all taxes, duties and other 10% of sl no 2.1
levies as applicable. above.
3.5 Lumpsum firm price for supply of Pumps & Blowers with motor inclusive of all taxes, duties and 5% of sl no 2.1
other levies as applicable. above.
3.6 Lumpsum firm price for supply of Piping & Fittings inclusive of all taxes, duties and other levies as 10% of sl no 2.1
applicable. above.
3.7 Lumpsum firm price for supply of Resin media inclusive of all taxes, duties and other levies as 18% of sl no 2.1
applicable. above.
3.8 Lumpsum firm price for supply of agitators,heater, strainers, resin trap,filter nozzle inclusive of all 3% of sl no 2.1
taxes, duties and other levies as applicable. above.
3.9 Lumpsum firm price for supply of PLC system along with battery etc. inclusive of all taxes, duties 8% of sl no 2.1
and other levies as applicable. above.
3.10 Lumpsum firm price for supply of Balance items inclusive of all taxes, duties and other levies as 5% of sl no 2.1
applicable. above.
3.11 Submission & approval of all basic design documents such as data sheets /drawings, quality plans 5% of sl no 2.1
etc. as per tender technical specification (PE-TS-412-155A-A001) for 2X 660 MW ENNORE SEZ above.
STPP for CONDENSATE POLISHING UNIT.
Bidder shall furnish this price schedule in his offer only
Particulars of bidder / authorised representative
Name Designation Signature Date Company seal
Page 679 of 680

ANNEXURE-B
LIST OF CIF CONTENTS FOR CONDENSATE POLISHING UNIT FOR
2 X 660 MW ENNORE SEZ STPP.
S.NO. DESCRIPTIONS UNIT TOTAL CIF CONTENT

1) Resins
Page 680 of 680

Tech Spec of Cpu - Ennore

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TAMILNADU GENERATION AND DISTRIBUTION

2X660 MW ENNORE SEZ

BHARAT HEAVY ELECTRICALS LIMITED

SECTION‐A INTENT OF SPECIFICATIONS 1‐3

i) ANNEXURE‐I: LIST OF MAKES 246‐265

1.1 CONDENSATE POLISHING UNIT

2.0 GENERAL TECHNICAL INSTRUCTIONS

PROJECT INFORMATION WITH WIND AND SEISMIC DESIGN CRITERIA

1.0 GENERAL BACKGROUND AND SALIENT FEATURES

Tamilnadu Generation and Distribution Corporation owns the proposed

The nearest Railway station is at Athipattu Pudunagar (approx 5 kms)

All weather road from Pattamandri on the Thiruvottiyur-Ponneri district

The nearest airport is at Chennai at a distance of 60 km.

1.3 Type of Plant

The proposed 2x660 MW Super-Critical Power Project consists of coal fired

1.4 PROJECT INFORMATION

Project Title : 2 x 660 M W E nnore S EZ C oal B ased

Owner : TAMIL N ADU GENERATION AND DI STRIBUTION

The site is located near Vayalur Village, Ennore

Nearest Railway Station is : Athipattu Pudunagar (approx 5 kms)

Climatological data : Ambient temp. (0C)

Prevailing Wind Direction

Feb to Mar – From East & SE

1.5 Access to Site

1.6 Plant Rating, Capacity, Availability, PLF

 Ambient air temperature

The plant load factor (PLF) being considered is 85%.

1.7 Power Evacuation

1.8 Site Selection

1.9.1 Source of Fuel

The steam generator shall be designed for the following conditions :

• Best Coal – 100% Imported Coal

The analysis of fuel is given below :

1.9.2 Coal Analysis:

Coal Quality Parameters

SL.NO DESCRIPTION DOMESTIC COAL IMPORTED COAL

VALUE received basis) dried basis)

Sr. No. Particulars Units Parameters

Sr. No. Particulars Units Parameters

Sr. Particulars Units Parameters

Sr. Particulars Units Parameters

S. Particulars Unit Parameter

1.9.3 Specification of LDO

Specific gravity @ 15° C 0.8348

Gross calorific value, Kcal/kg 10400

Pour point “°C” max. 12

Flash point “°C” min. 66

Sulphur % “T” max. 0.5

K. Viscosity in Centistokes @ 50° C max. 7.5

Ash by wt. % 0.01

Water & sediment Vol. Max. % 0.25

1.9.4 Specification of HFO

Flash point “°C” min. 66

K. Viscosity in Centistokes @ 50° C max. 370

Ash by wt. % 0.1

Water content by volume % max 1

Sediment by weight % max 0.25

Total Sulphur by weight % max 4.5

Gross calorific value, Kcal/kg 10800

1.9.5 Fuel Linkage

TANGEDCO has approached Ministry of Coal through Ministry of Power for

The coal requirement has been worked as under:-

Per day 20928 tonnes.